ESAB PAL 1 User manual

Brand: ESAB

Model: PAL 1

Category: Welding System

Type: User manual

This manual is also suitable for

Unit MECHTIG 315 valid from Serial NO 824 XXX-XXXX

Unit PROTIG 315 valid from Serial NO 807 XXX-XXXX

0456 997 001 GB 20110615

PAL 1

PAL 2

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Connection 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 General 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 PAL 1 - new tube welding tools 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 PAL 2 - new tube welding tools 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 MAINTENANCE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 General 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Daily 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 ACCESSORIES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ORDERING OF SPARE PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

Users of ESAB 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 equipment. The following recommendations should be ob

served in addition to the standard regulations that apply to the workplace.

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

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

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 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 precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the 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 take fumes and gases away 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 earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

2 INTRODUCTION

2.1 General

S PAL 1 enables TIG welding with the MECHTIG 315 power source and the new

generation of tube welding tools A21 PRB 17-49 / 33-90 / 60-170, A21 PRH 6-40

/ 25-90, A22 POC and wire feed unit MEI 21.

S PAL 2 enables TIG welding with the PROTIG 315 power source and the new

generation of tube welding tools A21 PRB 17-49 /33-90/ 60-170, A21 PRC 17-49

/ 33-90 / 60-170, A21 PRH 6-40 / 25-90, A22 POC, the welding station /

automatic welding machine A25 and wire feed unit MEI 21.

The units transform pulse signals from the tube welding tool into analogue signals.

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.

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3 INSTALLATION

3.1 General

The installation must be carried out by a professional.

3.2 Connection

MECHTIG 315

PROTIG 315

AH 0434

A-A Motor cabel - AVC unit C-C Motor cabel - rotation

B-B Motor cabel - weaving unit D-D Motor cabel - wire feed

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Connect an extra conductor inside MECHTIG 315 according to diagram on page 12.

When the AVC unit is to be used with A21 PRC and A25:

S Order measuring cable (ACCESSOIRES) 0442 355 880.

S Remove the old measuring cable (1).

S Fit the new measuring cable supplied.

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4 OPERATION

4.1 General

General safety regulations for handling the equipment can be found on

page 5. Read through before you start using the equipment!

4.2 PAL 1 - new tube welding tools

Current tool codes for MECHTIG 315 with serial number 749 and earlier.

Welding tool Size Code Remark. Measure

A21 PRB 17-49, 33-90 PRB

60-170 Rotary direction rever

sed

Indicate ROT.DIR = -

A21 PRH 6-40, 25-90, 40-115 PRH The welding process

can only be started

over the control box.

A22 POC 12-60 POB

We recommend you to order a special program upgrading kit (order number

0457 634 880) to get access to the MECTIG 315 tool codes from serial number 750

(see the following table).

Current tool codes for MECHTIG 315 from serial number 750.

Welding tool Size Code

A21 PRB 17-49, 33-90 PRB

60-170 PRB 60-170

A21 PRH 6-40, 25-90 PRH

40-115 PRH 40-115

A22 POC 12-60 POC

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4.3 PAL 2 - new tube welding tools

Current tool codes for PROTIG 315.

Welding tool Size Code Correction factor

rotation *)

A21 PRB 17-49 18.40 2,780

17-49 36.80 1,617

33-90 36.80 2,425

60-170 **) 71.60 1,905

A21 PRC 17-49 36.80 1,617

33-90 36.80 2,425

60-170 **) 71.60 1,905

A21 PRH 6-40 18.40 2,420

6-40 36.80 1,410

25-90 36.80 2,398

40-115 36.80 1,50

A22 POC 12-60 2.00 1,00

*) To avoid positioning erros, multiply the breakpoint of the current sector by the

correction factor.

**) Reversed direction of rotation. Indicate direction of rotation .

To avoid tacho errors coming up when running with high-speed rotation in

combintaiton with a pulse generator of bad symmetry, capacitor C23 on the motor

board A10 in PROTIG 315 should be replaced.

The capacitor C23 can also be replaced on motor board A09 (for wire feed) and A08

(for weaving) to get a more linear operation.

C23:

Replace PME 261 0,01 μF order number 0192 883 030

by PME 261 0,0022 μF order number 0192 883 026

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Motor board A08, A09, A10

5 MAINTENANCE

5.1 General

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

5.2 Daily

Check that all cables are undamaged and that they are properly connected.

6 ACCESSORIES

Order number

Measuring cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0442 355 880

Program upgrading kit (MECHTIG 315) 0457 634 880. . . . . . . . . . . . . . . . . . . . . . . . .

7 ORDERING OF SPARE PARTS

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 16.

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

Diagram

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MECHTIG 315

C = Component designation in the circuit diagram

C Denomination C Denomination

AP01 Circuit board

F01 Fuse 0.315 A

R01 Resistor 20 Ω, 10 W

R02 Resistor 10 Ω, 10 W

XS01 Connector 23-pol Burndy

XS02 Connector 12-pol Burndy

XS03 Connector 7-pol Cannon

XS04 Connector 10-pol Cannon

XS05 Connector 6-pol

XS06 Connector 4-pol

XS07 Connector 2-pol

XS08 Connector

TC01 Control transformer 5-pol

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PROTIG 315

C = Component designation in the circuit diagram

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C Denomination C Denomination

AP01 Circuit board

C01 Capacitor 0,022 μF

C02 Capacitor 0,022 μF

C03 Capacitor 0,022 μF

C04 Capacitor 4.7 μF 100 V

R01 Resistor 10 Ω, 10 W

R02 Resistor 10 Ω, 10 W

R03 Resistor 68 Ω, 10 W

XP01 Connector 2-pol

XS01 Cable AVC 12-pol

XS02 Connector 12-pol

XS03 Connector 23-pol

XS04 Connector 12-pol

XS05 Connector 2-pol

XS06 Connector 6-pol

XS07 Connector 7-pol

XS08 Connector 4-pol

XS09 Connector 2-pol

XS10 Connector 24-pol AMPH.

Spare parts list

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Edition 980428

Ordering no. Denomination Notes

0456 926 880 Matching unit PAL 1 (MECHTIG 315)

0457 217 880 Matching unit PAL 2 (PROTIG 315)

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Item

no.

Qty. Ordering no. Denomination Notes

0456 926 880 Matching unit PAL 1 (MECHTIG 315)

1 0456 989 001 Control transformer

Manövertrafo Manövertrafo

2 0567 900 129 Fuse

Säkring

0.315 A

Säkring

3 0486 432 880 PC-board

Kretskort Kretskort

4 0456 990 001 Mounting plate

Fästplåt Fästplåt

5 0192 579 018 Resistor

Motstånd

20 Ω

Motstånd

6 0456 281 001 Plate

Gavel Gavel

7 0456 991 001 Cover plate

Lock Lock

8 0456 993 001 Profile

Profil Profil

9 0153 554 006 Fitting

Förskruvning Förskruvning

10 0456 992 881 Cable

Kabel Kabel

11 0457 537 001 Support

Stöd Stöd

12 0457 535 001 Support

Stöd Stöd

13 0457 538 002 Plate

Gavel Gavel

14 0368 544 005 Sleeve socket

Hylsuttag

23-pol

Hylsuttag

15 0368 544 003 Sleeve socket

Hylsuttag

12-pol

Hylsuttag

16 0456 283 001 Lid

Lucka Lucka

17 0456 992 880 Cable

Kabel Kabel

18 0212 602 207 Nut Pr 12,5

19 0336 285 001 Cover

20 0455 516 001 Cover

21 0192 579 015 Resistor 10 Ω

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Item

no.

Qty. Ordering no. Denomination Notes

0457 217 880 Matching unit PAL 2 (PROTIG 315)

1 0457 632 880 Capacitor

Manövertrafo Manövertrafo

2 0457 657 880 Resistor with capacitor

Säkring Säkring

3 0486 517 880 PC-board

Kretskort Kretskort

4 0456 281 001 Plate

Gavel Gavel

5 0456 991 001 Cover plate

Lock Lock

6 0457 536 001 Mounting plate

Fästplåt Fästplåt

7 0456 993 001 Profile

Profil Profil

8 0457 537 001 Support

Stöd Stöd

9 0457 538 001 Plate

Gavel Gavel

10 0456 283 001 Lid

Lucka Lucka

11 0457 535 001 Support

Stöd Stöd

12 0212 602 206 Nut Pr 15,2

13 0153 554 007 Fitting

Förskruvning Förskruvning

14 0457 660 880 Cable

Kabel Kabel

15 0192 579 015 Resistor

Motstånd

10Ω 10W

Motstånd

16 0457 540 880 Cover with cable complet.

17 0336 285 001 Cover

18 0368 544 005 Sleeve socket

Hylsuttag

23-pol

Hylsuttag

19 0455 516 001 Cover

20 0368 544 003 Sleeve socket

Hylsuttag

12-pol

Hylsuttag

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ESAB PAL 1 User manual

Brand: ESAB

Model: PAL 1

Category: Welding System

Type: User manual

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