ESAB PROTIG 315 User manual

Brand: ESAB

Model: PROTIG 315

Category: Welding System

Type: User manual

TIG welding equipment

0740 801 001

Valid from machine no 240 244--00799502

PROTIG 315

INVERTER

Service manual

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List of contents Page

INTRODUCTION 2

RATING PLATE 4

DESCRIPTION OF OPERATION 7

THE CONTROL UNIT 7

THE POWER UNIT 27

CONNECTION DIAGRAM, PROTIG 315 30

BLOCK DIAGRAM, C ONTROL BOARD, K70.1 32

COMPONENT POSITIONS CONTROL BOARD, K70.1 34

COMMUNICATION, POWER UNIT / CONTROL UNIT 44

COOLING UNIT 44

FAULT--TRACING IF THE MAIN FUSE BLOWS 45

SWITCH UNITS 46

MOS TESTER 46

SOFT START 47

TECHNICAL DESCRIPTION 48

ELECTRONIC UNIT (CIRCUIT BOARD RACK) 52

INSTALLATION 55

OPERATION 57

WELDING 57

MAINTENANCE 57

ORDERING SPARE PARTS 58

FAULT / ERROR CODES 58

ASSEMBLY INSTRUCTIONS 60

MAIN DIMENSIONS 62

SPARE PARTS LIST, PROTIG 315 63

INTRODUCTION

This service manual is intended for use by technicians with electrotechnical training. Use it

for fault tracing and repair of the PROTIG 315 inverter.

A programming guide, which can be of help when programming the machine, is available for

the PROTIG 315. Ordering numbers for the respective languages are as follows:

S 442 446--004 Swedish

S 442 446--005 English

S 442 446--006 German

S 442 446--007 French

This manual applies to machines with serial numbers of 240 244--0079 and above. It contains

details of all design modifications incorporated up to and including December 1994.

The Protig 315 has been designed and tested in accordance with the international

EN 60 974--1 (IEC 974--1).

On completion o f service or repair, it is the responsibility of the person(s) performing

the work to ensure that the product still complies with the requirements of the above

standard.

ESAB reserves the right to make changes without prior 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 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 inju re eyes and b u rn 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 m aterials nearby.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE

INSTALLING OR OPERATING THE EQUIPMENT

PROTECT YOURSELF AND OTHERS!

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RATING PLATE

The rating plate is fitted to the rear of the machine. It is shown in the diagram below,

followed by an explanation of the various terms.

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1 PROTIG 315 INVERTER is the type designation for this machine. PROTIG

indicates that it is a programmable TIG welding power unit. The numerals

’315’ indicate the maximum welding current, while INVERTER is the

principle of operation.

2 These symbols indicate that PROTIG incorporates an inverter, a transformer

and a rectifier.

3 The figures indicate that the current range is 5 -- 315 A and give the voltage/

current characteristic for TIG welding.

The specified voltages of 10 and 23 V show that ESAB complies with the

international arc voltage characteristic as specified in IEC 974--1.

X = The intermittence factor, which describes for how long welding

can be carried out at the specified welding data, expressed as a percentage of

a ten--minute period..

I2 = The current at the respective intermittence factor.

U2 = The arc voltage.

U0 = The no--load (= open--circuit) voltage..

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4 Indicates that the equipment is intended for connection to a three--phase 50 Hz

or 60 Hz supply. Alteration of internal connections allows the machine to be

connected to different mains voltages (208 -- 500 V).

I1 indicates the primary currents at the respective intermittence factors.

5 AF indicates that the machine is fan--cooled..

IP23 is the enclosure class in respect of protection against water and

penetrating objects.

6 The machine’s serial number, in the form of three groups of numerals (xxx

yyy zzz)

The first group (xxx) is the version. The figures shows the year and week of

design approval..

The second group (yyy) shows the year and week of final test of the machine,

e.g. 203 indicates 1992, week 3.

The third group (zzz) consists of three or four numerals, and is a consecutive

serial number in the range 0001 -- 9999.

7 Shows that ESAB complies with applicable national and international

standards.

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SIMPLIFIED BLOCK DIAGRAM, PROTIG 315

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DESCRIPTION OF OPERATION

This description of operation refers to the diagrams shown under the heading for each feature.

For the sake of clarity, the circuit board designations are shown in brackets.

The description is divided up into four parts: the control unit, the power unit, the cooling unit

and communication between them.

PROTIG 315 has three different electrical neutral points.

In the power unit, the negative pole of the welding power supply is the neutral..

In the control unit, it is the chassis that is the neutral, except for the current regulator

board and parts of the AVC board, which take the positive pole of the welding current

circuit as their neutral (DC00).

When making any measurements, make sure that you are measuring with respect to the

correct neutral.

WARNING! MAINS VOLTAGE!

Mains transformer K3, terminal block K11, main contactor K8, rectifiers K27, filters K96 and

K96.1, capacitor K88, HF unit K74, switch units K77, parts of the control circuit board and

the cooling unit are at mains voltage.

Don’t forget to refit the Perspex cover after working on live parts at mains voltage, such as

buffer capacitor K88.

THE CONTROL UNIT

General

The control unit controls the motors, the gas valves, the welding current and starting/stopping

the power unit.

The control unit contains a computer consisting of a counter board (A01), the CPU board

(A03) and t he I/O board (A06), which monitor and control the process with the help of the

regulator boards and the relay board. The power supply unit (A21) provides the various

voltages required by the control equipment.

Welding programs are stored in the CPU board memory circuits. When the machine is turned

off, the contents of the memory are retained by a lithium battery that is fitted to the board.

The battery has a life of 2500 hours if the machine is not in use. See page 56 for instructions

on how to replace the battery.

Motor regulator boards A08, A09 and A10 are identical, and can be interchanged, which can

be helpful when testing to see if one of them is defective.

Functions that are identical from one board to another are described only once, for ’rotation’.

Descriptions of wire feed and weaving refer to the rotation description.

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BLOCK DIAGRAM, PROTIG 315

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POWER SUPPLY UNIT, A16

Power supply unit A21 provides the necessary voltages to the circuit boards in the control

unit. It also incorporates protective functions, interrupting the supplies if the voltages vary by

more than 5% from the nominal value. An LED (A42) on the front of the unit indicates that

the supply has not been interrupted.

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42 V AC is supplied to the PSU input from transformer K53 via the front suppression board

(A16). Connection is to pins 1 and 2 in connector K3.

The output voltages can be measured at connector K2, where the wires are marked P. The

wires run to the back plane (A14) and supply the circuit boards on the rack. The voltages

shown below are as measured at K2 with the chassis as the neutral point.

P2 = about +36V NB:with no load here, the voltage is about 55V.

P3 = +60V

P8 = --12V

P9 = +12V

P10 = +5V

P11 = +10V

Connector K2. Voltages measured relative to P5 (the positive welding current terminal) as the

neutral (DC00):

P4 = --15V

P6 = +15V

The front HF suppression card (A16) receives its power supply through connector K3. 42

V AC is supplied to pins 1 and 2 from the power unit to PSU A21.

Connector K3. The chassis as the neutral:

Pin 6 = +5V

” 7 = --12V

” 8 = +12V

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Connector K3. Pin 4 (welding current positive terminal) as the neutral (DC00):

Pin 3 = --15V

” 5 = +15V

Power supply unit A16

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ADJUSTING THE POWER SUPPLY VOLTAGES

If any voltage from the PSU varies by more than about 5% under normal load conditions, it

may be necessary to adjust the voltage in order to prevent the protective circuitry from

operating and interrupting the power supplies.

When adjusting the voltages, measure them at the PSU circuit board in order to avoid any

voltage drops across the PSU connector terminals.

The adjustment and test points on the PSU are as follows:

Adjustment potentiometer Test points

P1 = adjustment of +5 volt Left --hand side of R63 to the chassis

P3 = ” +12 volt ” ” R65 ” ”

P4 = ” --12 volt ” ” R61 ” ”

P5 = ” +15 volt ” ” R 67 to the welding positive

P6 = ” --15 volt ” ” R 69 ” ”

MONITORING THE POWER SUPPLY VOLTAGES

Two separate, stabilised voltages of 8 V, which are each dropped to 3.00 V and 3.30 V by

potential dividers, are used for monitoring the power supply voltages.

Each output voltage supply feeds a potential divider which produces an output voltage signal

of 3.15 V when the output voltage is correct. If this voltage signal varies outside the limits of

3.00 V or 3.30 V, it indicates that the voltage from which it is derived has varied by more than

5%, and the PSU interrupts all the supply voltages.

Measure the 8.00 V monitoring voltage for the 12 V and +5 V supplies at the top of resistor

R38, relative to the chassis as neutral. See the diagram on page 9.

Measure the 8.00 V monitoring voltage for the 15 V supply at the top of resistor R81,

relative to t he positive pole of the welding current supply (DC00) (pin 4 in K3). See the

diagram on page 10.

The 3.00 V and 3.30 V reference voltages cannot be adjusted, although it can be worth

checking them if the PSU constantly trips out.

Measure the voltages at the integrated circuits on the board, as shown in the table below and

in the diagram on page 9

IC no. LEG VOLTAGE

U5 11 3.30 V To the chassis

U5 6 3.00 V To the chassis

U6 9 3.30 V To the chassis

U6 4 3.00 V To the chassis

U5 7 3.15 V (--12 V) To the chassis

U4 5 3.15 V (+ 5 V) To the chassis

U4 7 3.15 V (+12 V) To the chassis

U6 5 3.15 V (+15 V) To the chassis

U6 7 3.15 V (--15 V) To the chassis

If the voltages are not as shown above, after the output voltages have been adjusted, replace

the entire PSU.

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CIRCUIT DIAGRAM, CIRCUIT BOARDS A08--A10 ( ROTATION, WIRE FEED and

WEAVING )

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ROTATION

SUPPLY VOLTAGES to the motor regulator boards (A08, A09, A10)

C2, C31, A10 and C10 0V

A8 and C8 about +60V

C32 +12V

C1 --12V

A32 +5V

Signals are received from the I/O board (A06), via the front board (A15) and the connection

board (A07), which control the motor regulator board (A10).

S A binary 10 --bit signal, defining the set speed, is supplied to pins A2 (MSB) to C21

(LSB) on board A10, where ’1’ = 0V and ’0’ = about 4V: in other words, the signal is

active high.

Be careful when measuring these signal voltages, as the I/O board will be destroyed by any

short circuit between ’1’ and ’0’. The codes have been selected so that pins on the same side

should be at the same potential.

Use the extension board when making the measurements. The test points for the various pins

are marked on the board.

Speed 682 341 ( Programmed value )

Pin Code Code

A2 0 1 0 = 4V To the chassis

C3 1 0 1 = 0V ” ”

A3 0 1

C4 1 0

A4 0 1

C5 1 0

A5 0 1

C6 1 0

A21 0 1

C21 1 0

S Pins A6 and C7 are the inputs for signals that control the direction of rotation.

A6 = 5V and C7 = 5V when the motor is stationary.

A6 = 5V and C7 = 0V for forward rotation.

A6 = 0V and C7 = 5V for reverse rotation.

Measure these signals between A6 and 0 and between C7 and 0 respectively, but never

between A6 and C7, as this could damage the I/O board and the motor board.

The speed signal from the tachogenerator is received via the rear HF suppression card (A17)

and the back plane (A14) at pins A16 and C16 on the motor regulator board. At maximum

speed, it must be about 1.80 V AC, as measured between pins A16 and C16. Note that DC

tachogenerators may also be used, giving outputs of about 1.62 V DC (e.g. the PRI 18 -- 220).

Pins A11 and A12 are inputs for the armature voltage. They are connected via the back plane

to the rear HF suppression card. At a speed of 400 r/min, the voltages are:

Forward rotation A11 = about 7.5V and A12 = about 0.5V To the chassis

Reverse rotation A11 = about 0.5V and A12 = about 7.5V ” ”

Stationary A11 = about 0.5V and A12 = about 0.5V ” ”

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WIRE FEED

For circuit board A09, see the diagram on page 13

Power supply voltages for the motor regulator board: see Rotation on page 14.

In the same way as for the Rotation control function, signals are received from the I/O board

(A06) via front board (A15) and connection board (A07) to the motor regulator board (A09).

S A binary 8--bit signal, defining the set speed, is supplied to pins A2 (MSB) to C6 (LSB),

where ’1’ = 0V and ’0’ = about 4V. Be careful when measuring these signal voltages, as

the I/O board will be destroyed by any short circuit between ’1’ and ’0’.

’1’ = 0V and ’0’ = about 4V.

Speed 180 r/min must give 10101010 onpinsA2--C6.

Speed 90 r/min must give 01010101 onthesamepins.

S Signals controlling the wire feed direction are supplied to pins A6 and C7.

A6 = 5 V and C7 = 5V when the motor is stationary.

A6 = 5V and C7 = 0V for forward feed.

A6 = 0V and C7 = 5V for reverse feed.

Measure these signals between A6 and 0 and between C7 and 0 respectively, but never

between A6 and C7, as this could damage the I/O board and the motor board.

The speed signal from the tachogenerator is received via the rear HF suppression card (A17)

and the backplane (A14) at pins A16 and C16 on the motor regulator board (A09). At

maximum speed (264 r/min), it must be about 1.62 V AC, as measured between pins A16 and

C16.

WEAVING

For circuit board A08, see the diagram on page 13.

Power supply voltages for the motor regulator board: see Rotation on page 14.

In the same way as for the Rotation control function, signals are received from the I/O board

(A06) via front board (A15) and connection board (A07) to the motor regulator board (A08).

S A binary 8--bit signal, defining the set speed, is supplied to pins A2 (MSB) to C6 (LSB),

where ’1’ = 0V and ’0’ = about 4V. Be careful when measuring these signal voltages, as

the I/O board will be destroyed by any short circuit between ’1’ and ’0’.

’1’ = 0V and ’0’ = about 4V.

A speed of 6.8 must produce a code of 10101010onpinsA2--C6..

A speed of 3,4 must produce a code of 01010101onthesamepins.

S Signals from the I/O board indicating the motor direction are received on pins A6 and

C7.

See Rotation on the previous page.

Measure these signals between A6 and 0 and between C7 and 0 respectively, but never

between A6 and C7, as this could damage the I/O board and the motor board.

The speed signal from the tachogenerator is received via the rear HF suppression card (A17)

and the backplane (A14) at pins A16 and C16 on the motor regulator board.(A08). At

maximum speed (10.0), it must be about 1.80 V AC, as measured between pins A16 and C16.

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AVC

Circuit board A11: see the circuit diagram on page 17.

AVC (arc voltage control) is a function that monitors the arc voltage and adjusts the distance

between the wire and the workpiece during welding. A motor, controlled by the AVC--

regulator board, adjusts the arc length.

Power supplies to the AVC--regulator:

A25 and C25 0V Welding positive (DC00)

A31 +15V

A1 --15V

A2, C31, A10, C10 0V

A32 +5V

A7 +10V

The arc voltage can be measured internally at the welding terminals or externally by means of

an instrument cable connected to the welding gun. When using internal measurement, a link

is fitted in connector K82. See the circuit diagram on page 8.

The measured value is received on the filter board (A18) and passes to D1 on the backplane

(A14) and pin A6 on the AVC board (A11). The relay on the filter board is controlled by the

control board in the power unit (K70.1), and disconnects the signal input while HF ignition is

activated.

An 8--bit code, indicating the arc voltage set value, is received by the AVC regulator from the

I/O board (A06) via front board A15 and connection board A07. Pin A24 is the Most

Significant Bit and A22 is the Least Significant Bit.

’1’ = 0V and ’0’ = about 4V.

For an arc voltage of 16.5 V the code must be 01010101onA24--C22.

For an arc voltage of 25.0 V the code must be 10101010onA24--C22.

The AVC board compares the measured value with the set value. The result is output on A30

and C30 and passed to the counter board (A01). From I/O board, the signal is then passed to

pins A29 and C29, which control whether the AVC motor is to run forwards or backwards or

remain still.

A29 = 5 V and C29 = 5V The welding head remains stationary.

A29 = 0 V and C29 = 5V the welding head moves down.

A29 = 5 V and C29 = 0V the welding head moves up.

The AVC motor does not have a tachogenerator: when it runs, it does so at maximum speed..

The motor armature voltage (ca 10V) appears on pins C19 and A19, and runs through the rear

HF suppression card to connector A48.

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CIRCUIT DIAGRAM, CIRCUIT BOARD A11

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CURRENT REFERENCE

See the circuit diagram on page 19.

Power supply voltages to current reference board A12:

A25, C25 0V (DC00)

A31 +15V

A1 --15V

C31, C2 0V

A32 +5V

When the arc has struck, the power unit circuit board applies a signal on M1.

This signal can be measured at connector K 45.4 on control circuit board K 70.1.

When the arc is struck: 0V as measured from the earth terminal

on the control circuit board.

When the arc is extinguished about 3.5V ” ” ”

The signal s upplies an optocoupler on the backplane (A14) which, with two potential

dividers, applies t he voltage signals to pins C13 and C14 on the current reference board

(A12).

A red LED on the current reference board lights to show that the signal is present.

The voltage, as measured between C14 and C13, with the negative on C14, must be:

with the arc lit about +1.3V

with the arc extinguished about --1.3V

A21 supplies a signal to the counter board, which must be:

with the arc lit 5V To the chassis

with the arc extinguished 0V ” ”

A 12--bit code, indicating the welding current set value, is received by the current reference

board (A12) from the I/O board (A06) via front board A15 and connection board A17. Pin

C20 is the Most Significant Bit and C21 is the Least Significant Bit.

Be careful when measuring these signal voltages, as the I/O board will be destroyed by any

short circuit between ’1’ and ’0’.

’1’ = 0V and ’0’ = about 4V.

A current of 136A must give a code of 0101010101onC20--A22.

A current of 273A must give a code of 1010101010onC20--A22.

The current reference signal from pin A13 is taken through a buffer amplifier and relay (RE1)

on the backplane to M10 on the power unit control circuit board (K70.1). The relay protects

the power unit against uncontrolled current reference signal in the event of loss of power

supply to the buffer amplifier input.

The voltage between A13 and A25 is about 2.5 V at 100 A welding current set value.

The voltage between M10 and M7 is about 2.5 V at 100 A welding current set value.

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CIRCUIT DIAGRAM, CIRCUIT BOARD A12

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CURRENT REGULATION, SIMPLIFIED

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ESAB PROTIG 315 User manual

Brand: ESAB

Model: PROTIG 315

Category: Welding System

Type: User manual

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ESAB PROTIG 315 User manual

ESAB PROTIG 315 User manual

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