Reservado el derecho de cambiar las especificaciones sin previo aviso.
Specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Rights reserved to alter specifications without notice.
∆ιατηρεßται το δικαßωmα τροποποßησηj προδιαγραφþνΧωρßj προειδοποßηση.
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 MANU-FACTURER’S 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 p rotection.
SWarn bystanders of the risk.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
mmvarnea
-- 5 8 --
SAFETY
SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring
that anyone who works on or near the equipment observes all the relevant safety
precautions.
The following recommendations should be observed in addition to the standard regulations that apply to the work place.
All work must be carried out according to the specified instructions by personnel who
are thoroughly familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous situation which can result in injury to the operator and damage to the equipment.
1.Anyone who uses the automatic welding machine must be familiar with:
Sits operation
Sthe location of emergency stops
Sits function
Srelevant safety precautions
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
2.The operator must ensure that:
Sno unauthorized person is stationed within the working area of the machine
when it is started up.
Sthat no--one is in a hazardous position when the carriage or slide mechan-
isms are operated.
3.The work place must:
Sbe clear of mechanical components, tools, or other obstructions that could
prevent the operator from moving freely within the working area.
Sbe organized so that there is free access to the emergency stop.
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, b racelets, etc., which could
become trapped.
5.General precautions
Live electrical components are normally shielded from accidental contact.
SMake sure the return cable is connected securely.
SWork on high voltage components may only be carried out by a qualified
electrician.
SAppropriate fire extinguishing equipment must be clearly marked and close
at hand.
SLubrication and maintenance must not be carried out on the equipment dur-
ing its operation.
-- 5 9 --df00f1ea
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
The PEG1 control unit is used together with standard automatic welding machines
A2, A6 and column and boom units for adjusting and controlling welding parameters.
It is used for automated and mechanised submerged arc and MIG/MAG welding with
AC or DC.
The table below shows the order numbers for the various base models available and
which automatic welding machines they can be used with.
Order numberControl unit PEG1
333 001--884Control unit for A2S Mini Master (A2 SFD, A2 SGD)
333 001--885Control unit for A2S Mini Master and CaB control system
333 001--891Control unit for A2 Multitrac (A2 TFD, A2 TGD)
333 001--892Control unit for A2S Mini Master and CaB control system
333 001--893Control unit for A2 BFD/BGD
333 001--894Control unit for A2 Mini Master --ARISTO
333 001--895Control unit for A2 MULTITRAC --ARISTO
333 001--896Control unit for A2 MKR RCC
333 001--901Control unit for A6S Arc Master (A6 SFD) and A6S G Master (A6 SGD)
333 001--903Control unit for A6S Arc Master with CaB control system
333 001--905Control unit for A6S Arc Master --AC and A6S Tandem Master
333 001--906Control unit for A6S Arc Master RCC
333 001--910Control unit for A6 Mastertrac (A6 TFD, A6 TGD)
333 001--912Control unit for A6B Master (A6 BFD, A6 BGD)
333 001--913Control unit for A6S Arc Master with CaB control system
333 001--914Control unit for A6 MKR AC RCC
333 001--915Control unit for A6 MKR RCC
Technical data:
Control unit PEG1
Supply voltage from ESAB: automatic welding power sources, semi--automatic
welding power sources or external
Supply output530 VA
Output voltage rotor circuit (adjustable)0--42 V DC
Output voltage winding circuit (can be reconfigured)36/60 V DC
Output power (per rotor circuit) RMS160 VA
Output power (per rotor circuit) mean value155 W
Switching function for current switch7,5 A
Switching function for (external use) gas valve7,5 A
Switching function for (electrically isolated) remote control2A
Enclosure class
(Equipment that is marked IP 23 is designed for indoor and outdoor use).
42V, 50--60 Hz
IP 23
Max ambient temp.45_C
Weight5,5 kg
Width175 mm
Depth255 mm
Height210 mm
dga7d1ea
-- 6 0 --
TECHNICAL DESCRIPTION
The PEG1 control unit has the following controls on the front panel:
A01Potentiometer
for selecting welding current.
A02Switch
for manual choice of electrode
A03Potentiometer
for selecting welding voltage.
A04Switch
for increasing (+) or decreasing (--) welding voltage using the motor-driven
potentiometer in the welding power source.
Presetting of the welding voltage using switch A 07 is not possible in the
way described on page 62 in point 3 (”Presetting”).
A05Potentiometer
for selecting travel speed.
A06Switch
for selecting automatic start, touch start or manual start, and travel direction.
SPosition 1 (automatic start) -- travel starts once arc has been struck.
SPosition 2 (touch start) -- travel starts at the same time as wire feed.
SPosition 3 (manual start) -- travel starts immediately without wire feed.
dga7d03a
-- 6 1 --dga7d1ea
TECHNICAL DESCRIPTION
A07Switch
for presetting, see wiring instructions on page 74.
1.Position 1 -- ”Voltage feedback”
Normally used for MIG/MAG, submerged arc welding and aluminium
welding with thin wires.
At welding voltages below 26 V the wire feed motor runs at a
constant speed, which is selected using potentiometer A 03.
Suitable for aluminium welding.
At welding voltages above 26 V the wire feed speed -- and hence
welding current -- follows variations in the welding voltage, i.e. if the
welding voltage increases so does the welding current, and vice versa.
2.Position 2 -- ”Current feedback”
Normally used for MIG/MAG, submerged arc welding and for welding
thicker aluminium.
Wire feed speed is controlled b y the welding current.
The preset current is adjusted using potentiometer A 01 (see position
3 on page 62) and is independent of the wire diameter used.
3.Position 3 -- ”Presetting”
The welding current, voltage and travel speed are preset using the respective potentiometers.
SThe travel speed can always be preset. Travel speed is adjusted
using the ”Speed” potentiometer A 05.
SThe welding voltage can only be p reset when using a welding
power source equipped with a preselector device
(order no. 365 580--880). The welding voltage is selected using potentiometer V (A 03).
SThe welding current can only be preset when welding with the
switch in position 2.
d. Set A 07 to position 3.
e. Select the welding current using potentiometer A (A 01).
f.Set A 07 to position 2 once all preselections have been made.
A08Pushbutton (with yellow lamp)
used to start welding. The lamp indicates that welding current is available.
The button must be held down until the arc has been struck, i.e. until welding current is flowing.
A09Pushbutton (red)
used to stop welding
--Numerical display ”A”
displays average welding current in Amps, accuracy 1.5%, 3 figure display
(1000 indication + 3 figures, giving maximum 1999 A)
--Numerical display ”V”
displays true RMS welding voltage in Volts, accuracy 1.5%, 3 figures
--Numerical display ”Speed cm/min”
shows average travel speed in cm/min, 3 figures
dga7d1ea
-- 6 2 --
On the rear panel of the control unit are:
A16Socket (8 pin) ”Control Cable”
for connecting the control cable of the
welding power source 42 V.
A17Socket (2 pin) ”Gas/Flux Valve”
for connecting the gas valve or flux valve.
A18Socket (2 pin) ”Pilot Lamp”
for connecting a pilot lamp (6 V max 1 A).
A19Socket (5 pin) ”Electrode Motor”
for connecting wire feed motor.
SA + to motor rotor
SB 0 to motor rotor
SC + to motor winding
SD 0 to motor winding
TECHNICAL DESCRIPTION
aga7d002
SE spare
A20Socket (5 pin) ”Travel Motor”
for connecting travel motor.
SA + to motor rotor
SB 0 to motor rotor
SC + to motor winding
SD 0 to motor winding
SE spare
A21Cable
for connecting meter shunt
800 A /60 mV or 1500 A/6 mV.
A23Fuse (10 A rapid)
for supply voltage 42 V.
A24Potentiometer ”Burn--back Time”
for adjusting burn--back time,
range 0.1 -- 1.2 sec.
--Three plugged holes
to allow routing of cables (1, 2 and 3).
A25Socket
for connecting emergency stop and
remote control functions (column and boom).
d412094s
-- 6 3 --dga7d1ea
TECHNICAL DESCRIPTION
The control unit consists of the following units:
AConnection block
for connecting external supply voltage
--Display card (circuit card)
located inside front panel
D, ERegulator card (2 identical circuit cards)
for wire feed motor (D) and travel motor (E).
Sthe regulator can be configured for a variety of different motors
(see point 3 on page 66.)
Sthe regulator also provides 2 current overload protection functions.
The first is triggered immediately the motor current exceeds 20 A.
The second has a time delay and on delivery is set for 1.5 x the
motor current rating.
S1,S2+/-- 15 V and -- 5 V (1A slow).
S3+ 5 V and pilot lamp (3.15 A slow).
A2for primary supply to transformer (1 A slow).
A3 Single phase rectifier bridge
A4 Voltage regulator
A6 Connection block for supply voltage 42 V
NOTE! The supply voltage is marked on the control unit.
ISpace for additional card
prepared connections as shown in wiring diagram.
dga7d1ea
aga7d007
-- 6 4 --
INSTALLATION
INSTALLATION
IMPORTANT!
Read all relevant manuals and safety precautions carefully before starting to
unpack and install the equipment!
NOTE! Make sure installation is carried out by suitably trained personnel.
Check that the control unit is properly connected and set up for the intended
purpose.
If you are certain that this has been done then points 1 to 5 below can be omitted.
1.Dismantling of control unit PEG1, see fig on page 65.
SUndo the four screws that hold the front panel (1) in place.
SDisconnect the display card (2) from the meter card (3) by unplugging the 96 pin
plug (4).
SRelease the front panel (1) from the sequence card (5) by unplugging the ribbon
cable (6) and plug (7) on the supply unit (8).
SRemove the rear panel by removing all the circuit cards, followed by the four
screws that hold the panel in place.
SWhen refitting the front panel make sure the flexible section of the display card is
not trapped. Position the left side of the front panel first and then slide it into
place.
2.Supply voltage 42 V.
aga7d008
-- 6 5 --dga7i1ea
INSTALLATION
3.Choice of motors
Check that regulator cards D and E for the wire feed motor and travel motor
respectively are configured for the correct motor, as shown in the table and diagram on page 66.
Regulator card order no. 341 859--880 , --884, --886.
SCable x to pin 1 for A6 VEC 8000 r/min, 4000 r/min.
SCable x to pin 1 for Parvalux travel motor (MKR column and boom).
SCable x to pin 2 for A6 VEC 2000 r/min.
SCable x to pin 2 for A6 Mastertrac for travel.
SCable x to pin 3 for A6 VEC 1000 r/min.
SCable x to pin 4 for A2 Elektrolux for wire feed (sub--arc welding)
SCable x to pin 4 for A6 VEC, 4,000 r.p.m. for travel motion.
SCable x to pin 5 for A2 Elektrolux for travel.
SCable x to pin 5 for Dunker motor for Multitrac.
SCable x to pin 1 for A2 Elektrolux for wire feed (MIG/MAG welding)
SCable B to pin 7 for A6 VEC 4000, 2000, 1000 r/min for wire feed.
SCable B to pin 7 for Parvalux travel motor (MKR column and boom).
SCable B to pin 8 for all A2 motors.
SCable B to pin 8 for Dunker motor for Multitrac.
SCable B to pin 8 for A6 VEC for travel.
SCable B to pin 8 for Mastertrac for travel.
SCable B to pin 8 for A6 VEC 8000 r/min for wire feed.
SCable B to pin 8 for A6 VBE (DK) for travel.
SCable B to pin 8 for spare.
aga7d001
Refer also to the table for connection instructions on page 74.
Note: Figures given, e.g: A6 VEC 8000 r/min refer to the actual speed at 42 V
(not rotor version).
dga7i1ea
-- 6 6 --
INSTALLATION
When cable x is connected to the motor, RI compensation and current limiting functions are automatically adapted to the rating of the selected motor.
4.Configuring the sequence card
SOn the end of the sequence card (end nearest control panel) there is a 3 pin
edge connector which is configured usinga2pinsocketconnector.
Bottom pin connected to middle pin
-- Submerged arc and MIG/MAG welding with tube wire.
Top pin connected to middle pin
-- General MIG/MAG welding and submerged arc welding with TWIN arc.
-- 6 7 --dga7i1ea
INSTALLATION
5.External equipment (I/O option)
At the rear of the control unit are three plugged holes marked 1, 2 och 3 desig-
ned for the passage of cables (se diagram on page 63). When any of these
inputs are used the plug must be replaced with a grommet, Pr 15,2, to seal the
incoming cables.
It is possible to control the welding cycle remotely by connecting external equipment to the connection block in the control unit.
See the diagram on page 95.
For column and boom versions see the diagram on page 99.
SExternal emergency stop, see fig 11 on page 68.
SStop switch for travel movement (left or right), see fig 12 on page 68.
SExternal start switch for welding.
SExternal stop switch for welding.
SRemote control of manual travel movement, see fig 13 on page 68.
SElectrically isolated current relay function, see fig 14 on page 68.
Electrically isolated when welding current is flowing.
SMonitoring of welding voltage using meter cable connected from work piece
to connection block B 9. Welding voltage is normally monitored using shunt
input and socket A 16, pin G.
dga7i1ea
aga7d005
-- 6 8 --
OPERATION (Standard and column and boom)
OPERATION (Standard and column and boom)
1.Position the automatic welding head at the start of the weld joint.
2.Position the wire near the work piece using switch A 02.
3.Cut the wire at an angle.
4.Set switch A 07 to position 3 ”Presetting”.
5.Adjust the welding current using potentiometer A 01.
6.Adjust the travel speed using potentiometer A 05.
7.For welding power sources equipped with a preselector device:
SAdjust the welding current using potentiometer A 03.
For welding power sources not equipped with preselector device:
SAdjust the welding voltage using switch A 04.
8.Set switch A 07 to position 1 ”Voltage feedback” or position 2 ”Current feedback”.
9.Select the start mode and travel direction using switch A 06.
(position 1 automatic start, position 2 touch start, position 3 manual start).
10. Start welding by pressing pushbutton A 08 until welding current flows and indica-
tor lamp A 08 lights up.
11. Press pushbutton A 09 to stop welding.
12. If necessary adjust burn--back time u sing potentiometer A 22.
13. If switch A 07 is set to position 1 ”Voltage feedback” during welding, it will not be
possible to preset the welding current as described in point 5 (on page 69).
SAdjust the welding current using potentiometer A 01 after welding has
started.
dga7d03a
-- 6 9 --dga7o1ea
OPERATION (ARISTO 500)
OPERATION (ARISTO 500)
1.Position the welding head at the start by setting switch A06 to position 3.
2.Position the wire near the work piece using switch A 02.
3.Set switch A 07 to position 3 ”Presetting.
4.Adjust the travel speed using potentiometer A 05.
5.Choose a suitable welding program using the Aristo 500 control unit, e.g. MIG/
MAG, Pulse, Almg, Ar and 1,2 mm.
6.Adjust the wire feed speed using the Aristo 500 control unit.
7.Set switch A07 to the welding position.
8.Select the start mode and travel direction using switch A 06
(position 1 automatic start, position 2 touch start, position 3 manual start).
9.Start welding by pressing pushbutton A 08 until welding current flows and indica-
tor lamp A 08 lights up.
10. If necessary adjust the voltage using the increase/decrease buttons on the
Aristo control unit.
The current can also be adjusted using the wire feed speed increase/decrease
buttons.
11. Press pushbutton A 09 to stop welding.
12. If necessary adjust burn--back time u sing potentiometer A 22.
dg412094
dga7o1ea
-- 7 0 --
TROUBLESHOOTING
Equipment
SSee diagram 333 232 on page 95.
For column and boom versions see diagram 443 386 on page 99.
SUniversal meter
S2 types of extension cards for Euro card format:
1.Model DIN 41612 type C equipped for a--c
2.Model DIN 41612 type D equipped for a--c
Check
Sthat the control unit is correctly connected as shown in diagram
333 232,
see diagram 443 386 for column and boom versions
Sthat cables and connections, including those for external equipment,
are undamaged and correctly connected.
Sthat the controls are correctly set.
Sthat all supply voltages are correct.
TROUBLESHOOTING
Note
Sthat the 3 row connectors on the meter card are connected to the dis-
play card.
Sthat cables or circuit cards must not be disconnected while power is on.
Wait 20 seconds after switching off before doing anything.
Sthat the circuit card contact rows are marked as follows:
a = nearest circuit card
b = middle row
c = Furthest from circuit card
1 = the top 3(2) connections
32 = the bottom 3(2) connections
Sthat the system zero is connected to the shunt/electrode and does not
carry earth voltage.
POSSIBLE FAULTS
It is possible to reverse the connections!
1. SymptomFuse A 23 on back panel blows when power is switched on.
Cause 1.1Shorting in either motor regulator
ActionMeasure resistance between a18 -- a30 on both motor regulators.
If it is less than 10 ohm, replace the regulator.
Cause 1.2Shorting in a drive or brake transistor.
ActionMeasure the resistance between the transistor casing and each leg individ-
ually. The resistance should be higher than 10 ohm.
-- 7 1 --dga7f1ea
TROUBLESHOOTING
2. SymptomFluctuating or faulty meter readings.
Cause 2.1
Defective meter card.
ActionReplace meter card.
Cause 2.2+ 5 V supply voltage from supply unit is faulty.
ActionReplace supply unit.
Cause 2.3Sequence card defective
Action
Replace sequence card.
3. SymptomWire feed motor or travel motor do not start.
Cause 3.1Motor defective or wrongly connected.
ActionDisconnect the motor plug from the control unit and check the resistance
between pins A and B. It should be less than 50 ohm.
Cause 3.2Motor regulator defective.
ActionReplace the motor regulator.
Cause 3.3Sequence card defective.
ActionReplace the sequence card.
Cause 3.4Motor field windings defective or wrongly connected (only applies to motors
with field windings).
ActionCheck the resistance between pins C and D in the motor plug. It should be
between 100 -- 1000 ohm.
Cause 3.5No field voltage (only applies to motors with field windings).
ActionMeasure the voltage between pins C and D. If zero, replace S 4 on the
supply unit.
4. SymptomGas valve not working
Cause 4.1Gas valve defective. It should have the same control voltage as the weld-
ing power source.
ActionCheck the gas valve and its connections.
Cause 4.2Sequence card defective.
ActionReplace sequence card
5. SymptomPilot lamp does not light.
Cause 5.1Lamp defective.
ActionCheck the lamp and its connections.
Cause 5.2Supply unit defective.
ActionMeasure the voltage between pins A and B of socket A 18. It should be 6 V
AC. If there is no voltage check the supply unit and replace if defective.
Check fuse S 3 in the supply unit.
6. SymptomWelding power source main contactor not activated when A 08 is pressed.
Cause 6.1Sequence card defective.
Action
Press A 08. If the wire feed starts but the power source does not supply
any voltage, replace the sequence card.
dga7f1ea
-- 7 2 --
Cause 6.2Front panel or connections are defective.
Action
Check the circuit (as shown in fig
13 on page 68) on the rear panel, se-
quence card and front panel.
7. SymptomPresetting does not work satisfactorily.
Cause 7.1Meter card defective.
ActionReplace meter card.
Cause 7.2Sequence card defective.
ActionReplace sequence card.
8. SymptomDisplay too dark or too bright.
TROUBLESHOOTING
Cause 8.1
Action
Fuse S 3 in supply unit defective.
Replace fuse.
Cause 8.2Faulty + 5 V supply.
ActionReplace supply unit.
9. SymptomDifficulty starting.
Cause 9.1Slag on tip of wire.
ActionCut wire at an angle.
10. Symptom
Incorrect welding voltage (too high or too low).
Cause 10.1Meter card defective.
ActionReplace meter card.
Cause 10.2Faulty communication between meter card and receiver.
ActionCheck circuit as shown in figure on page 73.
Cause 10.3Receiver card defective.
ActionReplace receiver card.
aga7d004
-- 7 3 --dga7f1ea
8,0 -- 12,7mm
Carbon electrode
Arc air gouging
X--1
Position 2
Connect bottom
pintomiddlepin
B--7
Strip
0,5x30--100mm
Submerged arc
Aluminium
Gas metal arc
1,2 -- 1,6mm
Steel -- stainless
Gas metal arc
1,2 -- 4mm
Hollow wire
Gas metal arc
welding
welding
welding
welding
Position 1
Position1or2Position1or2Position 1
Connect bottom
pin to middle
pin
Connect top pin
to middle pin
Connect top pin to
middle pin
Connect bottom
pintomiddlepin
X--1
X--1
X--1
X--1
X--1
X--1
B--7
B--8
B--8
B--7
B--8
B--7
74:174:174:174:174:1156:1156:1
X--6
X--6
X--6
X--6
B--8
B--8
B--8
B--8
CONNECTION INSTRUCTIONS FOR PEG1, A6 VEC AND A2
Twin wire
Single wire
Electrode
2x1,2 -- 3,0mm
Submerged arc
2,5 -- 6mm
Submerged arc
welding
welding
Welding method
DirectDirectDirectDirectDirectDirect
Alter-
Current typeDirect
nating
Switch
Position 1
Position1or2
(feed--back)
Connect bottom
pintomiddlepin
Connect bottom
pintomiddlepin
2--pin edge socket
74
X--1
B--7
156:1
(74:1)
X--1
B--7
Regulator card
connection
(A6 VEC)
Ratio (A6 VEC)156:1
Motor rotor r.p.m.
400040004000800040008000800040004000
(A6 VEC)
X--4
B--8
X--4
B--8
Regulator card
connection
(A2)
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