ESAB LTO 160 Instruction manual

MECHTIG 160
MECHTIG 250
LTO 160, LTO 250
105107106023104022041
Instruction manual
Betriebsanweisung
0456 779 041
980902
Manual d’instructions
Gebruiksaanwijzing
LTO 160 valid for Serial NO 728 XXX--XXXX
LTO 250 valid for Serial NO 745 XXX--XXXX
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
-- 2 --
ENGLISH
1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
5
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
4.1
4.2
4.3
4.4
4.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of a complete welding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
8
8
9
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
5.1 Genral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
12
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Check--up and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
7 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
7.14
7.15
The mode of operation of the control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual tool codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Division into functional areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The SEL key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The SET key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The MEM key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The OPE key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control of the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The POB, POC tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing sectors in the course of running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Associations within a sequential sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the memory to aero / basic parameter values . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start/stop over external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The length of a transport sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The influence of sector changes on pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
14
15
19
22
25
29
30
30
31
32
32
33
33
8 ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
8.1
8.2
8.3
8.4
8.5
Memory errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communictions errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors in the course of welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors in the course of sequential running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blocking messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
35
36
36
9 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
LIST OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
TOCe
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1
DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTO 160 / LTO 250 from serial number 636 / 745 complies with standard EN 60974--1, in accordance with the requirements of directive
73/23/EEA and addendum 93/68/EEA and standard EN 50199 in accordance with
the requirements of directive 89/336/ EEA and addendum 93/68/ EEA .
-------------------------------------------------------------------------------------------------------------------------------------Laxå 97--10--30
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN
2
Tel: + 46 584 81000
Fax: + 46 584 12336
SAFETY
Users of ESAB welding equipments have ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions.
Safety precautions must meet the requirements that apply to this type of welding equipment.
The following recommendations should be observed in addition to the standard regulations that apply
to the work place.
All work must be carried out by trained personnel who are familiar with the operation of the welding
equipment.
Incorrect operation of the equipment may lead to a hazardous situation which can result in injury to
the operator and damage to the equipment.
1.
Anyone who uses the welding equipment must be familiar with:
S
its operation
S
its function
S
relevant safety precautions
S
welding
2.
The operator must ensure that:
S
no unauthorized person is stationed within the working area of the equipment when it is
started up.
S
that no--one is unprotected when the arc is struck
3.
The work place must:
S
be suitable for the purpose
S
be free from draughts
4.
Personal safety equipment
S
Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S
Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S
Make sure the return cable is connected securely.
S
Work on high voltage equipment may only be carried out by a qualified electrician.
S
Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S
Lubrication and maintenance must not be carried out on the equipment during its operation.
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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S
Install and earth the welding unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use ear defenders or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
INTRODUCTION
3.1
General
LTO 160 / LTO 250 is a transistor--controlled welding power source for TIG welding.
It is programmable and provided with a memory so that different welding programs
can be set and stored by means of a control box. The welding programs can be
divided into sectors with different sets of parameters. The division into sectors is
time--controlled.
LTO 160 / LTO 250 has battery backup so that the settings remain in memory even
when the machine is switched off or disconnected from the power supply.
LTO 160 / LTO 250 is a machine of inverter type, which means that the mains
voltage first is rectified and then converted back to alternating current of very high
frequency. After this it is transformed to welding current.
Rectifier
Inverter
Transformer
Rectifier
Control system
The inverter principle makes it possible to control every sequence of the welding
process by means of electronics, which results in better welding properties.
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The LTO 160 / LTO 250 microcomputer is of type Siemens 805 15. It is programmed
to provide for optimal starting properties. The microcomputer supervises the welding
procedure and provides for the right static and dynamic qualities.
LTO 160 / LTO 250 is designed both for manual and mechanized welding, and as a
result it can drive the ESAB welding tools PRB, PRG, PRI, POB, POC and PRH. For
manual welding a TIG torch for OKC connection is used.
LTO 160 / LTO 250 is composed of the following units:
S
Power module containing power units and control electronics. Here the
incoming mains voltage is transformed to high--frequency alternating voltage
which is then transformed to welding voltage.
S
Control box for the selection of welding procedure (sequence or
non--sequence), HF or LIFTARC start, programming, parameter changes,
memory handling, sector classification, manual gas pre--flow, manual rotation,
manual wire feed, start and stop. The values for current and voltage are
continuously displayed on the control box during the welding process. The
communication between the control box and the power source is very reliable
from interference point of view as the signals are transmitted via optical fibres.
(L=10m.)
3.2
Technical data
LTO 160
LTO 250
Mains voltage
230 V, 1
400 V, 3
Mains frequency
50--60 Hz
50--60 Hz
Permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
160 A / 16 V
110 A / 15 V
80 A / 13 V
250 A / 20 V
180 A / 17 V
140 A / 16 V
No--load power
55 W
50 W
Power factor
0,68
0,61
Efficiency
0,70
0,80
Primary current at 100% duty
cycle
10 A
15 A
Dimensions L x W x H
515 x 285 x 505 mm
515 x 285 x 505 mm
Weight
32 kg
33 kg
Temperature class
F (155 C)
F (155 C)
Enclosure type
IP 23
IP 23
Capacity of internal memory,
number of parameter sets
100
100
Battery back--up MECHTIG
160
2 years
2 years
Battery back--up Control box
2 years
2 years
Application class
Arc strike for tube welding
HF
tools
Arc strike for manual welding HF and LIFT ARC
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HF
HF and LIFT ARC
GB
Setting range
LTO 160
LTO 250
Pulse, background and cont.
current
3--160 A
3--250 A
Steps of adjustment, current
1A
1A
Wire feed speed
0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
Rotation speed
5--100 % of max. speed
5--100 % of max. speed
Pulse and background time
0.02--5.0 s
0.02--5.0 s
Pre--heat time
0--99.8 s
0--99.8 s
Gas pre--flow
1--250 s
1--250 s
Gas post--flow
3--250 s
3--250 s
Slope--up and slope down
0--25 s
0--25 s
Sector time
0.01--33.59 min
0.01--33.59 min
Steps of adjustment, sector
time
0.1 s
0.1 s
Application class
The symbol
indicates that the power source is designed for use in areas with
increased electrical hazard.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against
penetration by solid objects or water. Equipment marked IP 23 is designed for
indoor and outdoor use.
Duty cycle
The duty cycle refers to the time in per cent of a ten--minute period that you can
weld at a certain load without overloading the welding power source.
4
INSTALLATION
4.1
General
WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interference. It is the user’s responsibility to take
adequate precautions.
Installation must be carried out by a qualified electrician.
4.2
Placing
Place the machine so that there is nothing to prevent the cooling air from passing
through it.
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4.3
Lifting instructions
4.4
Mains voltage connection
The rating plate with production number and connection data is located on the rear
panel of the welding eqipment.
S
Make sure the machine is connected for the correct mains voltage and properly
fused. Earth according to applicable directives.
LTO 160
LTO 250
Mains voltage
230 V
400 V
Mains frequency
50--60 Hz
50--60 Hz
Fuse, slow rupture
16 A
16 A
Mains cable, cross section
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3 x 2.5
mm2
4 x 1.5 mm2
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GB
4.5
Connection of a complete welding system
B--B
Motor cable --wire feed
C--C
Motor cable -- rotation
G--G
Cooling--water hose in
H--H
Cooling--water hose out
J--J
Welding cable
L--L
Torch contact
M--M
Gas hose out
N--N
Gas hose in
Q--Q
Return cable +
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B--B
Motor cable --wire feed
C--C
Motor cable -- rotation
G--G
Cooling--water hose in
H--H
Cooling--water hose out
J--J
Welding cable
L--L
Torch contact
M--M
Gas hose out
N--N
Gas hose in
Q--Q
Return cable +
5
OPERATION
5.1
Genral
General safety regulations for the handling of the equipment appear from
page 4. Read through before you start using the equipment!
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WARNING!
Rotating parts can cause injury, take great care.
1. Make sure the welding and return cables and the welding tool are properly
connected.
2. Make sure there are no gas leaks.
3. Set the starting switch to position 1. The indicating lamp goes on to show that
mains voltage is supplied.
4. Set data according to instructions under CONTROL BOX
5.2
Controls and connections
1. Mains power switch
2. Indicating lamp thermostat (yellow)
3. Indicating lamp mains (white)
10. Connection rotation PRB 9--20,
18--40, 36--80, 71--160, 140--220,
PRG, PRI, POB
4. Control box
11. Connection for cooling unit 230 V,
1.25 A
5. Connection for return cable (+)
12. Connection for shielding gas
6. Connection for welding cable (--),
cross section 25 mm2
13. Connection for remote start -- TIG
torch
7. Connection wire feed MEI 21, POC
14. Mains cable
8. Connection rotation PRB 17--49,
33--90, 60--170, PRH 6--40, 25--90,
POC
15. Gas nipple, connection of gas bottle
9. Connection wire feed MEI 20, POB,
PRI
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16. Control box cable
17. Fuse, slow rupture 1.25 A
(connection 230 V)
18. Connection for flow--guard
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GB
5.3
Overheating protection
The machine has been equipped with an integrated thermostat that trips if the
temperature becomes too high.
When this occurs the welding current is cut out and the yellow indicating lamp comes
on. When the temperature has dropped the thermostat automatically resets.
6
MAINTENANCE
6.1
General
Note:
All supplier guarantees will expire if the customer himselft during the
guarantee period takes measures in order to order to remedy an error in the
machine.
6.2
Check--up and cleaning
Generally LTO 160 / LTO 250 does not require any maintenance. Normally, it is
sufficient to blow out the machine using clean, compressed air (reduced pressure)
annually, and the dust filter should be cleaned regularly. If the machine is set up in
dusty or dirty environment the machine and the dust filter should be cleaned more
often.
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7
CONTROL BOX
7.1
The mode of operation of the control box
The process equipment is continuously updated via the control box.
A central unit in the control box is the working storage where all actual values
regarding methods and parameters are collected.
The working storage always contains a complete set of values for the process.
The whole working storage can be stored in a larger storage area, the library, which
holds up to 100 parameter sets from the working storage.
Each parameter set in the library forms a sector.
(The reason for naming it sector is the following: A parameter set recalled to the
working storage supplies the process with data within the geometrical sector
described by the rotation during the time entered.)
The contents of the working storage can be influenced by:
S
S
changing separate parameters
recalling a sector (the whole working storage will be overwritten)
The contents of the library can be influenced by:
S
S
storing a sector
erasing a sector
The contents of the working storage and the library normally remain from operation
to operation (owing to battery backup).
A sector can be either of the weld or transport type and they can be mixed
arbitrarily. A transport sector can only cause rotation, according to the entered data
for direction, speed and time, (no welding parameters are available).
Within each sector sequential or non--sequential running is indicated.
Sequential running:
When running a sequential sector, the sector values control the process during the
time entered into the sector. Then the nearest higher sector is automatically recalled
from the library (blanks are permitted). The sequence keeps running till an end
sector is found. When this in other respects quite normal sector has run to its end,
the sequence is terminated and the start sector which started the sequence is
automatically recalled. We have come to the starting--point of a new identical
sequence.
Any sequential sector can serve as a start sector. There is nothing in the contents of
the sector to indicate start sector information. Instead the start sector concept is
associated with the sector where the last sequence started.
The end sectors, however, are pre--defined by the fact that they contain a special
parameter for this.
Any number of end sectors can exist in the library. (In the extreme case 100 different
end sectors are possible, corresponding to an equal number of sequences
consisting of one sector.)
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The concept of welding program can be identical with a sequence of sectors. A
welding program is recalled by manually recalling the sector which is to constitute
the start sector.
Non--sequential running:
The sector values control the process until the running is interrupted manually. A
desired sector change before the next start is executed manually. The concepts of
start and end sector have no significance here.
7.2
Actual tool codes
Welding tool
A21 PRB
Size
Code
9--20, 18--40, 36--80,
71--160, 140--220,
17--49, 33--90
PRB
60--170
PRB 60-- 170
A21 PRH
6--40, 25--90
PRH
A21 PRG
25--45
PRG
A21 PRI
36--80, 71--160, 140--220
PRI
A22 POB
12--60
POB
A22 POC
12--60
POC
7.3
Division into functional areas
All handling of the control box takes place within four functional areas, represented
by the main keys SEL (select), SET (set), MEM (memory) and OPE (operate):
METHOD SELECTION
SEL
S
Select welding method in the
working storage.
SETTING
SET
S
Enter weld and transport data into
the working storage.
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MEMORY HANDLING
OPERATION
MEM
OPE
S
Store the contents of the working
storage in an empty storage
area.
S
Recall previously stored data to the
working area.
S
Erase previously stored data in the
working area.
S
Start welding/transport or manual
functions.
The main keys are described in separate chapters. The function of the other keys
appears from these chapters.
7.4
The SEL key
SEL is one of the four main keys of the control box.
Under SEL the method is selected.
Four different selections are possible, distributed on each one level on the display.
All method selections are available under two pictures:
Level 1, select method: SEQUENCE/NON SEQUENCE
Level 2, select type of current: PULSED CURR./
CONT.CURR/. /TRANSP. SECTOR
Level 3, select starting method: HF--START/LIFTARC
Level 4, select tool: POB/PRI/PRB/PRG
The contents on the four lines together determine the actual method (irrespective of
the location of the square brackets). The brackets mark a line where changes can be
made.
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(In the exemplified method selection above, the start values selected by ESAB have
been used.)
It is not possible to reach the SEL mode when an activity is going on!
Proceedings under SEL
An overview of keys having significance in the SEL mode. The SEL mode can be
quitted by way of the other three main keys.
The active keys are described below.
Select level by moving the brackets with the level
keys:
(You can step up and down between the four levels.
The pictures change automatically. Nothing regarding
the method can be changed using these keys What
you read is what already applies.)
Select alternative within the respective level using:
(The alternatives come up cyclically within each level.
When an alternative comes up it is also selected.)
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SEL -- Example 1
A non--sequential method is to be selected.
SEL -- Example 2
A transport sector is to be selected.
[
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SEL -- Example 3
A POB tool is to be selected.
[
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7.5
The SET key
SET is one of the four main keys of the control box.
Under SET the setting of welding and transport parameter values takes place.
Under SET the parameters are shown in pairs, one on each line on the display, for
example
The actual parameter set is the result of the selections made under SEL with regard
to:
S
PULSED CURR./CONT.CURR./TRANSP. SECTOR
S
SEQUENCE/NON SEQUENCE
Possible sets of parameters are shown later in the text.
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Proceedings under SET
An overview of keys having significance in the SET mode. The SET mode can be
quitted by way of the other three main keys.
The active keys are described below.
Change parameter pictures using the level keys:
(By means of these keys you can read all existing
parameters in the actual parameter set.)
Set the values for the parameters shown using the four
increase/decrease keys:
(For + and YES, use the increase key and for -- and
NO the decrease key.)
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Parameter values
Parameter sets
(The values shown are basic values selected by ESAB.)
PULSED CURRENT
CONTINUOUS CURRENT
TRANSPORT
Sector time and end sector data are indicated only in SEQUENCE mode:
Comments regarding min/max values of parameters
For some parameters zero is the min. limit. In practice these parameters can be
cancelled by setting their value to zero. (Pre--heat and slope times.)
The min value of the wire feed speed is always higher than zero and can be
cancelled by way of a special parameter. (Wf = YES/NO)
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7.6
The MEM key
MEM is one of the four main keys of the control box.
Under MEM all memory handling takes place, i.e. all handling with regard to the
library. All operations are contained in one and the same picture:
The MEM picture shows proposals from the library regarding:
S
free sector number for storing of sector (STO).
S
stored sector number for recalling of sector (RCL).
stored sector number for deletion of sector (DEL).
(In case the library is quite empty or full up a stroke is shown in the picture
instead of a sector number.)
The MEM picture also shows the number of sectors stored out of the 100 possible
ones.
S
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Proceedings under MEM
An overview of keys having significance in the MEM mode. The MEM mode can be
quitted by way of the other three main keys.
The active keys are described below.
Move the brackets using the level keys:
Select sector number within the brackets by way
of:
S
Regarding the selection of number:
As to STO only free numbers in the library are
searched.
As to RCL and DEL only occupied numbers in
the library are searched.
The search for a number in the library is always
done cyclically.
Execute the selected operation using:
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Regarding memory operations
Any operation executed in the memory is acknowledged by a temporary picture, for
example:
when trying to execute a prohibited operation in the memory a temporary picture
comes up, for example:
or
Other information in the MEM picture:
In case the sector number shown contains an end sector this is indicated by a
square:
In case the shown sector number contains a non--sequential sector this is indicated
by an I--beam:
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7.7
The OPE key
OPE is one of the four main keys on the control box.
OPE forms the initial status for the start of welding/transport (W/TR) or manual
functions (GAS, ROT. or WIRE).
The starting possibilities for all four activities are contained in one display under
OPE:
The actual rotation and wire feed directions are always shown on the display.
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Procedures before start
An overview of keys of significance in the OPE mode. The OPE mode can be left by
way of the other three main keys.
The active keys are described below.
Select activity by moving the brackets by way of the level
keys:
(Manual wire feed is not possible, the ’WIRE’ level is not
available when the current sector is of the TRANSPORT’
type. Wire feed speed parameter is missing.)
Change direction within the brackets using:
Regarding the rotary direction: Is based on the rotary
direction parameter which is handled within SET.
(Two alternatives exist to read and modify this
parameter.)
Regarding the wire feed direction: When switching on
the machine the wire feed direction is automatically set
to ’+’.
All starts within W/TR automatically result in ’+’ direction.
(No parameter exists for wire feed direction under SET.)
Start(/Stop) of the selected activity with:
Start/Stop can also be executed over external controls,
TIG torch or POB tool, if used. (See separate chapter
START/STOP FROM EXTERNAL CONTROLS.)
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CONDITIONS DURING AN ACTIVITY IN PROGRESS
Common to all activities (W/TR or manual functions):
After start on one level on the OPE display it is possible to select the SET, MEM or
OPE mode.
It is possible to change welding or transport data (in SET), to store and erase sectors
(in MEM), but it is not possible to change method. (The SEL mode is not available.)
The ongoing activity can always be interrupted irrespective of the actual mode (SET,
MEM or OPE) using
or over an external control, if used.
Manual functions (GAS, ROT. and WIRE):
After start one of the following three pictures is permanently shown (as long as
remaining in the OPE mode):
The speed references for manual rotation and wire
feed originate from the current parameters in SET,
which means that they can be modified during manual
running.
Pressing the STOP key results in this temporary
display which will be replaced by the permanent one
for the actual mode (SET, MEM or OPE).
Special case:
Temporary display when stopping manual rotation.
The data can be of use when setting the sector time
parameter.
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Welding/transport (W/TR):
The following is displayed after start:
within transport sectors and
within welding sectors.
The actual values (voltage mean value and current
peak value) are shown within welding sectors. The
present sector number is shown within all sectors.
If the sector is of the non--sequential type, the sector
number is shown within brackets.
If no sector has been called after erasing the whole
memory, i.e. the starting values are available in the
working memory, [SECTOR NO --1] comes up after
start of non--sequential running and is to be read as
undefined sector number. Start of sequential running is
blocked in the corresponding situation.
When welding is in progress the actual current
references (cont. current, pulsed current and
background current) can be changed in OPE mode.
The change is made with the same increase/decrease
keys as in SET mode. The result of the current
modification can be read from the actual value. If other
parameters are to be modified, SET mode must be
selected!
When down--slope is in progress this comes up on the
display (if remaining in or having returned to
OPEmode).
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If the OPE mode is left while welding/transport is in progress:
In the SET and MEM modes (SEL mode is not available) the ordinary display of the
respective mode comes up. Also temporary displays can come up here while
welding or tranport is in progress:
S
During sequential running this display comes up temporarily:
both when passing from one sector to another and when the sequence is
terminated and the start sector is automatically called back. (The latter applies
even in OPE mode.)
When the welding is terminated, either after the welding sector time is out
(without being immediately followed by a new welding sector) or after forced
stop, the following is displayed temporarily:
This always comes up in the SET and MEM modes when the down--slope phase
starts. The same picture also comes up when a transport sector is forced to stop,
or when welding or transport is interrupted during non--sequential running.
Accelerated welding stop:
In case welding is in progress and is interrupted for some reason, the down--slope
phase starts. In addition to this normal stop function there is an accelerated welding
stop for emergency situations. This means that a second touch of the stop key (while
the down--slope is already going on) will stop the rotation and extinguish the arc.
If the down--slope phase has started because the sector time has elapsed, two
touches of the stop key are still required for accelerated stop (the first one having no
visible influence).
7.8
Control of the process
The welding procedure and other activities are based on continuous interaction
between the control box and the process equipment.
Without going into the distribution of the different functions the welding procedure
runs as follows: The start signal brings about the gas pre--flow, followed by arc strike
(HF or Lift--arc). Once the arc is struck, the up--slope and pre--heat phases start.
After finished pre--heat rotation and wire feed start at the same time as the sector
time starts running.
In case further welding sectors follow, the sector transition implies that the welding
goes on with a new set of parameters.
When the sector time has run out and no new welding sector is to follow the
termination phase starts: The wire feed stops at the same time as the down--slope
phase starts. After terminated down--slope the rotation stops and the gas post--flow
starts. (In case a transport sector will follow, the rotation begins immediately.)
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7.9
The POB, POC tool
When using the POB, POC tool for sequential running it is not possible to run more
than 1.5 turns from the start point. An internal counter mechanism controls the
distance which is accumulated sector by sector.
When starting again after an interruption in the sequence, the counter mechanism
starts counting at the point of interruption.
The end position of each new sector to be started is checked to make sure it is within
the permitted interval. In case a sector is not accepted the following applies:
S
When trying to start
Nothing happens. The following temporary picture comes up:
S
When passing from one sector to another while the sequence is in progress
The sequence is interrupted. Error state is indicated:
The starting point of the motion area is defined (the accumulated distance is cleared)
S
each time the machine is switched on
S
when a sector is recalled manually (MEM mode)
S
when a sequence has run out (i.e. a start sector has been recalled automatically)
S
when starting a non--sequential sector
Regarding inaccuracy as to the accumulated distance: The distance covered during
the down--slope phase is not included in the accumulated distance. Modification of
the distance due to changed speed parameter after the sector time has started
running is not included in the accumulated distance either.
7.10
Storing sectors in the course of running
When running a sequence the working memory will be overwritten as new sectors
are automatically recalled.
Problem:
In case parameter values are changed in the course of running, the working memory
must be stored before the sector time has run out to make the modified values
remain. If the modifications are to be stored under the same sector number, the
original one must first be erased from the library.
Recommendation:
A quick way of storing is temporary storing under another free sector number
(outside the number interval of the running sequence). The memory handling can
then be completed as soon as the sequence is terminated.
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Proceed as follows:
Every time the MEM mode is called the [STO] position is shown, indicating a
previously selected number:
For each new storing (even after having selected another number), the [STO]
function automatically goes to the next free number and further temporary
storing can take place.
Consequently, temporary storing in the course of running can be executed in the
OPE (or SET) mode by touching twice the following keys:
and
Temporary storing can be repeated during the same running as long as there are
free sector numbers available.
Alternative application:
It is possible to create sectors by trimming parameters during for instance a
non--sequential test running during which suitable ’basic sectors’ are stored.
7.11
Associations within a sequential sector
General features:
S
When the rotary speed is changed the same sector length shall be retained,
which means that the sector time is automatically compensated.
When the sector time is changed the sector length will be changed
correspondingly, i.e. the rotary speed will remain unchanged.
This applies to the parameters referred to in the working area.
S
In case modifications are made in the course of running the following applies as
well:
S
The already existing speed reference is updated, i.e. the new speed takes
over promptly.
S
The running sector time is not affected.
The consequences with regard to the running sector will therefore be:
S
When the rotary speed is changed the sector length changes
correspondingly.
S
When the sector time is changed the sector length remains unchanged.
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NB! In order to preserve the modified values for the next running of the same
sequence, storing must be executed before the sector has run out.
The next running will thus be the result of the general associations mentioned
above.
7.12
Setting the memory to aero / basic parameter values
The whole memory for method selection and parameter values has battery back--up.
When the machine is switched on the memory contents are normally identical with
the contents of the previous running. In case the contents are not formally correct
when the machine is switched on this error message comes up:
The machine must now be switched off and on again. The whole memory is now
automatically erased. This means that the 100 positions in the memory are zeroed,
and the working memory is supplied with appropriate basic values (the method
structure and the sets of parameters).
7.13
Start/stop over external controls
In addition to the START/STOP key on the control box, welding, transport and
manual functions can be started or stopped over the following external controls (OPE
mode must have been selected):
S
The control switch on the TIG torch. (Active in pos. ON, i.e. four--stroke.)
S
The switch on the POB, POC, PRH tool. Functions in the same way as the
START/STOP switch on the control box -- one push for start and one for stop
(four--stroke).
This is possible through the fact that the start switch on the POB, POC, PRH tool
is connected to the input on the power source for external start signal via a relay
function.
In the two cases above the start/stop functions alternate in strict order. Cf:
Activations of the START/STOP switch on the control box are always interpreted
freely by the control box (as START if no activity is going on and as STOP if an
activity is in progress).
The control box can reject an order, no matter how it is interpreted, freely or
strictly.
The start is blocked under prohibited start conditions, for instance.
Accelerated welding stop over external controls:
Accelerated welding stop can be executed over external controls in the same way as
described with regard to the START/STOP switch on the control box.
The function implies in general that a second push of the switch while the
down--slope phase is already in progress will cause rotation stop and arc extinction.
Due to the strict alternating order it is in fact an external starting command that
results in accelerated welding stop.
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Particulars regarding external start (1)
Due to the strict alternating function it can sometimes happen that you come
out of step, i.e. the start signal comes when the activity is already in progress, or the
stop signal comes when the activity has already stopped.
The reason for this can be:
S The control box rejects a command.
S The sequence has run out.
S An error has stopped the sequence, see the error code list.
S An accelerated welding stop has been made.
For external start/stop activation a blind command is sometimes required (which in
fact is rejected by the control box) in order to come into phase again.
As to the control switch on the TIG torch it is quite evident when you have
dropped out of step and it is natural to correct.
S As to the POB switch there is nothing outwardly to indicate start or stop position.
(Alternating function over a relay.) A blind--push for stop position can be
necessary before start.
Particulars as to external start (2)
If, after external start, the arc is extinguished in the course of welding (between arc
strike and started down--slope), you will return to the OPE basic mode (or after
welding stop remain in SET or MEM mode, if this has been selected after start).
S
This is not to have to reset WELDING ERROR before a new start, which would be
necessary in the corresponding situation if the welding was started over the control
box.
Unsuccessful strike is an example in this connection.
Particulars as to external start (3)
If external start -- of one kind or other -- has taken place and a non--sequential sector
has been selected, the references for both rotation and wire feed are blocked,
irrespective of what is said about these parameters in the sector.
If external start -- of one kind or other -- has taken place and a sequential sector
has been selected no blocking will take place.
7.14
The length of a transport sector
Due to the valid sector time resolution (full seconds) it is not possible to run from one
selected point to another at max rotary speed with sufficient accuracy.
S
S
Measure, alt.1:
Going out from the sector time resulting in a slightly too long sector, the rotary
speed is decreased from max value so as to match the length of the sector.
Measure, alt.2:
Divide the transport into two sectors. Run the first one as close as possible at
max rotary speed. Fine adjustment is made at low speed with the second one.
7.15
The influence of sector changes on pulsing
At each sector change during sequential running, a number of parameter values are
sent to the power source. If pulsing has already been selected, the change for new
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pulse parameters is depending on where in the pulse cycle you are at that very
moment.
S
In case measures must be taken:
Increase/decrease the pulse and/or background time within the sector by so
many steps of 0.02 sec that the pulse cycles within the sector are even.
8
ERROR MESSAGES
8.1
Memory errors
Memory errors can come up when switching on the machine, without necessarily
disturbing the process.
Defective memory cell in the read-- write memory of
the machine.
Defective memory cell in the read--only memory of the
machine.
Defective memory cell in the internal read--write
memory of the control box.
Defective memory cell in the read-- only memory of the
control box
Defective memory cell in the external read/write
memory of the control box. The memory contains
among other things stored welding data.
Contents of welding data memory distorted. Switch the
machine off and on. Contents of working memory will
be reset to basic values. The 100 memory positions
have been erased.
8.2
Communictions errors
The machine must be switched off and on again. These errors are all related to the
series communication between the machine and the control box and can occur
occasinally. Reset by switching the machine off and on again. If the errors occur
more frequently, the macine must be carefully examined and measures must be
taken to eliminate the error.
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Wrong checking sum has been detected 5 times in a
row during the transmission from machine to control
box.
Wrong checking sum has been detected 5 times in a
row during the transmission from control box to
machine.
The control box has sent a message to the machine
which has not been acknowledged.
The control box has failed in handling incoming
messages at the pace they came in so the receiving
buffer memory has been filled.
The machine has failed in receiving incoming
messages from the control box at the pace they came
in so the sending buffer memory of the control box has
been filled.
The machine has sent a message to the control box
which has not been acknowledged.
8.3
Errors in the course of welding
Comes up if the message ’arc extinguished’ is
spontaneously sent from the power source to the
control box during welding (between arc strike and
started down--slope phase) in case the welding has
been started from the control box.
Cf. cases which for practical reasons do not lead to
error state:
If welding is started via an external start signal, you
return to the OPE basic mode in case of arc extinction
(or remain in SET or MEM if one of these modes has
been selected after start).
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8.4
Errors in the course of sequential running
These errors come up during sequential running when recalling the next sector.
All sectors have been erased after start of the running
sector. (Incl. the case where the start sector is recalled
automatically after the last sector has run out.)
The end point of the new sector is outside the
permissible interval. (Applies to the POB tool.)
The new sector is non--sequential.
The tool indicated in the new sector is not the same as
was previously used in the sequence.
8.5
Blocking messages
Come up as temporary pictures (about 2 sec.) in case the key activated was not
accepted. After that return to the previous mode takes place.
WHEN STARTING MEMORY OPERATIONS: No memory operations are executed
in any of the following four situations.
All 100 memory positions in the library are empty.
(Comes up when trying to recall a sector from the
library).
All 100 memory positions in the library are occupied.
(Comes up when trying to store a sector in the
library).
All 100 memory positions in the library are empty.
(Comes up when trying to erase a sector in the library.)
An activity is going on. (Comes up when trying to recall
a sector from the library.)
WHEN STARTING A SEQUENCE:
No sequence start takes place in any of the following three situations
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All 100 memory positions in the library are empty.
Applies to the POB tool. +/-- 1.5 rotary turns has been
exceeded.
Different tools are used within the same sequence.
(Comes up when trying to restart a sequence and the
stop was caused by the error of Wrong tool.)
9
ACCESSORIES
Order number
Tube welding tool A21 PRB, water--cooled . . . . . . . . . . . . . . . . . . . . 17--49 . . . . . . . 0443 750 880
33--90 . . . . . . . 0443 760 880
60--170 . . . . . . 0443 770 880
Tube welding tool A21 PRB, air--cooled . . . . . . . . . . . . . . . . . . . . . . . 17--49 . . . . . . . 0443 750 881
33--90 . . . . . . . 0443 760 881
60--170 . . . . . . 0443 770 881
Tube welding tool A21 PRH, enclosed . . . . . . . . . . . . . . . . . . . . . . . . 6--40 . . . . . . . . . 0456 940 880
25--90 . . . . . . . 0456 941 880
Tube welding tool A22 POC, wire feed . . . . . . . . . . . . . . . . . . . . . . . 12--60 . . . . . . . 0443 930 880
TIG--hand torch HW 17R OKC 3,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0588 000 722
Wire feed unit MEI 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0443 830 880
Cooling unit OCF 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0457 216 882
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 804 880
Extension cable a, programming box (15 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0369 143 887
Extension cable b, wire (10 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 904 880
Extension cable c, rotation (10 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 906 880
Extension cable f, return cable (8 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 349 893
Extension set 1, current, water, gas (8 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 905 880
Extension set 2, current, water, gas, torch contact (8m) . . . . . . . . . . . . . . . . . . . . . . . . 0466 705 881
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10
ORDERING SPARE PARTS
LTO 160, LTO 250 is designed and tested in accordance with the EN 60
974--1 (IEC 974--1) international standard.
It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 161.
This will simplify dispatch and ensure you get the right part.
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