Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
SPARE P ARTS LIST237...................................................
TOCe
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1DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that control unit A2--A6 Process Controller from serial number 724 complies with
standard EN 60974--1, in accordance with the requirements of directive (73/23/EEA)
and addendum (93/68/EEA).
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDENTel: + 46 584 81000Fax: + 46 584 12336
2SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions.
Safety precautions must meet the requirements that apply to this type of welding equipment.
The following recommendations should be observed in addition to the standard regulations that apply
to the work place.
All work must be carried out by trained personnel well familiar with the operation of the welding equipment.
Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1.Anyone who uses the welding equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2.The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment when it is
started up.
Sthat no--one is unprotected when the arc is struck
3.The work place must:
Sbe suitable for the purpose
Sbe free from draughts
4.Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment shall only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
SProtect your ears. Use ear defenders or other hearing protection.
SWarn 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!
WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interference. It is the user’s responsibility to take
adequate precautions.
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3INTRODUCTION
3.1General
ESAB’s A2--A6 Process Controller (PEH) is a control unit which, when combined with
A2--A6 automatic welding equipment can be used for submerged--arc or MIG/MAG
welding.
The process controlle r is designed for use with ESAB’s LAF and TAF welding power
sources. Close integration of the control system with the welding power source
makes it possible to ensure very precise process reliability.
All the controls that are needed to control welding travel and the entire welding
process are situated on the control panel.
Incoming cables from various system components are connected to sockets at the
rear of the process controller or to the circuit board terminals inside the controller.
3.2Welding power sources
The welding power sources are specially adapted to work with the A2--A6 Process
Controller. T he welding power source and process controller are connected by a twin
wire bus that allows the welding process to be controlled and monitored much more
precisely than previously possible. T he power source settings can be adjusted from
the control panel on the process controller.
ESAB’s earlier generation of welding power sources, such as the LAH, LAE and TAE
can be adapted for use with the new process controller with the aid of a conversion
kit. The new welding power sources are already prepared for straightforward
connection to the A2--A6 Process Controller (PEH). The welding power sources also
supply the correct current to the process controller, thus eliminating the need for any
external power supply.
3.3Technical data
A2--A6 Process Controller (PEH)
Nominal voltage from power source:42V AC 50/60 Hz
Nominal load:Max. 900 V A
Motor connections adapted for ESAB’s
A2-- or A6-- motors:
Wire speed regulation:Internal EMK control or with AC tacho,
Welding speed:0.1--2 m/min (depending on travel unit))
Max. manual travel speed:2.0 m/min
Filler wire, wire feed speed:0.3--25 m/min (depending on wire feed unit)
Ambient temperature:Max. 45_ C,Min. --15_ C
Relative humidity:Max. 98 %
Weight:5.5 kg
Dimensions L x B x H:355 x 210 x 164 mm
Enclosure class:IP 23
Motor current 5 A continuous, max. 10 A
6 pulses per rev
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
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4INSTALLATION
4.1General
The installation shall b e executed by a professional.
4.2Motor connections for the wire feed motor, M1
A2 motor
SMotor cable, two conductors and screen, connected to connectors K10.1 and
K10.2.
SAC--Tachometer cable (accessory), two conductors and screen, connected to
connectors K10.5 and K10.6.
A6 motor
SMotor cable, four conductors and screen, connected to connectors K10.1 and
K10.2, with the field connections made to K10.3 and K10.4.
SThe AC tachometer cable (accessory), is connected to connectors K10.5 and
K10.6.
4.3Motor connections for travel motion (travel motor M2)
SMotor cable, two conductors with screen, connected to connectors K11.1 and
K11.2.
SThe motor field winding is connected to K11.3 and K11.4 (with screen).
SThe AC tachometer cable (accessory): two conductors and screen, connected to
K11.5 and K11.6.
Motor connections for the wire feed motor, M1
Motor connections for travel motion (travel motor M2)
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4.4Connection of flux or gas valve
SOutput for connecting a flux or gas valve, 42 V AC max. 0,5 A
2
SScreened 2--wire 2 x 0,75 mm
4.5Connection of welding power source
SConnect control cable (1) from the welding power source to connector XS1.
4.6Connection of the welding head
SArc voltage to terminal X2.1
Connection of flux or gas valve
, connected to K12.1 and K12.2.
Connection of the
welding head
Connection of welding
power source
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5OPERATIONAL DESCRIPTION
5.1General
Switch on welding power source
The process controller can be used in manual or automatic mode.
In manual mode the wire feed speed and travel speed are controlled manually and
you can preset all other essential welding parameters for the current weld.
In automatic mode you can choose a preset group of welding parameters and
fine--tune the actual welding parameters. Other settings made previously in manual
mode cannot be adjusted in automatic mode.
The process controller is ready for manual operation as soon as the mains power is
switched on. When welding begins the controller switches to automatic mode. When
welding stops, or if there is a fault, the controller switches back to manual mode.
5.2Control panel
1.Emergency stop
2.Retract wire
3.Travel
4.Travel, opposite direction
5.Advance wire
6.Change menu
7.Numerical key, number entry
8.ENTER key, Change row
9.SHIFT key
10. Stop welding.
Return to manual mode
11. Start welding. Switch to automatic mode
12. F a st, wire feed or travel
13. Scroll page (welding setup menu) or close valve (main menu)
The arrowed keys are used during welding to increase or
decrease the current, voltage and speed.
By pressing either
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,,
+
or
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+
it is possible to browse.
GB
6MANUAL OPERATION
6.1Travel and wire feed
Travel and wire feed commands can be given when not welding, as follows:
Switch on welding power source
SThe direction of travel is as shown by the square symbol on the power
source.
Normal speed
SThe direction of travel is as shown by the triangular symbol on the power
source.
Normal speed
To stop travel described above, press the same key again.
SRetract wire. Normal speed
Wire continues to retract until you release the key.
SAdvance wire. Normal speed
Wire continues to advance until you release the key.
SAfter switching on, you can select maximum speed by pressing the fast key
.
The LED in the key lights up.
STo return to normal speed press the fast key again
To stop immediately, press
Normal speed and max. speed can be adjusted under “PRESET SYSTEM MENU”.
.
.
.
.
.
,oreven at max. speed.
6.2Controlling valves
To operate a valve you must be in the “MAIN MENU”.
SOpen the valve for flux or gas by pressing
SClose an open valve by pressing the same key
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.
.
GB
7MENUS
7.1Menu overview
The A2--A6 Process Controller (PEH) software
is divided into several menus. The program
structure is described in the overview below.
MAIN MENU
MAIN MENU
DirectionY
StartDirect
STOP WELDING
WIRE DATA
RegulationCA
PRESET SYSTEM MENU
WELDING SETUP
S SET S Heat input per cm S Welding current
S Wire feed speed S Arc voltage S Travel speed
S Preset indicators
+
WELDING SETUP
S Arc start method S Type of weld finish
S Welding direction S Regulation method
S Wire type S Wire material S Wire size
PRESET SYSTEM MENU / DISPLAY MENU /
ERROR LIST
Menus that are not accessible by the user
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8MAINMENU
In the main menu you choose the welding current, arc voltage and travel speed you
want to use for welding. During welding you can adjust the welding parameters or
choose a complete new set of parameters.
Switch on the power source
.
The main menu will appear as follows:
Example of display if constant current (CA) has been chosen.
A
350
Chosen welding current in amperes.
Example of display if welding with constant wire feed speed (CW) is chosen.
cm/min
110
Indicates chosen wire feed speed.
Example of display during welding at constant wire feed speed (CW).
350 A
Resulting welding current after the
welding start.
For the selection of (CA) or (CW), see the menu WELDING SETUP on page 92.
SET 1Indicates that parameter set 1 of 10 available has been selected (can be hidden).
30 kJ/cm Indicates the heat input in kJ/cm that will result from the chosen values of welding
current, arc voltage and travel speed (can be hidden).
V
33.0
cm/min
23
Chosen arc voltage in volts.
Chosen travel speed in centimetres per minute.
Indicates the type of start
JIndicates the travel direction
Indicates if the valve output is open or closed.
Example of display in the event of a fault.
Error code appears in bottom left section of display .
Error message is cancelled by pressing
Max. 20 messages saved in chronological order.
SStart welding by pressing. The LED in the key lights up.
SStop welding by pressing
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8.1Entering welding parameters
When the power source is switched on, the main menu appears on the display.
In the “Display menu” you can choose how many sets of parameters you want to
work with. If more than one set of parameters is used then the SET number appears
in the top left corner.
1.Welding current or wire feed speed
2.SET no.
3.Arc voltage
4.Travel speed
If you choose to work with just one set of parameters then start at step 3.
SPress
SType in the desired SET number and press
SSelect the field for welding current or wire feed speed by pressing
SType in the desired welding current or wire feed speed. Max. 4 numbers, press
.
SSelect the field for arc voltage by pressing
SType in the desired arc voltage, max. 3 numbers, press
SSelect the field for travel speed by pressing
SType in the desired travel speed, max. 3 numbers and press
Now the whole set has been marked and is ready to use. A further 9 additional sets
can be stored. (Total 10 SETs).
+to mark the “parameter set field “.
.
.
.
.
.
.
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8.2Adjusting parameter values (during welding)
Once welding has startedthe welding parameters can be fine--tuned using the
arrowed numerical keys (over--ride function).
IncreaseDecrease
Welding current or wire feed speed
Arc voltage
Travel speed
Save the values as follows:
SStop welding with
SSave the changed values with
.
.
STo revert to the original values, press
+
.
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8.3Choosing a new set of parameters during welding
(Only possible when you have chosen to work with several sets of parameters by
programming the “Display” menu)
Immediate selection
Suppose that while welding with parameter set 1 (“SET 1”) you decide to change to
parameter set 6 (“SET 6”) without checking the parameters first.
SPress
The field “SET 1” is marked and parameter set 1 is active
SPress
The field “SET 6” flashes.
SPress
The field “SET 6” is marked and parameter set 6 is active
Check before choosing
Suppose that while welding with parameter set 1 (“SET 1”) you decide to change to
parameter set 6 (“SET 6”) after first checking the parameters.
SMark the field “SET 1 “ by pressing
SPress.
The field “SET 6” flashes.
SThe new parameter set can be checked before being chosen by pressing
+
The complete row displaying the welding parameters flashes and displays the values
for parameter set 6 (“SET 6”), although parameter set 1 (“SET1”) remains in use
during the cur r ent welding cycle.
+
.
.
.
.
+
.
SPress
The field “SET 6” is marked and parameter set 6 is active.
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9WELDING SETUP
9.1General
In WELDING SETUP you can choose a variety of settings including start method,
welding direction, wire diameter and similar variables in order to carry out a specific
welding task. These settings cannot be changed during welding.
You can cancel any error message in the main menu by pressing
SSwitch from the MAIN MENU to WELDING SETUP by pressing
The display will now show a number of variables in column A (see page 93) and the
relevant options in columns B and C. Other options can be scrolled forward one at a
time. You can change row in column A.
STo change a setting, move from column A to columns B and C by pressing
SScroll forward to the chosen option by pressing
your own values for rows 3 and 4 (”Number of wires”).
SReturn to column A to change row by pressing
SJump to the next row by pressing.
After the last row you will return to row 1.
SReturn to the previous row by pressing
This combination will also take you straight to row 6 from row 1
Explanations of terms:
+
or
+
.
.
.
.
+
or type in
.
When
hold it down while pressing the second key.
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is indicated in combination with another key you should pressfirst and
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9.2Available settings
ABC
1Direction
2Start
3STOP WELDING
4WIRE DATA
5RegulationCA, CW
6PRESET SYSTEM MENU
Y(TRIANGLE),
J(SQUARE)
Crater fill (ms)10--3000
Burnback time (ms)10--3000
Wire typeSolid wire, Flux cored, Strip
Wire diameter
if “Solid wire” is chosen
if “Flux cored” is chosen
if “Strip” is chosen
Wire materialFe, Al, SS
Number of wires1, 2
WELDING SETUP
ScratchDirect
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2
4.0 5.0 6.0
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2
4.0
30 x 0.5 60 x 0.5 100 x 0.5
Switches to sub--menus in rows 3 and 4:
SMark menu and press
.
SReturn to “WELDING SETUP” by pressing
SReturn to “MAIN MENU” by pressing
+
+
.
.
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9.3Definitions
1.Direction
Two alternatives can be chosen Y(triangle) and J (square) (these symbols are
repeated on all units)
SY(triangle) indicates travel in one direction.
SJ(square) indicate
2.Start
Two alternatives can be chosen: Direct start or Scratch start.
S
S
3.STOP WELDING
Crater fill and Burnback time canbeset.
Crater fill times between 10 and 3000 ms (0.01 -- 3 sec.) can be selected.
The crater fill function is used to finish the weld without leaving a crater. Crater fill
starts when the welding stop key
fill time. This function is most useful when MIG/MAG welding.
Burnback times between 10 and 3000 ms (0.01 -- 3 sec.) can be selected.
The burnback time starts after the crater fill sequence has ended.
Correct choice of the burnback time prevents:
Sthe wire sticking to the work piece
Sthe wire sticking to the nozzle
Direct start means that travel starts when the arc ignites.
Scratch start means that travel starts at the same time as wire feed. Scrape
start is used when welding rusty or dirty material.
is pressed, and continues for the preset crater
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4.WIRE DATA
type
Wire
The equipment can be preset for the wire you intend to weld with. The control
system must be given information about the wire shape in order to achieve optimum
start/stop characteristics.
Ssolid wire
Scored wire
Sstrip
Wire
diameter
The chosen wire diameter has a big effect on the start cycle and crater filling. When
welding with a wire diameter that is not given in the options table, choose the nearest
diameter from the menu.
Note! For certain wire materials a better welding result can be achieved, if a value
deviating from the real wire dimension by 1 step is set (normally 1 step from the real
value).
When metric units are used the following alternatives are available:
Ssolid wire0.8 / 1.0 / 1.2 / 1.6 / 2.0 / 2,4 / 3.0 / 3.2 / 4.0 / 5.0 / 6.0 mm
Scored wire0.8 / 1.0 / 1.2 / 1.6 / 2.0 / 2,4 / 3.0 / 3.2 / 4.0 mm
Sstrip30 x 0.5 / 60 x 0.5 / 100 x 0.5 mm
When inch units are used the following alternatives are available
When welding with different filler materials the start and stop method is affected by
the choice of materials. It is therefore important that the settings show whether you
are welding with steel--based or aluminium--based filler wires.
Values between 1 -- 2 can be entered.
For example, if welding with two wires (Twin Arc) enter the value 2.
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5.Regulation
Two different operating modes can be used for welding, either constant current, CA,
or constant wire feed speed, CW.
SCA, constant current. Normally used for submerged arc welding, which involves
working with large welds, large currents and large weld pools. The wire feed
speed is controlled by the power source to maintain a constant current.
SCW, constant wire feed speed. Normally used for MIG/MAG welding, for small
weld pools, thin sheet metal and thin filler wire. It is easier to achieve a constant
throat thickness when welding with this method. Welding is controlled by
selecting a fixed wire feed speed and the current is adjusted to achieve this
speed. The resulting current is displayed above the selected wire feed speed
(see display shot on page 96).
9.4Preset indicators
The numbers and symbols on the display show the chosen preset values, see table
below.
Shown in display
MAIN MENU as
Y
J
Shown in plain English
(e.g. 3.0)
WELDING SETUP
options
StartDirect
Scratch
DirectionTRIANGLE
SQUARE
Wire diameter:
Solid wire
Flux cored
Strip
OUTPUT
ON/OFF
0.8 1.0 1.2 1.6 2.0 2.5 3.0 3.2 4.0 5.0 6.0
0.8 1.0 1.2 1.6 2.0 2,4 3.0 3.2 4.0
30 x 0.5 60 x 0.5 100 x 0.5
Valve
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10ERROR LIST
10.1Error codes
M1.3OverheatingStopWait until temperature has fallen
Wire feed motor (Motor 1)
M1.1Tacho faultStopCheck wire feed unit / gearbox / tacho
M1.2Current too highStopCheck wire feed
Travel motor (Motor 2)
M2.1Tacho faultStopCheck travel motor / gearbox / tacho
M2.2Current too highStopCheck travel motor / gearbox
Welding power source (T1)
T1.01 Communication errorStopCheck cables and connections
T1.51 Incorrect welding voltageStopCheck joint preparation
T1.52 Incorrect currentStopCheck joint preparation
T1.53 Unsuccessful startStopCheck stick--out and welding parameters
T1.54 Current limitStopWelding short--circuited / Cure short--circuit
T1.55 Thermostat / overheatingStopWait until temperature has fallen
T1.57 Arc extinguishedStopCheck wire feed
Inputs / outputs
Display
(Flashing)
(Flashing)
No cooling water
(inlet K22 open) *
No gas flow
(inlet K23 open) *
StopCheck if the water is flowing or if the limit switch
is open.
StopCheck gas pressure
* Inputs are activated by using settings in menu “PRESET SYSTEM MENU”.
11ORDERING SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 237.
This will simplify dispatch and ensure you get the right part.
Reservdelsförteckning Reservedelsfortegnelse Reservedelsliste
Varaosaluettelo Spare parts list Ersatzteilliste L iste de pièces détachées
Reserveonderdelenlijst Lista de repuestos Elenco ricambi Lista de peças
sobressalentes РЯнбкбт бнфбллбкфйкюн месюн
РЙнбКБУ бнфблл бкфйкЩн мес Щн
A2- A6 Process Controller (PEH)
Edition 000615
Ordering no.DenominationNotes
0443 741 880 Control boxA2--A6 Process Controller (PEH)