GB
Valid for serial no. 910--xxx--xxxx, 306--xxx--xxxx0456 634 001 GB 041207
PROTIG 450
LTP 450
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
1DIREKTIV 3.........................................................
2SAFETY 3...........................................................
3 INTRODUCTION 4...................................................
3.1 Equipment 4................................................................
3.2 Programming box 5.........................................................
3.3 Applications 5..............................................................
4 TECHNICAL DATA 5.................................................
5 INSTALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Mains voltage connection 6...................................................
5.3 Other connections 7.........................................................
5.4 End resistor 8...............................................................
5.5 Connection of complete welding system 9......................................
6 OPERATION 10.......................................................
6.1 Controls and connections 10...................................................
6.2 Cooling water circuit 11.......................................................
6.3 Overheating protection 11.....................................................
6.4 Flow guard, water 11.........................................................
6.5 Flow guard, gas 11...........................................................
6.6 Error messages 11...........................................................
7 MAINTENANCE 11....................................................
7.1 Filling of coolant 12...........................................................
8 ORDERING OF SPARE PARTS 12......................................
DIAGRAM 14............................................................
ORDERING NUMBER 16.................................................
ACCESSORIES 17.......................................................
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1DIREKTIV
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTP 450 from serial number 737 complies with standard
EN 60974--1, in accordance with the requirements of directive 73/23/EEA and ad-
dendum 93/68/EEA.
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 97--09--04
2SAFETY
Users of ESAB welding 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 welding equipment. The following recommen-
dations should be observed 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 welding
equipment. Incorrect operation of the equipment may lead to hazardous situations 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 location of emergency stops
S its function
S relevant safety precautions
S welding
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 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 PRECAU-
TIONS 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 take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect y our 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 y our 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!
3 INTRODUCTION
PROTIG 450 is a welding power source of the rectifier type designed for m echanised
TIG welding. It is available in two different models:
S PROTIG 450 without mains voltage transformer for connection to 400 V mains
voltage 3 ∼ 50/60 Hz .
S PROTIG 450 with mains voltage transformer for connection to 208--500 V mains
voltage 3 ∼ 50/60 Hz .
The welding power source PROTIG 450 is fan--cooled and also includes a cooling
system for water--cooling o f t he welding tool.
PROTIG 450 is prepared for connection to an external PC.
3.1 Equipment
PROTIG 450 is supplied with:
S Programming box with connection cable (10 m)
S Return cable (5 m) with return cable clamp
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3.2 Programming box
PROTIG 450 is provided with a programming box for:
S Programming of welding procedures when welding with a welding tool.
S Execute a welding process.
S Store the welding program in an internal or external memory unit (PC board).
S Transfer of welding programs between programming units.
S Setting of different parameter values when welding with a TIG hand torch.
For the handling, see Programming manual
The programming manual is available in the following languages:
Language Article no. Language Article no.
English 0456 638 X74 French 0456 638 X76
German 0456 638 X75 Swedish 0456 638 X70
Italian 0456 638 X79 Finnish 0456 638 X73
Norwegian 0456 638 X72 Danish 0456 638 X71
Dutch 0456 638 X77 Spanish 0456 638 X78
Portuguese 0456 638 X80 Russian 0456 638 X86
3.3 Applications
Welding power source PROTIG 450 can be used for welding with:
S Tube welding tools for joining tubes
S Tube--to--plate welding tools for welding of tube diameters 12--60 mm
S Welding station A25 STA and automatic welding machine A25 STA/STB
S TIG hand torch
A wir e feed unit for filler wire can be connected to PROTIG 450.
Motors for external units (roller beds, turntables, etc.) can be controlled by way of the
PAL 3 motor control unit.
ESAB accessories for mechanised and manual TIG welding are found on
page 17.
4 TECHNICAL DATA
PROTIG 450, 400 V
PROTIG 450, 208--500 V
Mains connection 400V 3∼ 50/60 Hz 230/400/500V 3∼ 50Hz or
208/230/460/475V 3∼ 60 Hz
Permissible load at
100% duty cycle
360 A / 24,4 V 360 A / 24,4 V
60% duty cycle
425 A / 27 V 425 A / 27 V
45% duty cycle
450 A / 28 V 450 A / 28 V
Setting range, welding cur-
rent
5 A / 10 V -- 450 A / 28 V 5 A / 10 V -- 450 A / 28 V
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PROTIG 450, 208--500 V
PROTIG 450, 400 V
No--load power
310 W 310 W
Efficiency
83 % 83 %
Power factor
0.90 0.90
Enclosure class
IP 23 IP 23
Weight
113 kg 159 kg
Dimensions, l x w x h
734 x 486 x 695 mm 734 x 486 x 695 mm
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installatio n must be executed b y a professional.
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.
5.1 Placing
Place the welding power source so as not to prevent the cooling air from circulating
through the machine.
WARNING -- TIPPING RISK!
Fasten the equipment -- particularly if the
ground is uneven or sloping.
5.2 Mains voltage connection
The rating plate with connection data is placed at the rear of the power source.
S Make sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to the regulations valid.
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Recommende d cable areas and fu se sizes
PROTIG 450
Voltage 230 V
3∼ 50 Hz
400 V
3∼ 50 Hz
500 V
3∼ 50 Hz
208 V
3∼ 60 Hz
230 V
3∼ 60 Hz
460 V
3∼ 60 Hz
475 V
3∼ 60 Hz
Primary current at:
100% duty cycle 30 A 17.5 A 14 A 33.5 A 30 A 15 A 14.5 A
60% duty cycle 38 A 22 A 17.5 A 43.5 A 39.5 A 19 A 18.5 A
45% duty cycle 42 A 24 A 19,5 A 48 A 43 A 21 A 20.5 A
Cable area, mm
2
4x10 4x4 4x4 4x10 4x10 4x4 4x4
Fuse, slow--blow 35 A 16 A 16 A 50 A 35 A 16 A 16 A
5.3 Other connections
AH 0388
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5.4 End resistor
To avoid communication trouble the two end points of the CAN --bus should be fitted
with an end resistor.
One of the CAN--bus end points is in the programming box which has a built--in
resistor. The other one is in the power source and should be fitted with an end
resistor if the output in question is not used. F or the location of the resistor, see the
following figure.
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5.5 Connection of complete welding system
A--A Connection cable -- programming box
B--B, Z-- Z Motor cable --wire feed
C--C, S--S Motor cable -- rotation
D--D Signal cable -- external PC
E--E Motor cable -- AVC unit
F--F Motor cable -- weaving unit
G--G Cooling--water hose in
H--H Cooling--water hose out
J--J Welding cable
K--K Measurement cable
L--L Torch contact
M--M Gas hose out
N--N Gas hose in
P--P Signal cable -- external PC
Q--Q Return cable
R--R Connection cable -- puls transmitter
T--T, V--V Connection cable -- CAN 42 V
X Connection cable -- external motor
U--U Connection cable -- motor VEC
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6OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
6.1 Controls and connections
Front of welding power source
1 Switch for mains voltage ON/OFF 10 Connection for PC/printer
2 White indicating lamp, mains voltage ON 11 Connection for return water
3 Orange indicating lamp, overheating 12 Connection for cooling water
4 Switch for cooling unit ON/OFF 13 Connection for welding cable (--)
5 Connection for weaving 14 Connection for measurement cable
6 Connection for rotation 15 Connection for welding and start gas out
7 Connection for wire feed 16 Connection for torch contact, TIG hand torch
8 Connection for AVC 17 Connection for return cable (+)
9 Connection for programming box
Back of welding power source
18 Connection for start gas in 21 Connection for root gas out
19 Connection for welding gas in 22 Connection CAN 42 V for motor control unit
PAL 3 and A25 VEC motor
20 Connection for root gas in 23 Automatic fuse
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6.2 Cooling water circuit
S Connect the cooling water hoses of the welding tool
to the connections on the welding power source.
When welding with air--cooled welding tools,
interconnect the water hoses using the bridge
coupling supplied (see fig.).
S Before welding start, set switch (4) on the cooling
unit to position ON.
Note: The cooling water pump must always be set to
ON and the flowguard of the welding power source
must have detected the water flow to make welding
possible.
6.3 Overheating protection
Welding power source PROTIG 450 is provided with a thermal cut--out which trips in
case of too high temperature. The welding current is broken and an orange
indicating lamp on the front of the power source goes on. The programming box also
shows an error message. The thermal cut--out is reset automatically when the
temperature has gone down.
6.4 Flow guard, water
If there is no cooling water flowing, the flow guard will block the welding power
source. The welding current is then interrupted and an error message is displayed in
the character window of the programming unit.
6.5 Flow guard, gas
The flow guard breaks the ongoing welding process if the gas flow falls below 6
l/min. An error message is presented over the programming box.
6.6 Error messages
The welding power source has a built --in function for handling error messages. All
error messages are presented in the programming unit, and in some cases
measures will be taken automatically. See also pr ogramming manual 0456 638 xxx.
7 MAINTENANCE
Note!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
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Cleaning
Check regularly that the power source is free from dirt.
How often, and to what extent, cleaning should be carried out depends on the
welding process, ar c t ime, disposition and the surr ounding environment. It will
normally suffice to blow the power source clean using compressed air (reduced
pressure) once a year.
If the power source is very dirty, brushing and vacuuming are recommended.
S Disconnect the welding power source from the mains current supply.
S Remove the adapter from the socket. Lock the socket to prevent unauthorised
connection.
At fixed installations, the safety switch should be set to the off position. Lock
the switch.
S Remove the power source’s safety plates for best access.
After cleaning, all safety plates must be m ounted before you connect the power
source to the mains supply.
7.1 Filling of coolant
As coolant a mixture of 50% water and 50% glycol is recommended.
8 ORDERING OF SPARE PARTS
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Diagram
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PROTIG 450
Edition 041207
Ordering number
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Ordering no. Denomination Type Notes
0456 650 880 Welding power source PROTIG 450 400 V 50/60 Hz
0456 650 881 Welding power source PROTIG 450 230/400/500 V 50 Hz,
208/230/460/475 V 60 Hz
0456 634 990 Spare parts list PROTIG 450
The spare parts list is available on the Internet at www .esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can
both search for and download instruction manuals and spare parts lists.
PROTIG 450
Edition 041207
Accessories
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Order number
Tube welding tool
A21 PRB, water--cooled 17--49 0443 750 880................. ......................
33--90 0443 760 880......................
60--170 0443 770 880....................
A21 PRB, air--cooled 17--49 0443 750 881.................... ......................
33--90 0443 760 881......................
60--170 0443 770 881....................
A21 PRC with AVC 17--49 0443 751 880...................... ......................
33--90 0443 761 880......................
60--170 0443 771 880....................
A21 PRC, with AVC and weaving 17--49 0443 752 880.......... ......................
33--90 0443 762 880......................
60--170 0443 772 880....................
A21 PRD 100 0444 016 880........................................................
A21 PRH, enclosed 3--12 0444 300 880..................... .......................
3--38 0444 301 880.......................
6--76 0444 302 880.......................
Coolant for A21 PRH, 0007 810 012.................................................
A22 POC, wire feed 12--60 0443 930 880..................... ......................
Conversion kit
A21 PRB/PRC 8--17 0444 002 880..................................................
A21 PRB/PRC 20--33 0443 908 880.................................................
A21 PRB/PRC 44--60 0443 909 880.................................................
Driving unit 134:1 for the welding tools PRB/PRC 0443 544 880............................
Welding station A25 0443 910 880.....................................................
Automatic welding machine
A25 with AVC, TIG torch BTE 250 0443 911 880......................................
A25 with AVC, TIG torch BTE 500 0443 911 881......................................
A25 with AVC, weaving, TIG torch BTE 250 0443 911 882.............................
A25 with AVC, weaving, TIG torch BTE 500 0443 911 883.............................
A25 with AVC, manual slide, TIG torch BTE 250 0443 911 884..........................
A25 with AVC, manual slide, TIG torch BTE 500 0443 911 885..........................
A25 with floating head, TIG torch BTE 250 0443 912 880..............................
A25 with floating head, TIG torch BTE 500 0443 912 881..............................
TIG hand torch BTF 400W (4 m OKC) 0457 827 882.....................................
Wire feed unit MEI 21 0443 830 880....................................................
Carriage 0457 221 880................................................................
PC board (PCMCIA board) 0457 320 880.. ............................................
PROTIG 450
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Software kit 0459 370 881...........................................................
PC--card with software and programming manuals in English, French, German and Swedish.
Software kit 2 0459 370 882..........................................................
PC--card with software and programming manuals in English, Italian, Finnish and Norwegian.
Set of emergency stops 0457 823 880.................................................
Motor control unit PAL 3 0457 870 880.................................................
Documentation printer 0449 322 880...................................................
Documentation system
Weldoct WMS 4000 0457 410 880................................................
SPS 4000 0457 410 881..........................................................
OptoOptronic cables d (15 m) 0457 072 881.........................................
OptoOptronic cables d (2 m) 0457 072 882...........................................
Extension cable
b, wire, weaving, programming box, CAN 42 V (10 m) 0456 904 880....................
c, rotation (10 m) 0456 906 880.....................................................
e, AVC (10 m) 0457 219 880.......................................................
f, return cable 0152 349 888.......................................................
k, measurement cable (10 m) 0457 219 881..........................................
Extension set 1, current, water, gas (8 m) 0456 905 880...................................
Extension set 2, current, water, gas, torch contact (8m) 0466 705 881.......................
PROTIG 450
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PROTIG 450
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