Air Liquide ALW-M170500180 User manual

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.
A 160i Lift
A 160i Lift:ALW-M170500180
Air Liquide Welding is a trademark of L’Air Liquide S.A. 08/01

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 SPECIFICATIONS AND DESCRIPTION
2.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 COMES COMPLETE WITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.4 DUTY CYCLE AND OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.5 VOLT-AMPERE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 OPERATION
3.1 FRONT PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 LIFT-START TIG PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 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) . . . . . . . . . . . . . . . . . .11
5 MAINTENANCE AND TROUBLESHOOTING
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6 A 160i Lift ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7 A 160i Lift SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

3
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
Compliance with the following standards is fun-
damental to safety:
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 possible
to the operating area.
Do not pass welding equipment cables through
or near lifting chains, crane cables or any elec-
trical lines.
4. If earth grounding of the workpiece is required,
ground it directly with a separate cable.
5. Do not touch the electrode if you are in contact
with the work, ground or another electrode
from a different welding machine.
6. Use only well-maintained equipment. Repair or
replace damaged parts immediately. Maintain
welding equipment according to owner’s manual.
7. Never use welding equipment near water. Do
not spray water or other liquids on the welding
equipment.
8. Avoid direct contact between wet garments and
metal parts that are electrically charged.
9. Always wear gloves and rubber-soled shoes
when working in wet areas or standing on
metal surfaces.
10.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 completed
by qualified personnel only.
1.2 PERSONAL PROTECTION
1. Welding operations produce radiation, noise,
heat and noxious fumes. Suitable safety precau-
tions must be taken to minimize the risk.
2. Wear fire resistant work gloves, long
sleeve shirts, pants, safety shoes, cap and weld-
ing helmet to protect the skin from radiation and
metal sparks.
3. Always wear ear protection.
1. SAFETY PRECAUTIONS - READ BEFORE USING
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 A 160i Lift Owner’s Manual, whether such error results from negligence, acci-
dent or any other causes.

4
4. Always wear eye protection with side shields.
5. Position a fire resistant screen around the weld-
ing area to protect bystanders from radiation,
sparks and slag.
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 caution.
Containers and tubes that have been emptied
and thoroughly cleaned still represent a poten-
tial hazard.
2. Never perform welding operations or cut a
closed container or pipe.
3. Never perform welding operations on open con-
tainers or pipes that may have been contami-
nated with substances that could explode or
react when exposed to heat or humidity.
4. As a preventative measure, keep fire extinguish-
ers 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 paint-
ed 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 accom-
panied 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 chlori-
nated 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 symp-
toms 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 PACE-
MAKERS
1. Keep pacemaker wearers away from
welding operations.
2. Pacemaker wearers should consult with a
physician prior to being exposed to any welding
or cutting operation.

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,

6
EQUIPMENT INSTALLATION AND MAINTENANCE MUST BE PERFORMED IN COMPLIANCE
WITH LOCAL SAFETY STANDARDS.
• INSTALLATION AND MAINTENANCE OPERATIONS MUST BE PERFORMED BY QUALIFIED PERSONS ONLY.
• BEFORE INSTALLING the power source, check that the power socket satisfies ampere and voltage require-
ments (see data table plate). ENSURE that the socket is protected by appropriate fuses and automatic
switches.
• CONNECT an approved standard plug corresponding to the system socket to the power supply cable.
Electric shock could be fatal
1. Never touch exposed electrical
parts.
2. Switch off and disconnect the
power source before installing
or opening.
3. Installation may be performed
by qualified persons only.
4. Installation procedure must
comply with national electricity
standards and all other relevant
regulations.
Fumes and gases may represent
a safety hazard.
Fumes and gases generated dur-
ing welding may be dangerous if
inhaled over a long period of
time.
1. Keep clear of fumes.
2. Ventilate welding area or wear a
breathing mask.
3. Install a natural or forced air
ventilation system in the work
area.
Use a protective mask with suit-
able glass filter (at least NR10) to
safeguard eyes.
1. Wear appropriate eye, ear and
body protection equipment.
2. Protect face, ears and neck dur-
ing welding operations. Advise
other persons in the vicinity to
look away and stand clear of arc
rays and hot metal.
The positioning of welding equip-
ment on inflammable surfaces
could lead to fire outbreak or
explosion.
1. Never position equipment on
combustible or inflammable
surfaces.
2. Do not install equipment in the
vicinity of inflammable liquids.
A falling power source or other
equipment may cause serious
injury to persons or damage to
objects.
1. Always make use of the handle
to lift power source (applies to
portable models).
2. Use eye bolts and adequate lift-
ing equipment to raise the
power source.
WELDING MAY CAUSE FIRES OR
EXPLOSIONS. Never weld near
inflammable materials.
1. Beware of weld flame. Always
keep a fire extinguisher close at
hand.
2. Never place welding equipment
on inflammable surfaces.
3. Do not weld in closed containers.
4. Let welding equipment and
material cool before handling
them.
Moving parts may cause injury.
1. Keep clear of hazardous areas,
such as moving rollers.
2. Keep all doors, panels and
covers closed and in place.
Hot areas may cause injury.
Let the power source or other
parts cool before performing
any maintenance or servicing.
Welding wire may cause injury.
Do not point the torch toward
any part of the body, other per-
sons or any type of metal when
unwinding welding wire.

7
2. SPECIFICATIONS AND DESCRIPTION
2.3 COMES COMPLETE WITH:
1. Shoulder strap (carrying strap)
2. 2.4 m (8 ft) input power cord without plug
For options and accessories contact your distrib-
utor.
2.4 DUTY CYCLE AND OVERHEATING
Duty cycle is the percentage of 10 minutes that the
unit can weld at its rated output without overheat-
ing. If the unit overheats, the weld output will stop.
To correct this situation, wait fifteen minutes for
the unit to cool. Reduce amperage or duty cycle
before starting to weld again.
(See Duty Cycle Chart on page 8)
2.5 VOLT-AMPERE CURVES
Volt-ampere curves show the maximum voltage
and amperage output capabilities of the welding
power source. Curves of other settings fall under
curves shown.
(See Volt-Ampere Curve Chart on page 9)
2.1 SPECIFICATIONS
2.2 DESCRIPTION
The new A 160i Lift from Air Liquide Welding sets
a new standard for constant current, DC arc weld-
ing inverters. This 90–270 VAC input (Sinelink)
compact unit is a proven performer with serious
welding amperage for electrodes up to 4.0 mm
(5/32 in). This portable unit weighs in at an
impressive 9.9 kg (21.8 lb). The perfect sinus
input shape gains 35% in welding power over the
conventional welding machine.
Infinite current regulation and thermal overload
protection assist the welding operator in per-
forming smooth and consistent welds. Built in
anti-stick, hot start and arc force will ensure
ease of operation and increased operator satis-
faction. Throw on an optional TIG torch and you
have a unit capable of Lift TIG. The new A 160i
Lift: leading the way in performance, capabilities
and versatility.

8
115 Vac
0
50
100
150
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
OUTPUT AMPERES
230 Vac
0
50
100
150
200
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
OUTPUT AMPERES
TIG
STICK
TIG
STICK
A160i Lift Duty Cycle @ 230 VAC
A160i Lift Duty Cycle @ 115 VAC

9
3.1 FRONT PANEL CONTROLS
1. AMPERAGE ADJUSTMENT CONTROL
This control is used to adjust welding amperage.
2. Stick / Lift-Start TIG Selector Switch
This switch is used to select the Stick or Lift-Start
TIG welding process.
3. TEMPERATURE LIGHT
When illuminated, this light indicates that the unit
has overheated. If overheating occurs, weld output
to the terminals ceases and the fan motor contin-
ues to run until the unit has cooled down.
4. POWER LIMIT LIGHT
This light works when the unit is connected to a
115 VAC power supply. When illuminated, this light
indicates that the operator has requested more
weld amperage than what the machine is capable
of producing. At 115 VAC the unit is capable of
producing 110 amps for Stick welding and 130
amps for TIG welding.
5. POSITIVE WELD OUTPUT RECEPTACLE
For Stick welding using electrodes that operate on
DCEP (Direct Current Electrode Positive), connect
the electrode cable to this receptacle.
For Stick welding using electrodes that operate on
DCEN (Direct Current Electrode Negative), connect
the ground cable to this receptacle.
For TIG welding, connect the ground cable to this
receptacle.
6. NEGATIVE WELD OUTPUT RECEPTACLE
For Stick welding using electrodes that operate on
DCEP (Direct Current Electrode Positive), connect
the ground cable to this receptacle.
For Stick welding using electrodes that operate on
DCEN (Direct Current Electrode Negative), connect
the electrode cable to this receptacle.
For TIG welding, connect the TIG torch cable to this
receptacle.
0,00
10,00
20,00
30,00
40,00
50,00
60,00
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
AMPS
VOLTS
230 Vac
115 Vac
3. OPERATION
AMPS
VOLTS
A160i Lift Volt-Ampere Curve

10
3.2 LIFT-START TIG PROCEDURE
With the Stick / Lift-Start TIG selector switch in the
Lift-Start Tig position, start a welding arc as fol-
lows:
1. Touch the tungsten electrode to the workpiece
at the welding start point.
2. Hold the electrode to the workpiece for no
longer than one second.
3. Slowly lift the electrode from the workpiece. An
arc will form when the electrode is lifted.
3.3 BACK PANEL CONTROLS
7. POWER-ON SWITCH
8. INPUT POWER CORD
9. DATA PLATE
Before connecting, preparing or using
equipment, read Section 1: Safety Precautions.
7 9
8
2 3 4 1
65