ESAB PAL 3 User manual

Brand: ESAB

Model: PAL 3

Type: User manual

ESAB PAL 3 is a motor control unit designed to precisely control welding motions through integration with external motor regulators. It offers a speed reference ranging from 0-10V, proportional to programmed speed values. The unit features two relays for forward and backward control, additional inputs for external start/stop functions, and compatibility with a two-channel pulse transmitter for positioning feedback. Its applications include controlling wire feeders, roller beds, turntables, and positioners in welding plants.

Valid for Serial NO 837 XXX--XXXX0457 960 001 000926

PAL 3

101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

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Rätt till ändring av specifikationer utan avi sering förbehålles.

Ret til ændring af specifikationer uden varsel forbeholdes.

Rett til å endre spesifikasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehal ten.

Sous réserve de modifications sans avis préalabl e.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especifi caciones sin previo aviso.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

Reservamo--nos o direito de alterar as especificações sem aviso prévio.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

SVENSKA 3..............................................

DANSK 12................................................

NORSK 21................................................

SUOMI 30................................................

ENGLISH 39..............................................

DEUTSCH 48.............................................

FRANÇAIS 57.............................................

NEDERLANDS 66.........................................

ESPAÑOL 75..............................................

ITALIANO 84..............................................

PORTUGUÊS 93..........................................

ÅËËÇÍÉÊÁ 102.............................................

ENGLISH

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TOCe

1 DIRECTIVE 40........................................................

2SAFETY 40...........................................................

3 INTRODUCTION 41...................................................

3.1 General 41..................................................................

3.2 Voltage supply 41............................................................

3.3 Speed reference 42..........................................................

3.4 Pulse transmitter inputs 42....................................................

3.5 Relay outputs 42.............................................................

3.6 Additional inputs/outputs 43....................................................

4 INSTALLATION 44....................................................

4.1 General 44..................................................................

4.2 Connection 44...............................................................

5 OPERATION 46.......................................................

5.1 General 46..................................................................

6 MAINTENANCE 46....................................................

6.1 General 46..................................................................

6.2 Daily 46.....................................................................

7 ORDERING OF SPARE PARTS 47......................................

DIAGRAM 111............................................................

SPARE PARTS LIST 113...................................................

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1 DIRECTIVE

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Esab Welding Equipment AB, S--695 81 Laxå, Sweden, försäkrar under eget ansvar

att enhet 0457 870 880 från serienummer 837 överensstämmelse med standard EN

60974--1 enligt villkoren i direktiv 73/23/ EEG med tillägg 93/68/ EEG och standard

EN 50199 enligt villkor en i direktiv 89/336/ EEG me d tillägg 93/68/ EEG.

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Anders Birgersson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 99--06--22

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 recommendations should be observed in addition to the standard regulations that apply

to the work place.

All work must be carried out by trained personnel well familiar with the operation of the welding equip-

ment.

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 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 that no--one is unprotected when the arc is struck

3. The work place must:

S be suitable for the purpose

S be free from draughts

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 shall 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 keep fumes and gases from your breathing zone and

the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your 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 your ears. Use ear defenders 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

3.1 General

The welding motion is controlled over the PAL 3 motor control unit and an external

motor regulator. The control unit can be fitted to the LTP 450 (Protig) and the LTS

320 (Prowelder) power sources for the control of wire feed, roller beds, turntables

and positioners, for example.

The control unit is used in plants where the rotary motion is effected by way of

motors stronger than the ESAB VEC 1000 rpm.

The unit gives a speed reference of 0--10 V. It is provided with two relays emitting

signals for forward and backward control and some extra inputs for external start and

stop, for example.

A two--channel pulse transmitter fitted to the motor shaft is required as feed--back

enabling the power sources to keep the positioning under control. This applies to

welding programs with more than one sector.

Instead of the pulse transmitter an external input can be used for changing sectors.

3.2 Voltage supply

The motor control unit is supplied with 42 V AC over the pins XP1.J and XP1.B of the

CAN terminal.

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3.3 Speed reference

An analogue signal between +0.5 V and +10 V is emitted for the welding motion.

The voltage is proportional to the programmed speed value, i.e. the value 1000 rpm

will result in +10 V and 500 in +5 V.

To protect the machine from disturbances and earth fault the signal is galavanically

separated from other electronics by way of reinforced insulation.

Technical data

Speed reference +0.5 V -- +10 V

Max. load 5mA

Contact: XS6.A 0V

XS6.B Signal

3.4 Pulse transmitter inputs

The pulse signal lies between 0 and 24 V over the two ranges.

In order to protect the machine from earth fault and disturbances the inputs are

insulated by way of opto--couplers.

Technical data

Range of frequencies 25--1700 Hz / 200--13600 Hz

Current 15 mA

Contact: SX6.H Channel 1

SX6.G Channel 2

SX6.J Zero

3.5 Relay outputs

The board has two separate relay outputs with alternating functions. T he outputs are

used for controlling the forward and backward mot ions.

Forward: RE1--Off RE2--On

Backward: RE1--On RE2--Off

Idle: RE1--Off RE2--Off

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Technical data

Max. voltage 220 V AC 24 V DC

Max. current 5A 10 A

Contact: SX6.C COM RE1

SX6.N ON RE1

SX6.D OFF RE1

SX6.E COM RE2

SX6.P ON RE2

SX6.F OFF RE2

3.6 Additional inputs/outputs

The board contains five extra ports to be used as digital inputs/outputs. When they

are used as inputs the +15 V voltage of the board itself must be fed back to get a

high signal. A 10 ms long signal is required to enable the control unit to register the

change.

If the ports are used as out puts only the proce ssor will be driving. Therefore, a

galvanically insulated drive must be connected if other electronics are to be used.

Technical data

Input Output

Voltage 15 V 0and5V

Max. current 2mA 0.1 mA

Contact Normal function

SX6.X Not used

SX6.W Not used

SX6.T Sector change

SX6.S Start/Stop ( 4--stroke)

SX6.R Home position

SX6.M +15VDC

SX6.K +15VDC

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4 INSTALLATION

4.1 General

The installatio n shall be execu ted by a profession al.

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.

4.2 Connection

The control unit is to be connected to the external motor regulator.

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For LTP 450 applies that mother board AP9 must be disengaged before the control

unit can be connected.

To bridge the mother board, follow the instructions below.

S Undo the screws and lift off the cover of the power source.

S Dismount the cable and contact (1).

S Move the horizontal contact (2) to the place where contact (1) was previously

fitted.

S Move contact ( 3) to the place where contact (2) was previously fitted.

LTP 450

LTS 320

S Put back the cover.

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Screw the control unit onto the power source.

S Connect the control unit to the CAN terminal at the r ear of the power source.

5OPERATION

5.1 General

General safety regulations for the handling of the equipment appear from

page 40. Read through before you start using the equipment!

6 MAINTENANCE

6.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer

attempts to rectify any faults on the machine during the warranty period.

6.2 Daily

Check that the cables are in good condition and properly connected.

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7 ORDERING OF SPARE PARTS

PAL 3 is designed and tested in accordance with the EN 60 974--1 (IEC

974--1) international standard.

It is the obligation of the service unit which has carried out the service or re-

pair work to make sure that the product still conforms to the said standard.

Spare parts are ordered through your nearest ESAB representative, see back cover.

When ordering spare parts, please state machine type and number as well as desig-

nation and spare part number as shown in the spare parts list on page 113.

This will simplify dispatch and ensure you get the right part.

ESAB PAL 3 User manual

ESAB PAL 3 User manual

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