Valid for machine no 644--xxx--xxxx Valid for program version PEH4.0, PEH4.0C, PEH4.01, PEH4.01C, PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH 5.0, PEH5.0C, PEH 5.1 and PEH 5.1C A2- A6 Process Controller PEH Instruction manual 2 DECLARATION OF CONFORMITY Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee that control unit A2--A6 Process Controller from serial number 220 complies with standard EN 60974--1, in accordance with the requirements of directive (73/23/EEA) and addendum (93/68/EEA). -------------------------------------------------------------------------------------------------------------------------------------- Gteborg 2002--04--29 Greger Jacobson Senior Vice President ESAB AB SE--402 77 Gteborg Sweden Tel: +46 31 50 93 49 Fax: +46 31 50 94 36 -- 3 -- TOCe Rights reserved to alter specifications without notice. 1 SAFETY 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTRODUCTION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Welding power sources 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Technical data 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 General 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Connection of the welding power source 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Connection of the welding head 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATIONAL DESCRIPTION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 General 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Control panel 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MANUAL OPERATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Travel and wire feed 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Controlling valves 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 MENUS 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Menu overview 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 MAIN MENU 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 General 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Entering welding parameters 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Adjusting parameter values (during welding) 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Choosing a new set of parameters during welding 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Selecting the display language 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WELDING SETUP 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 General 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Changing settings 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Available settings 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Definitions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Preset indicators 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ERROR LIST 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Error codes 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAINTENANCE 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 General 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ORDERING SPARE PARTS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGRAM 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORIES 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARE PARTS LIST 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 4 -- fgb7safe 1 SAFETY 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 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 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 during operation. GB -- 5 -- fgb7safe 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 EMPLOYERS 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. PROTECT YOURSELF AND OTHERS! WARNING This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the users responsibility to take adequate precautions. GB -- 6 -- fgb7d1ea 2 INTRODUCTION 2.1 General ESABs A2--A6 Process Controller (PEH) is a control unit which, when combined with A2--A6 automatic welding equipment can be used for submerged--arc or MIG/MAG welding. The process controller is designed for use with ESABs LAF and TAF welding power sources. Close integration of the control system with the welding power source makes it possible to ensure very precise process reliability. All the controls that are needed to control welding travel and the entire welding process are situated on the control panel. Incoming cables from various system components are connected to sockets at the rear of the process controller or to the circuit board terminals inside the controller. 2.2 Welding power sources The welding power sources are specially adapted to work with the A2--A6 Process Controller. The welding power source and process controller are connected by a twin wire bus that allows the welding process to be controlled and monitored much more precisely than previously possible. The power source settings can be adjusted from the control panel on the process controller. ESABs earlier generation of welding power sources, such as the LAH, LAE and TAE can be adapted for use with the new process controller with the aid of a conversion kit. The new welding power sources are already prepared for straightforward connection to the A2--A6 Process Controller (PEH). The welding power sources also supply the correct current to the process controller, thus eliminating the need for any external power supply. 2.3 Technical data A2--A6 Process Controller (PEH) Nominal voltage from power source: 42V AC 50/60 Hz Nominal load: Max. 900 VA Motor connections adapted for ESABs A2-- or A6-- motors: Motor current 5 A continuous, max. 10 A Wire speed regulation: Internal EMK control or with AC tacho, 6 pulses per rev Welding speed: 0.1--2 m/min (depending on travel unit)) Max. manual travel speed: 2.0 m/min Filler wire, wire feed speed: 0.3--25 m/min (depending on wire feed unit) Ambient temperature: Max. 45_ C, Min. --15_ C Relative humidity: Max. 98 % Weight: 5.5 kg Dimensions L x B x H: 355 x 210 x 164 mm Enclosure class: IP 23 Enclosure class The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water. Equipment marked IP 23 is designed for indoor and outdoor use. GB -- 7 -- fgb7i1ea 3 INSTALLATION 3.1 General The installation must be executed by a professional. 3.2 Connection of the welding power source S Connect control cable (1) from the welding power source to connector XS1. 3.3 Connection of the welding head S Arc voltage to terminal X2.1 As to all other connections, contact ESAB. Connection of welding power source Connection of the welding head GB -- 8 -- fgb7fb1e 4 OPERATIONAL DESCRIPTION 4.1 General Switch on welding power source The process controller can be used in manual or automatic mode. In manual mode the wire feed speed and travel speed are controlled manually and you can preset all other essential welding parameters for the current weld. In automatic mode you can choose a preset group of welding parameters and fine--tune the actual welding parameters. Other settings made previously in manual mode cannot be adjusted in automatic mode. The process controller is ready for manual operation as soon as the mains power is switched on. When welding begins the controller switches to automatic mode. When welding stops, or if there is a fault, the controller switches back to manual mode. 4.2 Control panel 1. Emergency stop 2. The direction of travel is as shown by the triangular symbol on the welding equipment. 3. The direction of travel is as shown by the square symbol on the welding equipment. 4. Advance wire 5. Retract wire 6. Change menu 7. Numerical key, number entry 8. ENTER key, Change row 9. SHIFT key 10. Stop welding. Return to manual mode 11. Start welding. Switch to automatic mode 12. Fast, wire feed or travel 13. Scroll page (welding setup menu) or close valve (main menu) The arrowed keys are used during welding to increase or decrease the current, voltage and speed. By pressing either , , + or + it is possible to browse. GB -- 9 -- fgb7o1ea 5 MANUAL OPERATION 5.1 Travel and wire feed Travel and wire feed commands can be given when not welding, as follows: Switch on welding power source S The direction of travel is as shown by the square symbol on the welding equipment. Normal speed . S The direction of travel is as shown by the triangular symbol on the welding equipment. Normal speed . To stop travel described above, press the same key again. S Retract wire. Normal speed . Wire continues to retract until you release the key. S Advance wire. Normal speed . Wire continues to advance until you release the key. S After switching on, you can select maximum speed by pressing the fast key . The LED in the key lights up. S To return to normal speed press the fast key again . To stop immediately, press , or even at max. speed. Normal speed and max. speed can be adjusted under PRESET SYSTEM MENU. 5.2 Controlling valves To operate a valve you must be in the MAIN MENU. S Open the valve for flux or gas by pressing . S Close an open valve by pressing the same key . Valve (Open/ Closed) GB -- 10 -- fgb7me1e 6 MENUS 6.1 Menu overview The A2--A6 Process Controller (PEH) software is divided into several menus. The program structure is described in the overview below. MAIN MENU S SET S Heat input per cm S Welding current S Wire feed speed S Arc voltage S Travel speed S Preset indicators S Selecting the display language WELDING SETUP S Arc start method S Type of weld finish S Welding direction S Regulation method S Wire type S Wire material S Wire size PRESET SYSTEM MENU / DISPLAY MENU / ERROR LIST Menus that are not accessible by the user GB Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU MAIN MENU WELDING SETUP -- 11 -- fgb7hm1e 7 MAIN MENU 7.1 General In the MAIN MENU you choose the welding current, arc voltage and travel speed you want to use for welding. During welding you can adjust the welding parameters or choose a complete new set of parameters. S Switch on the power source . The main menu will appear as follows: Indicates that parameter set 1 of 10 available has been selected (can be hidden). Indicates the heat input in kJ/cm that will result from the chosen values of welding current, arc voltage and travel speed (can be hidden). Chosen arc voltage in volts. Chosen travel speed in centimetres per minute. Indicates the type of start Travel direction Indicates if the valve out- put is open or closed. Example of display if constant current (CA) has been chosen. Chosen welding current in amperes. Example of display if welding with constant wire feed speed (CW) is chosen. Chosen wire feed speed. Example of display during welding at constant wire feed speed (CW). Resulting welding current after the welding start. For the selection of (CA) or (CW), see the menu WELDING SETUP on page 17. GB -- 12 -- fgb7hm1e Example of display in the event of a fault. S Error code appears in bottom left section of display. S Error message is cancelled by pressing S Max. 20 messages saved in chronological order. S Start welding by pressing . The LED in the key lights up. S Stop welding by pressing GB -- 13 -- fgb7hm1e 7.2 Entering welding parameters When the power source is switched on, the main menu appears on the display. In the Display menu you can choose how many sets of parameters you want to work with. If more than one set of parameters is used then the SET number appears in the top left corner. 1. Welding current or wire feed speed 2. SET no. 3. Arc voltage 4. Travel speed If you choose to work with just one set of parameters then start at step 3. S Press + to mark the parameter set field . S Type in the desired SET number and press . S Select the field for welding current or wire feed speed by pressing . S Type in the desired welding current or wire feed speed. Max. 4 numbers, press . S Select the field for arc voltage by pressing . S Type in the desired arc voltage, max. 3 numbers, press . S Select the field for travel speed by pressing . S Type in the desired travel speed, max. 3 numbers and press . Now the whole set has been marked and is ready to use. A further 9 additional sets can be stored. (Total 10 SETs). GB -- 14 -- fgb7hm1e 7.3 Adjusting parameter values (during welding) Once welding has started the welding parameters can be fine--tuned using the arrowed numerical keys (over--ride function). Increase Decrease Welding current or wire feed speed Arc voltage Travel speed Save the values as follows: S Stop welding with . S Save the changed values with . S To revert to the original values, press + . GB -- 15 -- fgb7hm1e 7.4 Choosing a new set of parameters during welding (Only possible when you have chosen to work with several sets of parameters by programming the Display menu) Immediate selection Suppose that while welding with parameter set 1 (SET 1) you decide to change to parameter set 6 (SET 6) without checking the parameters first. S Press + . The field SET 1 is marked and parameter set 1 is active S Press . The field SET 6 flashes. S Press . The field SET 6 is marked and parameter set 6 is active Check before choosing Suppose that while welding with parameter set 1 (SET 1) you decide to change to parameter set 6 (SET 6) after first checking the parameters. S Mark the field SET 1 by pressing + . S Press . The field SET 6 flashes. S The new parameter set can be checked before being chosen by pressing + . The complete row displaying the welding parameters flashes and displays the values for parameter set 6 (SET 6), although parameter set 1 (SET1) remains in use during the current welding cycle. S Press . The field SET 6 is marked and parameter set 6 is active. GB -- 16 -- fgb7hm1e 7.5 Selecting the display language The selection is made in the MAIN MENU S Press . S The current language is shown in the top right corner of the display. S Scroll forward to the desired language with . S Return with . The following languages can be selected: Svenska=Swedish / Dansk=Danish / Norsk=Norwegian / Soumi=Finnish / English=English / Deutsch=German / Francaise=French / Nederlands=Dutch / Espanol=Spanish / Italiano=Italian / Portugues=Portuguese / Eesti=Estonian / Cesky=Czechoslovakian. N.B. The China version is only available in English and Chinese. GB Display language -- 17 -- fgb7fs1e 8 WELDING SETUP 8.1 General In WELDING SETUP you can choose a variety of settings including start method, welding direction, wire diameter and similar variables in order to carry out a specific welding task. These settings cannot be changed during welding. S Switch from the MAIN MENU to WELDING SETUP. Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU 8.2 Changing settings Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU General Scroll between the alternatives in the left column with or + . When all settings have been done return to the MAIN MENU with + . For available settings see on page 18. To change the settings for Direction, Start and Regulation: S Mark menu Direction, Start or Regulation and press . S Scroll forward to the chosen option with . S Return with + . To change the settings for STOP WELDING and WIRE DATA: S Mark menu STOP WELDING or WIRE DATA and press . S Select the alternative that is to be changed with . S Press . S Scroll forward to the chosen option with or type in your own values. S Return with + Explanations of terms: When is indicated in combination with another key you should press first and hold it down while pressing the second key. GB -- 18 -- fgb7fs1e 8.3 Available settings Press Press Direction Y , J Start Scratch Direct STOP WELDING Crater fill (ms) 10--3000 STOP WELDING Burnback time (ms) 10--3000 Wire type Solid wire, Flux cored, Strip, Gauging WIRE DATA Wire diameter if Solid wire is chosen if Flux cored is chosen if Strip is chosen if Gauging is chosen 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 30x0.5 60x0.5 100x0.5 8.0 9.5 13.0 Wire material Fe, Al, SS Number of wires 1, 2 Regulation CA, CW PRESET SYSTEM MENU N.B! The menu PRESET SYSTEM MENU is not accessible to the user GB -- 19 -- fgb7fs1e 8.4 Definitions 1. Direction Two alternatives can be chosen Y (triangle) and J (square) (these symbols are repeated on all units) S Y (triangle) indicates travel in one direction. S J (square) indicate 2. Start Two alternatives can be chosen: Direct start or Scratch start. S Direct start means that travel starts when the arc ignites. S Scratch start means that travel starts at the same time as wire feed. Scrape start is used when welding rusty or dirty material. 3. STOP WELDING Crater fill and Burnback time can be set. Crater fill times between 10 and 3000 ms (0.01 -- 3 sec.) can be selected. The crater fill function is used to finish the weld without leaving a crater. Crater fill starts when the welding stop key is pressed, and continues for the preset crater fill time. This function is most useful when MIG/MAG welding. Burnback times between 10 and 3000 ms (0.01 -- 3 sec.) can be selected. The burnback time starts after the crater fill sequence has ended. Correct choice of the burnback time prevents: S the wire sticking to the work piece S the wire sticking to the nozzle GB -- 20 -- fgb7fs1e 4. WIRE DATA Wire type The equipment can be preset for the wire you intend to weld with. The control system must be given information about the wire shape in order to achieve optimum start/stop characteristics. S solid wire S cored wire S strip S gauging Wire diameter The chosen wire diameter has a big effect on the start cycle and crater filling. When welding with a wire diameter that is not given in the options table, choose the nearest diameter from the menu. Note! For certain wire materials a better welding result can be achieved, if a value deviating from the real wire dimension by 1 step is set (normally 1 step from the real value). When metric units are used the following alter- natives are available: When inch units are used the following alterna- tives are available Solid wi- re: Cored wire: Strip: Gauging: Solid: Cored wire: Strip: Gauging: 0.8 mm 0.8 mm 30x0.5 mm 8.0 mm 0.030 0.030 1.25 x 0.02 1/2 1.0 mm 1.0 mm 60x0.5 mm 9.5 mm 0.040 0.040 2.5 x 0.02 5/6 1.2 mm 1.2 mm 100x0.5 mm 13.0 mm 0.047 0.047 4 x 0.02 3/8 1.6 mm 1.6 mm 1/16 1/16 2.0 mm 2.0 mm 5/64 5/64 2.4 mm 2.4 mm 3/32 3/32 3.0 mm 3.0 mm 7/64 7/64 3.2 mm 3.2 mm 1/8 1/8 4.0 mm 4.0 mm 5/32 5/32 5.0 mm 3/16 6.0 mm 1/4 Wire composition When welding with different filler materials the start and stop method is affected by the choice of materials. It is therefore important that the settings show whether you are welding with steel--based or aluminium--based filler wires. S Fe Steel filler wire S Al Aluminium filler wire S SS Stainless steel filler wire Number of wires Values between 1 -- 2 can be entered. For example, if welding with two wires (Twin Arc) enter the value 2. GB -- 21 -- fgb7fs1e 5. Regulation Two different operating modes can be used for welding, either constant current, CA, or constant wire feed speed, CW. S CA, constant current. Normally used for submerged arc welding, which involves working with large welds, large currents and large weld pools. The wire feed speed is controlled by the power source to maintain a constant current. S CW, constant wire feed speed. Normally used for MIG/MAG welding, for small weld pools, thin sheet metal and thin filler wire. It is easier to achieve a constant throat thickness when welding with this method. Welding is controlled by selecting a fixed wire feed speed and the current is adjusted to achieve this speed. The resulting current is displayed above the selected wire feed speed (see display shot on page 21). 8.5 Preset indicators The numbers and symbols on the display show the chosen preset values, see table below. Shown in display MAIN MENU as WELDING SETUP options Start Direct Scratch Y J Direction TRIANGLE SQUARE Shown in plain English (e.g. 3.0) Wire diameter: Solid wire Flux cored Strip gauging 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 30x0.5 60x0.5 100x0.5 8.0 9.5 13.0 OUTPUT Open/Closed Valve GB -- 22 -- fgb7f1ea 9 ERROR LIST 9.1 Error codes Analogue board 203.01 Communication error with Analogue card Stop Check cables and connections I/O board 301.01 Communication error with Digital I/O Stop Check cables and connections Wire feed motor (Motor 1) 201.2 Current too high Stop Check wire feed 201.3 Overheating (Motor 1) Stop Wait until temperature has fallen 201:5 Communication error ** Stop Check the cabling. Travel motor (Motor 2) 202.2 Current too high Stop Check travel motor / gearbox 202.3 Overheating (Motor 2) Stop Wait until temperature has fallen 202:5 Communication error ** Stop Check the cabling. Drive unit (PEH4.2) 204.2 Short--circuit, drive unit ** Stop Replace the PC board 204.3 Overheating, drive unit ** Stop Wait for a while and then check the heat dissipating element Welding power source (T1) 111.01 Communication error Stop Check cables and connections 111.53 Unsuccessful start Stop Check stick--out and welding parameters 111.54 Current limit/ Arc extinguished *** Stop Welding short--circuited, Cure short--circuit / Check wire feed 111.54 Current limit ** Stop Welding short--circuited, Cure short--circuit 111.55 Thermostat / overheating Stop Wait until temperature has fallen 111.57 Arc extinguished ** Stop Check wire feed Inputs / outputs No cooling water (inlet K22 open) * (Flashing) Display Stop Check if the gas is flowing or if the limit switch is open. No gas flow (inlet K23 open) * (Flashing) Stop Check gas pressure or if the limit switch is open. * Inputs are activated by using settings in menu PRESET SYSTEM MENU. ** Only valid for control box with program version PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH5.0, PEH5.0C, PEH5.1 and PEH 5.1 C. *** Only valid for control box with program version PEH4.0, PEH4.0C, PEH4.01 and PEH 4.01C. GB -- 23 -- fgb7f1ea 10 MAINTENANCE 10.1 General Note: All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period. In the event of malfunction: S Contact your nearest ESAB representative, see last page. 11 ORDERING 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 27. This will simplify dispatch and ensure you get the right part. GB Diagram -- 24 -- fgb7e12a -- 25 -- fgb7e12a Accessories -- 26 -- Tillb Remote control PHH1, including cable Ordering no.: 0449 040 880 Remote control PHH2 Ordering no.: 0449 040 881 Spare parts list -- 27 -- pehspare A2- A6 Process Controller (PEH) Edition 2004--12--17 Ordering no. Denomination Notes 0443 741 880 Control box A2--A6 Process Controller (PEH) Abbreviations used in the spare parts list: C = Component designation in the circuit diagram -- 28 -- f443741r Item no. Qty Ordering no. Denomination Notes C 0443741880 CONTROL BOX PEH 3 1 0443638880 Control panel KB1 4 1 0443740001 Emergency stop ST1 8 2 0457278001 Rail 9 1 0443748880 Cable complete XS1 10 0443730880 Circuit board AP1 + AP2 14 1 0443849001 Insulation 20 1 0449130001 Display, ccfl backlight DY1 21 0192526003 Sealing strip 530 mm 23 10 0192645002 Bushing 26 2 0467911884 Capacitor Valid from programversion PEH1.2 41 1 0449137880 Inverter with screen box -- 29 -- f443748s Item no. Qty Ordering no. Denomination Notes 0443 748 880 Cable with connectors 1 1 0368 543 003 Pin socket, Burndy 4 1 0443 841 880 Cable set 6 1 0456 489 005 Circuit board connection 7 1 0456 489 004 Circuit board connection 8 1 0193 275 002 Connection block 3 pole 9 0190 209 109 Hose 10 2 0192 541 003 Pin cable clip 2,5 mm 2 -- 30 -- s443730r Item no. Qty Ordering no. Denomination Notes C 0443 730 880 Circuit board AP1 + AP2 2 0456 489 002 Connection terminal 6 poles K10, K11 3 0456 489 001 Connection terminal 2 poles K12, K17, K22, K23 4 0456 489 004 Connection terminal 2 poles K13, K14 5 1 0486 471 880 Flash memory IC15 7 0456 489 005 Connection terminal 4 poles K9, K9X -- 31 -- f456500s Item no. Qty Ordering no. Denomination Notes 0456500880 Control cable L = 15 m, Accessories 1 1 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500881 Control cable L = 25 m, Accessories 1 1 0449449881 Control cable 25m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500882 Control cable L = 35 m, Accessories 1 1 0449449882 Control cable 35m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500883 Control cable L = 50 m, Accessories 1 1 0449449883 Control cable 50m, 12--28p 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500884 Control cable L = 75 m, Accessories 1 1 0449449884 Control cable 75m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500885 Control cable L = 100 m, Accessories 1 1 0449449885 Control cable 100m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) -- 32 -- f449449s Item no. Qty Ordering no. Denomination Notes 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449881 Control cable 25m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 contact sleeve max 2.5mm2 0449449882 Control cable 35m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 -- 33 -- f449449s Item no. Qty Ordering no. Denomination Notes 0449449883 Control cable 50m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449884 Control cable 75m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449885 Control cable 100m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 -- 34 -- f449448s Item no. Qty Ordering no. Denomination Notes 0449448880 Adapter 28--12POL(PEH--LAF12P) 1 1 0368546106 Sleeve cable socket 28--pol 2 3 0323945003 Connector sleeve 0,52--1,50 3 5 0323945002 Contact sleeve 0,32--0,52 4 1 0368541303 Pin plug burndy 12 pol. 5 5 0323945001 Connector pin 0,32--0,52 6 3 0323945004 Connector pin 0,52--1,50 0,52--1,50 7 1 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945007 Contact sleeve max 2.5mm2 9 4 0323945008 Contact pin max 2.5mm2 ESAB AB SE--695 81 LAX SWEDEN Phone +46 584 81 000 www.esab.com 061127 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 THE CZECH REPUBLIC ESAB VAMBERK s.r.o. 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