PROTIG 315
TIG--welding equipment
WIG--Schweissausrüstung
Programming
Programmierung
443 425--003 9604 Valid from Machine no 606 XXX--XXXX
SAFETY 2.........................................................
TECHNICAL DESCRIPTION 3.......................................
BLOCK DIAGRAM 7...............................................
FUNCTION DESCRIPTION 8........................................
Programming block 12............................................
PROGRAMMING FUNCTIONS 13.....................................
Programming unit 14.............................................
Programming rules 16............................................
KEY FUNCTION 17..................................................
Non--SHIFT function 17...........................................
Stepping in program 18...........................................
Erasing (delete) 19...............................................
Sector concepts 20...............................................
Slope concepts 24...............................................
Increase/decrease function 26.....................................
Start/stop function 27.............................................
START--UP 29......................................................
Actual tool codes 29..............................................
Write position 30.................................................
Read position 31.................................................
Notebook 32.....................................................
PROGRAMMING 33.................................................
Representation of decimal point 33.................................
Manual program 33...............................................
WELDING PROGRAMS 37...........................................
Testing of welding program without welding 42.......................
Transmission of welding programs between working area and library area 43
Pulsed welding 44................................................
Arc voltage 48...................................................
Tack welding 49..................................................
Weaving 49.....................................................
Special pulsing function 52........................................
Interval welding 55...............................................
Rotation to the start position 56....................................
CODES 58..........................................................
Acknowledge code 58............................................
Activity code 58..................................................
Blocking code 59.................................................
TRANSMISSION OF WELDING PROGRAMS 62........................
Transmission of welding programs between the PROTIG 315 and an
external storing unit 62........................................
Transmission from control equipment to cassette tape 63..............
Transmission from tape to control equipment 64......................
Transmission of welding programs 65...............................
Printing of welding programs from the control equipment to the
HX--20 printer 65.............................................
Handling of cassette tapes 66......................................
Rights reserved to alter specifications without notice.
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 MANU-FACTURER’S 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 injure eyes an d bu 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 materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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SAFETY
SAFETY
Users of ESAB welding equipment have 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 work place.
All work must be carried out by trained personnel who are familiar with the operation
of the welding equipment.
Incorrect operation of the equipment may lead to a hazardous situation 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 the location of emergency stops
S its function
S relevant safety precautions
S welding
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
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 that no--one is unprotected when the arc is struck
3. The work place must:
S be suitable for the purpose
S be free from draughts
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 dur-
ing its operation.
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TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
PROTIG 315 is a programmable TIG welding equipment offering facilities for programming of welding processes, storing of welding programs and transfer of welding
programs between similar welding equipment.
A fully compatible IBM personal computer in combination with the ESAB data base
program PROfile can be used as exterior store unit. The old EPSON HX--20 unit can
also be used.
PROTIG 315 is designed to be used together with the tube welding tools PRB/PRC/
PRD/PRE/PRF/PRG/PRI and the wire feed unit MTC20/MEI20 as well as the tube
welding tools POA/PIA/POB and the component system A25. PROTIG 315 can also
be used together with manual TIG torches. It complies with the IEC 974 regulations.
The complete welding equipment contains:
S Welding power source
Field of application, technical data,
design and function.
S Electronic unit
PC board rack including boards.
S Programming unit
Layout and programming.
S TIG welding tools
See the respective operator’s manual.
S Wire feed unit
See the respective operator’s manual.
PROTIG 315 is intended to be used in
combination with a new version of the
programming unit EPROM R5E and R6A
(the old version cannot be used).
Entered value or position is indicated on a
digit/character display.
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TECHNICAL DESCRIPTION
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TECHNICAL DATA
PROTIG 315
Permissible load (DC), power source
Duty cycle % 100 60 35
Current (A) 200 250 315
Voltage (V) 18 20 23
Permissible load (DC), welding tool See the respective operator’s
manual
Setting range(DC) 5 -- 315 A
Max open--circuit voltage 67 V
Open--circuit power 500 -- 600 W
Ambient temperature:
during transportation
during welding
Relative atmospheric humidity:
up to 50%
up to 90%, storing only
-- 2 5_C--+55_C
-- 1 0_C--+40_C
at +40_C
at + 20_C
Temperature class F (155_C)
Enclosure class IP 23 AF
Efficiency and power factor See operator’s manual for
PROTIG 315
Mains voltage variation Less than 2 A at 10% mains
voltage variation
Program sectors 1--999
Storage capacity Some 150 programs
Battery back--up 2 years
Mains connection
3x208 V 3x230 V 3x380 V 3x400 V 3x415 V 3x440 V 3x460 V 3x480 V 3x500 V
50 -- 60 Hz
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TECHNICAL DESCRIPTION
The main components of the control equipment are:
1. Programming unit
2. Electronic unit
S The programming unit is provided with numeric keys, control function keys, para-
meter keys and a numeric character display.
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TECHNICAL DESCRIPTION
S The electronic unit contains:
A01 Counting board ( printed circuit board)
S Controls the process together with the CPU board.
S Includes time functions for welding, pulsing and slope--up/slope--
down.
S Adapts keyboard and display to the computer.
A03 CPU board with 16 k byte RWM and EPROM (printed circuit board)
S Storage of welding programs
S Processes and executes instructions.
A06 I/O board (printed circuit board) controls all activities during welding.
A07 Connecting board (printed circuit board)
A08 Motor board (printed circuit board) for weaving motion.
A09 Motor board (printed circuit board) for wire feed motion.
A10 Motor board (printed circuit board) for rotary motion. NOTE that motor
boards A 08 -- A10 are identic.
A11 Motor board (printed circuit board) for arc length regulation.
A12 Current reference board (printed circuit board)
A13 Relay board (printed circuit board) with relays for switching solenoid val-
ves on/off and starting functions on/off.
A14 Rear plate (printed circuit board) .
A15 Front board (printed circuit board).
A16 Front disturbance elimination board (printed circuit board).
A17 Rear disturbance elimination board (printed circuit board).
A18 Filter board for arc voltage measuring.
A21 Feed unit.
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BLOCK DIAGRAM
BLOCK DIAGRAM
Control and programming unit
Exterior storage unit
Electronic unit
(PC board rack)
Welding power
source
Regulating
amplifier and
slope--unit
Tube welding tool
and tube--to--plate
welding tool
Wire feed unit
Accessory unit:
Printer registrating welding parameters, welding current, arc voltage and rotary motion of tool.
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FUNCTION DESCRIPTION
FUNCTION DESCRIPTION
The complete welding equipment can be divided into the following functions.
S Welding circuit
S Shielding gas circuit
S Feed and control circuit
S Motor circuit
S Program handling
Welding circuit
The built--in current regulator of the electronic unit provides together with the
measuring shunt of the power source a very good accuracy regarding setting and
repetitivness of the welding current.
When programming, you can choose pulsing of the welding current between certain
desired values during the whole procedure or parts of it.
When programming, you can also choose the slope--up and slope--down functions.
They can be used not only at the beginning and the end of the welding program, but
also within certain desired parts of the program.
The slope--function can be of different types: it can either be based on time or position--oriented. The position--oriented slope--function admits continuous current
change during parts of the welding program.
At the beginning of the welding process the HF unit is connected and the striking of
the arc can be supervised over the welding current circuit. When the arc is struck the
HF unit is automatically disconnected.
As an extra protective measure, a water fuse is connected in the welding circuit. The
fuse--link is continuously cooled by the surrounding circulating water. In case the
water should stop circulating, the fuse--link melts and the welding circuit is broken.
The e lectronic unit is internally prepared for a supervisory function which will be
blocked in case the water circulation should stop.
Shielding gas
circuit
On the rear of the electronic unit are connections for root gas, start gas and welding gas.
S The root gas can be connected manually or be programmed for the desired
length of time.
S The start and weld in g gases are in many cases identic, but it is possible to use
different types of gas.
The pre-- and post--flow times of the shielding gas can be programmed optionally between 0 -- 999 seconds.
In addition to the three solenoid valves for the different gas functions also a gas flow
guard is connected to indicate if there is a flow of shielding gas during the ongoing
welding process.
If no start or welding gas is flowing, the welding process is interrupted. The root gas
function is not connected to the gas flow guard.
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FUNCTION DESCRIPTION
Supply voltage and control circuit
The electronic unit is connected to 42 V AC from the welding power source and the
control transformer.
42 V AC is used via printed board relays and interlocking functions to the supply unit,
the solenoid valves and the starting circuit.
The supply unit provides +5, --5, +12 --12, +15 and --15 V DC as supply voltage for
the board rack as well as 36 and 60 V DC for the motor circuits.
The supply unit has an automatic reclosing function in case of mains failure, short-circuit proof outputs and a function where the supply unit is disconnected in case the
supply voltage for the racks deviates by more than +/-- 5% from the rated value.
The supply voltage is indicated by a green LED on the electronic unit.
Motor circuit
The electronic unit is designed for four motor functions: rotatary motion, wire feed
motion, arc length regulation and weaving.
As to the arc length regulation the PC board differs from other motor regulators, but
for weaving the same motor regulator is used as for wire feed motion and rotary motion.
The supply voltage to the armature for the rotary and wire feed motions is 24 V and
both motors are provided with a tachometer generator.
The feedback control system makes use of the tachometer voltage to keep the rotation speed constant at varying load conditions. The control system has a current limit
for the respective motor.
The tachometer generator for the rotary motion is also used for keeping up the position of the motor. The tachometer generators provide a great number of pulses and
because of that also a very good positioning accuracy.
One exception regarding the supply voltage for the motors is the wire feed unit MTC
20 that has a 36 V motor with higher power than the other motors. When this unit is
connected a higher current limit is automatically obtained.
The smaller motors are of the permanent magnet type (even MEI 20), while the MTC
20 motor is provided with a stator with field winding.
If one of the motors is disconnected from the electronic unit, the voltage supply for
the whole unit is interrupted.
At reclosing or change of welding tools, the programming unit asks for a tool code
(identification code) that is to be answered. Then the equipment can be used for
welding again.
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FUNCTION DESCRIPTION
Welding power source
From electrotechnical point of view the power source can be divided into four units:
1. Power unit
2. Main PC board
3. High--frequency unit
4. Electronic equipment (PC board rack)
The power unit (fan--cooled) includes:
S Main transformer
S Transistor unit
S Diode bridges
S Auxiliary diodes
S Inductor
The transformer and inductor windings have silicon impregnation.
The inductor gives a smooth weld with only little spatter.
The shunt in the welding circuit provides proportional voltage that is fed back to the
control system which in this way can compensate for variations in the welding circuit.
The transistors control the level of welding current.
The power unit is provided with three overload protections (thermal type).
The main PC board contains:
S Processor
S Storage function
S Regulation function
S Control function
The control transformer supplies 42 V AC to the system.
The gas post--flow function has been transferred to the elctronic unit and has been
changed from a fixed time function to a programmable function.
The high frequency unit contains:
S HF unit
S HF transformer
The high frequency unit is automatically disconnected as soon as the arc is struck.
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FUNCTION DESCRIPTION
The electronic equipment (PC board rack) contains:
S Process area
S Data area
The interface between the areas is the connection boards (front and rear connectors,
pos 7 and 15).
Process area
S Weaving motor board pos 8
S Wire feed board pos 9
S Rotating motor board pos 10
These three motor boards (pos 8, 9 10) are identic.
The supply voltage is 42 V DC, full--wave rectified and smoothed by way of a 220
mF capacitor.
To control the motor speed a chopper--regulator is used (pulse interval control).
The reference is obtained through a 10--bit resolution D/A converter.
Each motor has tacho--feedback and current limit. The arc length motor has arc
voltage feedback instead of tachometer.
The reference is obtained through an 8--bit resolution D/A converter.
S Arc length motor board pos 11
S Current regulation board pos 12
The reference is obtained from the welding program over I/O and CPU boards.
The regulator is galvanically separated from the data area via a 12--bit D/A cont -
verter providing steps of 0.1 A between 5--315 A (theoretical value).
The shunt of the welding current circuit is important with regard to the total
measuring accuracy of the welding current.
The shunt voltage drop is a feedback from the welding current circuit.
S Relay board pos 13
The function of the relay board is to switch on and off the supply voltage (42 V)
for the three solenoid valves and the starting function of the power source (4 relays in all).
There is room for eight relay functions on the PC board.
All PC boards in the process area are activated over the I/O board.
Data area
S I/O board
The I/O board controls all activities in the welding process.
It contains 9 different 8 --bit ports -- in all 72 connections (pins).
The board also contains circuits for adressing logic.
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FUNCTION DESCRIPTION
S CPU board
The CPU board contains:
S One processor
S One bus buffer
S One internal clock (constituting the time basis for the whole system). The
function is to process and execute instructions (checking data and process
areas).
S One communication link for serial communication.
S A function for the process and welding program.
S The process program is stored in 2 EPROM capsules which preserve their
information also when the supply voltage has been broken. The contents can
only be erased by UV light.
S The welding program(s) is stored in a 16 kb read--write memory, 15 out of
which occupy welding data. Also the tachometer, the indicators (flags) and
temporary numbers are stored in this memory.
S Counting board
The counting circuit board includes three important circuits:
S 8259 -- controls the process together with the CPU board.
S 8253 -- contains time functions for the welding process and the slope--func-
tion.
S 8279 -- adapts the keyboard and the display to the microprocessor.
Programming block
Programming block over a key switch on the programming unit
1. Accessible functions in position Programming Block:
S Manual program, all functions.
S Shift of electrode centre line both during welding and in manual mode.
S Reading of parameter value.
S Program control (step function)
S Welding program transmission, from library to working area.
S Welding program transmission, from computer to working area.
S Erase program in the working area.
S Starting procedure.
S Stop and start of welding program and emergency stop by activating three
keys simultaneously.
2. Prohibited functions in position Programming Block:
S Erase welding parameters in a welding program.
S Erase welding program in the library area.
S Increase/decrease keys (+ och --).
S Modify contents of welding programs.
S Replace or modify parameter values.
S Transmission of welding program, from working area to library.
NB: The display indicates Bloc in case a prohibited function is selected. The computer does not react to the activation of a prohibited function.
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PROGRAMMING FUNCTIONS
PROGRAMMING FUNCTIONS
The following pages describe the individual programming functions, including
examples of programming, possible combinations and an error code list.
Pre-- welding functions:
S Manual gas pre --flow.
S Manual arc length regulation.
S Manual electrode adjustment (laterally).
S Manual filler wire adjustment.
S Manual adjustment of initial position for the rotation.
Before welding, all operations regarding t h e welding program are executed:
S Programming.
S Pre--weld test of completed program (without welding).
S Reading of existing program.
S Modification of individual parameter or part of program.
S Stepping through program or individual sector.
S Two--way transfer of welding program, working area/library area.
S Two--way trannsfer of welding program, working area/micro cassette alt. PROfile
program.
In the course of welding the following operations can be executed:
S Gas pre--flow and gas post --flow.
S Special start gas during arc strike.
S Root gas flow.
S Pulsing of welding current, rotary motion and wire feed motion.
S Synchronous pulsing of welding current and wire feed motion.
S Synchronous pulsing of welding current and rotary motion.
S Time-- related slope--up and slope--down.
S Position--dependent slope--up and slope--down.
S AVC -- and weaving function.
In the course of welding, the following adjustments and registrations can be
made:
S Stop and restart of welding process in the desired position of the rotary cycle.
S Positional tracking during rotary motion.
S Manual adjustment of electrode position (vertically and horizontally).
S Parameter display during slope function.
S Modification of individual parameter in welded sector.
S Registration of arc voltage, welding current and rotary motion.
S Stepping through welded sector.
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PROGRAMMING FUNCTIONS
S Entering of new sector.
Programming unit
On the programming unit is/are:
S a display with 7--segment indicators
S a program blocking key
S 37 keys, divided up as follows:
S Function keys
S Parameter keys
S Numeral keys
Function keys
Gas function keys
Delayed start of rotary motion
Rotation of welding tool,
clockwise and anti--clock -wise
Filler wire feed
Centre line adjustment
Welding start and stop key
Parameter keys
Pulsing keys
Delete key
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Arc length function key
Weave function key
Stepping function
Gives certain parameter
keys a 2nd function
Dividing welding pro-grams into different sectors
Increases displayed value
Decreases displayed value
Slope--up and slope--down
function
PROGRAMMING FUNCTIONS
Indicates program number
Numeral keys
Numeral keys
Decimal point
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PROGRAMMING FUNCTIONS
Programming rules
Represents dark display
Represents display with entered value
Represents display showing sector number.
Represents display showing error code, block code
Indicates that deletion is taking place.
Indicates that an entered program is transferred to the memory.
Indicates that a program is copied from the library area and
transferred to the working area.
The last operation of a welding program is finished.
Indicates that an operation is going on. Further key activation
is ignored.
Indicates that the SHIFT key is pressed.
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KEY FUNCTION
KEY FUNCTION
Shift function
The SHIFT key is used to assign a second signification to certain keys (compare
calculators).
Keep the SHIFT key pressed down and press another key simultaneously.
Explanations Touch Display shows Illuminated key
Tool code
”TOOL”
Starting gas
Pulsed wire feed
motion
Instantaneous
value displayed
(only in combination with welding)
Non--SHIFT function
Arc length control and weaving
Arc length control AVC during pulse time
Arc length control AVC during back -ground time
Weaving frequence, WEAVE RATE
Weaving frequence, WEAVE AMPL
Pause time, weave motion -- DWELL
LEFT”
Pause time, weave motion -- DWELL
RIGHT
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KEY FUNCTION
Stepping in program
Stepping throughout the program before welding.
Explanations Touch Display shows Illuminated key
Shows all parameters entered into
a program step by
step. The stepping
can be interrupted
anywhere in the
program.
Stepping through the program with regard to individual parameters.
1st
Shows the desired
parameter.
2nd
Both the parameter
key and the indicator go out.
3rd
By pressing the
same parameter
key again the value
of the next sector in
the same program
will be shown.
4th
By preassing the
same key once
more both the key
and the indicator
will go out.
During a welding sequence stepping can only take place within the activated sector.
Stepping is performed by way of the STEP key. 1, 3, 5 ... and so on show the parameter values.
2, 4, 6 ...... and so on make the parameter key and the display go out.
The stepping can be interrupted anywhere in the program.
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KEY FUNCTION
Erasing (delete)
Explanations Touch Display shows Illuminated key
Erasing can take
place during writing
(before the parameter key has
been pressed
down)
but the value is dis played.
Erasing of program
in the working area.
After erasing, the
code of the tool
connected is always shown.
Erasing of parameter. The parameter key activated
and the indicator
are erased only
when the same
parameter key is
pressed a second
time, e.g.
Initial position with
non--illuminated
parameter key results in erasing of
actual parameter
value in all sectors.
Erasing of sector
including all the
parameters in the
sector.
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KEY FUNCTION
Erasing of the sector displayed including all the parameters in the sector. Keep the sector
key down.
Erasing of empty
sectors (parameter
values missing) in
a program
N.B. Not preceded
by sector key activation. Keep the
sector key down.
Stepping to a desired program in
the library area.
Keep the Prog.Nr.
key down. This always results in the
tool code.
In case the key is
released the sector
number is displayed every second time
or
Erasing of a desired program in
the library area.
Keep the Prog.Nr
key down and the
displayed program
in the library area is
erased.
Sector concepts
The program is divided into different sector types, such as transport, welding start/
stop and welding sectors.
Definition: Transport sector = Motion without welding.
Welding stop sector = The welding current has a high initial value
and a low final value (0 A).
Welding start sector = The welding current has a low initial value
and a high final value.
Welding sector = The welding current has a high or a low
initial value and high or low final value.
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