ESAB PEH Instruction manual

A2-A6
Process Controller

PEH

112101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions

0443 745 201 2005--04--19

Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções

ПдзгЯет чсЮуещт

Instrukcja obs³ugi

Kezelési utasítások

Valid for machine no 220--xxx--xxxx
Valid for program version PEH4.0, PEH4.01, PEH4.2
and PEH4.3

SVENSKA 5..............................................

DANSK 26................................................

NORSK 47................................................

SUOMI 68................................................

ENGLISH 89..............................................

DEUTSCH 110.............................................

FRANÇAIS 132.............................................

NEDERLANDS 154.........................................

ESPAÑOL 175..............................................

ITALIANO 197..............................................

PORTUGUÊS 219..........................................

ЕЛЛЗНЙКБ 241.............................................

POLSKI 263.................................................

MAGYAR 284................................................

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.

ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.

Zastrzegamy sobie prawo do wprowadzenia zmian.

Fenntartjuk az elözetes bejelentés nélküli változtatás jogát.

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FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Esab Welding Equipment AB, 695 81 Laxå, Sweden, försäkrar under eget ansvar att
manöverlåda A2--A6 Process Controller från serienummer 220 är i överensstämmel­se med standard EN 60974--1 enligt villkoren i direktiv (73/23/EEG) med tillägg
(93/68/EEG).

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OVERENSSTEMMELSEERKLÆRING

Esab Welding Equipment AB, 695 81 Laxå, Sweden garanterer under eget ansvar,
at styreboks A2--A6 Process Controller fra serienummer 220 er i overensstemmelse
med standard EN 60974--1 ifølge betingelserne i direktiv (7 3/23/EEC) med tillægg
(93/68/EEC).

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FORSIKRING OM OVERENSSTEMMELSE

Esab Welding Equipment AB, 695 81 Laxå, Sweden, forsikrer på eget ansvar at bry­terskap A2--A6 Process Controller fra serienummer 220 er i samsvar med standard
EN 60974--1 i overensstemmelse med bestemmelsene i direktiv (73/23/EØF) med
tillegg (93/68/EØF).

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VAATIMUSTENMUKAISUUSVAKUUTUS

Esab Welding Equipment AB, 695 81 Laxå, Sweden, vakuuttaa omalla vastuullaan,
että ohjausyksikkö A2--A6 Process Controller sarjanumerosta 220 täyttää standardin
EN 60974--1 vaatimukset direktiivin (73/23/EEC) ja sen lisäyksen (93/68/EEC) mu­kaisesti.

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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 220 complies with
standard EN 60974--1, in accordance with the requirements of directive (73/23/EEA)
and addendum (93/68/EEA).

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KONFORMITÄTSERKLÄRUNG

Esab Welding Equipment AB, 695 81 Laxå, Sweden, versichert hiermit auf eigene
Verantwortung, daß die Bedieneinheit A2--A6 Process Controller ab Serien-- Nr 220
mit der Norm EN 60974--1 gemäß den Bedingungen der Richtlinien (73/23/EWG) mit
der Ergänzung (93/68/EWG) in Übereinstimmung steht.

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CERTIFICAT DE CONFORMITÉ

Esab Welding Equipment AB, 695 81 Laxå Sweden, certifie sous sa propre respon­sabilité que le boîtier de com mande A2-- A6 Process Controller à partir du numéro de
serie 220 répond aux normes de qualité EN 60974--1 conformément aux directives
(73/23/EEC) avec annexe (93/68/EEC).

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OVEREENKOMSTIGHEIDSVERKLARING

Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart op eigen verantwoor ­delijkheid dat bedieningsbox A2--A6 Process Controller van serienummer 220 over­eenkomt met norm EN 60974--1 volgens richtlijn (73/23/EEG) van de Raad met toe­voeging (93/68/EEG).

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DECLARACIÓN DE CONFORMIDAD

Esab Welding Equipment AB, 695 81 Laxå, Sweden, declara, asumiendo toda res ­ponsabilidad, que la caja de mandos A2--A6 Process Controller desde el número de
serie 220 está fabricada de conformidad con la normativa EN 60974--1 según los
requisitos de la directiva (73/23/EEC) con el suplemento (93/68/EEC).

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3

DICHIARAZIONE DI CONFORMITA

Esab Welding Equipment AB, 695 81 Laxå, Sweden, dichiara sotto la propria re­sponsabilità che la centralina di contro llo A2--A6 Process Controller dal numero di
serie 220 è conforme alla norma EN 60974--1 ai sensi dei requisiti previsti dalla di­rettiva (73/23/CEE) e successive integrazioni nella direttiva (93/68/CEE).

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DECLARAÇÃO DE CONFORMIDADE

Esab Welding Equipment AB, 695 81 Laxå, Sweden, certifica, sob a sua própria res­ponsabilidade que, a caixa de controlo A2--A6 Process Controller desde número de
série 220 está em conformidade com a norma EN 60974--1, segundo os requisitos
constantes na directiva (73/23/EEC) e com o suplemento (93/68/EEC).

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ВЕВБЙЩУЗ УШМЦЩНЙБУ

Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, вевбйюней ме дйкЮ фзт ехиэнз
oфй з рзгЮ кйвюфйп чейсйумпэ A2--A6 Process Controller брь фпн бсйимь уейсЬт
220 всЯукефбй уе ухмцщнЯб ме фп уфбнфбсф ЕН 60974-1 уэмцщнб ме фпх ьспхт
фзт пдзгЯбт (73/23/ЕЕC) кбй фзн рспуиЮкз (93/68/ЕЕC).

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CERTYFIKAT ZGODNO¦CI

Firma Esab Welding Equipment AB, 695 81 Laxå, Szwecja, gwarantuje pod rygorem
odpowiedzialno¶ci, ¿e A2--A6 Process Controller od numeru seryjnego 220 spe³nia
wymagania normy EN 60974-1 wed³ug dyrektywy (73/23/EEA) z poprawkami
(93/68/EEA).

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MEGFELELÕSÉGI NYILATKOZAT

Esab Welding Equipment AB, 69581 Laxaa, Svédország, minden korlátozás nélkül
garantálja, hogy az A2--A6 Process Controller folyamatvezérlõ berendezés a 220 gyári
számtól kezdve megfelel az EN 60974-1 szabványnak, a 73/23/EEC irányelv és a
93/68/EEC kiegészítés követelményei szerint.

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Göteborg 2002--04--29

Greger Jacobson
Senior Vice President
ESAB AB
SE-- 402 77 Göteborg
Sweden Tel: [phone] Fax: [phone]

4

ENGLISH

1SAFETY 90...........................................................

2 INTRODUCTION 92...................................................

2.1 General 92..................................................................

2.2 Welding power sources 92.....................................................

2.3 Technical data 92............................................................

3 INSTALLATION 93....................................................

3.1 General 93..................................................................

3.2 Connection of the welding power source 93......................................

3.3 Connection of the welding head 93.............................................

4 OPERATIONAL DESCRIPTION 94......................................

4.1 General 94..................................................................

4.2 Control panel 94.............................................................

5 MANUAL OPERATION 95..............................................

5.1 Travel and wire feed 95.......................................................

5.2 Controlling valves 95..........................................................

6 MENUS 96...........................................................

6.1 Menu overview 96............................................................

7MAINMENU 97.......................................................

7.1 General 97..................................................................

7.2 Entering welding parameters 99................................................

7.3 Adjusting parameter values (during welding) 100..................................

7.4 Choosing a new set of parameters during welding 101..............................

7.5 Selecting the display language 102..............................................

8 WELDING SETUP 103..................................................

8.1 General 103..................................................................

8.2 Changing settings 103.........................................................

8.3 Available settings 104..........................................................

8.4 Definitions 105................................................................

8.5 Preset indicators 107..........................................................

9 ERROR LIST 108.......................................................

9.1 Error codes 108...............................................................

10 MAINTENANCE 109....................................................

10.1 General 109..................................................................

11 ORDERING SPARE PARTS 109..........................................

DIAGRAM 306............................................................

ACCESSORIES 308.......................................................

SPARE PARTS LIST 309...................................................

TOCe

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GB

1SAFETY

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 workplace.

All work must be carried out by trained personnel well--acquainted 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:

S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding

2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose
S be free from draughts

4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication 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

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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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2 INTRODUCTION

2.1 General

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 controller 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.

2.2 Welding power sources

The welding power sources are specially adapted to work with the A2--A6 Process
Controller. The 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. The 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.

2.3 Technical data

A2--A6 Process Controller (PEH)

Nominal voltage from power source: 42V AC 50/60 Hz
Nominal load: Max. 900 VA
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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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Connection of the welding power source

S Connect control cable (1) from the welding power source to connector XS1.

3.3 Connection of the welding head

S Arc voltage to terminal X2.1

As to all other connections, con tact ESAB.

Connection of the
welding head

Connection of welding
power source

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4 OPERATIONAL DESCRIPTION

4.1 General

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 r eady for manual operation as soon as the m ains 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.

4.2 Control panel

1. Emergency stop

2. The direction of travel is as shown
by the triangular symbol on the
welding equipment.

3. The direction of travel is as shown
by the square symbol on the welding
equipment.

4. Advance wire

5. Retract 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 ast, 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

5 MANUAL OPERATION

5.1 Travel and wire feed

Travel and wire feed commands can be given when not welding, as follows:

Switch on welding power source

S The direction of travel is as shown by the square symbol on the welding

equipment.
Normal speed .

S The direction of travel is as shown by the triangular symbol on the welding

equipment.
Normal speed

To stop travel described above, press the same key again.

S Retract wire. Normal speed

Wire continues to retract until you release the key.

S Advance wire. Normal speed .

Wire continues to advance until you release the key.

S After switching on, you can select maximum speed by pressing the fast key

.

The LED in the key lights up.

S To return to normal speed press the fast key again .
To stop immediately, press , or even at max. speed.
Normal speed and max. speed can be adjusted under “PRESET SYSTEM MENU”.

.

.

5.2 Controlling valves

To operate a valve you must be in the “MAIN MENU”.

S Open the valve for flux or gas by pressing .

S Close an open valve by pressing the same key

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.

Valve
(Open/ Closed)

GB

6 MENUS

6.1 Menu overview

MAIN MENU

Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU

WELDING SETUP

The A2--A6 Process Controller ( PEH) software
is divided into several menus. The program
structure is described in the overview below.

MAIN MENU

S SET S Heat input per cm S Welding current
S Wire feed speed S Arc voltage S Travel speed
S Preset indicators
S Selecting the display language

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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7MAINMENU

7.1 General

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.

S Switch on the power source .

The main menu will appear as follows:

I

Indicates that parameter set 1 of
10 available has been selected
(can be hidden).

cates theheat
values of welding current, arc voltage and travel speed (can be
hidden).

at w

esult

ose

Indicates the
type of start

Chosen arc voltage in volts.

Example of display if constant current
(CA) has been chosen.

Example of display if welding with
constant wire feed speed (CW) is
chosen.

Example of display during welding at
constant wire feed speed (CW).

Chosen travel speed in
centimetres per minute.

Chosen welding current in amperes.

Chosen wire feed speed.

Result
welding start.

gweld

Travel direction

Indicates if the valve out­put is open or closed.

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e

For the selection of (CA) or (CW), see the menu WELDING SETUP on page

103.

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Example of display in the event of a fault.

S Error code appears in bottom left section

of display.

S Error message is cancelled by pressing
S Max. 20 messages saved in chronological

order.

S Start welding by pressing . The LED in the key lights up.
S Stop welding by pressing

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7.2 Entering 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.

S Press + to mark the “parameter set field “.

S Type in the desired SET number and press .

S Select the field for welding current or wire feed speed by pressing .
S Type in the desired welding current or wire feed speed. Max. 4 numbers, press

.

S Select the field for arc voltage by pressing

S Type in the desired arc voltage, max. 3 numbers, press .

S Select the field for travel speed by pressing

S Type 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).

.

.

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7.3 Adjusting parameter values (during welding)

Once welding has started the welding parameters can be fine--tuned using the
arrowed numerical keys (over--ride function).

Welding current or wire feed speed

Arc voltage

Travel speed

Save the values as follows:

S Stop welding with .

S Save the changed values with .

S To revert to the original values, press

Increase Decrease

+

.

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7.4 Choosing 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.

S Press

The field “SET 1” is marked and parameter set 1 is active

S Press .

The field “SET 6” flashes.

S Press .

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.

S Mark the field “SET 1 “ by pressing

S Press .

The field “SET 6” flashes.

S The 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 current welding cycle.

+

.

.

+

.

S Press .

The field “SET 6” is marked and parameter set 6 is active.

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7.5 Selecting the display language

The selection is made in the “ MAIN MENU”

Display language

S Press .
S The current language is shown in the

top right corner of the display.

S Scroll forward to the desired language

with .

S Return with .

The following languages can be selected:

Svenska=Swedish / Dansk=Danish / Norsk=Norwegian / Soumi=Finnish /
English=English / Deutsch=German / Francaise=French / Nederlands=Dutch /
Espanol=Spanish / Italiano=Italian / Portugues=Portuguese / Eesti=Estonian /
Cesky=Czechoslovakian.

N.B. The China version is only available in English and Chinese.

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8 WELDING SETUP

8.1 General

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.

S Switch from the MAIN MENU to WELDING SETUP.

Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU

8.2 Changing settings

Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU

General

Scroll between the alternatives in the left column with or

When all settings have been done return to the “MAIN MENU” with

+

.

+

For available settings see on page 104.

To change the settings for Direction, Start and Regulation:

S Mark menu Direction, Start or Regulation and press

S Scroll forward to the chosen option with

S Return with

+

.

.

.

To change the settings for STOP WELDING and WIRE DATA:

S Mark menu STOP WELDING or WIRE DATA and press

.

S Select the alternative that is to be changed with .

S Press .

S Scroll forward to the chosen option with or type in your own values.

.

S Return with

+

Explanations of terms:

When is indicated in combination with another key you should press first and
hold it down while pressing the second key.

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8.3 Available settings

Press Press

Direction

Start

STOP WELDING

WIRE DATA

Regulation CA, CW

PRESET SYSTEM MENU

Y , J

ScratchDirect

Crater fill (ms) 10--3000
Burnback time (ms) 10--3000
Wire type Solid wire, Flux cored, Strip, Gauging
Wire diameter

if “Solid wire” is chosen

if “Flux cored” is chosen

if “Strip” is chosen
if “Gauging” is chosen

Wire material Fe, Al, SS
Number of wires 1, 2

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
30x0.5 60x0.5 100x0.5

8.0 9.5 13.0

N.B! The menu “ PRESET SYSTEM MENU” is not accessible to the user

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8.4 Definitions

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 Direct start means that travel starts when the arc ignites.

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:

S the wire sticking to the work piece
S the wire sticking to the nozzle

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
Wire type

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.

S solid wire
S cored wire
S strip
S gauging

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:

Solid wi­re:

0.8 mm 0.8 mm 30x0.5 mm 8.0 mm 0.030 0.030 1.25 x 0.02 1/2

1.0 mm 1.0 mm 60x0.5 mm 9.5 mm 0.040 0.040 2.5 x 0.02 5/6

1.2 mm 1.2 mm 100x0.5 mm 13.0 mm 0.047 0.047 4 x 0.02 3/8

1.6 mm 1.6 mm 1/16 1/16

2.0 mm 2.0 mm 5/64 5/64

2.4 mm 2.4 mm 3/32 3/32

3.0 mm 3.0 mm 7/64 7/64

3.2 mm 3.2 mm 1/8 1/8

4.0 mm 4.0 mm 5/32 5/32

5.0 mm 3/16

6.0 mm 1/4

Cored
wire:

Strip: Gauging: Solid: Cored

When inch units are used the following alterna­tives are available

Strip: Gauging:

wire:

Wire composition

When welding with different filler materials the start and stop meth od 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.

S Fe Steel filler wire
S Al Aluminium filler wire
S SS Stainless steel filler wire

Number of 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.

S CA, 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.

S CW, 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 107).

8.5 Preset 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

Start Direct

Scratch

Direction TRIANGLE

SQUARE

Wire diameter:

Solid wire

Flux cored

Strip

gauging

OUTPUT

Open/Closed

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
30x0.5 60x0.5 100x0.5

8.0 9.5 13.0

Valve

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9 ERROR LIST

9.1 Error codes

Analogue board

203.01 Communication error with Analogue card Stop Check cables and connections

I/O board

301.01 Communication error with Digital I/O Stop Check cables and connections

Wire feed motor (Mo tor 1)

201.2 Current too high Stop Check wire feed

201.3 Overheating (Motor 1) Stop Wait until temperature has fallen
201:5 Communication error ** Stop Check the cabling.

Travel motor (Motor 2)

202.2 Current too high Stop Check travel motor / gearbox

202.3 Overheating (Motor 2) Stop Wait until temperature has fallen
202:5 Communication error ** Stop Check the cabling.

Drive unit (PEH4.2)

204.2 Short--circuit, drive unit ** Stop Replace the PC board

204.3 Overheating, drive unit ** Stop Wait for a while and then check the heat

dissipating element

Welding power source (T1)

111.01 Communication error Stop Check cables and connections

111.53 Unsuccessful start Stop Check stick--out and welding parameters

111.54 Current limit/ Arc extinguished *** Stop Welding short--circuited,

Cure short--circuit / Check wire feed

111.54 Current limit ** Stop Welding short--circuited,
Cure short--circuit

111.55 Thermostat / overheating Stop Wait until temperature has fallen

111.57 Arc extinguished ** Stop Check wire feed

Inputs / outputs

Display

(Flashing)

No cooling water
(inlet K22 open) *

Stop Check if the gas is flowing or if the limit

switch is open.

(Flashing)

No gas flow
(inlet K23 open) *

Stop Check gas pressure or if the limit switch

is open.

* Inputs are activated by using settings in menu “PRESET SYSTEM MENU”.
** Only valid for control box with program version PEH4.2 and PEH4.3.
*** Only valid for control box with program version PEH4.0 and PEH4.01.

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10 MAINTENANCE

10.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.

In the event o f malfunction:

S Contact your nearest ESAB representative, see last page.

11 ORDERING 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 309.
This will simplify dispatch and ensure you get the right part.

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWA Y

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Shah Alam Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA-- CIS

ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel:[phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

041227