Home

PEH A2- A6 Process Controller - ESAB Welding & Cutting Products

1. Storing trimming data 51 Strip Wire diameter 63 Submerged arc welding PEH1 00A PEH1 1 PEH1 2 28 64 PEH2 0 42 64 Tacho fault PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Technical data 53 Test menu PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Thermostat Overheating PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Travel motor M2 5 14 16 Travel speed 57 Trim data PEH1 00A PEH1 1 PEH1 2 27 51 PEH2 0 41 51 Unit PEH1 00A PEH1 1 PEH1 2 30 31 PEH2 0 46 47 Unsuccessful start PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Valve 64 Water flow guard 5 17
2. CHECKING NO 2 OUTPUT STAGE 14 GAS VALVE OUTPUT CONTROL 14 MEASURING THE MOTOR CURRENT 14 INSTALLATION 15 GENERAL 15 INTERNAL CONNECTIONS 15 EXTERNAL CONNECTIONS 16 DC DUO 18 NME 18 PRESET SY
3. Weld process PEH1 00A PEH1 1 PEH1 2 28 PEH2 0 42 Welding current 57 Welding parameters 57 Welding power source 53 WELDING SETUP 20 60 Wire diameter 63 Wire feed motor M1 5 14 16 Wire material 63 Wire type 63 69 alfaE ESAB Welding Equipment AB SE 695 81 LAX SWEDEN Phone 46 584 81 000 Fax 46 584 123 08 www esab com 001004 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 Te
4. A6 submerged arc automatic welding machine A6TGE A6 MIG MAG automatic welding machine FREE Any configuration of connections from two motors to the drive board For available drive motors and gears see table FREE below S To select FREE select it and press S Press to move from Column A to Column B S Press to move from Column B to Column A Function settings available for FREE FREE A B Wire feed axis see page 23 A6F A6G A2F A2G MEK4 FREE1 A6T A2T valid for PEH1 00A A2TE valid for PEH1 1 PEH1 2 A2TF valid for PEH1 1 PEH1 2 FREE2 Travel axis see page 24 A6T A2T valid for PEH1 00A A2TE valid for PEH1 1 PEH1 2 A2TF valid for PEH1 1 PEH1 2 FREE2 A6F A6G A2F A2G MEK4 FREE1 Binary inputs see page 26 Not used Guards Limit sw Start stop valid for PEH1 2 DRIVE TRIM MENU see page 27 The product codes in brackets are not normally used as wire feed motors The product codes in brackets are not normally used as travel motors 23 cpeh0de1 Wire feed axis Select wire feed motor here Alternatives A6F VEC 4000 r min art no 145 063 906 with 1 156 gear ratio A6G VEC 8000 r min art no 145 063 909 with 1 74 gear ratio A2F
5. WELDING POWER SOURCES 53 TECHNICAL DATA 53 OPERATIONAL DESCRIPTION 54 GENERAL 54 CONTROL PANEL 54 MANUAL OPERATION 55 TRAVEL AND WIRE SPEED 55 CONTROLLING VALVES 55 MENUS 56 MENU OVERVIE
6. Parameter set PEH1 00A PEH1 1 PEH1 2 30 31 PEH2 0 46 47 Password PEH1 00A PEH1 1 PEH1 2 29 PEH2 0 43 Pilot lamp 17 Power supply voltages 13 Preset indicators 57 PRESET SYSTEM MENU PEH1 00A PEH1 1 PEH1 2 20 PEH2 0 34 Product code PEH1 00A PEH1 1 PEH1 2 22 PEH2 0 36 Regulation 64 Safety 4 Scratch start 62 SET no 60 Solid wire wire diameter 63 Start 62 START SEQUENCE MENU PEH2 0 44 STOP SEQUENCE MENU PEH2 0 45 STOP WELDING 62
7. Alarm PEH1 00A PEH1 1 PEH1 2 32 PEH2 0 48 Arc extinguished PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Arc voltage 16 57 Binary inputs PEH1 00A PEH1 1 PEH1 2 26 PEH2 0 40 Burnback time 62 Bus termination 5 19 Cable area PEH1 00A PEH1 1 PEH1 2 29 PEH2 0 43 Cable length PEH1 00A PEH1 1 PEH1 2 29 PEH2 0 43 Cable complete 15 Calibrate speed PEH1 0 24 Change of program 51 Communications software 18 Constant wire feed speed 57 Contrast Adjusting the display 18 Control panel 54
8. SPARE PARTS LIST 65 ALPHABETICAL LIST OF CONTENTS 68 Rights reserved to alter specifications without notice 3 cpeh0de1 READ THIS FIRST GENERAL This service manual is intended for use by technicians with electrical electronic training for help in connection with fault tracing and or repair The component description refers to the component names in the connection diagram This manual contains details of all design changes that have been made up to and including February 2000 This manual is valid for program version PEH1 00A PEH1 1 PEH 1 2 and PEH2 0 The displays vary depending on what program version is being used Therefore there are two chapters about SYSTEM CONFIGURATION SOFTWARE VERSIONS From production start 97 07 04 PEH program Flash IC 15 486471880 PEH 1 00 A DCDUO program Prom IC304 68S07001A02 CHKSUM 0210 Dat 19970704 From 97 12 12 PEH program Flash IC 15 486478880 PEH 1 1 DCDUO program Prom IC304 68S07001A02 CHKSUM 0211 Dat 19971212 Miscellaneous improvements acc to error list error 1 through 43 VEC 8000RPM motor A6G can be used error 4 and 11 MEK 4 motor with tacho can be used error 7 Product code f
9. PEH2 0 49 Incorrect welding voltage PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 Language PEH1 00A PEH1 1 PEH1 2 30 31 PEH2 0 46 47 LED L02 RED 18 MAIN MENU 57 MIG MAG welding PEH1 00A PEH1 1 PEH1 2 28 64 PEH2 0 42 64 Motor cable 16 Motor control software 18 Motor current 14 Motor field winding 16 NME 5 10 18 19 Number of wires 63 Offset error PEH1 00A PEH1 1 PEH1 2 27 PEH2 0 41 Overheating PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 P D mm PEH1 00A PEH1 1 PEH1 2 23 PEH2 0 37
10. SYSTEM FUNCTION SETTINGS AVAILABLE 35 DEFINITIONS 36 PRESET SYSTEM MENU OVERVIEW 50 CHANGE OF PROGRAM 51 GENERAL 51 STORING TRIMMING DATA 51 CHANGING THE PROGRAM IN THE PEH ELECTRONICS 51 CHANGING PROGRAMS IN THE PEH ELECTRONICS AND THE WELDING POWER SOURCE 52 CHANGING THE COMPLETE PEH ELECTRONICS KEEPING THE SETTINGS OF THE SYSTEM 52 INTRODUCTION 53 A2 A6 PROCESS CONTROLLER 53
11. PEH2 0 37 38 Error categories PEH1 00A PEH1 1 PEH1 2 32 PEH2 0 48 Error codes PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 ERROR LIST PEH1 00A PEH1 1 PEH1 2 32 PEH2 0 48 Error messages PEH1 00A PEH1 1 PEH1 2 32 57 PEH2 0 48 57 External emergency stop 17 Flash memory IC15 18 Font PEH1 00A PEH1 1 PEH1 2 30 31 PEH2 0 46 47 Gas flow guard 5 17 Gas postflow PEH1 00A PEH1 1 PEH1 2 28 PEH2 0 42 Gas preflow PEH1 00A PEH1 1 PEH1 2 28 PEH2 0 42 Gas valve 5 17 Heat input PEH1 00A PEH1 1 PEH1 2 30 31 57 PEH2 0 46 47 57 Incorrect current PEH1 00A PEH1 1 PEH1 2 33
12. FHP 36 r min art no 334 678 001 KSV 5035 375 A2G FHP 68 r min art no 334 678 002 KSV 5035 374 MEK4 FHP 258 r min art no 455 077 001 KSV 5035 603 FREE1 Any required motor alternative see the FREE1 table on page 23 N B When selecting this alternative settings must be made for both motors and gears Available function settings for FREE1 FREE1 Press to reach the sub menu A B Motor FHP36 FHP68 FHP258 VEC4000 VEC8000 DUNKER1 DUNKER2 Gear 1 A2TW MEK24 74A6 FREE1 156A6 1 1 A6TA A2TA A6TB A2TB A2TC valid for PEH1 1 PEH1 2 FREE2 FREE3 FREE4 Gear 2 1 1 74A6 156A6 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC valid for PEH1 1 PEH1 2 FREE1 FREE2 FREE3 FREE4 P D mm 1 10000 Encoder ppr 0 10000 Tacho poles valid for PEH1 00A 0 6 LOW MANUAL SPEED 1 1000 HIGH MANUAL SPEED 1 5000 Calibrate speed valid for PEH1 00A X The motor codes in brackets are not normally used as wire feed motors The gear ratio codes in brackets are not normally used as travel motors 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 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 Tacho poles valid for PEH1 00A indicates the number of poles revolution
13. Cored wire wire diameter 63 Crater fill 62 Current display PEH1 00A PEH1 1 PEH1 2 30 31 PEH2 0 46 47 Current limit PEH1 00A PEH1 1 PEH1 2 33 PEH2 0 49 DC DUO 5 10 11 18 19 Diagnostics NME 18 DIP switch SW1 10 18 Direct start 62 Direction travel direction 62 DISPLAY MENU PEH1 00A PEH1 1 PEH1 2 30 PEH2 0 46 DRIVE TRIM MENU PEH1 00A PEH1 1 PEH1 2 27 PEH2 0 41 Electro slag welding ESW PEH1 2 28 PEH2 0 42 Emergency stop PEH1 00A PEH1 1 PEH1 2 5 32 54 PEH2 0 5 48 54 Encoder ppr PEH1 00A PEH1 1 PEH1 2 23 24
14. S Switch from the MAIN MENU to WELDING SETUP by pressing The display will now show a number of variables in column A see page 61 and the relevant options in columns B and C You can change row in column A S To change a setting move from column A to columns B and C by pressing S Scroll forward to the chosen option by pressing or or type in your own values for rows 3 and 4 Number of wires S Return to column A to change row by pressing S Jump to the next row by pressing After the last row you will return to row 1 S Return to the previous row by pressing This combination will also take you straight to row 6 from row 1 Explanations of terms When is indicated in combination with another key you should press first and hold it down while pressing the second key 61 dgb7d1ea AVAILABLE SETTINGS WELDING SETUP A B C 1 Direction Y TRIANGLE J SQUARE 2 Start Scratch Direct 3 STOP WELDING Craterfill ms 10 3000 3 STOP WELDING Burnback time ms 10 3000 Wire type Solid wire Flux cored Strip 4 WIRE DATA Wire diameter if Solid wire is chosen if Flux cored is chosen if Strip is chosen 0 8 1 0 1 2 1 6 2 0 2 4 3 0 3 2 4 0 5 0 6 0 0 8 1 0 1 2 1 6 2 0 2 4 3 0 3 2 4 0 30 x 0 5 60 x 0 5 100 x 0 5 Wire material Fe Al SS Number of wires 1 2 5 Regulation CA CW 6 PRESET SYSTEM MENU Functions 1 5 are expla
15. 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 11 cpeh0de1 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 avail able 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 valid for program version PEH1 2 and PEH2 0 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 12 cpeh0de1 MOTOR REGULATOR STRUCTURE M CA Current M Motor DA
16. 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 5 cpeh0de1 COMPONENT DESCRIPTION AP1 DC DUO circuit board see the function description on page 11 AP2 NME circuit board see the function description on page 10 DY1 Display HL1 Pilot lamp accessory KB1 Control panel see page 54 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 monitor limit switch or external start function valid for program version PEH1 2 and PEH2 0 K23 Connector for the gas flow monitor limit switch or external stop function valid for program version PEH1 2 and PEH2 0 M1 Wire feed motor M2 Travel motor ST1 Emergency stop see page 32 PEH1 00A PEH1 1 PEH1 2 page
17. Differential current T Tachometer AC tacho VA Voltage PGEN Position generator PWM Pulse width modulation PREF Position reference DC BUS DC supply voltage VREG Voltage regulator VREF Voltage reference CREG Current regulator SREG Speed regulator SLPF Low pass filter SEST Speed estimation PACK Position acknowledge PEST Position estimation PREG Position regulator PM Process manager SD Self diagnostics TEST Test routine IPC Inter processor communication 13 cpeh0de1 TEST POINTS TESTING THE EXTERNAL POWER SUPPLY FROM THE WELDING POWER SOURCE S Measure the voltage at contact K13 The voltage is OK if 37 8 VAC UAC 46 2 VAC cpeh0e05a TESTING THE INTERNAL POWER SUPPLY VOLTAGES S 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 60V 53 VDC U 65 VDC Positive connected to K1 1 5V 4 8 V U 5 2 V Positive connected to cathode D206 12V 10 5V U 13 5V Positive connected to anode D207 12V 13 5V U 10 5V Positive connected to cathode Z402 15 A 13V U 16V Positive connected to cathode Z401 15 B 13V U 16V Positive connected to cathode Z403 15 C 13V U 16V Positive connected to catho
18. The function Calibrate speed valid for PEH1 00A is unstable and should not be used FREE1 FREE2 FREE3 and FREE4 Column B are explained on page 25 24 cpeh0de1 Travel axis Select travel motor here Alternatives A6T Dunker 2 art no 334 658 880 for A6 tractor with 1 187 5 gear ratio A2T valid for PEH1 00A Dunker 1 art no 332 967 880 for A2 tractor with 1 750 gear ratio A2TE valid for PEH1 1 PEH1 2 Dunker 1 art no 332 967 880 for A2 tractor with 1 750 gear ratio A2TF valid for PEH1 1 PEH1 2 MEK4 51 for A2 Weldtrac with 1 51 gear ratio FREE2 Any required motor alternative see the FREE2 table on page 24 N B When selecting this alternative settings must be made for both motors and gears Available function settings for FREE2 FREE2 Press to reach the sub menu A B Motor DUNKER1 DUNKER2 FHP258 VEC8000 VEC4000 FHP36 FHP68 Gear 1 A6T valid for PEH1 1 PEH1 2 A2TE valid for PEH1 1 PEH1 2 A2TF valid for PEH1 1 PEH1 2 156A6 74A6 FREE3 1 1 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC valid for PEH1 1 PEH1 2 FREE1 FREE2 FREE4 Gear 2 1 1 FREE4 74A6 156A6 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC valid for PEH1 1 PEH1 2 FREE1 FREE2 FREE3 P D mm 1 10000 Encoder ppr 0 10000 Tacho poles v
19. 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 27 PEH1 00A PEH1 1 PEH1 2 or page 41 PEH2 0 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 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 elec tronics 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 CHANGING THE PROGRAM IN THE PEH ELECTRONICS S Store trimming data in the welding power source see Trimming data to the welding power source above S Replace the flash memory IC15 on the NME card AP2 S Recall trimming data from t
20. 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 amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 44 58 Asia Pacific AUSTRALIA ESAB Australia Pty Ltd Ermington 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
21. Tacho M2 2 Current too high Stop Check travel motor gearbox Welding power source T1 T1 01 Communication error Stop Check cables and connections T1 51 Incorrect welding voltage Stop Check joint preparation T1 52 Incorrect current Stop Check joint preparation T1 53 Unsuccessful start Stop Check stick out and welding parameters T1 54 Current limit Stop Welding short circuited Cure short circuit T1 55 Thermostat overheating Stop Wait until temperature has fallen T1 57 Arc extinguished Stop Check wire feed Inputs outputs No cooling water inlet K22 open Flashing Display Stop Check if the water is flowing or if the limit switch is open No gas flow inlet K23 open Flashing Stop Check gas pressure These inputs are activated by entries in the Product code menu FREE Binary inputs see page 36 12 Test When this menu is active the main menu displays information that is normally hidden Activate the menu by entering the numerical value 1 in Column B see the table on page 35 Loss of voltage deactivates the Test menu Speed commands in cm min are shown when the Test menu is active Wire feed speed commands are shown in the centre of the top line of the display Welding travel speed commands in cm min are shown at the right hand side of the top line of the display 50 cpeh0de1 PRESET SYSTEM MENU OVERVIEW 51 cpeh0de1 CHANGE OF PROGRAM
22. see page 22 A2TFE A2TGE A6TFE A6TGE FREE A2TFF valid for PEH1 1 PEH1 2 A2TGF valid for PEH1 1 PEH1 2 2 Weld process see page 28 SAW MIG MAG ESW valid for PEH1 2 3 Gas preflow s see page 28 1 99 4 Gas postflow s see page 28 1 99 5 Password see page 29 XXXXX 6 Cable length m see page 29 X 7 Cable area mm2 see page 29 X 8 DISPLAY MENU see page 30 9 ERROR LIST see page 32 10 Test see page 33 1 ON 0 OFF Functions 1 10 are explained on pages 22 33 22 cpeh0de1 DEFINITIONS The starting point for altering functions 1 10 is selection of the PRESET SYSTEM MENU see page 21 1 Product code 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 S Select the Product code row and press S Scroll forward to the required product code by pressing Alternatives available A2TFE A2 submerged arc automatic welding machine A2TGE A2 MIG MAG automatic welding machine A2TFF valid for PEH1 1 and PEH1 2 A2 submerged arc automatic welding machine A2TGF valid for PEH1 1 and PEH1 2 A2 MIG MAG automatic welding machine A6TFE
23. 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
24. MENU display by entering For example if the password is 12345 the display will show 6 Cable length m The arc voltage is noticeably affected by the impedance of the cable The impedance is affected by such factors as the length and cross sectional area of the cable 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 in Column B see page 35 A maximum of five figures may be used 7 Cable area mm2 Enter the cross sectional area of the cable in mm2 in Column B see page 35 A maximum of five figures may be used Phase 1 voltage 50 Phase 1 current 40 Phase 1 Wire feed 50 Phase 2 time 0 1s 30 Phase 2 speed 80 Phase 2 voltage 70 Phase 2 current 80 Phase 2 Wire feed 90 44 cpeh0de1 8 START SEQUENCE MENU 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 Phase 1 and Phase 2 The time and percentage values of of the two phases can be adjusted Phase 2 has no effect if t 0 in Phase 1 t the durability of the seq
25. 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 42 cpeh0de1 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 controlled wire feed VXNscale 19200 Negative armature voltage measurement speed controlled wire feed CXPscale 3200 Positive armature current measurement CXNscale 3200 Negative armature current measurement VYPscale 19200 Positive armature voltage measurement speed controlled travel motor VYNscale 19200 Negative armature voltage measurement speed controlled travel motor CYPscale 3200 Positive
26. carried out according to the specified instructions by personnel who are thoroughly familiar with the operation of the welding machine Incorrect or unintentional operation of the equipment may lead to a hazardous situation which can result in injury to the operator and damage to the equipment 1 Anyone who uses the automatic welding machine must be familiar with S its operation S the location of emergency stops S its function S relevant safety precautions 2 The operator must ensure that S no unauthorized person is stationed within the working area of the machine when it is started up S that no one is in a hazardous position when the carriage or slide mechanisms are operated 3 The work place must S be clear of mechanical components tools or other obstructions that could prevent the oper ator from moving freely within the working area S be organized so that there is free access to the emergency stop 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 etc which could become trapped 5 General precautions Live electrical components are normally shielded from accidental contact S Make sure the return cable is connected securely S Work on high voltage components may only be carried out by a qualified electrician S Appropriate fire extinguishing equipment must be c
27. display In the Display menu you can choose how many sets of parameters you want to work with If more than one set of parameters is used then the SET number appears in the top left corner 1 Welding current or wire feed speed 2 SET no 3 Arc voltage 4 Travel speed If you choose to work with just one set of parameters then start at step 3 S Press to mark the parameter set field S Type in the desired SET number and press S Select the field for welding current or wire feed speed by pressing S Type in the desired welding current or wire feed speed Max 4 numbers press S Select the field for arc voltage by pressing S Type in the desired arc voltage max 3 numbers press S Select the field for travel speed by pressing S Type in the desired travel speed max 3 numbers and press Now the whole set has been marked and is ready to use A further 9 additional sets can be stored Total 10 SETs 59 dgb7d1ea ADJUSTING PARAMETER VALUES DURING WELDING Once welding has started the welding parameters can be fine tuned using the arrowed numerical keys over ride function Increase Decrease Welding current or wire feed speed Arc voltage Travel speed Save the values as follows S Stop welding with S Save the changed values with S To revert to the original values press CHOOSING A NEW SET OF PARAMETERS DURING WELDING Only p
28. for flux or gas by pressing S Close an open valve by pressing the same key 56 dgb7d1ea MENUS MENU OVERVIEW The A2 A6 Process Controller PEH software is divided into several menus The program structure is described in the overview below MAIN MENU see on page 57 S SET S Heat input per cm S Welding current S Wire feed speed S Arc voltage S Travel speed S Preset indicators WELDING SETUP see on page 60 S Welding direction S Arc start method S Type of weld finish S Wire data Wire type Wire material Wire size S Regulation method PRESET SYSTEM MENU see on page 20 or on page 34 S Product code S Weld process S Gas preflow S Gas postflow S Password S Cable length S Cable area S Display menu S Error list S Test DISPLAY MENU see on page 30 or on page 46 S Language S Unit S Current display S Heat input S Parameter set S Font S Parameter set MAIN MENU WELDING SETUP PRESET SYSTEM MENU DISPLAY MENU Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU Product code A2TFE Weld process SAW Gas preflow s Gas preflow s Password 0 Cable length m Cable area mm2 DISPLAY MENU Language English Unit Metric Current display Real value Heat input Off Font Large Parameter set 1 57 dgb7d1ea MAIN MENU In the main menu you choose the welding current arc voltage and travel speed you want to use for welding During
29. stop See page 54 for an explanation of the functions of the other keys 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 ESAB s 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 S In the MAIN MENU press to get to the WELDING SETUP menu S Scroll forward to PRESET SYSTEM MENU by pressing When this menu is selected press If the system is password protected this must be entered while PRESET SYSTEM MENU is selected followed by pressing The display now shows a number of parameters that can be altered in Column A with their current settings in Column B see the table for PRESET SYSTEM MENU on page 35 Other alternatives that can be selected are displayed one after the other 35 cpeh0de1 USING THE PRESET SYSTEM MENU S To change a setting move from Column A to Column B with S Find the required alternative with or with or for rows 3 7 and row 12 ente
30. used 30 cpeh0de1 8 DISPLAY MENU This menu controls how the information on the display is presented language units and other information can be varied as required S Select the DISPLAY MENU row and press In Column A the display now shows functions that can be altered with the current choices in Column B see below Example How to select English from the DISPLAY MENU S Select Language from Column A and press S Find English by pressing or by pressing S Return to Column A by pressing S Return to the MAIN MENU with English has now been selected as the display language Available settings for DISPLAY MENU DISPLAY MENU A B Language Svenska Dansk Norsk Suomi English Deutsch Francaise Nederlands Espanol Italiano Portugues E_ _hnika Unit Metric Inches Current display Set value Real value Heat input On Off Font Small Large Parameter set X The available settings for DISPLAY MENU are explained on page 31 31 cpeh0de1 Language Svenska Swedish Dansk Danish Norsk Norwegian Soumi Finnish English English Deutsch German Francaise French Nederlands Dutch Espanol Spanish Italiano Italian Portugues Portuguese E_ _hnika Greek Units Metric Inches Speeds lengths or wire sizes in the MAIN MENU can be displayed in either metric units or inches Current Set value Real value The welding parameters c
31. welding you can adjust the welding parameters or choose a complete new set of parameters Switch on the power source The main menu will appear as follows Example of display if constant current CA has been chosen A 350 Chosen welding current in amperes Example of display if welding with constant wire feed speed CW is chosen cm min 110 Indicates chosen wire feed speed Example of display during welding at constant wire feed speed CW 350 A Resulting welding current after the welding start For the selection of CA or CW see the menu WELDING SETUP on page 60 SET 1 Indicates that parameter set 1 of 10 available has been selected can be hidden 30 kJ cm Indicates the heat input in kJ cm that will result from the chosen values of welding cur rent arc voltage and travel speed can be hidden V 33 0 Chosen arc voltage in volts cm min 23 Chosen travel speed in centimetres per minute Indicates the type of start J Indicates the travel direction Indicates if the valve output is open or closed Example of display in the event of a fault Error code appears in bottom left section of display Error message is cancelled by pressing Max 20 messages saved in chronological order S Start welding by pressing The LED in the key lights up S Stop welding by pressing 58 dgb7d1ea ENTERING WELDING PARAMETERS When the power source is switched on the main menu appears on the
32. 0740 801 006 000201 Valid for machine no 724 XXX XXXX Valid for program version PEH 1 00A PEH1 1 PEH1 2 PEH 2 0 PEH A2 A6 Process Controller Service manual SVENSKA 2 LIST OF CONTENTS Page READ THIS FIRST 3 GENERAL 3 SOFTWARE VERSIONS 3 SAFETY 4 WARNING 4 COMPONENT DESCRIPTION 5 CONNECTION DIAGRAM 6 COMPONENT POSITIONS ON CIRCUIT BOARD AP2 8 COMPONENT
33. 48 PEH2 0 or page 54 XS1 Connector 12 pin connector for the control cable from the welding power source X2 Terminal block emergency stop arc voltage 6 cpeh0de1 CONNECTION DIAGRAM 7 cpeh0de1 cpeh0e02 8 cpeh0de1 COMPONENT POSITIONS ON CIRCUIT BOARD AP2 cpeh0e03 9 cpeh0de1 COMPONENT POSITIONS ON CIRCUIT BOARD AP1 cpeh0e09 10 cpeh0de1 FUNCTION DESCRIPTION CIRCUIT BOARD Seriell buss GENERAL The drive unit consists of two circuit boards named NME AP2 and DC DUO AP1 See Page 8 and Page 9 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 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 board s system address As immunity to interference is particularly important communication is galvanically isolated through transformer TR1
34. 5 Advance 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 55 dgb7d1ea MANUAL OPERATION TRAVEL AND WIRE SPEED Travel and wire feed commands can be given when not welding as follows Switch on welding power source S The direction of travel is as shown by the square symbol on the power source Normal speed S The direction of travel is as shown by the triangular symbol on the power source Normal speed To stop travel described above press the same key again S Retract wire Normal speed Wire continues to retract until you release the key S Advance wire Normal speed Wire continues to advance until you release the key S After switching on you can select maximum speed by pressing the fast key The LED in the key lights up S To return to normal speed press the fast key again To stop immediately press or even at max speed Normal speed and max speed can be adjusted under the PRESET SYSTEM MENU CONTROLLING VALVES To operate a valve you must be in the MAIN MENU S Open the valve
35. POSITIONS ON CIRCUIT BOARD AP1 9 FUNCTION DESCRIPTION CIRCUIT BOARD 10 GENERAL 10 NME AP2 10 DC DUO AP1 11 MOTOR REGULATOR STRUCTURE 12 TEST POINTS 13 TESTING THE EXTERNAL POWER SUPPLY FROM THE WELDING POWER SOURCE 13 TESTING THE INTERNAL POWER SUPPLY VOLTAGES 13 CHECKING THAT THE PROGRAM IS RUNNING 14 CHECKING NO 1 OUTPUT STAGE 14
36. S Stainless Steel filler wire Number of wires Values between 1 2 can be entered For example if welding with two wires Twin Arc enter the value 2 64 dgb7d1ea 5 Regulation Two different operating modes can be used for welding either constant current CA or constant wire feed speed CW S CA constant current Normally used for submerged arc welding which involves work ing with large welds large currents and large weld pools The wire feed speed is con trolled by the power source to maintain a constant current S CW constant wire feed speed Normally used for MIG MAG welding for small weld pools thin sheet metal and thin filler wire It is easier to achieve a constant throat thick ness when welding with this method Welding is controlled by selecting a fixed wire feed speed and the current is adjusted to achieve this speed The resulting current is displayed above the selected wire feed speed see display shot on page 64 PRESET INDICATORS The numbers and symbols on the display show the chosen preset values see table below Shown in display MAIN MENU as WELDING SETUP options Start Direct Scratch Y J Direction TRIANGLE SQUARE Shown in plain English e g 3 0 Wire diameter Solid wire Flux cored Strip 0 8 1 0 1 2 1 6 2 0 2 5 3 0 3 2 4 0 5 0 6 0 0 8 1 0 1 2 1 6 2 0 2 4 3 0 3 2 4 0 30 x 0 5 60 x 0 5 100 x 0 5 OUTPUT ON OFF Valve Spare parts list 65 cp
37. STEM MENU FOR PEH1 00A PEH1 1 AND PEH1 2 20 CONTROL PANEL 20 GENERAL 20 USING THE PRESET SYSTEM MENU 21 SYSTEM FUNCTION SETTINGS AVAILABLE 21 DEFINITIONS 22 PRESET SYSTEM MENU FOR PEH2 0 34 CONTROL PANEL 34 GENERAL 34 USING THE PRESET SYSTEM MENU 35
38. W 56 MAIN MENU 57 ENTERING WELDING PARAMETERS 58 ADJUSTING PARAMETER VALUES DURING WELDING 59 CHOOSING A NEW SET OF PARAMETERS DURING WELDING 59 WELDING SETUP 60 GENERAL 60 AVAILABLE SETTINGS 61 DEFINITIONS 62 PRESET INDICATORS 64
39. al load Max 900 VA Motor connections adapted for ESAB s A2 or A6 motors Motor current 5 A continuous max 10 A Wire speed regulation Internal EMK control or with AC tacho 6 pulses per rev Welding speed 0 1 2 m min depending on travel unit Max manual travel speed 2 0 m min Filler wire wire feed speed 0 3 25 m min depending on wire feed unit Standards EN 50 199 EN 60974 1 Max ambient temperature 45_ C Min ambient temperature 15_ C Relative humidity Max 98 Weight 5 5 kg Dimensions L x B x H 355 x 210 x 164 mm Enclosure class IP 23 54 dgb7d1ea OPERATIONAL DESCRIPTION GENERAL Switch on welding power source The process controller can be used in manual or automatic mode In manual mode the wire feed speed and travel speed are controlled manually and you can preset all other essential welding parameters for the current weld In automatic mode you can choose a preset group of welding parameters and fine tune the actual welding parameters Other settings made previously in manual mode cannot be adjusted in automatic mode The process controller is ready for manual operation as soon as the mains power is switched on When welding begins the controller switches to automatic mode When welding stops or if there is a fault the controller switches back to manual mode CONTROL PANEL 1 Emergency stop 2 Retract wire 3 Travel 4 Travel opposite direction
40. alid for PEH1 00A 0 6 LOW MANUAL SPEED 1 1000 HIGH MANUAL SPEED 1 5000 Calibrate speed valid for PEH1 00A X The motor codes in brackets are not normally used as wire feed motors The gear ratio codes in brackets are not normally used as travel motors 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 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 Tacho poles valid for PEH1 00A indicates the number of poles revolution The function Calibrate speed valid for PEH1 00A is unstable and should not be used FREE1 FREE2 FREE3 and FREE4 Column B are explained on page 25 25 cpeh0de1 When selecting FREE1 FREE2 FREE3 or FREE4 column B the display below is shown 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 N2 49 N1 30 Motor Gear FHP 36 Motor shaft Outgoing shaft 26 cpeh0de1 Binary inputs The inputs K22 and K23 on the DCDUO board can be assigned different functions on this sub menu Adjusting and using the inputs are only possible if the product code FREE has been s
41. an 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 Font Small Large Selects small or large display figures for the welding parameters 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 32 cpeh0de1 9 ERROR LIST Error messages are displayed on the bottom row of the MAIN MENU Error messages that may occur are shown here When an error message is displayed it overwrites the information that it normally displayed on the bottom row welding preset values See page 33 for a list of error codes Error categories Emergency stop see page 20 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 Alarm Conditions that could result in unacceptable defects
42. armature current measurement CYNscale 3200 Negative armature current measurement 2 Weld process Three alternatives can be selected SAW GMAW and ESW S SAW for submerged arc welding S GMAW for gas metal arc welding S ESW for electro slag welding cladding 3 Gas preflow s only for MIG MAG 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 4 Gas postflow s only for MIG MAG 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 43 cpeh0de1 5 Password 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
43. ct 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 S Select the Product code row and press S Scroll forward to the required product code by pressing Alternatives available A2TFE A2 submerged arc automatic welding machine A2TGE A2 MIG MAG automatic welding machine A2TFF A2 submerged arc automatic welding machine A2TGF A2 MIG MAG automatic welding machine A6TFE A6 submerged arc automatic welding machine A6TGE A6 MIG MAG automatic welding machine FREE Any configuration of connections from two motors to the drive board For available drive motors and gears see table FREE below S To select FREE select it and press S Press to move from Column A to Column B S Press to move from Column B to Column A Function settings available for FREE FREE A B Wire feed axis see page 37 A6F A6G A2F A2G MEK4 FREE1 A6T A2TE A2TF FREE2 Travel axis see page 38 A6T A2TE A2TF FREE2 A6F A6G A2F A2G MEK4 FREE1 Binary inputs see page 40 Not used Guards Limit sw Start stop DRIVE TRIM MENU see page 41 The product codes in brackets are not normally used as wire feed motors The
44. d to weld with The control system must be given information about the wire shape in order to achieve optimum start stop characteristics S solid wire S flux cored S strip Wire diameter The chosen wire diameter has a big effect on the start cycle and crater filling When welding with a wire diameter that is not given in the options table choose the nearest diameter from the menu Remark For certain wire materials a better welding result can be achieved if a value deviating from the real wire dimension by 1 step is set normally 1 step from the real value When metric units are used the following alternatives are available S solid wire 0 8 1 0 1 2 1 6 2 0 2 4 3 0 3 2 4 0 5 0 6 0 mm S cored wire 0 8 1 0 1 2 1 6 2 0 2 4 3 0 3 2 4 0 mm S strip 30 x 0 5 60 x 0 5 100 x 0 5 mm When inch units are used the following alternatives are available S solid wire 0 030 0 040 0 047 1 16 5 64 3 32 7 64 1 8 3 32 7 64 1 8 5 32 3 16 1 4 S cored wire 0 030 0 040 0 047 1 16 5 64 3 32 7 64 1 8 3 32 7 64 1 8 5 32 S strip 30 x 0 5 60 x 0 5 100 x 0 5 Wire material When welding with different filler materials the start and stop method is affected by the choice of materials It is therefore important that the settings show whether you are welding with steel based or aluminium based filler wires S Fe Steel filler wire S Al Aluminium filler wire S S
45. de Z404 15 D 13V U 16V Positive connected to cathode Z1 12Vswitch 11 V U 13V 14 cpeh0de1 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 CHECKING NO 1 OUTPUT STAGE 1 Issue a RUN command 2 Check the voltage on IC407 11 It should normally be low at 0V 3 Check the waveform on IC407 5 It must be a square wave with 50 pulse width and an amplitude close to 60 V CHECKING NO 2 OUTPUT STAGE 1 Issue a RUN command 2 Check the voltage on IC407 11 It should normally be low at 0V 3 Check the waveform on IC409 5 It must be a square wave with 50 pulse width and an amplitude close to 60 V 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 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 cpeh0e05b 15 cpeh0de1 INSTALLATION GENERAL See pages 10 and 18 for information on the DC DUO and NME circuit boards The incoming power supply 42 V AC to the A2 A6 Pr
46. e shown in this menu S Select DRIVE TRIM MENU and press Actual trimming data are now displayed The preset values for an untrimmed electronics card are shown in the table on page 28 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 of how to adjust the offset error of the travel motor S Mark the line 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 28 cpeh0de1 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 Positi
47. ed roller diameter effective diameter of the gearwheel Encoder ppr is the number of pulses per revolution or tacho pulses per revolution FREE1 FREE2 FREE3 and FREE4 Column B are explained on page 39 38 cpeh0de1 Travel axis Select travel motor here Alternatives A6T Dunker 2 art no 334 658 880 for A2 tractor with 1 187 5 gear ratio A2TE Dunker 1 art no 332 967 880 for A2 tractor with 1 750 gear ratio A2TF MEK4 51 for A2 Weldtrac with 1 51 gear ratio FREE2 Any required alternative see the FREE2 table on page 38 N B When selecting this alternative settings must be made for both motors and gears Available function settings for FREE2 FREE2 Press to reach the sub menu A B Motor DUNKER1 DUNKER2 FHP258 VEC8000 VEC4000 MET3B FHP36 FHP68 Gear 1 A6T A2TE A2TF 156A6 74A6 FREE3 1 1 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC FREE1 FREE2 FREE4 Gear 2 1 1 FREE4 74A6 156A6 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC FREE1 FREE2 FREE3 P D mm 1 10000 Encoder ppr 0 6 LOW MANUAL SPEED 1 1000 HIGH MANUAL SPEED 1 5000 The motor codes in brackets are not normally used as wire feed motors The gear ratio codes in brackets are not normally used as travel motors Note that in the rows for P D mm Encoder ppr LOW MANUAL SPEED and HIGH MANUAL SPEED you enter your own val
48. eh0se1 A2 A6 Process controller PEH Edition 9809 Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover Kindly indicate type of unit serial number denominations and ordering numbers according to the spare parts list C component designation in the circuit diagram 66 cpeh0se1 Item no Qty Ordering no Denomination Notes C 0443 741 880 Control box 3 1 0443 638 880 Control panel KB1 4 1 0443 740 001 Emergency stop ST1 8 1 0457 278 001 Rail 9 1 0443 748 880 Cable complete XS1 10 0443 730 880 Circuit board AP1 AP2 14 1 0443 849 001 Insulation 20 1 0443 726 001 Display DY1 21 0192 526 003 Sealing strip 530 mm 22 0262 612 714 Cable 330 mm 24 0443 729 002 Inlet 25 0193 045 001 Connection block 2 pole X2 26 1 0467 911 883 Capacitor Valid from program version PEH1 2 67 cpeh0se1 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 6 1 0486 473 880 EPROM Capsule IC304 7 0456 489 005 Connection terminal 4 poles K9 K9X ALPHABETICAL LIST OF CONTENTS 68 alfaE AC Tachometer cable 16
49. elected If other product codes fixed ones are selected the inputs will not be active 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 Inlet K22 is open Flashing Display Inlet K23 is open Flashing The following alternative settings can be made on the Binary inputs menu Not used The inputs are not active 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 Limit switch Limit switches with normally 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 Start stop Valid for program version PEH1 2 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 27 cpeh0de1 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 18 The settings are therefore unique for each electronic unit and ar
50. er 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 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 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 41 cpeh0de1 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 18 The settings are therefore unique for each electronic unit and are shown in this menu S Select DRIVE TRIM MENU and press Actual trimming data are now displayed The preset values for an untrimmed electronics card are shown in the table on page 42 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 of how to adjust the offset error of the travel motor S Mark the line VXPoffset and press S Enter the desired value for example 32868 S Return to the MAIN MENU
51. erous 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 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 shown on the bottom line of the display 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 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 the ERROR LIST line and press S Step through the list with To erase the errors press S Return to the PRESET SYSTEM MENU with 49 cpeh0de1 Error codes The following codes generated by the DC DUO board can be shown on the display M1 3 Overheating Stop Wait until temperature has fallen Wire feed motor Motor 1 M1 1 Tacho fault Stop Check travel motor gearbox Tacho M1 2 Current too high Stop Check wire feed Travel motor Motor 2 M2 1 Tacho fault Stop Check travel motor gearbox
52. et for the best contrast If necessary it can be adjusted by potentiometer P101 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 NME 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 an A2 A6 Process Controller PEH Setting the DIP switch SW1 All eight poles of DIP switch SW1 must always be in closed position Communications software The communications software the keyboard controller display driver and the trim parameters for the motor circuit board are stored in flash memory IC15 The chip is mounted in a socket and can be changed Diagnostics There is one LED on the circuit board that can be used for system fault tracing S LED L02 RED lights to indicate failure of communication to the DC DUO board or in the event of a microprocessor fault cpeh0e08b 19 cpeh0de1 Bus termination connection When the NME circuit board is the first or last boa
53. he welding power source see Trimming data back to the PEH electronics above 52 cpeh0de1 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 above 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 above 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 T1 01 should come up the power source must be switched off and then on again for correct initiation CHANGING THE COMPLETE PEH ELECTRONICS KEEPING THE SETTINGS OF THE SYSTEM S Store the trimming data in the welding power source see Trimming data to the welding power source S Replace the complete PEH electronics S Remove the flash memory IC15 from the NME card S Move the flash memory IC15 from the old NME card to the new one S Recall trimming data from the welding power source see Trimming data back to the PEH electronics 53 dgb7d1ea INTRODUCTION A2 A6 PROCESS CONTROLLER ESAB s A2 A6 Process Controller PEH is a control unit which when combined with A2 A6 automatic welding equipment can be used for submerged arc or MIG MAG
54. 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 shown on the bottom line of the display 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 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 the ERROR LIST line and press S Step through the list with To erase the errors press S Return to the PRESET SYSTEM MENU with 33 cpeh0de1 Error codes The following codes generated by the DC DUO board can be shown on the display M1 3 Overheating Stop Wait until temperature has fallen Wire feed motor Motor 1 M1 1 Tacho fault Stop Check travel motor gearbox M1 2 Current too high Stop Check wire feed Travel motor Motor 2 M2 1 Tacho fault Stop Check travel motor gearbox M2 2 Current too high Stop Check travel motor gearbox M2 3 Overheating valid for PEH1 00A Stop Wait until temperature has fallen Welding power source T1 T1 01 Communication error Stop Check cables and connections T1 51 Incorrect welding vol
55. ined on pages 62 64 Switches to sub menus in rows 3 4 and 6 S Mark menu and press S Return to the WELDING SETUP by pressing S Return to the MAIN MENU by pressing 62 dgb7d1ea DEFINITIONS 1 Direction Two alternatives can be chosen Y triangle and J square these symbols are repeated on all units S Y triangle indicates travel in one direction S J square indicates travel in opposite direction 2 Start Two alternatives can be chosen Direct start or Scratch start S Direct start means that travel starts when the arc ignites S Scratch start means that travel starts at the same time as wire feed Scrape start is used when welding rusty or dirty material 3 STOP WELDING Crater fill and Burnback time can be set Crater fill times between 10 and 3000 ms 0 01 3 sec can be selected The crater fill function is used to finish the weld without leaving a crater Crater fill starts when the welding stop key is pressed and continues for the preset crater fill time This function is most useful when MIG MAG welding Burnback times between 10 and 3000 ms 0 01 3 sec can be selected The burnback time starts after the crater fill sequence has ended Correct choice of the burnback time prevents the wire sticking to the work piece the wire sticking to the nozzle 63 dgb7d1ea 4 WIRE DATA Wire type The equipment can be preset for the wire you inten
56. l 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 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 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 31 333 43 33 Fax 55 31 361 31 51
57. learly marked and close at hand S Lubrication and maintenance must not be carried out on the equipment during its operation WARNING READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAUTIONS WHEN WELDING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA ELECTRIC SHOCK Can kill S Install and earth the welding unit in accordance with applicable standards S Do not touch live electrical parts or electrodes with bare skin wet gloves or wet clothing S Insulate yourself from earth and the workpiece S Ensure your working stance is safe FUMES AND GASES Can be dangerous to health S Keep your head out of the fumes S Use ventilation extraction at the arc or both to keep fumes and gases 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 ear defenders or other hearing protection S Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction PROTECT YOURSELF AND OTHERS
58. 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 When the welding parameters are changed through the over ride function the values in the start sequence are changed correspondingly see page 59 46 cpeh0de1 10 DISPLAY MENU This menu controls how the information on the display is presented language units and other information can be varied as required S Select the DISPLAY MENU row and press In Column A the display now shows functions that can be altered with the current choices in Column B see below Example How to select English from the DISPLAY MENU S Select Language from Column A and press S Find English by pressing or by pressing S Return to Column A by pressing S Return to the MAIN MENU with English has now been selected as the display language Available settings for DISPLAY MENU DISPLAY MENU A B Language Svenska Dansk Norsk Suomi English Deutsch Francaise Nederlands Espanol Italiano Portugues Unit Metric Inches Current display Set value Real value Heat input On Off Font Small Large Parameter set X The available settings for DISPLAY MENU are explained on page 47 47 cpeh0de1 Language Svenska Swedish Dansk Danish Norsk Norwegian Soumi Finnish English English Deutsch German Francaise French Nederland
59. ocess 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 6 INTERNAL CONNECTIONS S Connect incoming cables to the 12 pole contact 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 S 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 terminal block X2 2 Two conductors x3 42 AC are connected to K13 1 and K13 2 2 5 mm2 Two conductors bus communication are connected to K9 1 and K9 2 0 5 mm2 on the NME circuit board AP2 One conductor arc voltage is connected to terminal block X2 1 One conductor emergency stop is connected to emergency stop switch ST1 Draw counter balancing for incoming cable 16 cpeh0de1 EXTERNAL CONNECTIONS Motor connections for travel motion travel motor M2 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 extra accessory two conductors and screen connected to K11 5 and K11 6 Connections to the welding head Arc voltage to terminal X2 1 Motor connections for the wire feed m
60. ollers diameters etc S In the MAIN MENU press to get to the WELDING SETUP menu S Scroll forward to PRESET SYSTEM MENU by pressing When this menu is selected press If the system is password protected this must be entered while PRESET SYSTEM MENU is selected followed by pressing The display now shows a number of parameters that can be altered in Column A with their current settings in Column B see the table for PRESET SYSTEM MENU on page 21 Other alternatives that can be selected are displayed one after the other 21 cpeh0de1 USING THE PRESET SYSTEM MENU S To change a setting move from Column A to Column B with S Find the required alternative with or with or for rows 3 7 and row 10 enter your own values S Return to Column A to move to another row with S Move to the next row with S Row 1 returns as the next row after row 10 S Move back to the previous row with This also provides a direct move from row 1 to row 10 S To reach the respective sub menus on rows 8 and 9 select the required menu and press S Return to the previous menu with Jump forward a whole page by pressing and return by pressing Explanation of symbols shown in combination with another key means that must be pressed first and then held while the second key is pressed SYSTEM FUNCTION SETTINGS AVAILABLE PRESET SYSTEM MENU A B 1 Product code
61. or A2TFF1 Weldtrac added Calibration menu deleted error 9 From 98 04 04 PEH program Flash IC 15 486478880 PEH 1 1 DCDUO program Prom IC304 68S07001A02 CHKSUM 0221 Dat 980404 DCDUO software 68S07001A02 CHKSUM 0221 compatible with hardware 971029 and all later versions Upgraded DCDUO program preventing unsafe usage of tacho function error 36 From 98 05 20 PEH program Flash IC 15 486478880 PEH 1 2 DCDUO program Prom IC304 68S07001A02 CHKSUM 0221 Dat 980404 Upgraded PEH program according to error list External start stop function see point 46 in error list Strip welding Stainless steel setting error 39 If this function is needed the power source board 486367001A in the LAF must be used ESW welding added new function added From 98 09 30 PEH program Flash IC 15 486478880 PEH 2 0 DCDUO program Prom IC304 68S07001A02 CHKSUM 0221 Dat 980404 LAF 2 0 program version is needed together with PEH 2 0 if all new features are needed Miscellaneous improvements acc to error list Inch conversion error 48 49 52 59 New manual programmable start method added error 61 4 cpeh0de1 SAFETY Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions The following recommendations should be observed in addition to the standard regulations that apply to the work place All work must be
62. ossible when you have chosen to work with several sets of parameters by programming the Display menu Immediate selection Suppose that while welding with parameter set 1 SET 1 you decide to change to parameter set 6 SET 6 without checking the parameters first S Press The field SET 1 is marked and parameter set 1 is active S Press The field SET 6 flashes S Press 60 dgb7d1ea The field SET 6 is marked and parameter set 6 is active Check before choosing Suppose that while welding with parameter set 1 SET 1 you decide to change to parameter set 6 SET 6 after first checking the parameters S Mark the field SET 1 by pressing S Press The field SET 6 flashes S The new parameter set can be checked before being chosen by pressing The complete row displaying the welding parameters flashes and displays the values for parameter set 6 SET 6 although parameter set 1 SET1 remains in use during the current welding cycle S Press The field SET 6 is marked and parameter set 6 is active WELDING SETUP GENERAL In WELDING SETUP you can choose a variety of settings including start method welding direction wire diameter and similar variables in order to carry out a specific welding task These settings cannot be changed during welding You can cancel any error message in the main menu by pressing
63. otor M1 A2 motor Motor cable two conductors and screen connected to connectors K10 1 and K10 2 AC Tachometer cable extra 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 is connected to connectors K10 5 and K10 6 Pilot lamp extra accessory Connect the transformer primary 42V to K14 1 and K14 2 The transformer and pilot lamp are included in a complete set of components for incorporation in the unit extra accessory and must be ordered separately Output for connecting a flux or gas valve 42 V AC max 0 5 A Screened 2 wire 2 x 0 75 mm2 connected to K12 1 and K12 2 Input for connection of a water flow switch NC limit switch or external start function valid for program version PEH1 2 and PEH2 0 Screened 2 wire 2 x 0 75 mm2 connected to K22 1 and K22 2 Input for connection of a gas flow switch NC limit switch or external stop function valid for program version PEH1 2 and PEH2 0 Screened 2 wire 2 x 0 75 mm2 connected to K23 1 and K23 2 External emergency stop extra accessory Remove the internal emergency stop connection and connect the external emergency stop circuit to X2 2 17 cpeh0de1 cpeh0e07 cpeh0e08 18 cpeh0de1 DC DUO Adjusting the display contrast As delivered the lighting is s
64. product codes in brackets are not normally used as travel motors 37 cpeh0de1 Wire feed axis Select wire feed motor here Alternatives A6F VEC 4000 r min art no 145 063 906 with 1 156 gear ratio A6G VEC 8000 r min art no 145 063 909 with 1 74 gear ratio A2F FHP 36 r min art no 334 678 001 KSV 5035 375 A2G FHP 68 r min art no 334 678 002 KSV 5035 374 MEK4 FHP 258 r min art no 455 077 001 KSV 5035 603 FREE1 Any required alternative see the FREE1 table on page 37 N B When selecting this alternative settings must be made for both motors and gears Available function settings for FREE1 FREE1 Press to reach the sub menu A B Motor FHP36 FHP68 FHP258 VEC4000 VEC8000 MET3B DUNKER1 DUNKER2 Gear 1 A2TW MEK24 74A6 FREE1 156A6 1 1 A6TA A2TA A6TB A2TB A2TC FREE2 FREE3 FREE4 Gear 2 1 1 74A6 156A6 MEK24 A6TA A2TA A2TW A6TB A2TB A2TC FREE1 FREE2 FREE3 FREE4 P D mm 1 10000 Encoder ppr 0 10000 LOW MANUAL SPEED 1 1000 HIGH MANUAL SPEED 1 5000 The motor codes in brackets are not normally used as wire feed motors The gear ratio codes in brackets are not normally used as travel motors 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 P D mm is the fe
65. r your own values S Return to Column A to move to another row with S Move to the next row with S Row 1 returns as the next row after row 12 S Move back to the previous row with This also provides a direct move from row 1 to row 12 S To reach the respective sub menus on rows 8 9 10 and 11 select the required menu and press S Return to the previous menu with Jump forward a whole page by pressing and return by pressing Explanation of symbols shown in combination with another key means that must be pressed first and then held while the second key is pressed SYSTEM FUNCTION SETTINGS AVAILABLE PRESET SYSTEM MENU A B 1 Product code see page 36 A2TFE A2TGE A2TFF A2TGF A6TFE A6TGE FREE 2 Weld process see page 42 SAW GMAW ESW 3 Gas preflow s see page 42 1 99 4 Gas postflow s see page 42 1 99 5 Password see page 43 XXXXX 6 Cable length m see page 43 X 7 Cable area mm2 see page 43 X 8 START SEQUENCE MENU see page 44 9 STOP SEQUENCE MENU see page 45 10 DISPLAY MENU see page 46 11 ERROR LIST see page 48 12 Test see page 49 1 ON 0 OFF Functions 1 12 are explained on pages 36 49 36 cpeh0de1 DEFINITIONS The starting point for altering functions 1 12 is selection of the PRESET SYSTEM MENU see page 35 1 Product code System configuration uses produ
66. rd in a network a short circuiting link must be fitted in socket K7 When the board is being used in an intermediate position in a network the short circuiting link must be fitted in socket K8 Connection between DC DUO and NME The NME circuit board is a separate unit that is secured above the DC DUO circuit board 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 cpeh0KB1 20 cpeh0de1 PRESET SYSTEM MENU FOR PEH1 00A PEH1 1 AND PEH1 2 CONTROL PANEL 1 Change menu 2 Numerical key number entry 3 ENTER key Change row 4 SHIFT key 5 Emergency stop See page 54 for an explanation of the functions of the other keys 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 ESAB s 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 r
67. rder 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 29 cpeh0de1 5 Password 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 6 Cable length m The arc voltage is noticeably affected by the impedance of the cable The impedance is affected by such factors as the length and cross sectional area of the cable 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 in Column B see page 21 A maximum of five figures may be used 7 Cable area mm2 Enter the cross sectional area of the cable in mm2 in Column B see page 21 A maximum of five figures may be
68. s Dutch Espanol Spanish Italiano Italian Portugues Portuguese Units Metric Inches Speeds lengths or wire sizes in the MAIN MENU can be displayed in either metric units or inches Current 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 Font Small Large Selects small or large display figures for the welding parameters 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 48 cpeh0de1 11 ERROR LIST Error messages are displayed on the bottom row of the MAIN MENU Error messages that may occur are shown here When an error message is displayed it overwrites the information that it normally displayed on the bottom row welding preset values See page 49 for a list of error codes Error categories Emergency stop see page 34 A special emergency stop function that is activated by pressing the emergency stop pushbutton in dang
69. tage Stop Check joint preparation T1 52 Incorrect current Stop Check joint preparation T1 53 Unsuccessful start Stop Check stick out and welding parameters T1 54 Current limit Stop Welding short circuited Cure short circuit T1 55 Thermostat overheating Stop Wait until temperature has fallen T1 56 Voltage loss valid for PEH1 00A Stop Loss of power check fuses T1 57 Arc extinguished Stop Check wire feed Inputs outputs No cooling water inlet K22 open Flashing Display Stop Check if the water is flowing or if the limit switch is open No gas flow inlet K23 open Flashing Stop Check gas pressure These inputs are activated by entries in the Product code menu FREE Binary inputs see page 22 10 Test When this menu is active the main menu displays information that is normally hidden Activate the menu by entering the numerical value 1 in Column B see the table on page 21 Loss of voltage deactivates the Test menu Speed commands in cm min are shown when the Test menu is active Wire feed speed commands are shown in the centre of the top line of the display Welding travel speed commands in cm min are shown at the right hand side of the top line of the display cpeh0KB1 34 cpeh0de1 PRESET SYSTEM MENU FOR PEH2 0 CONTROL PANEL 1 Change menu 2 Numerical key number entry 3 ENTER key Change row 4 SHIFT key 5 Emergency
70. uence indicated in intervals of 0 1 s max 9 9 s Example 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 When the welding parameters are changed through the over ride function the values in the start sequence are changed correspondingly see page 59 Phase 1 time 0 1s 30 Phase 1 speed 80 Phase 1 voltage 70 Phase 1 current 80 Phase 1 Wire feed 90 Phase 2 voltage 50 Phase 2 current 40 Phase 2 Wire feed 50 45 cpeh0de1 9 STOP SEQUENCE MENU The stop sequence menu is mainly used for programming the crater filling It is programmed in the same way as the start sequence menu The condition for activating the STOP SEQUENCE MENU is that the crater filling is set to 0 see the menu WELDING SETUP on page 61 In the stop sequence menu a phase can be interrupted by pressing the stop key Phase 2 has no effect if t 0 in Phase 1 t the durability of the sequence indicated in intervals of 0 1 s max 9 9 s Example 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
71. ues if necessary 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 FREE1 FREE2 FREE3 and FREE4 Column B are explained on page 39 39 cpeh0de1 When selecting FREE1 FREE2 FREE3 or FREE4 column B the display below is shown 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 N2 49 N1 30 Motor Gear FHP 36 Motor shaft Outgoing shaft 40 cpeh0de1 Binary inputs The inputs K22 and K23 on the DCDUO board can be assigned different functions on this sub menu Adjusting and using the inputs are only possible if the product code FREE has been selected If other product codes fixed ones are selected the inputs will not be active 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 Inlet K22 is open Flashing Display Inlet K23 is open Flashing The following alternative settings can be made on the Binary inputs menu Not used The inputs are not active Guards 2 transducers wat
72. ve current offset travel motor CYNoffset 32768 Negative current offset travel motor VXPscale 19200 Positive armature voltage measurement speed controlled wire feed VXNscale 19200 Negative armature voltage measurement speed controlled wire feed CXPscale 3200 Positive armature current measurement CXNscale 3200 Negative armature current measurement VYPscale 19200 Positive armature voltage measurement speed controlled travel motor VYNscale 19200 Negative armature voltage measurement speed controlled travel motor CYPscale 3200 Positive armature current measurement CYNscale 3200 Negative armature current measurement 2 Weld process Depending on which program version is being used either two or three alternatives can be selected SAW MIG MAG or ESW S SAW for submerged arc welding S MIG MAG for gas metal arc welding S ESW for electro slag welding cladding valid for program version PEH1 2 3 Gas preflow s only for MIG MAG 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 4 Gas postflow s only for MIG MAG The protective gas must continue to flow after the arc is extinguished in o
73. welding The process controller is designed for use with ESAB s LAF and TAF welding power sources Close integration of the control system with the welding power source makes it possible to ensure very precise process reliability All the controls that are needed to control welding travel and the entire welding process are situated on the control panel Incoming cables from various system components are connected to sockets at the rear of the process controller or to the circuit board terminals inside the controller WELDING POWER SOURCES The welding power sources are specially adapted to work with the A2 A6 Process Controller The welding power source and process controller are connected by a twin wire bus that allows the welding process to be controlled and monitored much more precisely than previously possible The power source settings can be adjusted from the control panel on the process controller ESAB s earlier generation of welding power sources such as the LAH LAE and TAE can be adapted for use with the new process controller with the aid of a conversion kit The new welding power sources are already prepared for straightforward connection to the A2 A6 Process Controller PEH The welding power sources also supply the correct current to the process controller thus eliminating the need for any external power supply TECHNICAL DATA A2 A6 Process Controller PEH Nominal voltage from power source 42V AC 50 60 Hz Nomin

PEH A2- A6 Process Controller - ESAB Welding & Cutting Products

Contents

Download Pdf Manuals

Related Search

Related Contents

PEH A2- A6 Process Controller - ESAB Welding &amp; Cutting Products

Contents

Download Pdf Manuals

Related Search

Related Contents

PEH A2- A6 Process Controller - ESAB Welding & Cutting Products