Page is loading ...
TIG welding equipment
0740 801 001
Valid from machine no 240 244--00799502
PROTIG 315
INVERTER
Service manual
-- 2 --
cpro1de1
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.
-- 3 --mvarnen1
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!
-- 4 --
cpro1de2
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.
cpro1p19
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..
-- 5 --cpro1de2
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.
-- 6 --
cpro1de3
SIMPLIFIED BLOCK DIAGRAM, PROTIG 315
cpro1e20
-- 7 --cpro1de3
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.
-- 8 --
cpro1de3
BLOCK DIAGRAM, PROTIG 315
cpro1e10
-- 9 --cpro1de3
cpro1e11
-- 1 0 --
cpro1de3
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.
cpro1e12
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
-- 1 1 --cpro1de3
Connector K3. Pin 4 (welding current positive terminal) as the neutral (DC00):
Pin 3 = --15V
” 5 = +15V
Power supply unit A16
cpro1e40
-- 1 2 --
cpro1de3
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.
-- 1 3 --cpro1de3
CIRCUIT DIAGRAM, CIRCUIT BOARDS A08--A10 ( ROTATION, WIRE FEED and
WEAVING )
cpro1e14
-- 1 4 --
cpro1de3
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 ” ”
-- 1 5 --cpro1de3
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.
-- 1 6 --
cpro1de3
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.
-- 1 7 --cpro1de3
CIRCUIT DIAGRAM, CIRCUIT BOARD A11
cpro1e13
-- 1 8 --
cpro1de3
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.
-- 1 9 --cpro1de3
CIRCUIT DIAGRAM, CIRCUIT BOARD A12
cpro1e19
-- 2 0 --
cpro1de3
CURRENT REGULATION, SIMPLIFIED
cpro1p23
/
