ESAB PROTIG 315 Programming Manual

443 425--003 9604 Valid from Machine no 606 XXX--XXXX

PROTIG 315

TIG--welding equipment

WIG--Schweissausrüstung

Programming

Programmierung

SAFETY 2.........................................................

TECHNICAL DESCRIPTION 3.......................................

BLOCK DIAGRAM 7...............................................

FUNCTION DESCRIPTION 8........................................

Programming block 12............................................

PROGRAMMING FUNCTIONS 13.....................................

Programming unit 14.............................................

Programming rules 16............................................

KEY FUNCTION 17..................................................

Non--SHIFT function 17...........................................

Stepping in program 18...........................................

Erasing (delete) 19...............................................

Sector concepts 20...............................................

Slope concepts 24...............................................

Increase/decrease function 26.....................................

Start/stop function 27.............................................

START--UP 29......................................................

Actual tool codes 29..............................................

Write position 30.................................................

Read position 31.................................................

Notebook 32.....................................................

PROGRAMMING 33.................................................

Representation of decimal point 33.................................

Manual program 33...............................................

WELDING PROGRAMS 37...........................................

Testing of welding program without welding 42.......................

T ransmission of welding programs between working area and library area 43

Pulsed welding 44................................................

Arc voltage 48...................................................

Tack welding 49..................................................

Weaving 49.....................................................

Special pulsing function 52........................................

Interval welding 55...............................................

Rotation to the start position 56....................................

CODES 58..........................................................

Acknowledge code 58............................................

Activity code 58..................................................

Blocking code 59.................................................

TRANSMISSION OF WELDING PROGRAMS 62........................

T ransmission of welding programs between the PROTIG 315 and an

external storing unit 62........................................

T ransmission from control equipment to cassette tape 63..............

T ransmission from tape to control equipment 64......................

T ransmission of welding programs 65...............................

Printing of welding programs from the control equipment to the

HX--20 printer 65.............................................

Handling of cassette tapes 66......................................

Rights reserved to alter specifications without notice.

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WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR

EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU--

FACTURER’S 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 d angerous 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 d amage hearing

S Protect your ears. Use ear defenders or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE OPERATING MANUAL

BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SAFETY

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SAFETY

Users of ESAB welding equipment have ultimate responsibility for ensuring that any-

one who works on or near the equipment observes all the relevant safety precau-

tions.

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 re-

gulations that apply to the work place.

All work must be carried out by trained personnel who are familiar with the operation

of the welding equipment.

Incorrect operation of the equipment may lead to a hazardous situation 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 the location of emergency stops

S its function

S relevant safety precautions

S welding

To make this easier each switch, pushbutton or potentiometer is marked with a

symbol or text that indicates its function when activated.

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 wor k place mu st:

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 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 dur-

ing its operation.

apa2dp03

TECHNICAL DESCRIPTION

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TECHNICAL DESCRIPTION

PROTIG 315 is a programmable T IG welding equipment offering facilities for pro-

gramming of welding processes, storing of welding programs and transfer of welding

programs between similar welding equipment.

A fully compatible IBM personal computer in combination with the ESAB data base

program PROfile can be used as exterior store unit. The old EPSON HX--20 unit can

also be used.

PROTIG 315 is designed to be used together with the tube welding tools PRB/PRC/

PRD/PRE/PRF/PRG/PRI and the wire feed unit MTC20/MEI20 as well as the tube

welding tools POA/PIA/POB and the component system A25. PROTIG 315 can also

be used together with manual TIG torches. It complies with the IEC 974 regulations.

The complete welding equipment contains:

S Welding power source

Field of application, technical data,

design and function.

S Electronic unit

PC board rack including boards.

S Programming unit

Layout and programming.

S TIG welding tools

See the respective operator’s manual.

S Wire feed unit

See the respective operator’s manual.

PROTIG 315 is intended to be used in

combination with a new version of the

programming unit EPROM R5E and R6A

(the old version cannot be used).

Entered value or position is indicated on a

digit/character display.

TECHNICAL DESCRIPTION

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TECHNICAL DATA

PROTIG 315

Permissible load (DC), power source

Duty cycle % 100 60 35

y

Current (A) 200 250 315

Voltage (V) 18 20 23

Permissible load (DC), welding tool See the respective operator’s

manual

Setting range(DC) 5 -- 315 A

Max open--circuit voltage 67 V

Open--circuit power 500 -- 600 W

Ambient temperature:

2

5

_

C

5

_

C

p

during transportation

-- 2 5 _C--+55_C

1

0

_

C

+

4

0

_

C

during welding

-- 1 0 _C--+40_C

Relative atmospheric humidity:

t

4

0

_

C

p

y

up to 50%

at +40_C

a

t

+

2

0

_

C

up to 90%, storing only

at + 20_C

Temperature class F (155_C)

Enclosure class IP 23 AF

Efficiency and power factor See operator’s manual for

PROTIG 315

Mains voltage variation Less than 2 A at 10% mains

voltage variation

Program sectors 1--999

Storage capacity Some 150 programs

Battery back--up 2 years

Mains connec-

tion

50 -- 60 Hz

3x208 V 3x230 V 3x380 V 3x400 V 3x415 V 3x440 V 3x460 V 3x480 V 3x500 V

TECHNICAL DESCRIPTION

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The main components of the control equipment are:

1. Programming unit

2. Electronic unit

S The programming unit is provided with numeric keys, control function keys, para -

meter keys and a numeric character display.

TECHNICAL DESCRIPTION

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S The electronic unit contains:

A01 Counting board ( printed circuit board)

S Controls the process together with the CPU board.

S Includes time functions for welding, pulsing and slope--up/slope--

down.

S Adapts keyboard and display to the computer.

A03 CPU board with 16 k byte RWM and EPROM (printed circuit board)

S Storage of welding programs

S Processes and executes instructions.

A06 I/O board (printed circuit board) controls all activities during welding.

A07 Connecting board (printed circuit board)

A08 Motor board (printed circuit board) for weaving motion.

A09 Motor board (printed circuit board) for wire feed motion.

A10 Motor board (printed circuit board) for rotary motion. NOT E that motor

boards A 08 -- A10 are identic.

A11 Motor board (printed circuit board) for arc length regulation.

A12 Current reference board (printed circuit board)

A13 Relay board (printed circuit board) with relays for switching solenoid val-

ves on/off and starting functions on/off.

A14 Rear plate (printed circuit board) .

A15 Front board (printed circuit board).

A16 Front disturbance elimination board (printed circuit board).

A17 Rear disturbance elimination board (printed circuit board).

A18 Filter board for arc voltage measuring.

A21 Feed unit.

BLOCK DIAGRAM

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BLOCK DIAGRAM

Control and pro-

gramming unit

Electronic unit

(PC board rack)

T ube welding tool

and tube--to--plate

welding tool

Exterior stor-

age unit

Welding power

source

Wire feed unit

Regulating

amplifier and

slope--unit

Accessory unit:

Printer registrating welding parameters, welding current, arc voltage and rotary mo-

tion of tool.

FUNCTION DESCRIPTION

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FUNCTION DESCRIPTION

The complete welding equipment can be divided into the following functions.

S Welding circuit

S Shielding gas circuit

S Feed and control circuit

S Motor circuit

S Program handling

Welding circuit

The built-- in current regulator of the electronic unit provides together with the

measuring shunt of the power source a very good accuracy regarding setting and

repetitivness of the welding current.

When programming, you can choose pulsing of the welding current between certain

desired values during the whole procedure or parts of it.

When programming, you can also choose the slope--up and slope--down functions.

They can be used not only at the beginning and the end of the welding program, but

also within certain desired parts of the program.

The slope--function can be of different types: it can either be based on time or posi-

tion--oriented. The position --oriented slope--function admits continuous current

change during parts of the welding program.

At the beginning of the welding process the HF unit is connected and the striking of

the arc can be supervised over the welding current circuit. When the arc is struck the

HF unit is automatically disconnected.

As an extra protective measure, a water fuse is connected in the welding circuit. The

fuse--link is continuously cooled by the surrounding circulating water. In case the

water should stop circulating, the fuse--link melts and the welding circuit is broken.

The electronic unit is internally prepared for a supervisory function which will be

blocked in case the water circulation should stop.

Shielding gas

circuit

On the rear of the electronic unit are connections for root gas, start gas and weld-

ing gas.

S The root gas can be connected manually or be programmed for the desired

length of time.

S The start and weldin g gases are in many cases identic, but it is possible to use

different types of gas.

The pre-- and post--flow times of the shielding gas can be programmed optionally be-

tween 0 -- 999 seconds.

In addition to the three solenoid valves for the different gas functions also a gas flow

guard is connected to indicate if there is a flow of shielding gas during the ongoing

welding pr ocess.

If no start or welding gas is flowing, the welding process is interrupted. The root gas

function is not connected to the gas flow guard.

FUNCTION DESCRIPTION

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Supply voltage and control circuit

The electronic unit is connected to 42 V AC from the welding power source and the

control transformer.

42 V AC is used via printed board relays and interlocking functions to the supply unit,

the solenoid valves and the starting circuit.

The supply unit provides +5, --5, +12 --12, +15 and --15 V DC as supply voltage for

the board rack as well as 36 and 60 V DC for the motor circuits.

The supply unit has an automatic reclosing function in case of mains failure, short--

circuit proof outputs and a function where the supply unit is disconnected in case the

supply voltage for the racks deviates by more than +/-- 5% from the rated value.

The supply voltage is indicated by a green LED on the electronic unit.

Motor circuit

The electronic unit is designed for four motor functions: rotatary motion, wire feed

motion, arc length regulation and weaving.

As to the arc length regulation the PC board differs from other motor regulators, but

for weaving the same motor regulator is used as for wire feed motion and rotary mo -

tion.

The supply voltage to the armature for the rotary and wire feed motions is 24 V and

both motors are provided with a tachometer generator.

The feedback control system makes use of the tachometer voltage to keep the rota-

tion speed constant at varying load conditions. The control system has a current limit

for the respective motor.

The tachometer generator for the rotary motion is also used for keeping up the posi-

tion of the motor. The tachometer generators provide a great number of pulses and

because of that also a very good positioning accuracy.

One exception regarding the supply voltage for the motors is the wire feed unit MTC

20 that has a 36 V motor with higher power than the other motors. When this unit is

connected a higher current limit is automatically obtained.

The smaller motors are of the permanent magnet type (even MEI 20), while the MTC

20 motor is pr o vided with a stator with field winding.

If one of the motors is disconnected from the electronic unit, the voltage supply for

the whole unit is interrupted.

At reclosing or change of welding tools, the programming unit asks for a tool code

(identification code) that is to be answered. T hen the equipment can be used for

welding again.

FUNCTION DESCRIPTION

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Welding power source

From electrotechnical point of view the power source can be divided into four units:

1. Power unit

2. Main PC board

3. High--frequency unit

4. Electronic equipment (PC board rack)

The power unit (fan--cooled) includes:

S Main transformer

S Transistor unit

S Diode bridges

S Auxiliary diodes

S Inductor

The transformer and inductor windings have silicon impregnation.

The inductor gives a smooth weld with only little spatter.

The shunt in the welding circuit provides proportional voltage that is fed back to the

control system which in this way can compensate for variations in the welding circuit.

The transistors control the level of welding current.

The power unit is provided with three overload protections (thermal type).

The main PC board contains:

S Processor

S Storage function

S Regulation function

S Control function

The control transformer supplies 42 V AC to the system.

The gas post--flow function has been transferred to the elctronic unit and has been

changed from a fixed time function to a programmable function.

The high frequency unit contains:

S HF unit

S HF transformer

The high frequency unit is automatically disconnected as soon as the arc is struck.

FUNCTION DESCRIPTION

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The electronic equipment ( PC bo ard rack) co n t ain s:

S Process area

S Data area

The interface between the areas is the connection boards (front and rear connectors,

pos 7 and 15).

Process area

S Weaving motor board pos 8

S Wire feed board pos 9

S Rotating motor board pos 10

These three motor boards (pos 8, 9 10) are identic.

The supply voltage is 42 V DC, full --wave rectified and smoothed by way of a 220

mF capacitor.

To control the motor speed a chopper--regulator is used (pulse interval control).

The reference is obtained through a 10--bit resolution D/A converter.

Each motor has tacho--feedback and current limit. The arc length motor has arc

voltage feedback instead of tachometer.

The reference is obtained through an 8--bit resolution D/A converter.

S Arc length motor board pos 11

S Current regulation board pos 12

The reference is obtained from the welding program over I/O and CPU boards.

The regulator is galvanically separated from the data area via a 12--bit D/A cont-

verter providing steps of 0.1 A between 5--315 A (theoretical value).

The shunt of the welding current circuit is important with regard to the total

measuring accuracy of the welding current.

The shunt voltage drop is a feedback from the welding current circuit.

S Relay board pos 13

The function of the relay board is to switch on and off the supply voltage (42 V)

for the three solenoid valves and the starting function of the power source (4 re -

lays in all).

There is room for eight relay functions on the PC board.

All PC boards in the process area are activated over the I/O board.

Data area

S I/O board

The I/O board controls all activities in the welding process.

It contains 9 different 8--bit ports -- in all 72 connections (pins).

The board also contains circuits for adressing logic.

FUNCTION DESCRIPTION

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S CPU board

The CPU board contains:

S One processor

S One bus buffer

S One internal clock (constituting the time basis for the whole system). The

function is to process and execute instructions (checking data and process

areas).

S One communication link for serial communication.

S A function for the process and welding program.

S The process program is stored in 2 EPROM capsules which preserve their

information also when the supply voltage has been broken. T he contents can

only be erased by UV light.

S The welding program(s) is stored in a 16 kb r ead--write memory, 15 out of

which occupy welding data. Also the tachometer, the indicators (flags) and

temporary numbers are stored in this memory.

S Counting board

The counting circuit board includes three important circuits:

S 8259 -- controls the process together with the CPU board.

S 8253 -- contains time functions for the welding process and the slope--func-

tion.

S 8279 -- adapts the keyboard and the display to the microprocessor.

Programming block

Programming block over a key switch on the programming unit

1. Accessible functions in position Programming Block:

S Manual program, all functions.

S Shift of electrode centre line both during welding and in manual mode.

S Reading of parameter value.

S Program control (step function)

S Welding program transmission, from library to working area.

S Welding program transmission, from computer to working area.

S Erase program in the working area.

S Starting procedure.

S Stop and start of welding program and emergency stop by activating three

keys simultaneously.

2. Prohibited functions in position Programming Block:

S Erase welding parameters in a welding program.

S Erase welding program in the library area.

S Increase/decrease keys (+ och --).

S Modify contents of welding programs.

S Replace or modify parameter values.

S Transmission of welding program, from working area to library.

NB: The display indicates Bloc in case a prohibited function is selected. The com-

puter does not react to the activation of a prohibited function.

PROGRAMMING FUNCTIONS

-- 1 3 --dpa4p1eb

PROGRAMMING FUNCTIONS

The following pages describe the individual programming functions, including

examples of programming, possible combinations and an error code list.

Pre--welding functions:

S Manual gas pre--flow.

S Manual arc length regulation.

S Manual electrode adjustment (laterally).

S Manual filler wire adjustment.

S Manual adjustment of initial position for the rotation.

Before welding, all operations regarding the welding program are executed:

S Programming.

S Pre--weld test of completed program (without welding).

S Reading of existing program.

S Modification of individual parameter or part of program.

S Stepping through program or individual sector.

S Two--way transfer of welding program, working area/library area.

S Two--way trannsfer of welding program, working area/micro cassette alt. PROfile

program.

In the course of welding the following operations can b e executed:

S Gas pre--flow and gas post--flow.

S Special start gas during arc strike.

S Root gas flow.

S Pulsing of welding current, rotary motion and wire feed motion.

S Synchronous pulsing of welding current and wire feed motion.

S Synchronous pulsing of welding current and rotary motion.

S Time--related slope--up and slope--down.

S Position--dependent slope--up and slope--down.

S AVC -- and weaving function.

In the course of welding, the following adjustments and registrations can be

made:

S Stop and restart of welding process in the desired position of the rotary cycle.

S Positional tracking during rotary motion.

S Manual adjustment of electrode position (vertically and horizontally).

S Parameter display during slope function.

S Modification of individual parameter in welded sector.

S Registration of arc voltage, welding current and rotary motion.

S Stepping through welded sector.

PROGRAMMING FUNCTIONS

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S Entering of new sector.

Programming unit

On the programming unit is/are:

S a display with 7--segment indicators

S a program blocking key

S 37 keys, divided up as follows:

S Function keys

S Parameter keys

S Numeral keys

Function keys

Gas function keys

Delayed start of rotary mo -

tion

Rotation of welding tool,

clockwise and anti--clock--

wise

Filler wire feed

Centre line adjustment

Welding start and stop key

Parameter keys

Pulsing keys

Delete key

PROGRAMMING FUNCTIONS

-- 1 5 --dpa4p1eb

Arc length function key

Weave function key

Stepping function

Gives certain parameter

keys a 2nd function

Dividing welding pro--

grams into different sectors

Increases displayed value

Decreases displayed value

Slope --up and slope--down

function

Indicates program number

Numeral keys

Decimal point

PROGRAMMING FUNCTIONS

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Programming rules

Represents dark display

Represents display with entered value

Represents display showing sector number.

Represents display showing error code, block code

Indicates that deletion is taking place.

Indicates that an entered program is transferred to the mem-

ory.

Indicates that a program is copied from the library area and

transferred to the working area.

The last operation of a welding program is finished.

Indicates that an operation is going on. Further key activation

is ignored.

Indicates that the SHIFT key is pressed.

KEY FUNCTION

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KEY FUNCTION

Shift function

The SHIFT key is used to assign a second signification to certain keys (compare

calculators).

Keep the SHIFT key pressed down and press another key simultaneously.

Explanations Touch Display shows Illuminated key

Tool code

”TOOL”

Starting gas

Pulsed wire feed

motion

Instantaneous

value displayed

(only in combina-

tion with welding)

Non--SHIFT function

Arc length control an d weaving

Arc length control AVC during pulse time

Arc length control AVC during back--

ground time

Weaving frequence, WEAVE RATE

Weaving frequence, WEAVE AMPL

Pause time, weave motion -- DWELL

LEFT”

Pause time, weave motion -- DWELL

RIGHT

KEY FUNCTION

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Stepping in program

Stepping throughout the program before welding.

Explanations Touch Display shows Illuminated key

Shows all para-

meters entered into

a program step by

step. The stepping

can be interrupted

anywhere in the

program.

Stepping through the program with regard to individual parameters.

1st

Shows the desired

parameter.

2nd

Both the parameter

key and the indica-

tor go out.

3rd

By pressing the

same parameter

key again the value

of the next sector in

the same program

will be shown.

4th

By preassing the

same key once

more both the key

and the indicator

will go out.

During a welding sequence stepping can only take place within the activated sector.

Stepping is performed by way of the STEP key. 1, 3, 5 ... and so on show the para -

meter values.

2, 4, 6 ...... and so on make the parameter key and the display go out.

The stepping can be interrupted anywhere in the program.

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ESAB PROTIG 315 Programming Manual

ESAB PROTIG 315 Programming Manual

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