GB

A2- A6 Process Controller

PEH

Instruction manual
0443 745 301 GB 2007-02-19 Valid for machine no 644-xxx-xxxx Valid for program version PEH4.0, PEH4.0C, PEH4.01, PEH4.01C, PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH 5.0, PEH5.0C, PEH 5.1 and PEH 5.1C

DECLARATION OF CONFORMITY Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee that control unit A2--A6 Process Controller from serial number 220 complies with standard EN 60974--1, in accordance with the requirements of directive (73/23/EEA) and addendum (93/68/EEA). -------------------------------------------------------------------------------------------------------------------------------------Gteborg 2002--04--29

Greger Jacobson Senior Vice President ESAB AB SE--402 77 Gteborg Sweden

Tel: +46 31 50 93 49

Fax: +46 31 50 94 36

1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Welding power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 6
6 6 6

3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Connection of the welding power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Connection of the welding head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7 7 7

4 OPERATIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8 8

5 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Travel and wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Controlling valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.2 7.3 7.4 7.5 8.1 8.2 8.3 8.4 8.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering welding parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting parameter values (during welding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choosing a new set of parameters during welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting the display language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Available settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preset indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
9 9 10 11 13 14 15 16 17 17 18 19 21 22 23

6 MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8 WELDING SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

9 ERROR LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 11 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 24 26 27

Rights reserved to alter specifications without notice.

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GB 1 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well--acquainted with the operation of the welding equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. 1. Anyone who uses the welding equipment must be familiar with: S its operation S location of emergency stops S its function S relevant safety precautions S welding The operator must ensure that: S no unauthorised person is stationed within the working area of the equipment when it is started up. S no--one is unprotected when the arc is struck The workplace must: S be suitable for the purpose S be free from draughts Personal safety equipment S Always wear recommended personal safety equipment, such as safety glasses, flame--proof clothing, safety gloves. S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. General precautions S Make sure the return cable is connected securely. S Work on high voltage equipment may only be carried out by a qualified electrician. S Appropriate fire extinquishing equipment must be clearly marked and close at hand. S Lubrication and maintenance must not be carried out on the equipment during operation.

2.

3.

4.

5.

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GB

WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill S Install and earth the welding unit in accordance with applicable standards. S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. S Insulate yourself from earth and the workpiece. S Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health S Keep your head out of the fumes. S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. S Protect bystanders with suitable screens or curtains. FIRE HAZARD S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing S Protect your ears. Use earmuffs or other hearing protection. S Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!

WARNING
This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the users responsibility to take adequate precautions.

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GB 2
2.1

INTRODUCTION
General

ESABs A2--A6 Process Controller (PEH) is a control unit which, when combined with A2--A6 automatic welding equipment can be used for submerged--arc or MIG/MAG welding. The process controller is designed for use with ESABs LAF and TAF welding power sources. Close integration of the control system with the welding power source makes it possible to ensure very precise process reliability. All the controls that are needed to control welding travel and the entire welding process are situated on the control panel. Incoming cables from various system components are connected to sockets at the rear of the process controller or to the circuit board terminals inside the controller.

2.2

Welding power sources

The welding power sources are specially adapted to work with the A2--A6 Process Controller. The welding power source and process controller are connected by a twin wire bus that allows the welding process to be controlled and monitored much more precisely than previously possible. The power source settings can be adjusted from the control panel on the process controller. ESABs earlier generation of welding power sources, such as the LAH, LAE and TAE can be adapted for use with the new process controller with the aid of a conversion kit. The new welding power sources are already prepared for straightforward connection to the A2--A6 Process Controller (PEH). The welding power sources also supply the correct current to the process controller, thus eliminating the need for any external power supply.

2.3

Technical data
A2-A6 Process Controller (PEH) 42V AC 50/60 Hz Max. 900 VA Motor current 5 A continuous, max. 10 A Internal EMK control or with AC tacho, 6 pulses per rev 0.1--2 m/min (depending on travel unit)) 2.0 m/min 0.3--25 m/min (depending on wire feed unit) Max. 45_ C, Max. 98 % 5.5 kg 355 x 210 x 164 mm IP 23 Min. --15_ C

Nominal voltage from power source: Nominal load: Motor connections adapted for ESABs A2- or A6- motors: Wire speed regulation: Welding speed: Max. manual travel speed: Filler wire, wire feed speed: Ambient temperature: Relative humidity: Weight: Dimensions L x B x H: Enclosure class:

Enclosure class The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

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GB 3
3.1

INSTALLATION
General

The installation must be executed by a professional.

3.2
S

Connection of the welding power source

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

3.3
S

Connection of the welding head

Arc voltage to terminal X2.1

As to all other connections, contact ESAB.

Connection of welding power source

Connection of the welding head

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GB 4
4.1

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.

4.2

Control panel

1. Emergency stop 2. The direction of travel is as shown by the triangular symbol on the welding equipment. 3. The direction of travel is as shown by the square symbol on the welding equipment. 4. Advance wire 5. Retract wire 6. Change menu 7. Numerical key, number entry 8. ENTER key, Change row 9. SHIFT key 10. Stop welding. Return to manual mode 11. Start welding. Switch to automatic mode 12. 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
-8-

it is possible to browse.

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GB 5
5.1

MANUAL OPERATION
Travel and wire feed

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

Switch on welding power source S The direction of travel is as shown by the square symbol on the welding equipment. Normal speed S . The direction of travel is as shown by the triangular symbol on the welding equipment.

. Normal speed To stop travel described above, press the same key again. S Retract wire. Normal speed .

Wire continues to retract until you release the key. S S Advance wire. Normal speed .

Wire continues to advance until you release the key. 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 , or .

To stop immediately, press

even at max. speed.

Normal speed and max. speed can be adjusted under PRESET SYSTEM MENU.

5.2

Controlling valves
To operate a valve you must be in the MAIN MENU.

S S

Open the valve for flux or gas by pressing

. . Valve (Open/ Closed)

Close an open valve by pressing the same key

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GB 6
6.1

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
MAIN MENU

S SET S Heat input per cm S Welding current S Wire feed speed S Arc voltage S Travel speed S Preset indicators S Selecting the display language WELDING SETUP S Arc start method S Type of weld finish S Welding direction S Regulation method S Wire type S Wire material S Wire size

Direction Start STOP WELDING WIRE DATA Regulation PRESET SYSTEM MENU

Y Direct CA

PRESET SYSTEM MENU / DISPLAY MENU / ERROR LIST Menus that are not accessible by the user

WELDING SETUP

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GB 7
7.1

MAIN MENU
General

In the MAIN MENU you choose the welding current, arc voltage and travel speed you want to use for welding. During welding you can adjust the welding parameters or choose a complete new set of parameters.

Switch on the power source

The main menu will appear as follows:

Indicates the heat input in kJ/cm that will result from the chosen Indicates that parameter set 1 of values of welding current, arc voltage and travel speed (can be 10 available has been selected hidden). (can be hidden).

Indicates the type of start

Travel direction

Chosen arc voltage in volts.

Chosen travel speed in Indicates if the valve outcentimetres per minute. put is open or closed.

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

Chosen welding current in amperes.

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

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

Resulting welding current after the welding start.

For the selection of (CA) or (CW), see the menu WELDING SETUP on page 17.

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GB
Example of display in the event of a fault. S S S Error code appears in bottom left section of display. Error message is cancelled by pressing Max. 20 messages saved in chronological order.

S S

Start welding by pressing Stop welding by pressing

. The LED in the key lights up.

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GB
7.2 Entering welding parameters

When the power source is switched on, the main menu appears on the display. In the Display menu you can choose how many sets of parameters you want to work with. If more than one set of parameters is used then the SET number appears in the top left corner.

1. Welding current or wire feed speed 2. SET no. 3. Arc voltage 4. Travel speed

If you choose to work with just one set of parameters then start at step 3. S S S S Press + to mark the parameter set field . . .

Type in the desired SET number and press

Select the field for welding current or wire feed speed by pressing .

Type in the desired welding current or wire feed speed. Max. 4 numbers, press

S S S S

Select the field for arc voltage by pressing

. .

Type in the desired arc voltage, max. 3 numbers, press Select the field for travel speed by pressing .

Type in the desired travel speed, max. 3 numbers and press

Now the whole set has been marked and is ready to use. A further 9 additional sets can be stored. (Total 10 SETs).

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GB
7.3 Adjusting parameter values (during welding)

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

Increase Welding current or wire feed speed Arc voltage Travel speed

Decrease

Save the values as follows: S S S Stop welding with . . + .

Save the changed values with

To revert to the original values, press

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GB
7.4 Choosing a new set of parameters during welding

(Only possible when you have chosen to work with several sets of parameters by programming the Display menu) Immediate selection Suppose that while welding with parameter set 1 (SET 1) you decide to change to parameter set 6 (SET 6) without checking the parameters first. S Press + .

The field SET 1 is marked and parameter set 1 is active S Press .

The field SET 6 flashes. S Press .

The field SET 6 is marked and parameter set 6 is active Check before choosing Suppose that while welding with parameter set 1 (SET 1) you decide to change to parameter set 6 (SET 6) after first checking the parameters. S S S Mark the field SET 1 by pressing Press . + .

The field SET 6 flashes. The new parameter set can be checked before being chosen by pressing + .

The complete row displaying the welding parameters flashes and displays the values for parameter set 6 (SET 6), although parameter set 1 (SET1) remains in use during the current welding cycle. S Press .

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

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GB
7.5 Selecting the display language
Display language

The selection is made in the MAIN MENU S S S Press .

The current language is shown in the top right corner of the display. Scroll forward to the desired language with . .

Return with

The following languages can be selected: Svenska=Swedish / Dansk=Danish / Norsk=Norwegian / Soumi=Finnish / English=English / Deutsch=German / Francaise=French / Nederlands=Dutch / Espanol=Spanish / Italiano=Italian / Portugues=Portuguese / Eesti=Estonian / Cesky=Czechoslovakian. N.B. The China version is only available in English and Chinese.

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GB 8
8.1

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. S Switch from the MAIN MENU to WELDING SETUP.
Direction Y Start Direct STOP WELDING WIRE DATA Regulation CA PRESET SYSTEM MENU

8.2

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

General Scroll between the alternatives in the left column with or + . + .

When all settings have been done return to the MAIN MENU with For available settings see on page 18. To change the settings for Direction, Start and Regulation: S S Mark menu Direction, Start or Regulation and press Scroll forward to the chosen option with . .

+ . S Return with To change the settings for STOP WELDING and WIRE DATA: S S S S S Mark menu STOP WELDING or WIRE DATA and press Select the alternative that is to be changed with Press . or type in your own values. . .

Scroll forward to the chosen option with Return with +

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

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GB
8.3 Available settings
Press Direction Start STOP WELDING Press

,J Direct Scratch 10--3000 10--3000 Solid wire, Flux cored, Strip, Gauging 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 30x0.5 60x0.5 100x0.5 8.0 9.5 13.0 Fe, Al, SS 1, 2

Crater fill (ms) Burnback time (ms) Wire type Wire diameter if Solid wire is chosen

WIRE DATA

if Flux cored is chosen if Strip is chosen if Gauging is chosen Wire material Number of wires

Regulation PRESET SYSTEM MENU

CA, CW

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

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GB
8.4 Definitions
(triangle) and J (square) (these symbols are

1. Direction Two alternatives can be chosen Y repeated on all units) S S Y J (square) indicate

(triangle) indicates travel in one direction.

2. Start Two alternatives can be chosen: Direct start or Scratch start. S S Direct start means that travel starts when the arc ignites. 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: S S the wire sticking to the work piece the wire sticking to the nozzle

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GB
4. WIRE DATA Wire type The equipment can be preset for the wire you intend to weld with. The control system must be given information about the wire shape in order to achieve optimum start/stop characteristics. S S S S solid wire cored wire strip gauging

Wire diameter The chosen wire diameter has a big effect on the start cycle and crater filling. When welding with a wire diameter that is not given in the options table, choose the nearest diameter from the menu. Note! For certain wire materials a better welding result can be achieved, if a value deviating from the real wire dimension by 1 step is set (normally 1 step from the real value).
When metric units are used the following alternatives are available: Solid wi- Cored re: wire: 0.8 mm 1.0 mm 1.2 mm 1.6 mm 2.0 mm 2.4 mm 3.0 mm 3.2 mm 4.0 mm 5.0 mm 6.0 mm 0.8 mm 1.0 mm 1.2 mm 1.6 mm 2.0 mm 2.4 mm 3.0 mm 3.2 mm 4.0 mm Strip: 30x0.5 mm 60x0.5 mm 100x0.5 mm Gauging: 8.0 mm 9.5 mm 13.0 mm When inch units are used the following alternatives are available Solid: 0.030 0.040 0.047 1/16 5/64 3/32 7/64 1/8 5/32 3/16 1/4 Cored wire: 0.030 0.040 0.047 1/16 5/64 3/32 7/64 1/8 5/32 Strip: 1.25 x 0.02 2.5 x 0.02 4 x 0.02 Gauging: 1/2 5/6 3/8

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

Number of wires Values between 1 -- 2 can be entered. For example, if welding with two wires (Twin Arc) enter the value 2.
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GB
5. Regulation Two different operating modes can be used for welding, either constant current, CA, or constant wire feed speed, CW. S CA, constant current. Normally used for submerged arc welding, which involves working with large welds, large currents and large weld pools. The wire feed speed is controlled by the power source to maintain a constant current. CW, constant wire feed speed. Normally used for MIG/MAG welding, for small weld pools, thin sheet metal and thin filler wire. It is easier to achieve a constant throat thickness when welding with this method. Welding is controlled by selecting a fixed wire feed speed and the current is adjusted to achieve this speed. The resulting current is displayed above the selected wire feed speed (see display shot on page 21).

8.5

Preset indicators

The numbers and symbols on the display show the chosen preset values, see table below.

Shown in display MAIN MENU as Start

WELDING SETUP options Direct Scratch TRIANGLE SQUARE 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0 0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 30x0.5 60x0.5 100x0.5 8.0 9.5 13.0 Valve

Y J Shown in plain English (e.g. 3.0)

Direction Wire diameter: Solid wire Flux cored Strip gauging OUTPUT Open/Closed

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GB 9
9.1

ERROR LIST
Error codes
Analogue board Check cables and connections

203.01 Communication error with Analogue card Stop I/O board 301.01 Communication error with Digital I/O Wire feed motor (Motor 1) 201.2 201.3 201:5 Current too high Overheating (Motor 1) Communication error ** Travel motor (Motor 2) 202.2 202.3 202:5 Current too high Overheating (Motor 2) Communication error ** Drive unit (PEH4.2) 204.2 204.3 Short--circuit, drive unit ** Overheating, drive unit ** Welding power source (T1) 111.01 Communication error 111.53 Unsuccessful start 111.54 Current limit/ Arc extinguished *** 111.54 Current limit ** 111.55 Thermostat / overheating 111.57 Arc extinguished ** Inputs / outputs
Display (Flashing)

Stop

Check cables and connections

Stop Stop Stop

Check wire feed Wait until temperature has fallen Check the cabling.

Stop Stop Stop

Check travel motor / gearbox Wait until temperature has fallen Check the cabling.

Stop Stop

Replace the PC board Wait for a while and then check the heat dissipating element

Stop Stop Stop Stop Stop Stop

Check cables and connections Check stick--out and welding parameters Welding short--circuited, Cure short--circuit / Check wire feed Welding short--circuited, Cure short--circuit Wait until temperature has fallen Check wire feed

No cooling water (inlet K22 open) * No gas flow (inlet K23 open) *

Stop

Check if the gas is flowing or if the limit switch is open. Check gas pressure or if the limit switch is open.

(Flashing)

Stop

* Inputs are activated by using settings in menu PRESET SYSTEM MENU. ** Only valid for control box with program version PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH5.0, PEH5.0C, PEH5.1 and PEH 5.1 C. *** Only valid for control box with program version PEH4.0, PEH4.0C, PEH4.01 and PEH 4.01C.
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fgb7f1ea

GB 10
10.1

MAINTENANCE
General

Note: All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period. In the event of malfunction: S Contact your nearest ESAB representative, see last page.

11

ORDERING SPARE PARTS

Spare parts are ordered through your nearest ESAB representative, see back cover. When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 27. This will simplify dispatch and ensure you get the right part.

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Diagram

fgb7e12a

- 24 -

fgb7e12a

- 25 -

Accessories

Remote control PHH1, including cable Ordering no.: 0449 040 880

Remote control PHH2 Ordering no.: 0449 040 881

Tillb

- 26 -

Spare parts list

A2- A6 Process Controller (PEH)

Edition 2004-12-17

Ordering no. 0443 741 880

Denomination Control box A2-A6 Process Controller (PEH)

Notes

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

pehspare

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Item no.

Qty

Ordering no. 0443741880

Denomination CONTROL BOX PEH Control panel Emergency stop Rail Cable complete Circuit board Insulation Display, ccfl backlight Sealing strip Bushing Capacitor Inverter with screen box

Notes

3 4 8 9 10 14 20 21 23 26 41

1 1 2 1

0443638880 0443740001 0457278001 0443748880 0443730880

KB1 ST1

XS1 AP1 + AP2

1 1

0443849001 0449130001 0192526003

DY1 530 mm

10 2 1

0192645002 0467911884 0449137880

Valid from programversion PEH1.2

f443741r

- 28 -

Item no.

Qty

Ordering no. 0443 748 880

Denomination Cable with connectors Pin socket, Burndy Cable set Circuit board connection Circuit board connection Connection block Hose Pin cable clip

Notes

1 4 6 7 8 9 10

1 1 1 1 1

0368 543 003 0443 841 880 0456 489 005 0456 489 004 0193 275 002 0190 209 109

3 pole 2,5 mm2

0192 541 003

f443748s

- 29 -

Item no.

Qty

Ordering no.

Denomination Circuit board Connection terminal Connection terminal Connection terminal Flash memory Connection terminal

Notes

C AP1 + AP2

0443 730 880 2 3 4 5 7 1 0456 489 002 0456 489 001 0456 489 004 0486 471 880 0456 489 005

6 poles 2 poles 2 poles

K10, K11 K12, K17, K22, K23 K13, K14 IC15

4 poles

K9, K9X

s443730r

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Item no.

Qty

Ordering no. 0456500880

Denomination Control cable Control cable Adapter Control cable Control cable Adapter Control cable Control cable Adapter Control cable Control cable Adapter Control cable Control cable Adapter Control cable Control cable Adapter

Notes L = 15 m, Accessories 15m, 12-28 pole (LAF/TAF-PEH) 28-12pol. (PEH-LAF 12p) L = 25 m, Accessories 25m, 12-28 pole (LAF/TAF-PEH) 28-12pol. (PEH-LAF 12p) L = 35 m, Accessories 35m, 12-28 pole (LAF/TAF-PEH) 28-12pol. (PEH-LAF 12p) L = 50 m, Accessories 50m, 12-28p 28-12pol. (PEH-LAF 12p) L = 75 m, Accessories 75m, 12-28 pole (LAF/TAF-PEH) 28-12pol. (PEH-LAF 12p) L = 100 m, Accessories 100m, 12-28 pole (LAF/TAF-PEH) 28-12pol. (PEH-LAF 12p)

1 2

1 1

0449449880 0449448880 0456500881

1 2

1 1

0449449881 0449448880 0456500882

1 2

1 1

0449449882 0449448880 0456500883

1 2

1 1

0449449883 0449448880 0456500884

1 2

1 1

0449449884 0449448880 0456500885

1 2

1 1

0449449885 0449448880

f456500s

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Item no.

Qty

Ordering no. 0449449880

Denomination Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin Contact sleeve Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin contact sleeve Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin Contact sleeve

Notes 15m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2 25m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2 35m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007 0449449881

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007 0449449882

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007

f449449s

- 32 -

Item no.

Qty

Ordering no. 0449449883

Denomination Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin Contact sleeve Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin Contact sleeve Control cable Pin plug, burndy Connector pin Connector pin Sleeve plug, burndy Contact sleeve Connector sleeve Cable, screened Contact pin Contact sleeve

Notes 50m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2 75m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2 100m, 12- 28 pole (LAF/TAF- PEH) 28 pol. 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007 0449449884

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007 0449449885

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 4 4

0368541106 0323945004 0323945001 0368542303 0323945002 0323945003 0193963001 0323945008 0323945007

f449449s

- 33 -

Item no.

Qty

Ordering no. 0449448880

Denomination Adapter Sleeve cable socket Connector sleeve Contact sleeve Pin plug burndy Connector pin Connector pin 0,52-1,50 Cable, screened Contact sleeve Contact pin

Notes 28- 12POL(PEH- LAF12P) 28-pol 0,52-1,50 0,32-0,52 12 pol. 0,32-0,52 0,52-1,50 5x0.5mm2 3x1.5mm2 4x2.5mm2 max 2.5mm2 max 2.5mm2

1 2 3 4 5 6 7 8 9

1 3 5 1 5 3 1 4 4

0368546106 0323945003 0323945002 0368541303 0323945001 0323945004 0193963001 0323945007 0323945008

f449448s

- 34 -

ESAB subsidiaries and representative offices

Europe
AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218 GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186 ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: +31 30 2485 377 Fax: +31 30 2485 260 NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03 POLAND ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277 SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41 SPAIN ESAB Ibrica S.A. Alcal de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

Asia/Pacific
CHINA Shanghai ESAB A/P Shanghai Tel: +86 21 5308 9922 Fax: +86 21 6566 6622 INDIA ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80 INDONESIA P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929 JAPAN ESAB Japan Tokyo Tel: +81 3 5296 7371 Fax: +81 3 5296 8080 MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 8027 9869 Fax: +60 3 8027 4754 SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Representative offices
BULGARIA ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88 EGYPT ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74 RUSSIA LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280 LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060

Distributors

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

North and South America

ARGENTINA CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313 BRAZIL ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440 CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79 MEXICO ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554 USA ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

ESAB AB SE- 695 81 LAX SWEDEN Phone +46 584 81 000 www.esab.com
061127