Aristotig 255

LTN 255

Instruction manual

0457 328 101

041101

Valid for serial no. 011--xxx--xxxx

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

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Rights reserved to alter specifications without notice.

.

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1
2
3
4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4
5
5
6

4.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
11
12

6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
25
26
27
28

TOCr

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1

!
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.
S
.
S
, .
S .
S .

S .
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ESAB
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2

LTN 255 - , ,
(TIG),
(MMA).
, .
, ,
, ,
.
LTN 255 -
ARC PLUS,
.
.
, Arc Force,
, ..
.
ARC PLUS,
.
LTN 255 : c
TIG.
LTN 255 : 5 , 5
, .
, .

,
.
2
. .
28.

35 % , TIG
35 % , MMA
60 %
100 %

250 A/20 V
250 A/30 V
180 A/27 V
140 A/26 V

, TIG
MMA

3-250 A
4-250 A

0-10
0-10

0-25
0-25

0,02-5,0 (0,001-5,0 )
0,02-5,0 (0,001-5,0 )

70-80 V

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RU

, P
. MMA
, S
. MMA

40 W

. MMA
.., . MMA

, lxwxh

0,65
0,85
16 A
4x1,5 2
515x285x415
25 kg

IP 23

8,78 kW
13,3 kVa

IEC 974-1
- .

( %%) ,
.

,

.

IP , ..,
. IP 23
.

.
.
.

400 V 10 % , 3-.

50-60 Hz

16 A

4x1.5 2

35 2

LTN 255 - , ..
10 %
0,2 %

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.
1.
2.
3.
4.

,
.
,
. .
.
TIG, .

4.1

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RU
5

. 4. !
4

3 2

10

11 12

1.

9.

2.

10. TIG

3.

12.

4.
5.
6.

11 12

7.

8.

.
,
.

E13 .
.

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5.1

,

. : , ,
.
.

.

.
- .
.
.
(//).
---.
:
S
S
S
S

1
2
3
4

S
S
1

6
bt07d002
7
(TIG)
()
MMA, ,
2-5 .
IG -
.

bt07t001

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RU

bt07t002

O O - O

2- 4-
2- - ,
..
2- -

,

.

bt07d003

1.
2.
3.
4.
5.
6.
7.
8.

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-- 10 --

0-25
0-10
3-250 A
0,02-5,0 (0.001-5.0 )
3-250 A
0.02-5.0 (0.001-5.0 )
0-10s
0-25

RU
6

7.

/

.
-
.
O O 1 O 2 O1-2 O
A

- 2 IG 2
.
:
IG: 3 ( )
5.
MMA:
, ,

.
M

, ,
.
.
O 1-2 4- ,

. 2- ,
.
..
,
.

5.2

(MMA)

.
,
.
.

2

-_- .
.
--- .
Arc Force (MMA)

.

2 . 0 100
.

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.
2 Arc Force .
/ (TIG)
0,02-5,0 .
2
0,001 . ,
. ,
0,250
.
()

TIG MMA .
.

.
A
. O
(! j L M
)
!
FS002
.

5.3

LTN 255 ,
.
:
E01
E02
E03
E04
E05
E06
E10
E11
E13
E14

, RAM
, RAM
, EPROM
, RAM
, RAM

20 V
-15 V
, .

,
, , -
.
.

ESAB.

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6

.
:
,
-
.
, ,
, ,

.
Aristotig 255 .

.
.

bt07d109

ESAB .
,
ESAB.
ESAB, (.
).

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ENGLISH

1
2
3
4
5

DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
15
16
17
18

5.1 Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20
22
23

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24
24
25
26
27
28

TOCe

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GB
1

DIRECTIVE

DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee
that welding power source LTN 255 from serial number 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).
-------------------------------------------------------------------------------------------------------------------------------------Lax 97--10--30

Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAX
SWEDEN

Tel: + 46 584 81000

Fax: + 46 584 12336

SAFETY

WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS 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 take fumes and gases away 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 earmuffs 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!

ESAB can provide you with all necessary welding protection and accessories.

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GB

WARNING!
Read and understand the instruction manual before installing
or operating.

WARNING!
Do not use the power source for thawing frozen pipes.

This product is solely intended for arc welding.

INTRODUCTION

LTN 255 are rectifiers designed using inverter technology and are intended for TIG -welding and welding using coated electrodes.
Inverter technology contributes towards low power consumption, a low weight and
compact dimensions.
The advanced electronics with microprocessor control provides, amongst others,
quick regulation and top class welding characteristics.
LTN 255 is equipped with ARC PLUS, a new type of control that with MMA welding
provides a more intensive, more concentrated and smoother arc. It reacts quicker
after a short circuiting drop transfer, which reduces the risk of the electrode sticking.
In addition, the machine is equipped with Arc Force, which means that the power
sources dynamics can be adjusted, softer or harder depending on the type of electrode and the welders preference.
ARC PLUS -- because of the regulators good characteristics it is only necessary to
change the Arc Force settings in exceptional circumstances.
When drop welding using stainless steel electrodes a special feature on the machine
can be activated to facilitate welding.
LTN 255 is available in two designs, one with a central connector and one with an
OKC connector for a TIG torch.
LTN 255 is supplied complete with a 5 metre mains cable, 5 metre return cable, gas
hose and hose clips. Machines with a central connector are also fitted with a safety
bar to protect the connectors from impact.
As an accessory there is a loop handle to fit on the machines which acts as a cable
reel as well protecting the control panel. There are also two carriages available for
transportation with a gas cylinder and cooling unit.
ESABs accessories for the product can be found on page 28.

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4

TECHNICAL DATA

Permitted load at
35 % duty cycle, TIG
35 % duty cycle, MMA
60 % duty cycle
100 % duty cycle

250 A/20 V
250 A/30 V
180 A/27 V
140 A/26 V

Setting range, TIG

Setting range, MMA

3--250 A
4--250 A

Slope up
Slope down

0--10 s
0--10 s

Gas pre--flow
Gas post--flow

0--25 s
0--25 s

Pulse time

0,02--5,0 s
(0,001--5,0 s)
0,02--5,0 s
(0,001--5,0 s)

Pause time
Open--circuit voltage
Open--circuit power
Useful Power, P
at max current MMA
Apparent Power, S
at max current MMA

70--80 V
40 W

Power factor, at max current MMA

Efficiency, at max current MMA
Fuse, slow rupture
Mains cable,cross section
Dimensions lxwxh
Weight

0,65
0,85
16 A
4x1,5 mm2
515x285x415 mm
25 kg

Application class
Class of enclosures

IP 23

8,78 kW
13,3 kVa

The welding power sources comply with the requirements set out in IEC 974--1
Cable areas acc. to Swedish regulations.
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a certain load without overloading.
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 IP23 is designed for indoor and outdoor use.

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5

INSTALLATION

The installation must be executed by a professional.

WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the users responsibility to take adequate precautions.
Mains voltage

400 V 10 % , 3--phase

Mains frequency

50--60 Hz

Fuse, slow rupture

Mains cable, cross section

16 A
4x1.5 mm2

Welding cable, cross section

35 mm2

LTN 255 are equipped with mains voltage compensation, which means that a 10 %
variation in the mains voltage only results in a 0,2 % variation in the welding current.
To reduce the voltage drop when using a long cable it can be advisable to select a
heavier cable cross section.
1.
2.
3.
4.

Place the equipment in a suitable place and make sure the rectifier is not covered or set-up so
that cooling is prevented.
Make sure the machine is connected to the correct mains voltage.
Earth according to applicable directives.
Connect the shielding gas.
Connect the TIG torch and the return cable or the MMA welding cables.

The machine is now ready for welding.

5.1

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Lifting instructions

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6

OPERATION

General safety regulations for the handling of the equipment can be found on
page 15. Read through before you start using the equipment!
4

3 2

10

11 12

1. Mains power switch

9. Gas nipple (connection of gas cylinder)

2. Yellow indicating lamp

10. Connection for TIG torch

3. White indicating lamp

12. Connection for return cable when TIG welding

4. Display
5. Setting knob
6. Push--buttons

The welding cable and return cable should be cont d to

t 11 and
d 12
nected

7. Remote control connection

8. Dust filter

When the main power switch is switched on the white indicating lamp, on the front,
comes on.
To take your mind off the risk of overloading the machine it 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. In addition, the error code E13 is displayed. When the temperature has
dropped the thermostat automatically resets.

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6.1

Control panel

On the front of the machine there is a control panel for the selection of functions and
setting of parameters. This consists of a display, setting knob, LEDs and push--buttons.
By using the push--buttons you can move between the different functions. The selected function is indicated by respective LEDs coming on.
One line at a time is set. The current line is indicated by a red LED. Movement between lines takes place using the red arrow keys.
Movement within each line takes place using the green arrow keys.
All settings are made using the setting knob. The LEDs to the right of the display
indicate the actual unit (ampere/volt/seconds). On the lines where only a function is
selected, ------ is shown on the display.
Description of the functions:
S
S
S
S

Line 1
Line 2
Line 3
Line 4

Line 5

S
S

Line 6
Line 7
bt07d002

Line 1

TIG welding or MMA welding

If MMA welding is chosen, the current is set here and lines 2--5 are
ignored.

Line 2

TIG/HF ignition or TIG/Liftarc ignition

bt07t001

Place the electrode against the

workpiece.

bt19d12e

Press in the torch switch.

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GB

Tilt the torch a little, lift and an arc is

produced.

To stop--release
the torch trigger.

bt07t002

Line 3

Continuous current or pulsed current O O -- O

Line 4

2 step or 4 step trigger action

2 step trigger action means that the arc is ignited when the torch
trigger is pressed in and is extinguished when the trigger is released.
4 step trigger action means that when the torch trigger is pressed in
1 the machine starts with the pilot current and then slopes up to the
set current when the trigger is released 2. When the trigger is
pressed in again 3 the machine slopes down to the pilot current. The
arc is extinguished when the trigger is released 4.

bt07d003

Line 5

Parameter setting
1. Gas pre flow
2. Slope up
3. Pulse current or continuous current
4. Pulse time
5. Pause current
6. Pause time
7. Slope down
8. Gas post flow

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0--25 s
0--10 s
3--250 A
0,02--5,0 s (0.001--5.0 s)
3--250 A
0.02--5.0 s (0.001--5.0 s)
0--10 s
0--25 s

GB
Line 6

Measurement instrument
Shows the welding current or arc voltage during the present welding
run.
The measurement instrument has a hold function that locks the
measurement value when the welding run is stopped.

Line 7

Welding data memory O O 1 O 2 O1--2 O

A
Four different sets of welding data settings can be stored in the machines memory, two for TIG mode and two for MMA mode.
The following can be stored:
TIG: selected option from line 3 (continuous or pulsed current) All settings on line 5.
MMA: Welding current
The welding data memory is changed using the green arrow
keys.
Changes can also be made by quickly pressing the torch trigger, regardless of whether you are welding or not.
To activate the possibility of jumping between programs both the
green arrow
keys should be pressed simultaneously.
When the jump function is activated an indicating lamp comes on.
O 1--2 If the 4 step trigger action is selected, quickly pressing the
trigger will switch the welding data. The same thing applies in 2 step
trigger action if you are not welding. During welding, using 2 step
trigger action, you release the trigger momentarily to change the
welding data.
Aristotig has battery backup so that the settings remain in memory
even when the machine is switched of or disconnected from the
power supply.

6.2

Other functions

Drop welding (MMA)

Drop welding can be used when welding with stainless steel electrodes.
The technique involves the arc switching between igniting and extinguishing to allow
better control over the heat transfer. The electrode only needs to be lifted a little for
the arc to be extinguished.
The machine should be in the current setting mode when the function is activated.
Press both of the green arrow
keys simultaneously for 2 seconds and the
symbol --_-- indicates that the function is activated.
This mode remains active even if the machine is switched off. The machine is reset
for normal welding again using the same method and ------ is then indicated on the
display.
Arc Force (MMA)
The Arc Force setting changes the machines dynamic. A softer or harder arc can be
obtained. The machine should be in the current setting mode when activating the
function by pressing the two red arrow keys
simultaneously for 2 seconds. The
display shows a value between 0 and 100. The higher the value the harder the arc.

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GB
Press one of the buttons and the power source returns to the normal operating
mode. The set Arc Force value remains. Different Arc Force settings can be stored in
the machines two sets of welding data memory.
Pulse time/Pause time (TIG)
Normally the setting range for these parameters is 0.02--5.0 s. Through pressing the
two green arrows simultaneously for 2 seconds, times down to 0.001 s can be set.
This extended setting range remains until the machine is reset using the same
method. When activating the function the machine should be in the mode for setting
the pulse time/pause time. Note that times below 0.250 s are displayed without the
decimal point.
Remote control
Using the remote control socket on the machine the current can be remotely regulated in TIG and MMA modes.
If pulsed current is selected in TIG mode, it is the pulsed current that is remotely
regulated. The set value from the remote control is shown on the display by stepping
to the position where the current should be set when not using the remote control.
Switching to the remote mode takes place automatically when the unit is connected.
A
This is confirmed by the LED coming on. O
(NOTE! the pins L and M in the remote controls connecting plug must be strapped
for automatic connection to take place).
NOTE!
When using FS002 the slope--up and slope--down times should be set to 0 sec.

6.3

Fault tracing

Error Codes
LTN 255 is equipped with integrated error monitoring. If an error should occur then
an error code is displayed. The error codes are as follows:
E01
E02
E03
E04
E05
E06
E10
E11
E13
E14

Memory error, internal RAM

Memory error, external RAM
Memory error, EPROM
Memory error, random test of battery backed up RAM
Memory error, variable value outside limit in battery backed up RAM
Low battery voltage
Incorrect supply voltage 20 V
Incorrect supply voltage --15 V
High temperature, thermal switch protection
Current--servo error
The error indications are shown if the machine is not able to maintain the set
current, for example, while MMA welding with an extremely long arc. The
indication should disappear after welding for a few seconds under normal
conditions.

If any of these error codes are displayed permanently or recur frequently the machine should be taken to an authorized ESAB service workshop to be rectified.

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7

MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
Generally, Aristotig 255 do not require any maintenance. Normally, it is sufficient to
blow out the machine using clean, compressed air annually, and the dust filter should
be cleaned regularly.
If the machine is set up in dusty or dirty environments the machine and dust filter
should be cleaned more often.

Dismantling the filter.

bt07d109

ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.
LTN 255 is designed and tested in accordance with the international and European
standards IEC/EN 60974--1 and EN 50199. 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 may be ordered through your nearest ESAB dealer, see the last page of
this publication.

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Diagram

bt19e11a

-- 25 --

Edition 041101

LTN 255
Ordering number

Ordering no.

Denomination

Type

Notes

0468 300 894 Welding power source

LTN 255

400V 50/60Hz,
with central connector for TIG welding

0468 300 895 Welding power source

LTN 255

400V 50/60Hz,
with OKC connector for TIG welding

0457 328 990 Spare parts list

LTN 255

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Edition 041101

LTN 255
Spare parts list

Item

Qty

Ordering no.

0441 819 001

Screw

0468 275 001

Grill

0468 519 001

Filter

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Denomination

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Edition 041101

LTN 255
Accessories

Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0468 530 880

for 5 l gas cylinder

Trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 804 880

for 10--50 l gas cylinder

Protective handle for connections . . 0458 311 001

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Edition 041101

LTN 255
Top handle . . . . . . . . . . . . . . . . . . . . . . . 0468 305 880

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For LTN 200 & LTN 255

Cooling unit OCF 2L . . . . . . . . . . . . . . 0457 216 880
For LTN 160
Cooling unit OCF 2A . . . . . . . . . . . . . . 0457 216 883

Remote control MMA 1 (10 m cable) . 0349 501 024

MMA and TIG: current

Remote control unit AT1 . . . . . . . . . . . 0459 491 896

MMA and TIG: current

Remote control unit AT1 CF . . . . . . . 0459 491 897

MMA and TIG: rough and fine setting
of current.

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Edition 041101

LTN 255
Remote cable 12 pole -- 8 pole
5m ...............................
10 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0459 552 880

0459 552 881
0459 552 882
0459 552 883

Foot control FS002,

including cable . . . . . . . . . . . . . . . . . . . 0349 090 886
MMA and TIG: current

LTN 255: Return cable, 35 mm2 (state the length when ordering) . . . . . . . . . . . . . . . 0262 613 602
LTN 160 & LTN 200: Return cable, 25 mm2 (state the length when ordering) . . . . . 0262 613 601
Return current clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0367 558 880
Welding current cable and return current cable, complete for MMA welding:
LTN 255

LTN 160 & 200

Welding current cable, 5 metre

0468 539 882

0468 539 880

Return current cable, 5 metre

0468 539 883

0468 539 881

Information on TIG torches and remote control units can be found in separate brochures.

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Edition 041101

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