A2-A6 PEH_644

GB

0443 745 301 GB 2007--02--19 Valid for machine no 644--xxx--xxxxValid 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 5.1and PEH 5.1C

A2-A6Process ControllerPEH

Instruction manual

2

DECLARATION OF CONFORMITYEsab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guaranteethat control unit A2--A6 Process Controller from serial number 220 complies withstandard EN 60974--1, in accordance with the requirements of directive (73/23/EEA)and addendum (93/68/EEA).--------------------------------------------------------------------------------------------------------------------------------------

Göteborg 2002--04--29

Greger JacobsonSenior Vice PresidentESAB ABSE--402 77 GöteborgSweden Tel: +46 31 50 93 49 Fax: +46 31 50 94 36

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Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Welding power sources 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Technical data 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 General 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Connection of the welding power source 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Connection of the welding head 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 OPERATIONAL DESCRIPTION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Control panel 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 MANUAL OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Travel and wire feed 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Controlling valves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MENUS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Menu overview 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAIN MENU 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 General 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Entering welding parameters 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3 Adjusting parameter values (during welding) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4 Choosing a new set of parameters during welding 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 Selecting the display language 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 WELDING SETUP 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 General 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2 Changing settings 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 Available settings 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4 Definitions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5 Preset indicators 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

10 MAINTENANCE 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1 General 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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1 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safety precautionsmust meet the requirements that apply to this type of welding equipment. The following recommen-dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the weldingequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS welding

2. The operator must ensure that:S no unauthorised person is stationed within the working area of the equipment when it is

started up.S no--one is unprotected when the arc is struck

3. The workplace must:S be suitable for the purposeS be free from draughts

4. Personal safety equipmentS Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautionsS 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.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BEBASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can killS 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 healthS 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 HAZARDS Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.NOISE -- Excessive noise can damage hearingS Protect your ears. Use earmuffs or other hearing protection.S Warn bystanders of the risk.MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

WARNINGThis product is intended for industrial use. In a domestic environment thisproduct may cause radio interference. It is the user’s responsibility to takeadequate precautions.

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2 INTRODUCTION

2.1 General

ESAB’s A2--A6 Process Controller (PEH) is a control unit which, when combined withA2--A6 automatic welding equipment can be used for submerged--arc or MIG/MAGwelding.

The process controller is designed for use with ESAB’s LAF and TAF welding powersources. Close integration of the control system with the welding power sourcemakes it possible to ensure very precise process reliability.

All the controls that are needed to control welding travel and the entire weldingprocess are situated on the control panel.

Incoming cables from various system components are connected to sockets at therear 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 ProcessController. The welding power source and process controller are connected by a twinwire bus that allows the welding process to be controlled and monitored much moreprecisely than previously possible. The power source settings can be adjusted fromthe control panel on the process controller.

ESAB’s earlier generation of welding power sources, such as the LAH, LAE and TAEcan be adapted for use with the new process controller with the aid of a conversionkit. The new welding power sources are already prepared for straightforwardconnection to the A2--A6 Process Controller (PEH). The welding power sources alsosupply the correct current to the process controller, thus eliminating the need for anyexternal power supply.

2.3 Technical data

A2--A6 Process Controller (PEH)

Nominal voltage from power source: 42V AC 50/60 Hz

Nominal load: Max. 900 VA

Motor connections adapted for ESAB’sA2-- 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)

Ambient temperature: Max. 45_ C, Min. --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

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

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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Connection of the welding power source

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

3.3 Connection of the welding head

S Arc voltage to terminal X2.1

As to all other connections, contact ESAB.

Connection of weldingpower source

Connection of thewelding head

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4 OPERATIONAL DESCRIPTION

4.1 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 andyou can preset all other essential welding parameters for the current weld.

In automatic mode you can choose a preset group of welding parameters andfine--tune the actual welding parameters. Other settings made previously in manualmode cannot be adjusted in automatic mode.

The process controller is ready for manual operation as soon as the mains power isswitched on. When welding begins the controller switches to automatic mode. Whenwelding 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 shownby the triangular symbol on thewelding equipment.

3. The direction of travel is as shownby the square symbol on the weldingequipment.

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 ordecrease the current, voltage and speed.

By pressing either , , + or + it is possible to browse.

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5 MANUAL OPERATION

5.1 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 weldingequipment.

Normal speed .

S The direction of travel is as shown by the triangular symbol on the weldingequipment.

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 “PRESET SYSTEM MENU”.

5.2 Controlling valves

To operate a valve you must be in the “MAIN MENU”.

S Open the valve for flux or gas by pressing .

S Close an open valve by pressing the same key .

Valve(Open/ Closed)

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6 MENUS

6.1 Menu overview

The A2--A6 Process Controller (PEH) softwareis divided into several menus. The programstructure is described in the overview below.

MAIN MENU

S SET S Heat input per cm S Welding currentS Wire feed speed S Arc voltage S Travel speedS Preset indicatorsS Selecting the display language

WELDING SETUP

S Arc start method S Type of weld finishS Welding direction S Regulation methodS Wire type S Wire material S Wire size

PRESET SYSTEM MENU / DISPLAY MENU /ERROR LIST

Menus that are not accessible by the user

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Direction YStart DirectSTOP WELDINGWIRE DATARegulation CAPRESET SYSTEM MENU

MAIN MENU

WELDING SETUP

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7 MAIN MENU

7.1 General

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

S Switch on the power source .

The main menu will appear as follows:

Indicates that parameter set 1 of10 available has been selected(can be hidden).

Indicates the heat input in kJ/cm that will result from the chosenvalues of welding current, arc voltage and travel speed (can behidden).

Chosen arc voltage in volts. Chosen travel speed incentimetres per minute.

Indicates thetype of start Travel direction

Indicates if the valve out-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 withconstant wire feed speed (CW) ischosen.

Chosen wire feed speed.

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

Resulting welding current after thewelding start.

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

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Example of display in the event of a fault.

S Error code appears in bottom left sectionof display.

S Error message is cancelled by pressing

S Max. 20 messages saved in chronologicalorder.

S Start welding by pressing . The LED in the key lights up.

S Stop welding by pressing

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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 towork with. If more than one set of parameters is used then the SET number appearsin 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 setscan be stored. (Total 10 SETs).

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7.3 Adjusting parameter values (during welding)

Once welding has started the welding parameters can be fine--tuned using thearrowed 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 + .

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7.4 Choosing a new set of parameters during welding

(Only possible when you have chosen to work with several sets of parameters byprogramming the “Display” menu)

Immediate selection

Suppose that while welding with parameter set 1 (“SET 1”) you decide to change toparameter 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 toparameter 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 valuesfor parameter set 6 (“SET 6”), although parameter set 1 (“SET1”) remains in useduring the current welding cycle.

S Press .

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

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7.5 Selecting the display language

The selection is made in the “MAIN MENU”

S Press .

S The current language is shown in thetop right corner of the display.

S Scroll forward to the desired language

with .

S 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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Display language

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8 WELDING SETUP

8.1 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 specificwelding task. These settings cannot be changed during welding.

S Switch from the MAIN MENU to WELDING SETUP.Direction YStart DirectSTOP WELDINGWIRE DATARegulation CAPRESET SYSTEM MENU

8.2 Changing settings

Direction YStart DirectSTOP WELDINGWIRE DATARegulation CAPRESET SYSTEM MENU

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 Mark menu Direction, Start or Regulation and press .

S Scroll forward to the chosen option with .

S Return with + .To change the settings for STOP WELDING and WIRE DATA:

S Mark menu STOP WELDING or WIRE DATA and press .

S Select the alternative that is to be changed with .

S Press .

S Scroll forward to the chosen option with or type in your own values.

S Return with +

Explanations of terms:

When is indicated in combination with another key you should press first andhold it down while pressing the second key.

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8.3 Available settings

Press Press

Direction Y ,J

Start ScratchDirect

STOP WELDINGCrater fill (ms) 10--3000

STOP WELDINGBurnback time (ms) 10--3000

Wire type Solid wire, Flux cored, Strip, Gauging

WIRE DATA

Wire diameterif “Solid wire” is chosen

if “Flux cored” is chosen

if “Strip” is chosenif “Gauging” is chosen

0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.24.0 5.0 6.00.8 1.0 1.2 1.6 2.0 2.4 3.0 3.24.030x0.5 60x0.5 100x0.58.0 9.5 13.0

Wire material Fe, Al, SS

Number of wires 1, 2

Regulation CA, CW

PRESET SYSTEM MENU

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

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8.4 Definitions

1. DirectionTwo alternatives can be chosenY (triangle) and J (square) (these symbols arerepeated on all units)

S Y (triangle) indicates travel in one direction.

S J (square) indicate

2. StartTwo 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. Scrapestart is used when welding rusty or dirty material.

3. STOP WELDINGCrater 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 craterfill 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 the wire sticking to the work piece

S the wire sticking to the nozzle

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4. WIRE DATA

Wire type

The equipment can be preset for the wire you intend to weld with. The controlsystem must be given information about the wire shape in order to achieve optimumstart/stop characteristics.

S solid wire

S cored wire

S strip

S gauging

Wire diameter

The chosen wire diameter has a big effect on the start cycle and crater filling. Whenwelding with a wire diameter that is not given in the options table, choose the nearestdiameter from the menu.

Note! For certain wire materials a better welding result can be achieved, if a valuedeviating from the real wire dimension by 1 step is set (normally 1 step from the realvalue).

When metric units are used the following alter-natives are available:

When inch units are used the following alterna-tives are available

Solid wi-re:

Coredwire:

Strip: Gauging: Solid: Coredwire:

Strip: Gauging:

0.8 mm 0.8 mm 30x0.5 mm 8.0 mm 0.030 0.030 1.25 x 0.02 1/2

1.0 mm 1.0 mm 60x0.5 mm 9.5 mm 0.040 0.040 2.5 x 0.02 5/6

1.2 mm 1.2 mm 100x0.5 mm 13.0 mm 0.047 0.047 4 x 0.02 3/8

1.6 mm 1.6 mm 1/16 1/16

2.0 mm 2.0 mm 5/64 5/64

2.4 mm 2.4 mm 3/32 3/32

3.0 mm 3.0 mm 7/64 7/64

3.2 mm 3.2 mm 1/8 1/8

4.0 mm 4.0 mm 5/32 5/32

5.0 mm 3/16

6.0 mm 1/4

Wire composition

When welding with different filler materials the start and stop method is affected bythe choice of materials. It is therefore important that the settings show whether youare welding with steel--based or aluminium--based filler wires.

S Fe Steel filler wire

S Al Aluminium filler wire

S 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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5. RegulationTwo 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 involvesworking with large welds, large currents and large weld pools. The wire feedspeed is controlled by the power source to maintain a constant current.

S CW, constant wire feed speed. Normally used for MIG/MAG welding, for smallweld pools, thin sheet metal and thin filler wire. It is easier to achieve a constantthroat thickness when welding with this method. Welding is controlled byselecting a fixed wire feed speed and the current is adjusted to achieve thisspeed. 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 tablebelow.

Shown in displayMAIN MENU as

WELDING SETUPoptions

Start DirectScratch

Y

J

Direction TRIANGLESQUARE

Shown in plain English(e.g. 3.0)

Wire diameter:Solid wireFlux cored

Stripgauging

0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.00.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0

30x0.5 60x0.5 100x0.58.0 9.5 13.0

OUTPUTOpen/Closed

Valve

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9 ERROR LIST

9.1 Error codes

Analogue board

203.01 Communication error with Analogue card Stop Check cables and connections

I/O board

301.01 Communication error with Digital I/O Stop Check cables and connections

Wire feed motor (Motor 1)

201.2 Current too high Stop Check wire feed

201.3 Overheating (Motor 1) Stop Wait until temperature has fallen

201:5 Communication error ** Stop Check the cabling.

Travel motor (Motor 2)

202.2 Current too high Stop Check travel motor / gearbox

202.3 Overheating (Motor 2) Stop Wait until temperature has fallen

202:5 Communication error ** Stop Check the cabling.

Drive unit (PEH4.2)

204.2 Short--circuit, drive unit ** Stop Replace the PC board

204.3 Overheating, drive unit ** Stop Wait for a while and then check the heatdissipating element

Welding power source (T1)

111.01 Communication error Stop Check cables and connections

111.53 Unsuccessful start Stop Check stick--out and welding parameters

111.54 Current limit/ Arc extinguished *** Stop Welding short--circuited,Cure short--circuit / Check wire feed

111.54 Current limit ** Stop Welding short--circuited,Cure short--circuit

111.55 Thermostat / overheating Stop Wait until temperature has fallen

111.57 Arc extinguished ** Stop Check wire feed

Inputs / outputs

No cooling water(inlet K22 open) *(Flashing)

Display Stop Check if the gas is flowing or if the limitswitch is open.

No gas flow(inlet K23 open) *(Flashing)

Stop Check gas pressure or if the limit switchis open.

* 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 andPEH 4.01C.

GB

-- 23 --fgb7f1ea

10 MAINTENANCE

10.1 General

Note:All warranty undertakings given by the supplier cease to apply if the customerattempts 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 desig-nation 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.

GB

Diagram

-- 24 --fgb7e12a

-- 25 --fgb7e12a

Accessories

-- 26 --Tillb

Remote control PHH1, including cable

Ordering no.: 0449 040 880

Remote control PHH2

Ordering no.: 0449 040 881

Spare parts list

-- 27 --pehspare

A2-A6 Process Controller (PEH)

Edition 2004--12--17

Ordering no. Denomination Notes

0443 741 880 Control box A2--A6 Process Controller (PEH)

Abbreviations used in the spare parts list:C = Component designation in the circuit diagram

-- 28 --f443741r

Itemno. Qty Ordering no. Denomination Notes C

0443741880 CONTROL BOX PEH

3 1 0443638880 Control panel KB1

4 1 0443740001 Emergency stop ST1

8 2 0457278001 Rail

9 1 0443748880 Cable complete XS1

10 0443730880 Circuit board AP1 + AP2

14 1 0443849001 Insulation

20 1 0449130001 Display, ccfl backlight DY1

21 0192526003 Sealing strip 530 mm

23 10 0192645002 Bushing

26 2 0467911884 Capacitor Valid from programversion PEH1.2

41 1 0449137880 Inverter with screen box

-- 29 --f443748s

Itemno. Qty Ordering no. Denomination Notes

0443 748 880 Cable with connectors

1 1 0368 543 003 Pin socket, Burndy

4 1 0443 841 880 Cable set

6 1 0456 489 005 Circuit board connection

7 1 0456 489 004 Circuit board connection

8 1 0193 275 002 Connection block 3 pole

9 0190 209 109 Hose

10 2 0192 541 003 Pin cable clip 2,5 mm2

-- 30 --s443730r

Itemno. Qty

Ordering no.Denomination Notes C

0443 730 880 Circuit board AP1 + AP2

2 0456 489 002 Connection terminal 6 poles K10, K11

3 0456 489 001 Connection terminal 2 poles K12, K17, K22, K23

4 0456 489 004 Connection terminal 2 poles K13, K14

5 1 0486 471 880 Flash memory IC15

7 0456 489 005 Connection terminal 4 poles K9, K9X

-- 31 --f456500s


0456500880 Control cable L = 15 m, Accessories

1 1 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH)

2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p)








1 1 0449449883 Control cable 50m, 12--28p








-- 32 --f449449s


0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH)

1 1 0368541106 Pin plug, burndy 28 pol.

2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52

4 1 0368542303 Sleeve plug, burndy 12 pol.

5 5 0323945002 Contact sleeve 0,32--0,52

6 3 0323945003 Connector sleeve 0,52--1,50

7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2

8 4 0323945008 Contact pin max 2.5mm2

9 4 0323945007 Contact sleeve max 2.5mm2



2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52


5 5 0323945002 Contact sleeve 0,32--0,52




9 4 0323945007 contact sleeve max 2.5mm2



2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52


5 5 0323945002 Contact sleeve 0,32--0,52





-- 33 --f449449s




2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52


5 5 0323945002 Contact sleeve 0,32--0,52







2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52


5 5 0323945002 Contact sleeve 0,32--0,52







2 3 0323945004 Connector pin 0,52--1,50

3 5 0323945001 Connector pin 0,32--0,52


5 5 0323945002 Contact sleeve 0,32--0,52





-- 34 --f449448s


0449448880 Adapter 28--12POL(PEH--LAF12P)

1 1 0368546106 Sleeve cable socket 28--pol


3 5 0323945002 Contact sleeve 0,32--0,52

4 1 0368541303 Pin plug burndy 12 pol.

5 5 0323945001 Connector pin 0,32--0,52

6 3 0323945004 Connector pin 0,52--1,50 0,52--1,50

7 1 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2



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www.esab.com

061127

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A2-A6 PEH_644

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