Valid for program version PEH4.0, PEH4.0C, PEH4.01,
PEH4.01C, PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH 5.0, PEH5.0C, PEH 5.1 and PEH 5.1C 0740 801 106 A2- A6 Process Controller PEH 104 Service manual -- 2 -- TOCe 1 READ THIS FIRST 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 General 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Software versions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COMPONENT DESCRIPTION 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONNECTION DIAGRAM 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 COMPONENT POSITIONS ON CIRCUIT BOARD AP2 16 . . . . . . . . . . . . . . . . . . 6 COMPONENT POSITIONS ON CIRCUIT BOARD AP1 17 . . . . . . . . . . . . . . . . . . 7 FUNCTION DESCRIPTION (CIRCUIT BOARD) 18 . . . . . . . . . . . . . . . . . . . . . . . . 7.1 General 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 NME (AP2) 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 DC DUO (AP1) 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TEST POINTS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Testing the external power supply (from the welding power source) 20 . . . . . . . . . . . . . . . 8.2 Testing the internal power supply voltages 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Checking that the program is running 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 Checking NO. 1 output stage 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Checking NO. 2 output stage 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 Gas valve output control 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 Measuring the motor current 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 General 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Internal connections 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 External connections 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Adjusting the DC DUO 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 NME connection 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 Connection between the DC DUO and the NME 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 USING THE CONTROL PANEL 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Control panel 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Using the keys 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PRESET SYSTEM MENU 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 General 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 System function settings available 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DEFINITIONS (PRESET SYSTEM MENU) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Product code 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Weld process 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 POWER SOURCE MENU 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Gas preflow (s) (only for GMAW) 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Gas postflow (s) (only for GMAW) 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6 Password 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 Cable length (m) 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 Cable area (mm2) 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9 Weldhead offset, mm 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10 START SEQUENCE MENU 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11 STOP SEQUENCE MENU 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12 CALIBRATION MENU 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13 DISPLAY MENU 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14 ERROR LIST 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15 Test 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 PRESET SYSTEM MENU OVERVIEW 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CHANGE OF PROGRAM 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 General 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 Storing trimming data 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 Changing the program in the PEH electronics: 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 Changing programs in the PEH electronics and the welding power source: 64 . . . . . . . . -- 3 -- TOCe Rights reserved to alter specifications without notice. SPARE PARTS LIST 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALPHABETICAL LIST OF CONTENTS 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 4 -- fzb2d1ea 1 READ THIS FIRST 1.1 General This service manual is intended for use by technicians with electrical/electronic training, for help in connection with fault--tracing and/or repair. This manual contains details of all design changes that have been made up to and including October 2006. This manual is valid for program version PEH4.0, PEH4.01, PEH4.2, PEH 4.3 and PEH 5.0. (Includes the chinese versions) For older versions see service manual 0740 801 006. For further information see the A2--A6 Process controller (PEH) instruction manual 0443 745 xxx. GB -- 5 -- fzb2d1ea 1.2 Software versions PEH From production start 97.07.04 PEH program (Flash, IC 15) 486471880 PEH 1.00 A DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0210 Dat. 1997.07.04 From 97.12.12 PEH program (Flash, IC 15) 486471880 PEH 1.1 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0211 Dat. 1997.12.12 VEC 8000RPM motor (A6G) can be used. MEK 4 motor with tacho can be used. Product code for A2TFF1 (Weldtrac) added. Calibration menu deleted. From 98.04.04 PEH program (Flash, IC 15) 486471880 PEH 1.1 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 DCDUO software 68S07001A02, CHKSUM 0221 compatible with hardware 971029 and all later versions. Upgraded DCDUO program, preventing unsafe usage of tacho function. From 98.05.20 PEH program (Flash, IC 15) 486471880 PEH 1.2 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 External start/stop function Strip welding Stainless steel setting. If this function is needed the power source board 486367001A in the LAF must be used and LAF program version LAF 2.0 ESW welding added (new function added). From 98.09.30 PEH program (Flash, IC 15) 486471880 PEH 2.0 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 For access to all new features program version LAF 2.0 (part no 486525880) must be used together with PEH 2.0. Inch conversion. New manual programmable start method added. From 99.03.20 PEH program (Flash, IC 15) 486471880 PEH 2.1 and PEH 2.2 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 Improved motor regulator data for better performance at low speed. GB -- 6 -- fzb2d1ea From 00.04.04 PEH program (Flash, IC 15) 486471880 PEH 3.1 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 One software version for all applications (Tractors and C&B). From 02.11.15 PEH program (Flash, IC 15) 486471880 PEH 4.0 PEH program, China (Flash, IC 15) 486471881 PEH 4.0C DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 Gauging process added. Complete support for Weldoc. (Not in the Chinese version) Added new languages. (In the Chinese version only English and Chinese can be selected) Safer bus communication. Calibration function. (Not in the Chinese version) The following must be used: LAF/TAF version 4.0, digio 4.0, and Analogue Motor node 4.0. From 03.04.14 PEH program (Flash, IC 15) 486471880 PEH 4.01 PEH program, China (Flash, IC 15) 486471881 PEH 4.01C DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 Bug fixes, for example tandem welding. The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor node 4.0. From 04.01.01 PEH program (Flash, IC 15) 486471880 PEH 4.2 PEH program China (Flash, IC 15) 486471881 PEH 4.2C DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 Added wire creep speed menu. New product code. Added Russian language (Not in China version). New motor selection for parallel driving. New alarm codes. Increased maximum speed for motor vec4000. Bug fixes. The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor node 4.0. GB -- 7 -- fzb2d1ea From 05.01.01 PEH program (Flash, IC 15) 486471880 PEH 4.3 PEH program China (Flash, IC 15) 486471881 PEH 4.3C DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 Added wire creep speed menu. (Valid for the chinese version) Added Polish language (Not in China version). Error log, permanent memory. The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor node 4.0. From 06.10.01 PEH program (Flash, IC 15) 486471880 PEH 5.0 PEH program china (Flash, IC 15) 486471881 PEH 5.0C DCDUO program (Prom, IC304) ************** CHKSUM 0221 Dat. 1998.04.04 Improved functions for tandem welding. Possible to restart master. Possible to use craterfill and stopsequense together. From 07.02.19 PEH program (Flash, IC 15) 486471880 PEH 5.1 PEH program china (Flash, IC 15) 486471881 PEH 5.1C DCDUO program (Prom, IC304) ************** CHKSUM 0221 Dat. 1998.04.04 Bug fix Limit switch GB -- 8 -- fzb2d1ea Welding Power Source From production start 97.07.04 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 1.00A From 99.01.01 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 2.0 Strip welding and ESW welding. Stainless steel setting. If this function is needed the power source board 486367001A in the LAF must be used. Inch conversion. From 00.02.29 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 2.1 Improved wire creep speed LAF 1000ES From 00.10.04 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 2.4 Improved welding starts and welding Safer detection of arc strike. Changed sequence of weld start. Faster engagement of the regulators. Modified voltage regulation. From 02.11.15 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 4.0 Improved welding performance, better regulators. Improved arc--ignition. Parallel connection of LAF TAF 800 60% duty factor Complete support for Weldoc. (Not in the Chinese version) Gauging process added. Calibration function. (Not in the Chinese version) Program version 4.0 or 4.0C is needed. From 03.04.14 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 4.01 Increased wire creep speed. Voltage regulations for analogue interface (PEI). Program version from PEH 4.0, PEH 4.0C is needed. From 04.01.01 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 4.2 Added new alarm. Improved regulation. Program version from PEH 4.0, PEH 4.0C is needed. From 05.01.01 LAF/TAF program (Flash, IC 6) 486525880 LAF/TAF 4.3 Improved welding, analogue Interface. From 06.10.01 LAF/TAF program (Flash, IC 6) 486525880 LAF 5.0 Changed regulation, improved with dynamic characteristic. Program version from PEH 5.0, PEH 5.0C is needed. New hardware is needed, for LAF 486367008 and 486376005 for TAF. GB -- 9 -- fzb2d1ea PEH in C&B From 99.04.01 PEH program (Flash, IC 15) 486471880 PEH 2.3 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 PEH program for use in stations with a Roller bed/ Positioner (Analogue Motor node) and an RCC--unit (Digital I/O node). Note! This program version cannot handle a Roller bed/positioner without an RCC--unit. Contact ESAB for custom--made program. From 99.01.15 Digital I/O -- node 486592880 DIG IO 1.0 From 99.06.01 Digital I/O -- node 486592882 DIG IO 1.1 Safer readings of push buttons preventing unrequested stop during welding. From 02.11.15 Digital I/O -- node 486592882 DIG IO 4.0 Safer bus communication with PEH. Programversion PEH4.0 or PEH4.0C is needed. From 99.01.15 Analogue Motor node 486569880 RB 1.1 From 99.06.20 Analogue Motor node 486569880 RB 1.2 Roller bed / Positioner can be controlled from PEH (using SHIFT + 9), RCC unit not necessary. For PEH program, contact ESAB for custom--made program. From 02.11.15 Analogue Motor node 486569880 RB 4.0 Returns actual speed for external travel axis. Programversion PEH4.0 or PEH4.0C is needed. GB -- 10 -- fzb2d1ea GB -- 11 -- fzb2safe 2 SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding equipment. The following recommen- dations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well--acquainted with the operation of the welding equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. 1. Anyone who uses the welding equipment must be familiar with: S its operation S location of emergency stops S its function S relevant safety precautions S welding 2. The operator must ensure that: S no unauthorised person is stationed within the working area of the equipment when it is started up. S no--one is unprotected when the arc is struck 3. The workplace must: S be suitable for the purpose S be free from draughts 4. Personal safety equipment S Always wear recommended personal safety equipment, such as safety glasses, flame--proof clothing, safety gloves. S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5. General precautions S Make sure the return cable is connected securely. S Work on high voltage equipment may only be carried out by a qualified electrician. S Appropriate fire extinquishing equipment must be clearly marked and close at hand. S Lubrication and maintenance must not be carried out on the equipment during operation. GB -- 12 -- fzb2safe WARNING READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU- TIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK -- Can kill S Install and earth the welding unit in accordance with applicable standards. S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. S Insulate yourself from earth and the workpiece. S Ensure your working stance is safe. FUMES AND GASES -- Can be dangerous to health S Keep your head out of the fumes. S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAYS -- Can injure eyes and burn skin. S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. S Protect bystanders with suitable screens or curtains. FIRE HAZARD S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE -- Excessive noise can damage hearing S Protect your ears. Use earmuffs or other hearing protection. S Warn bystanders of the risk. MALFUNCTION -- Call for expert assistance in the event of malfunction. PROTECT YOURSELF AND OTHERS! WARNING This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the users responsibility to take adequate precautions. GB -- 13 -- fzb2d2ea 3 COMPONENT DESCRIPTION The component description refers to the component names in the connection diagram. AP1 DC DUO circuit board: see the function description on page 19. AP2 NME circuit board: see the function description on page 18. DY1 Display HL1 Pilot lamp (accessory) KB1 Control panel (see page 27) K1 Connector for the graphic display. K2 Keyboard connector K3 Connector between the DC DUO circuit board and the NME board. K5 Circuit board contact K5:1 is normally closed K5:2 is connected to the display control voltage supply K5:3 is connected to + 5 V K5:4 is connected to + 5 V K5:5 is connected to 0 V K5:6 is connected to 0 V K7 Bus termination (on NME circuit board) K9 Connection of the serial bus connection K10 Connector for the wire feed motor (M1) K11 Connector for the travel motor (M2) K12 Connector for the gas valve K13 42 V AC (input from power source) K14 42 V AC (Pilot lamp) K17 60 V DC K22 Connector for the water flow guard, limit switch or external start function. K23 Connector for the gas flow guard, limit switch or external stop function. M1 Wire feed motor. M2 Travel motor ST1 Emergency stop (see page 27 and 59). XS1 Connector 12--pin (connector for the control cable from the welding power source). X2 Terminal block (emergency stop, arc voltage) GB -- 14 -- fzb2d2ea 4 CONNECTION DIAGRAM GB -- 15 -- fzb2d2ea GB -- 16 -- fzb2d2ea 5 COMPONENT POSITIONS ON CIRCUIT BOARD AP2 GB -- 17 -- fzb2d2ea 6 COMPONENT POSITIONS ON CIRCUIT BOARD AP1 GB -- 18 -- fzb2d2ea 7 FUNCTION DESCRIPTION (CIRCUIT BOARD) Serial buss 7.1 General The drive unit consists of two circuit boards, named NME (AP2) and DC DUO (AP1). (See Page 16 and Page 17 for component positions on the circuit boards.) The NME board deals with all communication with the higher level system via a two--wire serial bus. It also manages the control panel (KB1) and the display (DY1), as well as communication with the DC DUO circuit board processor (IC300). The DC DUO board controls the speed of two DC motors, which may be separately excited or of permanent magnet type. Speed control is effected either by measurement of the armature voltage or by tachometer control. 7.2 NME (AP2) This board is built up around an MC 143150 Neuron processor (IC1), with associated memory, working memory and program memory (IC15) and necessary address decoding. An 8--pole DIP switch (SW1) on the board is used to set the boards system address. As immunity to interference is particularly important, communication is galvanically isolated through transformer TR1. The communication is disconnected by a single--pole relay, when the board is not powered but still connected to the system. Communication with the DC DUO circuit board is via a parallel bus. GB -- 19 -- fzb2d2ea 7.3 DC DUO (AP1) The DC DUO circuit board can be divided into five function blocks: 1. Internal power supply Generates the necessary power supplies for the electronic circuitry. 2. The processor (IC300) Controls the motors and communication with the NME circuit board. The microprocessor controls the motors by measuring their armature voltages, the available DC bus voltage and the motor currents. 3. Analogue part Converts the measured quantities from the power section to voltage levels that allow A/D conversion. 4. Power section Consists of two full--wave MOSFET transistor bridges and associated drive circuits and current shunts. 5. Inputs and outputs For connection of the gas valve, guards, limit switch and the external start/stop function. In the interests of a robust system, the heat sinks on which the power semiconductors are mounted, also carry a thermistor that monitors the temperature of the heat sinks. Protection against short circuits is provided by a high--speed overload protection circuit that shuts down the power section if a short circuit occurs. GB -- 20 -- fzb2d2ea 8 TEST POINTS 8.1 Testing the external power supply (from the welding power source) Measure the voltage at contact K13. The approved value range for the voltage is 37,8 V AC U AC 46,2 V AC 8.2 Testing the internal power supply voltages The following test measurements can be made when the motor is not running. Connect a voltmeter across the following components (negative to GND) : Set value Approved value range Positive connected to K17:1 +60 V 53 V DC U 65 V DC Positive connected to K1:1 +5 V 4,8 V U 5,2 V Positive connected to cathode D206 +12 V 10,5 V U 13,5V Positive connected to anode D207 --12 V --13,5 V U --10,5V Positive connected to cathode Z402 +15 A 13 V U 16V Positive connected to cathode Z401 +15 B 13 V U 16V Positive connected to cathode Z403 +15 C 13 V U 16V Positive connected to cathode Z404 +15 D 13 V U 16V Positive connected to cathode Z1 +12 V switch 11 V U 13V GB -- 21 -- fzb2d2ea 8.3 Checking that the program is running Measure the signal on K3:12 using an oscilloscope, and make sure that it is constant at +5V. If the program is not running normally, the signal will go low. The software will then perform a reset and the signal will again go high. 8.4 Checking NO. 1 output stage S Issue a RUN command. S Check the voltage on IC407:11. It should normally be low, at 0V. S Check the waveform on IC407:5. It must be a square wave with 50 % pulse width and an amplitude close to +60 V. 8.5 Checking NO. 2 output stage S Issue a RUN command. S Check the voltage on IC407:11. It should normally be low, at 0V. S Check the waveform on IC409:5. It must be a square wave with 50 % pulse width and an amplitude close to +60 V. 8.6 Gas valve output control Press and measure the voltage over K12.1 and K12.2 (42 V AC). If there is no voltage available, either T201 is defective or the current path on the card is burnt--off. 8.7 Measuring the motor current The current through motor M1 (the wire feed motor) can be measured at IC402: 7, while the current through motor M2 (the travel motor) can be measured at IC405:7 (1 V is equivalent to 5 A). GB -- 22 -- fzb2i1ea 9 INSTALLATION 9.1 General The incoming power supply (42 V AC) to the A2--A6 Process Controller (PEH) is obtained from the welding power source via the control cable, which also carries the bus communication between the two units. See the connection diagram on page 14. 9.2 Internal connections S Connect incoming cables to the 12--pole connector (XS1) and the circuit board contacts on the inside of the control unit. All the cables are screened, and the screens must be connected to the earth points intended for them. The 12--pole connector, XS1, is connected internally to circuit board connectors K13 and K9 and to terminal block X2. One conductor (emergency stop) is connected to emergency stop switch ST1. One conductor (emergency stop) is connected to terminal block X2.2 One conductor (arc voltage) is connected to terminal block X2.1 Draw counter balancing for incoming cable. Two conductors (x3) (42 AC) are connected to K13.1 and K13.2 (2,5 mm 2 ). Two conductors (bus communication) are connected to K9.1 and K9.2 (0,5 mm 2 ) on the NME circuit board (AP2). GB -- 23 -- fzb2i1ea 9.3 External connections GB Motor connections for the wire feed motor, M1 A2 motor Motor cable, two conductors and screen, connected to connectors K10.1 and K10.2. AC--Tachometer cable (accessory), two conductors and screen, connected to connectors K10.5 and K10.6. A6 motor Motor cable, four conductors and screen, connected to connectors K10.1 and K10.2, with the field connections made to K10.3 and K10.4. The AC tachometer cable (accessory), is connected to connectors K10.5 and K10.6. Connection of the welding head Arc voltage to terminal X2.1 Motor connections for travel motor M2 (travel motion) Motor cable, two conductors with screen, connected to connectors K11.1 and K11.2. The motor field winding is connected to K11.3 and K11.4 (with screen). The AC tachometer cable (accessory): two conductors and screen, con- nected to K11.5 and K11.6. Connection of a Pilot lamp (accessory) Connect the transformer primary (42V) to K14.1 and K14.2. The transformer and pilot lamp are included in a complete set of compo- nents for incorporation in the unit and must be ordered separately. Connection of an external emergency stop (accessory) Remove the internal emergency stop connection and connect the external emergency stop circuit to X2.2. Input for connection of a gas flow guard (NC), limit switch or external stop function. Screened 2--wire 2 x 0,75 mm 2 , connected to K23.1 and K23.2. Output for connecting a flux or gas valve, 42 V AC max. 0,5 A Screened 2--wire 2 x 0,75 mm 2 , connected to K12.1 and K12.2. Input for connection of a water flow guard (NC), limit switch or external start function. Screened 2--wire 2 x 0,75 mm 2 , connected to K22.1 and K22.2. -- 24 -- fzb2i1ea GB -- 25 -- fzb2i1ea 9.4 Adjusting the DC DUO Adjusting the display contrast As delivered, the lighting is set for the best contrast. If necessary, it can be adjusted by potentiometer P101 Connection of jumper J1: For the green display place the jumper on 1 and 2. For the blue display place the jumper on 2 and 3. Motor control software The motor control program is stored in an EPROM, IC 304. It is marked to show the version number of the software supplied. 9.5 NME connection The graphic display is to be connected to connector K1. The keyboard is to be connected to connector K2. The bus connection in the control cable (from the welding power source) is to be connected to connector K9. DIP switch The NME circuit board carries a DlP switch (SW1) which is preset on delivery for use with A2--A6 units, and its settings must not be altered in the field. When supplied as a spare part, the settings of the switch must be checked, and adjusted if necessary, before the board is fitted in the control box. Setting the DIP switch SW1: DIP switch SW1 must be set to Closed position, i.e. all eight poles must be set to Closed position. Communications software The communications software, the keyboard controller, display driver and the trim parameters for the DCDUO circuit board are stored in flash memory IC15. The chip is mounted in a socket and can be changed. Diagnostics There is one LED (L02 RED) on the circuit board that can be used for system fault tracing: S The LED lights to indicate failure of communication to the DC DUO board, or in the event of a microprocessor fault. S The LED flashes to indicate that there is a fault in the program. GB -- 26 -- fzb2i1ea Bus termination/connection When the NME circuit board is the first or last board in a network, a short--circuiting link must be fitted in socket K7. 9.6 Connection between the DC DUO and the NME The NME circuit board (AP2) is a separate unit that is secured above the DC DUO circuit board (AP1) by means of four screws. Connectors K3 (communication between the boards), K4 (guard inputs and gas valve output) and K5 (supply voltage for the NME circuit board) provide the electrical link between the two boards. GB -- 27 -- fzb2d3ea 10 USING THE CONTROL PANEL 10.1 Control panel 1. Emergency stop 2. The direction of travel is as shown by the triangular symbol on the welding equipment. 3. The direction of travel is as shown by the square symbol on the welding equipment. 4. Advance wire 5. Retract wire 6. Change menu 7. Numerical key, number entry 8. ENTER key, Change row 9. SHIFT key 10. Stop welding. Return to manual mode 11. Start welding. Switch to automatic mode 12. Fast, wire feed or travel 13. Scroll page (welding setup menu) or close valve (main menu) The arrowed keys are used during welding to increase or decrease the current, voltage and speed. By pressing either , , + or + it is possible to browse. N.B. When an I/O board is connected the keys 2, 3, 4, 5, 10, 11 and 12 can no longer be used. GB -- 28 -- fzb2d3ea 10.2 Using the keys To explain how to use the keys the WELDING SETUP menu has been used as an example. Note that the keys are used in the same way in all of the menus. For a detailed description of the MAIN MENU and the WELDING SETUP, read the instruction manual for PEH (0443 745 xxx). S Switch from the MAIN MENU to WELDING SETUP. Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU WELDING SETUP A B 1 Direction Y, J 2 Start Direct, Scratch 3 STOP WELDING 4 WIRE DATA 5 Regulation CA, CW 6 PRESET SYSTEM MENU S To change a setting, move from Column A to Column B with . S Find the required alternative with or with + . Note that for certain rows you have to enter your own values. S Return to Column A with + . S Move forward to the next row with . S Move back to the previous row with + . (This also provides a direct move from row 1 to row 6.) S To reach the respective sub--menus on rows 3, 4 and 6 select the required menu and press . N.B. If the PRESET SYSTEM MENU is password--protected, enter the password while the menu is selected and then press . S Return to the previous menu with . Jump forward a whole page by pressing and jump backwards with + . Explanation of symbols: shown in combination with another key means that must be pressed first, and then held while the second key is pressed. GB -- 29 -- fzb2d3ea 11 PRESET SYSTEM MENU 11.1 General The PRESET SYSTEM MENU is used to configure the equipment connected to the A2--A6 Process Controller (PEH) to give the correct performance of the complete system. The control unit variables are set to their optimum settings before the equipment is delivered from ESAB, and should not normally need to be changed when the equipment has been supplied to the customer. If changing any of the variables, use the product codes for ESABs A2--A6 automatic welding machines or for other systems that can be directly connected to the control system. The product code includes information on gear ratios, motor types, drive rollers, diameters etc. For information about the Control panel and information about how to use the keys, see pages 27 --28. 11.2 System function settings available PRESET SYSTEM MENU A B 12:1 Product code (see page 30) A2TFE / A2TGE / A2TFH / A2TGH / A6TFE / A6TGE / FREE2AX / FREE3AX 12:2 Weld process (see page 41) SAW / GMAW / ESW / Gauging 12:3 POWER SOURCE MENU (see page 42) X 12:4 Gas preflow (s) (see page 47) 1--99 12:5 Gas postflow (s) (see page 47) 1--99 12:6 Password (see page 48) XXXXX 12:7 Cable length (m) (see page 49) X 12:8 Cable area (mm2) (see page 49) X 12:9 Weldhead offset, mm (see page 50) X 12:10 START SEQUENCE MENU (see page 51) 12:11 STOP SEQUENCE MENU (see page 53) 12:12 CALIBRATION MENU (see page 55) 12:13 DISPLAY MENU (see page 57) 12:14 ERROR LIST (see page 59) 12:15 Test (see page 61) 0 / 1 / 2 GB -- 30 -- fzb2d3ea 12 DEFINITIONS (PRESET SYSTEM MENU) 12.1 Product code Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X System configuration uses product codes that are explained below. Selection of the appropriate product codes automatically also selects the correct details of the motor types and gear ratios used in the particular product. N.B. This is not the case for FREE2AX and FREE3AX. 12.1.1 Alternatives: For program version 4.0 and 4.01: S A2TFE A2 SAW automatic welding machine S A2TGE A2 MIG/MAG automatic welding machine S A2TFH A2 SAW automatic welding machine S A2TGH A2 MIG/MAG automatic welding machine S A6TFE A6 SAW automatic welding machine S A6TGE A6 MIG/MAG automatic welding machine S FREE2AX Optional configuration for connection of two motors to the drive board. S FREE3AX Optional configuration for connection of external Roller bed, Positioner or Linear axis. Also for connection of two motors to the drive board. For program version 4.2, 4.3 and 5.0: S A2TFH A2 SAW automatic welding machine S A2TGH A2 MIG/MAG automatic welding machine S A6TFH A6 SAW automatic welding machine S A6TGH A6 MIG/MAG automatic welding machine S FREE2AX Optional configuration for connection of two motors to the drive board. S FREE3AX Optional configuration for connection of external Roller bed, Positioner or Linear axis. Also for connection of two motors to the drive board. For A2TFE, A2TGE, A2TFH, A2TGH, A6TFE, A6TGE, A6TFH and A6TGH see on page 31. To select FREE2AX / FREE3AX, select it and press . Available settings for FREE2AX see on page 32. Available settings for FREE3AX see on page 37. GB -- 31 -- fzb2d3ea The wire feed motor and wire feed axis are automatically set when either A2TFE, A2TGE, A2TFH, A2TGH, A6TFE, A6 TGE, A6TFH or A6TGH have been selected. Table for program version 4.0 and 4.01: Wire feed axis (wire feed motor): A2TFE A2TGE A2TFH A2TGH A6TFE (*1) A6TGE Motor FHP36 FHP68 FHP36 FHP68 VEC4000 VEC8000 Gear1 49:1 49:1 49:1 49:1 156:1 74:1 Gear2 1:1 1:1 1:1 1:1 1:1 1:1 P.D.mm 49 49 49 49 49 49 Encoder ppr 6 0 6 0 0 0 Low manual speed 150 150 150 150 150 150 High manual speed 300 300 300 300 300 300 Travel axis (travel motor): A2TFE A2TGE A2TFH A2TGH A6TFE (*2) A6TGE Motor DUNKER2 DUNKER2 FHP258 FHP258 DUNKER1 DUNKER1 Gear1 750:1 750:1 24:1 24:1 375:2 375:2 Gear2 158:100 158:100 51:1 51:1 427:100 427:100 P.D.mm 158 158 158 158 180 180 Encoder ppr 0 0 6 6 0 0 Low manual speed 100 100 100 100 100 100 High manual speed 200 200 200 200 200 200 Table for program version 4.2, 4.3, 5.0 and 5.1: N.B. For A6 Mastertrac with serial number 232 or earlier use motor data (*1) and (*2). Wire feed axis (wire feed motor): A2TFH A2TGH A6TFH A6TGH Motor FHP36 FHP68 VEC4000 VEC8000 Gear1 49:1 49:1 156:1 74:1 Gear2 1:1 1:1 1:1 1:1 P.D.mm 49 49 49 49 Encoder ppr 6 0 0 0 Low manual speed 150 150 150 150 High manual speed 300 300 300 300 Travel axis (travel motor): A2TFH A2TGH A6TFH A6TGH Motor FHP258 FHP258 FHP258 FHP258 Gear1 24:1 24:1 24:1 24:1 Gear2 51:1 51:1 51:1 51:1 P.D.mm 158 158 180 180 Encoder ppr 6 6 6 6 Low manual speed 100 100 100 100 High manual speed 200 200 200 200 GB -- 32 -- fzb2d3ea 12.1.2 Function settings available for FREE2AX: The following menu is shown when FREE2AX has been selected: WIRE FEED AXIS PEH TRAVEL AXIS Binary inputs Not used, Guards, Limit sw, Start/stop DRIVE TRIM MENU See on page 32 See on page 32 See on page 34 See on page 35 1. WIRE FEED AXIS / PEH TRAVEL AXIS WIRE FEED AXIS is used to adjust the wire feed motor. PEH TRAVEL AXIS is used to adjust the travel motor. The following menu is shown when either WIRE FEED AXIS or PEH TRAVEL AXIS has been selected: Motor FHP36/ FHP68/ FHP258/ VEC8000/ VEC4000/ DUNKER1/ DUNKER2/ MET3B (PEH 4.0, PEH4.01), VEC4000Par (PEH 4.2, PEH4.3) GEAR 1 GEAR 2 P.D. mm 1--10000 Encoder ppr 0--10000 Low manual speed 1--1000 High manual speed 1--5000 GEAR1 and GEAR2 see on page 33. P.D. mm is the feed roller diameter (effective diameter of the gearwheel). Encoder ppr is the number of pulses per revolution or tacho pulses per revolution. The default value is 6. Low manual speed, the default value is 100 N.B Only for Wire feed motor. The travel motor follows the value entered into the MAIN MENU. High manual speed, the default value is 150. Note that in the rows for P.D. mm, Encoder ppr, Low manual speed and High manual speed you enter your own values if necessary. GB -- 33 -- fzb2d3ea The following menu is shown when either GEAR1, GEAR2 or GEAR3 has been selected: N1 X N2 X By entering values for N1 and N2 any gear ratio located after the motor gears (for example FHP 36) can be selected. N1 = the number of teeth of the gear wheel of the motor shaft. N2 = the number of teeth of the gear wheel of the outgoing shaft. Example: GB (Flashing) Inlet K22 or K23 is open. -- 34 -- fzb2d3ea 2. Binary inputs WIRE FEED AXIS PEH TRAVEL AXIS Binary inputs Not used, Guards, Limit sw, Start/stop DRIVE TRIM MENU Adjusting and using the inputs are only possible if product code FREE2AX or FREE3AX have been selected. If other product codes (fixed ones) are selected the inputs will not be active. The following alternatives are available: S Not used The inputs are not active. S Guards 2 transducers (water and gas flow guards with normally closed (NC) contact function) can be connected. Note. If only one transducer is connected the other input must be bridged. S Limit switch Limit switches (normally with closed (NC) contact function) are to be connected to the inputs. When one of the limit switches is activated (opened) the motion of the motor ceases, and only the motion in the opposite direction is possible. S Start/stop The function is used when external start and stop of the welding is desired. A starting contact (closing NO) is to be connected to input K22. The stop function is to be connected to K23. The contact function of a transducer connected to the inputs shall normally be closed (NC). When the switch (Guards or Limit switch) is opened this will be indicated in the bottom right part of the display by a flashing contact symbol. The inputs K22 and K23 on the DCDUO board can be assigned different functions on this sub--menu. GB -- 35 -- fzb2d3ea 3. DRIVE TRIM MENU WIRE FEED AXIS PEH TRAVEL AXIS Binary inputs Not used, Guards, Limit sw, Start/stop DRIVE TRIM MENU Use this menu to set up the required parameter and setting values for the PEH electronics. Data settings are stored in the IC15 flash memory chip (see page 25). The settings are therefore unique for each electronic unit and are shown in this menu. The preset values for an untrimmed electronics card are shown in the table on page 36. The values for a trimmed electronics card will differ from those of the Preset Values. Set your own offset values for the wire feed motor (M1) VXPoffset 32768, and for the travel motor (M2) VYPoffset 32768. Example: How to adjust the offset error of the travel motor: S Select DRIVE TRIM MENU and press . S Select VXPoffset and press . S Enter the desired value, for example 32868. S Return to the MAIN MENU by holding + down. The value of the VXP offset is now 32868. Proceed in the same way to adjust the offset error VYPoffset 32768 of the travel motor. If necessary, trimming data for the respective electronics card can be ordered from ESAB. When ordering trimming data, the manufacturing number must be indicated (to be found on the DC DUO card, capacitor C201). GB -- 36 -- fzb2d3ea The preset values for an untrimmed electronics card are shown in the following table: Name Trim menu Trimming Default values Explanation (meaning) VNscale 20480 Power supply to DC bus VXPoffset 32768 Positive voltage offset, wire feed motor VXNoffset 32768 Negative voltage offset, wire feed motor CXPoffset 32768 Positive current offset, wire feed motor CXNoffset 32768 Negative current offset, wire feed motor VYPoffset 32768 Positive voltage offset, travel motor VYNoffset 32768 Negative voltage offset, travel motor CYPoffset 32768 Positive current offset, travel motor CYNoffset 32768 Negative current offset, travel motor VXPscale 19200 Positive armature voltage measurement / speed--con- trolled wire feed VXNscale 19200 Negative armature voltage measurement / speed--con- trolled wire feed CXPscale 3200 Positive armature current measurement CXNscale 3200 Negative armature current measurement VYPscale 19200 Positive armature voltage measurement / speed--con- trolled travel motor VYNscale 19200 Negative armature voltage measurement / speed--con- trolled travel motor CYPscale 3200 Positive armature current measurement CYNscale 3200 Negative armature current measurement GB -- 37 -- fzb2d3ea 12.1.3 Function settings available for FREE3AX: The following menu is shown when FREE3AX has been selected: PEH AXES EXTERNAL AXIS ROL, POS, LIN See on page 37 See on page 32 When welding demands connection of an external Roller bed (ROL), Positioner (POS) or Linear axis (LIN) settings must be made in FREE3AX. To steer ROL, POS or LIN the analogue PCB card must be connected. The PCB gives a reference signal of 0--10V and two direction signals (right and left). 1. PEH AXES The following menu is shown when PEH AXES has been selected: WIRE FEED AXIS PEH TRAVEL AXIS Binary inputs Not used, Guards, Limit sw, Start/stop DRIVE TRIM MENU See on page 32 See on page 32 See on page 34 See on page 35 For available settings, see on page 32 -- 36. GB -- 38 -- fzb2d3ea 2. EXTERNAL AXIS PEH AXES EXTERNAL AXIS ROL, POS, LIN The following alternatives are available: S ROL when using external Roller bed S POS when using external Positioner S LIN when using external Linear axis Available settings for ROL and LIN: GEAR 1 GEAR 2 GEAR 3 P.D. mm 1--10000 Encoder ppr 0--10000 Motor rpm Frequency ratio High manual speed 1--5000 Available settings for POS: GEAR 1 GEAR 2 GEAR 3 Encoder ppr 0--10000 Motor rpm Frequency ratio High manual speed 1--5000 GEAR1, GEAR2 and GEAR3, see on page 33. P.D. mm is the effective diameter of the gearwheel. Encoder ppr is the number of pulses per revolution or tacho pulses per revolution. The default value is 6. Motor rpm is the maximum rpm for the motor. Frequency ratio N1, setting frequency converter values N2, power supply frequency in Hz High manual speed, is manual travel motion with high speed. GB -- 39 -- fzb2d3ea MAIN MENU settings for Roller bed, Positioner and Linear axis Roller bed (ROL) When the Roller bed settings have been made, the active motion is displayed on the MAIN MENU (see figure below). Select an axis by pressing the Axis selection key on the remote control unit RCC. In systems without an RCC unit, press + to select an axis. LINEAR CIRCULAR The axis activated is presented here: PEH 4.0 PEH 4.0 LINEAR = Boom or carriage (LINEAR1 = Boom, LINEAR2 = Carriage) CIRCULAR = Roller bed Positioner (POS) To select active axis, proceed in the same way as for the Roller bed. LINEAR POS PEH 4.0 PEH 4.0 The axis activated is presented here: LINEAR AXIS (LIN) To select active axis, proceed in the same way as for the Roller bed. LINEAR 1 LINEAR 2 PEH 4.0 PEH 4.0 The axis activated is presented here: GB -- 40 -- fzb2d3ea PRESET SYSTEM MENU when setting Roller bed Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU Weld_diameter Roller_diameter Weld joint Weld diameter Roller bed Roller diameter PRESET SYSTEM MENU when setting Positioner Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU Weld_diameter Weld joint Weld diameter GB -- 41 -- fzb2d3ea 12.2 Weld process Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXX Cable length (m) X Cable area (mm2) X The following alternatives can be selected: S SAW for submerged arc welding S GMAW for gas metal arc welding S ESW for electro--slag welding (cladding) S Gauging for arc--air gouging GB -- 42 -- fzb2d3ea 12.3 POWER SOURCE MENU This menu is used for configuration of the welding power source. Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X The following menu is shown when POWER SOURCE MENU has been selected: For program version 4.0 and 4.01: Power source type LAF, TAF / Other / None Max weld voltage, dv Min weld voltage, dv Max ref voltage, mV Power source # See on page 42 See on page 43 See on page 43 See on page 43 See on page 44 For program version 4.2, 4.3 and 5.0: Power source type LAF, TAF / Other / None Power source # Wire Creep Speed Max weld voltage, dv Min weld voltage, dv Max ref voltage, mV See on page 42 See on page 43 See on page 43 See on page 44 See on page 43 See on page 43 1. Power source type: LAF, TAF -- Welding power sources that are specially adapted to work with the A2--A6 Process Controller. Other -- Welding power source other than LAF/TAF, that is used together with an analogue PCB card to get a voltage reference and start/stop signal. If Other has been selected its only possible to weld with a constant wire feed speed (CW), N.B This alternative is not available in the Chinese version. None -- Control box PEH is used only to steer the travel direction. GB -- 43 -- fzb2d3ea 2. Max weld voltage, dv (valid when Other has been selected) Max weld voltage that is allowed to be entered into the control box (20.0--60.0 V). Note that this affects the resolution. 3. Min weld voltage, dv (valid when Other has been selected) Min weld voltage that is allowed to be entered into the control box (0.0--30.0 V). Note that this affects the resolution. 4. Max ref voltage, dv (valid when Other has been selected) Max reference voltage out (1.000--10.000 V). Reference voltage out from the PCB depends on which welding power source that is being used. PEH bus Analogue PCB C15 C16 C12 C13 Welding power source (not LAF/TAF) Reference Start/ Stop Example: Max requested reference voltage is 0--5 V, write 5000 in the menu. The lowest requested weld voltage is 15 V, write 150 in the menu. Max requested weld voltage is 50 V, write 500 in the menu. Program version 4.0, 4.01: Program version 4.2, 4.3, 5.0, 5.1: Power source type Other Max weld voltage, dv 500 Min weld voltage, dv 150 Max ref voltage, mV 5000 Power source # Power source type Other Power source # Wire Creep Speed Max weld voltage, dv 500 Min weld voltage, dv 150 Max ref voltage, mV 5000 5. Wire creep speed (Valid for PEH4.2, PEH4.3, PEH4.3C) Used for setting the desired wire creep speed of the feed motor at the start. Entering for example the value 10 into the Wire Creep Speed menu will result in a creep speed of 10 cm/min. The preset value 0 will result in a creep speed calculated according to the set welding data. GB -- 44 -- fzb2d3ea 6. Power source # General Used for Tandem welding to get both Systems to start welding at the same point. This is only possible if the function Weldhead offset has been set (see on page 50). N.B. Make sure that both control boxes have the same settings for Weldhead offset and that they have the same welding speed. The Master control box is number 1 (PEH1) and the Slave control box is number 2 (PEH2). Travel motion is always steered from PEH1. System1 (PEH1 and Welding power source no. 1) System2 (PEH2 and Welding power source no.2) Weldhead offset Start sequence/ Stop sequence S The function start sequence can be used for both System1 and System2. N.B. The speed must be the same for both Systems. The function stop sequence can only be used for System2. Gas metal arc welding (GMAW) S To use GMAW, set Gas postflow (s) to 1 second, see on page 47. GB -- 45 -- fzb2d3ea Example 1 System1 (PEH1 and Welding power source no. 1) System2 (PEH2 and Welding power source no.2) Weldhead offset S Press start for both PEH1 and PEH2 at the same time. S System1 starts welding. System2 doesnt start welding until it has reached the starting point for System1 (the distance is set in Weldhead offset). S Press stop for both PEH1 and PEH2 at the same time. S System1 stops welding while the travel motion continues. System2 stops welding when it has reached the point where System1 stopped welding (the distance is set in Weldhead offset). S The weld is finished. Example 2 When using a remote control box (RCC) the two systems must be connected to each other (see manual A2- A6 Process Control System article no. 0458 081 074). System 1 System 2 bus bus DIG I/O 1 DIG I/O 2 D7 C2 When using an RCC one can when necessary use only Welding power source 2. S Set Weldhead offset to 0 in the menu for PEH2. S Press start for Welding power source 2 on the RCC. System1 starts to move and System2 starts to weld S Press stop for Welding power source 2 on the RCC to finish. GB -- 46 -- fzb2d3ea Example 3 S Set Weldhead offset to 0 in the menu for PEH2. S Press start for Welding power source 2 on the RCC. System1 starts to move and System2 starts to weld S Press stop for Welding power source 1, system2 continues welding, start welding power source 1 and both systems weld. Both systems can be stopped and started independently of each other. GB -- 47 -- fzb2d3ea 12.4 Gas preflow (s) (only for GMAW) Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X The protective gas must start to flow before the arc is struck in order to provide time for it to cover the weld position. A suitable preflow time must therefore be loaded into the system, and this is done by entering the required time, in seconds, into the selected field. Times between 1 and 99 seconds can be entered. The default value is 1 second. 12.5 Gas postflow (s) (only for GMAW) Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X The protective gas must continue to flow after the arc is extinguished in order to protect the weld while it cools. A suitable postflow time must therefore be loaded into the system, and this is done by entering the required time, in seconds, into the selected field. Times between 1 and 99 seconds can be entered. The default value is 2 seconds. GB -- 48 -- fzb2d3ea 12.6 Password Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X Access to the PRESET SYSTEM MENU can be protected by entering a password in the Password field. The password must consist of not more than five numerals, XXXXX. If no password is required, enter the numerical value 0. If the password consists of more than one numeral, press a few times until there is only one 0. The password that has been entered can be shown in the MAIN MENU display by entering + For example if the password is 12345 the display will show: GB -- 49 -- fzb2d3ea 12.7 Cable length (m) Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X The arc voltage is noticeably affected by the impedance of the welding cables. The impedance is affected by such factors as the length, the cross--sectional area and the laying of the cables. This effect is particularly marked when using AC welding current sources. The volt drop that occurs in long cables can be compensated for by entering the exact length of the cable being used. The total length of the cable in metres (welding current and return current cables together) must be entered. The value can be set between 10--1000 m. The default value is 10 m. 12.8 Cable area (mm2) Product code A2TFH Weld process SAW POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1--99 Password XXXXX Cable length (m) X Cable area (mm2) X Enter the cross--sectional area of the cable in mm 2 . The value can be set between 25--1000 mm 2 . The default value is 95 mm 2 . N.B. When using two cables the cross--sectional area for both cables must be added together. GB -- 50 -- fzb2d3ea 12.9 Weldhead offset, mm Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 Weldhead offset is the distance between the welding heads. Used for Tandem welding so that both Systems start welding at the same point, see on page 44. IMPORTANT! When setting the distance, Offset between welding head no.1 and welding head no.2, the distance is converted by the PEH to a time between the start of welding head no.1 and the start of welding head no.2. The time that PEH can calculate for the distance between start/stop of the welding power sources is max. 65 seconds. This means that if for example a welding speed of 50 cm/min is set, it is only possible to add max. 540 mm as an Offset. This is to prevent the time from elapsing before welding head no.2 has come to the start point. GB -- 51 -- fzb2d3ea 12.10 START SEQUENCE MENU Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 The following menu is shown when START SEQUENCE MENU has been selected: START PHASE 1 START PHASE 2 Max OCV Off / On On some occasions, for example when welding with special electrodes or materials, it can be necessary to make up a special start sequence. The start method can also influence the appearance of the weld bead. The start sequence is divided into two phases (PHASE1 and PHASE2). The time and percentage values of the two phases can be adjusted. N.B. PHASE2 is not available in the Chinese version. PHASE2 has no effect if t = 0 in PHASE1. t = the durability of the sequence, indicated in intervals of 0.1 s (max. 99.9 s). Max OCV (Max open circuit voltage) On -- 50 V at start, after weld arc it returns to set value. Off -- Set value at start. GB -- 52 -- fzb2d3ea Example: Time 0,1s 20 Speed % 100 Voltage % 50 Current % 100 Wire feed % 100 Time 0,1s 30 Speed % 100 Voltage % 70 Current % 100 Wire feed % 100 START PHASE 1 START PHASE 2 100 % Phase 1 = 2,0 s Phase 2 = 3,0 s 70 % voltage 50 % Current, voltage and speed are adjusted by indicating a percentage value of the welding parameters on the main menu. Max. adjustable value is 150% as long as the capacity of the welding power source and the max. possible welding speed are not exceeded. Preset value is 100. When the welding parameters are changed through the over--ride function, the values in the start sequence are changed correspondingly, see the Instruction manual. GB -- 53 -- fzb2d3ea 12.11 STOP SEQUENCE MENU Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 The following menu is shown when STOP SEQUENCE MENU has been selected: STOP PHASE 1 STOP PHASE 2 The stop sequence menu is mainly used for programming the crater filling. It is programmed in the same way as the start sequence menu. In the stop sequence menu a phase can be interrupted by pressing the stop key . PHASE2 has no effect if t = 0 in PHASE1. t = the durability of the sequence, indicated in intervals of 0.1 s (max. 99.9 s). N.B. PHASE2 is not available in the Chinese version. GB -- 54 -- fzb2d3ea Example: Time 0,1s 30 Speed % 100 Voltage % 70 Current % 100 Wire feed % 100 Time 0,1s 20 Speed % 100 Voltage % 50 Current % 100 Wire feed % 100 STOP PHASE 1 STOP PHASE 2 100 % Phase 2 = 2,0 s Phase 1 = 3,0 s 70 % voltage 50 % Current, voltage and speed are adjusted by indicating a percentage value of the welding parameters on the main menu. Max. adjustable value is 150% as long as the capacity of the welding power source and the max. possible welding speed are not exceeded. Preset value is 100. When the welding parameters are changed through the over--ride function, the values in the start sequence are changed correspondingly, see the Instruction manual. GB -- 55 -- fzb2d3ea 12.12 CALIBRATION MENU Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 Choosing the CALIBRATION MENU the following menu comes up: Current at PEH % 100 Voltage at PEH % 100 Current at head % 100 Voltage at head % 100 Travel speed % 100 Wire speed % 100 Current at PEH % Shows the real value in the PEH display expressed as a percentage of the desired current reference value. Voltage at PEH % Shows the real value in the PEH display expressed as a percentage of the desired voltage reference value. Current at head % Shows how many per cent the set reference value constitutes of the measured current value at the welding head. This also affects the real value in the PEH display. Voltage at head % Shows how many per cent the set reference value constitutes of the measured voltage value at the welding head. This also affects the real value in the PEH display. Travel speed % Adjustment as a percentage of the measured speed of the travel motor in relation to the speed desired (valid for LINEAR 1). Wire speed % Adjustment as a percentage of the measured speed of the wire feed motor in relation to the speed desired. GB -- 56 -- fzb2d3ea Example 30 V PEH + -- LAF / TAF 28 V { Welding head The value shown in the PEH is 30V. The measured value at the welding head is 28V. The value for Voltage at head % will in this case be 107% (30/28 = 1,07107). Adjusting the Voltage at head % results in an increase of the value shown in the PEH. The Voltage at PEH % must therefore be adjusted. In order to reduce the value shown on the screen, indicate for instance 30/32 = 0,94% 94%. Current at PEH % 100 Voltage at PEH % 94 Current at head % 100 Voltage at head % 107 Travel speed % 100 Wire speed % 100 Before changing the CALIBRATION MENU, make sure all connectors are properly fitted. IMPORTANT! S In order not to affect the voltage answer through inductance, the voltage reference cable shall not be laid together with the current cable. S The calibration shall be carried out by way of the existing cables at a known load. In order to get reliable measurement test results a measuring device in accordance with the British standard BS 7570:2000 must be used. Note that the system need not be linear within its working range. The linearity is affected by induction and other disturbing factors coming up when using different welding parameters. The same adjustment in per cent within the whole range signifies that high values are more affected than low ones. GB -- 57 -- fzb2d3ea 12.13 DISPLAY MENU This menu controls how the information on the display is presented. Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 The following menu is shown when DISPLAY MENU has been selected: Unit Metric/ Inches Current display Real value/ Set value Heat input On/ Off Parameter set 1 Units Metric, Inches Speeds, lengths or wire sizes in the MAIN MENU can be displayed in either metric units or inches. Current display Set value, Real value The welding parameters can be displayed as either set values or real values. The set values are stable and are not subject to rapid fluctuations. On the other hand, if information on the actual welding current is required, select real value and the current will be shown in figures on the MAIN MENU display. Heat input On, Off This shows how much energy is supplied to the weld, calculated from the set values of voltage and current. It is displayed on the MAIN MENU as kJ/cm. Parameter set This specifies the number of parameter sets to be used: a maximum of ten is allowed. Enter a numerical for the number of sets in Column B. The default value is 1. GB -- 58 -- fzb2d3ea Example: How to select the unit Metric: S Select Unit and press . S Find Metric by pressing . S Return to the MAIN MENU with + The unit has now been set to Metric. GB -- 59 -- fzb2d3ea 12.14 ERROR LIST Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 Error messages are displayed on the bottom row of the MAIN MENU. Error messages that may occur are shown here: Error codes, see on page 60. Error categories Emergency stop (see page 27) A special emergency stop function that is activated by pressing the emergency stop pushbutton in dangerous situations (e.g. risk of injury etc.). When the reason for the emergency stop has been corrected, the emergency stop function can be reset by deactivating the emergency stop pushbutton. Incorrect entry of numerical values If incorrect numerical values are entered (e.g. for voltage, current or speed), a message is generated indicating the values that are allowed. Error messages shown on the bottom line of the display. Alarm Conditions that could result in unacceptable defects in the process and which automatically generate an emergency stop. When such a fault occurs, the error message must be acknowledged by pressing after the fault has been corrected. Error messages are displayed in sequence by the system and can be inspected in the ERROR LIST menu. The system can store up to 20 messages, after which the oldest messages are erased as new messages are added at the top of the list. S Select ERROR LIST and press . S Step through the list with . To erase the errors press + . S Return to the PRESET SYSTEM MENU with + . GB -- 60 -- fzb2d3ea Error codes The following codes generated by the DC DUO board can be shown on the display: Analogue board 203.01 Communication error with Analogue card Stop Check cables and connections I/O board 301.01 Communication error with Digital I/O Stop Check cables and connections Wire feed motor (Motor 1) 201.2 Current too high Stop Check wire feed 201.3 Overheating (Motor 1) Stop Wait until temperature has fallen 201:5 Communication error ** Stop Check the cabling. Travel motor (Motor 2) 202.2 Current too high Stop Check travel motor / gearbox 202.3 Overheating (Motor 2) Stop Wait until temperature has fallen 202:5 Communication error ** Stop Check the cabling. Drive unit (PEH4.2) 204.2 Short--circuit, drive unit ** Stop Replace the PC board 204.3 Overheating, drive unit ** Stop Wait for a while and then check the heat dissi- pating element Welding power source (T1) 111.01 Communication error Stop Check cables and connections 111.53 Unsuccessful start Stop Check stick--out and welding parameters 111.54 Current limit/ Arc extinguished*** Stop Welding short--circuited, Cure short--circuit / Check wire feed 111.54 Current limit ** Stop Welding short--circuited, Cure short--circuit 111.55 Thermostat / overheating Stop Wait until temperature has fallen 111.57 Arc extinguished ** Stop Check wire feed Inputs / outputs No cooling water (inlet K22 open) * (Flashing) Display Stop Check if the gas is flowing or if the limit switch is open. No gas flow (inlet K23 open) * (Flashing) Stop Check gas pressure or if the limit switch is open. * These inputs are activated by entries in the menu Binary inputs (see page 34). ** Only valid for control box with program version PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH5.0, PEH5.0C, PEH5.1 and PEH 5.1 C. *** Only valid for control box with program version PEH4.0, PEH4.0C, PEH4.01 and PEH 4.01C. GB -- 61 -- fzb2d3ea 12.15 Test Cable area (mm2) X Weldhead offset, mm START SEQUENCE MENU STOP SEQUENCE MENU CALIBRATION MENU DISPLAY MENU ERROR LIST Test 0 / 1 / 2 When this menu is active, the main menu displays information that is normally hidden Test = 0 The function is not active. Test = 1 Wire feed speed is shown in the MAIN MENU according to the figure below. This is Not deactivated when the power is off. Wire feed speed (cm/ min) Test = 2 Speed and motor current for both motors are shown in the MAIN MENU according to the figure below. This is deactivated when the power is off. Travel speed (cm/ min) Wire feed speed (cm/ min) Motor current for travel Motor current for wire feed GB -- 62 -- fzb2menye 13 PRESET SYSTEM MENU OVERVIEW GB MAIN MENU Direction Start STOP WELDING WIRE DATA Crater fill Burnback time Wire type Wire size Wire material Number of wires Regulation PRESET SYSTEM MENU Weld process Product code WIRE FEED/TRAVEL AXIS Binary inputs Motor GEAR 1 GEAR 2 GEAR 3 * P.D. mm Motor rpm * Encoder ppr Frequency ratio* Low manual speed High manual speed DRIVE TRIM MENU POWER SOURCE MENU Gas preflow (s) Password Gas postflow (s) Cable area (mm2) Cable length (m) START SEQUENCE MENU Weldhead offset, mm START PHASE 1 START PHASE 2 STOP SEQUENCE MENU DISPLAY MENU STOP PHASE 1 STOP PHASE 2 Unit Current display Heat input Parameter set ERROR LIST Test * FREE3AX Max ocv CA CW GMAW ESW SAW GAUG Not used Guards Limit sw Start/Stop CALIBRATION MENU Current at PEH % Voltage at PEH % Current at head % Voltage at head % Travel speed % Wire speed % Weld diameter *1 Roller diameter *2 Power source type Max weld voltage, dV Min weld voltage, dV Max ref voltage, mV Power source # Wire Creep Speed *3 *1 Setting, Roller bed/ Positioner *2 Setting, Roller bed *3 Valid from PEH4.2 -- 63 -- fzb2d4ea 14 CHANGE OF PROGRAM 14.1 General When changing programs, the flash memory (IC15) must be replaced. In doing this, the trimming data set will be replaced by the preset values of the new flash memory, see page 35. To keep the set trimming data, the data must first be stored in the welding power source and then be sent back to the PEH electronics when the new flash memory is installed. Store trimming data for future upgradings of the program if the complete PEH electronics are to be replaced. N.B. When changing the flash memory (IC15) make sure that the program versions are compatible between for example the PEH and the welding power source. 14.2 Storing trimming data Trimming data to the welding power source: S Press + . Trimming data are sent from the PEH electronics to the welding power source where they are stored. Trimming data back to the PEH electronics: S Press + . Trimming data are sent from the welding power source to the PEH electronics. Existing trimming data will be overwritten. NOTE! After the trimming data have been recalled, the voltage supply to the PEH electronics must be switched off, in order to activate the new trimming data. NOTE! To be sure that the trimming data of the PEH electronics are stored in the welding power source, the data should always be stored before changing the program. GB -- 64 -- fzb2d4ea 14.3 Changing the program in the PEH electronics: S Store trimming data in the welding power source (see Trimming data to the welding power source on page 63). S Replace the flash memory (IC15) on the NME card (AP2). S Recall trimming data from the welding power source (see Trimming data back to the PEH electronics on page 63). 14.4 Changing programs in the PEH electronics and the welding power source: S Store trimming data in the welding power source (see Trimming data to the welding power source on page 63). S Replace the flash memory (IC15) on the NME card (AP2). S Recall trimming data from the welding power source (see Trimming data back to the PEH electronics on page 63). The right trimming data for the PEH electronics are now available in the new electronics program. S Replace the flash memory (IC6) in the welding power source. S Switch on the welding power source. In the event error code 111.01 should come up, the power source must be switched off and then on again for correct initiation. GB Spare parts list -- 65 -- pehspare A2- A6 Process Controller (PEH) Edition 2004--12--17 Ordering no. Denomination Notes 0443 741 880 Control box A2--A6 Process Controller (PEH) Abbreviations used in the spare parts list: C = Component designation in the circuit diagram -- 66 -- f443741r Item no. Qty Ordering no. Denomination Notes C 0443741880 CONTROL BOX PEH 3 1 0443638880 Control panel KB1 4 1 0443740001 Emergency stop ST1 8 2 0457278001 Rail 9 1 0443748880 Cable complete XS1 10 0443730880 Circuit board AP1 + AP2 14 1 0443849001 Insulation 20 1 0449130001 Display, ccfl backlight DY1 21 0192526003 Sealing strip 530 mm 23 10 0192645002 Bushing 26 2 0467911884 Capacitor Valid from programversion PEH1.2 41 1 0449137880 Inverter with screen box -- 67 -- f443748s Item no. Qty Ordering no. Denomination Notes 0443 748 880 Cable with connectors 1 1 0368 543 003 Pin socket, Burndy 4 1 0443 841 880 Cable set 6 1 0456 489 005 Circuit board connection 7 1 0456 489 004 Circuit board connection 8 1 0193 275 002 Connection block 3 pole 9 0190 209 109 Hose 10 2 0192 541 003 Pin cable clip 2,5 mm 2 -- 68 -- s443730r Item no. Qty Ordering no. Denomination Notes C 0443 730 880 Circuit board AP1 + AP2 2 0456 489 002 Connection terminal 6 poles K10, K11 3 0456 489 001 Connection terminal 2 poles K12, K17, K22, K23 4 0456 489 004 Connection terminal 2 poles K13, K14 5 1 0486 471 880 Flash memory IC15 7 0456 489 005 Connection terminal 4 poles K9, K9X -- 69 -- f456500s Item no. Qty Ordering no. Denomination Notes 0456500880 Control cable L = 15 m, Accessories 1 1 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500881 Control cable L = 25 m, Accessories 1 1 0449449881 Control cable 25m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500882 Control cable L = 35 m, Accessories 1 1 0449449882 Control cable 35m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500883 Control cable L = 50 m, Accessories 1 1 0449449883 Control cable 50m, 12--28p 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500884 Control cable L = 75 m, Accessories 1 1 0449449884 Control cable 75m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) 0456500885 Control cable L = 100 m, Accessories 1 1 0449449885 Control cable 100m, 12--28 pole (LAF/TAF--PEH) 2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p) -- 70 -- f449449s Item no. Qty Ordering no. Denomination Notes 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449881 Control cable 25m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 contact sleeve max 2.5mm2 0449449882 Control cable 35m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 -- 71 -- f449449s Item no. Qty Ordering no. Denomination Notes 0449449883 Control cable 50m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449884 Control cable 75m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 0449449885 Control cable 100m, 12--28 pole (LAF/TAF--PEH) 1 1 0368541106 Pin plug, burndy 28 pol. 2 3 0323945004 Connector pin 0,52--1,50 3 5 0323945001 Connector pin 0,32--0,52 4 1 0368542303 Sleeve plug, burndy 12 pol. 5 5 0323945002 Contact sleeve 0,32--0,52 6 3 0323945003 Connector sleeve 0,52--1,50 7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945008 Contact pin max 2.5mm2 9 4 0323945007 Contact sleeve max 2.5mm2 -- 72 -- f449448s Item no. Qty Ordering no. Denomination Notes 0449448880 Adapter 28--12POL(PEH--LAF12P) 1 1 0368546106 Sleeve cable socket 28--pol 2 3 0323945003 Connector sleeve 0,52--1,50 3 5 0323945002 Contact sleeve 0,32--0,52 4 1 0368541303 Pin plug burndy 12 pol. 5 5 0323945001 Connector pin 0,32--0,52 6 3 0323945004 Connector pin 0,52--1,50 0,52--1,50 7 1 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2 8 4 0323945007 Contact sleeve max 2.5mm2 9 4 0323945008 Contact pin max 2.5mm2 ALPHABETICAL LIST OF CONTENTS -- 73 -- IndexE A AC--Tachometer cable, 23 Adjusting the display contrast, 25 Alarm, 59 Arc voltage, 23 Arc--air gouging (Gouging), 41 B Binary inputs, 34 Bus termination, 13 , 26 C Cable area, 49 Cable length, 49 Cable, complete, 22 CALIBRATION MENU, 55 Change of program, 63 Communications software, 25 Control panel, 27 Current display, 57 D DC DUO, 13 , 18 , 19 , 25 , 26 Diagnostics (NME), 25 DIP switch (SW1), 18 , 25 DISPLAY MENU, 57 DRIVE TRIM MENU, 35 E Electro--slag welding (ESW), 41 Emergency stop, 13 , 59 Encoder ppr, 32 , 38 Error categories, 59 Error codes: Arc extinguished, 60 Current limit, 60 Overheating, 60 Thermostat / overheating, 60 Unsuccessful start, 60 ERROR LIST, 59 Error message, 59 EXTERNAL AXIS, 38 External emergency stop, 24 F Flash memory (IC15), 25 G Gas flow guard, 13 , 24 Gas postflow, 47 Gas preflow, 47 Gas valve, 13 , 24 H Heat input, 57 L LED (L02 RED), 25 Linear axis, 39 M MENU OVERVIEW, 62 MIG/MAG welding, 41 Motor cable, 23 Motor control software, 25 Motor current, 21 Motor field winding, 23 N NME, 13 , 18 , 25 , 26 O Offset error, 35 P P.D. mm, 32 , 38 Parameter set, 57 Password, 48 PEH AXES, 37 PEH TRAVEL AXIS, 32 Pilot lamp, 24 Positioner, 39 POWER SOURCE MENU, 42 Power supply voltages, 20 PRESET SYSTEM MENU, 29 Product code, 30 R Roller bed, 39 S Safety, 11 START SEQUENCE MENU, 51 STOP SEQUENCE MENU, 53 Storing trimming data, 63 Submerged arc welding, 41 T Test menu, 61 Travel motor (M2), 13 , 21 , 23 Trimming data, 35 U Unit, 57 W Water flow guard, 13 , 24 Weld process, 41 Weldhead offset, 50 WIRE FEED AXIS, 32 Wire feed motor (M1), 13 , 21 , 23 ESAB AB SE--695 81 LAX SWEDEN Phone +46 584 81 000 www.esab.com 061127 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna--Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218 GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186 ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: +31 30 2485 377 Fax: +31 30 2485 260 NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03 POLAND ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277 SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41 SPAIN ESAB Ibrica S.A. Alcal de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313 BRAZIL ESAB S.A. Contagem--MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440 CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79 MEXICO ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554 USA ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48 Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: +86 21 5308 9922 Fax: +86 21 6566 6622 INDIA ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80 INDONESIA P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929 JAPAN ESAB Japan Tokyo Tel: +81 3 5296 7371 Fax: +81 3 5296 8080 MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 8027 9869 Fax: +60 3 8027 4754 SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63 Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88 EGYPT ESAB Egypt Dokki--Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74 RUSSIA LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280 LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060 Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.com