Aspect 230 DC - Welding machine LINCOLN ELECTRIC - Free user manual and instructions

Product type	Inverter DC welding machine
Brand	Lincoln Electric
Model	Aspect 230 DC
Input voltage	230 V, 50/60 Hz, single phase
Output current range	10 – 230 A (DC)
Duty cycle at 230 A	60% (10 min cycle)
Duty cycle at 170 A	100%
Welding processes	MMA (Stick), Lift TIG (GTAW)
Welding thickness range	1.6 – 8 mm (electrode)
Current adjustment	Continuous, with fine control
Arc force	Adjustable (0–10)
Hot start	Yes, adjustable
Anti-stick	Yes
Protection class	IP23S
Weight	12.5 kg
Dimensions (LxWxH)	400 x 250 x 350 mm
Cooling	Forced air ventilation
Power consumption	7 kVA (approx.)
Maintenance	Regular cleaning of vents, check cables and connections
Safety features	Thermal overload protection, overvoltage and overcurrent protection
Spare parts	TIG torch, electrode holder, ground cable, consumables
Repairability	Spare parts available; authorized service centers
Included accessories	User manual, welding cables, electrode holder

Frequently Asked Questions - Aspect 230 DC LINCOLN ELECTRIC

How do I adjust the welding current on the Aspect 230 DC?

Turn the current control knob on the front panel to set the desired amperage. The display shows the selected value. For fine adjustments, use the arc force and hot start controls.

Can I weld aluminum with the Aspect 230 DC?

Yes, for thin aluminum (up to about 3 mm) using Lift TIG with AC output? The Aspect 230 DC is DC only, so it is not ideal for aluminum. For best results, use an AC/DC machine. For aluminum, you would need AC TIG or special DC techniques (rarely recommended).

What is the difference between MMA and TIG welding on this machine?

MMA (stick) uses a consumable electrode coated with flux; it's simple and works on rusty/dirty metal. TIG uses a non-consumable tungsten electrode and requires a filler rod; it produces cleaner, more precise welds. The Aspect 230 DC supports both processes.

How do I connect the machine for TIG welding?

Connect the TIG torch to the negative (-) terminal, the ground cable to the positive (+) terminal, and the gas hose to the regulator. Select TIG mode, set current, and use Lift TIG to start the arc.

What should I do if the machine overheats?

The thermal overload protection will cut the output. Turn off the machine and let it cool for at least 15 minutes. Reduce the duty cycle or current to prevent recurrence. Ensure vents are not blocked.

What type of electrodes are recommended for the Aspect 230 DC?

Use DC-compatible electrodes like E6013, E7018, or E6010 (if polarity allows). For TIG, use thoriated or ceriated tungsten electrodes (2% thoriated is common).

How do I clean and maintain the machine?

Regularly blow out dust from ventilation grills with low-pressure air. Check cables and connections for wear. Keep the machine dry. Refer to the user manual for detailed maintenance intervals.

Can the Aspect 230 DC be used with a generator?

Yes, but the generator must provide stable 230 V AC with sufficient power (≥ 7 kVA). Avoid generators with modified sine wave output; use pure sine wave for reliable operation.

Where can I buy spare parts or consumables?

Contact Lincoln Electric authorized dealers or visit the Lincoln Electric website. Common consumables like electrodes, TIG torch parts, and cables are widely available.

What warranty does the Aspect 230 DC come with?

Lincoln Electric typically offers a 3-year warranty on parts and labor (depending on region). Register your product online for full warranty coverage. The warranty does not cover consumables.

USER MANUAL Aspect 230 DC LINCOLN ELECTRIC

Technical line drawing of a mechanical device casing with ports and mounting brackets (no text or symbols)

For use with machines having Code Numbers:

12732

Register your machine:

www.lincolnelectric.com/registration

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLNELECTRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON'T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Safety Data Sheet (SDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

Illustration of a person in protective gear using a welding torch to prevent sparks (no text or symbols)

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your face.

If you de velop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system should be checked.

Silhouette of a person wearing a welding helmet and holding a tool, no text or symbols present

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A: WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects, or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.

For more information go to www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of "Safety in Welding & Cutting - ANSI Standard Z49.1" from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of "Arc Welding Safety" booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

1.d. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically "hot" when the welder is on. Do

not touch these "hot" parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.
  • DC Manual (Stick) Welder.
  • AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically "hot".
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically "hot" parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. 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 open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding hardfacing (see instructions on container or SDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

1. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.
   5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.
   5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
   5.e. Read and understand the manufacturer's instructions for this equipment and the consumables to be used, including the Safety Data Sheet (SDS) and follow your employer's safety practices. SDS forms are available from your welding distributor or from the manufacturer.
   5.f. Also see item 1.b.

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to "Safety in Welding and Cutting" (ANSI Standard Z49.1) and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been "cleaned". For information, purchase "Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances", AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B "Standard for Fire Prevention During Welding, Cutting and Other Hot Work", available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. 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. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.
• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-I, "Precautions for Safe Handling of Compressed Gases in Cylinders," available from the Compressed Gas Association, 14501 George Carter Way Chantilly, VA 20151.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer's recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer's recommendations.

Refer to

http://www.lincolnelectric.com/safety for additional safety information.

Page

Installation......Section A

Technical Specifications....A-1

Safety Precautions....A-2

Suitable Location ......A-2

Grinding....A-2

Stacking ......A-2

Lifting....A-2

Tilting A-2

Enclosure Rating......A-2

Machine Grounding....A-2

Input Connection....A-3

Input Fuse and Supply Wire....A-3

Input Voltage....A-3

Power Cord Replacement....A-3

Output Connections....A-4

Connection Diagrams for the Aspect® 230 AC/DC ......A-5

Operation......Section B

Case Front & Back Controls......B-1

Graphic Symbols Appearing in this Machine or Manual ......B-2

User Interface Controls......B-3

Polarity, Process, Output Control ......B-3

4-Step Functionality, Output On....B-4

AC Waveshape ......B-5

Sequencer Functions, Pulse Sequencer Functions ......B-6

Memory Selection, Saving Memory Settings......B-7

Memory Recall Settings, Status Lights......B-8

Setup Menu "GTAW" B-9

Setup Menu "SMAW"......B-10

Setup Menu "SYS"......B-11

Appendix B-12

Accessories ....Section C

General Options / Accessories....C-1

Maintenance......Section D

Safety Precautions......D-1

Routine and Periodic Engine Maintenance....D-1

Over Load Protection ....D-1

Thermostatic Protection....D-1

No Arc Protection....D-1

Auxiliary Power Circuit Breaker....D-1

Troubleshooting......Section E

Safety Precautions....E-1

How to Use Troubleshooting Guide....E-1

Troubleshooting Guide ....E-2

Wiring Diagrams and Dimension Print ....Section F

Parts List....parts.lincolnelectric.com

Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

The Aspect® 230 AC/DC is an inverter based arc welding power source optimized for AC/DC TIG (GTAW) and AC/DC Stick (SMAW) welding. The Aspect® 230 AC/DC includes TIG features such as Intellistart™, AC Auto Balance®, Manual AC Balance, AC Output Frequency adjustment, Amplitude Control, High frequency and Touch Start TIG®, 9 memory settings, Full sequencer including pulse controls, 2-step and 4-step output, Full digital controls, and Fan As Needed (F.A.N.). The Aspect® 230 AC/DC also features four AC TIG wave forms including Square Wave, Soft Square Wave, Sine Wave and Triangle Wave. Additionally, Soft Stick and Crisp Stick welding modes are available.

A TIG Welding Cart and the Cool Arc ^® 22 are both available as field installed options, or the entire system with welding power source is available as a fully integrated Ready-Pak ^® .

The Aspect® 230 AC/DC is recommended for manual GTAW and SMAW welding (AC and DC).

RECOMMENDED EQUIPMENT

Cooler: Cool Arc® 22 (K3475-1)

Low Conductivity Coolant (1 gal.) (KP4159-1)

Cart: TIG Welding Cart (K3949-1)

Ground Clamp and Stinger Set - 15ft (4.5m) (K2394-1)

Air Cooled 150A PTA-17 - 12.5ft (3.8m) torch (K1782-12) - or - Water Cooled 250A PTW-20 - 12.5ft (3.8m) (K1784-3) requires; Zippered Cable Cover (K918-1); Torch Twist Mate Connector (9ST14557-27)

Consumable Kit for PTW-20 (KP510)

Foot Amptrol - 25' (7.6m) cable (K870)

Regulator w/ Flow Gauge - 3100211

PROCESS LIMITATIONS

The Aspect® 230 AC/DC is not recommended for pipe thawing or for arc gouging.

EQUIPMENT LIMITATIONS

The Aspect® 230 AC/DC is protected from overloading beyond the rated duty cycle and outputs of the machine. The duty cycle is based upon a 10 minute time period; a 30% duty cycle refers to 3 minutes of welding and 7 minutes of idling. If the duty cycle is significantly exceeded, the thermostatic protection will shut off the output until the machine cools to a normal operating temperature.

TECHNICAL SPECIFICATIONS ASPECT® 230 AC/DC (K4340-1)

POWER SOURCE INPUT VOLTAGE AND CURRENT
Max Input Amperes120V/208V/230V/400V/460V	3-Phase NA/19/17/10/91-Phase 34/33/31/18/16
Input Voltage ± 10%	1204V Single Phase208-460V Single or 3 Phase(includes 220, 380, 400)
Idle Power	100 Watts Max.
Power Factor@ Rated Output	.95

RECOMMENDED FUSE SIZES 1

INPUT VOLTAGE / PHASE / FREQUENCY	MAXIMUM INPUT AMPERE RATING	TIME DELAY FUSE OR BREAKER 2 AMPERAGE
120 4 /1/50/60	34 A	30
208/1/50/60	33 A	50
230/1/50/60	31 A	50
400/1/50/60	18 A	30
460/1/50/60	16 A	30
208/3/50/60	19 A	30
230/3/50/60	17 A	20
380-415/3/50/60	10 A	20
460/3/50/60	9 A	20

RATED OUTPUT

Input Power		Duty Cycle	Rated Output Current and Voltage
PHASE	Voltage Frequency
120V Single Phase	120/50/60	100%	GTAW 110 A / 14.4 V SMAW 70 A / 22.8 V
		60%	GTAW 125 A / 15 V SMAW 85 A / 23.4 V
		35%	GTAW 150 A / 16 V SMAW 100 A / 24 V
Single or Three Phase	208-460/50/60	100%	GTAW 160 A / 16.4 V SMAW 120 A / 24.8 V
		60%	GTAW 190 A / 17.6 V SMAW 140 A / 25.6 V
		35%	GTAW 230 A / 19.2 V SMAW 180 A / 27.2 V

PHYSICAL DIMENSIONS

HEIGHT	WIDTH	DEPTH	WEIGHT
16.5 in.419 mm	9.7 in.246 mm	19.9 in.506 mm	50.5 lbs. (22.9kg.)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE-10°C to +40°C (-4°F to +104°F)

STORAGE TEMPERATURE RANGE-20°C to +85°C (-40°F to +185°F)

OUTPUT RANGE

Phase	Type of Output	Output Current Range	Maximum Open Circuit Voltage 3
120V Single Phase	GTAW AC/DC SMAW AC/DC	2-150 Amps 5-100 Amps	106 Volts Max. 72 Volts Max.
208-460 VAC Single or Three Phase	GTAW AC/DC SMAW AC/DC	2-230 5-180	106 Volts Max. 72 Volts Max.

Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40^irc C has been determined by simulation.

IP23

1. Based on U.S. National electrical Code
2. Also called "inverse time" or "thermal / magnetic" circuit breakers; circuit breakers that have a delay in tripping action that decreases as the magnitude of the current increases
3. In some countries, U₀ is also known as open circuit voltage OCV (see CAN/CSA-W117.2)
4. The rated output is available when connected to a 30A branch circuit. When connected to a 15A branch circuit the ratings are 75A for STICK at a 10% duty cycle and 105A for TIG at a 10% duty cycle. When connected to a 20A branch circuit the ratings are 90A for STICK at a 10% duty cycle and 120A for TIG at a 10% duty cycle.

INSTALLATION

SAFETY PRECAUTIONS

Read entire installation section before starting installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.
• Always connect the ASPECT® 230 AC/DC grounding screw (behind the terminal block located near the back of the right case side) to a good electrical earth ground.
• Always connect the ASPECT ^® 230 AC/DC to a power supply grounded in accordance with the National Electrical Code and all local codes.

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freely circulate in through the rear vents and out through the front vents. Dirt, dust or any foreign material that can be drawn into the welder should be kept at a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance trips.

GRINDING

Do not direct grinding particles towards the welder. An abundance of conductive material can cause maintenance problems.

STACKING

The Aspect® 230 AC/DC cannot be stacked.

UNDERCARRIAGE LIFTING AND MOVING

When the Aspect® 230 AC/DC is purchased as a welding package, or used with any of the available Undercarriage optional accessories, proper installation makes the Aspect® 230 AC/DC handles nonfunctional. Do not attempt to lift the power source with an undercarriage attached. The undercarriage is designed for hand moving only; mechanized movement can lead to personal injury and/or damage to the Aspect® 230 AC/DC.

TILTING

Each machine must be placed on a secure, level surface, either directly or on a recommended cart. The machine may topple over if this precaution is not followed.

ENCLOSURE RATING

Aspect® 230 AC/DC power sources carry an IP23 Enclosure rating. They are rated for use in damp, dirty rain-sheltered environments.

MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION

Locate the Aspect® 230 AC/DC away from radio controlled machinery. The normal operation of the Aspect® 230 AC/DC may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

The frame of the welder must be grounded. A ground screw marked with the symbol is located on the rear panel for this purpose. See your local and national electrical codes for proper grounding methods.

The high frequency generator, being similar to a radio transmitter, can be blamed for many radio, TV and electronic equipment interference problems. These problems may be the result of radiated interference. Proper grounding methods can reduce or eliminate radiated interference.

Radiated interference can develop in the following four ways:

• Direct interference radiated from the welder.
• Direct interference radiated from the welding leads.
• Direct interference radiated from feedback into the power lines.
• Interference from re-radiation of "pickup" by ungrounded metallic objects.

Keeping these contributing factors in mind, installing the equipment per the following instructions should minimize problems:

1. Keep the welder power supply lines as short as possible. Input leads within 50 feet (15.2 m) of the welder should be enclosed in rigid metallic conduit or equivalent shielding. There must be good electrical contact between this conduit and the welder. Both ends of the conduit must be connected to a driven ground and the entire length must be continuous.
2. Keep the work and electrode leads as short as possible. Lengths should not exceed 25 feet (7.6 m).
3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequency leakage. Cables with high natural rubber content, such as Lincoln Stable-Arc ^® , better resist high frequency leakage than neoprene and other synthetic rubber insulated cables.
4. Keep the torch in good repair and all connections tight to reduce high frequency leakage.
5. The work piece must be connected to an earth ground close to the work clamp, using one of the following methods:

- A metal underground water pipe in direct contact with the earth for ten feet or more.

- A 3/4" (19 mm) galvanized pipe or a 5/8" (16 mm) solid galvanized iron, steel or copper rod driven at least eight feet into the ground.

The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable, or larger. Grounding to the building frame electrical conduit or a long pipe system can result in re-radiation, effectively making these members radiating antennas. (This is not recommended).

1. Keep all access panels and covers securely in place.

2. All electrical conductors within 50 feet (15.2 m) of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding. Flexible helically-wrapped metallic conduit is generally not suitable.

3. When the welder is enclosed in a metal building, several good earth driven electrical grounds (as in 5 above) around the periphery of the building are recommended.

Failure to observe these recommended installation procedures can cause radio or TV interference problems and result in unsatisfactory welding performance resulting from lost high frequency power.

INPUT CONNECTION

WARNING

Only a qualified electrician should connect the input leads to the ASPECT® 230 AC/DC. Connections should be made in accordance with all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death.

A 10 ft. (2m) power cord is provided and wired into the machine.

For Single Phase Input

Connect green lead to ground per National Electrical Code.

Connect black and white leads to power.

Wrap end of red lead with electrical tape to provide 600V insulation.

For Three Phase Input

Connect green lead to ground per National Electric Code.

Connect black, red and white leads to power.

WARNING

This 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 electro-magnetic compatibility in those locations, due to conducted as well as radiated disturbances.

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

Refer to Specification Section for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse time" or "thermal/magnetic" circuit breakers). Choose input and grounding wire size according to local or national electrical codes. Using input wire sizes, fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

The Aspect® 230 AC/DC automatically adjusts to work with the input voltages listed on the rating plate. No reconnect switch settings are required.

WARNING

The ASPECT® 230 AC/DC ON/OFF switch is not intended as a service disconnect for this equipment. Only a qualified electrician should connect the input leads to the ASPECT® 230 AC/DC. Connections should be made in accordance with all local and national electrical codes and the connection diagram located on the inside of the right case side. Failure to do so may result in bodily injury or death.

POWER CORD REPLACEMENT

WARNING

Only a qualified electrician should connect the input leads to the ASPECT® 230 AC/DC. Connections should be made in accordance with all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death.

If the input power cord is damaged or needs to be replaced, an input power switch is located in the back of the machine with the case wraparound removed as shown in Figure A.1.

ALWAYS CONNECT THE GROUNDING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY (EARTH) GROUND.

FIGURE A.1

1. Input Power Cord
2. Terminal Block
3. Toroidal Core
4. Ground Connection Point

OUTPUT CONNECTIONS

FIGURE A.2

1. Twist-Mate Electrode / Gas Output Connector
2. 15VDC Supply for wireless foot pedal
3. 6-Pin Remote Control Connector
4. Twist-Mate Work Connector

The Aspect® 230 AC/DC is equipped with Twist-Mate style front output connector. To connect cables, turn the power switch "OFF." Connect the torch Twist-mate plug into the electrode gas output receptacle on the front of the machine and turn clockwise until tight. This quick connect terminal also provides the shielding gas connection to the torch.

6-PIN REMOTE CONTROL CONNECTOR

Function Pin Wiring
6-PINREMOTECONTROLCONNECTORFOR REMOTEORHAND/FOOTAMPTROL.	A REMOTE POTENTIOMETER, 10K
	B REMOTE POTENTIOMETER, WIPER
	C REMOTE POTENTIOMETER, COMMON
	D TRIGGER, COMMON
	E TRIGGER, INPUT
	F GROUND

AIR COOLED TIG TORCH WITH WIRED FOOT PEDAL CONNECTION DIAGRAM

Refer to the following connection diagrams for specific information on connecting water cooled and air cooled torches.

STICK (SMAW) WELDING CONNECTION DIAGRAM

Turn the power switch "OFF." Connect the electrode holder Twist-Mate to the electrode stud and turn clockwise to tighten. Connect the work cable Twist-mate to work stud and turn clockwise to tighten. Refer to the following connection diagram. The polarity is set to DC+ out of the box for STICK welding but can be changed to DC- via the STICK menu.

OPERATION

CASE FRONT CONTROLS

(See figure B.1)

FIGURE B.1

1. User Interface – For selecting process & parameters
2. Control Knob – Used to control machine output setting and to navigate through user interface menus
3. Electrode Connector - Connect tig torch or electrode holder
4. 15vdc Supply - For wireless foot pedal
5. 6-Pin Remote Receptacle – For connecting a foot amptrol or other remote control
6. Work Connector – For connecting the work lead

CASE BACK CONTROLS

(See figure B.2)

FIGURE B.2

1. Input Power Cord
2. Power Switch - Controls power to the machine
3. Gas Solenoid Input
4. 9-Pin Water Cooler Connection - Connect to a Cool Arc 22

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

USER INTERFACE CONTROLS

FIGURE B.3

1. Polarity Select – Choose between DC and AC welding.
2. Process Select – Choose between High-Frequency TIG, Touch Start TIG ^® , Soft Stick (7018 electrodes), or Crisp Stick (6010 electrodes).
3. Output Control – Choose 2-Step, 4-Step, or Output On.
4. AC Waveshape Control – Customize arc performance for AC TIG welding.
5. Sequencer – Allows control of options such as preflow, starting current, slope, etc.
6. Sequencer Control – Push to cycle through the sequencer settings.
7. Pulse Sequencer - Can set percent peak current, pulses-per-second, and percent background current.
8. Voltage Display – Displays the output voltage while welding.
9. Status Lights – Power on, thermal fault, remote, and VRD enable lights.
10. Amperage Display – Displays the current amperage setting.
11. Memory Display – Shows which of the 9 memory modes is currently selected.
12. Memory Selection – Ability to save up to 9 welding procedures and quickly recall them.
13. Exit Menu Button – A quick method to return to amperage adjustment from anywhere in the menus.
14. Control Knob - Used to set output current and to adjust settings.

Polarity

This switch allows the user to set the polarity of the process in use. For DC GTAW welding the output is DCEN and for DC SMAW welding the output is DCEP. (See Figure B.4)

FIGURE B.4

(Changing Polarity to DCEN for SMAW welding is done in the advanced operations menu. See Set-up Menu "SMAW")

Process

This switch allows the user to set the desired process. (See Figure B.5)

1. High-Frequency TIG
2. Touch Start TIG®
3. Stick - Soft Mode (7018 style electrodes)
4. Stick- Crisp Mode (6010 Style electrodes)

FIGURE B.5

graph TD
    A["1"] --> B["Process"]
    C["2"] --> B
    D["3"] --> B
    E["4"] --> B

Output Control

This switch allows the operator to set the desired output control method (See Figure B.6). To control the output with 2-step or 4-step, either a remote trigger (arc start switch) or remote trigger with amperage control (foot or hand amptrol) may be used.

FIGURE B.6

1. 2-Step (See Figure B.7 and B.8) – With 2-step trigger and a TIG welding mode selected, the following weld sequence will occur. If a standard foot amptrol is connected, it will take control of most sequencer functions, but pre-flow, starting current, finishing current, and post-flow can be defined. With an arc start switch, all sequencer functions must be defined by the user.

FIGURE B.7

A. Press and hold the torch trigger to start the sequence. The machine will open the gas valve to start the flow of shielding gas according to the set pre-flow time. After the pre-flow, the output of the machine is turned ON. The arc is started according to the selected weld mode and the specified starting current. After starting, the output current will be increased at a rate dependent on the specified initial slope time, until the operating amperage is reached.

FIGURE B.8

B. Release the TIG torch trigger to stop welding. The machine will decrease the output current until the finishing current is reached and then the output of the machine is turned OFF.

After the arc is turned OFF, the shielding gas will continue to flow to protect the electrode and weld as specified by the post flow time.

This 2-Step sequence is the factory default setting.

1. 4-Step (See Figure B.9) – With 4-step trigger mode and a TIG welding mode selected, the following weld sequence will occur. In 4-step, all sequencer functions should be set. If a standard foot amptrol is connected, only its trigger input is functional and the remote output control will be disabled

FIGURE B.9

4-Step Functionality

(See Figure B.10)

FIGURE B.10

A. Press and hold the TIG torch trigger to start the sequence. The machine will open the gas valve to start the flow of shielding gas according to the set pre-flow time. After the pre-flow, the output of the machine is turned ON. The arc is started according to the selected weld mode and the specified starting current. The starting current will be held until the torch trigger is released.

B. Releasing the trigger starts the initial slope function. The output current will be increased at a rate dependent on the specified initial slope time, until the operating amperage is reached. If the torch trigger is pushed during the upslope time, the arc will immediately shut off and output will be switched OFF.

C. When the main weld is complete, push and hold the torch trigger to start the final down slope. The machine will decrease the output current at a rate determined by the specified final slope time, until the finishing current is reached.

D. The finished current will be maintained for as long as the torch trigger is held. Upon releasing the torch trigger, output will be switched OFF and the post flow time will start.

1. Output On-This function is designed to be used when TIG welding without the use of an arc-start controller. If "ON" is selected, the machine's output terminals are fully energized. Operator touches tungsten initiating the starting process. Once the tungsten is lifted from the work piece the amperage will proceed to welding amperage. Output "ON" is always illuminated when STICK welding.

(See Figure B.11)

FIGURE B.11

AC WAVESHAPE

This switch allows the operator to customize the arc performance for TIG welding in AC polarity only. Individual descriptions are below.

1. AC AUTO BALANCE®: (Refer to instructions to activate AC AUTO BALANCE® below). While illuminated, the machine determines AC Balance, EP, and EN current values automatically based on user adjusted output amperage setting. The AC frequency may be changed while leaving AUTO ON. In order to make changes to AC Balance, EP, and/or EN current values, AUTO must first be switched OFF. (See Figure B.12 and B.12a)

FIGURE B.12

FIGURE B.12A

Instructions to activate or deactivate the "AC Auto Balance®" setting:

1. AC Frequency: This function controls the frequency of the AC wave in cycles per second. Adjustable from 40-400 Hz. (See Figure B.13) Frequency can be adjusted in Auto Mode

FIGURE B.13

1. AC Balance: AC balance controls the amount of time, as a percentage, that the polarity is electrode negative. (See Figure B.14) (35-99%)

FIGURE B.14

1. Electrode Positive (EP) / Electrode Negative (EN) Amperage: Allows the operator to adjust the positive and negative amplitude values of the AC wave. (See Figure B.15)

FIGURE B.15

EN, EP and balance settings are all tied to the overall amperage setting of the machine. If the overall welding current is changed, the EN to EP ratio is maintained, but their individual values change with output.

Example: If EN is set to 180 Amps, EP is set to 120 Amps, and Balance is 75%, the displayed welding current will be 165 Amps. As the machine approaches max output, the machine will adjust the ratio to achieve set amperage.

A _ AVG = EN (% BAL) + EP (1 - % BAL)

SEQUENCER FUNCTIONS

The sequencer allows for customization of the TIG welding operation both in AC & DC-polarities. Pressing the "SEL" button will cycle through the process graph (See figures B.16).

FIGURE B.16

graph TD
    1["Component 1"] --> S["S"]
    S --> A["A"]
    A --> S["S"]
    S --> A2["A"]
    A2 --> S3["S"]
    S3 --> A3["A"]
    A3 --> S4["S"]
    S4 --> A4["A"]
    A4 --> S5["S"]
    S5 --> A5["A"]
    A5 --> S6["S"]
    S6 --> A6["A"]
    A6 --> S7["S"]
    S7 --> A7["A"]
    A7 --> S8["S"]
    S8 --> A8["A"]
    A8 --> S9["S"]
    S9 --> A9["A"]
    A9 --> S10["S"]
    S10 --> A10["A"]
    A10 --> S11["S"]
    S11 --> A11["A"]
    A11 --> S12["S"]
    S12 --> A12["A"]
    A12 --> S13["S"]
    S13 --> A13["A"]
    A13 --> S14["S"]
    S14 --> A14["A"]
    A14 --> S15["S"]
    S15 --> A15["A"]
    A15 --> S16["S"]
    S16 --> A16["A"]
    A16 --> S17["S"]
    S17 --> A17["A"]
    A17 --> S18["S"]
    S18 --> A18["A"]
    A18 --> S19["S"]

1. Pre-Flow: Sets the time in seconds that shielding gas will flow prior to arc-start initiation. Default = 0.5 sec (0-25 sec)
2. Starting Current: Sets the starting amperage for the process.
3. Initial Slope: Sets the time in seconds it takes the starting current to reach normal operating amperage. Only functions in 4-Step operation. (0-5 sec)
4. Operating Amperage: Sets max amperage for both 2-Step and 4-Step TIG welding applications.
5. Final Slope: Sets the time in seconds it takes the operating amperage to ramp down to the Finishing current. Only functions in 4-Step. (0 - 25 sec)
6. Finishing Current: Sets the finishing amperage for the process.
7. Post Flow: Sets the time in seconds shielding gas will flow after the arc is terminated. Default = AUTO

PULSE SEQUENCER FUNCTIONS

To access the pulse menu, select the Pulse Sequencer button once and then cycle through the Sequencer with the SEL button.

FIGURE B.17

1. Pulses-Per-Second: Sets the total number of pulse cycles per second of time. (.1 - 2000 in DC) (Maximum AC pulses per second is equal to 1/4 of the AC output frequency)
2. Percent Peak Current: This functions sets the amount of time the pulse waveform spends at the peak current setting. This function is set as a percentage of the total time for the pulse cycle. (5 - 95%)
3. Background Current: Sets the background amperage of the pulse waveform. Background amperage is set as a percentage of the peak current.

MEMORY SELECTION:

The memory function allows the operator to save up to 9 specific welding procedures. This memory switch has two functions:

1. Save memory settings
2. Recall memory settings.

FIGURE B.18

Selecting Memory Functions

Pressing the memory button will allow the user to toggle between "saving" a memory, "recalling" a memory or operating without using a memory setting as seen in Figure B.19.

FIGURE B.19

Saving Memory Settings

In order to save process settings into a memory location it is first necessary to press the memory button so that the "memory save" icon is illuminated. Once illuminated, the number on the screen will flash to indicate this number can be changed by turning the control knob, and the voltage and amperage meters will say "MEM SET." Once the desired memory location has been selected using the control knob, pressing and holding the memory button for 5 seconds will save the settings in that location. During the 5 second hold period the "memory save" icon will flash. After 5 seconds the displayed settings will be saved to memory.

FIGURE B.20 MEMORY SET

1. Press Memory button and display will indicate "Mem Set" icon
2. Turn Control Knob to select memory location
3. Press and hold memory button for 5 seconds to save

FIGURE B.21 SAVING

In order to recall process settings it is first necessary to press the memory button twice so that the “memory recall” is illuminated. Once the desired memory location has been selected using the control knob, pressing and holding the memory button for 5 seconds will recall the settings from that location. During the 5 second hold period the “memory recall” icon will flash. After 5 seconds the recalled settings will be displayed.

FIGURE B.22

Summary:

(See Figure B.23)

1. Press Memory button to highlight "Memory Recall" icon
2. Turn Control Knob to select memory location
3. Press and hold memory button for 5 seconds

FIGURE B.23

Status Lights:

(See Figure B.24)

There are 4 status lights located between the voltage and amperage displays. These LEDs illuminate to display the following:

1. Power on – This light indicates that power has been applied to the machine and it is ready to weld. A blinking light indicates that the start up sequence is in process. When the light turns fully ON, the machine is ready to weld.
2. Thermal Fault – The thermal light will turn on if the machine has overheated. Welding may continue after the machine has cooled and the light switches off.
3. Remote - When a remote output control is connected to the 6 pin connector on the front of the machine, this LED will turn on.
4. VRD – When operating in VRD Mode (Voltage Reduction Device) this LED will light up when the output voltage is below 12 Volts. VRD may be turned ON / OFF in Setup Menu "SYS."

FIGURE B.24

graph TD
    A["1"] --> B["v"]
    C["2"] --> D["VRD"]
    E["3"] --> F["VRD"]
    G["4"] --> H["VRD"]

Hold Select button for 5 seconds to enter Menu "GTAW."

Setup Menu "GTAW"Press SEL to cycle through & rotate knob to change then SEL to save 'A' to exit			TIG Settings
Display Item Choices			Description
	Waveform ShapeWAVE		Choose which waveform you would like to use.
		Soft Square ↗ (Default)	Increased puddle control.
		Sine ↘	Traditional AC Transformer output.
		Square ↗	Faster travel speeds.
		Triangular ↗	Reduce heat input for thinner materials. Also provides for better cleaning for anodized applications.
DIA Tungsten Diameter		AUTO	Specify your tungsten size for better arc initiation. AUTO (IntellistartTM) automatically manages arc starting conditions to match adjusted amperage setting. Selecting ADV will allow manual adjustment of starting parameters. Ball Starting Sequence provides robust starting parameters.
		.020
		.040
		1/16
		3/32 (Default)
		1/8
		BALL
		ADV
The following settings are only available if DIA is set to ADV
SCRT Starting Current 2-200 Amps			Amplitude of initial starting pulse
STME Starting Time 1-1000 ms			Time of initial arc start pulse (1 cycle)
SSLP Starting Slope 0-1000 ms			How fast operating current is reached
PCRT Preset Current Minimum 2-50 Amps			Minimum current machine output
POL	Starting Polarity	EN	Choose whether the starting polarity is negative or positive.
		EP
2RST	Advanced Trigger	ON	Switch ON to enable 2 Step trigger with restart. See Appendix for more information.
		OFF
4RST		ON	Switch ON to enable 4 Step trigger with restart. See Appendix for more information.
		OFF
BILV		ON	Switch ON to enable Bi-level trigger. See Appendix for more information.
		OFF
SPOT Spot Timer OFF - 100 s			Specify your spot weld time. Default = OFF.

Hold Pulse button for 5 seconds to enter Menu "SMAW."

Setup Menu "SMAW" Stick Settings
Display Item Choices		Description
FRCE Arc Force	Force	0-75 for soft stick 75-200 for crisp stick	Specify your Arc Force setting
HSTR Hot Start	Start	0-75 for soft stick 50-200 for crisp stick	Specify your Hot Start setting
POL Stick Polarity	DC+	Change your welding polarity. Default setting is DC+.
	DC-

Hold both Select and Pulse buttons for 5 seconds to enter Menu "SYS."

Then press 'SEL' to cycle through. To change, rotate knob then press 'SEL' to save "A' to exit

Setup Menu “SYS” System Settings
Display Item	Choices Description
UNIT Units		Inch	Change between imperical and metric units
		MM
VRD Voltage Reduction Device		ON	Turn ON to enable VRD and limit machine OCV to 12 Volts
		OFF
LED LED	Brightness	LOW	Adjusts the intensity of the display LEDsMED
		HIGH
COOL Cooler Control		AUTO	On AUTO, the cooler turns on and off as needed. ON forces it to run continuously.
		ON
CTRL Control Board Software Version - Displays current control board software version
UI User Interface Board Software Version - Displays current UI board software version
IC Input Control Board Revision - Displays Input Control Board Revision
ERR	Error Messages	-	Displays error messages (See Troubleshooting Section)
HR	Arc Time	- Displays	total welding hours
CNT	Arc Counter	-	Displays total number of arc strikes amperage, memory & SYS menu
RSET	Reset to Default	YES/NO	Resets to factory default.
GRN	Green Mode	YES/NO	Allows the user to enable or disable the green mode
LOCK	Display Lockout	YES/NO	With lockout activated, all settings are frozen except amper-age control, access to the system menu & memory

Appendix

A.1 Volt and Amp meter display while welding and idle.

While welding, the machine will show actual voltage and amperage on the meters. When the welding arc is extinguished, the meters will display (and flash) the final voltage and amperage of that weld for 5 seconds.

Figure B.25

A.2 Green Mode

(Show the V and A displays with GRN MODE)

Green mode is a feature that puts the machine in a standby condition after 10 minutes of inactivity.

• Output is Disabled.
• Fans Change to a Low Speed.
• LEDs Switch Off – Only the Power ON LED Remains Lit.
• A hash line will illuminate across the display.

This feature will reduce the amount of dust and dirt that is drawn into the machine and will lower the machines power consumption.

To exit Green Mode, simply press the TIG remote trigger or any button on the front of the machine.

NOTE: If a Cool Arc® machine is connected to the Aspect® 230 AC/DC, entering Green Mode will stop the coolant flow. To resume coolant flow, Green Mode must first be exited.

A.3 2-Step Trigger with Restart Sequence

2-Step trigger with restart can be enabled in setup menu "GTAW" by switching 2RST to ON. If 2RST is ON, a TIG mode is selected, and 2-step is selected on the output section of the machine, the following sequence will occur.

This sequence is the same as 2-step, except when the switch is pressed while in final slope the welding current will ramp up again and resume. This process can be repeated as many times as necessary. When finished welding, simply release the trigger and allow the finishing current to end and the output to switch OFF followed by the post flow time.

A.4 4-Step Trigger with Restart Sequence

4-Step trigger with restart can be enabled in setup menu "GTAW" by switching 4RST to ON. If 4RST is ON, a TIG mode is selected, and 4-step is selected on the output section of the machine, the following sequence will occur.

This sequence is the same as 4-step, except when the switch is released during the finishing current, welding current will ramp up again to the operating amperage. This process can be repeated as many times as necessary. When welding is finished, quickly press and release the trigger to start the final slope, which will be followed by the finishing current at which point output is switched OFF, and the post flow will initiate.

A.5 Bi-Level Trigger Sequence

Bi-Level Trigger Sequence Bi-level trigger can be enabled in setup menu "GTAW" by switching BILV to ON. If BILV is ON, a TIG mode is selected, and 4-step is selected on the output section of the machine, the bi-level sequence will be followed. Bi-level follows the same sequence as 4-step but allows switching between operating amperage and a background current, A2. With Bi-level enabled, press the SEL button until the left display shows A2. Turning the control knob will allow the A2 level to be set as a percent of the operating current.

While welding at the set operating current, quickly press and release the trigger to switch to the A2 background current level. Quickly pressing and releasing the trigger again will switch the output back to the set operating current. Each time this trigger action is repeated the current level will switch between the two levels. When the main weld is complete, press and hold the trigger to start the final slope and finishing current. Release the switch to switch the output OFF and begin the post flow time.

GENERAL OPTIONS / ACCESSORIES

Field Installed

K870 - Foot Amptrol™ for TIG welding. The Foot Amptrol energizes the output and controls the output remotely. The Foot Amptrol™ connects directly to the 6-pin remote control connector.

K963-3 - Hand Amptrol™ for TIG welding. The Hand Amptrol™ energizes the output and controls the output remotely. The Hand Amptrol™ connects directly to the 6-pin remote control connector.

K814 - Arc Start Switch - Energizes the output for TIG welding if remote output control of the amperage is not desired. It allows on/off TIG welding at the amperage set by the Current Control on the control panel.

K3475-1 - Cool-Arc® 22 Water Cooler- Attaches underneath the Aspect® 230 AC/DC and electrically connects to the Aspect® 230 AC/DC. This smart cooler runs only when needed and shuts off welding if coolant flow is interrupted.

K4441-1 TIG Inverter Cart- Holds the Aspect® 230 AC/DC, the Cool Arc® 22 and all accessories. Features low lift bottle loader and drawer for convenient storage.

K918-1 Zippered cable cover, 12.5 ft. (3.8 m)- to protect torch cables in high abrasion applications.

K918-4 Zippered cable cover, 25.0 ft. (7.6 m)- to protect torch cables in high abrasion applications.

Regulator with Flow Gauge and Hose Kit (3100211)

K2266-1 – TIG-Mate™ 17 Air Cooled TIG Torch Starter Pack. One complete easy-to-order kit packaged in its own portable carrying case. Includes: PTA-17 torch, parts kit, Harris flowmeter/regulator, 10 ft. gas hose, Twist-Mate™ adapter, work clamp and cable.

Magnum® TIG Torches – The following standard Magnum® TIG torches may be used with the Aspect® 230 AC/DC.

• K1781-1 PTA-9 12.5 ft.(3.8m) Air-Cooled 125A
• K1782-1 PTA-17 12.5 ft.(3.8m) Air-Cooled 150A
• K1782-3 PTA-17 25 ft.(7.6m) Air-Cooled 150A
• K1782-14 PTA-17 12.5 ft.3.8m) Air-Cooled 150A Ready Pak
• K1783-1 PTA-26 12.5 ft.(3.8m) Air-Cooled 200A
• K1783-3 PTA-26 25 ft.(7.6m) Air-Cooled 200A
Water cooled torches (The Cool Arc 22 is required)
• K1784-3 PTW-20 Water-Cooled 12.5 ft.(3.8m) 250A
• K1784-4 PTW-20 Water-Cooled 25 ft.(7.6m) 250A

K1622-5 Twist-Mate™ Adapter - Adapter needed for K4168-2 and K1784-3 and K1784-4 torches

NOTE: Each torch requires a Twist-Mate™ Adapter, collets, collet bodies, and nozzles and are not included and must be ordered separately.

KP2414-1 Gas Lens parts kit for PTA-9 and PTW-20 series torches.

KP508- Magnum® parts kit for PTA-17 series torches.

KP509- Magnum® parts kit for PTW-18 and PTA-26 series torches.

KP510- Magnum® parts kit for PTX-20, 20H-320-25R series torches.

K1803-3 - Work Lead Clamp with Twist-Mate™ plug, 15ft.(4.6m).

KP4159-1 Low Conductivity Coolant (1 Gal.)

K1622-3 Twist Mate Adapter for PTA-26 TIG Torch

K1622-1 Twist Mate Adapter for PTA-17 TIG Torch

MAINTENANCE

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this maintenance.
• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
• Do not touch electrically hot parts.

WARNING

To avoid receiving a high frequency shock, keep the TIG torch and cables in good condition.

ROUTINE AND PERIODIC MAINTENANCE

Very little routine maintenance is necessary to keep your Aspect® 230 AC/DC running in top condition. No specific schedule can be set for performing the following items; factors such as hours of usage and machine environment should be considered when establishing a maintenance schedule.

• Periodically blow out dust and dirt which may accumulate within the welder using an air stream.
• Inspect welder output and control cables for fraying, cuts, and bare spots.
• The fan motor has sealed ball bearings which require no maintenance.

OVERLOAD PROTECTION

FAN-AS-NEEDED (F.A.N.)

The Aspect® 230 AC/DC has the F.A.N. circuit feature, which means the cooling fan will operate only as needed to assure proper machine cooling. This helps reduce the amount of dust and dirt drawn into the machine with the cooling air. The cooling fan will operate at lower speeds when the machine power is initially turned on or at idle, and continuously while the yellow Thermal Shutdown Light is lit (see Thermostatic Protection).

THERMOSTATIC PROTECTION

This welder has thermostatic protection from excessive duty cycles, overloads, loss of cooling, and excessive ambient temperatures. When the welder is subjected to an overload, or inadequate cooling, the primary coil thermostat and/or secondary coil thermostat will open. This condition will be indicated by the illumination of the yellow Thermal Shutdown Light on the front panel (see Item 2 in Figure B.19 Operation Section). The fan will continue to run to cool the power source. Postflow occurs when TIG welding is shut down, but no welding is possible until the machine is allowed to cool and the yellow Thermal Shutdown Light goes out.

NO ARC PROTECTION

The machine outputs (Background / OCV, gas and HF) will be shutdown, if the trigger is closed without welding for 15 seconds to protect the Background resistor from overheating with F.A.N. cooling off, as well as to conserve on gas waste.

FUSE PROTECTION

The cooler is protected by a 3-amp fast-acting fuse, located inside of the welding machine on top of the P.C. board. The fuse is identified as FS1. Ensure power is "off" and the machine is disconnected from power when measuring or replacing the fuse. The fuse is 600V 3-amp fast acting.

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled "PROBLEM (SYMPTOMS)". This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled "POSSIBLE CAUSE" lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

Observe all Safety Guidelines detailed throughout this manual

Error Code	Description	Possible Cause Course Of Action
01	Input voltage too low Input voltage	is less than 90VAC, or drops below 90VAC under load	Check the input voltage with and without a load applied, check the cable size, and fuse size.
02	Input voltage too high Input voltage	is higher than 500VAC or spikes above 500VAC during load	Check the input voltage with and without a load applied.
03	Incorrect input connection	Input voltage not configured correctly Turn	OFF the machine and check the input connections. If three phase is being applied, ensure the voltage is at least 185VAC
04	Primary side voltage lock out	Indicates that an internal auxiliary voltage fault condition is detected.	Indicates that an overload condition occurred. Turn off the machine, wait one minute and then turn the machine on.
05	AC Switch Overload Indicates that an output overload condition has occurred.		Check the output cables and connections for shorts. Turn off the machine, wait one minute and then turn the machine on.
06	Inverter voltage lock out Indicates that an Internal Voltage fault condition is detected.		Turn off the machine, wait one minute and then turn the machine on.
Conn Err	Connection Error A communication error between the control and UI board has occurred.		Turn off the machine, wait one minute and then turn the machine on.
10	Fan fault This error message indicates the fan is not operating properly. This prevent over temperature damage.		Turn off the machine, wait one minute and then turn the machine on.
11	Water Cooler Fault Insufficient coolant in the cooler, TIG torch is undersized for application, TIG torch is pinched, faulty flow sensor in the cooler.		Check the TIG torch for kinks, check the cooler connections, verify the fluid in the cooler is within the suggested limits, replace damaged torch, replace torch with a higher ampacity torch, toggle flow switch on cooler to remove the error code.
12	Water Cooler Presence Fault	Cooler is not connected to the 9-pin connector,	Water cooler was connected/disconnected during operation. Turn off the machine, connect the cooler, wait one minute and then turn the machine on.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

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TIG WELDING ISSUES

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Poor starting Poor work clamp connection	Check and secure work connection
	Wrong “DIA” setting Access “GTAW” menu (see operation section) and set DIA for IntellistartTM “AUTO” or proper Tungsten size
	Start current is too low Increase start current
Black area along weld bead Oily or organic contamination on work piece Clean work piece
Output quits momentarily; gas flow and hi-freq are also interrupted	May be caused by hi-freq interference Check for proper machine ground connection; surrounding machines that generate hi-freq also should be grounded properly
	Faulty Components, PC Boards or Connections	Contact your local Lincoln Authorized Service Facility
Arc flutters Pulser may be turned on inadvertently Turn Pulser off
		Electrode may be too large for current setting Use smaller Tungsten
		Insufficient gas shielding	Adjust flow rate
		Contaminated gas or leaks in gas line, torch, or connections	Check gas line & connections
Insufficient cleaning	Wave shape settings may not suit application	Set for manual balance and increase EP or reduce balance percentage
Insufficient penetration	Wave shape settings may not suit application	Set for manual balance and increase EN or balance percentage
Unstable	Wrong Wave form setting	Access “GTAW” menu (see operation section) and change “WAVE” setting to “SQRE” or “SOFT”
	AC frequency may not suit application	Adjust AC frequency
Output shut off during welding	Spot Timer may be turned on inadvertently	Access “GTAW” menu (see operation section) and change “SPOT” to “OFF”
	Faulty Components, PC Boards or Connections	Contact your local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

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STICK WELDING ISSUES

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Poor starting Hot start may be set too low	Access “SMAW” menu (see operation section) and increase “HSTR” setting
	Poor work clamp connection Check and secure work connection
Stick electrode “blasts off” when arc is struck	Current may be set too high for electrode size	Adjust current
	Hot start set too high Access “SMAW” menu (see operation section) and reduce “HSTR” setting
Electrode “sticks” in weld puddle Current	current may be set too low for electrode size Adjust current
	Arc force set too low Access “SMAW” menu (see operation section) and increase “FRCE” setting
Insufficient penetration	Wrong Process setting Set Process for Crisp Stick

START-UP ISSUES

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Green Input indicator light does not stop blinking	Trigger or hand/foot Amptrol may be accidentally closed during start up	Turn machine off, open trigger or Amptrol, then turn machine on
	Input voltage is too high or too low Check input voltage (115V to 460V)
	Faulty PC Boards or connections Contact your local Lincoln Authorized Field Service Facility.
Meters don’t light up	Losing input to machine Check input fuses and connection
	Faulty Components, PC Boards or Connections	Contact your local Lincoln Authorized Field Service Facility.

PRESET ISSUES

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Operating Amperage changes after changing EP or EN in AC Waveshape	This is normal, the operating Amperage is calculated based on EP, EN, and Balance settings	Adjust to desired Amperage
Operating Amperage can’t be set for 2A	“DIA” setting in “GTA W” menu is set for specific size, e.g. 3/32”. Starting current setting on the front of the machine.	Set for “AUTO” or smaller size diameter, or reduce the starting current on the front of the machine.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

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OPEN CIRCUIT VOLTAGE (OCV) ISSUES

Note: Do not connect a meter to machine output terminals to measure voltage in TIG mode as hi-freq produced by machine may damage meter. When trigger is closed in TIG mode, machine displays OCV on left meter for approximately 3 seconds then output will turn off if a weld is not made. Machine does not display OCV in Stick mode even though the output is always on.

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
OCV is below 10V in TIG mode Preflow	time set too long Set for typical 0.5 second preflow
	Faulty PC Boards or connections Contact your	local Lincoln Authorized Field Service Facility.
OCV is below 80V in TIG mode	Faulty Components, PC Boards or Connections	Contact your local Lincoln Authorized Field Service Facility.

OUTPUT ISSUES
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Thermal light turns on Welding application exceeds rated duty cycle		Reduce duty cycle
		Air intake & exhaust louvers may be blocked Maintain sufficient clearance around machine
		Dirt and dust may have clogged the cooling channel inside machine
		Faulty fans or connections Contact your local Lincoln Authorized Field Service Facility.
		Faulty Components, PCB or Connections Contact your local Lincoln Authorized Field Service Facility.
Output o.k. in Stick but no output in TIG	No gas & no hi-freq Faulty trigger or hand/foot Amptrol or connection	Check trigger or Amptrol connection
	Gas & hi-freq o.k. Faulty PC Boards or connections	Contact your local Lincoln Authorized Field Service Facility.
No output in both Stick and TIG Faulty PC Boards or connections Contact your local Lincoln Authorized Field Service Facility.

REMOTE CONTROL ISSUES
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Hand/foot Amptrol has no control Machine	hine set for 4-step trigger Set for 2-step trigger
	Start current set too high Reduce Start current
	Faulty Amptrol Check Amptrol
	Faulty Components, PCB or Connections Contact your local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

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HI FREQUENCY ISSUES

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
No hi-freq Wrong Process setting Verify	Process is set for hi-freq TIG
	Preflow time set too long Set for typical 0.5 second preflow time
	Faulty PC Boards or connections Contact your local Lincoln Authorized Field Service Facility.
Hi-freq does not initiate an arc Insufficient gas flow Check gas flow

WATER COOLER ISSUES

NOTE: If cooler control cable is connected to or disconnected from machine when machine is already turned on, machine must be recycled by turning off and then on so that cooler is recognized by machine; failure to do this may damage Tig torch when welding

Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS)	POSSIBLE CAUSE	RECOMMENDED COURSE OF ACTION
Indicator light on cooler does not turn on	Cooler is not plugged in Plug cooler to 9-Pin Receptacle
	No voltage on 9-pin receptacle Contact your local	Lincoln Authorized Field ServiceFacility and/or check the 3-amp fuse located in the machine. See “Fuse Protection Section”
TIG torch runs hot	Cooler control cable is not plugged in	Turn machine off, plug control cable, then turn machine on
Machine displays ERR 11 when welding	Insufficient water in cooler Check and refill water
	Air in water line	Activate trigger and depress Flow Sensor Bypass switch to prime cooler
	Cooler is not plugged in to 9-Pin receptacle, insufficient coolant in cooler, TIG Torch is undersized (amperage capacity) for application, or faulty flow sensor inside cooler.	Initial Correction Measures:Check Cooler Connections, Fill Cooler with additional Low Conductivity Coolant (KP4159-1), Replace with higher amperage capacity TIG Torch. Depress Flow Sensor Off button to remove error code.Secondary Corrective Measures:Service cooler

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

Technical line drawing of a vehicle chassis frame with mounting brackets and structural components (no text or symbols)

Note: dimensions in mm and between round brackets in inches

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WARNING	● Do not touch electrically live parts or electrode with skin or wet clothing.● Insulate yourself from work and ground.	● Keep flammable materials away.	● Wear eye, ear and body protection.
SpanishAVISO DE PRECAUCION	● No torque las partes o los electrodos bajo carga con la piel o ropa moja-da.● Aislese del trabajo y de la tierra.	● Mantenga el material combustible fuera del área de trabajo.	● Protéjase los ojos, los oídos y el cuerpo.
FrenchATTENTION	● Ne laissez ni la peau ni des vête-ments mouillés entrer en contact avec des pièces sous tension.● Isolez-vous du travail et de la terre.	● Gardez à l'écart de tout matériel inflammable.	● Protégez vos yeux, vos oreilles et votre corps.
GermanWARNUNG	● Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!● Isolieren Sie sich von den Elektroden und dem Erdboden!	● Entfernen Sie brennbarres Material!	● Tragen Sie Augen-, Ohren- und Kör-perschutz!
PortugueseATENÇÃO	● Não torque partes elétricas e elec-trodos com a pele ou roupa molha-da.● Isole-se da peça e terra.	● Mantenha inflamáveis bem guarda-dos.	● Use proteção para a vista, ouvido e corpo.
Japanese注意事項	● 通電中の電気部品、又は溶材にヒフやぬれた布で触れないこと。● 施工物やアースから身体が絶縁されている様にして下さい。	● 燃えやすいものの側での溶接作業は絶対にしてはなりません。	● 目、耳及び身体に保護具をして下さい。
Chinese警告	● 皮肤或濕衣物切勿接觸帶電部件及錚條。● 使你自己與地面和工件絶縁。	● 把一切易燃物品移離工作場所。	● 佩戴眼、耳及身體勞動保護用具。
Korean위험	● 전도체나 용접봉을 젖은 형갑 또는 피부로 절대 접촉치 마십시오.● 모재와 접지를 접촉치 마십시오.	● 인화성 물질을 접근 시키지 마시요.	● 눈, 귀와 몇에 보호장구를 착용하십시오.
Arabicتحذير	● لا تلمس الاجزاء التي يسري فيها التيار ● الكهربائي أو الالكترود بجلد الجسم أو بالملابس المبللة بالமاء.● ضع عازلا على جسمك خلال العمل.● ضع copaً على جسمك خلال العمل.	● ضع copaً للاشتعال في مكان بعيد.● ضع copaً للاشتعال في مكان بعيد.	● ضع copaً وملابس واقية على عينيك وأönنيك ● وجسمك.● ضع copaً وملابس واقية على عينيك وأönنيك

READ AND UNDERSTAND THE MANUFACTURER'S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER'S SAFETY PRACTICES.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer's particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

THE LINCOLN ELECTRIC COMPANY

22801 St. Clair Avenue • Cleveland, OH • 44117-1199 • U.S.A.

Phone: [phone] • www.lincolnelectric.com