Home

PUA 1 ver 3

1. or decrease the value of a setting The two plus minus keys are each marked with their own symbol Most settings can be entered with either the plus or minus key but certain settings must be made with the key marked H or the key marked k the symbols are visible in the display Pressing a key rapidly increases or decreases a setting in small steps If the key is held down for longer the size of the steps increases Soft keys The five keys in a row under the display have a variety of functions these are soft keys e they can have different functions OVDODOO depending on which menu you are using The current functions of these keys are shown by the text in the bottom line of the display when a function is active this is shown by a white dot alongside the text B mare oo oo d 1 6 Settings in general There are three main types of settings e Settings with numerical values e Settings with fixed options e Settings of the type ON OFF or YES NO 1 6 1 Numerical settings To set a numerical value you use either the plus or minus key to increase or decrease the existing setting bu14d01e 1 6 2 Settings with fixed options Certain settings are made by selecting an alternative from a list The list might look like this MIG MA MMA TIG CARBON ArcAir Here the cursor is positioned on the line for MIG MAG By pressing the ENTER key now you would select the MIG MAG option If instead yo
2. Ar 8 CO2 0 8 0 9 1 0 1 2 1 6 Ar 2 CO2 0 8 1 0 1 2 1 6 Ar 2 Oo 0 8 0 9 1 0 1 2 1 6 Stainless wire SS Ar 2 02 Ar 2 COs Ar 30 He 1 0 Ar 3 CO 1 Ho Ar 32 He 3 C0 1 Ho Stainless duplex wire Ar 30 He 1 0 SS Duplex Ar 2 Oo Magnesium alloyed aluminium wire Ar 0 8 09 1 0 1 2 1 6 AlMg Ar Silicon alloyed aluminium wire Al 09 10 1 2 1 6 Si Ar 50 He 0 9 1 0 1 2 1 6 Metal powder cored wire Fe Ar 20 CO 1 0 1 2 1 4 1 6 Ar 8 COs 1 2 1 2 1 4 1 6 Metal powder cored stainless wire Ar 2 Oo 1 2 SS Ar 2 CO 1 2 Ar 8 CO 1 2 Nickel alloy wire Ar 0 9 1 0 1 2 Nickel base Ar 50 He 0 9 1 0 1 2 LUD 450 12 bu14d01e 2 4 Welding data settings The following is an summary of the welding parameters that affect the welding process when using MIG and MAG welding methods With the power source in synergic mode it is only necessary to set the wire feed speed The voltage parameter may also be adjusted if required When the wire feed speed is adjusted the synergic control system automatically adjusts certain other parameters to compensate The parameters in italics remain constant and are unaffected by changes in the wire feed speed Method DIP SPRAY Method PULSING e Wire feed speed e Wire feed speed e Voltage e Voltage e Inductance e Pulse current e Control type e Pulse time e Pulse frequency e Background current Ka e Ki A table
3. MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION GENERAL DEFAULTS The function WELD DATA SHIFT WITH PISTOL makes it possible using the trigger button on the welding pistol to shift between up to five pre selected weld data options With a quick squeeze on the welding pistol trigger quicker than 3 10ths of a second you can shift to the next weld data option CONFIGURATION GENERAL DEFAULTS Place the cursor on the row TRIGG FAST MODE LIMITS WELD DATA press DOUBLE START SOURCE OFF ENTER TRIGG WELD DATA SWITCH fur m TRIGG WELD DATA SWITCH Place the cursor on the row TRIGG TRIGG WELD DATA SWITCH WELD DATA press ADD DELETE WELDDATA ENTE TO eLa lotor SELECTED WELDDATA 3 options Select ON il STORE DELETE QUIT ENTER Select the weld data options and shift between them in the following way TRIGG WELD DATA SWITCH Place the cursor on the row add remove TRIGG WELD DATA SWITCH ON Select the memory ADD DELETE WELDDATA 1 number under which the weld data are SELECTED WELDDATA 3 stored using the plus minus buttons and press STORE stone ome jor The row SELECTED WELD DATA displays which weld data are selected and what content order they have listed from left to right To remove selected weld data do as above but press the button REMOVE 62 bu14d01e 9 2 9 Multiple wire feed units AUXILIARY EUNCTIONS CONFIGURATION MULTIPLE WIRE FEEDERS All new wire feed units are delivere
4. PUA 1 Programming manual 0456 685 174 010815 Valid for program version 3 00V 3 01V 3 02V 3 03V 1 INTRODUCTION ia ai ete mew a 4 O Lee Me As Paes 4 1 2 Using the Controller eresas ead ent Aa 4 1 3 Choice of language ooooccccccocnnn ene tenes 5 14 DISPIAY 0 A A eRe ated gonna Laue ena eae aoe 7 Toe KOYS ii AA hate ee ec Ste ee eee eee 8 1 6 Settings in general oooococcccccnnc aaaeeeaa aaan aaa 8 1 7 ENTER and QUIT sii gas Mea aa Garin Mea eee ee e 9 2 MIG MAG WEIGING 03 000 a be dhe ee eh eee See 10 2 1 The expression Wire 0 00 ccc eee eens 10 272 Synergie Weld ga ic A A da das 10 2 3 Basic Songs cis A ed 10 2 4 Welding data settingS c o e teiaa teii e E E a 13 2 5 Start and stop Settings ares eange a lada tal ERA EES ene eds 13 2 6 Gas purge cold wire feed and trigger latch 00 cece eee 14 2 7 MIG MAG configuration 0 beeen eee 16 2 8 Setting up example MIG MAG 0 00 cect eens 16 3 MMA welding gt or A en Ghia Oe sehen aba Garena ac 25 Bel Synergi Mod ren eR eis gag ee ae ee cee i et 25 3 2 Basic SCHINGS icc ined peep E ied Pas pik cule sawed ed a Pee 25 3 3 Welding dativo cosa sales cite Tales nas sales ioe Tale sha lindos Tales aN 26 3 4 MMA configuration c3 0 snes ded vem obese ee Ee se ole oe bE an eee ee E 27 3 5 Setting up example MMA 0 000 cece tenets 27 4 DIG WelGinG tie esac ine cea ci onan AAA ON 29 4 1 BaSiC SCHINGS
5. bu14d01e Trigger latch off 2 Stroke 2 Craterfill stop data Gas pre flow Gas post Hot Welding Crater Start flow fill With the trigger latch off the gas pre flow if set begins when the gun trigger is pressed 1 The welding parameters then rise to their set values or if set Hot start values When the gun trigger is released 2 the crater fill period begins After this has elapsed the welding parameters drop to back zero and the gas post flow if set finishes the welding sequence TIP If the gun trigger is pressed in again during the crater fill period then you can continue welding using the final crater fill parameters for as long as required dotted line Crater fill can also be cut short by pressing and releasing the gun trigger quickly during the crater fill period Trigger latch on 4 Stroke Craterfill stop data Gas pre Welding Crater Gas post flow Hot flow Start fill When the trigger latch is on the gas pre flow begins when the gun trigger is pressed 1 When the trigger latch is released 2 the welding parameters rise to their set values When the gun trigger is pressed again 3 the crater fill period begins When this has elapsed the values of the welding parameters drop to stop data The gas post flow period begins when the gun trigger is released 4 TIP Crater fill stops when the gun trigger is released 4 If instead the trigger is held in for lon
6. copy aurr The last stored set of data is marked automatically If there is more than one set of data you can move the cursor between them using the arrow left and arrow right keys Example RECALL WELD DATA NR 10 Press ENTER to confirm that you want to recall data set number 10 P DIP SPRAY Fe Ar 20 CO2 1 2 mm Return to the memory menu by pressing the QUIT key 7 4 Copy You can copy the contents of a previously stored set of data into another memory location Start by pressing the COPY key MEMORY FUNCTIONS STORED DATA SETS DIP SPRAY Fe Ar 20 CO2 1 2 mm STORE DELETE RECALL copy aurr 45 bu14d01e Example The last stored set of data is marked automatically If more than one set of data has been stored you can move the cursor between them using the arrow left and arrow right keys We will now copy the contents of memory location 10 into location 50 Use either of the plus minus keys to mark the memory location you want to copy to COPY WELD DATA NR 10 TILL NR 50 Scroll forward to number 50 using the plus key and ENTER DIP SPRAY Fe Ar 20 CO2 1 2 mm p lt Ss four fer STORE OVER EXISTING WELD DATA p gt DIP SPRAY Fe Ar 20 CO2 1 2 mm The weld data in location 10 has now been copied to memory location 50 If memory location 50 was already occupied a message appears in the display COPY WELD DATA NR 10 TILL NR 50 p gt DIP SPRAY Fe Ar 20 C
7. c cece cece teens 9 7 Serial commun A A A sce eek a a aces eeu a Slate 9 8 Program Upgrades aie Aue eo ee A Se el oe ee hed ea read 10 APPENDIX 10 1 Setting ranges 10 2 Menu structure AAPP en tae eee ee 49 51 65 66 67 70 73 74 77 79 1 INTRODUCTION ARISTO 2000 is one of the most practical welding power sources on the market In order to get the maximum benefit from your welding equipment we recommend that you read this manual carefully You will find that there are many features to improve your work and make it easier All settings are made using the PUA 1 controller You will quickly find this very easy to use To help you find the sections of the manual that are of special interest see the following Section 1 Introduction and basics Sections 2 5 MIG MAG MMA TIG and arc air gouging settings directly related to these parameters Sections 6 8 Measured value display using the memory and quick settings Sections 9 10 Auxiliary functions and appendix See also the menu structure on the last page of this manual 1 1 Main menu PROCESS MIG MAG METHOD DIP SPRAY WIRE TYPE Fe SHIELDING GAS Ar 20 CO2 WIRE DIMENSION 1 2mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER 1 2 Using the controller The controller can be said to consist of two units the working memory and the weld data memory COLLECT WELD DATA WORKING MEMORY MEMORY The working memory is used to store a c
8. ser measure memory mope enren The next line in the menu is AUXILIARY FUNCTIONS You can read more about these functions in the section AUXILIARY FUNCTIONS See step 9 We have now completed the settings for MMA welding bu14d01e 28 4 TIG welding 4 1 Basic settings The basic settings for TIG welding are made in the main menu 1 Welding process TIG 2 Welding method With TIG welding you have a choice of two different welding methods e Constant current e Pulse 3 Start method There is also a choice of two start methods e Liftarc e HF START With Liftarc start you touch the electrode to the workpiece to strike the arc then raise it slightly With HF start the arc is struck by a high frequency spark that is produced when the electrode is a certain distance from the workpiece 4 Gun trigger mode In TIG welding you can choose whether you want the TIG torch to operate with the trigger latch off or on The main difference is that with the trigger latch off you have to hold the trigger in during welding but when it is on you can release the trigger during welding The difference between having the trigger latch off or on is illustrated in the following diagrams along with the other functions in the start stop cycle Trigger latch off 2 1 a ee A lopEa db a Gas pre flow up y Gas i I post flow With the trigger latch off gas pre flow begins when the TIG gun trigger is press
9. 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 30 248 59 22 Fax 31 30 248 52 60 NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp z o o Warszaw Tel 48 22 813 99 63 Fax 48 22 813 98 81 PORTUGAL ESAB Lda Lisbon Tel 351 1 837 1527 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 Ib rica S A Alcobendas Madrid Tel 34 91 623 11 00 Fax 34 91 661 51 83 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 1741 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 31 333 43 33 Fax 55 31 361 31 51 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 44 58 Asia Pacific AUSTRALIA ESAB Australia Pty Ltd Erm
10. bu14d01e 9 AUXILIARY FUNCTIONS 9 1 Memory card operations Insert PC In order to use the memory card functions you must card here first install the PC card gt 1 Turn off the power to the welding machine DA 2 Insert the PC card y H 3 Turn on the power a a E 4 Press auxiliary functions ENTER S 5 Press memory card operation ENTER The following display appears MEMORY CARD OPERATIONS WELD DATA SETS store DELETE RECALL out STORE This is used to save weld data settings in memory locations 1 99 to the PC card using the controller If the same weld data is already stored on the card it will be written over by the data in the controller s own memory Exempel Setting control PC card The weld data The PC settings in the 1 2 3 10 12 50 card controller are is empty PC card Press STORE The weld data settings from the controller are now stored on the PC card 1 2 3 10 12 50 49 bu14d01e DELETE Use this if you want to delete the contents of the PC card memory all weld data settings Example PC card The weld data settings on the PC card are 12 3 10 12 50 PC card Press DELETE The PC card s memory is now empty RECALL This is used to copy weld data settings from the PC card to the controller If a weld data setting is already stored in the controller s own memory it will be written over by the settings stored on the PC card Example Setting control PC card Press RECA
11. cursor on the line that shows the chosen weld You can enter the length of the weld in the appropriate field to obtain the heat input in the same way 65 bu14d01e 9 4 Production statistics MAIN MENU AUXILIARY FUNCTIONS PRODUCTIONS STATISTIC The production statistics keep track of the total arc time the total mass of wire used and the number of welds made since the last reset They also record the arc time and the amount of wire used during the last weld For additional reference the display also tells you what value of mass per length the wire consumption is based on and when the last restart took place The weld count does not increase if the arc time is less than 1 seconds For this reason the wire consumption is not displayed for welds this short However the wire consumption and time for such welds are both included in the total figures for wire consumption and arc time When you press RESET all the counters are reset to zero and the last reset display shows the current date and time PRODUCTION STATISTICS pts wet TOTAL ARCTIME 181 min 24s CONSUMED WIRE BASED ON NUMBER OF WELD 66 bu14d01e 95 Error log MAIN MENU AUXILIARY FUNCTIONS ERROR LOG All faults that occur while the welding equipment is in use are recorded as error messages in the error log Up to 99 error messages can be stored If the error log becomes full i e if 99 error messages have been saved then the oldest error mess
12. ia ota wah Sy ena ea ew en 29 4 2 Welding data settingS jerrr ri seeriaga tiaia a da saws 30 4 3 TlG configuration 0 e E hea ar ented eens 32 4 4 Setting up example TIG 0 eee ene 32 5 Are alt GOUGING in 37 5 1 Synergie MOE ces circa hee et ea danse pee eis 37 5 2 BASIC SCHINGS cicero gasses ii oa 37 5 3 Werking dada A pales Vein Pes Seabee PRA ev attend Gee eae Pan as 37 5 4 Setting up example for arc air gouging 2 c cee 38 6 MEASURED VALUE DISPLAY 00 cece eee eee eee eee 40 6 1 Description of measured value display 000 cece ects 40 6 2 Changing set values 0 cece ented tees 41 T MEMORY ccc NA 42 Tale STO rian ota te Mout ie Sri aie es Me at OCR ES Mok sa dives aa nee 42 Ta MOS sical hearin ae Ke ee ea eis ee Ma el Rec Mn a AA ee 44 feds A Oh len aon atari otek aoa ead ee ead nai Se ae 45 LAs A COPY siden Nate A A A cda 45 29 SREMOLE COMUON A A a ee oA i a as 47 S FAST MODE inde Dada 48 8 1 Description of fast mode 0 66 eee nea 48 8 2 Configuring the fast mode keys 0 00 cece 48 TOCe 2 9 AUXILIARY FUNCTIONS 2 02 cee cece eee eee eee eee eens 9 1 Memory card operations 0 0 eects TOCe 9 2 Configuration 9 37 Quality TUNCUONS seguros neta tems esate nee ET agate beet a ete dries 9 4 Production stat 9 5 Errorlog ISTIOS a AS A A AA ac AS eck 9 6 User defined synergic lines for MIG MAG 0
13. mixture requires its own unique combination of wire feed speed and voltage arc length in order to produce a stable arc ARISTO 2000 has several pre programmed synergic lines Once you have chosen the pre programmed synergic line that matches your choice of wire type wire diameter and gas mixture all you need to do is select a suitable wire feed speed for the welding job The voltage arc length automatically follows the pre programmed synergic line you have chosen which makes it much easier to find the right welding parameters quickly In MIG MAG welding there is an option to use the welding power source in synergic mode This means that the user chooses a setting or value for e method wire type e shielding gas e wire diameter On the basis of these basic settings and the selected value of wire feed speed a microprocessor then selects appropriate values for the various welding parameters The values of these parameters are linked to the method you have chosen dip spray or pulse See also Weld data settings under section 2 4 It is also possible to weld with a combination of wire and shielding gas other than those offered by the controller This could however mean that the user will have to set one or more parameters himself 2 3 Basic settings Basic settings are chosen from the controller s main menu 1 Welding process MIG MAG 2 Welding method In the case of MIG MAG welding you can choose between two differe
14. the weld data number that precedes it e the parameters inductance regulatortype and hot start voltage must have the same values in all four weld data numbers e The two coordinates for a pulse welding line must be saved as numbers 96 and 97 In addition 70 bu14d01e e the higher weld data number must contain higher values of voltage wire feed speed pulse frequency pulse amplitude and background current than the weld data number that precedes it e the parameters pulse time hot start voltage Ka Ki and the Slope parameters must have the same values in both weld data numbers e Crater fill data must be saved as weld data number 96 for both methods dip spray and pulse 4 Define the number of coordinates that are needed then move on to Specifying the relevant wire gas combination 9 6 2 Specifying the relevant gas wire combination Do as follows 1 Setup the display to handle user defined synergic lines MAIN MENU AUXILIARY FUNCTIONS USER DEFINED SYN DATA MAKE CUSTOMISED SYNERGIC LINES Position the cursor WIRE TYPE Fe on the line WIRE SHIELDING GAS Ar 20 CO2 TYPE and press WIRE DIMENSION 1 2mm ENTER STORE NEW LINE FROM WELD DATA MEMORY 96 97 98 99 DELETE SYNERGIC LINE jom e Choose an option from the list displayed mark the option and press ENTER 2 Now choose a shielding gas and the wire diameter in the same way 3 Mark the line STORE NEW LINE and press ENTER The pro
15. 0 1s Gas pre flow time 0 0 25 0 s Gas post flow time 0 0 25 0 s Arc air gouging Setting range Seting step wees roy 025 mame 0 100 Control type Type number 1 2 5 SI The parameters in italics are not available in sudowngic mode The parameter control type does not have a true setting range In arc air gouging you can choose from three different control types numbered 1 2 and 5 78 bu14d01e 10 2 Menu structure MAIN MENU MEASURED HANDLING sid 42 START DATA MIG MAG RECALL sid 45 sid 45 CONFIGU PRODUC TION STA NOT USED LANGU AGE sid 51 79 bu14d01e 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 2 726 80 05 THE CZECH REPUBLIC ESAB VAMBERK s r o Prague Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Copenhagen Valby 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 49 212 298 204 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
16. 2 1 0 mm FAST SET MEMORY MODE ENTER Position the cursor on the line for DIP SPRAY in the list and press ENTER We have now set the METHOD DIP SPRAY Wire type DIP SPRAY PULSE ESAB LUD 450 Position the cursor on the line for WIRE PROCESS MIG MAG TYPE Press ENTER METHOD DIP SPRAY to display the list of WIRE TYPE AIS options SHIELDING GAS WIRE DIMENSION AUXILIARY FUNCTIONS Ar 20 C02 1 0 mm FAST SET MEMORY MODE ENTER Here is an example of a list that has so many options that they cannot all be displayed at the same time The arrow in the bottom right cordown of the list indicates that more options will become visible as you scroll down the list Now position the cursor on the line for Fe and press ENTER We have now set the WIRE TYPE Fe 17 bu14d01e Ss Stainless Ss duplex AlMg AlSi Metal cored Fe Rutile FC Fe Shielding gas ESAB LUD 450 Position the cursor on the line for PROCESS MIG MAG SHIELDING GAS METHOD DIP SPRAY vi a T WIRE TYPE Fe options SHIELDING GAS Ar 20 CO WIRE DIMENSION 1 0 mm AUXILIARY FUNCTIONS FAST ser measure memory mobe enter Position the cursor on the line for Ar 8 CO2 and CO2 press ENTER We have now set the Ar 20 CO2 SHIELDING GAS Ar 8 CO2 Ar 2 02 Ar 5 024 5 CO2 Ar 8 CO2 Ar 23 CO2 Ar 15 CO2 5 02 Y Wire dimension ESAB LUD 450 Position the cursor on the lin
17. ILL YES e CRATER FILL TIME 1 5 s e FINAL WIRE FEED SPEED 3 0 m min e BURNBACK TIME 0 11 s e GAS POST FLOW 2 0 s WELD DATA SETTING Position the cursor on the line STOP VOLTAGE 29 0 0 0 V DATA and press WIRE SPEED 10 0 m min ENTER INDUCTANCE 70 SYNERGIC MODE ON START DATA STOP DATA CRATR HOT e 4 FILL START STROKE QUIT ENTER 22 bu14d01e Crater fill Begin by choosing whether you want to use the crater fill function or not If you choose to use crater fill you will then also have to set the crater fill time and wire feed speed Move the cursor on the line CRATER FILL and press ENTER to display the list of options Select YES Crater fill time Position the cursor on the line TIME Set it to 1 5 s using one of the plus minus keys Final wire feed speed STOP DATA SYNERGIC MODE CRATERFILL YES CRATR e FILL TIME FIN WIRE SPEED BURNBACKTIME GASPOSTFLOW CRATERFILL 1 58s 2 8 m min 0 12s 0 5s HOT e 4 START STROKE QUIT ENTER STOP DATA SYNERGIC MODE YES TIME 1 58 CRATR e FILL FINAL WIRE SPEED BURNBACKTIME GASPOSTFLOW 2 8 m min 0 12s 0 5s HOT e 4 START STROKE QUIT This is used to set the wire feed speed that will be used when crater fill is complete Position the cursor on the line FINAL WIRE SPEED Set it to 3 0 m min using one of the plus minus keys bu14d01e CRAT
18. LL 12 3 10 12 50 2345 6 Setting control The controller now has 3 new sets of weld data settings 4 5 6 and sets 2 and 3 have been 123 45 6 updated with the settings that were stored on the 10 12 50 PC card Error codes If the controller detects an error in the PC card you will see an error code that briefly describes the error in question Check the following That the PC card is properly installed That the PC card is not of an unknown or unapproved make That the data stored on the card is compatible with the software in the controller That the PC card has the correct version number and is using the correct format 50 bu14d01e 9 2 Configuration 9 2 1 Language and Unit of length See step 1 3 9 2 2 Lock function MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION LOCK FUNCTION Sometimes you may want to restrict access to certain controller functions to prevent someone else from changing important parameters or settings When the password function is active and the measure remote control or fast mode menus are selected a password is requested whenever you try to return to the main menu by pressing the QUIT or MENU keys Normally the equipment starts up in one of these three menus when you first switch it on and the only way to exit in order to go to other memories is to give the right password LOCK FUNCTION LOCK STATUS OFF SET CHANGE LOCK CODE QUIT ENTER In PASSWORD MODE the password
19. LTS TIG DEFAULTS GENERAL DEFAULTS MULTIPLE WIRE FEEDERS UNIT OF LENGTH jom jae Position the cursor on the line for choice of language in the list and press ENTER SVENSKA SUOMI DANISH AUXILIARY FUNCTIONS CONFIGURATION Press ENTER to display the list of LANGUAGE SVENSKA options LOCK FUNCTION OFF REMOTE CONTROLS MIG MAG DEFAULTS MMA DEFAULTS TIG DEFAULTS GENERAL DEFAULTS MULTIPLE WIRE FEEDERS UNIT OF LENGTH Inch jo jae Position the cursor on the line for choice of UNIT OF LENGTH in the list and press ENTER INCH bu14d01e 1 4 Display ESAB LUD 450 PROCESS MIG MAG METHOD DIP SPRAY WIRE TYPE Fe SHIELDING GAS Ar 20 CO2 WIRE DIMENSION 1 2mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER Cursor The cursor is shown in this manual as a box around the selected text The controller cursor actually appears as a shaded field with the selected text highlighted in white Text boxes At the bottom of the display are five boxes containing text that explains the current functions of the five keys in a line below them Saver mode To extend the life of the display illumination it is switched off after three minutes if there is no activity bu14d01e 15 Keys By using the cursor keys you can move the cursor to different lines in the display Pressing the menu Koy CE always brings you back to the main menu The plus minus keys H H are used to increase
20. N GASPREFLOW GASPOSTFLOW 4 Puree srmoxe Jow We have now completed the set up procedure for TIG welding 36 bu14d01e 5 Arc air gouging 5 1 Synergic mode The power source has a synergic mode for arc air gouging This means that the power source automatically selects a suitable value for the voltage on the basis of the chosen electrode diameter It is possible to use electrodes with a different diameter to those displayed on the controller but this means that the user must make the necessary settings for certain parameters 5 2 Basic settings The basic settings for arc air gouging are made in the controller s main menu 1 Welding process ARC AIR GOUGING Carbon ArcAir 2 Electrode diameter The table below shows the electrode diameters that can be used when the power source is in synergic mode Electrode diameter 4 mm 3 16 in 5 mm 6 mm 1 4 in 8 mm 5 3 Welding data If you use the power source in synergic mode there is actually no need to set any of the welding parameters The voltage parameter can however be adjusted if wished The parameters shown in italics are constant i e they are unaffected by any change in voltage Welding parameters for arc air gouging e Voltage e Inductance e Control type See the APPENDIX See step 10 for a table giving the full range of parameter settings 37 bu14d01e 5 4 Setting up example for arc air gouging 5 4 1 Ba
21. O2 1 2 mm Press the QUIT key to return to the memory menu 46 bu14d01e 7 5 Remote control To start we call up the main menu by pressing the MENU key Then select the measure menu by pressing the MEASURE key DIP SPRAY Fe Ar 8 CO2 1 2 mm From the measure menu you can switch to Tf 22 5 Vo It operating the 5 equipment by remote control by pressing the Remote key There are four different remote control devices 6 0 m min J I fe The digital remote control is used when you want to recall weld data settings from the weld data memory without using the standard controller Digital remote control e Aristo Control 5 program This remote control lets you recall 5 different sets of weld data settings from memory You save them in memories 1 5 You can also adjust the voltage for the welding program you have recalled Analogue remote control With an analogue remote control you can control the primary parameters of the welding process from a unit other than the standard controller e Aristo Control Synergic PAE 2 With this remote control you can increase decrease the wire feed speed and voltage either side of the synergic line you have chosen e Esab PSF welding torch with 2 knobs This welding torch has 2 knobs that allow you to increase decrease the wire feed speed and voltage either side of the synergic line you have chosen It is also possible to adjust these during welding e Esab PSF weldin
22. OWER SOURCE C WIRE FEED UNIT C WELD DATA UNIT UPGRADE QUIT NOW Specifies the active program version for this unit PC card Specifies the program version stored on the PC card for this unit 2 There is a unit but the computer is unable to determine its version number EN There is no program for this unit on the PC card System version Specifies the software set up stored on the PC card A software set up can consist of 1 4 programs one for each unit 74 bu14d01e How to upgrade Choose the unit or units that need to be upgraded by placing the cursor on the appropriate line and marking M them After making your selection press EXECUTE UPGRADE and confirm with YES to start the upgrade SOFTWARE UPGRADE Place the cursor on Curr ver the line for the unit to be upgraded SYSTEM VERSION BOOT SOFTWARE V POWER SOURCE 1 50A C WIRE FEED UNIT 2 00A C WELD DATA UNIT 1 31E UPGRADE NOW e Press the first button to select the unit a checkmark will appear You can cancel your selection by pressing the button again the checkmark will disappear If more than one unit is to be upgraded select them in the same way SOFTWARE UPGRADE Press YES to Curr ver upgrade Upgrading can take up to five THE SOFTWARE UPGRADING CAN TAKE UP TO 5 minutes MINUTES AND CANNOT BE INTERRUPTED DO YOU STILL WANT TO DO IT 75 bu14d01e The following dialogue box is shown in the display window w
23. PULSE MLC 30C po our jae Motor strength The motor strength is a measure of the torque that the electric push wire feed motor will exert on the wire The motor strength is preset to 1 50 A This torque is suitable for most wires and a range of hose lengths If you use a soft thin aluminium wire it may be advisable to reduce the motor strength to 1 25 A to avoid wire feed problems If on the other hand you are using a 16 m hose with a worn wire liner and wire feeding is sluggish it may be necessary to increase the motor strength to 1 75 A Note that it is very important that the rear wire feed unit feeds smoothly since the power source uses the speed of the rear wire feed unit as a control signal MIG MAG DEFAULT SETTING MLC 30C Position the cursor over MOTOR MOTOR STRENGTH 10A STRENGTH STOP WIRE FEED SPEED 0 7 m min Press ENTER to display a list of options curr fenren Position the cursor on the line for the selected motor strength See the table of wire types and 1 25 A 1 50A 1 75A 58 bu14d01e motor strengths in the user manual for MLC 30C Press ENTER Wire feed speed The stop wire feed speed is the feed speed at which the power source is switched off This is to ensure as clean a stop as possible and prevent the wire burning back into the contact tip If you are welding at 13 m min for example then the stop speed can be set to 10 m min which means that the wire feed un
24. R e FILL CRATERFILL TIME STOP DATA SYNERGIC MODE YES 3 0 S FINAL WIRE SPEED 3 0 m min BURNBACKTIME GASPOSTFLOW 23 0 12s 0 5s HOT e 4 START STROKE QUIT Burnback time STOP DATA SYNERGIC MODE Position the cursor on the line CRATERFILL YES BURNBACK TIME TIME 3 0s Set it to 0 11 s using FINAL WIRE SPEED 4 0 m min one of the BURNBACKTIME 0 11s plus minus keys GASPOSTFLOW 0 5 s CRATR e HOT e 4 FILL START STROKE QUIT Gas post flow Use this to set the time for which the gas continues to flow after welding is complete STOP DATA SYNERGIC MODE Position the cursor on the line GAS CRATERFILL YES POST FLOW Set TIME 1 5s it to 2 0 s using one FINAL WIRE SPEED 3 0 m min of the plus minus BURNBACKTIME 0 118 keys GASPOSTFLOW 2 0s CRATR e HOT e 4 FILL START STROKE QUIT This completes the stop data settings and means that all the weld data settings for MIG MAG welding have been entered 24 bu14d01e 3 MMA welding 3 1 Synergic mode The welding power source also has a synergic mode for MMA welding This means that the welding power source automatically optimises the welding characteristics to suit the type and size of electrode you have chosen 3 2 Basic settings The basic settings for MMA welding are entered using the controller s main menu 1 Welding process MMA 2 Electrode type Three different types of electrode can
25. SHIELDING GAS Ar 20 C02 WIRE DIMENSION 1 2 mm STORE NEW LINE FROM WELD DATA MEMORY 96 97 98 99 DELETE SYNERGIC LINE _ Jomm four fenren A user defined wire or gas option cannot be deleted if it forms part of a set of weld data that is currently in the working memory 72 bu14d01e 9 6 4 Deleting a user defined synergic line A user defined synergic line can be deleted if it is not active i e if itis not part ofa set of weld data that is currently in the working memory MAKE CUSTOMISED SYNERGIC LINES Position the cursor WIRE TYPE Fe on the line DELETE SHIELDING GAS Ar 20 CO2 SYNERGIC LINE WIRE DIMENSION 1 2mm Press ENTER STORE NEW LINE FROM WELD DATA MEMORY 96 97 DELETE SYNERGIC LINE po four jae The display will change By using the NEXT key you can scroll through the user defined synergic lines that have been saved Scroll to the line you MAKE CUSTOMISED SYNERGIC LINES want to delete and press the DELETE CHOOSE SYNERGIC LINE TO BE DELETED key P PULSE Ss duplex Ar 1 4 mm no ome four 9 7 Serial communication Function intended for future use 73 bu14d01e 9 8 Program Upgrades MAIN MENU AUXILIARY FUNCTIONS SOFTWARE UPGRADE Application area With this function you can use a PC card to upgrade software for the controller the current source and the measurement unit SOFTWARE UPGRADE Curr ver PC card SYSTEM VERSION BOOT SOFTWARE L P
26. T MEMORY MODE ENTER Position the cursor on the line for LIFTARC in the list and press ENTER We have now set the START METHOD LIFTARC HF START 33 bu14d01e Gun trigger mode Position the cursor on the line GUN TRIGGER MODE Press ENTER to display a list of options ESAB LUD 450 PROCESS METHOD START METHOD TIG CONSTANT LIFTARC GUN TRIGGER MODE 4 STROKE AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER Position the cursor on the line for 2 STROKE in the list and press ENTER We have now set the GUN TRIGGER MODE 2 STROKE 2 STROKE 4 STROKE ESAB LUD 450 PROCESS METHOD START METHOD GUN TRIGGER MODE TIG CONSTANT LIFTARC 2 STROKE AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER The next line in the menu is AUXILIARY FUNCTIONS See the section AUXILIARY FUNCTIONS See step 9 for more information bu14d01e 34 4 4 2 Weld data settings Use the settings menu to set the values of the various welding parameters We will make the following settings e CURRENT 200 A e SLOPE UP TIME 2 0 s e SLOPE DOWN TIME 1 48s e GAS PRE FLOW 3 0 s e GAS POST FLOW 5 0 s Press MENU key call up the settings menu by pressing the SET key Current WELD DATA SETTING Position the cursor on the line for CURRENT CURRENT SLOPE UP TIME Set the value to SLOPE DOWN TIME 200 A using one of GASPREFLOW th
27. The hot start creep start and crater fill functions can be switched on or off using the soft keys see the section on MIG MAG configuration see step 9 2 4 2 The start data and stop data menus are used to set the values for the following parameters Gas pre and post flow The parameters gas pre flow and gas post flow specify the length of time that the gas continues to flow before and after welding Burnback time Burn back time is used to adjust the electrode stick out at the end of welding 2 6 Gas purge cold wire feed and trigger latch Like hot start and the others the following three functions can be controlled using the soft keys To find out how to do this see MIG MAG configuration see step 9 2 4 2 Gas purge The gas purge function is used to fill the gas hoses with shielding gas or in order to measure the gas flow rate The gas flows when you press the key and stops when you release it Cold wire feed This function is used to feed wire out manually when fitting a new reel of wire When the key is pressed the wire is fed forward and when it is released the wire stops Gun trigger mode In MIG MAG welding the torch switch can operate in two ways with trigger latch off or trigger latch on Trigger latch off on can be assigned to one of the soft keys The difference between having the trigger latch off or on is illustrated in the following diagrams together with other functions in the start stop cycle 14
28. age is automatically deleted when the next fault occurs 12 Date Error 970422 15 52 24 CBOX Lost contact with wire feeder 970422 16 54 04 CBOX Lost contact with power source 970423 09 14 33 PSOURCE High temperature DELETE VIEW DELETE ALL TOTAL QUIT 9 5 1 Deleting error messages If you want to delete error messages there are two options each with their own key e Delete marked messages e Delete all messages 9 5 2 Reviewing errors By pressing the VIEW TOTAL key you can view all the recorded error messages in the error log You can also see the date and time of the most recent recorded error message ERROR LOG TOTAL LISTING TOTAL ERROR MESSAGES 12 OLDEST ERROR 970417 11 09 11 LATEST ERROR 970429 13 04 45 67 bu14d01e 9 5 3 Error messages This is a list of the error messages that may appear CBOX Checksum control failed in EPROM Program memory error Test PSOURCE only carried out on start up when power is switched on This error WFEED does not override any functions CBOX RAM test failed in microprocessor Error in microprocessor s inter PSOURCE nal RAM Test only carried out on start up when power is switched WFEED on This error does not override any functions CBOX Failed external RAM test Test only carried out on start up when power is switched on This error does not override any functions source Drop down in 5V supply line Computer supply voltage has dropped PSOURCE for som
29. be chosen if you want to weld in synergic mode e Basic e Rutile e Cellulosic 3 Electrode diameter The table below shows the electrode diameters that can be selected when the power source is in synergic mode Electrode type Electrode diameter mm 1 6 2 0 2 5 3 2 4 0 4 5 5 0 5 6 6 0 16 2 0 2 5 3 2 4 0 4 5 5 0 5 6 6 0 Cellulosic 2 5 3 2 25 bu14d01e 3 3 Welding data If you stay in synergic mode you only need to set the welding current The welding current can also be adjusted during welding by using the keys When you adjust the welding current the arc force is automatically adjusted to compensate if the welding power source is in synergic mode In the settings menu you can see what value has been chosen for the parameter welding current Display the SETUP menu by pressing PROCESS MMA the SET key ELECTRODE TYPE RUTILE ELECTRODE DIAMETER 2 5 mm AUXILIARY FUNCTIONS p ser measune memory mone enren WELD DATA SETTING combination of CURRENT With our chosen electrode type and SYNERGIC MODE electrode diameter the power source has set the welding current to 80 A 26 bu14d01e 3 4 MMA configuration See step 9 2 6 3 5 Setting up example MMA Here is an example of how to set up for MMA welding 3 5 1 Basic settings The main menu is used to make the settings that concern choice of electrode First we call up the main menu if this has not already been d
30. ber 1 recalls weld data from locations 11 15 The wire feed unit with ID number 2 recalls weld data from locations 21 25 The wire feed unit with ID number 3 recalls weld data from locations 31 35 IMPORTANT All limits that are set in fast mode and the remote control configuration menu apply to all wire feed units 64 bu14d01e 9 3 Quality functions MAIN MENU AUXILIARY FUNCTIONS QUALITY FUNCTIONS The quality functions keep track of a range of useful data about individual welds These functions are Time of weld start How long the weld took Mean maximum and minimum current for weld Mean maximum and minimum voltage for weld Mean maximum and minimum power for weld You can also key in the length of the joint manually and the weld data unit will calculate the heat input The number of welds made since the last reset is also displayed Information on up to 100 different welds can be stored The weld must take longer than seconds in order to register The last recorded weld is shown on the display but you can also scroll through all the other recorded welds When you press RESET all the variables are zeroed QUALITY FUNCTIONS WELD 1 START 01 JUN 97 12 00 02 WELD TIME 0 0s W LENGTH O cm HEAT INPUT 0 0kJ cm AVE MAX MIN Amp 0 00 0 00 0 00 U V 0 00 0 00 0 00 P KW 0 00 0 00 0 00 NUMBER OF WELDS SINCE LAST RESET You can choose a particular weld by scrolling up or down using or El to position the
31. bu14d01e The number shown in the top line of the display is the first empty position found in STORE IN DATA NR 10 the memory Select number 10 using the plus minus keys Press ENTER gt fav m The set of data is now stored as number 10 At the bottom of the display you can see part of the contents of data set 10 STORE IN DATA NR 10 DIP SPRAY Fe CO2 1 2 mm p lt Ss four fer To return to the memory menu press the QUIT key Tip If the display indicates STORE IN DATA NR 1 you can go directly to set 99 by pressing the minus on either or El 43 bu14d01e 7 2 Delete In the memory menu you can delete one or more sets of weld data Example We will now delete the set of data we stored in the earlier example Press the MEMORY FUNCTIONS STORED DATA SETS DELETE key DIP SPRAY Fe Ar 20 CO2 1 2 mm STORE DELETE RECALL copy aurr The last stored set of data is marked automatically If more than one set of data has been stored you can move the cursor between them using the arrow left and arrow right keys DELETE WELD DATA NR 10 Press ENTER to confirm you want to delete data set number 10 P DIP SPRAY Fe Ar 20 CO2 1 2 mm p lt four fer 44 bu14d01e 7 3 Recall To recall a previously stored set of data first check that the memory menu is displayed Press the RECALL key MEMORY FUNCTIONS STORED DATA SETS STORE DELETE RECALL
32. cess is now complete a new synergic line has been defined NOTE If you want to use the crater fill function when pulse welding then there must be a corresponding synergic line for dip spray welding since all crater fill data is based on dip spray parameters When you create a new synergic line for pulse welding you will therefore always be warned if a corresponding line has not been created for dip spray welding WARNING No corresponding synergic line for dip spray welding 71 bu14d01e 9 6 3 Creating user defined wire gas options The list of wire and gas options can be extended to include up to 10 user defined options At the bottom of each list is an empty line By placing the cursor on this line and pressing ENTER you gain access to a keyboard that allows you to type in your own options Ar 20 CO2 Ar 5 024 5 CO2 Ar 2 O2 Ar 8 CO2 Ar 23 CO2 The controller keyboard is used as follows e Position the cursor over the chosen keyboard character using the arrow keys Press the soft key PRESS KEY Type in a string of text of up to 20 characters in this way e Mark the keyboard s ENTER key 1 and press the soft key PRESS KEY and the name of your user defined option will appear in the list Deleting a user defined gas wire option Mark the user defined wire or gas option in the current list MAKE CUSTOMISED SYNERGIC LINES Press the DELETE WIRE TYPE Fe key
33. d to the customer with the identity number 0 The first thing you need to do is change the ID number node address of one of the wire feed units this only applies to multiple wire feed units AUXILIARY FUNCTIONS CONFIGURATION Move the cursor to the line for multiple LANGUAGE ENGLISH WITE 1ESc units LOCK FUNCTION press ENTER REMOTE CONTROLS MIG MAG DEFAULTS MMA DEFAULTS TIG DEFAULTS GENERAL DEFAULTS MULTIPLA WIRE FEEDERS UNIT OF LENGTH METRIC jo jae Change the ID number as follows First connect a new wire feed unit go to the MULTIPLE WIRE FEED UNITS menu and press the torch trigger to activate the wire feed unit then read the ID number of the wire feed unit from the top line should be 0 first time Now select a new ID number between 0 3 MULTIPLE WIRE FEEDERS Move the cursor to the line CHOOSE NEW ID CURRENT ID NUMBER NUMBER Set the required number between 0 3 by CONNECTED WIRE FEEDERS ID stepping with the plus minus keys Press ENTER jom jae The ID number on the top line will change to the chosen number Now connect the next wire feed unit and press the torch trigger to activate this unit This wire feed unit will probably have an ID number of 0 as well 63 bu14d01e Configuration is now complete and you can start using the equipment as normal It is now also possible to configure and run four different wire feed units in the same way It
34. does not matter which ID number you assign to each wire feed unit but it is important that you give each one a different ID number to distinguish between them If you accidentally give two wire feed units the same ID number then error message 15 will be displayed continuously If this happens you should disconnect one of the wire feed units and repeat the above procedure You can always return to the configuration display and check the ID numbers of the connected wire feed units by pressing the torch trigger The line CONNECTED WIRE FEED IDs shows the ID numbers of all the wire feed units connected 9 2 10 Multipla wire feeders Weld data can be individually assigned to each wire feed unit To assign data toa wire feed unit it must first be active When it is active you can recall data as normal See memory use in section 7 and make any adjustments These will be assigned to the active wire feed unit For the next wire feed unit you again press the torch trigger to make this feed unit active then recall the data you want to assign to this feed unit You can assign any weld data number you want to any wire feed unit you choose 9 2 11 Multipla wire feeders Remote control units control the wire feed units they are connected to The digital 5 program remote control recalls data from various memory locations depending on its ID number The wire feed unit with ID number O recalls weld data from locations 1 5 The wire feed unit with ID num
35. e for WIRE PROCESS MIG MAG DIMENSION Press METHOD DIP SPRAY ENTER to display WIRE TYPE Fe the list of options SHIELDING GAS Ar8 CO2 WIRE DIMENSION 1 0 mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER Position the cursor on the line for 1 2 mm and press ENTER We have now set the WIRE DIMENSION 1 2 mm 18 bu14d01e The next line in the main menu is AUXILIARY FUNCTIONS You can read more about these functions in the section AUXILIARY FUNCTIONS see step 9 ESAB LUD 450 PROCESS MIG MAG METHOD DIP SPRAY WIRE TYPE Fe SHIELDING GAS Ar8 CO2 WIRE DIMENSION 1 2 mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER 2 8 2 Weld data settings You can use the settings menu to set the values of various welding parameters such as voltage and wire feed speed If you switch to synergic mode the microprocessor will take care of several of these settings To start we call up the main menu by pressing the MENU key Then select the settings menu by pressing the SET key We will now make the following settings e WIRE FEED SPEED 10 0 m min Wire feed speed WELD DATA SETTING Position the cursor on the line VOLTAGE 29 0 0 0 V WIRE SPEED _ WIRE SPEED 10 0 m min Set it to 10 0 m min INDUCTANCE 85 using SYNERGIC MODE ON START DATA STOP DATA CRATR HOT 4 FILL START STROKE QUIT In the settings menu you can now also see the values t
36. e plus minus GASPOSTFLOW keys 4 Puree stroke owr Slope up and Slope down The Slope up and Slope down parameters are each linked to the plus and minus keys respectively To set the Slope up time use the uper key and to set the Slope down time use the lower key WELD DATA SETTING Move the cursor to the line for SLOPE UP and CURRENT SLOPE DOWN TIME SLOPE UP TIME Set the SLOPE DOWN TIME SLOPE UP TIME to GAS PRE FLOW 2 0 s by stepping with GAS POST FLOW the upper plus minus 4 STROKE QUIT key 35 bu14d01e WELD DATA SETTING Set the SLOPE DOWN TIME to 1 4 s by CURRENT stepping with the lower SLOPE UP TIME plus minus key SLOPE DOWN TIME GASPREFLOW GASPOSTFLOW 4 Puree stroke Jow Gas pre flow and gas post flow The parameters gas pre flow and gas post flow are each linked to their own specific plus minus key in the same way as the Slope parameters above The uper plus minus key is used to set the gas pre flow and the lower one is used to set the gas post flow WELD DATA SETTING Move the cursor to the line for GAS CURRENT PRE FLOW and GAS SLOPE UP TIME POST FLOW SLOPE DOWN TIME Set the GAS GASPREFLOW PRE FLOW to 3 0 s by GASPOSTFLOW stepping with the upper 4 STROKE QUIT plus minus key WELD DATA SETTING Set the GAS PRE FLOW to 5 0 s by CURRENT stepping with the lower SLOPE UP plus minus key SLOPE DOW
37. e reason May occur if machine is switched off but may also source be due to fault in voltage supply to card PSOURCE DC voltage outside limit DC voltage from rectifier is either too high or too low possibly as a result of mains voltage spikes or low mains voltage The inverter is automatically shut down immediately and pow er is only restored when the voltage drops below the limit pe High temperature The temperature of the welding power source is too high possibly as a result of overloading a defective cooling fan or oe Teoh other component fault PSOURCE High primary current The inverter is drawing too much current from the rectifier that supplies it The inverter is automatically shut down immediately and power is only restored when the problem has been corrected CBOX DC voltage 1 outside safe limits CBOX Battery voltage is too low PSOURCE PSOURCE The internal 15VC supply is either too high or too low WFEED WFEED The internal 15V supply is either too high or too low PSOURCE DC voltage 2 outside safe limits PSOURCE The internal 15V WFEED supply is either too high or too low WFEED The internal 20V supply is either too high or too low 10 PSOURCE DC voltage 3 outside safe limits The internal 15VB supply is either too high or too low 11 PSOURCE Servo error PSOURCE The current servo cannot supply the current WFEED demanded by the microprocessor There is a persistent difference be tween the shunt response a
38. ect you will see an error message that gives the user the option of trying again or going back to the original menu i e the measure menu or fast mode menu If the password is correct all restrictions on moving to another menu will be lifted but the password function will still remain active this means that you can leave the measure fast mode menus temporarily but when you go back to them the password will be activated again If you want to make changes outside the measure fast mode menus e g change settings deactivate password function etc you can return to them and password mode and reactivate the password to restrict the user to the measure fast mode menus again 52 bu14d01e 9 2 3 Remote controls MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION REMOTE CONTROLS All remote control configurations apply to any wire feed unit that is connected If you deselect ANALOG1 this will affect both wire feed units if you are using twin wire feed units MIG MAG REMOTE CONTROLS DIGITAL OP 5 PROG ANALOG 1 NONE ANALOG 2 NONE Jom fenren Move the cursor to the line FORGET CHANGE and press ENTER to display a list of options The forget change function in on mode means you always have access to the original weld data in the selected memory location when you come to the end of a weld In other words if you have made a change to a synergic line for example increased the voltage by 2 V when you finish the current we
39. ed 1 The current then rises to the pilot level a couple of amperes and the arc ignites The current then rises to the set value following the Slope up slope if applicable When the trigger is released 2 the current falls back to the pilot level following the Slope down slope if applicable and the arc is extinguished The gas continues to flow for the post flow period if applicable 29 bu14d01e Trigger latch on jJ lope own mn Oo jo o an gt Gas z 1 Up Gas pre flow post flow With the trigger latch on gas pre flow begins when the TIG gun trigger is pressed 1 When the gas pre flow period has elapsed the current rises to the pilot level a couple of amperes and the arc ignites When the trigger is released 2 the current rises to the set value following the Slope up slope if applicable When the trigger is pressed again 3 the current again rises to the pilot level following the Slope down slope if applicable When the trigger is released again 4 the arc is extinguished and the gas post flow period begins if applicable When you are in the weld data settings menu or the measure menu you can switch the trigger latch off or on using one of the soft keys 4 2 Welding data settings The values of the welding parameters are set using the settings menu Certain parameters are specific to the chosen method and certain are common to both TIG methods The following para
40. elf which may stop working 32 WFEED No gas flow The gas flow monitor has detected that there is no gas flow 29 30 69 bu14d01e 9 6 User defined synergic lines for MIG MAG MAIN MENU AUXILIARY FUNCTIONS USER DEFINED SYN DATA It is possible to create user defined synergic lines that relate the wire feed speed to the voltage A maximum of ten such synergic lines can be saved Creating a new synergic line is done in two stages 1 Define the new synergic line by specifying a number of voltage wire feed speed coordinates see steps A D in the following diagram Voltage 2 Specify which wire gas combination the new synergic line will apply to 9 6 1 Specify feed speed voltage coordinates To create a new synergic line for dip spray welding you need four coordinates while for pulse welding you need two coordinates These coordinates must then be saved under special weld data numbers in the weld data memory Do as follows 1 Call up the main menu and choose the MIG MAG method dip spray or pulse that you intend to use with the new synergic line 2 Key in the desired values of voltage and wire feed speed for the first coordinate 3 Call up the memory menu and save the first coordinate as weld data number 96 e The four coordinates for a dip spray synergic line must be saved as numbers 96 97 98 and 99 In addition e each weld data number must contain higher values of voltage and wire feed speed than
41. ey ASSOCIATE FUNCTIONS TO SOFT KEYS Function NONE GAS PURGE WIRE INCHING TRIGGER MODE 2 4 CRATERFILL ON OFF CREEPSTART ON OFF HOT START ON OFF TRIGG WELD DATA SWITCH ON OFF The other two keys can each be assigned a function in the same way by matching one of the functions in the left column with a key number in the right column If you want to assign a new function to a key move the cursor to the line NONE and press the soft key you want to assign the function to The display will show the key text NONE and this can now be reassigned a new function 9 2 4 3 Voltage measurement for dip MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION MIG MAG DEFAULTS VOLTAGE MEASUR DIP The voltage measurement options for dip welding are as follows average pulse voltage average overall voltage Average pulse voltage The voltage is only measured during pulses and is filtered before displaying the voltage value Average overall voltage The voltage is measured continuously and is filtered before displaying the voltage value The measured values that are displayed are used as input data for internal and external quality functions 57 bu14d01e 9 2 5 Wire feed unit MLC 30C CAUTION Upgrade card for MLC 30C is supplied together with the wire feed unit MIG MAG DEFAULT SETTING MLC 30C Position the cursor on the line for MLC TRIGGER SWITCH MODE 30C press ENTER SOFT KEY SETTING VOLTAGE DURING
42. following explains how to set up for TIG welding using the constant current method The setting up procedure is similar for pulse welding 4 4 1 Basic settings We start by displaying the main menu if this has not already been done by pressing the MENU key We will make the following four settings e PROCESS TIG e METHOD CONSTANT CURRENT e START METHOD LIFT ARC e GUN TRIGGER MODE 2 STROKE Process ESAB LUD 450 Use the arrow keys to select PROCESS MMA PROCESS Press ELECTRODE TYPE RUTILE ENTER to display ELECTRODE DIAMETER 2 5mm the list of options AUXILIARY FUNCTIONS ser measure memory Move enter Position the cursor on the TIG option in the list and MIG MAG press ENTER We have now set the PROCESS MMA TIG CARBON ArcAir 32 bu14d01e Method ESAB LUD 450 Position the cursor on the line PROCESS TIG METHOD Press METHOD PULSED ENTER to display START METHOD LIFTARC the list of options GUN TRIGGER MODE 4 STROKE AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER Position the cursor on the line for CONSTANT in the list and press ENTER We have now set the METHOD CONSTANT PULSED CURRENT Start method ESAB LUD 450 Position the cursor on the line START PROCESS TIG METHOD Press METHOD CONSTANT ENTER to display START METHOD LIFTARC the list of options GUN TRIGGER MODE 4 STROKE AUXILIARY FUNCTIONS FAST SE
43. function can be switched off without deleting the existing password If you try to switch on the password function when no password is stored the display shows a computer like keyboard which you can use to enter a new password When you activate the password a small icon of a key appears on the first line of the display to show that the password function is activated You can then move freely between the menus until you go into the measure menu or fast mode menu which trigger the password function and prevent the user from exiting these menus without first entering the password In ENTER CHANGE PASSWORD you can edit the existing password or enter a new one The password can consist of up to any10 letters or numbers 51 bu14d01e Deactivating password function When you are in the measure menu or fast mode menu with the password function deactivated you can exit these menus at any time by pressing QUIT or the MENU key to get back to the main menu If the lock function is active and you try to exit the following message will be displayed to warn the user about the password protection Qa PRESS ENTER TO LOCK CODE From here you can choose QUIT if you change your mind and want to go back to the previous menu or continue by pressing ENTER to input the password This will take you to the keyboard display so that you can type in the password and confirm it by pressing the enter key on the keyboard If the password is incorr
44. g torch with 3 programs This welding torch has a three position key The key lets you recall 3 different sets of weld data settings from memory for example for root beads and filler beads It is also possible to change welding program during welding 7 5 1 Configuring a remote control See step 9 2 3 47 bu14d01e 8 FAST MODE 8 1 Description of fast mode If you have stored one or more sets of weld data in the weld data memory you can make one or more of them maximum of four available through the FAST MODE key in the main menu ESAB LUD 450 PROCESS MIG MAG METHOD DIP SPRAY WIRE TYPE Fe SHIELDING GAS Ar 8 C02 WIRE DIMENSION 1 2 mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER When you press the fast mode key the display may appear like this DIP SPRAY Fe Ar 20 CO2 1 2 mm H 22 5 Volt 134 Amp 6 0 m mi 0 m min WELD WELD WELD WELD 2ND DATA 1 DATA 2 DATA 3 DATA 4 FUNCT Four of the soft buttons can thus be linked to a weld data setting of their own in the weld data memory See soft button function under section 9 2 4 2 The fifth soft button s 2nd function is used to shift functions for the four soft buttons You can shift the four soft buttons from having weld data settings to having those functions available in measure mode gas purge hot start wire inching trigger mode crater fill creep start etc 8 2 Configuring the fast mode keys See step 9 2 8 1 48
45. ger then you can continue welding using the final crater fill parameters dotted line 15 bu14d01e 2 7 MIG MAG configuration See step 9 2 4 2 8 Setting up example MIG MAG The following is an example of how to set up the controller for MIG MAG welding using dip spray transfer Setting up for pulse welding is done in a similar way The example assumes that the power source is in synergic mode 2 8 1 Basic settings You use the main menu to make settings such as wire method and material type We start by pressing the MENU key to call up the main menu We will make the following five settings e PROCESS MIG MAG e METHOD DIP SPRAY e WIRE TYPE Fe e SHIELDING GAS Ar 8 CO2 e WIRE DIAMETER 1 2 mm Process ESAB LUD 450 The first setting is the type of welding PROCESS MIG MAG process Use the METHOD PULSE a WIRE TYPE A Si PROCESS Press SHIELDING GAS Ar 20 CO2 ENTER to display WIRE DIMENSION 1 0 mm the list of options AUXILIARY FUNCTIONS ser measure memory mope enren Position the cursor on the line for MIG MAG in the MIG MA list and press ENTER again Now we have set MMA PROCESS MIG MAG TIG CARBON ArcAir 16 bu14d01e Method ESAB LUD 450 Position the cursor on the line for PROCESS MIG MAG METHOD Press METHOD PULSE ENTER to display WIRE TYPE the list of options SHIELDING GAS WIRE DIMENSION AUXILIARY FUNCTIONS AlSi Ar 20 C0
46. hat the microprocessor has chosen for voltage and inductance The voltage parameter may also be adjusted if required 19 bu14d01e 2 8 3 Start data settings Using the start data menu you can adjust the settings that affect the starting sequence during MIG MAG welding We will set the following e GAS PRE FLOW 0 8 s e CREEP START YES e HOT START YES e HOT START time 1 0 s e HOT START wire feed speed 2 5 m min Start by opening the main menu by pressing the MENU key Then go to the settings menu by pressing the SET key WELD DATA SETTING Position the cursor on the line START VOLTAGE 29 0 0 0 V DATA and press WIRE SPEED 10 0 m min ENTER INDUCTANCE 70 SYNERGIC MODE ON START DATA STOP DATA CRATR HOT 4 FILL START STROKE QUIT Gas pre flow time Here you enter the length of time you want the shielding gas to flow before welding begins START DATA SYNERGIC MODE Position the cursor on the line for GAS GASPREFLOW PREFLOW Set it to CREEPSTART 0 8 s using one of the plus minus keys HOTSTART CRATR HOT 4 FILL START STROKE QUIT 20 bu14d01e Creep start Here you simply choose whether you want to use the creep start function or not i e YES or NO Wire feed speed and creep start are preset and cannot be changed Position the cursor on the line CREEP START Press ENTER to display the list of options Set it to YES press ENTER Hot sta
47. hile the upgrade is in progress SOFTWARE UPGRADE DO NOT SWITCH OFF THE EQUIPMENT DURING THIS PROCESS UPGRADING POWER SOURCE 23 Compl SUCCESSFUL UPGRADE YOU MAY NOW RESTART THE EQUIPMENT All selected units have now been upgraded To use the welding equipment restart the current source e Turn the switch for line voltage on the current source to the O position e Turn the switch for line voltage to the 1 position WARNING Be sure that the current source s line voltage is not disconnected during an upgrade If this happens at an early stage during the upgrade you will need to contact ESAB s service technicians 76 bu14d01e 10 APPENDIX 10 1 Setting ranges and setting steps MIG MAG or ms 2 Sapo me TS a Ra C C ERN Re Crate filie Reguiatorype enm 12 7 The parameters in italics are not available in synergic mode The parameter control type does not have a true setting range In MIG MAG welding you can choose from twelve different control types numbered 1 12 MMA Setting range Setting step Welding current 16 320 A Aristo 320 1 A 16 450 A Aristo 450 1 A mctre je 1 The parameters in italics are not available in synergic mode 77 bu14d01e Setting range Setting step Current Pulse current Background 4 320 A Aristo 320 4 A current 4 450 A Aristo 450 4A nosos Woo Background time 0 001 5 000 s 0 001 s Slope up time 0 0 25 0 s Slope down time 0 0 25 0 s
48. ington Tel 61 2 9647 1232 Fax 61 2 9748 1685 CHINA Shanghai ESAB A P Shanghai Tel 86 21 6539 7124 Fax 86 21 6543 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 01 88 Fax 62 21 461 29 29 MALAYSIA ESAB Malaysia Snd Bhd Selangor Tel 60 3 703 36 15 Fax 60 3 703 35 52 SINGAPORE ESAB Singapore Pte Ltd Singapore Tel 65 861 43 22 Fax 65 861 31 95 ESAB Asia Pacific Pte Ltd Singapore Tel 65 861 74 42 Fax 65 863 08 39 SOUTH KOREA ESAB SeAH Corporation Kyung Nam Tel 82 551 289 81 11 Fax 82 551 289 88 63 THAILAND ESAB Thailand Ltd Samutprakarn Tel 66 2 393 60 62 Fax 66 2 748 71 11 UNITED ARAB EMIRATES ESAB Middle East Dubai Tel 971 4 338 88 29 Fax 971 4 338 87 29 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 CIS ESAB Representative Office Moscow Tel 7 095 937 98 20 Fax 7 095 937 95 80 ESAB Representative Office St Petersburg Tel 7 812 325 43 62 Fax 7 812 325 66 85 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com o d ESAB Welding Equipme
49. it will stop and the power source will switch off when the wire feed speed drops below 10 m min This reduces the risk of the wire burning back into the contact tip If you are welding at 3 4 m min then the stop speed should be set to a lower value for example 1 0 m min The range of possible settings is 0 7 10 m min MIG MAG DEFAULT SETTING MLC 30C Position the cursor over STOP WIRE MOTOR STRENGTH 1 0A FEED SPEED STOP WIRE FEED SPEED 0 7 m min Use the plus minus keys to select the desired value Press ENTER mem m 59 bu14d01e 9 2 6 MMA defaults Function intended for future use 9 2 7 TIG defaults Function intended for future use 9 2 8 General defaults 9 2 8 1 Fast set up limits MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION GENERAL DEFAULTS FAST MODE LIMITS To configure a soft key for fast mode proceed as described below GENERAL DEFAULTS FAST MODE Position the cursor SOFT KEY NUMBER on the line for key number VOLTAGE 0 0 V 0 0 V WIRE SPEED 0 0 m min 0 0 m min ASSOCIATED WELD DATA 16 DIP SPRAY Fe aR 20 CO2 1 2mm lo The keys are numbered 1 4 from left to right Choose the desired key by selecting its number using the plus minus keys Then scroll down with the arrow down key onto the line ASSOCIATED WELD DATA Here you can browse through the sets of weld data that are stored in the weld data memory Choose the desired weld data
50. ld that change will be cancelled and the original data will be recalled This is useful when testing new welding parameters for example Configuring a digital remote control When using a digital remote control you must specify the type of device that is used a 5 program device or 32 program device BINARY CODED If you position the cursor on the line DIGITAL OP and press ENTER you will see a list of the available options BINARY CODED 5 PROG 53 bu14d01e Configuring an analogue remote control When you use an analogue remote control you should use the controller to specify which potentiometer s you want to use maximum of two The controller designates the potentiometers ANALOG 1 and ANALOG 2 and assigns specific welding parameters to each depending on the welding process e g voltage ANALOG 1 and wire feed speed ANALOG 2 for MIG MAG If you position the cursor on the line ANALOGUE 1 and press ENTER you will see a list NONE VOLTAGE You can now choose whether the potentiometer ANALOG 1 is to be used VOLTAGE or not NONE Select the line VOLTAGE from the list and press ENTER MIG MAG REMOTE CONTROLS The following OF OVERRID TABLED display apppears DIGITAL OP 5 PROG ANALOG 1 VOLTAGE ANALOG 2 NONE RANGE ON INPUTS ANALOG 1 DIG MIN 8 0 V MAX 50 0 V our _enrer If you position the cursor on the line ANALOGUE 2 NONE and press ENTER you will see a list You can
51. m 19 20 21 22 5 6 7 8 HE ber does not match the version used by the controller then it sends this error code PSOURCE Watchdog reset triggered The processor s internal watchdog has WFEED been triggered i e something has prevented the processor from car rying out its normal duties in the program main loop within the given time limit 64 ms When this happens the processor is reset and starts again When the program restarts it detects that the restart was caused by the watchdog and sends this message This error does not override any functions WFEED No welding wire The wire feed unit has run out of welding wire CBOX Stack overflow The stack the part of the memory the processor PSOURCE uses to store data temporarily has overflowed This fault can occur if WFEED the processor has an excessive work load PSOURCE No water flow The water flow monitor has detected that there is no 2 2 2 2 water flow CBOX Lost contact with TIG I O unit An identification message is used to keep an ongoing check that a certain unit is still in the network This message appears if there is no response within the Time out The stop command is immediately sent to the power source 31 CBOX No response from display unit The processor does not get any response from the display unit normally the display unit confirms all commands from the processor This error does not override any func tions apart from the display its
52. meters can be set for TIG welding See the APPENDIX step 10 for details of parameter setting ranges Method CONSTANT CURRENT Method PULSE e Current e Pulse current e Slope up e Background current Slope down e Pulse time e Gas pre flow e Background time e Gas post flow e Slope up e Slope down e Gas pre flow e Gas post flow 30 bu14d01e Current The term current refers here to the welding current when welding with constant current Pulse current and background current When using pulsed current you have to set several parameters that are linked to the welding current Pulse current and background current indicate the uper and lower limits of the current see the diagram below Current PULSE TIME gt BACKGROUND TIME PULSE CURRENT BACKGROUND CURRENT Time Pulse time and background time The pulse time sets the duration of the current pulses The background time sets the time between pulses For welding with pulse current see the above diagram The adjustment range for pulse time and background time is 0 001 5 000 s Gas pre flow and gas post flow The parameters gas pre flow and gas post flow are used to set how long you want the gas to flow before and after welding Slope up and Slope down The Slope parameters govern the gradual rise and fall of the we Iding current over a given time 31 5 bu14d01e 43 TIG configuration See step 9 2 6 4 4 Setting up example TIG The
53. nd the set current WFEDD The wire feed servo is unable to provide the wire feed speed demanded by the microprocessor CBOX Warning state in bus interface The bus circuit error count has PSOURCE reached a value that triggers the error message If the error count WFEED continues to rise the bus circuit is switched to the bus off state and contact with the weld data unit controller is broken CBOX Bus off state communication breakdown The bus circuit error count has reached a value that switches it to the bus off state The power must be turned off and on again to reset CBOX Message lost in bus communication The bus circuit detects that a PSOURCE message has been lost because a later message has been written over it This error does not override any fun 17 Lost contact with wire feeder An identification message is used to keep an ongoing check that a certain unit is still in the network This message appears if there is no response within the Time out The stop command is immediately sent to the power source message appears if there is no response within the Time out The stop command is immediately sent to the wire feeder 18 Lost contact with power source An identification message is used to keep an ongoing check that a certain unit is still in the network This 68 bu14d01e E CBOX Unaccepted settings stored in RAM An illegal value has been de tected among the non numerical setting parame
54. ng process is selected The parameter values that can be changed are always identified by H o DIP SPRAY Fe Ar 8 CO2 1 2 mm eR tt 22 5 Volt The window that VOLTAGE 22 5 3 5 V pops up will disappear after 1 5 s if neither of the buttons are used lp m w 41 bu14d01e 7 MEMORY The controller can store up to 99 sets of weld data Each of these sets is given a number from 1 to 99 If the weld data memory is full i e if 99 sets of data are already stored and you want to save an additional set of data then the oldest set of weld data is automatically deleted You can also delete and copy sets of weld data and recall a set of weld data to the working memory Here is an example showing how to store recall copy and delete data 7 1 Store When you want to store a set of data first make sure the main menu is displayed Press the MEMORY key If the weld data memory is empty the display will appear as follows MEMORY FUNCTIONS STORED DATA SETS NO STORED DATA SETS Example We will now store a set of weld data We will store it in memory location 10 Press the STORE key The display will appear as follows STORE IN DATA NR 1 If you press ENTER now the set of data will be saved as number 1 as indicated by the top line of the display You can use the plus minus keys to select the memory location you want to store the set of data in This is shown in the top line of the display 42
55. now choose whether the potentiometer ANALOG 2 is to be used WIRE SPEED or not NONB Select the line WIRE SPEED from the list and press ENTER MIG MAG REMOTE CONTROLS The following OR OVERRID NABLED display apppears DIGITAL OP 5 PROG ANALOG 1 VOLTAGE ANALOG 2 WIRE SPEED RANGE ON ANALOG INPUTS ANALOG 1 DIG MIN 8 0 V MAX x 60 V ANALOG 2 MIN 1 5 m min MAX 25 m min gt aur ente You should also set the control range for the potentiometer s you will use You do this by using the plus minus keys on the controller to specify a minimum and maximum value This only applies to non synergic mode In synergic mode you set ANALOG1 to 10 V in relation to the chosen synergic line while ANALOG 2 wire feed is set to non synergic 54 bu14d01e 9 2 4 MIG MAG defaults MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION MIG MAG DEFAULTS 9 2 4 1 Trigger functions CONFIGURATION MIG MAG DEFAULTS Use the arrow keys to select the line GUN TRIGGER MODE 4 STROKE GUN TRIGGER SOFT KEYS SETUP MODE VOLT MEASURE IN PULSED AVERAGE Press ENTER to display the list of options jom jae Position the cursor on the line for 2 STROKE in the list and press ENTER We have now set the GUN TRIGGER MODE 2 STROKE 4 STROKE CONFIGURATION MIG MAG DEFAULTS GUN TRIGGER MODE 2 STROKE SOFT KEYS SETUP VOLT MEASURE IN PULSED AVERAGE jo jae 55 bu14d01e 9 2 4 2 Soft ke
56. nt AB SE 695 81 LAXA SWEDEN Phone 46 584 81 000 Fax 46 584 123 08 www esab com 001004
57. nt welding methods e Dip spray e Short Pulse 3 Wire type shielding gas wire size The following tables show the combinations of wire type shielding gas and wire size that can be selected when the welding power source is in synergic mode 10 bu14d01e Low alloy or unalloyed wire Fe CO2 Ar 23 CO Ar 25 CO Ar 20 CO Ar 15 COs 5 Oo Ar 16 CO Ar 5 0 gt 5 CO Ar 8 CO Ar 2 COs Ar 2 Oo Stainless solid wire SS Ar 2 Obo 1 6 Ar 2 CO 1 2 1 6 Ar 3 C0 1 Ho 1 2 1 6 Ar 30 He 1 0 1 6 Ar 32 He 3 C0 1 Ho S 1 2 1 6 Stainless duplex wire Ss duplex Ar 2 Oo 1 0 Ar 30 He 1 0 1 0 Magnesium alloyed aluminium wire Ar 09 1 0 1 2 1 6 AlMg Ar 0 9 1 0 Silicon alloyed aluminium wire Al Si 1 2 1 6 Ar 50 He Metal powder cored wire Fe 10 Ar 20 CO Ar 8 CO2 Rutile flux cored wire CO Fe Ar 20 CO Basic flux cored wire COs Fe Ar 20 COs Stainless flux cored wire SS Ar 20 CO gt Ar 8 CO2 SELF SHIELDED 12 Metal powder cored stainless wire Ar 2 Oo Ar 2 CO2 Ar 8 CO Ar 20 CO Nickel base Ar 50 He LUD 450 atia bu14d01e PULSE Shielding gas Wire diameter mm Low alloy or unalloyed wire Fe Ar CO 0 8 1 0 1 2 1 6 Ar 25 CO2 0 9 Ar 20 CO2 0 8 0 9 1 0 1 2 1 6 Ar 23 CO2 0 8 1 0 1 2 1 6 Ar 16 CO gt 0 8 1 0 1 2 1 6 Ar 5 07 5 CO2 0 8 0 9 1 0 1 2 1 6
58. number using the plus minus keys When you recall a set of weld data using the fast mode key you still have the option of adjusting the available welding parameters If you want to restrict the range of adjustment for these parameters you can set uper and lower limits for each parameter 60 bu14d01e The following welding parameters can be adjusted e for MIG MAG e Wire feed speed and e Voltage e for MMA e Welding current e for TIG e Welding current e for Arc air gouging e Voltage To set the limits for parameter adjustment do as follows For each parameter you specify a plus value uper limit and a minus value lower limit using the original weld data setting as a reference point GENERAL DEFAULTS FASTMODE Position the cursor SOFT KEY NUMBER 1 on the line for the chosen parameter VOLTAGE 0 0 V e g VOLTAGE 0 0 V WIRE SPEED 0 0 m min 0 0 m min ASSOCIATED WELD DATA 16 DIP SPRAY Fe aR 20 CO2 1 2 mm lo Specify the desired value for the uper and lower limits using the plus minus keys 9 2 8 2 Twin start signals CONFIGURATION GENERAL DEFAULTS FAST MODE LIMITS TRIGG WELD DATA SWITCH jom jae This option allows you to start the MIG MAG wire feed unit from the TIG card universal It also enables the TIG torch to be started from the wire feed unit This function can be used for mechanised applications 61 bu14d01e 9 2 8 3 Weld data shift with pistol
59. of parameter setting ranges is given in the APPENDIX see step 10 2 55 Start and stop settings The following settings affect the start and stop cycle during MIG MAG welding All the settings that affect the start stop cycle and the way welding finishes are described under the following headings Start settings Stop settings e Gas pre flow e Gas post flow e Creep start Burnback time e Hot start e Shake off pulse only for DIP SPRAY e Hot start time when not in synergic mode e Increase wire feed speed Crater fill 2 m min unless stated e Crater fill time otherwise e Final wire feed speed e Increase voltage only e Final voltage only when not in when not in synergic synergic mode mode There are three different functions that are designed to meet special requirements at the start and end of welding These functions and auxiliary settings are made in the start data menu and stop data menu 13 bu14d01e Hot start Hot start should be selected if you want a hotter arc at the start of the welding cycle to prevent welding defects at the start of the weld Crater fill The crater fill function makes it easier to avoid porosity hot cracks and crater cracking in the weld when you stop welding Creep start The creep start function gives a lower wire feed speed and is suitable to use when wanting to obtain the best possible start The creep start speed is 50 of the set wire feed speed The function is activated on delivery TIP
60. omplete set of welding parameters which can then be saved in the weld data memory The welding process is always controlled by the contents of the working memory This also makes it possible to download a set of welding parameters from the weld data memory to the working memory Note that the working memory always contains the last set of welding parameters that were used in other words the working memory is never empty or initialised bu14d01e 1 3 Choice of language The controller is programmed in up to four different languages one of which is always English How to Choose the Language and Unit of length Metric Inch We start by pressing the MENU key to call up the main menu ESAB LUD 450 Using the arrow keys move the PROCESS MIG MAG cursor to the METHOD DIP SPRAY line AUXILIARY A WIRE TYPE Fe FUNCTIONS and press SHIELDING GAS Ar 8 C02 ENTER WIRE DIMENSION 1 2 mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER AUXILIARY FUNCTIONS Position the cursor on the line MEMORY CARDS OPERATIONS CONFIGURATION CONFIGURATION and press ENTER QUALITY FUNCTIONS PRODUCTION STATISTICS ERROR LOG USER DEFINED SYNERGIC DATA SERIAL COMMUNICATION SOFTWARE UPGRADE jom jae bu14d01e AUXILIARY FUNCTIONS CONFIGURATION Press ENTER to display the list of LANGUAGE SVENSKA options LOCK FUNCTION OFF REMOTE CONTROLS MIG MAG DEFAULTS MMA DEFAU
61. one by pressing the MENU key We will make the following three settings e PROCESS MMA e ELECTRODE TYPE RUTILE e ELECTRODE DIAMETER 2 5 mm Process ESAB LUD 450 Use the arrow keys to select PROCESS PROCESS Press ELECTRODE TYPE ENTER to display ELECTRODE DIAMETER the list of options AUXILIARY FUNCTIONS ser measure memory mope enren Position the cursor over the MMA option in the list and MIG MAG press ENTER We have now set the PROCESS MMA IMMA TIG Electrode type CARBON ArcAir Use the arrow keys to select PROCESS MMA ELECTRODE TYPE ELECTRODE TYPE BASIC Press ENTER to ELECTRODE DIAMETER 6mm display the list of AUXILIARY FUNCTIONS options ser measune memory mone fenter Position the cursor over the RUTILE option in the list BASIC and press ENTER We have now set the ELECTRODE TYPE RUTILE CELLULOSA 27 bu14d01e Electrode diameter Use the arrow keys to select ELECTRODE DIAMETER Press ENTER to display the list of options ESAB LUD 450 PROCESS ELECTRODE TYPE MMA RUTILE ELECTRODE DIAMETER 6mm AUXILIARY FUNCTIONS ser measure memory mope enren Position the cursor over the value 2 5 mm in the list and press ENTER We have now set the ELECTRODE DIAMETER 2 5 mm ESAB LUD 450 PROCESS ELECTRODE TYPE ELECTRODE DIAMETER MMA RUTILE 2 5 mm AUXILIARY FUNCTIONS
62. rt GASPREFLOW START DATA SYNERGIC MODE CREEPSTART HOT START CRATR HOT 4 FILL START STROKE QUIT ENTER To begin with you choose whether you want to use the hot start function or not If you decide to use the hot start function you should then enter the hot start time and any increase in the wire feed speed Position the cursor on the line HOT START Press ENTER to display the list of options Set it to YES press ENTER Position the cursor on the line HOT START TIME Set it to 1 0 s using one of the plus minus keys bu14d01e GASPREFLOW CREEPSTART START DATA SYNERGIC MODE 0 8s YES HOT START YES HOT START TIME WIRE SP GASPREFLOW CREEPSTART HOTSTART 1 58 2 0 m min CRATR HOT e 4 FILL START STROKE QUIT ENTER START DATA SYNERGIC MODE 0 8 s YES YES HOT START TIME 1 0 s WIRE SP 21 2 0 m min CRATR HOT e 4 FILL START STROKE QUIT START DATA SYNERGIC MODE Position the cursor on the line GASPREFLOW WIRE SP CREEPSTART Set it to 2 5 m min HOTSTART HOT START TIME WIRE SP CRATR HOT e 4 FILL START STROKE QUIT All the start settings have now been made Return to the settings menu by pressing QUIT 2 8 4 Stop data settings The stop data menu is used to make the settings that affect the stop sequence during MIG MAG welding We will enter the following stop data e CRATER F
63. sic settings Use the main menu to set the electrode diameter To start call up the main menu by pressing the MENU key We will make the following two settings e PROCESS ARC AIR GOUGING Carbon ArcAir e ELECTRODE DIAMETER 8 mm Process ESAB LUD 450 Use the arrow keys to select the PROCESS PROCESS line ELECTRODE TYPE Press ENTER to ELECTRODE DIAMETER display the list of AUXILIARY FUNCTIONS options FAST SET MEMORY MODE ENTER Position the cursor on the line CARBON ArcAlir in MIG MAG the list and press ENTER We have now set the MMA PROCESS ARC AIR GOUGING 16 Use the arrow keys to select the line PROCESS CARBON ArcAir ELECTRODE ELECTRODE DIAMETER 6mm DIAMETER AUXILIARY FUNCTIONS Press ENTER to display the list of Electrode diameter options ser measure memory mone enter Position the cursor on the line 8 mm and press 4 mm ENTER The setting ELECTRODE DIAMETER Sii 8mm is now complete The set up procedure for arc air gouging is now complete 38 bu14d01e 5 4 2 Welding data In the settings menu you can see what value has been selected for the voltage parameter If necessary you can also adjust the voltage setting Go to the settings menu by pressing PROCESS CARBON ArcAir the SET key ELECTRODE DIAMETER 8mm AUXILIARY FUNCTIONS ser measure memory Move enter WELD DATA SETTING electrode diameter VOLTAGE On the ba
64. sis of our setting the power SYNERGIC MODE source has set the voltage to 43 V 39 bu14d01e 6 MEASURED VALUE DISPLAY 6 1 Description of measured value display The measured value display lets you see the measured values of various welding parameters during welding Which parameters are displayed depends on which welding process you have selected The example below shows a measured value display for MIG MAG TIP In pulse welding you can choose whether the voltage is displayed as the overall average or the pulse average This setting can be made under MIG MAG basic settings See section 9 2 4 3 If you want to see the measured value display first make sure the main menu is displayed Press the MEASURE key ESAB LUD 450 PROCESS MIG MAG METHOD DIP SPRAY WIRE TYPE Fe SHIELDING GAS Ar 8 C02 WIRE DIMENSION 1 2 mm AUXILIARY FUNCTIONS FAST SET MEMORY MODE ENTER The measured value display could look like this The arrow at the bottom right of the display indicates that there is more information than can be displayed DIP SPRAY Fe Ar 8 C02 1 2 mm Scroll down using ss l 22 5 Volt key J 6 0 m min 40 bu14d01e A fourth value is visible in the display DIP SPRAY Fe Ar 8 CO2 1 2 mm 134 Amp 6 0 m min 3 01 kW 6 2 Changing set values You can change the value of certain parameters in the measured value display Which parameters can be changed depends on which weldi
65. ters The weld data memory is reset when this error occurs This test is only carried out during start up after the power is switched on This error does not override any functions CBOX Incompatible settings stored in RAM An illegal combination of val ues for method material gas and wire have been entered The weld data memory is reset when this error occurs This error does not over ride any functions CBOX Overflow in transmit buffer The transmit buffer memory is full An interruption in the bus circuit can cause this error The power must be switched on and off again to reset 3 CBOX Overflow in receive buffer The receive buffer memory is full This error occurs when the microprocessor in the controller is overloaded as a result of receiving more messages than it can handle The power must be turned off and on again to reset it CBOX Incompatible weld data format When welding data is input into the controller not individual data but block transfer of weld data it in cludes a version number for the weld data format If this version num CBOX Failed integrity control in RAM One byte in the battery powered RAM memory is used for random checking If the battery voltage is lost this value will not match when the test is carried out at the next start up and the weld data memory will be reset The reset process means that all weld data settings return to their de fault settings which are MIG MAG DIP SPRAY Fe CO2 1 2 m
66. u wanted to choose another option then you would move the cursor to the chosen line by moving up or down using the cursor keys Then you press the ENTER key If you wanted to exit the list without making a selection you would simply press the QUIT key For some settings there are so many options that they cannot all be displayed at the same time An arrow at the top or bottom of the list indicates that more options will become visible if you scroll up or down using the cursor keys 1 6 3 ON OFF or YES NO settings With certain functions you can switch the setting to ON or OFF or to YES or NO The synergic function in MIG MAG and MMA welding is an example of such a function ON OFF or YES NO settings can be selected in either of two ways You can select ON or OFF or YES or NO from a list of options as described above Or you can use the plus minus keys to select ON OFF or YES NO e plus ON or YES e minus OFF or NO 1 7 ENTER and QUIT Both of the soft keys at the bottom right are reserved for ENTER and QUIT e By pressing ENTER you confirm the selected option in a menu or list e By pressing QUIT you return to the previous menu or display bu14d01e 2 MIG MAG welding 2 1 The expression wire In MIG MAG welding you use an electrode that is wound on a reel or drum In this manual this type of electrode is always referred to as wire 2 2 Synergic welding Each combination of wire type wire diameter and gas
67. y functions MAIN MENU AUXILIARY FUNCTIONS CONFIGURATION MIG MAG DEFAULTS SOFT KEYS We have already mentioned the five soft keys on the controller During MIG MAG welding the user has the opportunity to select the functions of these keys from several options Of the five soft keys the three on the left can be assigned a chosen function You can choose from the following options Gas purge Wire inching Trigger mode 2 4 Crater fill ON OFF Creep start ON OFF Hot start ON OFF Trigg weld data switch ON OFF A soft key is assigned to one of these functions as follows The following appears in the character display The display has two columns one for function and another for key number The figures 1 2 and 3 each represent a key i e the key on the far left is number 1 and so on In the following example we will assign key number 1 the function CRATER FILL ON OFF ASSOCIATE FUNCTIONS TO SOFT KEYS Position the cursor Function on the line NONE CRATER FILL GAS PURGE ON OFF Press WIRE INCHING key number 1 i e TRIGGER MODE 2 4 the key on the far CRATERFILL ON OFF left CREEPSTART ON OFF HOT START ON OFF TRIGG WELD DATA SWITCH ON OFF 56 bu14d01e The display shows that key number 1 has now been assigned the function CRATER FILL ON OFF The number 1 has moved down to the line CRATER FILL ON OFF and at the bottom of the display you can see the key caption CRATERFILL for the left hand k

PUA 1 ver 3

Contents

Download Pdf Manuals

Related Search

Related Contents