ESAB PROWELDER Programming manual

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PROWELDER

Programming manual

Valid for program version 2.80B, 2.81B0457 706 174 GB 050420

1 INTRODUCTION 4...................................................

1.1 Mode of operation -- Control box 4.............................................

1.2 Sectors 4..................................................................

1.3 Display and keyset 5........................................................

2 WELDING PARAMETERS 9...........................................

2.1 Welding current 9...........................................................

2.2 Gas 9.....................................................................

2.3 Wire feed speed 10..........................................................

2.4 Preheating time 10...........................................................

2.5 Rotation speed 1 1...........................................................

3 START AND STOP 11.................................................

3.1 Start 11.....................................................................

3.2 Stop 11.....................................................................

3.3 Restart 11...................................................................

4 TO GET STARTED 12.................................................

4.1 General 12..................................................................

4.2 How to indicate a tool code 12.................................................

4.3 How to define your own tool code 13............................................

4.4 How to change languages 17..................................................

5 PROGRAM EDITING 18................................................

5.1 Entering a parameter value 18.................................................

5.2 Increasing/decreasing a parameter value 18.....................................

5.3 Creating a new sector 18......................................................

5.4 Changing the breakpoint of a sector 19..........................................

5.5 Creating a transport sector 19..................................................

5.6 Finding the home position 20..................................................

5.7 Entering a slope 20...........................................................

5.8 Moving within a program 21....................................................

5.9 Deleting in a program 21......................................................

5.10 Changing weld data during welding 22..........................................

5.11 Zeroing the control box 22.....................................................

6 PROGRAMMING EXAMPLES 23.......................................

6.1 Example 1a: 23..............................................................

6.2 Example 1b: 26..............................................................

6.3 Example 1c: 28..............................................................

6.4 Example 1d: 30..............................................................

6.5 Example 1e: 33..............................................................

7 THE LIBRARY 35.....................................................

7.1 Storing a program 35.........................................................

7.2 Recalling a program 35.......................................................

7.3 Viewing the tool code 36......................................................

7.4 Deleting a program 36........................................................

8 MANUAL MODE 37...................................................

8.1 Field of application 37.........................................................

8.2 Editing a parameter 37........................................................

Rights reserved to alter specifications without notice.

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9 PC--CARD 39.........................................................

9.1 Field of application 39.........................................................

9.2 How to install the card 39......................................................

9.3 How to recall a program 39....................................................

9.4 How to store a program 40....................................................

9.5 How to delete a program 40...................................................

9.6 How to take out the PC--card 41................................................

10 ERROR CODES 41....................................................

10.1 Error handling 41.............................................................

10.2 Incorrect editing codes 46.....................................................

11 SHOW CURRENT PARAMETER VALUES 47.............................

1 1.1 Field of application 47.........................................................

1 1.2 How to view actual parameter values 47.........................................

12 SOFTWARE UPGRADE 48.............................................

12.1 Application field 48...........................................................

12.2 Menu explanation 48..........................................................

12.3 How to upgrade 48...........................................................

12.4 Measures to be taken when the upgrading of the power source units failed 51........

12.5 Measures to be taken when the upgrading of the control box failed 51...............

13 SOFWARE KEY 52....................................................

13.1 General 52..................................................................

13.2 Locking the control box 52.....................................................

13.3 Unlocking the control box 53...................................................

13.4 Changing the code 54.........................................................

13.5 Forgotten the code? 54.......................................................

13.6 How to indicate limit values 54.................................................

14 NOTEBOOK 56.......................................................

14.1 Field of application 56.........................................................

14.2 How to enter data in the notebook 56...........................................

14.3 Example 2a: 57..............................................................

15 MANUAL WELDING 62................................................

15.1 Field of application 62.........................................................

15.2 How to create a welding program 63............................................

15.3 Example 3a: 63..............................................................

15.4 How to weld 67..............................................................

16 APPENDIX 67........................................................

16.1 Tool codes 67................................................................

16.2 Symbols 68..................................................................

16.3 Setting ranges -- welding parameters 68.........................................

17 MENU STRUCTURE 69................................................

18 TECHNICAL TERMS 70................................................

19 PROGRAMMING NOTES 71............................................

ORDERING NUMBER 75.................................................

Rights reserved to alter specifications without notice.

TOCe

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1 INTRODUCTION

1.1 Mode of operation -- Control box

The control box consists of four units, the working area, the library, the notebook and the auxiliary function.

S In the working area the welding program is created. S In the library the program can be stored.

During welding it is always the contents of the working area that control the welding process. Thus it is also possible to call in a welding program from the library to the working area.

S In the notebook you can make your own notes about special welding

parameters, for example.

S In the auxiliary function you can:

S change languages S view all existing error messages S show actual parameter values S software upgrade S sofware key

1.2 Sectors

A welding program for welding of tubes can be divided into different parts or sectors. Each sector corresponds to a special part of the circumference of the tube. Max. number of sectors for one program is one hundred (100).

Sector 4

Sector 3

A sector can be assigned its own set of values for different welding parameters, such as current, rotation speed, wire feed speed, etc. In this way the welding can be performed using different parameter settings for different parts of the joint of the tube.

The division into sectors is done by indicating different breakpoints along the circumference of the tube. Each such breakpoint constitutes the starting point of a new sector. In the figure below, the breakpoint 0.000 is the starting point of sector 1, breakpoint 0.250 the starting point of sector 2, etc.

Sector 1

Sector 2

Breakpoint 0,750

Sector 3

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Breakpoint 0,000

Sector 4

Breakpoint 0,500

Sector 1

Breakpoint 0,250

Sector 2

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LTS allows welding of up to 10 turns in the same welding joint, i.e. the welding tool can be rotated 10 times round the tube.

The breakpoints in the previous figure all start with the integer 0 which means that they form the breakpoints of turn 1. The breakpoints of turn 2 (if there is one) always start with the integer 1,etc.

S Turn 1 = breakpoints 0.000 -- 0.999 S Turn 2 = breakpoints 1.000 -- 1.999 S Turn 3 = breakpoints 2.000 -- 2.999 S Turn 4 = breakpoints 3.000 -- 3.999 S Turn 5 = breakpoints 4.000 -- 4.999 S Turn 6 = breakpoints 5.000 -- 5.999 S Turn 7 = breakpoints 6.000 -- 6.999 S Turn 8 = breakpoints 7.000 -- 7.999 S Turn 9 = breakpoints 8.000 -- 8.999 S Turn 10 = breakpoints 9.000 -- 9.999

To terminate a welding program a so--called end sector is indicated. For a sector to be counted as an end sector the following two conditions must be

fulfilled:

S There is no sector following. S The welding current value of the sector = 0 ampere.

1.3 Display and keyset

A Display, B Soft keys, C Function keys

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Display

SECTOR 2(4)

WELD GAS

ROOT GAS

START GAS

0.500

s s s

WELD

GAS

ROOT

GAS

START GAS

The following information is shown in the display.

a The program sector at present involved. b The number of sectors in the current program. c The breakpoint of the sector (sector 2 in this example). d The digit box shows the numerical value entered and different

numerical characters. For further information, see page 68.

e Showing that the indicated value has been borrowed from a previous

sector (in this example from sector 1).

g 5 text boxes describing the function of the so --called soft keys (f). h Message line describing the actual state.

WELDING = a welding sequence is going on. END = a welding sequence is completed. TRANSPORT= transfer without welding. STOP = the welding sequence was interrupted due to activation of the stop key.

keys

Soft

By way of the soft keys (a) the functions connected with the respective display (in this case the GAS parameter display), the significance of which is indicated in the text boxes (b). Depending on the display selected, up to five soft keys can be activated.

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Function keys Parameter keys

The welding parameters are divided into five different groups, each group represented by one ordinary key and a set of soft keys.

Welding current Gas

Rotation speed Wire feed speed

Preheating time

SHIFT key

This key is used for changing the significance of other keys on the keyboard.

PLUS/MINUS keys

These keys are used for increasing/decreasing set values.

Numerical keys

These keys are used for entering the digits 0--9 and decimal point.

Other keys

SLOPE

This key is used when you want to add a slope function to a parameter and is

indicated in the following way in the display

. By slope is meant a gradual change of a set value. Slope up = gradual increase

Slope down = gradual decrease The following parameters can be assigned a slope function:

Current (both peak and background current) when pulsed current is used, rotation, wire feed speed.

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A slope can be time--controlled by indicating that it shall go on for a certain number of seconds. It can also be sector--controlled, making it a so--called sector slope, by indicating between which two breakpoints it shall be located.

SECTOR

This key indicates the breakpoint of a program and moving to indicated sector.

STEP

This key is used for stepping forward in the program.

DELETE

This key is used for deleting the whole program, part of a program in the working area, or just the figures in the digit box.

MANUAL MODE

This key is used for positioning the electrode before welding, and for making sure that the program in the working area functions as desired.

MEMORY (library)

This key is used for entering or leaving the library and for storing a program, or for recalling a program from the library to the working area.

MODE (auxiliary fu nctions)

This key is used for getting to the different auxiliary functions, such as language, error log, show actual parameter values and software upgrading.

This key is not used.

NOTEBOOK

These keys are used if you want to make notes on a welding sequence.

TOOL CODE

These keys are used if you want to view the code of the connected tool.

RESTART

These keys are used for restarting a welding sequence.

SECTOR SLOPE

These keys are used if you want to create a sector slope.

DIRECT STOP

Pressing th is key will lead to direct stop of the welding. The gas postflow takes place according to settings in the end sector.

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START

This key is used for starting a welding sequence.

STOP

This key is used for stopping a welding sequence. The welding sequence is terminated according to the settings in the end sector.

2 WELDING PARAMETERS

Setting ranges for the welding parameters can be found in the APPENDIX on page

68.

2.1 Welding current

There are four different parameters for welding current:

S PEAK CURRENT S BACKGROUND CURRENT S PEAK TIME (1 s) S BACKGROUND TIME (1 s)

The values in brackets are preset values.

Peak time

Background time

Peak current

Background current

The welding current can be either pulsed or continuous (not pulsed). If you want to weld using pulse current a value must be entered for all four

parameters. When welding with continuous current, however, you only need to enter the value for peak current. Entering a value also for background current will result in pulsed current with preset pulse and background times. Of course, the pulse and background times can also be changed.

2.2 Gas

In the Shielding Gas parameter group three parameters are represented:

S WELD GAS S ROOT GAS S START GAS

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By weld gas is meant the shielding gas on the upper side of the joint. The weld gas parameter indicates the time the shielding gas is to flow on the upper side of the joint before and after welding. The values of the weld gas parameter are preset. The following values for preflow and postflow of the weld gas apply at the start if nothing else has been indicated:

S Weld gas preflow = 2 s S Weld gas postflow = 4 s

By root gas is meant the shielding gas on the underside of the joint. The root gas parameter indicates the time the shielding gas is to flow on the underside of the joint before and after welding.

Some shielding gases, for example helium (He), can cause difficulty with regard to striking the arc. If such a shielding gas is to be used as weld gas, it could be advisable to use another gas mixture at the start moment -- a so--called start g as .

If one value is entered for weld gas in sector 1 and one for start gas, only the start gas is going to flow. The weld gas starts flowing when the arc is struck.

2.3 Wire feed speed

This parameter is used to indicate the desired feed speed of the filler wire in cm /m in. The wire feed speed can be pulsed or continuous (not pulsed). In the Wire Feed Speed parameter group two parameters are represented:

S PEAK WIRE FEED SPEED S BACKGROUND WIRE FEED SPEED

For welding with continuous (not pulsed) wire feed speed, only the peak wire feed parameter shall be entered.

For welding with pulsed wire feed speed, both the peak wire feed speed and the background wire feed speed parameters shall be entered.

The pulsed wire feed speed is always automatically synchronised with the welding current. The wire feed speed is high using pulse current and low using background current.

2.4 Preheating time

Preheating is used for heating the workpiece at the starting point in order to obtain correct penetration of the molten pool. The preheating time is defined as the time elapsing between arc strike and start of the rotary motion. If no value has been entered for the preheating param eter, the arc will strike at the same time as rotation is started.

NOTE! In the Welding Current parameter group you cannot indicate a sector slope when preheating is involved.

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-- 1 0 --

2.5 Rotation speed

This parameter indicates the rotation speed of the electrode round the workpiece. It is indicated in per mill (thousandths) of the max. rotation speed of the welding tool used.

Just like welding current and wire feed speed, the r otation speed can be pulsed or continuous (not pulsed).

In the Rotation Speed parameter group four parameters are represented:

S ROTATION FORWARDS S ROTATION BACKWARDS S PULSED ROTATION FORWARDS S PULSED ROTATION BACKWARDS

Pulsed rotation is automatically synchronised with the welding current so that the welding tool stands still when the peak current sets in and rotates during background current.

3 START AND STOP

3.1 Start

To start the welding, use the START key . It is impossible to start a welding program if another tool code has been indicated than the one used in the program in question.

3.2 Stop

A requested welding stop over the STOP key means that the program jumps to the following end sector, no matter which sector you are in at the moment. The welding is terminated according to the settings of the end sector.

A requested welding stop over the DIRECT STOP key of the welding. The gas postflow takes place according to the time set in the end sector.

leads to immediate stop

3.3 Restart

If the welding was interrupted it is restarted with the SHIFT and START keys

Irrespective of whether the welding was stopped over the STOP

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-- 1 1 --

or the DIRECT STOP key , the start parameters of the preceding start sector are used. The program then continues from the position in the welding program where it was interrupted.

4 TO GET STARTED

4.1 General

Some of the factors controlling the welding process are specific to each one of the welding tools, for example the rotation speed. Therefore, every welding program must be connected to a tool code, associated with the tool that the program was made up for.

4.2 How to indicate a tool code

S Turn the mains switch on the welding power source to position 1. S The following display comes up:

CHOOSE CONNECTED TOOL

PRB " PRH PRD POC 12--60 mm TIG HAND TORCH A25

ENTER

Example: You have connected PRB 33-- 90

S Move the marking to the line for PRB using the soft key NEXT. Choose the

desired tool and press ENTER. A window comes up, showing available tool sizes.

S Move the marking to the size of the tool you have connected (in this example

33 --90 mm) using the soft key NEXT and press ENTER.

CHOOSE CONNECTED TOOL

PRB " 8-- 17 mm PRH 17-- 49 mm PRD 33-- 90 mm POC 12--60 mm 60--170 mm TIG HAND TORCH A25

QUIT ENTER

Result: The new tool code is accepted and the following text is displayed: CONNECTED TOOL: PRB 33--90 mm.

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-- 1 2 --

ftkeyPressthesoftkey

TOOLTYPEMISMATC

NOTE! In the event a program with another tool code should already be stored in the

working area this must first be deleted. If you want to preserve the old program, don’t

forget to save it in the library by pressing the MEM key

The following information is displayed in the display:

ress

delete existing program.

eso

WARNING! TOOLTYPE MISMATCH

PROGRAM NO 1

PROGRAM MADE FOR: PRB 17-- 49 mm

CONNECTED TOOL: PRB 33-- 90 mm

DELETE

PROG.

Result: The new tool code is accepted and the display displays: CONNECTED TOOL: PRB 33 --90 mm.

If no figure is entered after PROGRAM NO: _ no welding program has been recalled from the library.

Note! If the welding data in the working area is changed, the welding program will not match the program recalled from the library. If you wish to keep the changes, save them as a new welding program in the library.

4.3 How to define your own tool code

To define your own tool code you might have to calculate some of the following parameter factors:

ROTAT ION LENGTH, example A, see page 15. SCALE FACTOR ROTATION, example B, see page 15. SCALE FACTOR WIRE, example E, see page 16. NB. The values set under self--defined tool codes remain even if you choose an

ordinary tool code.

Preset

Rotation length 55350 55350 55350 Scale factor, rotation 846024 960000 678000 Prescaler no yes no Scale factor, wire 120700 230826 230826

S Set the mains voltage switch on the power source to position 1.

values

Parameter factor PRD A25 PRB, PRC

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-- 1 3 --

set

entertwic

Example A: PRD 160

The following display comes up:

CHOOSE CONNECTED TOOL:

PRB PRH

PRD " POC 12--60 mm TIG HAND TORCH A25

ENTER

S Move the marking to the PRD line using the soft key next and press enter. The following display comes up:

S Press the soft key

CHOOSE CONNECTED TOOL:

PRB PRH PRD " CUSTOMIZED POC 60--170 mm TIG HAND TORCH A25

SET QUIT ENTER

The following display comes up:

S Press the soft key

INSERT PARAMETERS

DEFAULT PRD A 25 PRB ROTATIONS LENGTH 55350 SCALE FACTOR ROT 678000

NEXT QUIT ENTER

Result: The PRD tool is marked.

S Enter rotation length and scale factor. For correct values, see instruction manual

0440 100 xxx for PRD 160.

S Press the soft key quit.

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-- 1 4 --

enter

ftkeyesstesote

LTY

prog

TOOLTYPEMISMATC

program

The following display comes up:

S Press the soft key

CHOOSE CONNECTED TOOL:

PRB PRH PRD " CUSTOMIZED POC 60--170 mm TIG HAND TORCH A25

SET QUIT ENTER

Result: The new tool code was accepted and the text CONNECTED TOOL: PRD comes up.

NB. If there is already a program with another tool code stored in the working area, this program must be deleted. (If you want to preserve the program, save it in the

library by pressing the MEM key

The following information is displayed in the display:

ress

delete existing

ram.

eso

WARNING! TOO

PROGRAM NO 1

PE MISMATCH

PROGRAM MADE FOR: PRB 17-- 49 mm CONNECTED TOOL: PRD

DELETE

PROG.

Result: The new tool code was accepted and in the display the text CONNECTED TOOL: PRD comes up.

Calculating and setting the rotation

length

ROTATION LENGTH= enter number of pulses / revolution (from start point 0.000 to

1.000)

Calculating and setting the scale

factor

Example B: PRH 6--40, rotation.

S Max rotation speed (V) = 2.778 rpm S Mechanical gear ratio of drive unit (N) = 2140:1 S Value for pulse generator signals per revolution of motor shaft (P) =15 S Max. adjustable rotation value (M) = 1000. S The time between the pulses from the pulse generator, indicated in

micro--seconds at the desired max. speed (the data can be found in the specification of the drive unit used).

-- 1 5 --

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factorSCALE

LEFA

(T)= 60s

x 1 000 000

VxNxP

S Constant (K) is to be indicated so that K/T = max. adjustable value in the display

(M). K = T x M = 672843

SCALE FACTOR = 672843

S Step to the following display, see example A, page 15.

S Step to parameter

FACTOR ROTATION using the soft key

next.

INSERT PARAMETERS

DEFAULT PRD A 25 PRB ROTATIONS LENGTH 55350

SCALE FACTOR ROT. 672843

NEXT QUIT ENTER

S Press the soft key enter. S Enter the value 672843 for the scale factor using the numerical keys. S Press the soft key enter.

Result: The rotation scale factor has been set.

Prescaler

In this window you can choose to count all the pulses or only every eight pulses. Choosing the latter alternative 8 pulses are counted as 1, so as to enable the use of high frequency pulse generators (max. 2000 Hz).

INSERT PARAMETERS

SC WEAVE -- pulses/mm. 84

PRESCALER

SCALE FACTOR WIRE 230826 SCALE FACTOR WEAVE 119048

NEXT QUIT ENTER

CTORVOLT. 30

Calculating and setting the wire feed scale factor Example E: Wire feed unit MEI 21

S Max. wire feed speed (V) = 2500 mm/min S Mechanical gear box ratio (N) = 159:1 S Effective circumference of the feed rollers (O) ≈ (29.2 x π )mm S Value for pulse generator signals per revolution of motor shaft (P) =15 S Max. adjustable wire feed speed x 10 (M) = 25.0 x 10 = 250. S Motor speed corresponding to max. speed (R) = (V /O) x N rpm

-- 1 6 --

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ftkeyPressthesoftkey

ftkeyesstesote

ggg

S The time between the pulses from the pulse generator, indicated in

micro--seconds at the desired max. speed (the data can be found in the specification of the drive unit used). (T)= 60s

x 1 000 000

RxP VxNxP

S The constant (K) is to be indicated so that K/T = max. adjustable value in the

display, K = T x M = 230 779

SCALE FACTOR WIRE = 230 779

Enter the values for SCALE FACTOR WIRE F EED in the same way as in example B on page 15.

4.4 How to change languages

The different texts displayed on the control box are available in the following four languages:

S English, German, Franch, Swedish. The following groups of languages are available as accessories (see instruction

manual for the respective power source).

=60xO

x 1 000 000

S English, German, French, Swedish S English, Italian, Finnish, Norwegian

On delivery and after resetting the box, all texts displayed are in English.

Language

S Press the MODE key

selection

to get to the auxiliary functions, and the following

display comes up:

ress

language.

eso

AUXILIARY FUNCTIONS

LANGUAGE "

ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

SOFT--. WARE UPGR.

SOFT-WARE KEY

S Press the soft key next language and step to the desired language. S

ress

change language.

eso

CHOSEN LANGUAGE: ENGLISH

AVAILABLE LANGUAGES ENGLISH SVENSKA DEUTSCH

FRANCAIS

NEXT LANG

CHANGE

LANG

QUIT

Result: All texts will from now on be in the new language (in this example Swedish).

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Terminateby

pgy

erminateby

pressing the soft key

avbryt.

VALT SPRÅK: SVENSKA

TILLGÄNGLIGA SPRÅK ENGLISH SVENSKA DEUTSCH FRANCAIS

NÄSTA SPRÅK

BYT

SPRÅK

AVBRYT

S Press the MODE key to return to the working area.

5 PROGRAM EDITING

5.1 Entering a parameter value

S Make sure the right group of parameters is displayed in the display by pressing

one of the five parameter keys.

S Enter a value in the digit box. S Press the soft key of the desired parameter.

Note that the parameters always inherit the value from the previous sector if no new value is entered.

5.2 Increasing/decreasing a parameter value

The parameter value to be altered must be shown in the digit box.

S Mark the desired parameter using one of the soft keys. The set value comes up

in the box.

S Press the PLUS

or the MINUS key .

5.3 Creating a new sector

A new sector is created by entering a new breakpoint into an existing sector.

S Enter a new value for the breakpoint of the new sector.

S Press the SECTOR key .

In doing this, a new sector is created which is a copy of the original sector, but with another breakpoint and another sector number. The new sector is automatically positioned in the right place in the program. This is determined by the value of the new breakpoint.

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Creating a new sector during welding

Proceed as follows to create a new sector during the welding:

S Enter a value into one of the following parameter groups using the numerical

keys:

S Press the corresponding soft key. A new sector is now automatically created.

5.4 Changing the breakpoint of a sector

Make sure the existing breakpoint value of the sector is displayed in the digit box.

S Press the SECTOR key

The breakpoint value is now shown in the digit box.

S Enter the new breakpoint value.

S Press the SECTOR key

S Change the breakpoint value using the PLUS key

or the MINUS key .

5.5 Creating a transport sector

If you want to rotate the welding tool without welding within a sector, you can create a transport sector. Sector 1 cannot function as a transport sector -- it can only function as a delayed start.

Transpo rt sector

S Enter a value for the breakpoint of the new sector using the numerical keys.

S Press the SECTOR key .

S Set the WELDING CURRENT

NOTE! If the welding current value is inherited, the welding current value of the following sector will also be 0. Don’t forget to change them to the right value.

All the other parameter values can remain.

Delayed start

Change the breakpoint of sector 1 in the following way in order to delay the start:

S Press the STEP key

S Press the SECTOR key .

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and go to sector 1.

(the peak current) to 0.

-- 1 9 --

S Enter the breakpoint, for example 0.100 instead of 0.000, using the numerical

keys.

S Press the SECTOR key

again.

5.6 Finding the home position

When the tube welding tools PRH and POC are used, it can sometimes be necessary to return to the home position (start position), for example in the event of a welding stop.

S Rotate the tool manually till it is within a tenth of a rotation to the left or right of

the home position. See also under the section “Manual Mode” on page 37.

S Press the START key

Once this is done, the welding tool automatically starts rotating to the home position, and a welding sequence starts.

5.7 Entering a slope

A time slope or a sector slope can be indicated for the following parameter groups:

Welding current Rotation speed

Wire feed speed

Time slope

S Press the key for the parameter group in question. S Mark the desired parameter using one of the soft keys. S Enter the desired slope time value.

S Press the SLOPE key

Sector slope

To create a sector slope no time value is to be entered. A sector slope always goes on from one breakpoint to the next one.

NOTE! In the Welding Current parameter group you cannot indicate a sector slope when preheating is involved.

S Press the key for the parameter group in question.

S Mark the desired parameter using one of the soft keys.

S Press the SHIFT key

slope is created.

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and the SLOPE key simultaneously, and a sector

-- 2 0 --

Whatisaslope?

A slope is a linear change between two parameter values, based on time or position (breakpoint).

A time--based slope (time slope) is active during the time indicated. A position--based slope (sector slope) is active between two adjacent breakpoints.

5.8 Moving within a program

Move to the next parameter group

Using the STEP key using the STEP function, only the parameter groups that have been assigned a value are displayed.

When stepping through the end sector, you will automatically jump to the tool code.

Move between

By entering a sector number in the digit box in the display and then pressing the

SECTOR key When jumping to a new sector you always end up in the same group of parameters as the one you left.

sectors

it is possible to jump between the different sectors of the program.

you can step through the whole welding program. When

5.9 Deleting in a program

Delete a parameter value

You can delete a parameter value if it has not been borrowed from a previous sector. For the value to be deleted, it must be displayed in the digit box.

S Press the DELETE key

. The digit box asks DEL?

S Press the soft key of the parameter to confirm.

Delete a

You can only delete the sector in which you are at the moment. It can be done in two different ways:

Alternative 1

S Press the DELETE key and then the SECTOR key .

Alternative 2

S Press the SECTOR key . The breakpoint of the sector comes up in the digit

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sector

box.

-- 2 1 --

S Press the DELETE key . The digit box asks DEL?

S Press the SECTOR key

Delete the contents of the working

The working area always contains the welding program last used. Maybe you want to clear the working area completely, for example to change the tool code.

Delete a program in the working area in the following way:

S Press the DELETE key

to confirm.

area

and then the MEMORY key .

5.10 Changing weld data during welding

To change welding data in the course of welding, a value must be displayed in the digit box.

S Mark the parameter in question using one of the soft keys. The set value now

comes up in the digit box.

S Enter the new value using the numerical keys, or increase/decrease the value

using the PLUS

NOTE! When a value is changed in the working area, the old value will be overwritten and the new one applies. If the value is inherited, the value in the following sector will also be changed.

/ MINUS keys.

5.11 Zeroing the control box

In the event the control box should get blocked, i.e. it does not react when the keys are activated, it is necessary to reset the box. This is done in the following way:

S Set the mains voltage switch on the power source to 0. S Hold down the mid one of the five soft keys on the control box, and turn the

mains voltage switch to position 1.

dpa8d1ea

-- 2 2 --

ftkeyesstesote

6 PROGRAMMING EXAMPLES

6.1 Example 1a:

The first example is a simple welding program, consisting of two sectors, sector 2 being a stop sector. The program contains four parameters: weld ing current,

rotation, weld gas preflow and weld gas postflow.

Sector 1 Sector 2

Breakpoint 0.000 1.010 Welding current (continuous) (A) 160 0 Rotation (continuous) (‰) 250 250 Gas preflow (weld gas) (s) 5 Gas postflow (weld gas) (s) 7

Sector 1 Breakpoint

Sector 1 automatically is assigned the breakpoint 0.000, if nothing else is indicated.

Welding current Pulse current = 160 A

S Press the key for WELDING CURRENT

. The picture for welding current

settings comes u p in the display.

S Enter the value 160 using the numerical keys. S

ress

continuous peak pulse current.

eso

SECTOR 1(1) 0.000

PEAK CURRENT A

BACKG. CURRENT A PEAK TIME s BACKGR.TIME s

CONT/ PEAK CURR.

BACKGR.

CURR.

PEAK TIME

160

BACKGR

TIME

Result: PEAK CURRENT = 160 A in sector 1.

Rotation speed Continuous rotation forward = 250 ‰ of the max. rotation speed.

S Press the key for ROTATION SPEED

S Enter the value 250 using the numerical keys. S

ress

rotation forward.

eso

SECTOR 1(1) 0.000

250

ROTATION FORWARD

ROTATION BACKW. PULSE ROT. FORW. PULSE ROT. BACKW.

ROTA TION FORW

ROTA-TION BACKW

PULSE

ROT. FORW

Result: ROTATION FORWARD = 250 in sector 1.

dpa8d1eb

-- 2 3 --

PULSE ROT. BACKW.

ftkeyPressthesoftkey

heSECTORessteSC

ftkeyesstesote

Gas Preflow of weld gas = 5sin sector 1.

S Press the key for gas

S Enter the value 5 using the numerical keys.

The gas preflow has a preset value of 2 s, which applies if no other value is entered and displayed in the display at the start.

ress

weld gas.

eso

SECTOR 1(1) 0.000

WELD GAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START-GAS

Result: WELD GAS = 5 s in sector 1.

Sector 2 Breakpoint

S Enter the value of the new breakpoint 1.010 using the numerical keys. S

ress

key.

SECTOR 1(1) 0.000

1.010

1 WELD GAS 5 s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: Sector 2 out of 2 sectors in all.

Welding current

Peak current = 0A As sector 2 is to be a stop sector, the welding current must be assigned the value of

0 amperes. Note that the parameter (peak current) has been assigned the value 160 as the value was inherited from the preceding sector.

S Press the key for WELDING CURRENT

S Enter the value 0 using the numerical keys. S

ress

continuous peak current.

eso

SECTOR 2(2) 1.010

1 PEAK CURRENT 160 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

dpa8d1eb

CONT/ PEAK CURR.

BACKGR

CURR.

-- 2 4 --

PEAK TIME

BACKGR

TIME

ftkeyPressthesoftkey

Result: PEAK CURRENT = 0 A in sector 2 (end sector).

Rotation speed

As this is the last sector of the program and the welding current is set to 0, the sector will be interpreted as a stop sector, irrespective of the rotation value. In other words, we can keep the rotation value that was borrowed from the previous sector.

S Press the key for ROTATION SPEED

SECTOR 2(2) 1.010

1 ROTATION FORWARD 250

ROTATION BACKW. PULSE ROT. FORW. PULSE ROT. BACKW.

ROTA TION FORW.

ROTA-TION BACKW.

to view the result.

PULSE

ROT. FORW.

PULSE ROT. BACKW.

Result: ROTATION FORWARD = 250 ‰ in sector 2 (borrowed value)

Gas The weld gas preflow of = 7s.

S Press the key for gas

S Enter the value 7 using the numerical keys. The gas postflow has a preset value

of 4 s, which applies if no other value is entered and displayed in the display a t the start.

ress

weld gas.

eso

SECTOR 2(2) 1.010

1WELDGAS s

ROOT GAS s START GAS s

WELD GAS

Result: WELD GAS = 7 s in sector 2.

ROOT GAS

START GAS

dpa8d1eb

-- 2 5 --

heSECTORessteSC

Entert

teteaue

PresstheSLOPE

6.2 Example 1b:

We now want to extend the previous program by adding a slope up and slope down time to the welding current. We also add a new sector to the program, which

is to be placed between the other two sectors.

Sector 1 Sector 2 Sector 3 Breakpoint 0.000 0.500 1.010 Welding current (continuous) (A) 160 145 0

Slope up (s) 2 -- -Slope down (s) -- -- 4

Rotation, continuous (‰) 250 250 250 Gas preflow (weld gas) (s) 5 -- -Gas postflow (weld gas) (s) -- -- 7

Sector 1 Go back to sector 1.

S Enter the value 1 using the numerical keys. S

ress

key.

SECTOR 2(2) 1.010

2 WELD GAS 7 s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: Return to sector 1 with the breakpoint 0.000.

Slope

The slope--up time = 2sfor the peak current of sector 1. When a slope function is to be added, first make sure the corresponding picture is

displayed in the display.

S Press the key for WELDING CURRENT

S Press the soft key for continuous peak current. S

S Press the SLOPE

key.

evalue2.

SECTOR 1(2) 0.000

1 PEAK CURRENT 160 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 160 A, 2.0 s in sector 1.

dpa8d1eb

-- 2 6 --

Entert

Enterthevalue

ftkeyesstesote

Entert

3teteaue3

Sector 2

New breakpoint = 0.500

We are now going to add a sector to the program. The breakpoint of the new sector is to be 0.500, and the sector will automatically be placed between the two sectors already existing.

0.5.

S Press the SECTOR

key.

evalue

SECTOR 1(2) 0.000

1 PEAK CURRENT 160 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

0.5

BACKGR

TIME

2.0 s

Result: Breakpoint 0.500 is placed as sector no. 2 (borrowed value).

Welding current Peak current = 145 A

S Press the key for WELDING CURRENT

S Enter the value 145 using the numerical keys. S

ress

continuous peak current.

eso

SECTOR 2(3) 0.500

1 PEAK CURRENT 160 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

145

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 145 A in sector 2.

Sector 3

Go to sector 3.

using the numerical keys.

S Press the SECTOR

key.

evalue

SECTOR 2(3) 0.500

2 PEAK CURRENT 145 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: You have moved to sector 3 with the breakpoint 1.010.

dpa8d1eb

-- 2 7 --

Entert

Enterthevalue

Entert

1teteau

Slope Slope down = 4sfor the peak current of sector 3.

S Press the soft key for continuous peak current. S

evalue

SECTOR 3(3) 1.010

S Press the SLOPE

key.

3 PEAK CURRENT 0 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 0 A, 4.0 s in sector 3 (stop sector).

6.3 Example 1c:

We now extend the previous program by changing the welding current of sector 1 from 200 A to 180 A. We also add a new sector to the program, which will automatically be placed between sector 1 and sector 2.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.500 1.010 Welding current (continuous) (A) 155 150 145 0 Slope up (s) 2 -- -- -Slope down (s) -- 4 -- 4 Rotation, continuous (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7

Sector 1 Go back to sector 1.

using the numerical keys.

S Press the SECTOR

key.

evalue

SECTOR 3(3) 1.010

3 PEAK CURRENT 0 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: Return to sector 1 with the breakpoint 0.000.

dpa8d1eb

-- 2 8 --

BACKGR

TIME

4.0 s

ftkeyPressthesoftkey

Entert

5.teteaue05

PresstheSECTO

ftkeyesstesote

Welding current Peak current = changed from 160 A to 155 A.

S Enter the value 155 using the numerical keys. S

ress

continuous peak current.

eso

SECTOR 1(3) 0.000

1 PEAK CURRENT 160 A

BACKGR CURRENT A PEAK TIME s BACKGR. TIME s

155

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 155 A, 2.0 s in sector 1.

Sector

New breakpoint = 0.250

We are now going to add a sector to the program. The new sector is to have the breakpoint 0.250 and will automatically be placed in the right position between sector 1 and sector 2.

S S Press the SECTOR

key.

evalue0.

SECTOR 1(3) 0.000

1 PEAK CURRENT 155 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

0.25

BACKGR

TIME

2.0 s

Result: SECTOR 0.250 is placed as sector 2 in the program (values borrowed from sector 1).

Welding current Peak current = 150 A.

S Enter the value 150 using the numerical keys. S

ress

continuous peak current.

eso

SECTOR 2(4) 0.250

1 PEAK CURRENT 155 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: PEAK CURRENT = 150 A in sector 2.

dpa8d1eb

-- 2 9 --

150

BACKGR

TIME

2.0 s

Entert

4Enterthevalue4

Entert

1teteau

Slope Slope down = 4sfor the peak current in sector 2.

S Press the soft key for continuous peak current . S

using the numerical keys.

S Press the SLOPE

key.

evalue

SECTOR 2(4) 0.250

2 PEAK CURRENT 155 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 155 A, 4.0 s in sector 2.

6.4 Example 1d:

We now extend the program further by adding some new welding parameters.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.500 1.010 Welding current (continuous) (A) 155 150 145 0

Welding current (background current) (A) 100 100 100 100 Welding current (pulse time) (s) 0.5 0.5 0.5 0.5 Welding current (Background time) (s) 1.0 1.0 1.0 1.0

Slope up (s) 2 -- -- -Slope down (s) -- 3 -- 4 Preheating (s) 2 2 2 2 Rotation, (cont. forward) (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7

Wire feed (continuous) (cm/min)

110 110 110 110

Sector 1 Go back to sector 1.

using the numerical keys.

S Press the SECTOR

key.

evalue

SECTOR 2(4) 0.250

2 PEAK CURRENT 150 A

BACKGR CURRENT A PEAK TIME s BACKGR TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

4.0 s

Result: Return to sector 1 with the breakpoint 0.000.

dpa8d1eb

-- 3 0 --

ftkeyPressthesoftkey

ftkeyesstesote

Welding current Background current = 100 A.

S Press the key for WELDING CURRENT

S Enter the value 100 using the numerical keys. S

ress

back--ground current.

eso

SECTOR 1(4) 0.000

1 PEAK CURRENT 155 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR

BACKGR

CURR.

PEAK TIME

100

BACKGR

TIME

2.0 s

Result: BACKGR. CURRENT = 100 A. 2.0 s in sector 1 and PULSE TIME = 1.00 s and BACKGR. TIME = 1.00 s (preset values)

Pulse time = 0.5 s instead of 1.0.

S Enter the value 0.5 using the numerical keys. S

ress

peak time.

eso

SECTOR 1(4) 0.000

1 PEAK CURRENT 155 A

BACKGR. CURRENT 100 A PEAK TIME 1.00 s BACKGR.TIME 1.00 s

0.5

2.0 s

CONT/ PULSE CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK TIME = 0.50 s instead of 1.00 s in sector 1.

Preheating time The preheating time = 2s

S Press the key for PREHEATING TIME

S Enter the value 2.0 using the numerical keys. S

ress

preheat.

eso

SECTOR 1(4) 0.000

PREHEAT s

PRE-HEAT.

Result: PREHEAT = 2.0 in sector 1.

Wire feed speed

2,0

We are now going to use filler wire. As we intend to weld using continuous wire feed (not pulsed) only the pulsed wire parameter need to be entered.

-- 3 1 --

dpa8d1eb

ftkeyPressthesoftkey

Entert

2teteau

Entert

3teteaue3

Pulsed wire = 1 10 cm/min

S Press the key for WIRE FEED SPEED

S Enter the value 110 using the numerical keys S

ress

continuous peak wire feed.

eso

SECTOR 1(4) 0.000

PEAK WIRE. cm/min BACKGR WIRE. cm/min

CONT/ PEAK WIRE

BACKGR

WIRE

Result: PEAK WIRE FEED = 1 10 cm/min in sector 1.

Sector

Go to sector 2.

using the numerical keys.

S Press the SECTOR

evalue

SECTOR 1(4) 1.010

PEAK WIRE 110 cm/min BACKGR WIRE cm/min

key.

110

CONT/ PEAK WIRE

BACKGR

WIRE

Result: You have moved to sector 2(4) with the breakpoint 0.250.

Slope

We are now going to change the slope-- down time in sector 2. Make sure the corresponding parameter picture is shown in the display.

S Slope down = 3sinstead of 4 s.

Press the key for WELDING CURRENT

Press the soft key for continuous peak current .

using the numerical keys.

S Press the SLOPE

key.

evalue

SECTOR 2(4) 0.250

2 PEAK CURRENT 150 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

4.0 s

2.0 s

CONT/ PULSE CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 150 A 3.0 s SLOPE in sector 2.

dpa8d1eb

-- 3 2 --

Entert

3teteaue3

6.5 Example 1e:

We now want to make changes in the program by moving the breakpoint in sector 3 from 0.500 to 0.750 and a sector slope in sector 2 and sector 3.

Sector 1 Sector 2 Sector 3 Sector 4 Breakpoint 0.000 0.250 0.750 1.010 Welding current (continuous) (A) 155 150 145 0 Welding current (background current) (A) 100 100 100 100 Welding current (pulse time) (s) 0.5 0.5 0.5 0.5 Welding current (background time) (s) 1.0 1.0 1.0 1.0 Slope up (s) 2 -- -- -Slope down (s) -- Sector

slope

Preheating (s) 2 2 2 2 Rotation, (cont. forward) (‰) 250 250 250 250 Gas preflow (weld gas) (s) 5 -- -- -Gas postflow (weld gas) (s) -- -- -- 7 Wire feed (continuous)

110 110 110 110 (cm/min)

Sector slope

We want to add a sector slope in sector 2.

S Press the soft key for continuous peak current .

S Press the keys SHIFT

and SLOPE .

SECTOR 2(4) 0.250

2 PEAK CURRENT 150 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: PEAK CURRENT = 150 A in sector 2.

Sector

Go to sector 3.

using the numerical keys.

S Press the SECTOR

key.

evalue

SECTOR 2(4) 0.250

2 PEAK CURRENT 150 A 1 BACKGR CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

BACKGR

TIME

2.0 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

-- 3 3 --

dpa8d1eb

heSECTORPresstheSECTO

Result: You have moved to sector 3.

Breakpoint

The breakpoint = 0.750 instead of 0.500. To change the breakpoint, proceed as follows:

S Press the SECTOR key

. The digit box now shows 0.500.

S Enter the value 0.75 using the numerical keys. S

ress

key again.

SECTOR 3(4) 0.500

3 PEAK CURRENT 145 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

3 SPECIAL PULSING

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

Result: The new breakpoint = 0.750 in sector 3.

Sector slope

We now want to add a sector slope to sector 3.

S Press the soft key continuous peak current.

0.75

BACKGR

TIME

3.0 s

SPEC. PULS

S Press the keys SHIFT

and SLOPE .

SECTOR 3(4) 0.750

3 PEAK CURRENT 145 A 1 BACKGR. CURRENT 100 A 1 PEAK TIME 0,50 s 1 BACKGR. TIME 1,00 s

CONT/ PEAK CURR.

BACKGR

CURR.

Result: PEAK CURRENT = 145A .

PEAK TIME

BACKGR

TIME

2.0 s

dpa8d1eb

-- 3 4 --

ftkeyesstesote

7 THE LIBRARY

Welding programs created in the working area are stored in the library. You can save 250 places depending on how big the programmes are. (See the section PC-- CARDS, page 39.)

7.1 Storing a program

S Make up a program in the working area.

S Press the MEMORY key

S Enter the position no. of the program (for example 3) using the numerical keys. S

ress

store.

eso

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE RECALL PC--

CARD

DELETE

PROG.

STO flashes in the digit box. Result: The program is to be found under program position 3 in the library. NOTE! If the directory is full when you save, the directory is compressed. This takes

approx. 10 seconds. If there is space for the programme, it is saved. If there is no space for the programme, the error editing code xxx will appear.

S Leave the library and use the MEMORY key

to return to the working area.

7.2 Recalling a program

Note! When recalling a program from the library, the working area must be empty.

S Press the MEMORY key S Select a program position (for example 3) using the numerical keys.

ress

eso

recall.

(NEXT) PAGE

RCL flashes in the digit box.

dpa8d1ec

LIBRARY Page 1 (1)

STORE

-- 3 5 --

RECALL

PC-CARD

DELETE

PROG.

heSHIFTPresstheSHIF

ftkeyesstesote

S Press the MEMORY key to get back to the working area. Result: You have recalled a copy of program no. 3 from the library to the working

area.

7.3 Viewing the tool code

In the library you can also view the tool code that is connected with a particular program position.

S Press the MEMORY key

S Select a program position (for example 3) using the numerical keys. S

ress and MEM keys at thesametime.

LIBRARY Page 1 (1)

(NEXT) PAGE

STORE

RECALL

PC-CARD

DELETE

PROG.

Result: The display shows the tool code (PRB 33 --90 mm) connected with program position no. 3.

S Press the MEMORY key

to get back to the working area.

7.4 Deleting a program

S Press the MEMORY key . S Select a program position (for example 3) using the numerical keys

ress delete program.

eso

LIBRARY Page 1 (1)

(NEXT) PAGE

The following display comes up:

ress yes.

dpa8d1ec

eso

Library Page 1 (1)

STORE RECALL PC--

-- 3 6 --

CARD

NO YES

DEL?

DELETE

PROG.

Result: You have deleted program position no. 3 in the library.

S Press the MEMORY key

to get back to the working area.

8 MANUAL MODE

8.1 Field of application

Manual mode is used for correct positioning of the tungsten electrode before the

welding, and for making sure that the program in the working area functions as desired.

The following welding parameters can be modified:

NOTE! When pressing START in any of the manual menus (except the gas menu), the program will be ru n in the working area without arc.

Gas

Wire feed speed

Rotation speed

8.2 Editing a parameter

S Press the MANUAL MODE key .

Change rotation speed forward

S Press the ROTATION SPEED key

MANUAL

ROTATION FORWARD ROTATION BACKW:

ROTA-TION FORW.

ROTA-TION BACKW.

S Press the soft key rotation forward and run the motor by pressing the PLUS

key

or the MINUS key .

NOTE! If the soft key for rotation backward and the PLUS key pressed, the result will be rotation forwards,

-- 3 7 --

dpa8d1ec

are

Themessagelinedispl

aysgp

S Enter a value using the numerical keys and press the soft key rotation forward

(the rotation stops after 1 turn).

When you return to the working area, the program will start from the adjusted position.

MANUAL

ROTATION FORW ROTATION BACKW.

ROTA-TION FORW.

ROTA-TION BACKW.

Result: The program will start without the arc (i.e. the value of the welding current parameter = 0).

The same procedure is used for changing the value of the parameters for wire feed speed.

The followin g applies with regard to the gas parameter:

S Press the soft key weld gas to open the gas valve, S Press the soft key weld gas once again to close the gas valve.

From this position the welding (with arc) is started in the following way:

S Press the START key

welding.

MANUAL

WELDING

WELD GAS

ROOT GAS

START GAS

You will get back to the working area automatically.

dpa8d1ec

-- 3 8 --

ftkeyesstesote

9 PC--CARD

9.1 Field of application

The PC --card is used for storing all the welding programs in the library. It also makes it possible to copy welding programs between different control boxes.

9.2 How to install the card

S Open the door on the left side panel of the control box. S Insert the PC--card into the card reader so that the lock

catches.

S Close the door.

9.3 How to recall a program

S Press the MEM key .

Note! When a program is recalled from the PC--card, all the programs in the

library are automatically deleted. If you want to keep the library programs, you must first store them on another PC--card.

S Press the soft key PC--card. S

ress recall.

eso

PC--CARD

STORE

RECALL

QUIT

DELETE

CARD

After a couple of seconds a pop--up menu confirms the action.

PC--CARD

RECALLED WELD DATA

SET FROM PC--CARD

STORE RECALL QUIT

DELETE

CARD

Result: All the programs previously stored on the PC--card have now been copied and stored in the library.

S Press the soft key quit to return to the library.

dpa8d1ec

-- 3 9 --

ftkeyPressthesoftkey

ftkeyesstesote

9.4 How to store a program

S Press the MEMORY key S Press the soft key PC--card.

Note! When a program is stored on the PC- card, all other programs on

the card will automatically be deleted.

ress

store.

eso

PC--CARD

STORE RECALL QUIT

DELETE

CARD

After a couple of seconds a pop--up menu confirms the action.

PC--CARD

STORED WELD DATA

SET IN PC--CARD

STORE RECALL QUIT

DELETE

CARD

Result: All programs stored in the library have now been copied and stored on the PC--card.

S Press the soft key quit to return to the library.

9.5 How to delete a program

S Press the MEM key . S Press the soft key PC--card.

ress delete card.

eso

PC--CARD

STORE RECALL QUIT

After a couple of seconds a pop--up menu confirms the action.

dpa8d1ec

-- 4 0 --

DELETE

CARD

PC--CARD

DELETEDWELDDATA

SET IN PC--CARD

STORE RECALL QUIT

DELETE

PROG

Result: You have deleted all the programs on the PC--card.

S Press the soft key quit to return to the library,

9.6 How to take out the PC--card

S Open the door on the left side panel of the control box. S Press the small black button to the right of the PC--card. S Draw the PC--card out of the card reader. S Close the door.

10 ERROR CODES

10.1 Error handling

Error codes are used to indicate that an error has occurred in the welding process. The code is shown in the display by way of a pop--up menu, displayed for 2,5

seconds. After that an exclamation mark

is shown in the top left corner of the

display. All error codes are stored in an error list and can be studied later on.

SECTOR 3(4) 0.500

CONT/ PEAK CURR.

BACKGR

CURR

PEAK TIME

BACKGR

TIME

Result: An error has occurred in the weld data unit (control box).

dpa8d1ec

-- 4 1 --

ftkeyerrorlo

ftkeyesstesote

Howtoviewtheerrorlog:

S Press the MODE key . S

ress

eso

AUXILIARY FUNCTIONS

LANGUAGE "

ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

SOFT--. WARE UPGR.

SOFT--. WARE KEY

Result: You get into the error log codes.

This can be viewed on the display:

1. The queue number of the error.

2. When the error occurred (Date and time).

3. Where the error occurred.

4. The error code number. For further information about what is wrong, proceed as follows:

NOTE!

disappears from the display as soon as you enter this menu.

S Enter for example error no. 2, using the numerical keys. S

ress view error number.

eso

ERROR LOG Page 1(2 ) 2

Error No" Date Tim Unit Error

1 " 971007 13:07.03 PSOURCE 1 2 " 971007 13:07.50 CBOX 18 3 " 971007 14:56.07 ROT/WIRE 2

(NEXT) PAGE

PAG E

VIEW ERROR NO.

QUIT DELETE

ALL

Result: Information about error code 18 is shown, CBOX (the weld data unit in the control box) has lost contact with the welding power source.

A more detailed description of the error and measures to be taken are shown in the table over Error Codes Resulting from Incorrect Editing on page 44.

How to delete an error

ress

eso

delete error.

dpa8d1ec

log

ERROR LOG -- VIEW MESSAGE 1

Error 18: " Lost contact with power source Unit: CBOX Date: 971007 Time: 13:07.50

-- 4 2 --

QUIT DELETE

ERROR

Result: The error code disappears from the display. If you want full control over errors occurring over a period you need not delete the

errors. Up to 100 error numbers can be stored in the control box.

Overview of erro r handling

Code Description CBOX ROOT/

1 EPROM x x x 2 RAM x x x 3 External RAM (write, read) x x 4 Supply voltage 5V x 5 High + DC voltage x 6 High temperature x 7 High primary current x 8 Supply voltage 1* x x x 9 Supply voltage 2* x x 10 Supply voltage 3* x 11 Current servo/Wire speed servo x 12 Communication error (warning) x x x 13 Servo 1 x 14 Communications error (bus off) x 15 Lost messages x x x 16 Servo 2 x 17 Contact lost with the motor unit x 18 Contact lost with weld. power source x 19 Memory error in battery--fed computer memory x 20 Prohibited setting values x 21 Current limit 1 x 22 Spill in buffer transmitter x 23 Spill in buffer receiver x 25 Incompatible weld data format x 26 Watch dog x x 28 Spill in stack x x x 29 No water flow x 30 Contact lost with TIG card x 31 No response from display unit x 32 No gas flow x

codes

PSOURCE

WIRE

Unit Supply voltage 1* Supply voltage 2* Supply voltage 3*

CBOX +3V ROOT/WIRE + 15V + 60V PSOURCE +15VC --15V +15VB

CBOX = Weld Data card, control box ROOT/WIRE = Motor ca rd for controlling the rotation and wire feed motors. PSOURCE = Circuit card for controlling the welding power source.

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-- 4 3 --

Error handling codes

Code Description

1 Program memory error (EPROM)

Cause: The program memory has lost a value. I.e the value in a particular memory position

no longer agrees with the original value. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

2 Error in the microprocessor RAM

Cause: The microprocessor cannot write/read a certain memory position in its own internal

memory. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

3 Error in external RAM

Cause: The microprocessor cannot write/read a certain memory position in its own external

memory. No functions are blocked through this error. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

4 Voltage drop in the 5 V supply voltage

Cause: Supply voltage too high.

All normal microprocessor activities cease, waiting for switch--off. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

5 High + DC voltage outside limit value

Cause: Voltage too high or too low. Too high a voltage can be due to powerful transients on

the mains supply or to a weak supply system (high inductance on the mains) The welding power source is automatically switched off. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

6 High temperature

Cause: The thermal cut--out has tripped.

The welding power source is automatically switched off and cannot be switched on again until the temperature has gone down and the cut--out is reset. Measure: Check that the cooling air intake/outlet are not blocked or dirty. Check that the work cycle does not exceed the ratings.

7 High primary current

Cause: Current too high in the welding power source.

The welding power source is automatically switched off and permanently blocked. Measure: Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

8 Low battery voltage, weld data card (control box)

Cause: Battery voltage too low.

No functions are blocked through this error.

Measure: Make a backup on a PC--card. Call in a service technician.

8 Supply voltage +15 VC, PC --card (welding power source)

Cause: Voltage too high or too low. Measure: Call in a service technician.

8 Supply voltage +15 V, motor card (rotation/wire)

Cause: Voltage too low. Measure: Call in a service technician.

9 Supply voltage --15V, PC--card (welding power source)

Cause: The voltage is either too high or too low. Measure: Call in a service technician.

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-- 4 4 --

9 Supply voltage +60 V, motor card (rotation/wire)

Cause: Current too low. Measure: Call in a service technician.

10 Supply voltage +15 VB, PC--card (welding power source)

Cause: Voltage too high or too low. Measure: Call in a service technician.

11 Incorrect current, PC--card (welding power source)

Cause: The welding power source failed in supplying the current determined by the proces-

sor. No functions are blocked through this error.

Measure: Call in a service technician.

12 Communication error (warning)

Cause: The CAN circuit error counter shows too high value.

The contact with the control box can be broken. This can result from occasional overload.

Measure: Check the handling of the program during welding.

13 Incorrect rotation speed

Cause: Cannot keep up the speed determined by the processor. The welding is interrupted Measure: Check the cabling. If the error remains, call in a service technician.

14 Communication error

Cause: The CAN circuit error counter shows too high value.

The welding process is stopped. This can result from occasional overload. Measure: Check the handling of the program during welding. Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

15 Lost messages

Cause: A message has been overwritten by another message. A too frequent use of the

pushbuttons on the control box, during welding, may cause this fault. The welding process is stopped. Measure: Check the handling of the program during welding. Voltage disconnection necessary for resetting. If the error remains, call in a service technician.

16 Incorrect wire feed speed

Cause: Cannot keep up the speed determined by the processor. Measure: Check the cabling.

17 Contact lost

Cause: The control box has lost contact with one or both the motor units. Activities in pro-

gress are disabled.

Measure: Check the cabling. If the error remains, call in a service technician.

18 Contact lost

Cause: The control box has lost contact with the power source. Activities in progress are

disabled.

Measure: Check the cabling. If the error remains, call in a service technician.

19 Error in computer memory (RAM)

Cause: Can result from program upgrading. Measure: Switch on the mains voltage, and automatic resetting is effected.

20 Unpermitted setting values stored (RAM)

Cause: Unpermitted values found at the start. The error may result from software upgra-

ding. All data in the control box are deleted.

Measure: Switch on the mains voltage, and automatic resetting is effected.

21 Current limit 1

Cause: Motor overload for rotation or weaving. Measure: Check the welding tool and its cabeling.

22 Spill in buffer transmitter

Cause: The buffer transmitter is full. Activities in progress are disabled. Measure: Check the handling of the program during welding.

dpa8d1ec

-- 4 5 --

23 Spill in buffer receiver

Cause: CAN messages are received faster than the weld data card can cope with. Activities

in progress are disabled.

Measure: Check the handling of the welding program during welding.

25 Incompatible weld data format

Cause: Tried to store weld data on a PC--card. The PC--card contained other data format

than the weld data memory.

Measure: Use another PC--card.

26 Watchdog

Cause: Something prevented the processor executing its normal tasks in the program.

No functions are blocked through this error.

Measure: Check the handling of the welding program during welding.

28 Spill in the stack

Cause: The internal memory is full. The error may be caused by abnormal load on the pro-

cessor.

Measure: Check the handling of the welding program during welding.

29 No water flow

Cause: The cooling water flow has gone down below 0.7 l/min. Activities in progress are

disabled.

Measure: Check the cooling water.

30 Contact lost with the TIG--card

Cause: The control box has lost contact with the TIG--card.

Activities in progress are disabled.

Measure: Check the cabling. If the error remains, call in a service technician.

31 No response from the display unit

Cause: The microprocessor gets no acknowledgement from the display unit. Measure: Call in a service technician.

32 No gas flow

Cause: The gas flow has gone down below 6 l/min. Measure: Check the gas valve, gas hoses and connections.

10.2 Incorrect editing codes

Codes depending on incorrect editing come up in the digit box when the wrong key is activated. The error code number always starts with

Code Cause

13 Error in running the program. 110 Working area not empty when a program is recalled from the library. 111 The program number does not exist in the library. 131 Key activation prohibited during welding. 133 Permitted only during welding. 134 PC--card missing. 135 PC--card model for the welding power source (LTS 320) not accepted. 136 Wrong program version of PC--card. 160 Working area is full. 163 The value in the digit box cannot be interpreted by the control box. 176 Welding program not accepted for welding. 177 Welding start prohibited in this program position in the control box. 178 The reset function does not work; must be preceded by a stop. 198 Welding start prohibited in manual program when the motors are activated.

dpa8d1ec

-- 4 6 --

ftk

parameter

Code Cause

199 Welding start prohibited when activities are going on in the library. 204 A sector value cannot be changed so as to be placed before the previous sector or after the

following one.

205 A key is activated on the control box when the tool is started. 206 Tool code for the connected tool is missing. 207 Tool code not accepted. 212 Soft key not activated. 213 Delete state: Key prohibited. 221 Key not defined in this state. 222 When starting: Only tool code permitted. 223 Delete state: Key not defined. 229 Corr. state: Key activation prohibited. 233 Desired slope function: Parameter empty or not defined. 252 The tool code of the connected tool does not correspond to the one of the welding program

in the working area.

11 SHOW CURRENT P ARAMETER VALUES

11.1 Field of application

Using this function it is possible to view the measured values of different welding parameters in the course of welding. The values are updated every 0.5 seconds.

The following parameter groups can show actual parameter values:

Welding current Wire feed speed

Rotation speed Gas

11.2 How to view actual parameter values

S Press the MODE key and you get to the Auxiliary Functions. S

ress

eso

ey show

AUXILIARY FUNCTIONS

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

ERROR LOG

SHOW PARA-METER

SOFT-WARE UPGR.

SOFT-WARE KEY

Result: SHOW ACTUAL PARAMETER VALUES is marked and you have activated

show actual parameter valu es.

dpa8d1ec

-- 4 7 --

S Press the START key to start welding. S Press the desired parameter key.

The actual parameter values can now be viewed in the display.

12 SOFTWARE UPGRADE

12.1 Applicatio n field

Using the upgradE function you can replace (upgrade) programs in the different units (PC-- cards) of the welding equipment by new software from a PC--card.

By unit is here meant a PC--card, containing software that can be upgraded.

12.2 Menu explanation

SOFTWARE UPGRADE

Unit Curr.ver PC--card

SYSTEM VERSION. 1.00B BOOT SOFTWARE 1.12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? -- j WELD DATA UNIT 0.00 --

Curr--ver Describes which program version that is active in this unit. PC--card Describes the program version stored on the PC--card. ? A unit exists but the computer does not know which version it is.

-- There is no program for this unit on the PC--card. SYSTEM VERSION Indicates the program version stored on the PC--card. A program

version can consist of 1--4 programs (1 for each unit).

BOOT SOFTWARE Program for upgrade handling. POWER SOURCE PC--card for controlling the welding power source. ROT/WIRE UNIT PC--card for controlling the rotation and wire feed motors. WELD DATA UNIT The PC--card in the control box.

j j

QUIT UP--

GRADE

12.3 How to upgrade

When upgrading the control box, all existing weld data will be deleted. Do not forget to store the data on a PC--card before the upgrade procedure is started.

To upgrade the ROT/WIRE WELD DATA (control box) unit, proceed in the same way as for the POWER SOURCE.

dpa8d1ec

-- 4 8 --

ftkeysoftwareupgrade

ftk

“

ftk

Upgrading the power source unit

Make sure the mains voltage for the welding power source will not be disconnected in the course of upgrading.

S Insert the PC--card containing the upgrading program.

S Press the MODE key to get to the auxiliary functions. S

ress

eso

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

AUXILIARY FUNCTIONS

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

SOFT WARE

UPGR.

SOFT-WARE KEY

Result: You have come to the software upgrade menu. In this example the program version of the PC--card only consists of one upgrade

program for the power source unit. The following display comes up.

ress

next till you get to

power source”.

“

eso

Unit Curr.ver PC--card

SOFTWARE UPGRADE

”

SYSTEM VERSION. 1.00B BOOT SOFTWARE 1.12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? --

j WELD DATA UNIT 0.00 --

j j

QUIT UP

GRADE

S Press the second soft key to mark the power source unit (gets ticked off).

If further units are to be upgraded, they shall be marked in the same way. By pressing the second soft key once again, the selection marked is cancelled

(the marking disappears).

ress

upgrade.

eso

SOFTWARE UPGRADE

Unit Curr.ver PC--card

SYSTEM VERSION. 1,00B BOOT SOFTWARE. 1,12

j POWER SOURCE 1.00 2.00 j ROT/WIRE UNIT ? --

j WELD DATA UNIT 0,00 --

A dialogue box comes up in the display.

dpa8d1ec

j j

-- 4 9 --

QUIT UP--

GRADE

ftk

ress

yes for upgrading.

The following dialogue box comes up in the display while upgrading:

eso

SOFTWARE UPGRADE

THE SOFTWARE UPGRADING CAN

TAKE UP TO 5 MIN/UNIT AND.

CANNOT BE INTERRUPTED!

DO YOU STILL WANT TO DO IT ?

SOFTWARE UPGRADE

DO NOT SWITCH OF THE EQUIPMENT

DURING THIS PROCESS!!

UPGRADING POWER SOURCE .....

23% completed

kkkkkkkkkkkkkkkkk

YES NO

After completed upgrading the following comes up in the display:

SOFTWARE UPGRADE

SUCCESSFUL UPGRADE!

YOU MAY NOW RESTART THE EQUIPMENT !

Result: The power source unit has been upgraded to program version 2.00. To make it possible to use the welding equipment, restart the welding power source

S Turning the mains voltage switch to position 0. S Turning the mains voltage switch to position 1.

dpa8d1ec

-- 5 0 --

12.4 Measures to be taken when the upgrading of the power source

units failed

The software upgrade can for example fail if the supply voltage for the welding power source is interrupted while upgrading is going on.

Failure in upgrading the power source, rot/wire units

The following dialogue box comes up in the display when the software upgrade has failed:

SOFTWARE UPGRADE

UPGRADING PROCESS FAILED!: 6

UNIT: 2!

Try once more to upgrade:

S Turn the mains voltage switch on the power source to position 0. S Hold down the fourth one of the five soft keys on the control box and turn the

mains voltage switch to position 1. Hold down the soft key until a double--squeak is heard. The welding power source starts again, the power source, rot/wire units in an

upgrade position, permitting a new program upgrade. The control box shows the upgrade menu display.

Repeat the program procedure “how to upgrade”, see page 48.

12.5 Measures to be taken when the upgrading of the control box

failed

The software upgrade can for example fail if the supply voltage for the welding power source is interrupted while upgrading is going on.

Should this happen the first fifteen seconds during the upgrade

procedure, an ESAB service technician must be called in.

Try once more to upgrade:

S Turn the mains voltage switch on the welding power source to position 0. S Insert the PC--card containing the upgrade program for the control box. S Hold down the fifth one of the five soft keys at the same time as you turn the

mains voltage switch to position 1.

dpa8d1ec

-- 5 1 --

key

Hold down the soft key until a double--squeak is heard. While the control box is being upgraded the display is empty. When the

procedure is finished, the control box will start up in the normal way. The upgrade procedure takes about 5 minutes. N.B. Do not switch off the welding power source while upgrading is going on.

If it still does not work, call in a service technician.

13 SOFWARE KEY

13.1 General

The software key is for blocking some of the functions in the setting unit, for example changing setting data in a welding program, saving programs in the library or on a PC card. The auxiliary functions are also blocked when the software key is activated.

13.2 Locking the control box

S Press the MODE key to get to the auxiliary functions. S

ress

e so

ware

AUXILIARY FUNCTIONS

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

ERROR LOG

SHOW PARA- METER

Result: You have come to the software key menu.

dpa8d1ec

-- 5 2 --

SOFT--. WARE UPGR.

SOFT-WARE KEY

ftkeyPressthesoftkey

ftkeyesstesote

Entert

ttetecoec

(

e.g.1234)usingthe

S Enter 4 code numbers using the numerical keys. S

ress

enter.

eso

SOFTWARE KEY 1234

KEY CODE (4 NUMBERS):

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

The following display comes up:

ress

lock.

eso

SOFTWARE KEY

THE CONTROLBOX IS UNLOCKED!

LOCK UN

LOCK

KEY CODE (4 NUMBERS): 1234

Result: The control box is locked.

S Press the key

to return to the working area.

13.3 Unlocking the control box

S Press the MODE key . The following display comes up:

LIMITS QUIT ENTER

LIMITS. QUIT ENTER

e correc

code (4 numbers,

numerical keys.

THECONTROLBOXISLOCKED!

KEY CODE (4 NUMBERS):

ENTER

Each code number entered is acknowledged by :

S Press the soft key enter.

Result: The control box is unlocked and you have come to the auxiliary function menu.

dpa8d1ec

-- 5 3 --

ftkeyPressthesoftkey

ftkeyesstesote

13.4 Changing the code

S Enter 4 new code numbers using the numerical keys. S

ress

enter.

eso

SOFTWARE KEY 1111

KEY CODE (4 NUMBERS): 1234

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

LIMITS QUIT ENTER

The following display comes up:

ress

lock.

eso

SOFTWARE KEY

KEY CODE (4 NUMBERS): 1111

THE CONTROLBOX IS UNLOCKED!

LOCK UN--

LOCK

LIMITS QUIT ENTER

Result: The control box has got a new code and is locked.

S Press the key

to return to the working area.

13.5 Forgotten the code?

If you have forgotten the code, call your nearest ESAB service technician.

13.6 How to indicate limit values

For the following welding parameters limit values can be indicated in per cent of the set value, max. +10%:

CURRENT

Peak current and background current.

ROTATION Rotation forward, rotation backward, pulsed rotation forward or pulsed rotation backward.

WIRE FEED Wire feed speed during peak current and background current.

POSITION Breakpoint

dpa8d1ec

-- 5 4 --

ftk

softwarekey

ftkeyesstesote

desiredparamete

CURRENT TIME

Pulse time and background time. Limit values cannot be indicated until a program has been made up in the working

area.

S Press the MODE key S

ress

eso

LANGUAGE " ERROR LOG " SHOW ACTUAL PARAMETER VALUES SOFTWARE UPGRADE " SOFTWARE KEY "

LAN-GUAGE

The following display comes up:

ress

limits.

eso

SOFWARE KEY

to get into the auxiliary functions.

AUXILIARY FUNCTUIONS

ERROR LOG

KEY CODE (4 NUMBERS):

THECONTROLBOXISUNLOCKED!

SHOW PARA- METER

SOFT-WARE UPGR.

SOFT-WARE KEY

LOCK UN--

LOCK

LIMITS QUIT ENTER

Result: You have come into the menu software key limit values. The following display comes up:

ress

next to get to the

eso

SOFTWARE KEY LIMITS

+/-- +/--

CURRENT: 0% CURRENT TIME: 0% ROTATION: 0% WIRE FEED: 0% POSITION: 0%

QUIT

ENTER

S Press the soft key (--) or (+) to indicate a limit value in per cent of the set value,

max. +10%.

S When the settings are made, press the soft key enter (a beep is heard) to save

the settings.

S Press the soft key quit.

-- 5 5 --

dpa8d1ec

ftkeyPressthesoftkey

The following display comes up:

ress

lock.

eso

SOFTWARE KEY

KEY CODE (4 NUMBERS):

THECONTROLBOXISUNLOCKED

LOCK UN--

LOCK

LIMITS QUIT ENTER

Result: The setting box with the new limit values is locked. NB. Next time you go into the menu software key limit values the values are back

to 0% again. New limit values are calculated if you press the soft key enter.

S Press the key

to return to the working area.

14 NOTEBOOK

14.1 Field of application

The notebook is used for making notes on for example:

S MATERIAL, TUBE DIAMETER, WALL THICKNESS, RUN NUMBER S START POINT, WELD TIME S ELECTRODE DIAMETER, ELECTRODE STICKOUT, ELECTRODE ANGLE S DISTANCE: ELECTRODE--WIRE, ELECTRODE--WORKPIECE S WIRE TYPE, WIRE DIMENSION, ELECTRODE TYPE S WELD GAS S ROOT GAS S START GAS

All notes are stored together with the welding program in the library.

14.2 How to enter data in the notebook

S Press the SHIFT key and the STEP key to get to the notebook.

NOTEBOOK Page 1(8)

MATERIAL TUBE DIAMETER. WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

WALL THICKN

RUN NO

dpa8d1ec

-- 5 6 --

ftkeyesstesote

14.3 Example 2a:

Here a few examples of notes that can be made in the notebook.

Welding para-

meter

Material SIS designation for stainless steel. 2333 Tube diameter The external diameter of the tube. 60 mm Wall thickness The thickness of the tube wall. 3mm Run number Which joint number. 2 Start point Where on the tube the start point is. 3 o’clock Weld time The time required for running a welding a program. 1h20min30s Electrode

diameter Electrode

stick--out Electrode angle The angle of the tungsten electrode in relation to the tube. 30˚ Distance:

Electrode--wire Distance: Elec--

trode--workpiece

Wire type Type of filler wire used. OK 12.51 Wire dimension Dimension of the filler wire used. 0.8 mm Electrode type Quality of tungsten electrode (thorium, lanthan). 2% Th, 2% La Weld gas Weld gas components (argon, helium, hydrogen, nitrogen). 100 % Ar Root gas Root gas components (argon, helium, hydrogen, nitrogen). 100 % Ar Start gas Start gas components (argon, helium, hydrogen, nitrogen). 100 % He

The diameter of the tungsten electrode. 1.6 mm

The stick--out of the tungsten electrode from the electrode holder.

The distance between the tungsten electrode and the filler wire.

The distance between the tungsten electrode and the workpiece (the tube).

Explanation Value

5mm

Material = 2333

S Enter the value 2333 using the numerical keys. S

ress

material.

eso

NOTEBOOK Page 1(8)

MATERIAL TUBE DIAMETER. WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

2333

WALL THICKN

RUN NO

dpa8d1ec

-- 5 7 --

ftkeyPressthesoftkey

ftkeyesstesote

External tube diameter = 60 mm

S Enter the value 60 using the numerical keys. S

ress

tube diameter.

eso

NOTEBOOK Page 1(8)

MATERIAL 2333 TUBE DIAMETER. WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

WALL THICKN

RUN NO

(If you have entered a value for the external diameter of the tube, the measurement value of the rotation speed is indicated in cm/min.)

Wall thickness = 3 mm

S Enter the value 3 using the numerical keys. S

ress

wall thickness.

eso

NOTEBOOK Page 1(8)

MATERIAL 2333 TUBE DIAMETER. 60. mm WALL THICKNESS RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

WALL THICKN

RUN NO

Run number = No 2

S Enter the value 2 using the numerical keys. S

ress

run number

eso

NOTEBOOK Page 1(8)

S Press the soft key

next page.

dpa8d1ec

MATERIAL 2333 TUBE DIAMETER 60.0 mm WALL THICKNESS 3.00 mm RUN NUMBER

(NEXT) PAGE

MATER.

TUBE DIAM.

-- 5 8 --

TUBE THICKN

RUN NO

ftkeyPressthesoftkey

ftkeyesstesote

Start point = 3 o’clock

S Enter the value 3 using the numerical keys. S

ress

start point.

eso

NOTEBOOK Page 2(8)

START POINT WELD TIME

(NEXT) PAGE

START POINT

HOUR

Welding time = 1 h 20 min 30 s

S Enter the value 1 using the numerical keys. S Press the soft key hour. S Enter the value 20 using the numerical keys. S Press the soft key minute. S Enter the value 30 using the numerical keys. S Press the soft key second.

ress

next page.

eso

NOTEBOOK Page 2(8)

START POINT 3 o’clock WELD TIME 1 h

(NEXT) PAGE

START POINT

HOUR

20 min 30 s

MIN

SECOND

Electrode diameter = 1.6

S Enter the value 1.6 using the numerical keys. S

ress

diameter.

dpa8d1ec

eso

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER ELECTRODE STICKOUT ELECTRODE ANGLE

(NEXT) PAGE

DIAM.

-- 5 9 --

STICK- -

OUT

1.6

ANGLE

ftkeyPressthesoftkey

ftkeyesstesote

ftkeyPressthesoftkey

ftkeyesstesote

Electrode stick--out = 5 mm

S Enter the value 5 using the numerical keys. S

ress

stick--out.

eso

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER 1.6 mm ELECTRODE STICKOUT ELECTRODE ANGLE

(NEXT) PAGE

DIAM.

STICK--

OUT

Electrode angle = 30˚

S Enter the value 30 using the numerical keys. S

ress

angle.

S Press the soft key

next page.

eso

NOTEBOOK Page 3(8)

ELECTRODE DIAMETER 1.6 mm ELECTRODE STICKOUT 5.0 mm ELECTRODE ANGLE

(NEXT) PAGE

DIAM.

STICK- -

OUT

Distance: Electrode--Wire = 5 mm

S Enter the value 5 using the numerical keys. S

ress

electrode --wire.

eso

NOTEBOOK Page 4(8)

DISTANCE: ELECTRODE -- WIRE ELECT. -- WORKPIECE

ANGLE

(NEXT) PAGE

ELECT.

-WIRE

ELECT.

WORKP.

Distance: Electrode--workpiece = 5 mm

S Enter the value 5 using the numerical keys. S

ress

electrode -workpiece.

S Press the soft key

next page.

dpa8d1ec

eso

NOTEBOOK Page 4(8)

DISTANCE: ELECTRODE -- WIRE 5.0 mm ELECT. -- WORKPIECE

(NEXT) PAGE

ELECT.

-WIRE

ELECT.

WORKP.

-- 6 0 --

ftkeyPressthesoftkey

ftkeyesstesote

Wire quality = OK 12.51

S Enter the value 12.51 using the numerical keys. S

ress

wire type.

eso

NOTEBOOK Page 5(8)

WIRE TYPE WIRE DIAMETER ELECTRODE TYPE

12.51

(NEXT) PAGE

WIRE TYPE

WIRE.

DIAM.

Wire dimension = 0.8 mm

S Enter the value 0.8 using the numerical keys. S

ress

wire diameter.

eso

NOTEBOOK Page 5(8)

WIRE TYPE 12.51 WIRE DIAMETER ELECTRODE TYPE

(NEXT) PAGE

WIRE TYPE

WIRE.

DIAM.

Electrode quality = 2% Th, 2 % La

S Enter the value 2 using the numerical keys. S Press the soft key electrode % Th. S Enter the value 2 using the numerical keys.

ELECT. %Th

0.8

ELECT. %Th

ELECT. %La

S Press the soft key electrode % La. S

ress

next page.

eso

NOTEBOOK Page 5(8)

WIRE TYPE 12.51 WIRE DIAMETER 0.8 mm ELECTRODE TYPE

(NEXT) PAGE

WIRE TYP

WIRE.

DIAM.

ELECT. %Th

ELECT. %La

dpa8d1ec

-- 6 1 --

ftkey%Pressthesoftkey%

ftkey%esstesotey

ftkey%Pressthesoftkey%

Weld gas = 100 % Ar

S Enter the value 100 using the numerical keys. S

ress

Argon.

eso

NOTEBOOK Page 6(8)

100

S Press the soft key

WELD GAS

next page.

(NEXT) PAGE

%Ar

%He

Root gas = 100 % Ar

S Enter the value 100 using the numerical keys. S

ress

Argon.

S Press the soft key

eso

NOTEBOOK Page 7(8)

ROOT GAS

next page.

(NEXT) PAGE

%Ar

%He

%H %N

100

%H %N

Start gas = 100 % He

S Enter the value 100 using the numerical keys. S

ress

Helium.

eso

NOTEBOOK Page 8(8)

START GAS

(NEXT) PAGE

%Ar

%He

100

%H %N

S Press the keys SHIFT and STEP to return to the working area.

15 MANUAL WELDING

15.1 Field of application

Used for normal manual TIG welding with a hand torch (see the respective instruction manual).

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ftkeyesstesote

15.2 How to create a welding program

To enable hand--welding it is necessary to create a welding program, consisting of two sectors with the welding current and gas parameters indicated. NB. Rotation

cannot be indicated!

15.3 Example 3a:

Start by entering the correct tool code TIG HAND TORCH. This is a simple welding program, consisting of 2 sectors, sector 2 being a stop

sector.

Sector 1 Sector 2

Breakpoint 0.000 1.000 Welding current (continuous) (A) 80 0 Welding current (background current) (A) 40 40 Welding current (pulse time) (s) 0.5 0.5 Welding current (background time) (s) 0.5 0.5 Slope up (s) 2 -Slope down (s) -- 5 Gas preflow (weld gas) (s) 5 -Gas postflow (weld gas) (s) -- 10

Sector 1 Breakpoint

Sector 1 automatically is assigned the breakpoint 0.000, if nothing else is indicated. Start by indicating the welding current parameter.

Welding current Peak current = 80 A

S Press the key for WELDING CURRENT

The picture for setting the welding current comes up in the display.

S Enter the value 80 using the numerical keys. S

ress

continuous peak current.

eso

SECTOR 1(1) 0.000

PEAK CURRENT A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 80 A in Sector 1. Background current = 40 A

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ftkeyPressthesoftkey

ftkeyesstesote

ftkeyPressthesoftkey

S Enter the value 40 using the numerical keys. S

ress

continuous background current.

eso

SECTOR 1(1) 0.000

PEAK CURRENT 80 A

BACKGR. CURRENT A PEAK TIME s BACKGR. TIME s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: BACKGROUND CURRENT = 40 A in sector 1. Pulse time = 0.5 s instead of 1.0

S Enter the value 0.5 using the numerical keys. S

ress

peak time.

eso

SECTOR 1(1) 0.000

1 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 1.00 s BACKGR. TIME 1.00 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK TIME = 0.50 s instead of 1.00 s in sector 1. Background time = 0.5 s instead of 1.0

S Enter the value 0.5 using the numerical keys. S

ress

background time.

eso

SECTOR 1(1) 0.000

0.5

1 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 0. 50 s BACKGR. TIME 1.00 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: BACKGROUND TIME = 0.50 s instead of 1.00 s in sector 1.

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Entert

2Enterthevalue2

ftkeyesstesote

heSECTORessteSC

Slope Slope up = 2sfor peak current.

S Press the soft key continuous peak current. S

using the numerical keys.

S Press the SLOPE

key.

evalue

SECTOR 1(1) 0.000

2 PEAK CURRENT 80 A

BACKGR. CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 80 A, 2.0 s in sector 1, and BACKGROUND CURRENT = 40 A, 2.0 s in sector 1.

Gas Gas preflow, weld gas = 5s.

S Press the gas key . S Enter the value 5 using the numerical keys.

The gas preflow is preset to 2 seconds, which applies if nothing else is entered and indicated in the display at the start.

ress

weld gas.

eso

SECTOR 1(1) 0.000

WELD GAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: WELD GAS = 5 s in sector 1.

Sector 2 Breakpoint

S Enter the value of the new breakpoint 1.010 using the numerical keys. S

ress

key.

SECTOR 1(1) 0.000 1.010

1 WELD GAS 5 s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: Sector 2 out of 2 sectors in all.

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ftkeyPressthesoftkey

Entert

5teteaue5

Welding current

Pulse current = 0A

As sector 2 is to be a stop sector, the welding current must be set to 0 amperes.

S Press the key for WELDING CURRENT . S Enter the value 0 using the numerical keys.

ress

continuous peak current.

eso

SECTOR 2(2) 1.000

1 PEAK CURRENT 80 A

BACKGR CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

2,0 S

2.0 S

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 0 A in sector 2 (stop sector)

Slope Slope down = 5sfor peak current.

S Press the soft key continuous peak current. S

using the numerical keys.

S Press the SLOPE

key.

evalue

SECTOR 2(2) 1.000

2 PEAK CURRENT 0 A

BACKGR CURRENT 40 A PEAK TIME 0.50 s BACKGR. TIME 0.50 s

CONT/ PEAK CURR.

BACKGR

CURR.

PEAK TIME

BACKGR

TIME

Result: PEAK CURRENT = 0 A, 5.0 s in sector 12, and BACKGROUND CURRENT = 40 A,

5.0 s in sector 1.

Gas Gas postflow, weld gas = 10 s in sector 2.

S Press the GAS key

S Enter the value 10 using the numerical keys.

The gas postflow is preset to 4 seconds, which applies if nothing else is entered and indicated in the display at the start.

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-- 6 6 --

ftkeyPressthesoftkey

weld gas.

ress

eso

SECTOR 2(2) 1.000

1WELDGAS s

ROOT GAS s START GAS s

WELD GAS

ROOT GAS

START GAS

Result: WELD GAS = 10 s in sector 2.

15.4 How to weld

Starting a welding sequence (arc strike)

S Press the torch contact and then release it again.

The parameter values for sector 1 (the start sector) apply throughout the welding sequence.

Stopping a welding sequence

S Press the torch contact and then release it again.

The parameter values for sector 2 (the end sector) are used.

16 APPENDIX

16.1 Tool codes

Welding tool Size

PRB 8--17*

17--49*

33--90

60--170

PRH 3--12

PRD See self--defined tool codes on page 13. POC 12--60

Manual TIG torch --

A25 automatic welding machine With rotation

Without rotation

*) When the conversion kit PRB 8--17 is used, the tool code 17--49 applies.

When a drive unit with the gear ratio 134:1 is used, the tool code 8--17 applies.

3--38 6--76

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16.2 Symbols

The following numeric characters can be shown in the digit box.

Numeric character Explanation

STO Store. RCL Recall.

OK Accepted

DEL Delete.

DEL? To be deleted?

Error. (After this symbol always follows an error code number.) Correct the value.

Value too high.

Value too low.

Plus -- minus.

An error occurred in the welding process.

Submenu available.

This function is selected.

16.3 Setting ranges -- welding parameters

Parameter Setting range

Rotation speed 5 -- 100 % of the max.

speed of the tube welding

tool. Welding current* 5 -- 160, 250, 320 A Pulse time 0.01 -- 25 s Background time 0.01 -- 25 s Gas pre-- and post--flow times (weld gas, start gas, root gas)

0 -- 6000 s Preheating time 0 -- 600 s Wire feed speed 15 -- 250 cm/min Slope up/down times 0.1 -- 25 s

The values in brackets are preset. * Max. welding current for air--cooled tube welding tools is 100 A.

Max. welding current for water--cooled tube welding tools is 250 A.

See also the instruction manual of the respective tube welding tool.

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17 MENU STRUCTURE

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Start menu See page 12 Store See page 35 Working area See page 4 Recall See page 35 Library See page 35 PC--card See page 39 Note book See page 56 Delete See page 36 Auxiliary function See page 4 Language See page 17 Welding current See page 9 Error log See page 41 Gas See page 9 Show act. parameter values See page 47 Wire feed speed See page 10 Software upgrade See page 48 Preheating time See page 10 Software key See page 52 Rotation speed See page 11 Lock! See page 52 AVC See page

NO T AG

Weaving See page

NO T AG

Unlock See page 53

Indicate limit values See page 54

18 TECHNICAL TERMS

Background current

Background ti-meThe time for background current together with the time for pulsed current, resul-

Background wire feed speed

Boot program Program for start handling. Breakpoint The start point of a new sector. Digit box Shows the entered numerical values and digits. End sector The last welding sector in a welding sequence. Error handling

code Home position Start position. Incorrect edit-

ing code Library Memory for storing welding programs. Manual mode Machine state for manual positioning of the electrode. Notebook For your own comments on a welding sequence. PC--card Memory for external storing of welding programs. Peak current The highest current value out of two when using pulsed current, or the current

Peak wire feed speed

Preheat time Delay of welding motion for preheating of the workpiece. Pulse time The time of a pulse period during which the current is on. Root gas Shielding gas for the underside (root side) of the welding joint. Rotation speed The rotation speed of the electrode round the workpiece. Sector A defined part of the circumference of the tube.

The lowest current value out of two when using pulsed current.

ting in a pulse period. Wire feed speed during background current.

Code displayed in the error log when an error has occurred in the welding process.

Code resulting from incorrect key activation.

value when using continuous current. The wire feed speed when using continuous current.

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Slope down Gradual decrease of a value. Slope up Gradual increase of a value. Start gas Special gas with high ionising qualities, facilitating the arc strike. Start sector The first welding sector in a welding sequence. System version Indicates the program version stored on the PC card or in the setting box. Transport sec-

tor Unit A PC--card containing software that can be upgraded. Unit power

source Unit rot/wire Circuit card for control of the rotation and wire feed motors. Unit welding

data Weld gas Shielding gas for the upper side of the welding joint. Working area Memory for editing and execution of welding programs.

Electrode transfer in a sector without welding.

Circuit card for control of the power source.

Circuit card in the setting box.

19 PROGRAMMING NOTES

Breakpoint Welding current (continuous) (A) Welding current (background current) (A) Welding current (pulse time) (s) Welding current (background time) (s) Slope up (s) Slope down (s) Preheating (s) Rotation, (cont. forward) (‰) Gas preflow (weld gas) (s) Gas postflow (weld gas) (s) Wire feed (continuous) (cm/min)

Sector 1 Sector 2 Sector 3 Sector 4

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-- 7 1 --

Sector 1 Sector 2 Sector 3 Sector 4

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-- 7 2 --

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-- 7 3 --

notes

-- 7 4 --

PROWELDER

Ordering number

Ordering no. Denomination Type

0456 665 882 Control box PROWELDER 0457 706 170 Programming manual SE PROWELDER

0457 706 171 Programming manual DK PROWELDER 0457 706 172 Programming manual NO PROWELDER 0457 706 173 Programming manual FI PROWELDER 0457 706 174 Programming manual GB PROWELDER 0457 706 175 Programming manual DE PROWELDER 0457 706 176 Programming manual FR PROWELDER 0457 706 177 Programming manual NL PROWELDER 0457 706 178 Programming manual ES PROWELDER 0457 706 179 Programming manual IT PROWELDER 0457 706 180 Programming manual PT PROWELDER 0457 706 086 Programming manual RU PROWELDER

The programing manual is 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 search for and download instruction manuals and spare parts lists.

dpa8oLTS

-- 7 5 -Edition 050420

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041227

ESAB PROWELDER Programming manual

Specifications and Main Features

Frequently Asked Questions

User Manual