Air Liquide T 150i AC/DC User manual

08/01
OWNER’S MANUAL
KEEP THIS MANUAL
The technical specifications and the wiring diagrams contained in this owner’s manual are valid only
for the model that has the part number indicated below.
T 150i AC/DC
T 150i AC/DC:ALW-M170500182
Air Liquide Welding is a trademark of L’Air Liquide S.A.

TABLE OF CONTENTS
1 SAFETY PRECAUTIONS - READ BEFORE USING
1.1 INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 PERSONAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 METAL FUME HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 TRANSPORTING THE POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.6 MAGNETIC FIELDS CAN AFFECT PACEMAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7 H.F. RADIATION CAN CAUSE INJURY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.8 ARC WELDING CAN CAUSE INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.9 WELDING AND THE EFFECTS OF LOW FREQUENCY AND MAGNETIC FIELDS . . . . . . . . . . . . .5
1.10 PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 SPECIFICATION AND DESCRIPTION
2.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 DUTY CYCLE AND OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.4 VOLT-AMPERE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3 OPERATION
3.1 FRONT PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 BACK PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4 INSTALLATION
4.1 CONNECTING THE EQUIPMENT TO THE MAIN SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.2 SELECTING A LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3 CONNECTION AND PREPARATION OF EQUIPMENT FOR STICK-ELECTRODE WELDING . . . .11
4.4 CONNECTION AND PREPARATION OF EQUIPMENT FOR GTAW (TIG) . . . . . . . . . . . . . . . . . .12
5 MAINTENANCE AND TROUBLESHOOTING
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6 T 150i AC/DC ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7 T 150i AC/DC SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

The use of welding equipment can cause
injury to the operator. The reading and understanding
of the safety standards mentioned below is compulso-
ry prior to connecting, preparing, using or transporting
welding equipment.
1.1 INSTALLATION OF EQUIPMENT
1. Installation and maintenance of equipment
must be performed in compliance with local
safety standards.
2. Frequently inspect the welder plug,
receptacle and wiring. If damaged, replace
immediately with approved electrical connec-
tions and adequately sized wiring.
3. Connect the welding ground as near as possi-
ble to the operating area.
4. Do not pass welding equipment cables
through or near lifting chains, crane cables or
any electrical lines.
5. If earth grounding of the workpiece is
required, ground it directly with a separate
cable.
6. Do not touch the electrode if you are in con-
tact with the work, ground or another elec-
trode from a different welding machine.
7. Use only well-maintained equipment. Repair
or replace damaged parts immediately.
Maintain welding equipment according to
owner’s manual.
8. Never use welding equipment near water. Do
not spray water or other liquids on the welding
equipment.
9. Avoid direct contact between wet garments
and metal parts that are electrically charged.
10. Always wear gloves and rubber-soled shoes
when working in wet areas or standing on
metal surfaces.
11. Always turn off welding equipment that is not
being used. Do not leave welding equipment
unattended.
SIGNIFICANT DC VOLTAGE exists after the
removal of input power to inverters.
• Always discharge input capacitors before touch-
ing any parts. Service work should be complet-
ed by qualified personnel only.
1.2 PERSONAL PROTECTION
1. Welding operations produce radiation, noise,
heat and noxious fumes. Suitable safety pre-
cautions must be taken to minimize the risk.
2. Wear fire resistant work gloves,
long sleeve shirts, pants, safety shoes, cap
and welding helmet to protect the skin from
radiation and metal sparks.
3. Always wear ear protection.
4. Always wear eye protection with side shields.
5. Position a fire resistant screen around the
welding area to protect bystanders from radi-
ation, sparks and slag.
3
WARNING
Read and understand this entire Owner’s Manual before installing, operating or servicing this equipment. While the
information contained in this Owner’s manual represents our best judgment, Air Liquide assumes no liability for its
use.
Reproduction of this work, in whole or part, without written permission of the publisher is prohibited.
All rights reserved.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any
error or omission in the Air Liquide T 150i AC/DC Owner’s Manual, whether such error results from negligence, acci-
dent or any other causes.
1. SAFETY PRECAUTIONS - READ BEFORE USING

6. Compressed gas cylinders
are potentially dangerous. Consult the supplier
for correct handling procedures. Always protect
compressed gas cylinders from the sun’s rays,
flames and sudden temperature changes.
1.3 FIRE AND EXPLOSION PREVENTION
Hot slag and sparks can
cause fire. The risk of fire and explosion can be
minimized by removing all flammable material
from the welding area.
1. Always perform welding operation with cau-
tion. Containers and tubes that have been
emptied and thoroughly cleaned still repre-
sent a potential hazard.
2. Never perform welding operations or cut a
closed container or pipe.
3. Never perform welding operations on open
containers or pipes that may have been con-
taminated with substances that could explode
or react when exposed to heat or humidity.
4. As a preventative measure, keep fire extin-
guishers near the welding operation.
1.4 METAL FUME HAZARDS
Welding fumes and gases may be haz-
ardous if inhaled.
1. Install a ventilation system in the welding
area.
2. Use a forced air system when welding lead,
beryllium, cadmium, zinc, zinc-coated or
painted material. Always wear a protective
mask.
3. If the ventilation system is inadequate, use an
air respirator.
4. Beware of gas leaks. Shielding gases such as
argon are heavier than air and when used in
small spaces, will replace the air.
5. In the event that a welding operation occurs in
a confined place, the operator should be
accompanied by another person.
6. Always keep gas cylinders in a well-ventilated
area. Close the main gas valve when cylinder
is not in use.
7. Do not perform welding operations near chlo-
rinated hydrocarbon vapors produced by
degreasing or painting. The heat generated
by arc rays can react to form phosgene, a
highly toxic gas.
8. Irritation of the eyes, nose and throat are
symptoms of inadequate ventilation. Take
immediate steps to improve ventilation. Do
not continue welding if symptoms persist.
1.5 TRANSPORTING THE POWER SOURCE
1. The welding machine may be carried by the
handle.
2. Always disconnect the power source and
accessories from the main supply before lift-
ing or handling the welding equipment.
3. Do not drag, pull or lift welding equipment by
the weld cables.
1.6 MAGNETIC FIELDS CAN AFFECT
PACEMAKERS
1. Keep pacemaker wearers away
from welding operations.
2. Pacemaker wearers should consult with a
physician prior to being exposed to any weld-
ing or cutting operation.
4

5
1.7 H.F. RADIATION CAN CAUSE INJURY
1. High frequency (HF) emissions can
interfere with radio navigation, safety devices,
computers and communication equipment.
2. Installation of welding equipment should be
performed by a qualified electrician.
3. The operator is responsible for having a quali-
fied electrician correct any interference problem
resulting from the welding equipment installa-
tion.
4. If notified by the FCC about interference, stop
using the welding equipment immediately.
5. Have the welding equipment installation
checked and maintained on a regular basis.
6. Keep high-frequency source doors and panels
tightly shut. Keep spark gaps at the correct set-
ting and use grounding to minimize the possi-
bility of interference.
1.8 ARC WELDING CAN CAUSE
INTERFERENCE
1. Electromagnetic energy can interfere
with sensitive electronic equipment such as
computers and computer-driven equipment like
robots.
2. Be sure that all equipment in the welding area
is electro-magnetically compatible.
3. To reduce possible interference, keep weld
cables as short as possible, close together and
down low.
4. Locate welding operations at least 100 meters
(350 feet) away from any sensitive electronic
equipment.
5. Be sure welding equipment is installed and
grounded according to this manual.
6. If interference still occurs, the operator must
take extra measures such as moving the weld-
ing machine, using shielded cables, using line
filters or shielding the work area.
1.9 WELDING ANDTHE EFFECTS OF LOW
FREQUENCY AND MAGNETIC FIELDS
As welding current flows through welding cables, it
can cause electromagnetic fields.To reduce mag-
netic fields, use the following procedures:
1Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape coils around operators
body.
4. Keep welding power source and cables as far
away from the operator as practically possible.
5. Connect work clamp to workpiece as close to
the weld as possible.
1.10 PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard
Z49.1 from the American Welding Society, 550
N.W. Lejeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR
1910, from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from the American
Welding Society, 550 N.W.Lejeune Rd., Miami, FL
33126.
National Electrical Code, NFPA Standard 70, from
the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from the Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from the Canadian Standards
Association, Standard Sales, 178 Rexdale
Boulevard, Rexdale, Ontario M9W 1R3.
Safe Practices For Occupation And Educational
Eye And Face Protection, ANSI Standards Z87.1
from the American National Standards Institute,
1430 Broadway, NewYork, NY 10018.
Cutting And Welding Processes, NFPA Standards
51B, from the National Fire Protection Association,