Lincoln Electric ASPECT 200 Manuel utilisateur

IM3122

04/2020

REV01

ASPECT®200

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

English English

12/05

THANKS! For having chosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For future reference record in the table below your equipment identification information. Model Name, Code & Serial

Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Technical Specifications...............................................................................................................................................................1

Electromagnetic Compatibility (EMC) ..........................................................................................................................................2

Safety............................................................................................................................................................................................3

Introduction...................................................................................................................................................................................5

Installation and Operator Instructions ..........................................................................................................................................5

WEEE .........................................................................................................................................................................................24

Spare Parts.................................................................................................................................................................................24

REACh........................................................................................................................................................................................24

Authorized Service Shops Location...........................................................................................................................................24

Electrical Schematic ...................................................................................................................................................................24

Suggested Accessories..............................................................................................................................................................25

English 1 English

Technical Specifications

NAME INDEX

Aspect®200 K14189-2

INPUT

Input Voltage U1EMC Class Frequency

115 - 240Vac ± 15% A 50/60 Hz

Input Line Mode 20% 35% 60% 100% Input Amperes I1max PFmax

115Vac

STICK 3.2 kW 1.9 kW 1.4 kW

30 A 0.93

TIG DC 2.4 kW 1.8 kW 1.4 kW

STICK AC 3.2 kW 2.0 kW 1.5 kW

TIG AC 2.6 kW 2 kW 1.6 kW

Input Line Mode 30% 35% 60% 100%

240Vac

STICK 5.5 kW 3.7 kW 2.9 kW

27,2 A 0.88

TIG DC 4.8 kW 3.7 kW 2,8 kW

STICK AC 5.5 kW 3.9 kW 3.0 kW

TIG AC 5.0 kW 4.0 kW 3,2 kW

RATED OUTPUT

Output Current I2 Duty Cycle at % Output Voltage U2 Duty Cycle at %

Input Line Mode 20% 35% 60% 100% 20% 35% 60% 100%

115Vac 1ph

STICK DC 100A 60A 45A 24V 22.4V 21.8V

TIG DC 115A 90A 70A 14.6V 13.6V 12.8V

STICK AC 100A 60A 45A 24V 22.4V 21.8V

TIG AC 115A 90A 70A 14.6V 13.6V 12.8V

Input Line Mode 30% 35% 60% 100% 30% 35% 60% 100%

240Vac 1ph

STICK DC 160A 115A 95A 26.4V 24.6V 23.8V

TIG DC 200A 165A 130A 18V 16.6V 15.2V

STICK AC 160A 115A 95A 26.4V 24.6V 23.8V

TIG AC 200A 165A 130A 18V 16.6V 15.2V

OUTPUT RANGE

Welding Current Range Maximum Open Circuit Voltage OCV U0

2 – 200A 109 Vdc

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse (time delayed) or Circuit Breaker Size Input Power Cable

15A@115Vac – 15A@ 240Vac 3x2.5mm2

DIMENSIONS AND WEIGHT

Height Width Length Net Weight

419 mm 246 mm 506 mm 23 kg

Operating Temperature Storage

Temperature

Operating Humidity

(t=20°C) Protection Degree

-10°C to +40°C -25°C to 55°C Not Applicable IP23

English 2 English

Electromagnetic Compatibility (EMC)

01/11

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this

section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

This machine has been designed to operate in an industrial area. The operator must install and operate this

equipment as described in this manual. If any electromagnetic disturbances are detected the operator must put

in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln Electric.

The Class A equipment is not intended for use in residential locations where the electrical power is provided by

the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those

locations, due to conducted as well as radiated disturbances. Provided that the public low voltage system impedance at the

point of common coupling is lower than 83 mΩ(or the short circuit power is higher than 0,6 MVA), this equipment is

compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be connected to public low voltage systems. It is the

responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if

necessary, that the system impedance complies with the impedance restrictions.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure that

all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the work

piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work

piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public

low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,

due to conducted as well as radio-frequency disturbances.

English 3 English

Safety

01/11

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment.

Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages

caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss

of life, or damage to this equipment. Protect yourself and others from possible serious injury or death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this

equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause

serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode,

work clamp, or connected work pieces when this equipment is on. Insulate yourself from the electrode,

work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse

box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder

directly on the welding table or any other surface in contact with the work clamp to avoid the risk of

accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers,

and welders having a pacemaker shall consult their physician before operating this equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and

EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal

Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as required by

EN169 Standard.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough

ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from

sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with

suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area

and have a fire extinguisher readily available. Welding sparks and hot materials from the welding process

can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums,

containers, or material until the proper steps have been taken to insure that no flammable or toxic vapors

will be present. Never operate this equipment when flammable gases, vapors or liquid combustibles are

present.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

English 4 English

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct

shielding gas for the process used and properly operating regulators designed for the gas and pressure

used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or

transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,

work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located away

from areas where they may be subjected to physical damage or the welding process including sparks and

heat sources.

HF CAUTION: The high frequency used for contact-free ignition with TIG (GTAW) welding, can interfere with

the operation of insufficiently shielded computer equipment, EDP centers and industrial robots, even

causing complete system breakdown. TIG (GTAW) welding may interfere with electronic telephone

networks and with radio and TV reception.

NOISE APPEARES DURING WELDING CAN BE HARMFUL: Welding arc can cause noise with high

level of 85dB for 8-hour week day. Welders operating welding machines are obligated to wear the proper

ear protectors. Employers are obligated to carry examinations and measurements of health harmful

factors.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an

environment with increased hazard of electric shock.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the

operator’s manual.

English 5 English

Introduction

General Description

ASPECT®200 machine is designated to performe MMA

(SMAW) and TIG (GTAW) welding process in DC and AC

current.

Unit is designed mainly to satisfy TIG requestes in both

DC and AC mode: thanks an advance menu options both

beginners and experts welder can adjust welding

parameters to have the best welding performances.

Following paragraphs will show how to access to the

menu and the parameters tha can be set.

The following equipment has been added to

ASPECT®200:

0656-790-105 HOSE CLAMP

R-8040-356-1 GAS HOSE

W8800030 MOUNT HOSE

W8800031 NUT HALF BLIND 1/4F

W8800072 MALE QUICK COUPLING HOSE

Recommended equipment, which can be bought by user,

was mentioned in the " Suggested Accessories " section.

Installation and Operator Instructions

Read this entire section before installation or operation of

the machine.

Location and Environment

This machine will operate in harsh environments.

However, it is important that simple preventative

measures are followed to assure long life and reliable

operation.

Do not place or operate this machine on a surface with

an incline greater than 15° from horizontal.

Do not use this machine for pipe thawing.

This machine must be located where there is free

circulation of clean air without restrictions for air

movement to and from the air vents. Do not cover the

machine with paper, cloth or rags when switched on.

Dirt and dust that can be drawn into the machine

should be kept to a minimum.

This machine has a protection rating of IP23. Keep it

dry when possible and do not place it on wet ground

or in puddles.

Locate the machine away from radio controlled

machinery. Normal operation may adversely affect

the operation of nearby radio controlled machinery,

which may result in injury or equipment damage.

Read the section on electromagnetic compatibility in

this manual.

Do not operate in areas with an ambient temperature

greater than 40°C.

Input Supply Connection

Check the input voltage, phase, and frequency supplied to

this machine before turning it on. The allowable input

voltage is indicated in the technical specification section of

this manual and on the rating plate of the machine. Be

sure that the machine is grounded.

Make sure the amount of power available from the input

connection is adequate for normal operation of the

machine. The fuse rating and cable sizes are both

indicated in the "Technical Specification" section of this

manual.

The machines are designed to operate on engine driven

generators as long as the auxiliary can supply adequate

voltage, frequency and power as indicated in the

"Technical Specification" section of this manual. The

auxiliary supply of the generator must also meet the

following conditions:

240Vac 1 phases:

Vac peak voltage: below 280V

Vac frequency: in the range of 50 and 60Hz

RMS voltage of the AC waveform: 234Vac ± 15%

115Vac 1 phases:

Vac frequency: in the range of 50 and 60Hz

RMS voltage of the AC waveform: 115Vac ± 15%

Note: if connected @ 115Vac the equipment has output

derating

It is important to check these conditions because many

engine driven generators produce high voltage spikes.

Operation of this machine on engine driven generators not

conforming to these conditions is not recommended and

may damage the machine.

Caution: To provide fully performance of duty cycle You

need to change overcurrent protection for 25A type D and

change for a proper input plug (or connect directly to a

power network)

Example:

Output Connections

A quick disconnect system using Twist-Matecable

plugs is used for the welding cable connections. Refer to

the following sections for more information on connecting

the machine for operation of M welding (MMA) or TIG

welding (GTAW).

Table 1.

Quick Disconnect: Torch (for MMA and

GTAW process) output connector for the

welding circuit.

Quick Disconnect: workpiece output

connector for the welding circuit.

English 6 English

Stick Welding (MMA)

This machine does not include a MMA welding kit cables,

but may be purchased separately. Refer to the

accessories section for more information.

First determine the proper electrode polarity for the

electrode to be used. Consult the electrode data for this

information. Then connect the output cables to the output

terminals of the machine for the selected polarity. Shown

here is the connection method for torch.

Connect the electrode cable to the torch terminal and the

work clamp to the work piece terminal. Insert the

connector with the key lining up with the keyway and

rotate approximately ¼ turn clockwise. Do not over

tighten.

Polarity for Stick can be selected between (DC+, DC-, AC)

by front panel push button and menu, see following.

TIG Welding (GTAW)

This machine does not include a TIG torch necessary for

TIG welding, but one may be purchased separately.

Refer to the accessories section for more information.

Connect the torch cable to

the torch terminal of the

machine and the work

clamp to the work piece

terminal. Insert the

connector with the key

lining up with the keyway

and rotate approximately ¼ turn clockwise. Do not over

tighten. Finally, connect the gas hose from the TIG torch

to the gas connector (B) on the front of the machine. If

necessary, an extra gas connector for the fitting on the

front of the machine is included in the package. Next,

connect the fitting on the back of the machine to a gas

regulator on the cylinder of gas to be used. The required

fittings are included in the package. Connect the TIG

torch trigger to the trigger connector (A) on the front of the

machine.

TIG Welding with a Water Cooled Torch

A cooling unit can be applied to the Machine:

COOLARC-24

If a Coolarc unit listed above is connected to the Machine,

it will be automatically turned ON and OFF in order to

ensure the torch cooling. When Stick welding mode is

used the cooler will be OFF.

This machine does not include a cooled TIG torch, but

one may be purchased separately. Refer to the

accessories section for more information.

WARNING

The Machine is provided with an electrical connection for

the Coolarc unit on its rear side. This socket is ONLY for

the connection of the Coolarc unit listed above.

WARNING

Before connecting the cooler unit to the Machine and

operate, read and understand the Instruction Manual

supplied with the cooling unit.

WARNING

Connect and disconnect the cooler with the unit switched

OFF.

Remote Control Connection

Refer to the accessories section for a list of

remote controls. If a remote control is used, it

will be connected to the remote connector on

the front of the machine. The machine will

automatically detect the remote control, turn

on the REMOTE LED, and switch to remote control mode.

More information on this mode of operation will be given in

the next section.

Rear Panel

A. Power Switch: It turns ON

/ OFF the input power to

the machine.

B. Input cable: Connect it to

the mains.

C. Fan: Do not obstruct or

filter the fan inlet. The

“F.A.N.” (Fan As Needed)

feature automatically turns

OFF/ON the fan. The fan

will start with welding

operations and will

continue to run whenever

the Machine is welding. If

the Machine doesn’t weld for more than 10minutes, it

will go in Green Mode.

Green

Mode

The Green Mode is a feature that puts the machine in

a stand-by condition:

The output is disabled

The fans are speed down

All LEDs on the front panel are switched OFF

except the Power ON LED (solid ON) and the

VRD LED (solid ON) if the VRD is enabled

Display show the dash char

This reduces the amount of dirt that can be drawn

inside the Machine and the power consumption.

English 7 English

To restore the Machine restart to weld or push the

TIG trigger or push any buttons in the front panel or

turn the encoder knob.

NOTE: If a COOLARC TIG torch cooling unit is

connected to the machine, it will be turned ON/OFF

by the Green Mode feature based also to COOL

option. See Menu SYS section for more details.

NOTE: It is possible to allows the user to enable or

disable the green mode. See Menu SYS section for

more details.

Idle

Mode

After 30 minutes without welding the machine will

enter a deep low power mode. It will shut down all

indicators: only Power ON Led is blinking.

To restore the Machine restart to weld or push the

trigger or push any buttons in the front panel or turn

the encoder

Exit procedure will take 6-7s: after this time the unit is

ready to weld.

D. Gas Inlet: Connector for the TIG shielding gas. Use

the supplied connector to connect the machine to the

gas source line. The gas source must have a

pressure regulator and flow gage installed.

E. Power supply socket for Coolarc: 400VDC socket.

Connect here the Coolarc cooling unit.

Controls and Operational Features

Machine Start-Up:

When the machine is turned ON an auto-test is executed.

The Machine is ready to operate when on the Front

Control Panel lights up the “Power ON” LED, the “A” LED

(placed on the middle of the synoptic) with one of the LED

of the Welding “MODE” command. This is the minimum

condition: depending by the welding selection others

LEDs may be ON.

Front Panel Indicators and Controls

Power ON LED:

This LED blinks during the machine start-up or during

restart after idle mode and lights up steadily when the

machine is ready to operate.

If the Input Voltage Overrange protection becomes active,

the Power ON LED starts blinking and an error code is

shown on the displays. The machine restarts

automatically when the Input Voltage returns in the correct

range. For further detail read the Error Codes and

Troubleshooting section.

If the trigger is pushed before the unit is ready to weld, or

after a weld is completed in GTAW mode, the Power ON

LED will blink at a fast rate. Release the trigger to restore

normal operation.

Remote LED:

This indicator will turn on when a Remote command is

connected to the machine via the remote control

connector.

If a Remote command is connected to the Machine, the

Output Current knob operates in two different modes:

STICK and TIG:

STICK mode: with a Remote command connected

the output of the machine is ON. A Remote

Amptrol or Pedal are allowed (trigger is ignored).

Connecting the Remote command excludes the

Output Current Knob of the Machine’s user interface.

Through the Remote command is available the full

Output Current Range.

TIG mode: in Local and remote mode the output

of the machine is OFF. A Trigger is necessary to

enable the output.

The Output Current range selectable from the Remote

command depends by the Machine’s user interface

Output Current Knob. Eg.: if the Output Current is set

to 100A with the Machine’s user interface Output

Current Knob, the Remote command will adjust the

Output Current from the minimum allowable current to

a maximum of 100A.

The output current set by Output Current Knob is

shown for 3 second whenever the knob is moved.

After the 3 second the value shows is the current

select by the Remote command.

Remote Pedal: For a correct use, the “Menu GTAW”

and “Menu SYS” must be enabled in the setup menu:

2-step sequence is automatically selected

Upslope / Downslope ramps and Restart are

disabled.

Spot, Bi-Level and 4-step functions aren’t

selectable

(Normal operation is restored when the Remote

command is disconnected.)

English 8 English

Thermal LED:

This indicator will turn on when the machine is overheated

and the output has been disabled. This normally occurs

when the duty cycle of the machine has been exceeded.

Leave the machine on to allow the internal components to

cool. When the indicator turns off, normal operation is

again possible.

VRD LED (enabled on Australian Machines only):

This machine is provided by VRD (Voltage Reduction

Device) function: this reduces the voltage at the output

leads.

The VRD function is enabled by factory default only

on machines that meet the AS 1674.2 Australian

Standards. (C-Tick logo " " on/near the Rating Plate

applied on the machine).

The VRD LED is ON when the Output Voltage is below

12V with the Machine at idle (no welding time).

For others machines (CE & USA) this function is abled

into Menu SYS.

Polarity:

This icon is designated to set the polarity of the process in

use: DC+, AC stick, DC- & AC TIG operations.

NOTE: Pressing the button assigned to process

POLARITY will toggle the illumination of the icon between

DC & AC polarity.

Process:

The function of this icon is to allow the user to set the

determined process.

1. High-Frequency TIG

2. Lift-Start TIG

3. Stick – Soft Mode (7018 style electrodes)

4. Stick- Crisp Mode (6010 Style electrodes)

NOTE: Arc control parameters, Hot start and arc force

parameters, are different in two stick modes. In menu

SMAW is possible to change hot start and arc force

diagram.

NOTE: Pressing the button assigned to PROCESS

selection will toggle the illumination of the icon from left-to-

right following the progression of the numbers.

Output:

This section is designated to allow the operator to set the

desired output control method

1. 2 STEP

2. 4 STEP

3. ON: no trigger required to start.

Pressing the button assigned to OUTPUT selection will

toggle the illumination of the icon from left-to-right

AC Wave Shape:

These icons allow the operator to customize the arc-

performance for TIG welding in AC polarity only.

AUTO and Expert Mode:

By default the AUTO icon is lit. This means that AC

waveshape parameters are automatically managed

depending on the welding current. The only available

parameter is AC-Frequency.

AC-Frequency: This function controls the frequency of

the AC Wave shape in cycles per second

When AUTO is selected the relationship between

Amperage and Balance is shown in table below:

Table 2.

Amperage AC Balance %

I <= 50 60%

50 < I <= 93 65%

93 < I <= 120 65%

120 < I <= 155 70%

155 < I <= 200 70%

To enable Expert mode:

Push the AC WAVESHAPE button twice: The AUTO

icon will start to blink and the display will show the

message AUTO ON.

Turn the encoder to select AUTO OFF

Confirm the selection by pushing the AC

WAVESHAPE button again. The AUTO icon will turn

OFF and all the AC WAVESHAPE parameters will

become available.

To revert to AUTO mode perform again the steps above

pushing several times until AUTO icon will start blinking,

then select AUTO ON with the encoder.

Table des matières

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