ESAB LTS 320 Instruction manual

GB

PROWELDER 320

LTS 320

Instruction manual

Valid for serial no. 910--xxx--xxxx, 306--xxx--xxxx0457 690 001 GB 041210

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 1 1.......................................................

6.3 Overheating protection 1 1.....................................................

6.4 Flow guard, water 1 1.........................................................

6.5 Flow guard, gas 11...........................................................

6.6 Error messages 1 1...........................................................

7 MAINTENANCE 11....................................................

7.1 Filling of coolant 12...........................................................

8 ORDERING OF SP ARE PARTS 12......................................

DIAGRAM 14............................................................

ORDERING NUMBER 16.................................................

ACCESSORIES 17.......................................................

Rights reserved to alter specifications without notice.

TOCe

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1DIREKTIV

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTS 320 from serial number 811 complies with standard
EN 60974 --1, in accordance with the requirements of directive (73/23/EEA) and ad­dendum (93/68/EEA) and standard EN 50199 in accordance with the requirements
of directive 89/336/ EEA and addendum 93/68/ EEA .

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Laxå 98--02--11

Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

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 recommen­dations 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

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 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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

3 INTRODUCTION

PROWELDER 320 is a welding power source of the rectifier type designed for
mechanised TIG welding. It is available in two different models:

S PROWELDER 320 without mains voltage transformer for connection to 400 V, 3∼

50/60 Hz mains voltage.

S PROWELDER 320 with mains voltage transformer for connection to 208--500 V,

3∼ 50/60 Hz mains voltage.

The welding power source PROWELDER 320 is fan--cooled and also includes a
cooling system for water--cooling of the welding tool.

PROWELDER 320 is prepared for connection to an external PC.

3.1 Equipment

PROWELDER 320 is supplied with:

S Programming box with connection cable (10 m)
S Return cable (5 m) with r eturn cable clamp

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3.2 Programming box

PROWELDER 320 is provided with a programming box for:

S Programming of welding procedures when welding with a welding tool.
S Executing a welding process.
S Storing welding program in an internal or external memory unit (PC board).
S Transferring 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 0457 706 X74 French 0457 706 X76
German 0457 706 X75 Swedish 0457 706 X70
Italian 0457 706 X79 Finnish 0457 706 X73
Norwegian 0457 706 X72 Danish 0457 706 X71
Dutch 0457 706 X77 Spanish 0457 706 X78
Portuguese 0457 706 X80 Russian 0457 706 X86

3.3 Applications

Welding power source PROWELDER 320 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 Automatic welding machine A25 STB with floating head.
S TIG hand torch

A wire feed unit for filler wire can be connected to PROWELDER 320.
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

PROWELDER 320, 400 V

Mains connection 400V 3∼ 50/60 Hz 230/400/500V 3∼ 50Hz or

PROWELDER 320, 208--500 V

208/230/460/475V 3∼ 60 Hz

Permissible load at

100% duty cycle
60% duty cycle

Setting range, welding cur­rent

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270 A / 20.8 V 270 A / 20.8 V

320 A/ 22.7 V 320 A / 22.7 V

5 A / 10 V -- 320 A / 22.7 V 5 A / 10 V -- 320 A / 22.7 V

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PROWELDER 320, 400 V

No--load power
Efficiency
Power factor
Enclosure class
Weight
Dimensions, l x w x h
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 cer­tain 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.

310 W 310 W
82 % 82 %

0.80 0.80
IP 23 IP 23
110 kg 156 kg
734 x 486 x 695 mm 734 x 486 x 695 mm

PROWELDER 320, 208--500 V

5 INSTALLATION

The installation must be executed by 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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Recommended cable areas and fuse sizes

PROWELDER 320

Voltage 230 V

3∼ 50 Hz

Primary current at:

100% duty cycle 19,5 A 12 A 9A 21.5 A 19,5 A 10 A 9.5 A
60% duty cycle 25 A 15 A 12 A 27 A 24.5 A 12,5 A 12 A

Cable area, mm
Fuse, slow--blow 20 A 16 A 16 A 20 A 20 A 16 A 16 A

2

4x10 4x4 4x4 4x10 4x10 4x4 4x4

5.3 Other connections

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

3∼ 60 Hz

475 V

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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. For 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

G--G Cooling--water hose in

H--H Cooling--water hose out

J--J Welding cable

L--L Torch contact

M--M Gas hose out

N--N Gas hose in

P--P Signal cable -- external PC

R--R Connection cable -- pulsetransmitter

T--T, V--V Connection cable -- CAN 42 V

X Connection cable -- external motor

U--U Connection cable -- rotor 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 8 Connection for PC/printer
2 White indicating lamp, mains voltage ON 9 Connection for return water
3 Orange indicating lamp, overheating 10 Connection for cooling water
4 Switch for cooling unit ON/OFF 11 Connection for welding cable (--)
5 Connection for rotation 12 Connection for welding and start gas out
6 Connection for wire feed 13 Connection for torch contact, TIG hand torch
7 Connection for programming box 14 Connection for return cable (+)

Back of welding power source

15 Connection for start gas in 18 Connection for root gas out
16 Connection for welding gas in 19 Connection CAN 42 V for motor control unit

PAL3 and A25 VEC motor

17 Connection for root gas in 20 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 PROWELDER 320 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.

NOTE. This applies only if the cooling system was connected from the start (i.e.
switch (4) on the cooling unit was set to position 1, and the cooling water hose was
connected).

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 autom atically. See also programming manual 0457 706 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.

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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.

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, arc time, disposition and the surrounding 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 mounted 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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PROWELDER 320

Ordering number

Ordering no. Denomination Type Notes

0456 650 881 Welding power source PROWELDER 320 400 V, 50/60 Hz

0456 650 883 Welding power source PROWELDER 320 230/400/500 V, 50 Hz,

208/230/460/475 V, 60 Hz

0457 690 990 Spare parts list PROWELDER 320

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.

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PROWELDER 320

Accessories

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 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 8--17 0444 002 880.............................. ......................

30--33 0443 908 880......................

44--60 0443 909 880......................

Driving unit 134:1 for the welding tools PRB/PRC 0443 544 880............................

Automatic welding machine

A25 with floating head, TIG torch BTE 250 0443 912 880..............................

A25 with floating head, TIG torch BTE 500 0443 912 881..............................

VEC motor with gear and pulse generator complete 0457 258 880.........................

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.. ............................................

Software kit 0459 370 885...........................................................

PC--card with software and programming manuals in English, French, German and Swedish.

Software kit 2 0459 370 886..........................................................

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, programming box, CAN 42 V (10 m) 0456 904 880.............................

c, rotation (10 m) 0456 906 880.....................................................

f, return cable 0152 349 888.......................................................

Extension set 1, current, water, gas (8 m) 0456 905 880...................................

Extension set 2, current, water, gas, torch contact (8m) 0466 705 881.......................

Order number

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PROWELDER 320

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PROWELDER 320

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.z.o.o
Warszaw
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. Esabindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA-- CIS

ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel:[phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE--695 81 L AXÅ
SWEDEN
Phone [phone]

www.esab.com

031021