MECHTIG 160 MECHTIG 250

LTO 160, LTO 250

105107106023104022041

Instruction manual Betriebsanweisung

0456 779 141 991231

Manuel d’instructions Gebruiksaanwijzing

Valid for serial no. 837--xxx--xxxx

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 DEUTSCH FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 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.

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ENGLISH

1 DIREKTIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Mains voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Connection of a complete welding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Genral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Check--up and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 The mode of operation of the control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Actual tool codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Division into functional areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 The SEL key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 The SET key 7.6 The MEM key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 The OPE key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 Control of the process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 The POB, POC tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Storing sectors in the course of running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 Associations within a sequential sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 Setting the memory to aero / basic parameter values . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 Start/stop over external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 The length of a transport sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 The influence of sector changes on pulsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Memory errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Communictions errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Errors in the course of welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 Errors in the course of sequential running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Blocking messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 39 154 159 4 4 5

5 6

34

34 34 35 36 36

13

13 14 14 15 19 22 25 29 30 30 31 32 32 33 33

10

10 11 12

12

12 12

7

7 7 8 8 9 TOCe

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GB 1 DIREKTIV 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 com plies 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 Tel: + 46 584 81000 Fax: + 46 584 12336

2 SAFETY

Users of ESAB welding equipment have the 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 well familiar with the operation of the welding equip ment.

Incorrect operation of the equipment may lead to hazardous situations 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 S S S its operation its function relevant safety precautions 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.

4.

5.

The work place must: S be suitable for the purpose S be free from draughts 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.

General precautions S Make sure the return cable is connected securely.

S S S Work on high voltage equipment Lubrication and maintenance must

shall only be carried out by a qualified electrician.

Appropriate fire extinquishing equipment must be clearly marked and close at hand.

not

be carried out on the equipment during operation.

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WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU TIONS 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 S Insulate yourself from earth and the workpiece.

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

time--controlled.

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

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.

S S

LTO 160 / LTO 250 is composed of the following units: 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.

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 Mains voltage Mains frequency Permissible load at

35 % duty cycle 60 % duty cycle 100 % duty cycle

No--load power Power factor Efficiency Primary current at 100% duty cycle Dimensions L x W x H Weight Temperature class Enclosure type Application class Capacity of internal memory, number of parameter sets Battery back--up MECHTIG 160 Battery back--up Control box Arc strike for tube welding tools Arc strike for manual welding

230 V, 1  50--60 Hz 160 A / 16 V 110 A / 15 V 80 A / 13 V 55 W 0,68 0,70 10 A 515 x 285 x 505 mm 32 kg F (155  C) IP 23 100 2 years 2 years HF HF and LIFT ARC 400 V, 3  50--60 Hz

LTO 250

250 A / 20 V 180 A / 17 V 140 A / 16 V 50 W 0,61 0,80 15 A 515 x 285 x 505 mm 33 kg F (155  C) IP 23 100 2 years 2 years HF HF and LIFT ARC

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GB Setting range LTO 160 LTO 250 Pulse, background and cont.

current Steps of adjustment, current Wire feed speed Rotation speed Pulse and background time Pre--heat time Gas pre--flow Gas post--flow Slope--up and slope down Sector time Steps of adjustment, sector time

3--160 A 1 A 0,10--2,20 m/min (MEI 20/21) 0.15--1.50 m/min (POB, POC) 5--100 % of max. speed 0.02--5.0 s 0--99.8 s 1--250 s 3--250 s 0--25 s 0.01--33.59 min 0.1 s 3--250 A 1 A 0,10--2,20 m/min (MEI 20/21) 0.15--1.50 m/min (POB, POC) 5--100 % of max. speed 0.02--5.0 s 0--99.8 s 1--250 s 3--250 s 0--25 s 0.01--33.59 min 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.

Mains voltage Mains frequency Fuse, slow rupture Mains cable, cross section

230 V 50--60 Hz 16 A 3 x 2.5 mm 2

LTO 160

400 V 50--60 Hz 16 A 4 x 1.5 mm 2

LTO 250

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4.5

Connection of a complete welding system

B--B C--C G--G H--H J--J L--L M--M N--N Q--Q

Motor cable --wire feed Motor cable -- rotation Cooling--water hose in Cooling--water hose out Welding cable Torch contact Gas hose out Gas hose in Return cable + dpa6d1eb

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GB B--B C--C G--G H--H J--J L--L M--M N--N Q--Q

Motor cable --wire feed Motor cable -- rotation Cooling--water hose in Cooling--water hose out Welding cable Torch contact Gas hose out Gas hose in 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) 4. Control box 5. Connection for return cable (+) 6. Connection for welding cable (--), cross section 25 mm 2 7. Connection wire feed MEI 21, POC 8. Connection rotation PRB 17--49, 33--90, 60--170, PRH 6--40, 25--90, 40--115, POC 9. Connection wire feed MEI 20, POB, PRI 10. Connection rotation PRB 9--20, 18--40, 36--80, 71--160, 140--220, PRG, PRI, POB 11. Connection for cooling unit 230 V, 1.25 A 12. Connection for shielding gas 13. Connection for remote start -- TIG torch 14. Mains cable 15. Gas nipple, connection of gas bottle 16. Control box cable 17. Fuse, slow rupture 1.25 A (connection 230 V) 18. Connection for flow--guard, (water) dpa6d1eb

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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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GB 7 CONTROL BOX

7.1

The mode of operation of the control box

S S The process equipment is continuously updated via the control box.

A central unit in the control box is

the working storage

regarding methods and parameters are collected.

where all actual values 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, holds up to 100 parameter sets from the working storage.

the library

, which Each parameter set in the library forms a (The reason for naming it

sector

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: changing separate parameters recalling a sector (the whole working storage will be overwritten) S S The contents of the

library

can be influenced by: 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 automatically recalled. We have come to the starting--point of a new identical sequence.

start sector

which started the sequence is 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 the start sector.

welding program

can be identical with a sequence of sectors. A welding program is recalled by manually recalling the sector which is to constitute

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 A21 PRH A21 PRG A21 PRI A22 POB A22 POC

Size

9--20, 18--40, 36--80, 71--160, 140--220, 17--49, 33--90 60--170 6--40, 25--90 40--115 25--45 36--80, 71--160, 140--220 12--60 12--60

PRB Code PRB 60--170 PRH PRH 40--115 PRG PRI POB 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 SETTING

SEL SET

S S Select welding method in the working storage.

Enter weld and transport data into the working storage.

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MEMORY HANDLING OPERATION

MEM OPE

S S S S Store the contents of the working storage in an empty storage area.

Recall previously stored data to the working area.

Erase previously stored data in the working area.

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 SE QUENCE 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.) dpa6d1eb

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GB 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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GB 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 S S The actual parameter set is the result of the selections made under SEL with regard to: PULSED CURR./CONT.CURR./TRANSP. SECTOR SEQUENCE/NON SEQUENCE Possible sets of parameters are shown later in the text.

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GB 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.) dpa6d1eb

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GB 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 S free sector number for storing of sector (STO).

stored sector number for recalling of sector (RCL).

S 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.

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GB 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: dpa6d1eb

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GB 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

: dpa6d1eb

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GB

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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GB 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 parameter.) Regarding the to ’+’.

rotary direction

: Is based on the rotary direction parameter which is handled within SET.

(Two alternatives exist to read and modify this

wire feed direction:

When switching on the machine the wire feed direction is automatically set 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.) dpa6d1eb

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GB 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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GB 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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GB 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: S S S S The starting point of the motion area is defined (the accumulated distance is cleared) each time the machine is switched on when a sector is recalled manually (MEM mode) when a sequence has run out (i.e. a start sector has been recalled automatically) 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.

S 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.

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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GB 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 results in accelerated welding stop.

starting command

that

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GB 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 S S The control box rejects a command.

The sequence has run out.

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.

S 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).

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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GB

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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GB

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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GB

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:

in any of the following four situations.

No memory operations are executed 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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GB

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

Tube welding tool A21 PRB, water--cooled . . . . . . . . . . . . . . . . . . . .

Order number

17--49 33--90 60--170 . . . . . . .

. . . . . . .

. . . . . .

0443 750 880 0443 760 880 0443 770 880 Tube welding tool A21 PRB, air--cooled . . . . . . . . . . . . . . . . . . . . . . .

Tube welding tool A21 PRH, enclosed . . . . . . . . . . . . . . . . . . . . . . . .

17--49 33--90 60--170 . . . . . . .

. . . . . . .

. . . . . .

0443 750 881 0443 760 881 0443 770 881 6--40 25--90 . . . . . . . . .

40--115 . . . . . . .

. . . . . . .

0456 940 880 0456 941 880 0456 942 880 Tube welding tool A22 POC, wire feed . . . . . . . . . . . . . . . . . . . . . . .

12--60 . . . . . . .

0443 930 880 TIG--hand torch HW 17R OKC 3,8 m HW 20 OKC 3,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0588 000 722 0588 000 744 Wire feed unit MEI 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0443 830 880 Cooling unit OCF 2M Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0457 216 882 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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GB

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GB 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 re pair 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 desig nation and spare part number as shown in the spare parts list on page 159.

This will simplify dispatch and ensure you get the right part.

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