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Control panel MA6
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices
for arc welding equipment, we urge you to read our booklet, “Precations and Safe Practices for Arc, Cutting and Gouging, “Form
52--529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your
supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
0458 854 187 051003 Valid from program version. 1.30
1 INTRODUCTION 3...................................................
1.1 Do this first 3...............................................................
1.2 Control panel’s working method 4.............................................
1.3 Control panel 4.............................................................
1.4 Symbols in the display 5.....................................................
2 MENUS 5...........................................................
2.1 The main menu and the measurements menu 5.................................
2.2 The selection menu 6........................................................
2.3 Menu structure 7............................................................
3 MIG WELDING 9.....................................................
3.1 Settings 9..................................................................
4 STICK WELDING 15...................................................
4.1 Settings 15..................................................................
5 ARC--AIR GOUGING 16................................................
5.1 Settings 16..................................................................
6 GENERAL FUNCTIONS 17.............................................
6.1 Remote control unit 17........................................................
6.2 Settings 17..................................................................
7 MEMORY MANAGEMENT 18...........................................
7.1 Store welding data 18.........................................................
7.2 Recall welding data 19........................................................
7.3 Delete welding data 20........................................................
8 LOCK CODE 21.......................................................
9 FAULT CODES 22.....................................................
9.1 Fault code list 22.............................................................
9.2 Fault code descriptions 23.....................................................
10 ORDERING SPARE PARTS 26..........................................
SCHEMATIC DIAGRAM 27................................................
ORDERING NUMBER 28.................................................
Rights reserved to alter specifications without notice.
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1 INTRODUCTION
This manual describes operation of the MA6 control panel.
For general information on operation, see the power source or the wire feed unit
instruction manuals.
If this warning is shown in the display it m eans that the power source don’t support this
function.
Contact an authorised ESAB service engineer to get an updated software.
1.1 Do this first
This menu appears on the display the first time that you start the power unit.
When delivered, the control panel and display are set to English. There are 14
languages stored in the control panel: change to the one that you want as follows.
S Press
S Press to reach the configuration menu.
to reach the first selection menu.
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S Press (i.e. the soft button on the right beneath the display) until the correct
language is shown in the display.
1.2 Control panel’s working method
The control panel can be said to comprise two units: the primary m emory and the
welding data memory.
Store
Primary memory Welding data memory
Recall
In the primary memory, a complete set of welding data settings are created which can
be stored in the welding data memory.
When welding, it is always the content of the primary memory which controls the
process. It is therefore also possible to recall welding data settings from the welding
data memory to the primary memory.
Note that the primary memory always contains the most recently set welding data
settings. These can be recalled from the welding data memory or individually altered
settings. In other words, the primary memory is never empty or “reset”
1.3 Control panel
1 Display
2 Knob for setting the voltage
3 Knob for setting the wire feed speed and cur-
rent
4 Soft pushbuttons (function keys)
5 MENU button
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Soft pushbuttons
The functions of these buttons (i.e. what each one does) change, depending on the
sub--menu shown on the display. The particular function for each button is shown by
the text in the bottom line of the display, corresponding to the buttons. (A white dot
beside the text indicates that the button is active.)
MENU pushbutton
This pushbutton brings you to the selection menu (see item <>) if you are in the m ain
menu. If you are in some other menu, it moves you back up one menu.
1.4 Symbols in the display
Back to the main menu.
Move the cursor down to a new setting parameter.
Change the function in the selected line.
Increase the value. Decrease the value.
2 MENUS
The control panel uses several different menus: the main menu, the measurements
menu, the selection menu, the process menu, the settings menu, the configuration
menu and the memory menu. A startup display is also shown when starting, with
information on the type of panel and the software version in use.
2.1 The main menu and the measurements menu
The main menu always appears immediately after starting,
showing the values that are set. If you are in the main menu
when you start to weld, the menu changes automatically to
show the measured values (the measurements menu). The
measured values remain on the display even after welding
stops.
Other menus can be accessed without losing the measured values.
It is only when a knob is turned or the welding method changed that the setting values
are displayed instead of the measured values.
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2.2 The selection menu
Use the selection menu to select the next level menu to which
you want to go: process, settings, configuration or memory.
The process menu
Use this menu to
change the welding
process, material type
etc.
The configuration
menu
Use this menu to
change the language,
measurement units etc.
The settings menu
Use this menu to set
welding parameters,
such as gas pre--flow,
hot start time, crater fill
time etc.
The memory menu
Use this menu to store,
recall and/or erase
various stored welding
data settings. There are
ten storage positions for
welding data.
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STICK Arc gouging
MIG/MAG
Pulsed
MIG/MAG
STICK Arc gouging
MIG/MAG
STICK
STICK
Aric goug.
5) Lang
Dimension
Panel ena.
5) Lang.
Dimension
Panel ena.
Pulsed
MIG/MAG
5) Lang.
Dimension
Arc force
Hot start
Panel ena.
Store
Recall
Delete
Trigger dat.
Pulsed
2/4--stroke
MIG/MAG
MIG/MAG
Gas pre fl.
Hot start
Crater fill
Burnbackt
Gas post fl.
Spot welding
Gas pre fl.
Hot start
Craterfill
Burnbackt
Gas post fl.
Spot welding
MIG/MAG Pulsed
Arc gouging
2/4--stroke
Craterfill Craterfill
Hot start Hot start Hot start
Slow runin Slow runin
Gas purge Gas purge
Wire inch Wire inch
Process menu Setting menu Configuration menu Memory menu
STICK
Pulsed
MIG/MAG
4) E--diam Induktanc
3) E--type
2) Wire typ
E--diam
Gas
Wire diam.
MIG/MAG
2.3 Menu structure
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MIG/MAG
Synergic
1) Wire typ
Gas
Wire diam.
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1) The table below shows the electrode diameters that can be selected in the process settings menu
for MIG synergy welding.
Wire type
Low--alloy or non--alloy solid wire (Steel Fe) Ar + 20% CO
Shielding gas Wire diameter
0.040 0.045
2
Ar + 8% CO
2
0.040 0.045
Magnesium--alloyed aluminium wire (5000 Alum) Ar 0.045 1/16
Silicon--alloyed aluminium wire (4000 Alum) Ar 0.045 1/16
Stainless solid wire (Stainless Ss) Ar + 2%CO
2
Ar+3%CO21%H
Metal powder--filled cored wire (WCAW Steel) Ar + 20% CO
Basic flux--filled cored wire (BFCW) Ar + 20% CO
Rutile flux--filled cored wire (FCAWT1 Steel) Ar + 20% CO
0.030 0.040 0.045
0.030 0.040 0.045
0.045 0.052 1/16
2
0.045 0.052 1/16
2
0.045 0.052 1/16
2
2) The table below shows the electrode diameters that can be selected in the menu for pulsed MIG
welding.
Wire type
Low--alloy or non--alloy solid wire (Fe) Ar + 20% CO
Shielding gas Wire diameter
0.040 0.045
0.040 0.045
Ar + 8% CO
2
2
Magnesium--alloyed aluminium wire (AlMg) Ar 0.040 0.045
Silicon--alloyed aluminium wire (AlSi) Ar 0.040 0.045 1/16
Stainless solid wire (Ss) Ar + 2%CO
Ar+3%CO21%H
2
0.030 0.040 0.045
0.030 0.040 0.045
3) The table below shows the electrode diameters that can be selected in the STICK welding process
menu.
Electrode type
Electrode diameter
Basic E7018 3/32 1/8 5/32 11/64 3/16 7/32 1/4 9/32 1/16 5/64
Rutile E6013 3/32 1/8 5/32 11/64 3/16 7/32 1/4 9/32 1/16 5/64
Other E6010 3/32 1/8 5/32 11/64 3/16 7/32 1/4 5/64
4) Following electrode diameters can be selected in the process menu for air--arc gouging:
5/32 3/16 1/4 10/32
5) The text on the display panel is available in the following languages:
Swedish, Danish, Norwegian, Finnish, English, German, Dutch, French, Spanish (Castilian), Italian,
Portuguese, Polish, Czech, Hungarian, Turkish and US English.
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3MIGWELDING
The arc in MIG welding melts a filler wire (the electrode) that is continuously fed into the
weld, with the molten zone being protected by a shielding gas.
Pulsing the current affects the transfer of molten droplets from the wire, to produce a stable,
spatter--free arc even at low welding settings.
3.1 Settings
MIG welding without pulsing
Settings Setting range In steps of Default setting
2/4--stroke
Crater filling OFF or ON -- OFF
Crater fill time 0--5s 0.1 s 1.0 s
Hot start OFF or ON -- OFF
Hot start time 0--10s 0.1 s 1.5 s
Slow runin start OFF or ON -- ON
Gas purging
Cold wire feed -- -- --
Synergy OFF or ON -- ON
Inductance 0 -- 100 1 70
Gas pre-- flow 0.1 -- 25 s 0.1 s 0.1 s
Burnback time 0--0.35s 0.01 s 0.10 s
Gas post--flow 0.1 -- 20 s 1s 1s
Spot welding OFF or ON -- OFF
Spot welding time 0.1 -- 25 s 0,1 s 0.1 s
Voltage 8--60 0,25 (displayed with
Wire feed speed 31 -- 984 inch/min 4 inch/min 196 inch/min
Trigger data OFF,
Dimensions METRIC or INCH -- METRIC
Panel enable OFF or ON -- ON
Automatic save
Off arc feed
Limits
Lock code
1)
1)
3)
3)
3)
3)
2--stroke or 4--stroke -- 2--stroke
-- -- --
2)
synergy deviation
one decimal)
-- OFF
ON or
ARC OFF
OFF or ON -- OFF
OFF or ON -- OFF
OFF or ON -- OFF
OFF or ON -- OFF
¦ 0
1)
These functions cannot be changed while welding is in progress.
2)
The synergy line on delivery: solid wire (Steel Fe), shielding gas CO2with wire 0.030”.
3)
Contact an authorized ESAB service engineer to activate this function.
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MIG welding with pulsing
Settings Setting range In steps of Default setting
2/4--stroke
Crater filling OFF or ON -- OFF
Crater fill time 0--5s 0.1 s 1.0 s
Hot start OFF or ON -- OFF
Hot start time 0--10s 0.1 s 1.5 s
Slow runin start OFF or ON -- ON
Gas purging
Cold wire feed -- -- --
Gas pre-- flow 0.1 -- 25 s 0.1 s 0.1 s
Burnback time 0--0,35s 0.01 s 0.10 s
Gas post--flow 0--20s 1s 1s
Spot welding OFF or ON -- OFF
Spot welding time 0.1 -- 25 s 0.1 s 0.1 s
Voltage 8--60 0.25 (displayed with
Wire feed speed 31 -- 984 inch/min 4 inch/min 196 inch/min
Trigger data OFF,
Dimensions METRIC or INCH -- METRIC
Panel enable OFF or ON -- ON
Automatic save
Off arc feed
Limits
Lock code
1)
1)
2--stroke or 4--stroke -- 2--stroke
-- -- --
synergy deviation
one decimal)
¦ 0
-- DISABLE
ON or
ARC OFF
2)
2)
2)
2)
OFF or ON -- OFF
OFF or ON -- OFF
OFF or ON -- OFF
OFF or ON -- OFF
1)
These functions cannot be changed while welding is in progress.
2)
Contact an authorized ESAB service engineer to activate this function.
The synergy line on delivery: solid wire (Steel Fe), shielding gas Ar 8% CO
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2--stroke
Gas pre-- flow Hot
start
Functions when using 2--stroke control of the welding gun.
Welding Crater
fill
Gas post--flow
In the 2--stroke control mode, pressing the welding gun trigger switch starts gas
pre-- flow (if used) (1) and strikes the arc. Releasing the trigger switch (2) starts crater
filling (if in operation), extinguishes the arc and star ts gas post--flow (if in operation).
TIP: If the welding gun trigger switch is pressed again during the crater fill time, welding
can be continued for as long as required (shown by the dotted line), using the crater fill
data. Crater filling can also be interrupted by quickly pressing and releasing the trigger
switch while crater filling is in progress.
-- Activation of 2--stroke performed in the main menu.
4--stroke
Gas pre-- flow Hot
start
Function when using 4--stroke control of the welding gun.
Welding Crater fill Gas post--flow
In the 4--stroke control mode, pressing the welding gun trigger switch starts gas
pre-- flow (1). Releasing the trigger switch (2) starts the welding process. At the end of
welding, the welder presses the trigger switch again (3), which starts crater filling (if in
operation) and reduces the welding data to a lower value. Releasing the trigger switch
again (4) extinguishes the arc and starts gas post--flow (if used).
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TIP: Crater filling stops when the trigger switch is released. Keeping the button
pressed continues welding at the lower data settings of the crater filling function (dotted
line).
-- Activation of 4--stroke performed in the main menu.
Crater filling
Crater filling helps to avoid pores, thermal cracking and crater formatio n in the
workpiece at the end of the weld.
-- Setting of crater filling time performed in the settings menu.
Hot start
The hot start function increases the welding current for an adjustable time at the start of
welding, which reduces the risk of poor fusion at the start of the weld.
-- Setting of hot start time performed in the settings menu.
Slow runin start
The slow runin start function reduces the initial feed speed of the wire by 50 % of the set
speed until the wire contacts the workpiece.
-- Activation of slow runin start performed in the main menu.
Gas purging
The gas purging function is used when measuring the gas flow rate, or to purge the gas
hoses of any air or moisture before starting to weld. It continues as long as the button
is pressed, and prevents voltage from being applied and wire feed from starting.
-- Activation of gas purging performed in the main menu.
Cold wire feed
Cold wire feed is used in order to feed out wire without energizing the arc. The wire is
fed out for as long as the button is pressed.
-- Activation of cold wire feed performed in the main menu.
Synergy
Every combination of wire type, wire diameter and gas mixture requires a unique
relationship between wire feed speed and voltage (arc length) in order to ensure a
stable arc. The arc voltage (arc length) is automatically controlled in accordance with
the preprogrammed synergy line that has been selected by the welder, which makes it
much easier to quickly find the optimum welding parameters. The relationship between
the wire feed speed and the other parameters is referred to as the synergy
characteristic or synergy line.
Synergy ON: the main menu shows the set wire feed,
as well as positive and negative deviation from the
synergy line’s voltage.
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Positive deviation is displayed with a bar above SYN,
negative is displayed below.
Synergy OFF: the m ain menu shows the set value for voltage and wire feed.
-- Activation of synergy performed in the main menu.
Synergy line package
The synergy line package supplied with the machine is called “Standard synergic lines”
and contains the 33 most frequently used synergy lines.
It is also possible to order other packages of synergy lines, but these must be installed
by an authorized ESAB service engineer.
Inductance
Higher inductance produces a more flowing weld and less spatter. Lower inductance
produces a harsher sound and a stable, concentrated arc.
-- Setting of inductance performed in the settings menu.
Gas pre--flow
The gas pre--flow time is the time during which the shielding gas flows before the arc is
struck.
-- Setting of gas pre--flow time performed in the settings menu.
Burnback time
The burnback time is a delay between when the wire feed unit starts to brake the wire
until the power unit shuts off the welding current. Too short a burnback time leaves a
long piece of filler wire pr ojecting after welding has stopped, with resulting risk of the
wire freezing into the solidifying weld pool. On the other hand, too long a burnback time
reduces the stickout to such an extent that there is a risk of the arc striking from the
welding gun contact tip when welding is next started.
-- Setting of burnback time performed in the settings menu.
Gas post--flow
The gas post--flow function controls the time during which shielding gas continues to
flow after the arc has been extinguished.
-- Setting of gas post--flow time performed in the settings menu.
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Change of trigger data
Using this function, it is possible to switch to various pre--set welding data alternatives
by double--clicking on the welding gun’s trigger.
Switching takes place between the memory positions 1, 2 and 3 (see under chapter 7
“memory management”). If there is no data in m emory position 2, switching takes place
instead between positions 1 and 3.
ON -- Switching between memory positions can take place before, after or during
welding.
ARC OFF -- Switching between memory positions can only take place before or after
welding.
-- Activation of trigger data switching performed in the configuration menu.
Off arc feed
When this function is activated it is possible to use an Arc Voltage Controlled or
Off--The--Arc feeder, where the arc voltage from the power source is used to power the
feed unit.
Contact an authorized ESAB service engineer to activate this function.
-- Activation of Off arc feed performed in the configuration menu.
Spot welding
Select Spot welding when you want to “spot--weld” thin metal sheets.
-- Activation and setting of Spot welding is performed in the settings menu.
Vol tag e
A higher voltage gives a longer arc, with a hotter and wider weld pool.
Irrespective of which menu is displayed, the setting value for the voltage can always be
changed. The value is displayed in the main menu or selection menu.
Wire feed speed
The wir e feed speed is the speed at which the filler wire is supplied, measured in
inch/min.
Irrespective of which menu is displayed, the setting value for the wire feed speed can
always be changed. The value is displayed in the main menu or selection menu.
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4 STICK WELDING
STICK welding is welding with the use of coated electrodes. Striking the arc melts the
electrode and the coating, with the coating forming a protective slag.
4.1 Settings
Settings Setting range In steps of Default setting
Hot start
Hot start time 1--30 1 10
Arc force 0--10 0,5 3
Current
Dimensions METRIC or INCH -- METRIC
Panel enable OFF or ON -- OFF
Automatic save
Limits
Lock code
1)
2)
3)
3)
3)
ON or OFF -- OFF
16 -- 500 A 1A 164 A
OFF or ON -- OFF
OFF or ON -- OFF
OFF or ON -- OFF
1)
This function cannot be changed while welding is in progress.
2)
Maximal current depends on which machine type is used.
3)
Contact an authorized ESAB service engineer to activate this function.
The synergy line on delivery Rutile E6013 wire 5/32”.
Hot start
The hot start function increases the welding current for an adjustable time at the start of
welding. This reduces the risk of poor fusion defects at the start of the weld.
Setting of hot start time performed in the settings menu.
Arc force
The arc force function controls how the current changes when the arc length changes. A
lower value gives a less harsh arc with less spatter.
Setting of arc force performed in the settings menu.
Current
Higher current produces wider and deeper penetration into the workpiece.
Irrespective of which menu is displayed, the setting value for the current can always be
changed. The value is displayed in the main menu or selection menu.
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5 ARC--AIR GOUGING
Arc--air gouging involves the use of a special electrode consisting of a carbon bar with a
copper case. An arc is formed between the carbon bar and the workpiece, air is
supplied to blow away the melted material, and a seam is formed.
5.1 Settings
Settings Setting range In steps of Default setting
Wire diameter 4.0--8.0 mm 1mm 4,0 mm
Current 8--60 V 0,25 V (Displayed with
one decimal.)
Wire diameter
A larger wire diameter produces wider and deeper penetration into the workpiece.
Current
Higher current produces wider and deeper penetration into the workpiece
37.0 V
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6 GENERAL FUNCTIONS
6.1 Remote control unit
Aristo machines with intergral control panels should have program version 1.21 or
higher, in order for the remote control to function correctly.
Control panel’s behavior on connection of the remote control adapter
S The display freezes in the menu showing when the remote control is connected.
Measurement and setting values are updated, but only displayed in those menus in
which the values can be shown.
S If a fault code symbol is displayed, it cannot be removed until the remote control has
been disconnected.
S With 10--program remote control units, it is possible to switch between memory
positions 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10. If memory position 2 is empty, the values
from position 1 are retained. For further information, see chapter 7 “memory
management”.
6.2 Settings
Panel enable
When a remote control unit is connected it is possible to set current or voltage and wire
feed speed by the control panel or the remote control unit.
Note: this function must be activated before the remote control unit is connected.
-- Activation of panel enable performed in the configuration menu.
Auto save
If a welding data setting is recalled from the welding data memory and the settings are
adjusted, the changed settings will automatic be saved when a new welding data setting
is recalled from the memory.
Contact an authorized ESAB service engineer to activate this function.
-- Activation of auto save performed in the configuration menu.
Limits
By this function max. and min. values for wirefeed / current or voltage can be set. The
limits can be saved in the first 5 memory positions of the welding data memory.
Contact an authorized ESAB service engineer to activate this function.
-- Activation of limits performed in the configuration menu.
Lock code
By this function the settings menu can be locked, then it is only possible to select the
main menu and the measurements menu, see chapter 8 “Lock code”.
Contact an authorized ESAB service engineer to activate this function.
-- Activation of lock code performed in the configuration menu.
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7 MEMORY MANAGEMENT
Various welding data created in the primary memory can be stored in the memory
menu. Up to 10 different welding data settings can be stored.
7.1 Store welding data
S Set a welding data setting in the primary memory.
S Press to access the “selection menu” and then on to access the
relevant settings.
Check that the welding data settings are correct.
S Press to access the memory menu.
S Press until you come to the memory position in which you want to store the
welding data setting, e.g. position 2.
S Press , a welding data setting is now stored in memory position 2. The other
memory positions are empty.
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7.2 Recall welding data
S Press to access the selection menu and then on to access the
relevant settings.
S Press to access the memory menu.
S Choose which memory position you want to recall, e.g. position 2. Press until
youcometoposition2.
S Press to recall memory position 2. The following question appears:
S Press “YES” if you want to recall welding data from memory position 2 and change
the settings that are currently in the primary memory. (If you change your mind,
press “NO”)
This icon
position that is recalled.
in the main m enu shows which memory
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7.3 Delete welding data
S Press to access the selection menu and then on to access the
relevant settings.
S Press to access the memory menu.
S Choose which memory position you want to delete, e.g. position 2. Press until
youcometoposition2.
S Press to delete memory position 2. The following question appears:
S Press “YES” if you want to delete welding data from memory position 2, (if you
change your mind, press “NO”). Memory position 2 is now empty.
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8 LOCK CODE
Contact an authorized ESAB service engineer to activate the lock code.
S Press
S Press until the first digit of the PIN code is selected.
S Press , to store the first digit of the code. Repeat the procedure for the
remaining digits.
S Press to unlock the control panel.
to access the lock code menu.
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9 FAULT CODES
Fault codes are used to indicate that a fault has occurred in the equipment. They are
shown in the display in the form of a symbol as follows:
Fault codes are updated every three seconds. The upper numeral in the
symbol is the number of the particular fault code: see Item 9.1. The lower
figure indicates where the fault is:
The above symbol shows that the control panel (0) has lost contact with the power unit.
If several faults have been detected, only the code for the last fault to occur will be
displayed.
Press any of the function keys in order to clear the symbol from the display.
Symbols may be steady or flashing, depending on the type of fault.
Flashing symbols are highlighted with “o” in the list of fault codes.
9.1 Fault code list
0 = control panel 3 = wire feed unit
1 = cooling unit 4 = remote control
2 = power source
Fault
code
Description 0 1 2 3 4
1 Memory error, EPROM x x x x x
2 Memory error, RAM x x x x
3 Memory error, external RAM x x
4 5V power supply x x
5 High intermediate DC voltage x
6 High temperature x x
8 Power supply 1* x x x x x
9 Power supply 2* x x x
10 Power supply 3* x
11 Wire feed servo x
12 Communication error (warning) x x x x x
14 Communication error (bus off) x x
15 Messages lost x x x x
16 High open--circuit voltage x
17 Lost contact with the wire feed unit o
18 Lost contact with the power unit o
19 Incorrect settings values in external RAM x
20 Memory allocation error x
22 Transmitter buffer overflow x x
23 Receiver buffer overflow x x
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Fault
code
26 Watchdog x x x
27 Outofwire o
28 Stack overflow x x x x
29 No cooling water flow o
31 No reply from the display unit x
32 No gas flow o
Unit Power supply 1* Power supply 2* Power supply 3*
Cooling unit +24V
Control panel +3V
Power unit +15V --15V +24V
Wire feed unit 30/48--4
Wire feed unit 30L--4
Remote control +12V +10V
+15V
+15V
+ 20V
+ 60V
9.2 Fault code descriptions
Fault
code
Description
1 Program memory error, (EPROM)
There is a fault in the program memory.
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
2 Microprocessor RAM error
The microprocessor is unable to read/write from/to a certain memory position in its internal
memory
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
3 External RAM error
The microprocessor is unable to read/write from/to a certain memory position in its external
memory
This fault does not disable any functions.
Action: Restart the machine. If the fault persists, send for a service technician.
4 5 V power supply low
The power supply voltage is too low.
The current welding process is stopped, and cannot be restarted.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
43210Description
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Fault
code
10 +24V power supply
11 Wire feed speed
12 Communication error (warning)
Description
5 Intermediate DC voltage outside limits
The voltage is too low or too high. T oo high a voltage can be due to severe transients on the
mains power supply or to a weak power supply (high inductance of the supply or loss of a phase).
The power unit is stopped, and cannot be restarted.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
6 High temperature
The thermal overload cutout has operated.
The current welding process is stopped, and cannot be restarted until the cutout has reset.
Action: Check that the cooling air inlets or outlets are not obstructed or clogged with dirt.
Check the duty cycle being used, to make sure that the equipment is not being overloaded.
8 Low battery voltage +3V (in the control panel)
The voltage of the memory backup battery is too low. If the battery is not replaced, the contents of the welding data memory in the control panel will be lost.
This fault does not disable any functions.
Action: Send for a service technician to replace the battery.
8 +15V power supply (wire feed unit and power unit)
The voltage is too high or too low.
Action: Send for a service technician.
8 +13V power supply, (remote control unit)
The voltage is too high or too low.
Action: Send for a service technician.
9 --15V power supply (power unit)
The voltage is too high or too low.
Action: Send for a service technician.
9 +20V power supply, (wire feed unit)
The voltage is too high or too low.
Action: Send for a service technician.
9 +10 V power supply (remote control unit)
The voltage is too high or too low.
Action: Send for a service technician.
The voltage is too high or too low.
Action: Send for a service technician.
The wire feed speed differs from the set value.
Wire feed stops if this fault occurs.
Action: Send for a service technician.
The load on the system CAN bus is temporarily too high.
The power unit or wire feed unit may have lost contact with the control panel.
Action: Check the equipment to ensure that only one wire feed unit or remote control unit is
connected. If the fault persists, send for a service technician.
bi08fela9
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US
Fault
code
14 Communication error
15 Messages lost
16 High open--circuit voltage
17 Lost contact
18 Lost contact
19 Incorrect settings values in external RAM
20 Memory allocation error
22 Transmitter buffer overflow
23 Receiver buffer overflow
26 Watchdog
Description
The system’s CAN bus has temporarily ceased to work due to excessive load.
The current welding process is stopped.
Action: Check the equipment to ensure that only one wire feed unit or remote control unit is
connected. Turn off the mains power supply to reset the unit. If the fault persists, send for a
service technician.
The microprocessor is unable to process incoming messages quickly enough, with the result
that information has been lost.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a service technician.
The open--circuit voltage has been too high.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
The control panel has lost contact with the wire feed unit.
The current welding process is stopped.
Action: Check the cables. If the fault persists, send for a service technician.
The control panel has lost contact with the power unit.
The current welding process is stopped.
Action: Check the cables. If the fault persists, send for a service technician.
This fault will be detected if the information in the battery--backed memory has become corrupted.
Action: The fault will correct itself, but the data stored in the current memory position will be
lost.
The microprocessor is unable to reserve sufficient memory space.
This fault will generate fault code 26.
Action: Send for a service technician.
The control panel is unable to transmit information to the other units at a sufficiently high speed.
Action: Turn off the mains power supply to reset the unit.
The control panel is unable to process information from the other units at a sufficiently high
speed.
Action: Turn off the mains power supply to reset the unit.
Something has prevented the processor from performing its normal program duties.
The program restarts automatically. The current welding process will be stopped.
This fault does not disable any functions.
Action: If the fault recurs, send for a service technician.
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US
Fault
code
27 Out of wire (wire feed unit)
28 Stack overflow
29 No cooling water flow
31 No reply from the display unit
32 No gas flow
Description
The wire feed unit is not feeding any wire. The current welding process will be stopped, and
cannot be restarted.
Action: Load new wire.
Program execution is not working.
Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a ser-
vice technician.
The flow monitor switch has operated.
The current welding process is stopped, and cannot be restarted.
Action: Check the cooling water circuit and the pump.
The microprocessor is not in contact with the display board.
Action: Send for a service technician.
Gas flow is less than 6 l/min. Welding cannot be started.
Action: Check the gas valve, hoses and connectors.
10 ORDERING SPARE PARTS
Note!
Supplier warranty is void if customer attempts any work on product during the warranty
period.
When ordering replacement parts, orde r by part number and part name, as illustrated
on the figure. Always provide the series or serial number on the unit on which the parts
will be used. The serial number is stamped on the rating plate.
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Schematic diagram
bi03e11a
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Control panel MA6
Ordering number
Ordering no. Denomination
0458 535 886 Control panel MA6
0458 854 170 Instruction manual SE
0458 854 171 Instruction manual DK
0458 854 172 Instruction manual NO
0458 854 173 Instruction manual FI
0458 854 174 Instruction manual GB
0458 854 175 Instruction manual DE
0458 854 176 Instruction manual FR
0458 854 177 Instruction manual NL
0458 854 178 Instruction manual ES
0458 854 179 Instruction manual IT
0458 854 180 Instruction manual PT
0458 854 181 Instruction manual GR
0458 854 182 Instruction manual PL
0458 854 183 Instruction manual HU
0458 854 184 Instruction manual CZ
0458 854 127 Instruction manual RU, GB
0458 854 990 Spare parts list
The instruction manuals and the spare parts list are available on the Internet at www.esab.com
Under ”Products” and ”Welding & cutting equipment”, you will find a link to the page where you can both
bi03o11a
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Control panel MA6
search for and download instructions and spare parts lists.
bi03o11a
-- 2 9 -Edition 051003
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE -- CUSTOMER SERVICES
A CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362-- 7080 / Fax: (800) 634 -- 7548 Hours: 8.00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B ENGINEERING SERVICE:
Telephone: (834) 664-- 4416 / Fax: (800) 446 -- 5693 Hours: 7.30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C TECHNICAL SERVICE:
Telephone: (800) ESAB-- 123 / Fax: (843) 664 -- 4452 Hours: 8.00 AM to 5:00 PM EST
Part Numbers Technical Applications Spec ifications Equipment Recommendations
D LITERATURE REQUESTS:
Telephone: (843) 664-- 5562 / Fax: (843) 664 -- 5548 Hours: 7.30 AM to 4:00 PM EST
E WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-- 4487 / Fax: (843) 664 -- 5557 Hours: 7.30 AM to 3:30 PM EST
Repair Estimates Repair Status
F WELDING EQUIPMENT TRAINING:
Telephone: (843) 664-- 4428 / Fax: (843) 679 -- 5864 Hours: 7.30 AM to 4:00 PM EST
Training School Information and Registrations
G WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-- 123 Hours: 7.30 AM to 4:00 PM EST
H TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933-- 7070 Hours: 7.30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB--123
Fax: (843) 664--4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers:
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products
PO BOX 100545, Florence SC 29501--0545
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