A2, A6 PEK Control Unit
Instruction manual
0460 948 201 GB 20220217
Valid for: serial no. 628-xxx-xxxx
TABLE OF CONTENTS
1
SAFETY
2
INTRODUCTION
2.1 Equipment
2.2 Control panel
3
TECHNICAL DATA
4
INSTALLATION
4.1 Mains supply
5
OPERATION
5.1 Connections
5.2 USB connection
5.3 LAN/Ethernet connector
5.4 Key to symbols
6
MAINTENANCE
6.1 Inspection and cleaning
7
ORDERING SPARE PARTS
DIAGRAM
ORDERING NUMBERS
ACCESSORIES
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Rights reserved to alter specifications without notice.
0460 948 201 © ESAB AB 2022
1 SAFETY
1 SAFETY
NOTE!
The unit is tested by ESAB in a general set-up. The responsibility for safety and
function, of the specific set-up, lies with the integrator.
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Risk of crushing when replacing the wire bobbin! Do not use safety gloves when
inserting the welding wire between the feed rollers.
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© ESAB AB 2022
1 SAFETY
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should be
based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
FUMES AND GASES - Can be dangerous to health
ARC RAYS - Can injure eyes and burn skin
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases away
from your breathing zone and the general area
• Protect your eyes and body. Use the correct welding screen and filter lens and
wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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© ESAB AB 2022
1 SAFETY
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
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© ESAB AB 2022
2 INTRODUCTION
2 INTRODUCTION
PEK is a control unit intended for submerged arc welding (SAW) and for gas metal arc
welding (GMAW). The control unit is used together with automatic welding machines, power
sources, column and booms.
ESAB accessories for the product can be found in the "ACCESSORIES" chapter of
this manual.
2.1 Equipment
The control unit is supplied with:
• An instruction manual for the control unit
• An instruction manual for the control panel in English
Instruction manuals in other languages can be downloaded from: www.esab.com.
2.2 Control panel
See the separate instruction manual for a detailed description of the control panel
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© ESAB AB 2022
3 TECHNICAL DATA
3 TECHNICAL DATA
PEK
Supply voltage 42 V, 50/60 Hz
Power requirement Max 900 VA
Engine connections adapted for ESAB's
6 A 100%
motors
Speed control Feedback from pulse encoder
Operating temperature -15°C to +45°C
Transportation temperature -20°C to +55°C
Relative air humidity Max 95%
Dimensions l×w×h 246 × 235 × 273 mm
Weight 6.6 kg
Enclosure class IP23
Travel speed 0–200 cm/min *)
See separate instruction manual for
automatic welding machines.
Max manual travel speed 2.0 m/min
Wire feed speed, filler wire 0–2500 cm/min *)
See separate instruction manual for wire feed
unit.
*) The setting range is dependent on the product used.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration
by solid objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.
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© ESAB AB 2022
4 INSTALLATION
4 INSTALLATION
The installation must be executed by a professional.
4.1 Mains supply
NOTE!
Mains supply requirements
This equipment complies with IEC 61000-3-12 provided that the short-circuit power is
greater than or equal to S
the public system. It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power greater than or
equal to S
. Refer to the technical data in the TECHNICAL DATA chapter.
scmin
at the interface point between the user's supply and
scmin
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© ESAB AB 2022
5 OPERATION
5 OPERATION
General safety regulations for the handling of the equipment can be found in the "SAFETY"
chapter of this manual. Read through before you start using the equipment!
5.1 Connections
1. Emergency stop 7. Connection of speed feedback for travel
motion
2. Control panel, see separate instruction
manual
3. Connection (CAN) for remote control
unit or service tool
4. USB connection, see section of USB
connection
5. Connection for limit position switch or
cable with solenoid for gas
6. Connection of speed feedback for wire
feed
8. Connection for arc voltage feedback
9. Connection of motor cable for travel
motion
10. Connection of motor cable for wire feed
11. LAN connector, Ethernet port used to
connect to WeldCloud™ Mobile
12. Connection for control cable from power
source
5.2 USB connection
The external USB memory can be used to transfer programs to and from systems.
During normal use there is no risk of ”viruses” ”infecting” equipment. To eliminate the risk
entirely, we recommend that the memory, which is used together with this equipment, not be
used for any other purpose other than its intended.
Certain USB memories may not work with this equipment. We recommend using USB
memories from a reputable supplier.
ESAB assumes no responsibility for any damage caused as a consequence of incorrect use
of the USB memory.
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© ESAB AB 2022
5 OPERATION
To insert a USB memory
1. Switch off the power supply main switch.
2. Insert the USB memory into the USB socket.
3. Switch on the power supply main switch.
5.3 LAN/Ethernet connector
The PEK control unit is equipped with an Ethernet interface to be able to connect the unit to
an ESAB WeldCloud™ Mobile unit. For further information about the WeldCloud™ system,
see the WeldCloud™ instruction manual. For further information about the WeldCloud™
Mobile unit, see the WeldCloud™ Mobile instruction manual.
5.4 Key to symbols
Main menu Enter
Manual travel motion
in direction
Fast motion
Manual wire feed
downwards
Manual travel motion
in direction
Manual wire feed
upwards
Start
Stop Current
Wire feed speed Voltage
Travel speed
See separate instruction manual for more information regarding the control panel.
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© ESAB AB 2022
6 MAINTENANCE
6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Maintenance may only be carried out by an authorised technician. Only personnel with the
appropriate electrical skills (authorised staff) may remove safety plates.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
6.1 Inspection and cleaning
Check regularly that the control unit is not clogged with dirt.
How often and which cleaning methods apply depend on:
• welding process
• arc time
• location of the unit
• surrounding environment
Usually it will be sufficient to blow the unit clean once a year, using dry compressed air
(reduced pressure).
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© ESAB AB 2022
7 ORDERING SPARE PARTS
7 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.
PEK is designed and tested in accordance with the international and European
standards EN 60974-1 and EN 60974-10. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of this
publication.
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© ESAB AB 2022
DIAGRAM
DIAGRAM
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© ESAB AB 2022
DIAGRAM
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© ESAB AB 2022
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no. Denomination Type
0460 504 880 Control unit PEK
0459 839 036 Spare parts list PEK
0460 949 Instruction manual Control panel for PEK
Instruction manuals and the spare parts list can be downloaded from: www.esab.com
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© ESAB AB 2022
ACCESSORIES
ACCESSORIES
Control cable PEK - Power source
0460 910 881
0460 910 882
0460 910 883
0460 910 884
15 m
25 m
35 m
50 m
Cable restraining bracket
0460 861 880
USB Memory stick 2 Gb
0462 062 001
Ethernet cable (connectors included)
0465 816 001 0.5 m industrial
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© ESAB AB 2022
ACCESSORIES
0821 440 980 Laser lamp kit, 2 m (6ft 6.7in.) cable
0821 440 981 Laser lamp kit, 10m(33ft)cable
0821 440 982 Laser lamp kit, 25m(82ft)cable
0821 440 983 Laser lamp kit, 40m(131ft)cable
0821 440 984 Laser lamp kit, 0.5 m (1ft 7.7in.) cable
0821 441 980 Laser lamp kit, hair cross,
2m(6ft6.7in.)cable
0821 441 983 Laser lamp kit, hair cross, 25m(82ft)cable
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© ESAB AB 2022
ACCESSORIES
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© ESAB AB 2022
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
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