The manual describes use of the MA25 Pulse control panel.
For general information about operation, see the instruction manual for the power source or
the wire feed unit respectively.
When mains power is supplied, the unit runs a self diagnosis of the
LEDs and the display. The program version and panel version,
"Steel", "Alu", "SteelNA" or "AluNA", are presented. (In this example
the program version is 0.17A and the panel version is "Steel".)
(Long texts are automatically scrolled in the display.)
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com
General safety regulations for handling the equipment can be found in the "SAFETY
CHAPTER" of the power source instruction manual. General information about the
operation can be found in the "OPERATION" chapter of the power source instruction
manual. Read both chapters thoroughly before you start using the equipment!
2.1How to navigate
1.Buttons for weld data memory9.Toggling between 2-stroke and 4-stroke
2.Toggling between Crater filling time,
Inductance, Gas post flow time and
Synergy selection
3.Selection of Wire inching11.Selection of Hot start
4.Selection of Gas purging12.Setting voltage/QSet™
5.Display13.Indication of which variables and units
6.Toggling between welding method
MIG/MAG and MMA
7.Toggling between Synergy, QSet™ and
Manual setting
8.Toggling between Creep start and
Crater filling
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10.Toggling between Setting from panel,
Program change with welding torch
trigger switch and Remote control unit
are shown in the display
14.Toggling between amperage estimate
setting and Wire feed speed (amperage
estimate is only possible to select in
Synergy mode.)
15.Setting of the parameter selected by
button 2
16.Indication of activated VRD (Voltage
Reducing Device)
•Four available versions:
○ MA25 Pulse steel welding with 54 synergic lines
○ MA25 Pulse aluminium welding with 30 synergic lines
○ MA25 Pulse steel welding with 55 synergic lines (NA version)
○ MA25 Pulse aluminium welding with 29 synergic lines (NA version)
•Possibility to switch between wire feed speed and amperage estimate setting during
synergic welding
•QSet™ Parameter automation
•2/4 stroke torch switch activation
•Gas test and wire inching
•Gas pre- and post-flow settings
•Creep start and crater filling
•Continuous inductance setting
•3 memory slots, called up from the torch button or control panel
•MMA: ArcPlus™ II regulation, Hot Start and Arc Force can be set
3.2Welding data memory
Three different welding data programs can be stored in the control panel memory.
Hold selection button 1, 2 or 3 pressed in for 5 seconds to store welding data in the
memory. The welding data is stored when the green indicator lamp starts to flash.
To switch between the different welding data memories press button 1, 2 or 3.
The welding data memory has a back-up battery so that the settings remain even if
the equipment has been switched off.
3.3MIG/MAG Welding
MIG/MAG welding
MIG/MAG welding melts a continuously supplied filler wire, with the weld pool
being protected by shielding gas.
Wire feed speed
This sets the required feed speed of the filler wire in percent or metre/minute.
Each combination of wire type, wire diameter and gas mixture requires a unique
relationship between wire feed speed and voltage (arc length) to obtain a stable,
functioning arc. The voltage (arc length) automatically "conforms" to the selected
pre-programmed synergic line , which makes it much easier to find the correct
welding parameters quickly. The link between wire feed speed and other
parameters is known as the synergic line.
In synergy mode it is possible to display either the set wire feed speed or
estimate amperage, for more details, see "Displaying Amperage Estimate".
For detailed information about synergic lines included in MA25 Pulse, see
section "WIRE AND GAS DIMENSIONS".
It is also possible to order other synergy lines, but these must be installed by an
authorised ESAB service engineer.
When activating synergy, also remember to select the correct synergic line using
the setting knob.
The correct synergic line numbers are located on the sticker inside the wire
feeder.
When welding using the MA25 Pulse control panel in synergic mode it is
possible to use either wire feed speed or amperage estimate as setting. The
option for the welder to display amperage estimate exists to help out as a
reference if the welder doesn’t know what wire feed speed to set.
Use the setting knob to adjust amperage estimate. The set wire feed speed will
change accordingly when changing amperage estimate. It is possible to toggle
back and forth between displaying the wire feed speed or amperage estimate on
the display by pushing the button ~A/WFS.
When welding, the wire feed speed will be constant ensuring a predictable result
and an evenly filled weld joint. The weld results will be exactly the same no
matter if the welder uses wire feed speed or estimated amperage as way of
setting.
A constant wire feed speed during welding also means that there will be some
deviation between amperage estimate and the actual measured amperage,
depending on joint type and the stick out the welder uses (contact tip to work
piece distance). This is no different from when simply setting wire feed speed or
when adjusting the amperage estimate. If the deviation is large, adjust stick out
for optimal weld results, see sections below.
During welding the actual measured amperage is presented on the display. If
thebutton (item 14 in the illustration in the "PANEL OVERVIEW" chapter)
is pressed during welding, the amperage estimate appears on the display and
is visible for two seconds, after which the measured amperage appears again.
The measured amperage remains on the display until the setting is changed.
If the measured amperage for some reason deviates more than ±10 % from the
amperage estimate, the Current LED and the measured amperage presented
on the display starts flashing. A very long or a very short stick-out length of the
welding electrode may result in a large deviation between the amperage
estimate and the measured amperage. This means that the welder might get
better weld results by adjusting to a more suitable stick out. If the measured
amperage is significantly lower than the amperage estimate it may be better to
use a shorter stick out. If the measured amperage is significantly higher than the
amperage estimate it may be better to use a longer stick out. Note that different
joint types will also affect the actual measured amperage. It is possible to adjust
the "allowed” difference between the measured amperage and the amperage
estimate. The default value is ±10 %. See the "Hidden MIG/MAG functions"
section.
QSet™, is used to facilitate setting welding parameters.
How to use QSet™:
1.Set Wire feed speed. QSet™ will dynamically adjust voltage to get the
optimal welding results.
2.When changing material or thickness: make the first weld (6 seconds) with
QSet™ on a test piece to obtain all the correct data, before welding the
actual work piece.
QSet™ value fine tuning:
•Turning the knob clockwise increases (+) the arc length.
•Turning the knob anti-clockwise reduces (-) the arc length.
SHORT ARC
When first starting welding with a wire type / gas type QSet™ automatically sets
all the necessary welding parameters. After that QSet™ stores all the data to
produce a good weld. The voltage then automatically conforms to changes in the
wire feed speed.
SPRAY ARC
When approaching the spray arc area the value for QSet™ must be increased.
Disengage the QSet™ function when welding with pure spray arc. All settings
are inherited from QSet™, with the exception of the voltage which must be set.
Manual
Manual operation. The operator must set appropriate values for the wire feed
and voltage.
Creep start
Creep starting feeds out the wire at 1.5 m/min until it makes electrical contact
with the workpiece.
Crater filling
Crater filling helps to avoid pores, thermal cracking and crater formation in the
weld when welding stops.
Crater filling time
When activating crater filling also select crater filling time using the setting knob.
This function cannot be used with QSet™.
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2-stroke
With 2-stroke, gas pre-flow starts when the welding torch trigger switch is
pressed. The welding process then starts. Releasing the trigger switch stops
welding entirely and starts gas post-flow.
4-stroke
With 4 stroke, the gas pre-flow starts when the welding torch trigger switch is
pressed in and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, the wire feed then stops and when
the switch is released the gas post-flow starts.
This function permits changing between different welding data memories by a
press on the trigger of the welding torch.
To change without ongoing welding press quickly. If the trigger is pressed down
for too long, the program interprets this as a welding start.
Changing welding data during welding with 2-stroke
During ongoing welding the welding torch's trigger is pressed down, to change
welding data memory, release the trigger and press it quickly.
Changing welding data during welding with 4-stroke
During ongoing welding with 4-stroke the welding torch's trigger is released, to
change welding data memory, press the trigger and release it quickly.
When activating welding data 1 - 3, select welding data memory 1, 2 or 3.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on
the equipment before activation. When the remote control unit is activated the
panel is inactive.
With the remote control unit function activated one can change between different
welding data memories using a welding torch with program selector (RS3).
Voltage Reducing Device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35 V
when welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V
limit, this is indicated by an error message (16) appearing in the display and
welding cannot be started whilst the error message is displayed.
Gas purging
Gas purging is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas purging occurs for as long as the
button is pressed and occurs without voltage or wire feed starting.
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Wire inching
Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the button is pressed.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower
inductance produces a harsher sound but a stable, concentrated arc.
This controls the time during which shielding gas flows after the arc is
extinguished.
Hot start
Hot start increases the weld current for an adjustable time at the start of welding,
thus reducing the risk of poor fusion at the beginning of the joint.
3.3.1Hidden MIG/MAG functions
There are hidden functions in the control panel.
To access these hidden functions hold the selection button pressed for 5
seconds. The display will show a letter and a value. The knob for wire feed is
used to change the value of the selected function.
Function
Function
letter
AGas pre-flow time
CUnit of measurement
IBurnback time (only available when SCT=off)
tMemory positions for trigger data
hHot start time
oSCT on/off
SStart parameter R (only visible in Short Arc and when Synergy is not
selected)
dAmperage estimate settings tolerance
To leave the function hold the selection button pressed for 5 seconds.
AGas pre-flow
This controls the time during which shielding gas flows before the arc is struck.
CUnit of measurement
0 = inch/min, 1 = mm/min, default value = 1
IBurnback time
Burnback time is off by default, because of Short Circuit Termination (SCT).
The burnback time setting is only available when SCT is OFF. This will be the
case if SCT setting=1, or SCT setting=0 and the chosen synergic line has
SCT set to OFF.
Burnback time is a delay between the time when the wire starts to brake until the
time when the power source switches off the welding 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.
tMemory positions for trigger data
This function gives the possibility to select whether to use trigger data between 2
or 3 programs.
hHot start time
The hot start time can be set from 0.0 to 9.9 seconds, in steps of 0.1 seconds.
oSCT (Short Circuit Termination)
SCT is a function that gives small repeated short circuits at the end of the
welding, until the wire feeding has totally stopped and the contact with the
workpiece has been broken.
The following settings exist:
0 =The value (ON/OFF) is determined by the synergy line (default option)
1 =SCT is OFF
2 =SCT is ON
SStart parameter R
Start parameter R enables finetuning of the electric arc during the start moment
when welding. The parameter can be set from 8.0 to 60.0, in steps of 0.25. This
function is only visible och adjustable when synergy is not active (which means
that the chosen method is Short Arc).
dAmperage estimate settings tolerance
This parameter constitutes the maximum allowed relative difference between the
amperage estimate value and the measured amperage. The allowed difference
can be set from 5 to 50percent, in steps of 5percent. If the allowed difference is
exceeded during welding, the Current LED and the measured amperage
presented in the display flashes.
3.4MMA Welding
MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking
the arc melts the electrode, and its coating forms protective slag.
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on
the equipment before activation. When the remote control unit is activated the
panel is inactive.
With the remote control unit function activeted one can change between different
welding data memories using a welding torch with program selector (RS3).
Hot start
Hot start increases the weld current for an adjustable time at the start of welding,
thus reducing the risk of poor fusion at the beginning of the joint.
Voltage Reducing Device (VRD)
The VRD function ensures that the open-circuit voltage does not exceed 35 V
when welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V
limit, this is indicated by an error message (16) appearing in the display and
welding cannot be started whilst the error message is displayed.
To activate/deactivate VRD contact a service representative.
3.4.1Hidden MMA functions
There are hidden functions in the control panel.
To access these hidden functions hold the selection button pressed for 5
seconds. The display will show a letter and a value. The knob for wire feed is
used to change the value of the selected function.
Function
letter
CArc force
dDrop welding
FWelding regulator type (Welding regulator ArcPlus™)
HHot start amplitude
IMin current remote
hHot start time
To leave the function hold the selection button pressed for 5 seconds.
Function
CArc force
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The arc force is important in determining how the current changes in response to
a change in the arc length. A lower value gives a calmer arc with less spatter.
Drop welding can be used when welding with stainless electrodes. The function
involves alternately striking and extinguishing the arc in order to achieve better
control of the supply of heat. The electrode needs only to be raised slightly to
extinguish the arc.
F
Welding regulator ArcPlus™
Welding regulator ArcPlus™ is a new type of control that produces a more
intense, more concentrated and calmer arc. It recovers more quickly after a
spot short-circuit, which reduces the risk of the electrode getting stuck to the
work-piece.
•ArcPlus™ (0) is recommended with basic type of electrode
•ArcPlus™ ll (1) is recommended with rutile and cellulosic type of electrode
HHot start amplitude
When Hot start is activated, the Hot start amplitude parameter can be used to
set the preferred level of the weld current during the hot start time, in percentage
of the set weld current. If for instance the set weld current is 100A and the Hot
start amplitude is set to 10%, the weld current during the hot start time will be
110A.
IMin current remote
Used to set the minimum current for the remote control.
If the max current is 100 A and the min current is to be 50 A, set the hidden
function min current to 50 %.
If the max current is 100 A and the min current is to be 90 A, set the min current
to 90 %.
hHot start time
The hot start time can be set from 0.0 to 9.9 seconds, in steps of 0.1 seconds.
Fault codes are used to indicate that a fault has occurred in the
equipment. They are given in the lower part of the display with an E
followed by a fault code number.
A unit number is displayed to indicate which unit has generated the
fault.
Fault code numbers and unit numbers are shown alternately.
The example presented in the two graphics to the left, indicates that
the control panel (U0) has lost contact with the power source (E18).
If several faults have been detected only the code for the last
occurring fault is displayed. Press any function button or turn any
knob to remove the fault indication from the display.
NOTE!
If the remote control is activated, deactivate the remote control by the aid of the
selection button under the remote control symbol to remove the fault indication.
5.1List of fault codes
U 0 = welding data unitU 2 = power sourceU 5 = multivoltage
U 1 = cooling unitU 4 = remote control unit
5.2Fault code descriptions
The fault codes that the users can correct themselves are given below. If a different code
appears, call a service technician.
Fault
code
E 6High temperature
Description
The thermal overload cut-out has tripped.
The current welding process is stopped and cannot be restarted until the
temperature has fallen.
Action: Check that the cooling air inlets or outlets are not blocked or clogged with
dirt.
Check the duty cycle being used, to make sure that the equipment is not being
overloaded.
E 12Communication error (warning)
The load on the system's CAN-bus is temporarily too high.
The power unit / wire feed unit has lost contact with the control panel.
Action: Check the equipment and ensure that only one wire feed unit or remote
control unit is installed. If the fault persists, send for a service technician.
E 44Control panel not configured for the connected power source
The currently connected power source is of another type than the one last
connected to the panel.
Action: Connect the control panel to a power source of the same type as the one
last connected or configure the control panel for the appropriate type of power
source.
E 45Corresponding dip/spray line missing
The MA25 Pulse panel has detected that the dip/spray line corresponding to the
chosen synergy line for pulse welding, is not available. Applicable only when using
synergy group 99 with user defined synergy lines.
Action: Download the missing synergy line using ESAT and restart.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back
cover of this document. When ordering, please state product type, serial number, designation
and spare part number in accordance with the spare parts list. This facilitates dispatch and
ensures correct delivery.