ESAB PAL 1, PAL 2 Instruction manual

GB

PAL 1 PAL 2

Instruction manual

0456 997 001 GB 20110615

Unit MECHTIG 315 valid from Serial NO 824 XXX-XXXX Unit PROTIG 315 valid from Serial NO 807 XXX-XXXX

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

Rights reserved to alter specifications without notice.

TOCe

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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

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.

Read and understand the instruction manual before installing or operating.

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

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

AH 0434

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

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

A22 POC 12-60 POB

can only be started over the control box.

Indicate ROT.DIR = -

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.

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Diagram

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.

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Spare parts list

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

Qty. Ordering no. Denomination Notes

no.

0456 926 880 Matching unit PAL 1 (MECHTIG 315)

1 0456 989 001 Control transformer

Manövertrafo Manövertrafo

2 0567 900 129 Fuse

Säkring

3 0486 432 880 PC-board

Kretskort Kretskort

4 0456 990 001 Mounting plate

Fästplåt Fästplåt

5 0192 579 018 Resistor

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

15 0368 544 003 Sleeve socket

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

0.315 A

Säkring

20 Ω

Motstånd

23-pol

Hylsuttag

12-pol

Hylsuttag

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Item

Qty. Ordering no. Denomination Notes

no.

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

16 0457 540 880 Cover with cable complet.

17 0336 285 001 Cover

18 0368 544 005 Sleeve socket

Hylsuttag

19 0455 516 001 Cover

20 0368 544 003 Sleeve socket

Hylsuttag

10Ω 10W

Motstånd

23-pol

Hylsuttag

12-pol

Hylsuttag

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NOTES

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

notes

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NOTES

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

notes

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28

BULGARIA

ESAB Kft Representative Office Sofia Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Pacific Archerfield BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors

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

www.esab.com

ESAB PAL 1, PAL 2 Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual