GB
Valid for serial no. 910--xxx--xxxx, 306--xxx--xxxx0457 690 001 GB 041210
PROWELDER 320
LTS 320
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
1DIREKTIV 3.........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 4................................................................
3.2 Programming box 5.........................................................
3.3 Applications 5..............................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Mains voltage connection 6...................................................
5.3 Other connections 7.........................................................
5.4 End resistor 8...............................................................
5.5 Connection of complete welding system 9......................................
6 OPERATION 10.......................................................
6.1 Controls and connections 10...................................................
6.2 Cooling water circuit 11.......................................................
6.3 Overheating protection 11.....................................................
6.4 Flow guard, water 11.........................................................
6.5 Flow guard, gas 11...........................................................
6.6 Error messages 11...........................................................
7 MAINTENANCE 11....................................................
7.1 Filling of coolant 12...........................................................
8 ORDERING OF SPARE PARTS 12......................................
DIAGRAM 14............................................................
ORDERING NUMBER 16.................................................
ACCESSORIES 17.......................................................
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1DIREKTIV
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTS 320 from serial number 811 complies with standard
EN 60974--1, in accordance with the requirements of directive (73/23/EEA) and ad-
dendum (93/68/EEA) and standard EN 50199 in accordance with the requirements
of directive 89/336/ EEA and addendum 93/68/ EEA .
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 98--02--11
2SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from drafts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect y our eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect y our ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
3 INTRODUCTION
PROWELDER 320 is a welding power source of the rectifier type designed for
mechanised TIG welding. It is available in two different models:
S PROWELDER 320 without mains voltage transformer for connection to 400 V, 3∼
50/60 Hz mains voltage.
S PROWELDER 320 with mains voltage transformer for connection to 208--500 V,
3∼ 50/60 Hz mains voltage.
The welding power source PROWELDER 320 is fan--cooled and also includes a
cooling system for water--cooling of the welding tool.
PROWELDER 320 is prepared for connection to an external PC.
3.1 Equipment
PROWELDER 320 is supplied with:
S Programming box with connection cable (10 m)
S Return cable (5 m) with return cable clamp
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3.2 Programming box
PROWELDER 320 is provided with a programming box for:
S Programming of welding procedures when welding with a welding tool.
S Executing a welding process.
S Storing welding program in an internal or external memory unit (PC board).
S Transferring welding programs between programming units.
S Setting of different parameter values when welding with a TIG hand torch.
For the handling, see Programming manual.
The programming manual is available in the following languages:
Language Article no. Language Article no.
English 0457 706 X74 French 0457 706 X76
German 0457 706 X75 Swedish 0457 706 X70
Italian 0457 706 X79 Finnish 0457 706 X73
Norwegian 0457 706 X72 Danish 0457 706 X71
Dutch 0457 706 X77 Spanish 0457 706 X78
Portuguese 0457 706 X80 Russian 0457 706 X86
3.3 Applications
W elding power source PROWELDER 320 can be used for welding with:
S Tube welding tools for joining tubes
S Tube--to--plate welding tools for welding of tube diameters 12--60 mm
S Automatic welding machine A25 STB with floating head.
S TIG hand torch
A wir e feed unit for filler wire can be connected to PROWELDER 320.
Motors for external units (roller beds, turntables, etc.) can be controlled by way of the
PAL 3 motor control unit.
ESAB accessories for mechanised and manual TIG welding are found on
page 17.
4 TECHNICAL DATA
PROWELDER 320, 400 V
PROWELDER 320, 208--500 V
Mains connection 400V 3∼ 50/60 Hz 230/400/500V 3∼ 50Hz or
208/230/460/475V 3∼ 60 Hz
Permissible load at
100% duty cycle
270 A / 20.8 V 270 A / 20.8 V
60% duty cycle
320 A/ 22.7 V 320 A / 22.7 V
Setting range, welding cur-
rent
5 A / 10 V -- 320 A / 22.7 V 5 A / 10 V -- 320 A / 22.7 V
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PROWELDER 320, 208--500 V
PROWELDER 320, 400 V
No--load power
310 W 310 W
Efficiency
82 % 82 %
Power factor
0.80 0.80
Enclosure class
IP 23 IP 23
Weight
110 kg 156 kg
Dimensions, l x w x h
734 x 486 x 695 mm 734 x 486 x 695 mm
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installatio n must be executed b y a professional.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’ s responsibility to take adequate precautions.
5.1 Placing
Place the welding power source so as not to prevent the cooling air from circulating
through the machine.
WARNING -- TIPPING RISK!
Fasten the equipment -- particularly if the
ground is uneven or sloping.
5.2 Mains voltage connection
The rating plate with connection data is placed at the rear of the power source.
S Make sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to the regulations valid.
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Recommende d cable areas and fu se sizes
PROWELDER 320
Voltage 230 V
3∼ 50 Hz
400 V
3∼ 50 Hz
500 V
3∼ 50 Hz
208 V
3∼ 60 Hz
230 V
3∼ 60 Hz
460 V
3∼ 60 Hz
475 V
3∼ 60 Hz
Primary current at:
100% duty cycle 19,5 A 12 A 9A 21.5 A 19,5 A 10 A 9.5 A
60% duty cycle 25 A 15 A 12 A 27 A 24.5 A 12,5 A 12 A
Cable area, mm
2
4x10 4x4 4x4 4x10 4x10 4x4 4x4
Fuse, slow--blow 20 A 16 A 16 A 20 A 20 A 16 A 16 A
5.3 Other connections
AH 0388
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5.4 End resistor
To avoid communication trouble the two end points of the CAN --bus should be fitted
with an end resistor.
One of the CAN--bus end points is in the programming box which has a built--in
resistor. The other one is in the power source and should be fitted with an end
resistor if the output in question is not used. F or the location of the resistor, see the
following figure.
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5.5 Connection of complete welding system
A--A Connection cable -- programming box
B--B, Z-- Z Motor cable --wire feed
C--C, S--S Motor cable -- rotation
D--D Signal cable -- external PC
G--G Cooling--water hose in
H--H Cooling--water hose out
J--J Welding cable
L--L Torch contact
M--M Gas hose out
N--N Gas hose in
P--P Signal cable -- external PC
R--R Connection cable -- pulsetransmitter
T--T, V--V Connection cable -- CAN 42 V
X Connection cable -- external motor
U--U Connection cable -- rotor VEC
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6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Controls and connections
Front of welding power source
1 Switch for mains voltage ON/OFF 8 Connection for PC/printer
2 White indicating lamp, mains voltage ON 9 Connection for return water
3 Orange indicating lamp, overheating 10 Connection for cooling water
4 Switch for cooling unit ON/OFF 11 Connection for welding cable (--)
5 Connection for rotation 12 Connection for welding and start gas out
6 Connection for wire feed 13 Connection for torch contact, TIG hand torch
7 Connection for programming box 14 Connection for return cable (+)
Back of welding power source
15 Connection for start gas in 18 Connection for root gas out
16 Connection for welding gas in 19 Connection CAN 42 V for motor control unit
PAL3 and A25 VEC motor
17 Connection for root gas in 20 Automatic fuse
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6.2 Cooling water circuit
S Connect the cooling water hoses of the welding tool
to the connections on the welding power source.
When welding with air--cooled welding tools,
interconnect the water hoses using the bridge
coupling supplied (see fig.).
S Before welding start, set switch (4) on the cooling
unit to position ON.
Note: The cooling water pump must always be set to
ON and the flowguard of the welding power source
must have detected the water flow to make welding
possible.
6.3 Overheating protection
Welding power source PROWELDER 320 is provided with a thermal cut--out which
trips in case of too high temperature. The welding current is broken and an orange
indicating lamp on the front of the power source goes on. The programming box also
shows an error message. The thermal cut--out is reset automatically when the
temperature has gone down.
6.4 Flow guard, water
If there is no cooling water flowing, the flow guard will block the welding power
source. The welding current is then interrupted and an error message is displayed in
the character window of the programming unit.
NOTE. This applies only if the cooling system was connected from the start (i.e.
switch (4) on the cooling unit was set to position 1, and the cooling water hose was
connected).
6.5 Flow guard, gas
The flow guard breaks the ongoing welding process if the gas flow falls below 6
l/min. An error message is presented over the programming box.
6.6 Error messages
The welding power source has a built --in function for handling error messages. All
error messages are presented in the programming unit, and in some cases
measures will be taken automatically. See also pr ogramming manual 0457 706 xxx.
7 MAINTENANCE
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
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Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
Cleaning
Check regularly that the power source is free from dirt.
How often, and to what extent, cleaning should be carried out depends on the
welding process, ar c t ime, disposition and the surr ounding environment. It will
normally suffice to blow the power source clean using compressed air (reduced
pressure) once a year.
If the power source is very dirty, brushing and vacuuming are recommended.
S Disconnect the welding power source from the mains current supply.
S Remove the adapter from the socket. Lock the socket to prevent unauthorised
connection.
At fixed installations, the safety switch should be set to the off position. Lock
the switch.
S Remove the power source’s safety plates for best access.
After cleaning, all safety plates must be m ounted before you connect the power
source to the mains supply.
7.1 Filling of coolant
As coolant a mixture of 50% water and 50% glycol is recommended.
8 ORDERING OF SPARE PARTS
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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PROWELDER 320
Edition 041210
Ordering number
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Ordering no. Denomination Type Notes
0456 650 881 Welding power source PROWELDER 320 400 V, 50/60 Hz
0456 650 883 Welding power source PROWELDER 320 230/400/500 V, 50 Hz,
208/230/460/475 V, 60 Hz
0457 690 990 Spare parts list PROWELDER 320
The spare parts list is available on the Internet at www .esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instruction manuals and spare parts lists.
PROWELDER 320
Edition 041210
Accessories
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Order number
Tube welding tool
A21 PRB, water--cooled 17--49 0443 750 880............................... .......
33--90 0443 760 880.......
60--170 0443 770 880......
A21 PRB, air--cooled 17--49 0443 750 881.................................. .......
33--90 0443 760 881.......
60--170 0443 770 881......
A21 PRH, enclosed 3--12 0444 300 880................................... .........
3--38 0444 301 880.........
6--76 0444 302 880.........
Coolant for A21 PRH, 0007 810 012.................................................
A22 POC, wire feed 12--60 0443 930 880................................... .......
Conversion kit
A21 PRB 8--17 0444 002 880.............................. ......................
30--33 0443 908 880......................
44--60 0443 909 880......................
Driving unit 134:1 for the welding tools PRB/PRC 0443 544 880............................
Automatic welding machine
A25 with floating head, TIG torch BTE 250 0443 912 880..............................
A25 with floating head, TIG torch BTE 500 0443 912 881..............................
VEC motor with gear and pulse generator complete 0457 258 880.........................
TIG hand torch BTF 400W (4 m OKC) 0457 827 882.....................................
Wire feed unit MEI 21 0443 830 880....................................................
Carriage 0457 221 880................................................................
PC board (PCMCIA board) 0457 320 880.. ............................................
Software kit 0459 370 885...........................................................
PC--card with software and programming manuals in English, French, German and Swedish.
Software kit 2 0459 370 886..........................................................
PC--card with software and programming manuals in English, Italian, Finnish and Norwegian.
Set of emergency stops 0457 823 880.................................................
Motor control unit PAL 3 0457 870 880.................................................
Documentation printer 0449 322 880...................................................
Documentation system
Weldoct WMS 4000 0457 410 880................................................
SPS 4000 0457 410 881..........................................................
OptoOptronic cables d (15 m) 0457 072 881.........................................
OptoOptronic cables d (2 m) 0457 072 882...........................................
Extension cable
b, wire, programming box, CAN 42 V (10 m) 0456 904 880.............................
c, rotation (10 m) 0456 906 880.....................................................
f, return cable 0152 349 888.......................................................
Extension set 1, current, water, gas (8 m) 0456 905 880...................................
Extension set 2, current, water, gas, torch contact (8m) 0466 705 881.......................
PROWELDER 320
Edition 041210
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PROWELDER 320
Edition 041210
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ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.co m
031021
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel:+3612044182
Fax:+3612044186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB International AB
Gothenburg
Tel:+4631509000
Fax:+4631509360
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 3369 4333
Fax: +55 31 3369 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA--CIS
ESAB Representative Office
Moscow
Tel:+70959379820
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel:+78123254362
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.co m
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