ESAB LTS 320 Programming Manual

Valid for program version 2.10B and 2.11A0457 706 104 981110

PROWELDER 320

LTS 320

104

Programming manual

TOCe

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1 INTRODUCTION 4........................................................

1.1 Mode of operation -- Control box 4.......................................

1.2 Sectors 4............................................................

1.3 Display and keyset 6..................................................

2 WELDING PARAMETERS 12................................................

2.1 Welding current 12.....................................................

2.2 Gas 13...............................................................

2.3 Wire feed speed 13....................................................

2.4 Preheating time 14.....................................................

2.5 Rotation speed 14.....................................................

3 START AND STOP 15......................................................

3.1 Start 15...............................................................

3.2 Stop 15...............................................................

3.3 Restart 15............................................................

4 TO GET STARTED 16......................................................

4.1 General 16............................................................

4.2 How to indicate a tool code 16............................................

4.3 How to change languages 18.............................................

5 PROGRAM EDITING 19.....................................................

5.1 Entering a parameter value 19............................................

5.2 Increasing/decreasing a parameter value 19................................

5.3 Creating a new sector 20................................................

5.4 Changing the breakpoint of a sector 20....................................

5.5 Creating a transport sector 21............................................

5.6 Finding the home position 22.............................................

5.7 Entering a slope 22.....................................................

5.8 Moving within a program 23..............................................

5.9 Deleting in a program 24................................................

5.10Changing weld data during welding 25.....................................

5.11Zeroing the control box 26...............................................

6 PROGRAMMING EXAMPLES 27.............................................

6.1 Example 1a: 27........................................................

6.2 Example 1b: 31........................................................

6.3 Example 1c: 34........................................................

6.4 Example 1d: 38........................................................

6.5 Example 1e: 43........................................................

7 THE LIBRARY 46..........................................................

7.1 Storing a program 46...................................................

7.2 Recalling a program 46..................................................

7.3 Viewing the tool code 47.................................................

7.4 Deleting a program 48..................................................

8 MANUAL MODE 49........................................................

8.1 Field of application 49...................................................

8.2 Editing a parameter 49..................................................

9 PC--CARD 52.............................................................

9.1 Field of application 52...................................................

9.2 How to install the card 52................................................

9.3 How to recall a program 52..............................................

9.4 How to store a program 53...............................................

9.5 How to delete a program 54..............................................

9.6 How to take out the PC--card 55..........................................

TOCe

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10 ERROR CODES 55.........................................................

10.1 Error handling 55.......................................................

10.2 Incorrect editing codes 64...............................................

11 SHOW CURRENT PARAMETER VALUES 65..................................

11.1 Field of application 65...................................................

11.2 How to view actual parameter values 66...................................

12 SOFTWARE UPGRADE 66..................................................

12.1 Application field 66.....................................................

12.2 Menu explanation 67....................................................

12.3 How to upgrade 68.....................................................

12.4 Measures to be taken when the upgrading of the power source units failed 71....

12.5 Measures to be taken when the upgrading of the control box failed 72...........

13 SOFWARE KEY 73.........................................................

13.1 General 73............................................................

13.2 Locking the control box 73...............................................

13.3 Unlocking the control box 74.............................................

13.4 Changing the code 75...................................................

14 NOTEBOOK 76............................................................

14.1 Field of application 76...................................................

14.2 How to enter data in the notebook 76......................................

14.3 Example 2a: 77........................................................

15 MANUAL WELDING 87.....................................................

15.1 Field of application 87...................................................

15.2 How to create a welding program 87.......................................

15.3 Example 3a: 87........................................................

15.4 How to weld 93........................................................

16 APPENDIX 93.............................................................

16.1 Tool codes 93..........................................................

16.2 Symbols 94...........................................................

16.3 Setting ranges -- welding parameters 95....................................

17 TECHNICAL TERMS 96.....................................................

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1 INTRODUCTION

1.1 Mode of operation -- Control box

The control box consists of four memory units, the working area, the

library, the notebook and the auxiliary function.

S In the working area the welding program is created.

S In the library the program can be stored.

During welding it is always the contents of the working area that control

the welding process. Thus it is also possible to call in a welding program

from the library to the working area.

S In the notebook you can make your own notes about special welding

parameters, for example.

S In the auxiliary function you can:

S change languages

S view all existing error messages

S show actual parameter values

S software upgrade

S sofware key

1.2 Sectors

A welding program for welding of tubes can be divided into different parts or

sectors. Each sector corresponds to a special part of the circumference of

the tube. Max. number of sectors for one program is one hundred (100).

Sector 1

Sector 2

Sector 4

Sector 3

A sector can be assigned its own set of values for different welding

parameters, such as current, rotation speed, wire feed speed, etc. In this

way the welding can be performed using different parameter settings for

different parts of the joint of the tube.

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The division into sectors is done by indicating different breakpoints along

the circumference of the tube. Each such breakpoint constitutes the

starting point of a new sector. In the figure below, the breakpoint 0.000 is

the starting point of sector 1, breakpoint 0.250 the starting point of sector 2,

etc.

Sector 1

Sector 2

Sector 4

Sector 3

Breakpoint 0,000

Breakpoint 0,250

Breakpoint 0,500

Breakpoint 0,750

LTS 320 allows welding of up to 10 turns in the same welding joint, i.e. the

welding tool can be rotated 10 times round the tube.

The breakpoints in the previous figure all start with the integer 0 which

means that they form the breakpoints of turn 1. The breakpoints of turn 2

(if there is one) always start with the integer 1,etc.

S T urn 1 = breakpoints 0.000 -- 0.999

S T urn 2 = breakpoints 1.000 -- 1.999

S T urn 3 = breakpoints 2.000 -- 2.999

S T urn 4 = breakpoints 3.000 -- 3.999

S T urn 5 = breakpoints 4.000 -- 4.999

S T urn 6 = breakpoints 5.000 -- 5.999

S T urn 7 = breakpoints 6.000 -- 6.999

S T urn 8 = breakpoints 7.000 -- 7.999

S T urn 9 = breakpoints 8.000 -- 8.999

S T urn 10 = breakpoints 9.000 -- 9.999

To terminate a welding program a so--called end sector is indicated.

For a sector to be counted as an end sector the following two conditions

must be fulfilled:

S There is no sector following.

S The welding current value of the sector = 0 ampere.

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1.3 Display and keyset

A Display

B Soft keys

C Function keys

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Display

SECTOR 2(4)

5

WELD GAS

ROOT GAS

START GAS

WELD

GAS

ROOT

GAS

START

GAS

s

a

b

c

d

e

15

0.500

f

g

h

The following information is shown in the display.

a The program sector at present involved.

b The number of sectors in the current program.

c The breakpoint of the sector (sector 2 in this example).

d The digit box shows the numerical value entered and different

numerical characters. For further information, see page 94.

e Showing that the indicated value has been borrowed from a previous

sector (in this example from sector 1).

g 5 text boxes describing the function of the so--called soft keys (f).

h Message line describing the actual state.

WELDING = a welding sequence is going on.

END = a welding sequence is completed.

TRANSPORT = transfer without welding.

STOP = the welding sequence was interrupted due to activation

of the stop key.

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Soft keys

By way of the soft keys ( a) the functions connected with the respective

display (in this case the GAS parameter display), the significance of which is

indicated in the text boxes (b). Depending on the display selected, up to five

soft keys can be activated.

Function

keys

Parameter keys

The welding parameters are divided into five different groups, each group

represented by one ordinary key and a set of soft keys.

Welding current Gas

Rotation speed Wire feed speed

Preheating time

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SHIFT key

This key is used for changing the significance of other keys on the

keyboard.

PLUS/MINUS keys

These keys are used for increasing/decreasing set values.

Numerical keys

These keys are used for entering the digits 0--9 and decimal point.

Other keys

SLOPE

This key is used when you want to add a slope function to a parameter and

is indicated in the following way in the display

.

By slope is meant a gradual change of a set value.

Slope up = gradual increase

Slope down = gradual decrease

The following parameters can be assigned a slope function:

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Current (both peak and background current) when pulsed current is used,

rotation, wire feed speed.

A slope can be time--controlled by indicating that it shall go on for a certain

number of seconds. It can also be sector--controlled, making it a so--called

sector slope, by indicating between which two breakpoints it shall be

located.

SECTOR

This key indicates the breakpoint of a program and moving to indicated

sector.

STEP

This key is used for stepping forward in the program.

DELETE

This key is used for deleting the whole program, part of a program in the

working area, or just the figures in the digit box.

MANUAL MODE

This key is used for positioning the electrode before welding, and for making

sure that the program in the working area functions as desired.

MEMORY (library)

This key is used for entering or leaving the library and for storing a program,

or for recalling a program from the library to the working area.

MODE (auxiliary functions)

This key is used for getting to the different auxiliary functions, such as

language, error log, show actual parameter values and software upgrading.

NOTEBOOK

These keys are used if you want to make notes on a welding sequence.

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TOOL CODE

These keys are used if you want to view the code of the connected tool.

RESTART

These keys are used for restarting a welding sequence.

SECTOR SLOPE

These keys are used if you want to create a sector slope.

DIRECT STOP

Pressing this key will lead to direct stop of the welding. The gas postflow

takes place according to settings in the end sector.

START

This key is used for starting a welding sequence.

STOP

This key is used for stopping a welding sequence. The welding sequence is

terminated according to the settings in the end sector .

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2 WELDING PARAMETERS

Setting ranges for the welding parameters can be found in the APPENDIX

on page 95.

2.1 Weldin g current

There are four different parameters for welding current:

S PEAK CURRENT

S BACKGROUND CURRENT

S PEAK TIME (1 s)

S BACKGROUND TIME (1 s)

The values in brackets are preset values.

Peak time

Background time

Background current

Peak

current

The welding current can be either pulsed or continuous (not pulsed).

If you want to weld using pulse current a value must be entered for all four

parameters. When welding with continuous current, however, you only need

to enter the value for peak current. Entering a value also for background

current will result in pulsed current with preset pulse and background

times. Of course, the pulse and background times can also be changed.

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2.2 Gas

In the Shielding Gas parameter group three parameters are represented:

S WELD GAS

S ROOT GAS

S START GAS

By weld gas is meant the shielding gas on the upper side of the joint. The

weld gas parameter indicates the time the shielding gas is to flow on the

upper side of the joint before and after welding.

The values of the weld gas parameter are preset. The following values for

preflow and postflow of the weld gas apply at the start if nothing else has

been indicated:

S Weld gas preflow = 2 s

S Weld gas postflow = 4 s

By root gas is meant the shielding gas on the underside of the joint. The

root gas parameter indicates the time the shielding gas is to flow on the

underside of the joint before and after welding.

Some shielding gases, for example helium (He), can cause difficulty with

regard to striking the arc. If such a shielding gas is to be used as weld gas,

it could be advisable to use another gas mixture at the start moment -- a

so--called start gas.

If one value is entered for weld gas in sector 1 and one for start gas, only

the start gas is going to flow. The weld gas starts flowing when the arc is

struck.

2.3 Wire feed speed

This parameter is used to indicate the desired feed speed of the filler wire in

cm/min.

The wire feed speed can be pulsed or continuous (not pulsed).

In the Wire Feed Speed parameter group two parameters are represented:

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S PEAK WIRE FEED SPEED

S BACKGROUND WIRE FEED SPEED

For welding with continuous (not pulsed) wire feed speed, only the peak

wire feed parameter shall be entered.

For welding with pulsed wire feed speed, both the peak wire feed speed

and the background wire feed speed parameters shall be entered.

The pulsed wire feed speed is always automatically synchronised with the

welding current. The wire feed speed is high using pulse current and low

using background current.

2.4 Preheatin g time

Preheating is used for heating the workpiece at the starting point in order to

obtain correct penetration of the molten pool. The preheating time is defined

as the time elapsing between arc strike and start of the rotary motion. If no

value has been entered for the preheating parameter , the arc will strike at

the same time as rotation is started.

NOTE! In the Welding Current parameter group you cannot indicate a

sector slope when preheating is involved.

2.5 Rotation speed

This parameter indicates the rotation speed of the electrode round the

workpiece. It is indicated in per mill (thousandths) of the max. rotation speed

of the welding tool used.

Just like welding current and wire feed speed, the rotation speed can be

pulsed or continuous (not pulsed).

In the Rotation Speed parameter group four parameters are represented:

S ROTATION FORWARDS

S ROTATION BACKWARDS

S PULSED ROTATION FORWARDS

S PULSED ROTATION BACKWARDS

The pulse rotation is always automatically synchronised with the welding

current. The welding tool rotates when peak current is used, and stands still

when background current is used.

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3 START AND STOP

3.1 Start

To start the welding, use the START key .

It is impossible to start a welding program if another tool code has been

indicated than the one used in the program in question.

3.2 Stop

A requested welding stop over the STOP key means that the program

jumps to the following end sector, no matter which sector you are in at the

moment. The welding is terminated according to the settings of the end

sector.

A requested welding stop over the DIRECT STOP key

leads to

immediate stop of the welding. The gas postflow takes place according to

the time set in the end sector.

3.3 Restart

If the welding was interrupted it is restarted with the SHIFT and START

keys

.

Irrespective of whether the welding was stopped over the STOP

or the DIRECT STOP key , the start parameters of the preceding

start sector are used. The program then continues from the position in the

welding program where it was interrupted.

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4 TO GET STARTED

4.1 Gen eral

Some of the factors controlling the welding process are specific to each one

of the welding tools, for example the rotation speed. Therefore, every

welding program must be connected to a tool code, associated with the

tool that the program was made up for.

4.2 How to indicate a tool code

S T urn the mains switch on the welding power source to position 1.

S The following display comes up:

CHOOSE CONNECTED TOOL

PRB "

PRH

PRD

POC 12--60 mm

TIG HAND TORCH

A25

Example: You have connected PRB 33--90

S Move the marking to the line for PRB using the soft key NEXT. Choose

the desired tool and press ENT ER.

A window comes up, showing available tool sizes.

S Move the marking to the size of the tool you have connected (in this

example 33--90 mm) using the soft key NEXT and press ENTER.

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CHOOSE CONNECTED TOOL

PRB " 8-- 17 mm

PRH 17-- 49 mm

PRD 33-- 90 mm

POC 12--60 mm 60-- 170 mm

TIG HAND TORCH

A25

Result: The new tool code is accepted and the following text is displayed:

CONNECTED TOOL: PRB 33--90 mm.

NOTE! In the event a program with another tool code should already be

stored in the working area this must first be deleted. (If you want to keep the

old program that was stored in the working area, you must store it in the

library.)

The following information is displayed in the display:

S

P

r

e

s

t

h

e

s

o

f

t

S

P

r

e

s

t

h

e

s

o

f

t

k

d

l

t

key delete

existin

g

p

ro-

WARNING!

TOOLTYPE MISMATCH

e

x

i

s

t

i

n

g

p

r

o

g

ram.

T

O

L

T

Y

P

E

M

I

S

M

A

T

C

H

g

r

a

m

.

PROGRAM MADE FOR: PRB 17-- 49 mm

CONNECTED TOOL: PRB 33-- 90 mm

DELETE

PROG.

Result: The new tool code is accepted and the display displays:

CONNECTED TOOL: PRB 33--90 mm.

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4.3 How to change languages

The different texts displayed on the control box are available in the following

four languages:

S English, German, Swedish, Norwegian.

On delivery and after resetting the box, all texts displayed are in English.

Language

selection

S Press the MODE key

to get to the auxiliary functions, and the

following display comes up:

S

P

r

e

s

t

h

e

s

o

f

t

S

P

r

e

s

t

h

e

s

o

f

t

k

l

key language.

AUXILIARY FUNCTIONS

LANGUAGE "

ERROR LOG "

SHOW ACTUAL PARAMETER VALUES

SOFTWARE UPGRADE "

SOFTWARE KEY "

LAN--

GUAGE

ERROR

LOG

SHOW

PARA--

METER

SOFT--.

WARE

UPGR.

SOFT--

WARE

KEY

S Press the soft key next language and step to the desired language.

S

P

r

e

s

t

h

e

s

o

f

t

S

P

r

e

s

t

h

e

s

o

f

t

k

h

key change

l

a

n

g

u

a

g

e

CHOSEN LANGUAGE: ENGLISH

l

anguage.

AVAILABLE LANGUAGES

ENGLISH NORSK

DEUTSCH

SVENSKA

CHANGE

LANG

QUIT

Result: All texts will from now on be in the new language (in this example

Swedish).

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S

T

e

r

m

i

n

a

t

e

b

y

S

T

e

r

m

i

n

a

t

e

b

y

i

t

h

y

pressing the

s

o

f

t

k

e

y

a

v

-

VALT SPRÅK: SVENSKA

so

f

t

k

ey av-

bryt.

TILLGÄNGLIGA SPRÅK

ENGLISH NORSK

DEUTSCH

SVENSKA

NÄSTA

SPRÅK

BYT

SPRÅK

AVBRYT

S Press the MODE key to return to the working area.

5 PROGRAM EDITING

5.1 Entering a parameter value

S Make sure the right group of parameters is displayed in the display by

pressing one of the five parameter keys.

S Enter a value in the digit box.

S Press the soft key of the desired parameter.

Note that the parameters always inherit the value from the previous

sector if no new value is entered.

5.2 In creasing/decreasing a parameter value

The parameter value to be altered must be shown in the digit box.

S Mark the desired parameter using one of the soft keys. The set value

comes up in the box.

S Press the PLUS

or the MINUS key .

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5.3 Creating a new sector

A new sector is created by entering a new breakpoint into an existing sector.

S Enter a new value for the breakpoint of the new sector.

S Press the SECTOR key

.

In doing this, a new sector is created which is a copy of the original sector,

but with another breakpoint and another sector number. The new sector is

automatically positioned in the right place in the program. This is determined

by the value of the new breakpoint.

Creating a new sector during welding

Proceed as follows to create a new sector during the welding:

S Enter a value into one of the following parameter groups using the

numerical keys:

S Press the corresponding soft key.

A new sector is now automatically created.

5.4 Chang ing the b reakpoint of a sector

Make sure the existing breakpoint value of the sector is displayed in the digit

box.

S Press the SECTOR key

.

The breakpoint value is now shown in the digit box.

S Enter the new breakpoint value.

S Press the SECTOR key

or

S Change the breakpoint value using the PLUS key

or the MINUS

key

.

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ESAB LTS 320 Programming Manual

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