ESAB A2, A6 PEK Control Panel Instruction manual

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A2, A6 PEK Control Panel

Instruction manual

0460 949 474 GB 20210203

Valid for: From software version 5.00

INTRODUCTION

1.1 Control panel

1.1.1 Keys and knobs.................................................................................... 5

1.2 First step

1.2.1 Choice of language .............................................................................. 6

1.2.2 Unit of measurements .......................................................................... 8

1.3 Display

1.3.1 Symbols in the display.......................................................................... 9

1.4 General information about settings

1.4.1 Setting of numerical values .................................................................. 10

1.4.2 Setting with given alternatives.............................................................. 10

1.5 QUIT and ENTER

MENUS

2.1 Main Menu

2.1.1 Configuration menu .............................................................................. 11

2.1.2 Tools menu........................................................................................... 12

2.1.3 Weld data setting menu........................................................................ 12

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2.1.4 Measurements menu............................................................................ 14

2.1.5 Weld data memory menu ..................................................................... 15

2.1.6 Fast mode menu .................................................................................. 15

SUBMERGED ARC WELDING

3.1 Settings for submerged arc welding

GAS METAL ARC WELDING

4.1 Settings for gas metal arc welding

ELECTRO SLAG WELDING

5.1 Settings for electro slag welding

GOUGING

6.1 Settings for gouging

FUNCTION EXPLANATIONS

7.1 CA, constant amperage

7.2 CW, constant wire feed

7.3 CC, constant current

7.4 Wire / electrode dimension

7.5 Arc voltage

7.6 Wire feed speed

7.7 ICE wire feed speed

7.8 ICE wire start delay

7.9 Travel speed

7.10 Welding direction

7.11 AC frequency

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0460 949 474 © ESAB AB 2021

TABLE OF CONTENTS

7.12 AC balance

7.13 AC offset

7.14 Flux pre-flow (SAW)

7.15 Gas pre-flow (GMAW)

7.16 Start adjust

7.17 Air pre-flow (Gouging)

7.18 Start type

7.19 Wire creep start

7.20 Start phases

7.21 Max Open Circuit Voltage (OCV)

7.22 Flux post-flow (SAW)

7.23 Gas post-flow (GMAW)

7.24 Air post-flow (Gouging)

7.25 Crater filling

7.26 Burnback time

7.27 Stop phases

7.28 Dynamic regulation

7.29 Control parameters

7.30 Setting limits

7.31 Measure limits

7.32 PEK control unit as separate motor control

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MEMORY MANAGEMENT

8.1 Control panel working method

8.2 Store

8.3 Recall

8.4 Delete

8.5 Copy

8.6 Name

8.7 Edit

CONFIGURATION MENU

9.1 Code lock

9.1.1 Lock code status .................................................................................. 39

9.1.2 Specify/edit lock code........................................................................... 40

9.2 General configuration

9.2.1 Fast mode soft keys ............................................................................. 40

9.2.2 Quality data log to file........................................................................... 41

9.2.3 Soft key configuration........................................................................... 41

9.2.4 Auto save mode ................................................................................... 43

9.3 Machine configuration

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9.3.1 Product code ........................................................................................ 44

9.3.2 Wire feed axis....................................................................................... 45

9.3.3 Cold wire axis (ICE).............................................................................. 46

0460 949 474 © ESAB AB 2021

TABLE OF CONTENTS

9.3.4 Travel axis ............................................................................................ 46

9.3.5 External axis......................................................................................... 46

9.3.6 Tandem for LAF and TAF power sources............................................. 47

9.3.7 Tandem for Aristo® 1000 power source............................................... 50

9.3.8 Parallel power sources (applies only to Aristo® 1000 power sources) 52

9.3.9 ICE wire feed........................................................................................ 53

9.3.10 Step function ........................................................................................ 54

9.3.11 Intermittent welding ............................................................................. 56

9.3.12 Polarity (applies only to Aristo® 1000 power source)........................... 56

9.3.13 Node id settings (applies only to Aristo® 1000 power source)............. 56

9.3.14 System information (applies only to Aristo® 1000 power source)........ 56

9.4 Cable lengths (applies only to LAF and TAF power sources)

9.5 Maintenance

9.6 Measure–values filter factor

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TOOLS

10.1 Event handling

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10.1.1 Event log .............................................................................................. 59

10.1.2 Active errors ......................................................................................... 60

10.1.3 Unit IDs................................................................................................. 60

10.1.4 Description of fault management codes ............................................... 60

10.2 Export/Import

10.3 File manager

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10.3.1 Delete a file/folder ................................................................................ 64

10.3.2 Rename a file/folder ............................................................................. 65

10.3.3 Create new folder ................................................................................. 65

10.3.4 Copy and paste files............................................................................. 65

10.4 Setting limit editor

10.5 Measure limits editor

10.6 Production statistics

10.7 Quality functions

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10.7.1 Store quality data ................................................................................. 69

10.7.2 Import system settings ......................................................................... 69

10.8 Calendar

10.9 User accounts

10.10 Unit information

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ORDERING NUMBERS

Rights reserved to alter specifications without notice.

0460 949 474 © ESAB AB 2021

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1 INTRODUCTION

To benefit as much as possible from your welding equipment, we recommend that you read this instruction manual.

For general information about operation, see the instruction manual for the control unit, automatic welding machine, column and boom or power source.

The text presented in the display is available in the following languages: English, US English, Swedish, Finnish, Norwegian, Danish, German, French, Italian, Dutch, Spanish, Portuguese, Hungarian, Polish, Czech, Turkish, Chinese, Korean and Russian.

Instruction manuals in other languages can be downloaded from the Internet: www.esab.com

1.1 Control panel

1. Menu 10. Arc voltage / Setting knob

2. Positioning knob, for moving cursor 11. Fast motion

3. Enter 12. Manual travel motion

4. Green indication lamp, illuminates

when the function is active

5. Welding start 14. Emergency stop

6. Welding stop 15. Manual wire feed upwards

7. Travel speed / Setting knob 16. Soft keys

8. Manual travel motion 17. Display

9. Manual wire feed downwards

13. Welding current / Wire feed speed /

Setting knob

1.1.1 Keys and knobs

The Menu key always takes you back to the main menu in the relevant process.

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1 INTRODUCTION

Enter

Use the ENTER key to confirm a selection.

Soft keys

The five keys (S1 - S5) under the display have different functions. They are called soft keys, i.e. they can have different functions depending on which menu you are in. The current function for these keys can be seen from the text in the bottom row of the display. When the function is active, this is indicated by the field with the text box turning white.

Wire feed upwards

Key for reversing the wire without arc voltage, when replacing wire bobbin for example. The wire is fed as long as the button is depressed.

Wire feed downwards

Key for feeding wire without arc voltage. The wire is fed as long as the button is depressed.

Travel motion

Key for travel motion in the direction of welding where the symbol is indicated on

the weld equipment. To stop travel motion press , or . The LED illuminates during travel motion.

Welding start

Key for welding start.

Welding stop

Key for welding stop for all travel motions and all motors.

Positioning knob

The uppermost right-hand knob is the positioning knob and is used to position the cursor.

Settings knob

The three settings knobs are used to change the set values in the panel.

1.2 First step

1.2.1 Choice of language

This menu appears at first start:

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1 INTRODUCTION

SAW: CA

NONE NONE GAS / FLUX NONE 2ND FUNCT

The control panel is set to English on delivery. To select your language, proceed as follows:

Press Menu to access the main menu. Position the cursor on the CONFIGURATION row, using the positioning knob.

SAW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

SAW

Fe SOLID

3.0 mm

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

Press ENTER to confirm the selection. Position the cursor on the LANGUAGE row. Press ENTER to bring up a list of the languages

that are available in the control panel.

CONFIGURATION

LANGUAGE

ENGLISH

CODE LOCK►

GENERAL CONFIGURATION►

 

MACHINE CONFIGURATION►

CABLE LENGTHS►

MAINTENANCE►

MEASURE-VALUES FILTER FACTOR

Position the cursor on the row for your language and press ENTER.

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  

ONE

QUIT

1 INTRODUCTION

NORSK

POLSKI

PORTUGUES

SUOMI

SVENSKA

CHINESE

1.2.2 Unit of measurements

The control panel is set to metric measurement on delivery. To change measurement unit, proceed as follows:

Press Menu to access the main menu. Position the cursor on the CONFIGURATION row, using the positioning knob.

SAW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

Press ENTER to confirm the selection. Position the cursor on the GENERAL CONFIGURATION row.

CONFIGURATION

LANGUAGE

CODE LOCK

GENERAL CONFIGURATION►

SAW

Fe SOLID

3.0 mm

ENGLISH



MACHINE CONFIGURATION►

CABLE LENGTHS►

MAINTENACE►

MEASURE-VALUES FILTER FACTOR

QUIT

Press ENTER to confirm the selection. Position the cursor on the UNIT OF LENGTH row. Press ENTER to bring up a list of the

measurements that are available in the control panel.

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

ONE

1 INTRODUCTION

GENERAL CONFIGURATION

FAST MODE SOFT BUTTONS

QUALITY DATA LOG TO FILE

SOFT KEYS SETUP►

AUTO SAVE MODE

UNIT OF LENGTH



Position the cursor on the row for correct measurement and press ENTER.

METRIC

INCH.

1.3 Display

SAW

PROCESS

METHOD



OFF

METRIC

QUIT

SAW

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

Fe SOLID

3.0 mm

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

Cursor

The control panel's cursor is presented as a black field around the text, with the selected text turning white. The cursor is displayed in the instruction manual with bold text

Text boxes

At the bottom of the display are five boxes containing text that describes the current function of the five soft keys below the display.

1.3.1 Symbols in the display

A The selected weld data set B Welding direction C A fault has occurred, see

section "Event handling".

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D Recalled memory position

number

E Scroll bar. Further information

can be found in this menu

1 INTRODUCTION

Arrows

Where there is more information behind a row, this is indicated with a black arrow behind the text.

SAW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

SAW

Fe SOLID

0.8 mm

1.4 General information about settings

There are three types of setting:

• Setting of numerical values

• Setting of given alternatives

• Setting of ON/OFF mode

1.4.1 Setting of numerical values

The settings knobs are used to increase or decrease the set values when setting numerical values. In the measurements menu, the knobs for welding current / wire feed speed, arc voltage or travel speed are used.

1.4.2 Setting with given alternatives

Some settings are made by selecting an option from a list. This is an example of the list:

SAW

GMAW

GOUGING

The cursor is positioned on the row for SAW. By pressing ENTER in this position, the SAW option is selected. If you want to choose another option instead, position the cursor on the correct row by scrolling up or down using the positioning knob. Then press ENTER. If you want to exit the list without making a selection, press QUIT.

1.5 QUIT and ENTER

The soft key farthest to the right is used primarily for QUIT, although it is occasionally used for other functions.

• QUIT returns you to the previous menu or image.

• Pressing ENTER entails the execution of a selected choice in a menu or a list.

The key is called ENTER in this manual.

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2 MENUS

The control panel uses several different menus:

• Main menu

• Configuration menu

• Tools menu

• Weld data settings menu SET

• Measurments menu MEASURE

• Weld data memory menu MEMORY

• Fast mode menu FAST MODE

During start-up, a start-up screen containing information about the current program version is displayed briefly.

Start-up screen

2.1 Main Menu

In the MAIN MENU, you can change welding process, method, wire type, control method, wire dimension etc.

You can access other sub menus from this menu.

SAW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

2.1.1 Configuration menu

Fe SOLID

3.0 mm

SAW

MAIN MENU » CONFIGURATION

In the CONFIGURATIONmenu it is possible to change language, change password, make general configuration, make machine adjustments etc. The menu has different appearances depending on which power source type is selected under MACHINE CONFIGURATION.

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2 MENUS

CONFIGURATION

LANGUAGE

ENGLISH

CODE LOCK►

GENERAL CONFIGURATION►

MACHINE CONFIGURATION►

CABLE LENGTHS►

MAINTENANCE►

NETWORK SETTINGS

MEASURE-VALUES FILTER FACTOR

ONE

QUIT

2.1.2 Tools menu

MAIN MENU » TOOLS

In the TOOLS menu you can transfer files, view quality and production statistics, event logs, etc.

TOOLS

EVENT HANDLING►



 

EXPORT / IMPORT►

FILE MANAGER►

SETTING LIMIT EDITOR►

MEASURE LIMIT EDITOR►

PRODUCT STATISTICS►

QUALITY FUNCTIONS►

CALENDAR►

USER ACCOUNTS►

UNIT INFORMATION►

QUIT

2.1.3 Weld data setting menu

MAIN MENU » SET

In the weld data setting menu, SET, it is possible to change different welding parameters. The menu has different appearances depending on which welding process is selected.

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2 MENUS

SAW WELD DATA SETTING

VOLTAGE

CURRENT

TRAVEL SPEED

DIRECTION

START DATA►

STOP DATA►

REGULATION PAR.►

SETTING LIMITS►

MEASURE LIMITS►

POLARITY

Another example of the menu with Aristo® 1000:

SAW WELD DATA SETTING

VOLTAGE

CURRENT

20.5 V

395 A

0 cm/min

■



AUTO



DC+

QUIT

24.0 V

3200 A

TRAVEL SPEED

DIRECTION

AC FREQUENCY

AC BALANCE

AC OFFSET

START DATA►

STOP DATA►

REGULATION PAR.►

Example of the menu with LAF/ TAF power source

30 cm/min

■

50 HZ

50%

0 V

QUIT

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2 MENUS

SAW WELD DATA SETTING

VOLTAGE

CURRENT

TRAVEL SPEED

30.0 A

500 A

30 cm/min

DIRECTION

START DATA►

STOP DATA►

REGULATION PAR.►

SETTING LIMITS►

MEASURE LIMITS►

POLARITY

DC +

MEASURE QUIT

2.1.4 Measurements menu

MAIN MANU » MEASURE

In MEASURE menu, you can view measured values for various welding parameters while welding is in progress.

■



SAW: CA

EXT. AXIS DIR. SQUARE NONE SET VALUES 2ND FUNCT

• 450 Amp - Measured welding current

• 30.0 Volt - Measured arc voltage

• 50 cm/min - Measured travel speed

SAW: CA

NONE NONE ICE WF NONE 2ND FUNCT

• cm/min - Measured wire speed

• kJ/cm - Indicates energy per unit length, which is obtained using the values selected for welding current, arc voltage and travel speed

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2 MENUS

• cm/min - Measured ICE wire feed speed

• kg/h - Indicates used material per / hour

The measured values remain in the display even after welding has been completed. You can move to different menus without losing the measurement values. The settings knobs can be used to change the welding parameters in the measurement

display. If the set value is changed when welding is not in progress, the measurement value changes

to zero. For activating ICE wire feed, a soft key, ICE WF, is activated, see section "Soft key

configuration". When the key is depressed, the ICE wire speed is changed using the left settings knob A. If the soft key is not depressed, the settings knob affects the A current.

In the measurement display one can also see the set values if the soft key SET VALUES is activated. If both soft keys, ICE WF and SET VALUES are activated, the set feed speed for cold wire can be changed. For activating see section "Soft key configuration".

SAW: CW

NONE DIR: SQUARE NONE SET VALUES 2ND FUNCT

• 300 cm/min - Set wire feed speed

• 20.0 Volt - Set arc voltage

• 30 cm/min - Set travel speed

2.1.5 Weld data memory menu

MAIN MENU » MEMORY

In the WELD DATA MEMORY menu you can store, recall, delete and copy various set weld data. The weld data sets can be stored in 255 different memory positions.

WELD DATA MEMORY

1 (SAW)

7 (GMAW)

 

STORE 2ND FUNCT QUIT

For further information, see section "MEMORY MANAGEMENT".

2.1.6 Fast mode menu

MAIN MENU » FAST MODE

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2 MENUS

In the FAST MODE menu, you can link soft keys to weld data memory positions. These settings are carried out in the CONFIGURATION menu. The number of the selected memory position is displayed in the top right corner.

WELD DATA 1 WELD DATA 2 WELD DATA 3 WELD DATA 4 2ND FUNCT

For further information, see section "Fast mode soft keys".

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3 SUBMERGED ARC WELDING

MAIN MENU » PROCESS

During Submerged Arc Welding (SAW), an arc melts a continuously supplied wire. The weld pool is protected by flux.

Aristo® 1000: When the SAW process is selected, choose METHOD with the positioning knob and press ENTER. Choose AC or DC.

SAW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

SAW

Fe SOLID

0.8 mm

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

Aristo® 1000: When the SAW process is selected, you can choose between three control methods by marking REGULATION TYPE using the positioning knob and pressing ENTER. Choose between constant welding current CA or constant wire feed CW or constant current CC.

LAF/TAF: When the SAW process is selected, you can choose between three control methods by marking REGULATION TYPE using the positioning knob and pressing ENTER. Choose between constant welding current CA or constant wire feed CW.

See explanations in "CA, constant amperage", "CW, constant wire feed" and "CC, constant current".

If ICE wire feed is selected, see "ICE wire feed", page53, only regulation type CW can be selected.

3.1 Settings for submerged arc welding

Settings Setting range In steps of Value after

resetting

Arc voltage

For Aristo® 1000 14 -50 V 0.1 V (1V) 30 V For LAF/TAF 8 - 60 V 0.1 V (1V) 30 V

Welding current1)(CA)

Wire feed speed1)(CW)

Constant current

ICE wire feed speed

ICE wire start delay Travel speed * 0 - 200 cm/min 1 cm/min 30 cm/min

Welding direction ▲-■ - ■

AC frequency

0 - 3200 A 1 A 400 A

0 - 2500 cm/min 1 cm/min 100 cm/min

1) 3)

(CC)

0 - 3200 A 1 A 500 A

0 - 200% 1% 100%

0 - 99,0 s 0,1 s 2,5 s

10 - 100 Hz 1 50 Hz

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3 SUBMERGED ARC WELDING

Settings Setting range In steps of Value after

resetting

AC balance

AC offset

Start data

25 - 75% 1 50%

-300-+ A/-10 +10V 1 A / 0.1 V 0

Flux pre-flow 0 - 99.0 s 0.1 s 0 s

Start adjust Min = 50% 1% 100% Start type Direct orScratch - Direct Wire creep start Auto orSet speed - Auto

Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min Start phases OFF orON - OFF Open-circuit voltage OFF orON - OFF

Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V

Stop data

Flux post-flow 0 - 99.0 s 0.1 s 0 s Crater filling OFF orON - OFF

Crater filling time 0 - 10 s 0.01 s 0.0 s

Burnback time 0- 10 s 0.01 s 0.65 s Stop phases OFF orON - OFF

Control parameters Dynamics Auto orSet values - Auto Inductance Auto orSet values - Auto

Setting limits - - -

Measure limits - - -

The setting range is dependent on the product used.

The menu shows the settings that belong to the selected regulation type.

Applies only to Aristo®1000 power sources

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4 GAS METAL ARC WELDING

The process is available for certain machine types.

MAIN MENU » PROCESS

During Gas Metal Arc Welding (GMAW), an arc melts a continuously supplied wire. The weld pool is protected by shielding gas.

When the Gas Metal Arc Welding GMAW process is selected, you can choose between two control methods by marking REGULATION TYPE using the positioning knob and pressing ENTER. Choose between constant amperage CA or constant wire feed CW, see explanation in "CA, constant amperage" and "CW, constant wire feed".

GMAW

PROCESS

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

CONFIGURATION►

TOOLS►

QUIT

4.1 Settings for gas metal arc welding

Settings Setting range In steps of Value after

resetting

Arc voltage * 14 -50 V 0.1 V (1V) 30 V Welding current *(CA) 0 - 3200 A 1 A 500 A Wire feed speed *(CW) 0 - 2500 cm/min 1 cm/min 100 cm/min

GMAW

Fe SOLID

0.8 mm

Travel speed * 0 - 200 cm/min 1 cm/min 30 cm/min

Welding direction ▲-■ - ■

Start data

Gas pre/flow 0 - 99.0 s 0.1 s 0.2 s

Start adjust Min = 50% 1% 100% Start type Direct orScratch - Direct Wire creep start Auto orSet speed - Auto

Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min Start phases OFF orON - OFF Open-circuit voltage OFF orON - OFF

Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V

Stop data

Gas post-flow 0 - 99.0 s 0.1 s 0.2 s Crater filling OFF orON - OFF

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4 GAS METAL ARC WELDING

Settings Setting range In steps of Value after

resetting

Crater filling time 0 - 10 s 0.01 s 0.0 s

Burnback time 0- 10 s 0.01 s 0.20 s Stop phases OFF orON - OFF Dynamic regulation Auto orSet values - Auto

Setting limits - - -

Measure limits - - -

*) The setting range is dependent on the product used.

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5 ELECTRO SLAG WELDING

The process is available for LAF power sources.

MAIN MENU » PROCESS

Electro slag welding (ESW) is a single pass welding process.

ESW

PROCESS

METHOD

REGULATION TYPE

WIRE TYPE

WIRE DIMENSION

30×0,5 mm

CONFIGURATION►

TOOLS►

SET MEASURE MEMORY FAST MODE

5.1 Settings for electro slag welding

Settings Setting range In steps of Value after

resetting

Arc voltage

Welding current1)(CA)

Wire feed speed1)(CW) Travel speed * 0 - 200 cm/min 1 cm/min 30 cm/min

8 - 60 V 0.1 V (1V) 24 V

0 - 3200 A 1 A 400 A

0 - 2500 cm/min 1 cm/min 300 cm/min

ESW

SS Strip

Welding direction ▲-■ - ■

Start data

Flux pre-flow 0 - 99.0 s 0.1 s 0 s

Start adjust Min = 100% 1% 100% Start type Direct orScratch - Direct Wire creep start Auto orSet speed - Auto

Wire creep start speed 0 - 1000 cm/min 1 cm/min 2 cm/min Start phases OFF orON - OFF Open-circuit voltage OFF orON - OFF

Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V

Stop data

Flux post-flow 0 - 99.0 s 0.1 s 0 s Crater filling OFF orON - OFF

Crater filling time 0 - 10 s 0.01 s 0.0 s

Burnback time 0- 10 s 0.01 s 1.50 s Stop phases OFF orON - OFF

Control parameters Dynamics Auto orSet values - Auto

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5 ELECTRO SLAG WELDING

Settings Setting range In steps of Value after

resetting

Inductance Auto orSet values - Auto

Setting limits - - -

Measure limits - - -

The setting range is dependent on the product used.

The menu shows the settings that belong to the selected regulation type.

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6 GOUGING

Availability depending on connected equipment.

MAIN MENU » PROCESS

With arc air gouging, a special electrode comprising a carbon rod with a copper casing is used.

An arc is formed between the carbon rod and the work piece, which melts the material. Air is supplied so that the melted material is blown away.

When the GOUGING process is selected, you can choose between two control methods by marking REGULATION TYPE using the positioning knob and pressing ENTER. Choose between constant amperage CA or constant wire feed CW, see explanation in "CA, constant amperage", page25 and "CW, constant wire feed", page25.

GOUGING

PROCESS

METHOD

REGULATION TYPE

WIRE DIMENSION

GOUGING MODE

GOUGING

8.0 mm

N7500

CONFIGURATION►

TOOLS►

QUIT

Select GOUGING MODE with the positioning knob. Press ENTER. For Aristo® 1000, select AUTO or N7500. For LAF and TAF select AUTO or MANUAL.

GOUGING

PROCESS

METHOD

GOUGING

REGULATION TYPE

WIRE DIMENSION

GOUGING MODE

CONFIGURATION►

TOOLS►

N7500

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AUTO

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8.0 mm

N7500

QUIT

6 GOUGING

6.1 Settings for gouging

Settings Setting range In steps of Value after

resetting

Arc voltage * 14 -50 V 0.1 V (1V) 30 V Welding current *(CA) 0 - 3200 A 1 A 500 A Wire feed speed *(CW) 0 - 2500 cm/min 1 cm/min 100 cm/min Travl speed * 0 - 200 cm/min 1 cm/min 30 cm/min

Welding direction ▲-■ - ■

Start data

Air pre-flow 0 - 99.0 s 0.1 s 0 s

Start adjust Min = 50% 1% 100% Start type Direct orScratch - Direct Wire creep start Auto orSet speed - Auto

Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min Start phases OFF orON - OFF Open-circuit voltage OFF orON - OFF

Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V

Stop data

Air post-flow 0 - 99.0 s 0.1 s 0 s Crater filling OFF orON - OFF

Crater filling time 0 - 10 s 0.01 s 0.0 s

Burnback time 0- 10 s 0.01 s 1.50 s Stop phases OFF orON - OFF Dynamic regulation Auto orSet values - Auto

Setting limits - - -

Measure limits - - -

*) The setting range is dependent on the product used.

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7 FUNCTION EXPLANATIONS

7.1 CA, constant amperage

The wire feed is controlled by the power source so that a constant amperage can be achieved.

• Constant current value can be selected in the main menu.

7.2 CW, constant wire feed

The welding current is a result of the selected wire feed speed.

• Constant wire feed can be selected in the main menu.

7.3 CC, constant current

(applies only to Aristo® 1000 power source) The voltage is varied so that a constant welding current can be achieved.

• Constant current value can be selected in the main menu.

A higher wire speed gives a higher welding current.

7.4 Wire / electrode dimension

Selected dimensions have a great impact on the start procedure and crater filling. When welding with other wire dimensions other than those found in the table, select one that has a dimension close to one in the list.

• Wire / electrode dimension can be selected in the main menu. The available wire material and dimension are affected by the combination of power source and welding head.

7.5 Arc voltage

Higher arc voltage increases the arc length and produces a hotter, wider weld pool.

• The arc voltage is set in the measurement display, weld data setting menu, or fast mode menu.

7.6 Wire feed speed

This sets the required feed speed of the filler wire in cm/minute. A higher wire speed gives a higher welding current.

• The wire feed speed is set in the measurement display, weld data setting menu, or fast mode menu.

7.7 ICE wire feed speed

Cold wire feed speed is used to set a feed speed (cm/min or inch/min) for the cold wire.

• The cold wire feed speed is set in the measurement display, weld data setting menu, or fast mode menu.

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7 FUNCTION EXPLANATIONS

7.8 ICE wire start delay

Cold wire start delay is used to indicate how long (s) after welding start cold wire feed can start.

• Cold wire start delay is set in the weld data setting menu.

7.9 Travel speed

Travel speed indicates the required speed (cm/min) at which a column and boom or trolley is to move.

• The travel speed is set in the measurement display, weld data setting menu, or fast mode menu.

7.10 Welding direction

Travel motion in the direction that the symbol indicates.

• Welding direction is selected in the weld data setting menu.

7.11 AC frequency

(applies only to Aristo® 1000 power source) AC frequency refers to the number of oscillations per second through the zero level.

• AC frequency is selected in the weld data setting menu.

7.12 AC balance

(applies only to Aristo® 1000 power source) AC balance is the relationship between positive (+) and negative (-) pulses. The value that is

set indicates the percentage size of the period that is the positive section.

• AC balance is selected in the weld data setting menu.

7.13 AC offset

(applies only to Aristo® 1000 power source) With AC offset the AC level is offset positively or negatively in relation to the zero level.

• AC offset is selected in the weld data setting menu.

7.14 Flux pre-flow (SAW)

This controls the time during which flux flows before the arc is struck.

• Flux pre-flow is set in the weld data setting menu under start data.

7.15 Gas pre-flow (GMAW)

This controls the time during which shielding gas flows before the arc is struck.

• Gas pre-flow is set in the weld data setting menu under start data.

7.16 Start adjust

This is used to adjust the starting current values. If the equipment starts with lower current values, compared with equipment's factory values, they can be adjusted here.

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7 FUNCTION EXPLANATIONS

• Start adjust is set in the weld data setting menu under start data.

7.17 Air pre-flow (Gouging)

This controls the time during which air flows before the arc is struck.

• Air pre-flow is set in the weld data setting menu under start data.

7.18 Start type

There are two options for start type:

• Direct start, means that the travel speed starts when the arc is struck.

• Scratch start, means that the travel speed starts at the same time as wire feed.

• Start type is selected in the weld data setting menu under start data.

7.19 Wire creep start

Wire creep start is used to set the desired creep speed on the electrode motor upon start-up. If, for example, 50 is set in the menu a creep speed of 50 cm/min is obtained. Preset value ”AUTO” gives a creep speed calculated from the set values.

• Wire creep speed is set in the weld data setting menu under start data.

7.20 Start phases

When welding special wire or material, it may be necessary to create your own start sequence. The start sequence can affect the appearance of the weld pool.

The following can be set for Start phase1 ON

• Time s Time for welding in phase 1.

• Arc voltage % In percent of set voltage

• Wire feed % In percent of set wire feed

• Welding current % In percent of set welding current

• Travel speed % In percent of set travel speed

• Start phases are set in the weld data setting menu under start data.

The following can be set for Start phase2 ON

• Time s Time for welding in phase 2.

• Arc voltage % In percent of set voltage

• Wire feed % In percent of set wire feed

• Welding current % In percent of set welding current

• Travel speed % In percent of set travel speed

7.21 Max Open Circuit Voltage (OCV)

ON means that OCV can be set. OFF means that OCV is set to the set value for welding voltage.

• OCV is set in the weld data setting menu under start data.

7.22 Flux post-flow (SAW)

This controls the time during which flux flows after the arc is extinguished.

• Flux post-flow is set in the weld data setting menu under stop data.

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7 FUNCTION EXPLANATIONS

7.23 Gas post-flow (GMAW)

This controls the time during which shielding gas flows after the arc is extinguished.

• Gas post-flow is set in the weld data setting menu under stop data.

7.24 Air post-flow (Gouging)

This controls the time during which air flows after the arc is extinguished.

• Air post-flow is set in the weld data setting menu under stop data.

7.25 Crater filling

Crater filling makes a controlled reduction in the heat and size of the weld pool possible when completing the weld. This makes it easier to avoid pores, thermal cracking and crater formation in the weld joint.

• Crate filling is set in the weld data setting menu under stop data.

7.26 Burnback time

Burnback time is a delay between the time when the wire starts to brake until the time when the power source switches off the arc voltage. Too short burnback time results in a long wire stickout after completion of welding, with a risk of the wire being caught in the solidifying weld pool. Too long burnback time results in a shorter stickout, with increased risk of the arc striking back to the contact tip.

• Burnback time is set in the weld data setting menu under stop data.

7.27 Stop phases

Stop phases are mainly used for setting crater filling.

The following can be set for Stop phase1 ON

• Time s Time for welding in phase 1.

• Arc voltage % In percent of set voltage

• Wire feed % In percent of set wire feed

• Welding current % In percent of set welding current

• Travel speed % In percent of set travel speed

The following can be set for Stop phase2 ON

• Time s Time for welding in phase 2.

• Arc voltage % In percent of set voltage

• Wire feed % In percent of set wire feed

• Welding current % In percent of set welding current

• Travel speed % In percent of set travel speed

• Stop phases are set in the weld data setting menu under stop data.

7.28 Dynamic regulation

The dynamic regulation function is developed for multiple electrode welding and alters the characteristics of the power source. The characteristics of the power source are calculated from the set wire data.

• Dynamic regulation is selected in the weld data setting menu.

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7 FUNCTION EXPLANATIONS

7.29 Control parameters

In some applications the function Control parameters is displayed instead of Dynamic control. There are two settings to make under Control parameters:

• DYNAMICS - Affects the dynamic characteristics

• INDUCTANCE - Higher values give a wider weld pool and less spatter. Lower values produce a stable, concentrated arc and a harsher sound.

• Control parameters are selected in the weld data setting menu.

7.30 Setting limits

For information about setting limits see section "Setting limit editor".

7.31 Measure limits

For information about measurement parameters see section "Measure limits editor".

7.32 PEK control unit as separate motor control

PEK as motor control without a power source is used when you want to have a travel control and possibility to give a start signal to an external power source. Remote is also active via ATAS I/O so you can control a roller bed with relay out for the start and an analogue reference for speed.

Activate motor control

To activate the motor control function set PRODUCT CODE to MOTOR CONTROL. The supervision by the power source is now disabled.

MACHINE CONFIGURATION

PRODUCT CODE

WIRE FEED AXIS►

TRAVEL AXIS►

TANDEM►

PARALLEL POWERSOURCES►

ICE WIRE FEED►

NODE ID SETTINGS►

SYSTEM INFORMATION►

A6TF F1

MTW600

Motor control

QUIT



  

OFF

  

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FREE 2 AXIS

FREE 3 AXIS

N7500I

Motor control

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7 FUNCTION EXPLANATIONS

Travel axis and wire axis

Set travel axis and wire gearing by performing the same procedure as for product code external axis.

Setting menu

Here you can set travel speed and direction, start data and limits can be used for travel speed.

SAW WELD DATA SETTING

TRAVEL SPEED

30 cm/min

DIRECTION

START DATA►

SETTING LIMITS►

MEASURE LIMITS►

MEASURE QUIT

Start data menu

Flux/Gas pre-flow is active if the chosen start type is scratch. Start signal (relay output 2) will be generated, and when pre-flow time has elapsed travel will start. When start type direct is chosen, pre-flow has no function.

SAW START DATA

FLUX PREFLOW

START TYPE

0.0 s

DIRECT

MEASURE QUIT

Scratch start will start a travel and generate start signal out at the same time when the start button is pressed. Pre-flow has no function.

When starting relay output 2, a direct start will be generated, but travel will not start until digital input for current flow is active. So if no input on I/O ATAS for current flow, use scratch start instead.

■

  

SAW START DATA

FLUX PREFLOW

START TYPE

0.0 s

SCRATCH

MEASURE QUIT

Measure menu

In the measure menu, you can see measure values for travel speed and jog wire speed. The wire motor is not started when you press the start button on the PEK control unit, but you can use that motor for other work. In the setting menu, you can also set travel speed.

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7 FUNCTION EXPLANATIONS

SAW: CW FE SOLID ■

NONE DIR. SQUARE NONE SET VALUES 2ND FUNCT

Remote and external axis

Remote via ATAS I/O and external axis for controlling a roller bed can also be used together with motor control.

SAW_DC: DC+:EXT ▲

REMOTE IO DIR. SQUARE EXT. AXIS SET VALUES 2ND FUNCT

Machine configuration

With product code motor control you can set gearing as with free three axis on wire feed, travel and external axis.

MACHINE CONFIGURATION

PRODUCT CODE

Motor control

WIRE FEED AXIS►

TRAVEL AXIS►

EXTERNAL AXIS►

QUIT

ATAS I/O

Digital inputs:

1. Start weld, X22.1.

2. Stop, X22.2.

3. Jog travel square direction, X22.3.

4. Jog travel triangle direction, X22.4.

5. Wire up direction, wire motor is not started when weld start is pressed, X23.1.

6. Wire down direction, wire motor is not started when weld start is pressed, X23.2.

7. High speed jog, X23.3.

8. Limit switch square, X23.4.

9. Limit switch triangle, X24.1.

10. Current flow, will start travel when direct start is used, when falling it will stop weld,

X24.2.

  

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7 FUNCTION EXPLANATIONS

11. External axle, roller bed control, X24.3.

12. Not used, X24.4.

13. Not used, X25.1.

14. Not used, X25.2.

15. Error from external equipment, X25.3.

16. Not used, X25.4.

Digital relay outputs:

1. Roller bed active, X26.2.

2. Boom active, X26.4.

3. Not used, X26.6.

4. Not used, X26.8.

5. Start square direction when external axis is active, X27.2.

6. Start triangle direction when external axis is active, X27.4.

7. Roller bed active, X27.6.

8. Error active that prevent start, X27.8.

Analogue out

1. Speed reference signal in external axis method, 0-10V. X18.

Motor card

Start signal to external equipment’s as the power source is located on connector X1.15-16.

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8 MEMORY MANAGEMENT

8.1 Control panel working method

The control panel can be said to comprise two units: working memory and weld data memory.

Store

Working Memory

In the working memory, a complete set of weld data settings is created that can be stored in the weld data memory.

During welding, it is always the content of the working memory that controls the process. It is therefore also possible to recall a weld data set from the weld data memory to the working memory.

Note that the working memory always contains the most recently set weld data settings. They can be recalled from the weld data memory or individually altered settings. In other words, the working memory is never empty or “zeroed”.

MAIN MENU » MEMORY » WELD DATA MEMORY

WELD DATA MEMORY

  

STORE 2ND FUNCT QUIT

Recall

Welding data memory

It is possible to store up to 255 sets of weld data in the control panel. Each set is given a number from 1 to 255.

You can also delete, copy, change and name data sets and recall a set of weld data to the working memory.

8.2 Store

If the weld data memory is empty, the following screen appears in the display. Storing a set of weld data. This will be given memory position 5. Press STORE. Position 1 is displayed. Turn one of the settings knobs until you reach position 5. Press

STORE.

WELD DATA MEMORY

  

STORE 2ND FUNCT QUIT

The following screen appears in the display. The weld data set is now stored as number 5.

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8 MEMORY MANAGEMENT

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

STORE RECALL DELETE 2ND FUNCT QUIT

Parts of the content of weld data set number 5 are presented at the bottom of the display. If a data set is already stored in the selected location, you will be asked if you want to

overwrite that set or not, YES or NO.

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

OVERWRITE DATA SET5 IN MEMORY?

Return to the memory menu using NO.

8.3 Recall

We are going to recall a stored data set: Mark the row using the positioning knob. Press RECALL.

WELD DATA MEMORY

5 - (SAW)

  

NO YES

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

STORE RECALL DELETE 2ND FUNCT QUIT

Press YES to confirm that you want to recall data set number 5.

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8 MEMORY MANAGEMENT

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

NO YES

RECALL DATA SET 5 FROM MEMORY?



The icon in upper right corner of the measurement display shows which memory position number has been recalled.

SAW: FE SOLID 5

NONE NONE NONE NONE 2ND FUNCT

8.4 Delete

It is possible to delete one or more data sets in the memory menu. Deleting a data set. Select the data set. Press DELETE.

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

STORE RECALL DELETE 2ND FUNCT QUIT

Press YES to confirm that you want to delete.

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8 MEMORY MANAGEMENT

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

NO YES

DELETE WELD DATA NR. 5?



8.5 Copy

To copy the content of a weld data set to a new memory position, proceed as follows: Press 2ND FUNCT.

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

STORE RECALL DELETE 2ND FUNCT QUIT

Select the memory position you want to copy and press COPY.

WELD DATA MEMORY

5 - (SAW)

  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

COPY RENAME EDIT 2ND FUNCT QUIT

We are now going to copy the content of memory position 5 to position 50. Select memory position 1 and scroll through using one of the settings knobs to the selected

memory position; in this case, position 50. Press YES.

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8 MEMORY MANAGEMENT

WELD DATA MEMORY

1 -

5 - (SAW)

  

COPY

DATA SET 5 TO POSITION: 50

NO YES

Weld data number 5 has now been copied to memory position 50.

8.6 Name

To give a stored weld data set its own name, proceed as follows: Press 2ND FUNCT. Select the memory position you want to rename and press RENAME.

WELD DATA MEMORY

5 - (SAW)

50 -  

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

COPY RENAME EDIT 2ND FUNCT QUIT

Here you have access to a keyboard that is used as follows:

• Position the cursor on the desired keyboard character using the arrows and the positioning knob. Press DONE. Enter a complete text string with a maximum of 40 characters in this way.

• Press DONE to store. The alternative you have named can now be seen in the list.

KEYBOARD

A B C D E F G H

I J K L M N O P

Q R S T U V W X Y Z

0 1 2 3 4 5 6 7 8 9

SPACE CAPS

0 (MAX 40)

DELETE SYMBOL DONE

8.7 Edit

To edit the content of a weld data set, proceed as follows: Press 2ND FUNCT. Select the memory position you want to edit and then press EDIT.

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8 MEMORY MANAGEMENT

WELD DATA MEMORY

5 - (SAW)

   

SAW: CA: FE SOLID: 3.0 mm

30.0 V: 450 A: 50 cm/min

STORE RECALL DELETE 2ND FUNCT QUIT

Part of the main menu is displayed and the menu shows the symbol which means that you are in an editing mode.

Press SET and make the relevant changes.

SAW

REGULATION TYPE

WIRE TYPE

SS FLUX CORED

WIRE DIMENSION

 

SET QUIT

The following menu appears: In this example we change the welding current from 400 A to 500 A. Select the welding current and scroll through to 500 using one of the settings knobs. Press QUIT twice.

SAW WELD DATA SETTING

VOLTAGE

CURRENT

TRAVEL SPEED

DIRECTION

2.0 mm

20.0 V

500 A

0 cm/min

■

START DATA►

STOP DATA►

DYNAMIC REGULATION

SETTING LIMIT►

MEASURE LIMITS►

The setting for weld data number 5 has now been edited and stored.

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

AUTO

QUIT

9 CONFIGURATION MENU

MAIN MENU » CONFIGURATION

This menu contains the following sub-menus:

• Language, see section "Choice of language".

• Code lock, see section "Code lock".

• General configuration, see section "General configuration".

• Machine configuration, see section "Machine configuration".

• Cable lengths, see section "Cable lengths (applies only to LAF and TAF power sources)".

• Maintenance, see section "Maintenance".

• Measure–values filter factor, see section "Measure–values filter factor".

9.1 Code lock

MAIN MENU » CONFIGURATION » CODE LOCK

When the lock function is activated and you are in the measure screen or fast mode menu, a password (lock code) is required to exit from these menus.

Code lock is activated in the configuration menu.

CODE LOCK

LOCK STATUS

SET / CHANGE LOCK CODE



QUIT

OFF

9.1.1 Lock code status

In lock code status, you can activate/deactivate the lock function without deleting the existing lock code in the event you deactivate the function. If no lock code is stored and you try to activate the code lock, the keyboard is displayed for entering a new lock code.

KEYBOARD

A B C D E F G H

I J K L M N O P

Q R S T U V W X Y Z

0 1 2 3 4 5 6 7 8 9

SPACE CAPS

0 (MAX 16)

DELETE SYMBOL DONE

To exit lock status.

When you are in the measure screen or the fast mode menu and the code lock is deactivated, you can exit these menus without restrictions by pressing QUIT or MENU in order to go to the main menu.

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9 CONFIGURATION MENU

If it is activated and you try to exit, the following screen appears in order to warn the user about the lock protection.

PRESS ENTER FOR

LOCK CODE...

Here you can select QUIT to undo and return to the previous menu, or proceed by pressing ENTER to enter the lock code.

You will then move to the menu with the keyboard, where you can enter the code. Press ENTER after each character, and confirm the code by pressing ENTER again.

The following text box appears:

UNIT UNLOCKED!

If the code is not correct, an error message is displayed that offers the option of trying again or returning to the original menu, i.e. the measure screen or the fast mode menu.

If the code is correct, all blocks to other menus will be removed, although the code lock remains activated. This means that you can leave the measure screen and the fast mode menu temporarily, yet still retain the lock status when you return to these menus.

9.1.2 Specify/edit lock code

In specify/edit lock code, you can edit an existing lock code or enter a new one. A lock code can comprise a maximum of 16 optional letters or figures.

9.2 General configuration

MAIN MENU » CONFIGURATION » GENERAL CONFIGURATION

In this menu you can set:

• Fast mode soft keys, see section "Fast mode soft keys".

• Quality data log to file, see section "Quality data log to file".

• Setting soft keys, see section "Soft key configuration".

• Automatic weld data storage, see section "Auto save mode".

• Unit of length, see "Unit of measurements".

9.2.1 Fast mode soft keys

The soft keys WELD DATA 1 up to and including WELD DATA 4 are displayed in the fast mode menu.

SAW: CA 16

WELD DATA 1 WELD DATA 2 WELD DATA 3 WELD DATA 4 2ND FUNCT

These are configured as follows: Position the cursor on the row for SOFT KEY NUMBER.

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9 CONFIGURATION MENU

FAST MODE SOFT KEYS

SOFT KEY NUMBER

ASSOCIATED WELD DATA

  

SAW: CA: FE SOLID: 0.8 mm

20.0 V: 500 A: 0 cm/min

STORE DELETE QUIT

The keys are numbered 1-4 from left to right. Select the desired key by giving its number using the setting knobs.

Then scroll to the next row ASSOCIATED WELD DATA. Here you can browse through the weld data sets that are stored in the weld data memory. Selected the desired weld data number using the setting knobs. Press STORE to save. To delete the stored set, press DELETE.

9.2.2 Quality data log to file

Activate QUALITY DATA LOG TO FILE menu by selecting ON.

GENERAL CONFIGURATION

FAST MODE SOFT BUTTONS

QUALITY DATA LOG TO FILE

SOFT KEYS SETUP►

AUTO SAVE MODE

UNIT OF LENGTH

METRIC

QUIT

Read more about settings for the quality function in section "Quality functions".

9.2.3 Soft key configuration

For Submerged Arc Welding (SAW) and for Gas Metal Arc Welding (GMAW) welding, the user has the possibility of setting the function of these keys by selecting from a list of set options. There are eight soft keys that can be allocated a function.

It is possible to choose between the following options:

• None

• Gas / Flux

• Set values Set reference values are displayed instead of the measured values in the measurements menu.

• Relay 2 Sets relay output no.2 on the motor circuit board, which can be used for any function by the customer.

• Direction

• Remote I/O Used when you want to control PEK and a welding power source via an external I/O unit.



OFF

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9 CONFIGURATION MENU

• External axis To be activated when there is an external I/O unit for controlling a roller bed, for example.

• Tandem Used when welding with two welding heads.

• Cold wire (ICE) Used when a non-live wire is fed into the weld pool and the cold wire speed is to be shown in the display.

• Auto step Used in the step function

○ Auto step Off: Setting during preparation of the object before welding ○ Auto step On: Setting after preparation is finished when welding should be

executed

• Force step Used in the step function to manually force one auto step during welding

• Restart step When welding is stopped with 100mm left to the start of the next step. Press restart step and the next step is after 100mm, not after Xmm. Then press the welding start key.

• Stop zero Used to stop automatically at the started rotation position.

In the display screen there are two columns; one for SOFT KEYS and one for FUNCTION.

SOFT KEYS SETUP

SOFT KEYS FUNCTION

S1 2ND FUNCT

S2 2ND FUNCT

S3 2ND FUNCT

S4 2ND FUNCT

NONE

QUIT

When you allocate functions to these keys, they are numbered from the left as follows:

S1 S2 S3 S4 2ND FUNCT

S1 2ND FUNCT S2 2ND FUNCT S3 2ND FUNCT S4 SND FUNCT 2ND FUNCT

To allocate a new function to a soft key, proceed as follows: Position the cursor on the row with the soft key number you wish to use and press ENTER. A

pop-up menu shows the function selections. Select using the positioning knob and press ENTER.

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9 CONFIGURATION MENU

SOFT KEY SETUP

SOFT KEYS FUNCTION

S1 2ND FUNCT

S2 2ND FUNCT

S3 2ND FUNCT

S4 2ND FUNCT

NONE

QUIT

NONE

GAS / FLUX

SET VALUES

RELAY 1

DIRECTION

REMOTE IO

EXT. AXIS

AUTO STEP

FORCE STEP

RESTART STEP

STOP ZERO

You can allocate new functions to the other keys in the same way, by pairing a key number in the left-hand column with a function in the right-hand column.

9.2.4 Auto save mode

When a weld data set has been recalled from a memory position in the weld data memory and you change the settings, the changes will be saved in the working memory at welding stop in the last recalled memory position.

Saving weld data manually in a memory position disables the next automatic save. The memory position in which the weld data set is stored is displayed in the top right corner

of the measure screen.

9.3 Machine configuration

MAIN MENU » CONFIGURATION » MACHINE CONFIGURATION

In this menu you can set:

• Product code, see section "Product code".

• Wire feed axis, see section "Wire feed axis".

• Cold wire feed axis, see section "Cold wire axis (ICE)".

• Travel axis, see section "Travel axis".

• External axis, see section "External axis".

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9 CONFIGURATION MENU

• Tandem, see section "Tandem for LAF and TAF power sources", and "Tandem for Aristo® 1000 power source".

• Parallel power sources, see section "Parallel power sources (applies only to Aristo 1000® power sources)".

• ICE wire feed, see section "ICE wire feed".

• Step function, see section "Step function".

• Intermittent welding, see section "Intermittent welding "

• Polarity, see section "Polarity (applies only to Aristo® 1000 power source)".

• Node ID settings, see section "Node id settings (applies only to Aristo® 1000 power source)".

• System information, see section "System information (applies only to Aristo® 1000 power source)".

9.3.1 Product code

In the PRODUCT CODE menu it is possible to select the automatic welding machine, column and boom, roller bed or positioner to be used.

MACHINE CONFIGURATION

PRODUCT CODE

A2TF J1

WIRE FEED AXIS►

TRAVEL AXIS►

TANDEM►

PARALLEL POWERSOURCES►

ICE WIRE FEED►

STEP FUNCTION►

OFF

INTERMITTENT WELDING

NODE ID SETTINGS►

POSITIVE

SYSTEM INFORMATION►

QUIT

When selecting product code, the correct motor type and gear ratio for the used gearbox in the relevant product are selected automatically.



  



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The following options can be selected:

• A2TFJ1 A2 tractor automatic welding machine for Submerged Arc Welding (SAW)

• A2TGJ1 A2 tractor automatic welding machine for Gas-Shielded Metal Arc Welding (GMAW)

• A6TFF1 A6 tractor automatic welding machine for Submerged Arc Welding (SAW)

• MTW600 A6 tractor automatic welding machine for Submerged Arc Welding (SAW)

• FREE 2 AXIS Optional configuration for connecting 2 motors to the actuator board. One for wire feed and one for travel motion.

• FREE 3 AXIS Optional configuration for connecting external roller beds, positioners or linear axis as well as for 2 motors to the actuator board. One for wire feed and one for travel motion.

• N7500I Welding head for Gouging.

• Motor Control Optional configuration to use PEK control unit for separate motor control without a power source.

9.3.2 Wire feed axis

The wire feed motor is set automatically according to the tables below.

A2TFJ1 A2TGJ1 A6TFF1 MTW600

Motor 5035 38 RPM 5035 68 RPM VEC 4000 FHP258 Gear 1 49:1 49:1 156:1 24:1 Gear 2 1:1 1:1 1:1 1:1 Diameter feed rollers 49 mm 49 mm 49 mm 30 mm Pulse sensor 28 ppr 28 ppr 32 ppr 28 ppr Low manual speed 150 cm/min 150 cm/min 150 cm/min 150 cm/min High manual speed 300 cm/min 300 cm/min 300 cm/min 300 cm/min

FREE 2 AXIS FREE 3 AXIS N7500I Motor Control

Motor VEC 4000 VEC 4000 N7500i 10000 VEC 4000 Gear 1 156:1 156:1 576:1 156:1 Gear 2 1:1 1:1 1:1 1:1

Diameter feed rollers

49 mm 49 mm 40mm 49mm

Pulse sensor 32 ppr 32 ppr 128ppr 32ppr

Low manual

150 cm/min 150 cm/min 61cm/min 150cm/min

speed

High manual

300 cm/min 300 cm/min 150cm/min 300cm/min

speed

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9.3.3 Cold wire axis (ICE)

FREE 2 AXIS FREE 3 AXIS

Motor VEC 4000 VEC 4000 Gear 1 156:1 156:1 Gear 2 1:1 1:1 Diameter feed rollers 49 mm 49 mm Pulse sensor 32 ppr 32 ppr Low manual speed 150 cm/min 150 cm/min High manual speed 300 cm/min 300 cm/min

9.3.4 Travel axis

The travel motor is set automatically according to the tables below.

A2TFJ1 A2TGJ1 A6TFF1 MTW600

Motor 4030-350 4030-350 FHP258 FHP258 Gear 1 375:10 375:10 24:1 75:2 Gear 2 51:1 51:1 51:1 51:1 Wheel diameter 158 mm 158 mm 180 mm 158 mm Pulse sensor 60 ppr 60 ppr 28 ppr 60 ppr High manual speed 200 cm/min 200 cm/min 200 cm/min 200 cm/min

FREE 2 AXIS FREE 3 AXIS N7500I Motor Control

Motor VEC 4000 VEC 4000 VEC 4000 VEC 4000 Gear 1 312:1 312:1 75:2 312:1 Gear 2 1:1 1:1 51:1 1:1 Wheel diameter 65 mm 65 mm 158mm 65mm Pulse sensor 32 ppr 32 ppr 60ppr 32ppr

High manual

200 cm/min 200 cm/min 200cm/min 200cm/min

speed

9.3.5 External axis

When connecting an external roller bed, positioner or linear axis, FREE 3 AXIS must be selected.

When FREE 3 AXIS is selected, the motor is automatically set according to the tables below.

Roller bed Linear Positioner

Gear 1 560:1 560:1 560:1 Gear 2 111:22 111:22 111:22 Gear 3 1:1 1:1 1:1 Wheel diameter 160 mm 160 mm 160 mm Pulse sensor 30 ppr 30 ppr 30 ppr High manual speed 200 cm/min 200 cm/min 200 cm/min Frequency ratio 85:50 85:50 85:50 Motor 2000 rpm 2000 rpm 2000 rpm

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9 CONFIGURATION MENU

Weld diameter 1000 mm - 1000 mm Roller diameter 1000 mm - -

When the positioner and the speed wheel are ON, the speed wheel (encoder) is at the welding object.

When the positioner and the speed wheel are OFF, the speed wheel (encoder) is at the motor shaft.

When the roller bed and the speed wheel are ON, the speed wheel (encoder) is at the roller bed wheel.

When the roller bed and the speed wheel are OFF, the speed wheel (encoder) is at the motor shaft.

9.3.6 Tandem for LAF and TAF power sources

Used when welding with two welding heads. Position the cursor on the TANDEM row and press ENTER. Select ON, using the positioning

knob and press ENTER.

MACHINE CONFIGURATION

PRODUCT CODE

A2TF J1

WIRE FEED AXIS►

TRAVEL AXIS►

TANDEM►

└ WELDING HEAD └ WELD HEAD OFFSET └ WITH I/O

HEAD

20 mm

QUIT

In order to weld with two welding heads, the WELD HEAD OFFSET function must be set. WELD HEAD OFFSET is the distance in millimetres between the welding heads. When you specify the distance between welding head 1 HEAD and welding head 2 TAIL, the

value is recalculated by the control unit to a time between when welding head 1 starts and welding head 2 is to start.

The time that the control unit can calculate for the distance between the starting and stopping of the welding power sources is a maximum of 65 seconds. This means that if, for example, 50 cm/min is specified, 2000 mm can be entered as the maximum WELD HEAD OFFSET. This is so that time does not expire before welding head 2 reaches the start point.

 

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9 CONFIGURATION MENU

1. HEAD 3. WELD HEAD OFFSET

2. TAIL

NOTE!

Ensure that both control units have the same settings for WELD HEAD OFFSET and specify the same travel speed. The master control unit must be allocated HEAD and the slave control unit TAIL. Travel motion is always controlled from master.

Specify the values to weld with two welding heads as follows: Position the cursor on the WELDING HEAD row. Select whether the setting is to apply to

master control unit HEAD or slave control unit TAIL.

MACHINE CONFIGURATION

PRODUCT CODE

A2TF J1

WIRE FEED AXIS►

TRAVEL AXIS►

TANDEM

└ WELDING HEAD └ WELD HEAD OFFSET

HEAD

20 mm

└ WITH I/O





QUIT

• Position the cursor on the WELD HEAD OFFSET row and specify the distance between the two welding heads.

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9 CONFIGURATION MENU

Example, I/O ON

1. Head, Welding head 1 (master) 3. WELD HEAD OFFSET

2. Tail, welding head 2 (slave)

Press Start, for welding head1.

• Welding head1 starts to weld.

• Welding head2 only starts welding when the start position for welding head1 has been reached (the distance given in WELD HEAD OFFSET.

Press Stop, for welding head1.

• Welding head1 stops welding but continues travelling.

• Welding head2 stops welding once it reaches the point where equipment 1 stopped welding (the distance given in WELD HEAD OFFSET.

• Welding is complete.

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Example, I/O OFF

1. HEAD, Welding head 1 (master) 3. WELD HEAD OFFSET

2. TAIL, welding head 2 (slave)

Press Start, for welding head1 and welding head2 at the same time.

• Welding head1 starts to weld.

• Welding head2 starts to weld first when the start position for welding head1 has been reached (the distance given WELD HEAD OFFSET).

Press stop, for welding head1 and welding head2 at the same time.

• Welding head1 stops welding but travel motion continues.

• Welding head2 stops welding when it has reached the point where equipment 1 stopped welding (the distance that is given in WELD HEAD OFFSET).

• Welding is complete.

9.3.7 Tandem for Aristo® 1000 power source

Used when welding with two or more welding heads. The welding heads are each controlled by their own control unit (PEK).

Position the cursor on the TANDEM row and press ENTER. Select ON using the positioning knob and press ENTER.

The front welding head is selected.

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TANDEM

AC SYNC MASTER

PHASE SHIFT

TRAVEL CONTROL

TANDEM

└ WELDING HEAD └ SYNCRONIZED WELD START └ SYNCRONIZED AC WELD

The rear welding head is selected.

TANDEM

AC SYNC MASTER └ PHASE SHIFT

TRAVEL CONTROL

TANDEM └ WELDING HEAD



HEAD

QUIT

OFF

TAIL

└ SYNCRONIZED WELD START └ SYNCRONIZED AC WELDING

20 mm

QUIT

WELDING HEAD

Select whether the welding head is to be the front HEAD or rear TAIL.

AC SYNC MASTER

One power source in a tandem system has to be set as ACsynchronization master if synchronized ACwelding is used. Preferably the first ACwelding power source is set as ACsynchronization master.

TRAVEL CONTROL

Select whether the welding head is control the travel. Both the front and rear welding heads can control the travel, but only one at a time.

SYNCRONIZED WELD START

If ON is selected it means that one only need start the control unit for the front welding head. The rear one is started automatically. If OFF is selected all the welding heads must be started using the relevant control unit.

SYNCRONIZED AC WELDING

Synchronized AC welding means that the frequency and balance, the AC pulses, are synchronized to the same values for all welding heads in the tandem system.

WELD HEAD OFFSET

WELD HEAD OFFSET is the distance in millimetres between the welding heads. The weld head offset should always be set, whether a synchronised welding start is selected or not. If a non-synchronised welding start is selected, the offset is used to calculate a timedelay for the welding start on the TAIL welding head.

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9 CONFIGURATION MENU

1. HEAD, Welding head 1 (master) 3. WELD HEAD OFFSET

2. TAIL, welding head 2 (slave)

PHASE SHIFT (applies only to AC welding) Phase shift means a phase offset in relation to the front welding head. The unit is degrees.

9.3.8 Parallel power sources (applies only to Aristo® 1000 power sources)

To be able to set up two power sources in parallel, only the two power sources that are to be connected should have power on and be active on the CAN2 bus.

PARALLEL POWERSOURCES

Parallel couple ID

Connect with slave



QUIT

Perform settings for parallel power sources as follows:

1. Set the PARALLEL POWERSOURCES function to ON.

2. Set Parallel couple ID. The first parallel couple is set to 1, the next parallel couple is

set to 2 etc.

3. Select menu line Connect with slave and press ENTER.

A message Connect appears.

4. Press ENTER again.

OFF

- -

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9 CONFIGURATION MENU

PARALLEL POWERSOURCES

PARALLEL POWERSOURCES ON

Parallel couple ID

Connect with slave



QUIT

CONNECT

When the master and slave power sources are connected, the text Connected is presented.

9.3.9 ICE wire feed

NOTE!

ICE option is only available with purchasing of ICE license.

The option ICE WIRE FEEDON can be selected in the machine configuration menu. If ICE wire feed is selected, the option ICE WIRE FEED AXIS appears.

MACHINE CONFIGURATION

PRODUCT CODE

WIRE FEED AXIS

ICE WIRE FEED AXIS►

FREE 2 AXIS

- -



TRAVEL AXIS►

TANDEM

ICE WIRE FEED

NODE ID SETTINGS►

The ICE wire feed axis settings must be identical to the wire feed axis.

ICE WIRE FEED AXIS

MOTOR

GEAR 1►

└ N 1 └ N 2

GEAR 2►

└ N 1 └ N 2

FEED ROLLER DIAM



OFF

QUIT

5035 38 RPM

156

49 mm

ENCODER PULSES

LOW MANUAL SPEED

Motor is selected from a dropdown list with the following options:

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32 ppr

150 cm/min

QUIT

9 CONFIGURATION MENU

5035 38 RPM

5035 68RPM

FHP 258

VEC80000

VEC40000

DUNKER1

DUNKER2

MET3B

VEC4000Par

4030-350

• GEAR 1 must be set to ON. The value cannot be OFF.

• GEAR 2 must normally be set to ON, but OFF can be selected.

• The values N1 and N2 under GEAR 1 and GEAR 2 are set with one of the three settings knobs at the bottom of the panel. The interval for N1 and N2 depend on selected motor.

• The diameter of the feed rollers FEED ROLLER DIAM is selected with any settings knob. The interval depends on selected motor.

• The encoder for pulses ENCODER-PULSES is selected with any settings knob. The interval is between 1 - 9998 ppr (ppr = pulses per revolution).

• LOW MANUAL SPEED is selected with any of the settings knobs. The interval is 1 1000 cm/min.

• HIGH MANUAL SPEED is selected with any of the settings knobs. The interval is 1 5000 cm/min.

9.3.10 Step function

STEP FUNCTION

STEP CONTROL

STEP DIRECTION

STEP LENGTH

STEP SPEED

NUMBER OF STEPS

OVERLAP

MANUAL STEP LENGTH

WHEEL DIAMETER

WELD DIAMETER

ROLL DIAMETER

STEP CONTROL ON or OFF

On/off setting of the step function

TRIANGLE

76 mm

77 cm/min

10 mm

3 mm

1 mm

1 000 mm

QUIT

STEP DIRECTION SQUARE or TRIANGLE

Setting of direction for the auto step execution

STEP LENGTH The length of one auto step (minimum setting 1mm)

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STEP SPEED The travel speed of the auto step (minimum setting 3cm/min) NUMBER OF STEPS The number of steps during one rotational turn. OVERLAP The length of the overlap of one rotational turn. MANUAL STEP LENGTH The length of one manual step (minimum setting 1mm)

(for singular manual adjustments during welding)

NOTE!

To be able to run the step function, STEP CONTROL must be in the ON position, the EXT AXIS and AUTO STEP soft keys must be ON

If you want to have a restart of step, to restart step welding after a stop, press soft key RESTART STEP before you press the AUTO STEP before you start to weld.

For example, if you have 100mm to next step, press STOP, change the wire, position the object, press RESTART STEP, press AUTO STEP, and start to weld. Next step will be after 100mm.

When the “one turn switch” is activated, the step function executes one autostep in the direction and with the speed and length specified by the STEP DIRECTION, STEP SPEED and STEP LENGTH parameters.

If the FORCE STEP soft key is pushed, the step function executes one auto step in the direction and with the speed and length specified by the STEP DIRECTION, STEP SPEED and STEP LENGTH parameters.

If the square/triangle button is pushed, one manual step will be executed in the direction and with the speed and length specified by the square/triangle, STEP SPEED and STEP LENGTH parameters. This function can be used to make one small adjustment during welding.

There is always a possibility to interrupt an auto step or manual step movement by pushing the SQUARE or TRIANGLE button.

During the auto step or manual step movement, the LED above the square/triangle button is on to indicate movement and direction.

Speed wheel settings

When the positioner and the speed wheel are ON the speed wheel (encoder) is at the welding object.

When the positioner and the speed wheel are OFF the encoder is at the motor shaft. When the roller bed and the speed wheel are ON the speed wheel (encoder) is at the roller

bed wheel. When the roller bed and the speed wheel are OFF the encoder is at the motor shaft.

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9.3.11 Intermittent welding

INTERMITTENT WELDING

WELDING LENGTH

TRANSPORT LENGTH

NUMBER OF WELDS



QUIT

To activate the function set intermittent welding to ON. An intermittent welding sequence consists of weld and transport. At the last weld in a sequence, the transport will not be performed.

WELDING LENGTH is the length of the weld. TRANSPORT LENGTH is the length of the transport after a weld has finished. NUMBER OF WELDS is the number welds to be performed including transport. If the

number of welds is set to “0”, the intermittent welding sequence continues until the user stops the welding using the red weld stop button.

9.3.12 Polarity (applies only to Aristo® 1000 power source)

In the POLARITY menu you can set the welding polarity.

0 mm

• To weld with positive polarity on the welding wire and negative polarity on the work piece, select POSITIVE polarity.

• To weld with negative polarity on the welding wire and positive polarity on the work piece, select NEGATIVE polarity.

9.3.13 Node id settings (applies only to Aristo® 1000 power source)

If there are I/O nodes in the system the ID numbers are given here.

NODE ID SETTINGS

I/O NODE 1 ID

I/O NODE 2 ID

QUIT

9.3.14 System information (applies only to Aristo® 1000 power source)

The SYSTEM INFORMATION menu shows active power sources connected via the CAN2bus, if the power sources are in tandem or parallel mode and if they are configured as master or slave.

SYSTEM INFORMATION

Active power sources on CAN2

PS id Tandem Parallel

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9 CONFIGURATION MENU

SYSTEM INFORMATION

No contact with master power source

   

QUIT

9.4 Cable lengths (applies only to LAF and TAF power sources)

The arc voltage is affected by the impedance in the welding cables. The impedance is affected by the length and area of the cables as well as by how they are routed. This is especially prominent during AC welding.

Compensation for the voltage drop with long cables is maintained if the actual cable length is specified.

The total cable length (weld cable and connector together) must be fed in. Note! When using two cables, the areas must be combined for both cables.

This function is active during the start process before the power source has received a measurement value that it can regulate at.

If ”Max OCV” has been selected this function is inactive.

9.5 Maintenance

MAIN MENU » CONFIGURATION » MAINTENANCE

In this menu you set how often the contact tip is to be changed. Specify the number of weld starts after which the tip is to be changed by selecting the CONTACT TIP CHANGE INTERVAL row and pressing ENTER. Change the value using the setting knobs. When the interval has been passed, fault code 54 is displayed in the error log.

When TOTAL RUNNING TIME LIMIT is selected instead of the number of starts, an authorised ESAB service technician is contacted.

MAINTENANCE

CONTACT TIP CHANGE INTERVAL └ WELD COUNT

TOTAL RUNNING TIME LIMIT └ TOTAL RUNNING TIME

0 Welds

0d:00:00:00



QUIT

9.6 Measure–values filter factor

MAIN MENU » CONFIGURATION » MEASURE-VALUES FILTER FACTOR

This menu provides a filter factor for the measurement values of the welding current. The higher filter factor value you choose, the more stable welding current measurement value you will get. You can choose between filter factors 1, 2 and 4.

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Position the cursor on the MEASURE-VALUES FILTER FACTOR row and press ENTER. A pop-up menu shows filter factors ONE, TWO and FOUR. Select the preferred filter factor using the positioning knob and press ENTER.

CONFIGURATION

LANGUAGE

CODE LOCK►

GENERAL CONFIGURATION►

MACHINE CONFIGURATION►

CABLE LENGTHS►

MAINTENANCE►

MEASURE-VALUES FILTER FACTOR

ONE

TWO

FOUR

ENGLISH

    

ONE

QUIT

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10 TOOLS

MAIN MENU » TOOLS

This menu contains the following sub-menus:

• Event handling, see section "Event handling".

• Export/Import, see section "Export/Import".

• File manager, see section "File manager".

• Edit setting limits, see section "Setting limit editor".

• Edit measure limits, see section "Measure limits editor".

• Production statistics, see section "Production statistics".

• Quality functions, see section "Quality functions".

• Calendar, see section "Calendar".

• User accounts, see section "User accounts".

• Unit information, see section "Unit information".

10.1 Event handling

MAIN MENU » EVENT HANDLING

Fault management codes are used to indicate that a fault has occurred in the welding process. Indicated in the display via a pop-up menu and an exclamation mark appears in

the upper right-hand corner of the display.

NOTE!

disappears from the display as soon as you enter the event log menu.

The Event handling menu has got two sub-menus, Event log (see section "Event log") and Active errors (see section "Active errors").

EVENT HANDLING

EVENT LOG►

ACTIVE ERRORS►

  

QUIT

10.1.1 Event log

MAIN MENU » TOOLS » EVENT HANDLING » EVENT LOG

All errors that arise during the use of the welding equipment are documented as error messages in the error log. Up to 99 error messages can be saved. If the error log becomes full, i.e. if 99 error messages have been saved, the oldest message is automatically deleted when the next fault occurs.

The following information can be read in the error log:

• The error number of the error

• The day on which the error occurred

• The time at which the error occurred

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10 TOOLS

• The unit in which the error has occurred, see section "Unit IDs"

• The error's error management code, see section "Description of fault management codes"

ERROR LOG

Index Date Time Unit Error

1 081120 11:24:13 8 19

2 081120 10:24:18 8 18

3 081121 13:24:18 8 17

  

Error in battery-driven memory

DELETE ALL QUIT

10.1.2 Active errors

MAIN MENU » TOOLS » EVENT HANDLING » ACTIVE ERRORS

The Active errors menu shows only the errors active for the moment.

ACTIVE ERRORS

Error nr Node ID Device type

78 1 powersource

152 1 powersource

Error nr 78

QUIT

10.1.3 Unit IDs

Explanation of unit IDs for LAF and TAF power source: 2= Power source 6= Wire feed and travel motion (motor board) 8= Control panel

NOTE!

The unit IDs specified above apply to LAF and TAF power sources, and constitutes an example of unit IDs for Aristo®1000, as the nodes in an Aristo®1000 application may have different ID numbers depending on the configuration of the equipment.

10.1.4 Description of fault management codes

The fault management codes that users can correct themselves are given below. If another code appears, restart the machine and if the error persists, contact a service technician.

 6  High temperature

The power source has overheated. Welding is cancelled. Welding is permitted again when the temperature falls below the maximum temperature parameter.

1. Check that the cooling air inlets or outlets are not obstructed or clogged with dirt.

2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

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 7  Low welding current

The weld arc has been shut down due to too low welding current during the welding process.

1. Is reset at next weld start. If the error persists, send for a service technician.

 8  Low battery voltage

Battery voltage too low. If the battery is not replaced, all stored data will be lost. This error does not disable any functions.

1. Send for a service technician to replace the battery.

 11  Speed error on a motor (wire feed, travel motor)

A motor cannot maintain its speed. Welding stops.

1. Check that the wire feed has not jammed or runs too fast. If the error persists, send for a service technician.

2. If the error persists, send for a service technician.

 12  Internal communication error (warning)

The load on the system's CAN-bus is temporarily too high. The power source may have lost contact with the control unit

1. Check that all the equipment is correctly connected. If the error persists, send for a service technician.

 14  Communication error

The system's CAN bus has temporarily ceased to work due to excessive load.

The current welding process is stopped.

1. Check the equipment to ensure that only one wire feed unit or remote control unit is connected.

2. If the error is repeated, send for a service technician.

 17  Lost contact with the unit

Lost contact with a unit.

1. Check wiring and the connector between the control unit and power source.

 32  No gas flow

Start prevented.

1. Check the gas valve, hoses and connectors.

 43  High welding current

Power source have switched off the welding process because the current has exceeded the maximum current parameter for the power source.

1. Is reset at next weld start. If the error persists, send for a service technician.

 44  Current servo saturation

The welding process has stopped because it has not advanced within 10 seconds.

1. Is reset at next weld start. If the error persists, send for a service technician.

 168  A motor has stopped

There are no pulses from the motor pulse transducer.

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For LAF and TAF: 168 = Motor M1 (Wire feeder motor), 169 = Motor M2 (Travel motor).

1. Check the motor cables. Replace the pulse transducer.

 169  A motor has stopped

There are no pulses from the motor pulse transducer.

For LAF and TAF: 168 = Motor M1 (Wire feeder motor), 169 = Motor M2 (Travel motor).

1. Check the motor cables. Replace the pulse transducer.

 2310  Current servo saturation

The power source has temporarily delivered maximum current.

1. If the error persists, try lowering the weld data.

 3205  High DC voltage

1. Check if the main voltage is too low or too high.

 4201  High temperature

The power source has overheated. Welding is cancelled. Welding is permitted again when the temperature falls below the maximum temperature parameter.

1. Check that the cooling air inlets or outlets are not obstructed or clogged with dirt.

2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

 4202  High temperature

The power source has overheated. Welding is cancelled. Welding is permitted again when the temperature falls below the maximum temperature parameter.

1. Check that the cooling air inlets or outlets are not obstructed or clogged with dirt.

2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

 4203  High temperature

The power source has overheated. Welding is cancelled. Welding is permitted again when the temperature falls below the maximum temperature parameter.

1. Check that the cooling air inlets or outlets are not obstructed or clogged with dirt.

2. Check the duty cycle being used, to make sure that the equipment is not being overloaded.

 5010  High inductance

Inductance is too high, depending on long welding cables and/or high weld data.

1. Adjust the welding data.

 8117  Lost contact with the unit

Lost contact with a unit.

1. Check wiring and the connector between the control unit and power source.

 8411,

 Wire speed motor error subcode 0

A motor cannot maintain its speed. Welding stops.

1. Check that the wire feed has not jammed or runs too fast. If the error persists, send for a service technician.

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 8411,

 Travel speed motor error subcode 1

There are no pulses from the motor pulse transducer.

1. Check the motor cables. Replace the pulse transducer.

10.2 Export/Import

MAIN MENU » TOOLS » EXPORT / IMPORT

In the Export/Import menu, it is possible to transfer information to and from the control panel via a USB memory.

The following information can be transferred:

• WELD DATA SETS EXPORT / IMPORT

• SYSTEM SETTING EXPORT / IMPORT

• SETTING LIMITS EXPORT / IMPORT

• MEASURE LIMITS EXPORT / IMPORT

• ERROR LOG EXPORT

• QUALITY FUNCTION LOG EXPORT

• PRODUCTION STATISTICS EXPORT

Carry out the following to save on a USB memory: Insert the USB memory into the control unit. Select the row with the information that is to be transferred. Press EXPORT or IMPORT,

depending on whether the information is to be exported or imported.

EXPORT/IMPORT

WELD DATA SETS

SYSTEM SETTINGS

SETTING LIMITS

MEASURE LIMITS

ERROR LOG

QUALITY FUNCTION LOG

PRODUCTION STATISTICS

EXPORT IMPORT QUIT

10.3 File manager

MAIN MENU » TOOLS » FILE MANAGER

In the file manager it is possible to manage information on a USB memory (C:\). File manager makes it possible to delete and copy weld data and quality data manually.

When the USB memory is connected, the display shows the memory's default folder if one is not previously selected.

The control panel remembers where you were the last time you used file manager, so that you return to the same place in the file structure when you come back.

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10 TOOLS

FILE MANAGER

NEW FOLDER

QData.xml

 

INFO UPDATE ALT. QUIT

• In order to ascertain how much storage space remains for the memory, use the INFO function.

• Update the information by pressing UPDATE.

• When you want to delete, change name, create new folder, copy or paste, press ALT. A list then appears from which you can choose. If (..) or a folder is selected, you can only create a new folder or paste in a file that you have previously copied. If you have selected a file, the options RENAME, COPY or PASTE will be added if you have previously copied a file.

Select a folder or file and press ALT.

FILE MANAGER

WeldData

NEW FOLDER

ErrorLog.xml

QData.xml

~Weldoffice.dat

 

INFO UPDATE ALT. QUIT

This list is displayed when you have pressed ALT.

COPY

PASTE

DELETE

RENAME

NEW FOLDER

10.3.1 Delete a file/folder

Select the file or folder that is to be deleted and press ALT. Select DELETE and press ENTER.

DELETE

RENAME

NEW FOLDER

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10 TOOLS

The file/folder is now removed. In order to delete a folder it must be empty, i.e. first delete the files contained in the folder.

10.3.2 Rename a file/folder

Select the file or folder that is to be renamed and press ALT. Select RENAME and press ENTER.

DELETE

RENAME

NEW FOLDER

A keyboard appears in the display. Use the positioning knob to change row and the arrows to move left and right. Select the character/function that is to be used and press ENTER.

10.3.3 Create new folder

Select where the new folder is to be located and press ALT. Select NEW FOLDER and press ENTER.

DELETE

RENAME

NEW FOLDER

A keyboard then appears in the display. Use the positioning knob to change row and the arrows to move left and right. Select the character/function that is to be used and press ENTER.

10.3.4 Copy and paste files

Select the file that is to be copied and press ALT. Select COPY and press ENTER.

COPY

PASTE

DELETE

RENAME

NEW FOLDER

Position the cursor in the folder in which the copied file is to be located and press ALT. Select PASTE and press ENTER.

COPY

PASTE

DELETE

RENAME

NEW FOLDER

The copy is saved as Copy of plus the original name, e.g. Copy of WeldData.awd.

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10 TOOLS

10.4 Setting limit editor

MAIN MENU » TOOLS » SETTING LIMIT EDITOR

In this menu you set your own max. and min. values for various welding methods. The limits cannot be above or below the values for which the power source is dimensioned. There are 50 storage points. Select the row for an empty storage point and press ENTER. Select process by pressing ENTER and select the welding process using the positioning knob and press ENTER.

The maximum and minimum values for arc voltage, wire feed speed, travel speed and welding current can be selected for all processes.

EDIT LIMITS

PROCESS

VOLTAGE

WIRE SPEED

TRAVEL SPEED

CURRENT

STORE DELETE QUIT

LIMITS

1 SAW 2 GMAW 3 GOUGING 4 -

SAW

MIN 17.0

MAX 47.0

MIN 50

MAX 970

MIN 100

MAX 2400

MIN 70

MAX 1500

5 - 6 - 7 -

17.0 - 47.0 Volt , 50 - 970 cm/min

100 - 2400 cm/min , 70 - 1500 Amp

QUIT

When the values have been adjusted, press STORE. When asked if the limit value is to be saved at the selected storage point, press NO or YES. The storage point's values can be seen under the line at the bottom.

With the AUTO soft key, the parameters are set automatically according to the most recently used parameters.

When asked if the limit settings are to be set automatically, press NO or YES and then STORE if the setting is to be retained.

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10 TOOLS

10.5 Measure limits editor

MAIN MENU » TOOLS » MEASURE LIMITS EDITOR

In this menu you set your own measurement values for the various welding methods. There are 50 storage points. Select the row for an empty storage point and press ENTER. Select PROCESS by pressing ENTER and select the welding process using the positioning knob and press ENTER.

The following values can be selected:

• arc voltage: min, max

• wire feed speed: min, max

• welding current: min, max

• travel speed: min, max

• energy per unit length: min, max

Set the desired value using the setting knobs and press STORE. In the dialogue box, you are asked if you want to store the selected storage point. Press YES

to save the value. The storage point's values can be seen under the line at the bottom.

MEASURE LIMITS

1 SAW

2 GMAW

3 -

4 -

5 -

6 -

7 -

0.0 - 46.9 Volt , 0 - 2495 cm/min

3 - 994 cm/min , 3 - 990 Amp

5 - 500 kJ/min

QUIT

With the AUTO soft key, the parameters are set automatically according to the most recently used measurement values.

When asked if the measurement values are to be set automatically, press NO or YES and then STORE if the setting is to be retained.

10.6 Production statistics

MAIN MENU » TOOLS » PRODUCTION STATISTICS

The production statistics will keep track of the total arc time, the total amount of material and the number of welds since the most recent reset. They will also keep track of the arc time and the amount of material used in the most recent weld. For information purposes, the melted wire material per length unit that has been calculated and when the most recent reset occurred are also displayed.

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10 TOOLS

PRODUCTION STATISTICS

LAST WELD TOTAL

ARCTIME

CONSUMED WIRE

BASED ON

NUMBER OF WELDS

CONSUMED ICE WIRE

DEPOSITION RATE

1g/m

 

0 kg/h



0 kg/h

LAST RESET 081114 08:38:03

RESET UPDATE QUIT

When you press RESET, all counters are reset. Date and time show the most recent reset. If you do not reset the counters, these are all automatically reset when one of them has

reached its maximum value.

Maximum counter values

Time 999 hours, 59 minutes, 59 seconds Weight 13350000 grams Quantity 65535

10.7 Quality functions

MAIN MENU » TOOLS » QUALITY FUNCTIONS

Quality functions keep track of various interesting weld data for individual welds. These functions are:

• Time of welding start.

• Duration of welding.

• Maximum, minimum and average current during welding.

• Maximum, minimum and average voltage during welding.

• Maximum, minimum and average energy per unit length during welding.

The number of welds since the most recent reset is displayed in the row at the bottom. Information can be stored about a maximum of 100 welds. In the event of more than 100 welds, the first one is overwritten.

The most recently noted weld is presented in the display, although it is also possible to browse between other noted welds. All logs are deleted when you press RESET.

QUALITY FUNCTIONS

#WELD: 1 / 4

START 20190807 15:59:14

WELD TIME 00:00:20 WELD DATA:

HEAT INPUT: 3.12 kJ/min

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10 TOOLS

QUALITY FUNCTIONS



I (Amp)

U (V)

Q (kJ/min)

V(t) (cm/min)

V(w) (cm/min)

MAX

293.00

41.50

7.00

0.00

MIN

243.00

16.20

0.00

AVE.

289.00

39.40

2.00

0.00

NUMBER OF WELDS SINCE RESET: 4

RESET UPDATE QUIT

10.7.1 Store quality data

MAIN MENU » TOOLS » EXPORT / IMPORT

The files that are produced in the control panel are stored as xml files. The USB memory must be formatted as FAT32 in order to work.

Insert a USB memory in the control panel, see section "File manager". Select QUALITY FUNCTION LOG, press EXPORT.

EXPORT/IMPORT

WELD DATA SETS

SYSTEM SETTINGS

SETTING LIMITS

MEASURE LIMITS

ERROR LOG

QUALITY FUNCTION LOG

PRODUCTION STATISTICS

EXPORT QUIT

The entire set of quality data (information about the 100 most recent welds) that is stored in the control panel is now saved on the USB memory.

The file is in a folder called QData. QData is created automatically when you insert a USB memory.

10.7.2 Import system settings

When changing between Aristo® 1000 and LAF/TAF power sources use SYSTEM SETTINGS to import system settings.

When EXPORT/IMPORT is selected you can import settings by marking the SYSTEM SETTINGS using the positioning knob and pressing IMPORT.

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10 TOOLS

EXPORT/IMPORT

WELD DATA SETS

SYSTEM SETTINGS

SETTING LIMITS

MEASURE LIMITS

ERROR LOG

QUALITY FUNCTION LOG

PRODUCTION STATISTICS

EXPORT IMPORT QUIT

IMPORT

10.8 Calendar

MAIN MENU » TOOLS » CALENDAR

Date and time are set here. Select the row that is to be set: YEAR, MONTH, DAY, HOUR, MINUTES or SECONDS. Set

the correct value using one of the setting knobs. Press SET.

DATE & TIME

YEAR

MONTH

2019

NOV

DAY

HOUR

MINUTES

SECONDS

20100115 10:48:59

SET QUIT

10.9 User accounts

MAIN MENU » TOOLS » USER ACCOUNTS

Occasionally it is particularly important from a quality perspective that the product cannot be used by unauthorised parties.

User name, account level and password are registered in this menu.

Select USER NAME and press ENTER. Step down to an empty row and press ENTER. Key in a new user name on the keyboard using the positioning knob and the arrows and ENTER.

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10 TOOLS

USER ACCOUNTS

USER NAME └ACCOUNT LEVEL

ADMINISTRATOR

ADMIN

└PASSWORD

USER ACCOUNTS

OFF

 

STORE DELETE QUIT

There is space for 16 user accounts. In the quality data files it will be evident which users have executed a particular weld.

Under ACCOUNT LEVEL choose from:

ADMINISTRATOR FULL ACCESS (can add new users) SENIOR USER can access everything except: MACHINE CONFIGURATION, USER

ACCOUNTS and NETWORK SETTINGS

NORMAL USER can access: MAINTENANCE in CONFIGURATION menu. UNIT

INFORMATION in TOOLS menu. VOLTAGE, CURRENT / WIRE FEED, TRAVEL SPEED and WELDING DIRECTION in SETTINGS

menu.



In the PASSWORD row, key in a password using the keyboard. When the power source is switched on and the control panel activated, you are asked in the display to enter your password.

If you choose not to have this function, but instead want the power source and control panel to be unlocked for all users, select USER ACCOUNTS OFF.

10.10 Unit information

MAIN MENU » TOOLS » UNIT INFORMATION

In this menu you can see the following information:

• Machine ID

• Node ID (regarding node IDs specified below, see section "Unit IDs") 2 = power source 6 = wire feed and travel motion (motor board) 8 = control panel

• Software version

UNIT INFORMATION

Machine ID Node ID Software Version

1.00A

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2.00A

1.18A

10 TOOLS

UNIT INFORMATION

SETTING WELD DATA UNIT

QUIT

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ORDERING NUMBERS

Ordering no. Denomination

0460 504 880 0460 949 470 0460 949 471 0460 949 472 0460 949 473 0460 949 474 0460 949 475 0460 949 476 0460 949 477 0460 949 478 0460 949 479 0460 949 480 0460 949 481 0460 949 482 0460 949 483

Control unit PEK Instruction manual SE Instruction manual DK Instruction manual NO Instruction manual FI Instruction manual GB Instruction manual DE Instruction manual FR Instruction manual NL Instruction manual ES Instruction manual IT Instruction manual PT Instruction manual GR Instruction manual PL

Instruction manual HU 0460 949 484 0460 949 485 0460 949 486 0460 949 489 0460 949 490 0460 949 491 0460 949 492 0460 949 493

Instruction manual CZ

Instruction manual SK

Instruction manual RU

Instruction manual EE

Instruction manual LV

Instruction manual SI

Instruction manual LT

Instruction manual CN

Instruction manuals are available on the Internet at www.esab.com

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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00

http://manuals.esab.com

For contact information visit esab.com

ESAB A2, A6 PEK Control Panel Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1 INTRODUCTION

1.1 Control panel

1.1.1 Keys and knobs

1.2 First step

1.2.1 Choice of language

1.2.2 Unit of measurements

1.3 Display

1.3.1 Symbols in the display

1.4 General information about settings

1.4.1 Setting of numerical values

1.4.2 Setting with given alternatives

1.5 QUIT and ENTER

2 MENUS

2.1 Main Menu

2.1.1 Configuration menu

2.1.2 Tools menu

2.1.3 Weld data setting menu

2.1.4 Measurements menu

2.1.5 Weld data memory menu

2.1.6 Fast mode menu

3 SUBMERGED ARC WELDING

3.1 Settings for submerged arc welding

4 GAS METAL ARC WELDING

4.1 Settings for gas metal arc welding

5 ELECTRO SLAG WELDING

5.1 Settings for electro slag welding

6 GOUGING

6.1 Settings for gouging

7 FUNCTION EXPLANATIONS

7.1 CA, constant amperage

7.2 CW, constant wire feed

7.3 CC, constant current

7.4 Wire / electrode dimension

7.5 Arc voltage

7.6 Wire feed speed

7.7 ICE wire feed speed

7.8 ICE wire start delay

7.9 Travel speed

7.10 Welding direction

7.11 AC frequency

7.12 AC balance

7.13 AC offset

7.14 Flux pre-flow (SAW)

7.15 Gas pre-flow (GMAW)

7.16 Start adjust

7.17 Air pre-flow (Gouging)

7.18 Start type

7.19 Wire creep start

7.20 Start phases

7.21 Max Open Circuit Voltage (OCV)

7.22 Flux post-flow (SAW)

7.23 Gas post-flow (GMAW)

7.24 Air post-flow (Gouging)

7.25 Crater filling

7.26 Burnback time

7.27 Stop phases

7.28 Dynamic regulation

7.29 Control parameters

7.30 Setting limits

7.31 Measure limits

7.32 PEK control unit as separate motor control

8 MEMORY MANAGEMENT

8.1 Control panel working method

8.2 Store

8.3 Recall

8.4 Delete

8.5 Copy

8.6 Name

8.7 Edit

9 CONFIGURATION MENU

9.1 Code lock

9.1.1 Lock code status

9.1.2 Specify/edit lock code

9.2 General configuration

9.2.1 Fast mode soft keys