ESAB A2 Instruction manual

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ESAB A2 Instruction manual | Manualzz
GB
A2, A6
PEK Control panel
Instruction manual
0460 949 174 GB 111222
Valid from program version 2.00
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1
Keys and knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 First step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1
Choice of language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2
Unit of measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1
Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 General information about settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
Setting of numerical values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2
Setting with given alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 QUIT and ENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
7
7
9
10
10
11
11
11
11
2 MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
2.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1
Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2
Tools menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.3
Weld data setting menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.4
Measurements menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.5
Weld data memory menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.6
Fast mode menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
13
14
15
16
17
3 SUBMERGED ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
3.1
Settings for submerged arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
4 GAS METAL ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
4.1
Settings for Gas Metal Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
5 GOUGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
5.1
Settings for gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
TOCe
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20
6 FUNCTION EXPLANATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
6.29
6.30
21
CA, constant amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CW, constant wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CC, constant current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire / electrode dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold wire feed speed (ICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold wire start delay (ICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Travel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flux pre-flow (SAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas pre-flow (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air pre-flow (Gouging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire creep start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max Open Circuit Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flux post-flow (SAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas post-flow (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air post-flow (Gouging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crater filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burnback time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynamic regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
21
21
21
21
22
22
22
22
22
22
22
22
23
23
23
23
24
24
24
24
24
24
25
25
25
25
25
7 MEMORY MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Control panel working method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Store . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
TOCe
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26
27
28
29
30
31
32
8 CONFIGURATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
8.1 Code lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1
Lock code status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2
Specify/edit lock code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 General configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1
Fast mode soft keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2
Quality data log to file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.3
Soft key configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.4
Auto save mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Machine configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1
Product code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2
Wire feed axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3
Cold wire axis (ICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.4
Travel axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.5
Outer axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.6
Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.7
Tandem for Aristo 1000 power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.8
Parallel power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.9
Cold wire feed (ICE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.10 Node id settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 Network settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6.1
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
35
35
35
36
36
38
38
39
40
40
41
41
42
44
46
47
48
48
49
49
50
9 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
9.1 Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.1
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2
Description of fault management codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Export/Import . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 File manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1
Delete a file/folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2
Rename a file/folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.3
Create new folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.4
Copy and paste files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Setting limit editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Measure limits editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Production statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 Quality functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7.1
Store quality data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 Calendar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9 User accounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10 Unit information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
52
52
53
54
55
55
55
55
56
57
58
59
60
60
61
62
MENU STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
WIRE DIMENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
ORDER NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
Rights reserved to alter specifications without notice.
TOCe
-4-
GB
1
INTRODUCTION
To benefit as much as possible from your welding equipment, we recommend that
you read this instruction manual.
For general information about operation, see the instruction manual for the control
unit, automatic welding machine, column and boom or power source.
The text presented in the display is available in the following languages:
English, Swedish, Finnish, Norwegian, Danish, German, French, Italian, Dutch,
Spanish, Portuguese, Hungarian, Polish, American, Czech, Chinese and Russian.
1.1
Control panel
1
Menu
2
Knob for moving cursor
(positioning knob)
3
ENTER
4
Green indicating lamp,
illuminates when the
function is active
5
Welding start
6
Welding stop
7
Knob for setting the travel speed in
the measurements menu, in other
menus to increase or decrease the set values (settings knob)
8
Manual travel motion
9
Manual wire feed downwards
10 Knob for setting the arc voltage in the measurements menu, in other menus to
increase or decrease the set values (settings knob)
11 Fast motion
12 Manual travel motion
13 Knob for setting the welding current / wire feed speed in the measurements
menu, in other menus to increase or decrease the set values (settings knob)
14 Emergency stop
-5bi24d1ea
© ESAB AB 2009
GB
15 Manual wire feed upwards
16 Soft keys
17 Display
1.1.1
Keys and knobs
Menu
The Menu key always takes you back to the main menu in the relevant process:
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
MEASURE
SAW
DC
CA
Fe SOLID
3.0 mm
MEMORY
FAST
MODE
ENTER
Use the ENTER key to confirm a selection.
Soft keys
The five keys (S1 - S5) under the display have different functions. They are called
”soft” keys, i.e. they can have different functions depending on which menu you are
in. The current function for these keys can be seen from the text in the bottom row of
the display. When the function is active, this is indicated by the field with the text box
turning white.
Wire feed upwards
Key for reversing the wire without arc voltage, when replacing wire bobbin for
example. The wire is fed as long as the button is depressed.
Wire feed downwards
Key for feeding wire without arc voltage. The wire is fed as long as the button is
depressed.
Travel motion
Key for travel motion in the direction of welding where the symbol is indicated on the
weld equipment. To stop travel motion press
,
or
.
The LED illuminates during travel motion.
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Travel motion
Key for travel motion in the direction of welding where the symbol is indicated on the
weld equipment. To stop travel motion press
,
or
.
The LED illuminates during travel motion.
Fast motion
Key for fast motion of wire feed or travel motion.
The LED illuminates during fast motion.
Welding start
Key for welding start.
Welding stop
Key for welding stop for all travel motions and all motors.
Positioning knob
The uppermost right-hand knob is called the positioning knob in the instruction
manual and is used to position the cursor.
Settings knob
The three knobs under the panel are called settings knobs in the instruction manual
and are used to change the set values in the panel.
1.2
First step
1.2.1
Choice of language
This menu appears when the machine is first started:
SAW: CA
A
V
NONE
450 Amp
30.0 Volt
50 cm/min
NONE
GAS /
FLUX
NONE
|
|
|
|
|
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2ND
FUNCT
The control panel is set to English on delivery. To select your language, proceed as
follows:
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Press Menu
to access the main menu.
SAW
Position the cursor
using the positioning
knob on the CON­
FIGURATION row.
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
Press ENTER
MEASURE
SAW
DC
CA
Fe SOLID
3.0 mm
MEMORY
FAST
MODE
to confirm the selection.
Position the cursor on
the LANGUAGE row.
Press ENTER to bring
up a list of the lan­
guages that are avail­
able in the control
panel.
CONFIGURATION
LANGUAGE
CODE LOCK
GENERAL CONFIGURATION"
MACHINE CONFIGURATION"
CABLE LENGTHS"
MAINTENANCE "
NETWORK SETTINGS"
ENGLISH
QUIT
Position the cursor on the row for your language and NORSK
press ENTER.
POLSKI
PORTUGUES
SUOMI
SVENSKA
CHINESE
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1.2.2
Unit of measurements
The control panel is set to metric measurement on delivery. To select another
mesurement, proceed as follows:
Press Menu
to access the main menu.
SAW
Position the cursor
using the positioning
knob on the CON­
FIGURATION row.
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
Press ENTER
MEASURE
SAW
DC
CA
Fe SOLID
3.0 mm
MEMORY
FAST
MODE
to confirm the selection.
Position the cursor on
the GENERAL CON­
FIGURATION row.
CONFIGURATION
LANGUAGE
CODE LOCK
GENERAL CONFIGURATION"
MACHINE CONFIGURATION"
CABLE LENGTHS"
MAINTENANCE "
NETWORK SETTINGS"
ENGLISH
QUIT
Press ENTER
to confirm the selection.
Position the cursor on
the UNIT OF LENGTH
row. Press ENTER to
bring up a list of the
mesurements that are
available in the control
panel.
GENERAL CONFIGURATION
FAST MODE SOFT BUTTONS
QUALITY DATA LOG TO FILE
SOFT KEYS SETUP"
AUTO SAVE MODE
UNIT OF LENGTH
1
ON
OFF
METRIC
QUIT
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Position the cursor on the row for correct mesurement and press
ENTER.
1.3
METRIC
INCH.
Display
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
MEASURE
SAW
DC
CW
Fe SOLID
0.8 mm
MEMORY
FAST
MODE
Cursor
The control panel's cursor is presented as a black field around the text, with the
selected text turning white. The cursor is displayed in the instruction manual with
bold text.
Text boxes
At the bottom of the display are five boxes containing text that describes the current
function of the five soft keys below the display.
1.3.1
Symbols in the display
A
The selected weld data set
B
Welding direction
C
A fault has occurred. See chapter
9.1
D
Recalled memory position number
E
Scroll bar. Further information can
be found in this menu
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Arrows
Where there is more information behind a row, this is indicated with a black arrow "
behind the text.
1.4
General information about settings
There are three types of setting:
S
Setting of numerical values
S
Setting of given alternatives
S
Setting of ON/OFF mode
1.4.1
Setting of numerical values
The settings knobs are used to increase or decrease the set values when setting
numerical values. In the measurements menu, the knobs for welding current / wire
feed speed, arc voltage or travel motion are used.
1.4.2
Setting with given alternatives
Some settings are made by selecting an option from a list.
This is an example of the list:
SAW
GMAW
GOUGING
The cursor is positioned on the row for SAW. By pressing ENTER in this position, the
SAW option is selected. If you want to choose another option instead, position the
cursor on the correct row by scrolling up or down using the positioning knob. Then
press ENTER. If you want to exit the list without making a selection, press QUIT.
1.5
QUIT and ENTER
The “soft” key farthest to the right is used primarily for QUIT, although it is
occasionally used for other functions.
S
QUIT returns you to the previous menu or image.
S
Pressing ENTER entails the execution of a selected choice in a menu or a list.
The
key is called ENTER in this manual.
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2
MENUS
The control panel uses several different menus:
S
Main menu
S
Configuration menu
S
Tools menu
S
Weld data setting menu
S
Measurements menu
S
Weld data memory menu
S Fast mode menu
The menu trees are displayed on page 63 and onwards. During start-up, a start-up
screen containing information about the current program version is displayed briefly.
Start-up screen
2.1
Main menu
In the MAIN MENU,
you can change weld­
ing process, method,
wire type, control
method, wire dimension
etc.
You can access other
sub menus from this
menu.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
MEASURE
SAW
DC
CA
Fe SOLID
0.8 mm
MEMORY
FAST
MODE
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2.1.1
Configuration menu
Main menu Configuration
In the CONFIGUR­
ATION menu it is
possible to change
language, change
password, make
General configuration,
make machine
adjustments etc.The
menu has different
appearances depend­
ing on which power
source type is selected
under Machine
configuration.
CONFIGURATION
LANGUAGE
CODE LOCK
GENERAL CONFIGURATION"
MACHINE CONFIGURATION"
CABLE LENGTHS"
MAINTENANCE "
NETWORK SETTINGS"
ENGLISH
QUIT
2.1.2
Tools menu
Main menu Tools
In the TOOLS menu
you can transfer files,
view quality and
production statistics,
error logs, etc.
TOOLS
ERROR LOG"
EXPORT / IMPORT"
FILE MANAGER"
SETTING LIMIT EDITOR"
MEASURE LIMIT EDITOR"
PRODUCTION STATISTICS"
QUALITY FUNCTIONS"
CALENDAR"
USER ACCOUNTS"
UNIT INFORMATION"
QUIT
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2.1.3
Weld data setting menu
Main menu In the weld data setting
menu, SET, it is
possible to change
different welding
parameters. The menu
has different appear­
ances depending on
which welding process
is selected.
SAW WELD DATA SETTING
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
START DATA"
STOP DATA"
DYNAMIC REGULATION
SETTING LIMITS"
MEASURE LIMITS"
20.5 V
395 A
0 cm/min
J
AUTO
QUIT
Another example of the SAW WELD DATA SETTING
menu
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
AC FREQUENCY
AC BALANCE
AC OFFSET
START DATA"
STOP DATA"
REGULATION PAR."
24,0 V
3200 A
30 cm/min
J
50 HZ
50%
0A
I
I
I
I
I
I
QUIT
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2.1.4
Measurements menu
Main menu In MEASURE, you can view measured values for various welding parameters while
welding is in progress.
A 450 AMP
Measured welding
current
30.0 Volt
Measured arc voltage
SAW: CA
A
V
50 cm/min
Measured travel speed
NONE
450 Amp
30.0 Volt
50 cm/min
NONE
GAS /
FLUX
|
|
|
|
|
|
2ND
FUNCT
NONE
300 cm/min
Measured wire feed
speed
30 kJ/cm
SAW: CA
Indicates energy per
unit length, which is
obtained using the
values selected for
welding current, arc
voltage and travel
speed
300 cm/min
30.0 kJ/cm
300 cm/min
300 cm/min
Measured cold wire
feed speed
NONE
NONE
ICE
WF
2ND
FUNCT
NONE
The measured values remain in the display even after welding has been completed.
You can move to different menus without losing the measurement values.
The settings knobs can be used to change the welding parameters in the
measurement display.
If the set value is changed when welding is not in progress, the measurement value
changes to zero.
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GB
For activating cold wire feed, a soft key, ICE WF, is activated, see chapter "Setting
soft keys” 8.2.3 . When the key is depressed, the cold wire speed is changed using
the left settings knob A. If the soft key is not depressed, the settings knob affects the
A current.
In the measurement display one can also see the set values if the soft key SET
VALUES is activated. If both soft keys, ICE WF and SET VALUES are activated, the
set feed speed for cold wire can be changed. For activating see chapter ”Setting soft
keys“ 8.2.3 .
300 cm/min
SAW: CW
Set wire feed speed
300 cm/min
V 20.0 Volt
30 cm/min
20.0 Volt
Set arc voltage
30 cm/min
Set travel speed
NONE
2.1.5
NONE
SET
VALUES
NONE
|
|
|
|
|
|
2ND
FUNCT
Weld data memory menu
Main menu WELD DATA MEMORY
In the WELD DATA
MEMORY menu you
can store, recall, delete 1 (SAW)
7 (GMAW)
and copy various set
weld data. The weld
data sets can be stored
in 255 different memory
positions.
2ND
FUNCT
STORE
QUIT
For further information, see the chapter 7 “Memory management”.
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2.1.6
Fast mode menu
Main menu In the FAST MODE
menu, you can “link”
soft keys to weld data
memory positions.
These settings are
carried out in the
Configuration menu.
The number of the
selected memory
position is displayed in
the top right corner.
16
A
V
WELD
DATA 1
450 Amp
30.0 Volt
50 cm/min
WELD
DATA 2
WELD
DATA 3
WELD
DATA 4
2ND
FUNCT
For further information, see the chapter 8.2.1 “Fast mode soft keys”.
3
SUBMERGED ARC WELDING
Main menu Process
During Submerged Arc Welding (SAW), an arc melts a continuously supplied wire.
The weld pool is protected by flux.
When the SAW process is selected, you can choose between two methods by
marking METHOD using the positioning knob and pressing ENTER. Choose
between AC or DC.
When the SAW process is selected, you can choose between three control methods
by marking REGULATION TYPE using the positioning knob and pressing ENTER.
Choose between constant welding current CA or constant wire feed CW or constant
current CC, see explanation in chapter 6.1, 6.2 and 6.3.
If cold wire feed is selected, see chapter 8.3.9, only regulation type CW can be
selected.
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3.1
Settings for submerged arc welding
Settings
Setting range
In steps of
Value after
resetting
Arc voltage1)
14 - 50 V
0.1 V (1V)
30 V
Welding
Wire feed speed1)(CW)
Constant current1) (CC)
Cold wire feed speed1)(CW)
Cold wire start delay1)(CW)
0 - 3200 A
0 - 2500 cm/min
0 - 3200 A
0 - 2500 cm/min
0 - 99,0 s
1A
1 cm/min
1A
1 cm/min
0,1 s
400 A
300 cm/min
400 A
300 cm/min
2,5 s
Travel speed*
Welding direction
AC frequency
0 - 200 cm/min
Y - J
10 - 100 Hz
1 cm/min
1
50 cm/min
J
50 Hz
AC balance
AC offset
25 - 75%
-300 - +300 A/-10 - +10V
1
1 A / 0.1 V
50%
0
Start data2)
Flux pre-flow
Start type
0 - 99.0 s
Direct or Scrape
0.1 s
-
0s
Direct
Wire creep start
Wire creep start speed
Auto or Set speed
0 - 1000 cm/min
1 cm/min
Auto
20 cm/min
Start phases
Open-circuit voltage
Maximum open-circuit voltage
OFF or ON
OFF or ON
5 - 60 V
0.1 V
OFF
OFF
50 V
0 - 99.0 s
OFF or ON
0.1 s
-
0s
OFF
0 - 10 s
0 - 10 s
OFF or ON
0.01 s
0.01 s
-
1s
1s
OFF
Control parameters
Dynamics
Inductance
Auto or Set values
Auto or Set values
-
Auto
Auto
Setting limits
Measure limits
-
-
-
current1)(CA)
Stop data 2)
Flux post-flow
Crater filling
Crater filling time
Burnback time
Stop phases
1)
2)
The setting range is dependent on the product used.
The menu shows the settings that belong to the selected regulation type.
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4
GAS METAL ARC WELDING
The process is available for certain machine types.
Main menu Process
During Gas Metal Arc Welding (GMAW), an arc melts a continuously supplied wire.
The weld pool is protected by shielding gas.
When the Gas Metal Arc Welding (GMAW) process is selected, you can choose
between two control methods by marking REGULATION TYPE using the positioning
knob and pressing ENTER. Choose between constant amperage CA or constant
wire feed CW, see explanation in chapter 6.1 and 6.2.
4.1
Settings for Gas Metal Arc Welding
Settings
Setting range
In steps of
Value after
resetting
Arc voltage*
Welding current* (CA)
Wire feed speed* (CW)
14 - 50 V
0 - 3200 A
0 - 2500 cm/min
0.1 V (1V)
1A
1 cm/min
30 V
400 A
300 cm/min
Travel speed*
Welding direction
0 - 200 cm/min
Y - J
1 cm/min
-
50 cm/min
J
Start data
Gas pre-flow
Start type
0 - 99.0 s
Direct or Scrape
0.1 s
-
2.0 s
Direct
Auto or Set speed
0 - 1000 cm/min
OFF or ON
1 cm/min
-
Auto
20 cm/min
OFF
OFF or ON
5 - 60 V
0.1 V
OFF
50 V
Gas post-flow
Crater filling
0 - 99.0 s
OFF or ON
0.1 s
-
2.0 s
OFF
Crater filling time
Burnback time
Stop phases
0 - 10 s
0 - 10 s
OFF or ON
0.01 s
0.01 s
-
1s
1s
OFF
Auto or Set value
-
-
Auto
-
Wire creep start
Wire creep start speed
Start phases
Open-circuit voltage
Maximum open-circuit voltage
Stop data
Dynamic regulation
Setting limits
Measure limits
*) The setting range is dependent on the product used.
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5
GOUGING
The process is available for certain machine types.
Main menu Process
With arc air gouging, a special electrode comprising a carbon rod with a copper
casing is used.
An arc is formed between the carbon rod and the work piece, which melts the
material. Air is supplied so that the melted material is blown away.
When the GOUGING process is selected, you can choose between two control
methods by marking REGULATION TYPE using the positioning knob and pressing
ENTER. Choose between constant amperage CA or constant wire feed CW, see
explanation in chapter 6.1 and 6.2.
5.1
Settings for gouging
Settings
Setting range
In steps of
Value after
resetting
Arc voltage*
Welding current* (CA)
Wire feed speed* (CW)
Travel speed*
Welding direction
Start data
Air pre-flow
Start type
Wire creep start
Wire creep start speed
Start phases
Open-circuit voltage
Maximum open-circuit voltage
Stop data
Air post-flow
Crater filling
Crater filling time
Burnback time
Stop phases
Dynamic regulation
Setting limits
Measure limits
14 - 50 V
0 - 3200 A
0 - 2500 cm/min
0 - 200 cm/min
Y - J
0.1 V (1V)
1A
1 cm/min
1 cm/min
-
30 V
400 A
300 cm/min
40 cm/min
J
0 - 99.0 s
Direct or Scrape
Auto or Set speed
0 - 1000 cm/min
OFF or ON
OFF or ON
5 - 60 V
0.1 s
1 cm/min
0.1 V
0s
Direct
Auto
20 cm/min
OFF
OFF
50 V
0 - 99.0 s
OFF or ON
0 - 10 s
0 - 10 s
OFF or ON
Auto or Set value
-
0.1 s
0.01 s
0.01 s
-
0s
OFF
1s
1s
OFF
Auto
-
*) The setting range is dependent on the product used.
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6
FUNCTION EXPLANATIONS
6.1
CA, constant amperage
The wire feed is controlled by the power source so that a constant amperage can be
achieved.
- Constant current value can be selected in the main menu.
6.2
CW, constant wire feed
The welding current is a result of the selected wire feed speed.
- Constant wire feed can be selected in the main menu.
6.3
CC, constant current
The voltage is varied so that a constant welding current can be achieved.
-Constant current value can be selected in the main menu.
A higher wire speed gives a higher welding current.
6.4
Wire / electrode dimension
The table on page 68 shows the wire / electrode dimensions that can be selected.
Selected dimensions have a great impact on the start procedure and crater filling.
When welding with other wire dimensions other than those found in the table, select
one that has a dimension close to one in the list.
- Wire / electrode dimension can be selected in the main menu.
6.5
Arc voltage
Higher arc voltage increases the arc length and produces a hotter, wider weld pool.
- The arc voltage is set in the measurement display, weld data setting menu, or fast
mode menu.
6.6
Wire feed speed
This sets the required feed speed of the filler wire in cm/minute. A higher wire speed
gives a higher welding current.
- The wire feed speed is set in the measurement display, weld data setting menu, or
fast mode menu.
6.7
Cold wire feed speed (ICE)
Cold wire feed speed is used to set a feed speed (cm/min) for the cold wire.
- The cold wire feed speed is set in the measurement display, weld data setting
menu, or fast mode menu.
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6.8
Cold wire start delay (ICE)
Cold wire start delay is used to indicate how long (s) after welding start cold wire
feed can start.
- Cold wire start delay is set in the weld data setting menu.
6.9
Travel speed
Travel speed indicates the required speed (cm/min) at which a column and boom or
trolley is to move.
- The travel speed is set in the measurement display, weld data setting menu, or fast
mode menu.
6.10
Welding direction
Travel motion in the direction that the symbol indicates.
- Welding direction is selected in the weld data setting menu.
6.11
AC frequency
AC frequency refers to the number of oscillations per second through the zero level.
- AC frequency is selected in the weld data setting menu.
6.12
AC balance
AC balance is the relationship between positive (+) and negative (-) pulses. The
value that is set indicates the percentage size of the period that is the positive
section.
- AC balance is selected in the weld data setting menu.
6.13
AC offset
With AC offset the AC level is offset positively or negatively in relation to the zero
level.
- AC offset is selected in the weld data setting menu.
6.14
Flux pre-flow (SAW)
This controls the time during which flux flows before the arc is struck.
- Flux pre-flow is set in the weld data setting menu under start data.
6.15
Gas pre-flow (GMAW)
This controls the time during which shielding gas flows before the arc is struck.
- Gas pre-flow is set in the weld data setting menu under start data.
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6.16
Air pre-flow (Gouging)
This controls the time during which air flows before the arc is struck.
- Air pre-flow is set in the weld data setting menu under start data.
6.17
Start type
There are two options for start type:
S
Direct start, means that the travel speed starts when the arc is struck.
S Scrape start, means that the travel speed starts at the same time as wire feed.
- Start type is selected in the weld data setting menu under start data.
6.18
Wire creep start
Wire creep start is used to set the desired creep speed on the electrode motor upon
start-up.
If, for example, 50 is set in the menu a creep speed of 50 cm/min is obtained.
Preset value ”AUTO” gives a creep speed calculated from the set values.
- Wire creep speed is set in the weld data setting menu under start data.
6.19
Start phases
When welding special wire or material, it may be necessary to create your own start
sequence. The start sequence can affect the appearance of the weld pool.
The following can be set for Start
phase1 ON
The following can be set for Start
phase2 ON
S
S
Time s
Time for welding in phase 1.
S
Arc voltage %
Time for welding in phase 2.
S
In percent of set voltage
S
Wire feed %
Welding current %
S
Travel speed %
Wire feed %
In percent of set wire feed
S
In percent of set welding current
S
Arc voltage %
In percent of set voltage
In percent of set wire feed
S
Time s
Welding current %
In percent of set welding current
S
In percent of set travel speed
Travel speed %
In percent of set travel speed
- Start phases are set in the weld data setting menu under start data.
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6.20
Max Open Circuit Voltage (OCV)
ON means that OCV can be set.
OFF means that OCV is set to the set value for welding voltage.
- OCV is set in the weld data setting menu under start data.
6.21
Flux post-flow (SAW)
This controls the time during which flux flows after the arc is extinguished.
- Flux post-flow is set in the weld data setting menu under stop data.
6.22
Gas post-flow (GMAW)
This controls the time during which shielding gas flows after the arc is extinguished.
- Gas post-flow is set in the weld data setting menu under stop data.
6.23
Air post-flow (Gouging)
This controls the time during which air flows after the arc is extinguished.
- Air post-flow is set in the weld data setting menu under stop data.
6.24
Crater filling
Crater filling makes a controlled reduction in the heat and size of the weld pool
possible when completing the weld. This makes it easier to avoid pores, thermal
cracking and crater formation in the weld joint.
- Crate filling is set in the weld data setting menu under stop data.
6.25
Burnback time
Burnback time is a delay between the time when the wire starts to brake until the
time when the power source switches off the arc voltage. Too short burnback time
results in a long wire stickout after completion of welding, with a risk of the wire being
caught in the solidifying weld pool. Too long a burnback time results in a shorter
stickout, with increased risk of the arc striking back to the contact tip.
- Burnback time is set in the weld data setting menu under stop data.
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6.26
Stop phases
Stop phases are mainly used for setting crater filling.
The following can be set for Stop
phase1 ON
The following can be set for Stop
phase2 ON
S
S
Time s
Time for welding in phase 1.
S
Arc voltage %
Time for welding in phase 2.
S
In percent of set voltage
S
Wire feed %
Welding current %
S
Travel speed %
Wire feed %
In percent of set wire feed
S
In percent of set welding current
S
Arc voltage %
In percent of set voltage
In percent of set wire feed
S
Time s
Welding current %
In percent of set welding current
S
In percent of set travel speed
Travel speed %
In percent of set travel speed
- Stop phases are set in the weld data setting menu under stop data.
6.27
Dynamic regulation
The dynamic regulation function is developed for multiple electrode welding and
alters the characteristics of the power source. The characteristics of the power
source are calculated from the set wire data.
- Dynamic regulation is selected in the weld data setting menu.
6.28
Control parameters
In some applications the function Control parameters is displayed instead of
Dynamic control. There are two settings to make under Control parameters:
S
Dynamics - Affects the dynamic characteristics
S
Inductance - Higher values give a wider weld pool and less spatter. Lower values
produce a stable, concentrated arc and a harsher sound.
- Control parameters are selected in the weld data setting menu.
6.29
Setting limits
For information about setting limits see chapter 9.4 ”Setting limit editor”
6.30
Measure limits
For information about measurement parameters see chapter 9.5 ”Measure limits
editor”
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7
MEMORY MANAGEMENT
7.1
Control panel working method
The control panel can be said to comprise two units: working memory and weld data
memory.
Store
Working memory
Weld data memory
Recall
In the working memory, a complete set of weld data settings is created that can be
stored in the weld data memory.
During welding, it is always the content of the working memory that controls the
process. It is therefore also possible to recall a weld data set from the weld data
memory to the working memory.
Note that the working memory always contains the most recently set weld data
settings. They can be recalled from the weld data memory or individually altered
settings. In other words, the working memory is never empty or “zeroed”.
Main menu MEMORY Weld data memory
WELD DATA MEMORY
2ND
FUNCT
STORE
QUIT
It is possible to store up to 255 sets of weld data in the control panel. Each set is
given a number from 1 to 255.
You can also delete, copy, change and name data sets and recall a set of weld data
to the working memory.
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7.2
Store
If the weld data memory is empty, the following screen appears in the display.
WELD DATA MEMORY
Storing a set of weld
data. This will be given
memory position 5.
Press STORE. Position
1 is displayed. Turn
one of the settings
knobs until you reach
position 5. Press
STORE.
2ND
FUNCT
STORE
QUIT
The following screen appears in the display.
The weld data set is
now stored as number
5.
WELD DATA MEMORY
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
STORE
RECALL
DELETE
2ND
FUNCT
QUIT
Parts of the content of weld data set number 5 are presented at the bottom of the
display.
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If a data set is already
stored in the selected
location, you will be
asked if you want to
overwrite that set or
not, YES or NO.
WELD DATA MEMORY
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
NO
YES
Return to the memory menu using NO.
7.3
Recall
We are going to recall a WELD DATA MEMORY
stored data set:
5 - (SAW)
Mark the row using the
positioning knob. Press
RECALL.
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
STORE
Press YES to confirm
that you want to recall
data set number 5.
RECALL
DELETE
2ND
FUNCT
QUIT
WELD DATA MEMORY
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
NO
YES
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This icon in the measurement display shows
which memory position number has been
recalled.
7.4
Delete
It is possible to delete one or more data sets in the memory menu.
Deleting a data set.
WELD DATA MEMORY
Select the data set.
Press DELETE.
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
STORE
RECALL
DELETE
2ND
FUNCT
QUIT
WELD DATA MEMORY
Press YES to confirm
that you want to delete.
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
NO
YES
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7.5
Copy
To copy the content of a weld data set to a new memory position, proceed as
follows:
Press 2ND FUNCT.
WELD DATA MEMORY
5 - (SAW)
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
STORE
RECALL
DELETE
2ND
FUNCT
QUIT
Select the memory pos­ WELD DATA MEMORY
ition you want to copy
5 - (SAW)
and press COPY.
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
COPY
RENAME
EDIT
2ND
FUNCT
QUIT
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We are now going to copy the content of memory position 5 to position 50.
Select memory position WELD DATA MEMORY
1 and scroll through us­
1ing one of the settings
5 - (SAW)
knobs to the selected
memory position; in this
case, position 50.Press
YES.
COPY
DATA SET 5 TO POSITION: 50
NO
YES
Weld data number 5 has now been copied to memory position 50.
7.6
Name
To give a stored weld data set its own name, proceed as follows:
WELD DATA MEMORY
Press 2ND FUNCT.
Select the memory pos­
5 - (SAW)
ition you want to re­
50 name and press
RENAME.
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
COPY
RENAME
EDIT
2ND
FUNCT
QUIT
Here you have access to a keyboard that is used as follows:
S
Position the cursor on the desired
keyboard character using the arrows
and the positioning knob. Press
DONE. Enter a complete text string
with a maximum of 40 characters in
this way.
S
Press DONE to store. The alternative
you have named can now be seen in
the list.
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7.7
Edit
To edit the content of a weld data set, proceed as follows:
WELD DATA MEMORY
Press 2ND FUNCT.
Select the memory pos­
5 - (SAW)
ition you want to edit
and then press EDIT.
SAW: CA: FE SOLID: 3.0 mm
30.0 V: 450 A: 50 cm/min
COPY
EDIT
2ND
FUNCT
Part of the main menu is displayed and the menu shows the symbol
means that you are in an editing mode.
SAW
Press SET and make
the relevant changes. 7
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
SET
QUIT
which
CA
SS FLUX CORED
2.0 mm
QUIT
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The following menu appears:
In this example we
change the welding
current from 400 A to
500 A.
Select the welding
current and scroll
through to 500 using
one of the settings
knobs.
Press QUIT twice.
SAW WELD DATA SETTING
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
START DATA"
STOP DATA"
DYNAMIC REGULATION
SETTING LIMITS"
MEASURE LIMITS"
20.0 V
500 A
0 cm/min
J
AUTO
QUIT
The setting for weld data number 5 has now been edited and stored.
8
CONFIGURATION MENU
Main menu Configuration menu
This menu contains the following sub-menus:
S
Language, see chapter 1.2.1 “Choice of language”
S
Code lock, see chapter 8.1
S
General configuration, see chapter 8.2
S
Machine configuration, see chapter 8.3
S
Cable length, see chapter 8.4
S
Maintenance, see chapter 8.5
S
Network settings, see chapter 8.6
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8.1
Code lock
Main menu Configuration menu Code lock
When the lock function is activated and you are in the measure screen or fast mode
menu, a password (lock code) is required to exit from these menus.
CODE LOCK
LOCK STATUS
SET / CHANGE LOCK CODE
OFF
QUIT
Code lock is activated in the configuration menu.
8.1.1
Lock code status
In lock code status, you can activate/deactivate the lock function without deleting the
existing lock code in the event you deactivate the function. If no lock code is stored
and you try to activate the code lock, the keyboard is displayed for entering a new
lock code.
To exit lock status.
When you are in the measure screen or the fast mode menu and the code lock is
deactivated, you can exit these menus without restrictions by press QUIT or MENU
in order to go to the main menu.
If it is activated and you try to exit, the following screen appears in order to warn the
user about the lock protection.
PRESS ENTER FOR
LOCK CODE...
PRESS ENTER FOR LOCK CODE...
Here you can select QUIT to undo and return to the previous menu, or proceed by
pressing ENTER to enter the lock code.
You will then move to the menu with the keyboard, where you can enter the code.
Press ENTER after each character, and confirm the code by pressing ENTER again.
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The following text box appears:
UNIT UNLOCKED!
UNIT UNLOCKED!
If the code is not correct, an error message is displayed that offers the option of
trying again or returning to the original menu, i.e. the measure screen or the fast
mode menu.
If the code is correct, all blocks to other menus will be removed, although the code
lock remains activated. This means that you can leave the measure screen and the
fast mode menu temporarily, yet still retain the lock status when you return to these
menus.
8.1.2
Specify/edit lock code
In specify/edit lock code, you can edit an existing lock code or enter a new one. A
lock code can comprise a maximum of 16 optional letters or figures.
8.2
General configuration
Main menu Configuration menu General configuration
In this menu you can set:
S
Fast mode soft keys, see chapter 8.2.1
S
Quality data log to file, see chapter 8.2.2
S
Setting soft keys, see chapter 8.2.3
S
Automatic weld data storage, see chapter 8.2.4
S
Unit of length, see chapter 1.2.2 “unit of measurement”
8.2.1
Fast mode soft keys
The soft keys WELD DATA 1 up to and including WELD DATA 4 are displayed in the
fast mode menu.
SAW: CA
A
V
WELD
DATA 1
16
450 Amp
30.0 Volt
50 cm/min
WELD
DATA 2
WELD
DATA 3
WELD
DATA 4
2ND
FUNCT
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These are configured as follows:
Position the cursor on
the row for SOFT KEY
NUMBER.
FAST MODE SOFT KEYS
SOFT KEY NUMBER
ASSOCIATED WELD DATA
1
5
SAW: CA: FE SOLID: 0.8 mm
20.0 V: 500 A: 0 cm/min
STORE
DELETE
QUIT
The keys are numbered 1-4 from left to right. Select the desired key by giving its
number using the setting knobs.
Then scroll to the next row, ASSOCIATED WELD DATA. Here you can browse
through the weld data sets that are stored in the weld data memory. Selected the
desired weld data number using the setting knobs. Press STORE to save. To delete
the stored set, press DELETE.
8.2.2
Quality data log to file
In the QUALITY DATA
LOG TO FILE menu it
is possible to activate it
with ON.
GENERAL CONFIGURATION
FAST MODE SOFT BUTTONS
QUALITY DATA LOG TO FILE
SOFT KEYS SETUP"
AUTO SAVE MODE
UNIT OF LENGTH
1
ON
OFF
METRIC
QUIT
Read more about settings for the quality function in chapter 9.7.
8.2.3
Soft key configuration
We have previously described the control panel's “soft” keys. For Submerged Arc
Welding (SAW) and for Gas Metal Arc Welding (GMAW) welding, the user has the
possibility of setting the function of these keys by selecting from a list of set options.
There are eight soft keys that can be allocated a function.
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It is possible to choose between the following options:
S
S
S
None
Gas / Flux
Set values
Set reference values are displayed instead of the measured values in the
measurements menu.
S
S
S
Relay 2
Sets relay output no.2 on the motor circuit board, which can be used for any
function by the customer.
Direction
Remote I/O
S
Used when you want to control PEK and a welding power source via an external
I/O unit.
External axis
To be activated when there is an external I/O unit for controlling a roller bed, for
example.
S
Tandem
Used when welding with two welding heads.
S
Cold wire (ICE)
Used when a non-live wire is fed into the weld pool and the cold wire speed is to
be shown in the display.
In the display screen
there are two columns;
one for SOFT KEYS
and one for FUNC­
TION.
SOFT KEYS SETUP
SOFT KEYS
FUNCTION
S1
S2
S3
S4
S1 2ND FUNCT
S2 2ND FUNCT
S3 2ND FUNCT
S4 2ND FUNCT
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
QUIT
When you allocate functions to these keys, they are numbered from the left as
follows:
S1
S2
S3
S4
S1 2ND
FUNCT
S2 2ND
FUNCT
S3 2ND
FUNCT
S4 2ND
FUNCT
2ND
FUNCT
2ND
FUNCT
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To allocate a new function to a soft key, proceed as follows:
Position the cursor on
the row with the soft
key number you wish to
use and press ENTER.
A pop-up menu shows
the function selections.
Select using the posi­
tioning knob and press
ENTER.
SOFT KEYS SETUP
SOFT KEYS
FUNCTION
S1
S2
S3
S4
S1 2ND FUNCT
S2 2ND FUNCT
S3 2ND FUNCT
S4 2ND FUNCT
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
QUIT
You can allocate new functions to the other keys in the same way, by pairing a key
number in the left-hand column with a function in the right-hand column.
8.2.4
Auto save mode
When a weld data set has been recalled from a memory position in the weld data
memory and you change the settings, the changes will be saved in the working
memory at welding stop in the last recalled memory position.
Saving weld data manually in a memory position disables the next automatic save.
The memory position in which the weld data set is stored is displayed in the top right
corner of the measure screen.
8.3
Machine configuration
Main menu Configuration menu Machine configuration
In this menu you can set:
S
Product code, see chapter 8.3.1
S
Wire feed axis, see chapter 8.3.2
S
Cold wire feed axis, see chapter 8.3.3
S
Travel axis, see chapter 8.3.4
S
Outer axis, see chapter 8.3.5
S
Tandem, see chapter 8.3.6 and 8.3.7
S
Parallel power sources, see chapter 8.3.8
S
Cold wire feed, see chapter 8.3.9
S
NODE ID settings, see chapter 8.3.10
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8.3.1
Product code
In the PRODUCT
CODE menu it is poss­
ible to select the auto­
matic welding machine,
column and boom,
roller bed or positioner
to be used.
MACHINE CONFIGURATION
PRODUCT CODE
WIRE FEED AXIS"
TRAVEL AXIS"
TANDEM
A2TFX
OFF
QUIT
When selecting product code, the correct motor type and gear ratio for the used
gearbox in the relevant product are selected automatically.
The following options can be selected:
S
A2TFJ1
A2 tractor automatic welding machine for Submerged Arc Welding (SAW)
S
A2TGJ1
A2 tractor automatic welding machine for Gas-Shielded Metal Arc Welding
(GMAW)
S
A6TFF1
A6 tractor automatic welding machine for Submerged Arc Welding (SAW)
S
FREE 2 AXIS
Optional configuration for connecting 2 motors to the actuator board. One for
wire feed and one for travel motion.
S
FREE 3 AXIS
Optional configuration for connecting external roller beds, positioners or linear
axis as well as for 2 motors to the actuator board. One for wire feed and one for
travel motion.
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8.3.2
Wire feed axis
The wire feed motor is set automatically according to the tables below.
A2TFJ1
A2TGJ1
A6TFF1
Motor
5035 38 RPM
5035 68 RPM
VEC4000
Gear 1
49:1
49:1
156:1
Gear 2
1:1
1:1
1:1
Diameter feed rollers
49 mm
49 mm
49 mm
Pulse sensor
28 ppr
28 ppr
32 ppr
Low manual speed
150 cm/min
150 cm/min
150 cm/min
High manual speed
300 cm/min
300 cm/min
300 cm/min
FREE 2 AXIS
FREE 3 AXIS
Motor
VEC 4000
VEC 4000
Gear 1
156:1
156:1
Gear 2
1:1
1:1
Diameter feed rollers
49 mm
49 mm
Pulse sensor
32 ppr
32 ppr
Low manual speed
150 cm/min
150 cm/min
High manual speed
300 cm/min
300 cm/min
8.3.3
Cold wire axis (ICE)
FREE 2 AXIS
FREE 3 AXIS
Motor
VEC 4000
VEC 4000
Gear 1
156:1
156:1
Gear 2
1:1
1:1
Diameter feed rollers
49 mm
49 mm
Pulse sensor
32 ppr
32 ppr
Low manual speed
150 cm/min
150 cm/min
High manual speed
300 cm/min
300 cm/min
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8.3.4
Travel axis
The travel motor is set automatically according to the tables below.
A2TFJ1
A2TGJ1
A6TFF1
Motor
4030-350
4030-350
FHP258
Gear 1
375:10
375:10
24:1
Gear 2
51:1
51:1
51:1
Wheel diameter
158 mm
158 mm
180 mm
Pulse sensor
60 ppr
60 ppr
28 ppr
High manual speed
200 cm/min
200 cm/min
200 cm/min
FREE 2 AXIS
FREE 3 AXIS
Motor
VEC 4000
VEC 4000
Gear 1
312:1
312:1
Gear 2
1:1
1:1
Wheel diameter
65 mm
65 mm
Pulse sensor
32 ppr
32 ppr
High manual speed
200 cm/min
200 cm/min
8.3.5
Outer axis
When connecting an external roller bed, positioner or linear axis, FREE 3 AXIS must
be selected.
When FREE 3 AXIS is selected, the motor is automatically set according to the
tables below.
Roller bed
Linear
Positioner
Gear 1
560:1
560:1
560:1
Gear 2
111:22
111:22
111:22
Gear 3
1:1
1:1
1:1
Wheel diameter
160 mm
160 mm
160 mm
Pulse sensor
30 ppr
30 ppr
30 ppr
High manual speed
200 cm/min
200 cm/min
200 cm/min
Frequency ratio
85:50
85:50
85:50
Motor
2000 rpm
2000 rpm
2000 rpm
Weld diameter
1000 mm
-
1000 mm
Roller diameter
1000 mm
-
-
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8.3.6
Tandem
Used when welding with two welding heads.
Position the cursor on
the TANDEM row and
press ENTER.
Select ON using the
positioning knob and
press ENTER.
MACHINE CONFIGURATION
PRODUCT CODE
WIRE FEED AXIS"
TRAVEL AXIS"
TANDEM
b WELDING HEAD
b WELD HEAD OFFSET
b WITH I/O
A2TFX
ON
HEAD
20 mm
ON
QUIT
In order to weld with two welding heads, the WELD HEAD OFFSET function must be
set.
WELD HEAD OFFSET is the distance in millimetres between the welding heads.
When you specify the distance between welding head 1 HEAD and welding head 2
TAIL, the value is recalculated by the control unit to a time between when welding
head 1 starts and welding head 2 is to start.
The time that the control unit can calculate for the distance between the starting and
stopping of the welding power sources is a maximum of 65 seconds. This means
that if, for example, 50 cm/min is specified, 2000 mm can be entered as the
maximum WELD HEAD OFFSET. This is so that time does not expire before welding
head 2 reaches the start point.
TAIL
HEAD
WELD HEAD OFFSET
NOTE!
Ensure that both control units have the same settings for WELD HEAD OFFSET and
specify the same travel speed. The ”Master” control unit must be allocated HEAD
and the ”Slave” control unit TAIL. Travel motion is always controlled from ”Master”.
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Specify the values to weld with two welding heads as follows:
Position the cursor on
the WELDING HEAD
row.
Select whether the set­
ting is to apply to
”master” control unit
HEAD or ”slave” control
unit TAIL.
MACHINE CONFIGURATION
PRODUCT CODE
WIRE FEED AXIS"
TRAVEL AXIS"
TANDEM
b WELDING HEAD
b WELD HEAD OFFSET
b WITH I/O
A2TFX
ON
HEAD
20 mm
ON
QUIT
S
Position the cursor on the WELD HEAD OFFSET row and specify the distance
between the two welding heads.
Example, I/O ON
Welding head2, (slave)
Welding head1, (master)
TAIL
HEAD
WELD HEAD OFFSET
Example , I/O ON
S
Press
S
S
Welding head1 starts to weld.
Welding head2 only starts welding when the start position for welding head1 has
been reached (the distance given in WELD HEAD OFFSET.
S
Press
S
S
Welding head1 stops welding but continues travelling.
Welding head2 stops welding once it reaches the point where equipment1
stopped welding (the distance given in WELD HEAD OFFSET.
Welding is complete.
S
Start, for welding head1.
Stop, for welding head1.
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Example, I/O OFF
Welding head2, (slave)
Welding head1, (master)
TAIL
HEAD
WELD HEAD OFFSET
S
Press
S
Welding head1 starts to weld.
S
Welding head2 starts to weld first when the start position for welding head1 has
been reached (the distance given WELD HEAD OFFSET).
S
Press
S
Welding head1 stops welding but travel motion continues.
S
Welding head2 stops welding when it has reached the point where equipment1
stopped welding (the distance that is given in WELD HEAD OFFSET).
S
Welding is complete.
8.3.7
Start, for welding head1 and welding head2 at the same time.
stop, for welding head1 and welding head2 at the same time.
Tandem for Aristo 1000 power source
Used when welding with two or more welding heads. The welding heads are each
controlled by their own control unit (PEK).
Position the cursor on
the TANDEM row and
press ENTER.
Select ON using the
positioning knob and
press ENTER.
The front welding head
is selected.
TANDEM
TANDEM
b WELDING HEAD
b TRAVEL CONTROL
b SYNCRONIZED WELD START
b SYNCRONIZED AC WELDING
TANDEM INFORMATION"
ON
HEAD
ON
ON
ON
QUIT
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The rear welding head
is selected.
TANDEM
TANDEM
b WELDING HEAD
b TRAVEL CONTROL
b SYNCRONIZED WELD START
b WELD HEAD OFFSET
b SYNCRONIZED AC WELDING
b PHASE SHIFT
ON
TAIL
ON
ON
20 mm
ON
0
QUIT
WELDING HEAD
Select whether the welding head is to be the front (HEAD) or rear (TAIL).
TRAVEL CONTROL
Select whether the welding head is control the travel. Both the front and rear welding
heads can control the travel, but only one at a time.
SYNCRONIZED WELD START
If ON is selected it means that one only need start the control unit for the front
welding head. The rear one is started automatically. If OFF is selected all the
welding heads must be started using the relevant control unit.
SYNCRONIZED AC WELDING
Synchronized AC welding means that the frequency and balance, the AC pulses, are
synchronized to the same values for all welding heads in the tandem system.
TANDEM INFORMATION
The control unit for the front welding head displays information about what power
sources are in the system such as the rear welding head.
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WELD HEAD OFFSET
WELD HEAD OFFSET is the distance in millimetres between the welding heads.
This setting is only significant if a synchronised welding start is selected.
TAIL
HEAD
WELD HEAD OFFSET
PHASE SHIFT
Phase shift means a phase offset in relation to the front welding head. The unit is
degrees.
8.3.8
Parallel power sources
If one has a parallel
connected source, the
node ids are set here.
Position the cursor on
the SLAVE NODE ID
and select one of the
setting knobs.
MACHINE CONFIGURATION
PRODUCT CODE
WIRE FEED AXIS"
TRAVEL AXIS"
TANDEM"
PARALLEL POWER SOURCES
b SLAVE NODE ID
COLD WIRE FEED
NODE ID SETTINGS"
A2TFX
ON
10
OFF
QUIT
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8.3.9
Cold wire feed (ICE)
The option ICE WIRE
FEED (ON) can be se­
lected in the machine
configuration menu.
If cold wire feed (ICE)
is selected, the option
ICE wire feed axis ap­
pears.
MACHINE CONFIGURATION
PRODUCT CODE
WIRE FEED AXIS"
ICE WIRE FEED AXIS"
TRAVEL AXIS"
TANDEM
ICE WIRE FEED
NODE ID SETTINGS"
FREE 2 AXIS
OFF
ON
QUIT
The cold wire feed axis
settings must be
identical to the wire
feed axis.
ICE WIRE FEED AXIS
MOTOR
GEAR 1"
bN1
bN2
GEAR 2"
bN1
bN2
FEED ROLLER DIAM
ENCODER PULSES
LOW MANUAL SPEED
5035 38RPM
ON
156
1
ON
1
1
49 mm
32 ppr
150 cm/min
QUIT
S
Motor is selected from a dropdown list with the following options:
5035 38RPM
5035 68RPM
FHP 258
VEC8000
VEC4000
DUNKER1
DUNKER2
MET3B
VEC4000Par
4030-350
S
S
S
S
GEAR 1 must be set to ON. The value cannot be OFF.
GEAR 2 must normally be set to ON, but OFF can be selected.
The values N1 and N2 under Gear 1 and 2 are set with one of the three settings
knobs at the bottom of the panel. The interval for N1 and N2 depend on selected
motor.
The diameter of the feed rollers (FEED ROLLER DIAM) is selected with any
settings knob. The interval depends on selected motor.
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S
The encoder for pulses (ENCODER-PULSES) is selected with any settings knob.
The interval is between 1 - 9998 ppr (ppr = pulses per revolution).
S
LOW MANUAL SPEED is selected with any of the settings knobs. The interval is
1 - 1000 cm/min.
S
HIGH MANUAL SPEED is selected with any of the settings knobs. The interval is
1 - 5000 cm/min.
8.3.10 Node id settings
If there are I/O nodes in the system the ID numbers are given here.
During tandem operation the value for CAN 2 ID could be different for all control
units (PEK) in the system. It is suitable to set welding head 1 to CAN 2 ID = 1,
welding head 2 to CAN 2 ID = 2 and so on.
NODE ID SETTINGS
POWER SOURCE CAN 2 ID
I/O NODE 1 ID
I/O NODE 2 ID
1
17
25
QUIT
8.4
Cable length
The arc voltage is affected by the impedance in the welding cables. The impedance
is affected by the length and area of the cables as well as by how they are routed.
This is especially prominent during AC welding.
Compensation for the voltage drop with long cables is maintained if the actual cable
length is specified.
The total cable length (weld cable and connector together) must be fed in.
Note! When using two cables, the areas must be combined for both cables.
This function is active during the start process before the power source has received
a measurement value that it can regulate at.
If ”Max OCV” has been selected this function is inactive.
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8.5
Maintenance
Main menu Configuration menu Maintenance
In this menu you set how often the contact tip is to be changed. Specify the number
of weld starts after which the tip is to be changed by selecting the CONTACT TIP
CHANGE INTERVAL row and pressing ENTER. Change the value using the setting
knobs. When the interval has been passed, fault code 54 is displayed in the error
log.
When TOTAL RUNNING TIME LIMIT is selected instead of the number of starts, an
authorised ESAB service technician is contacted.
MAINTENANCE
CONTACT TIP CHANGE INTERVAL
b WELD COUNT
TOTAL RUNNING TIME LIMIT
b TOTAL RUNNING TIME
0 Welds
0 Welds
0d00:00:00
0d00:00:00
QUIT
8.6
Network settings
Main menu Configuration menu Network settings
This menu enables you to connect to an administrative tool on a local network.
For more information on the administrative tool, see the instruction manual for
WELDPOINT. The manual can be downloaded from www.esab.com.
NETWORK SETTINGS
DHCP
IP ADDRESS
SUBNET MASK
DEFAULT GATEWAY
HOSTNAME
ON
172.20.125.74
0.0.0.0.
0.0.0.0.
ESAB_W82
QUIT
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8.6.1
System overview
1
Welding power source
4
Administrative tool, Weldpoint
2
Wire feed unit / Automatic welder
5
Network connection
3
Weld data unit, PEK
6
USB memory
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9
TOOLS
Main menu Tools
This menu contains the following sub-menus:
S
Error log, see chapter 9.1
S
Export/Import, see chapter 9.2
S
File manager, see chapter 9.3
S
Edit setting limits, see chapter 9.4
S
Edit measure limits, see chapter 9.5
S
Production statistics, see chapter 9.6
S
Quality functions, see chapter 9.7
S
Calendar, see chapter 9.8
S
User accounts, see chapter 9.9
S
Unit information, see chapter 9.10
9.1
Error log
Main menu Tools Error log
Fault management codes are used to indicate that a fault has occurred in the
welding process. Indicated in the display via a pop-up menu and an exclamation
mark
appears in the upper right-hand corner of the display.
Note!
disappears from the display as soon as you enter the error log menu.
All errors that arise during the use of the welding equipment are documented as
error messages in the error log. Up to 99 error messages can be saved. If the error
log becomes full, i.e. if 99 error messages have been saved, the oldest message is
automatically deleted when the next fault occurs.
The following information can be read in the error log menu:
S
The error number of the error
S
The day on which the error occurred
S
The time at which the error occurred
S
The unit in which the error has occurred
S
The error's error management code
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ERROR LOG
Index
Date
Time
Unit
Error
1
2
3
081120
081120
081121
11:24:13
10:24:18
13:24:18
8
8
8
19
18
17
Error in battery-driven memory
DELETE
ALL
9.1.1
QUIT
Units
2
= Power source
6
= Wire feed and travel motion (motor board)
8
= control panel
9.1.2 Description of fault management codes
The fault management codes that users can correct themselves are given below. If
another code appears, restart the machine and if the error persists, contact a service
technician.
Error
code
Description
6
High temperature
The power source has overheated and cancels welding. Welding is permitted again when
the temperature falls below the maximum temperature parameter.
Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt.
Check the duty cycle being used, to make sure that the equipment is not being overloaded.
If the error persists, send for a service technician.
7
Low welding current
The weld arc has been shut down due to too low welding current during the welding
process.
Action:Is reset at next weld start. If the error persists, send for a service technician.
8
Low battery voltage
Battery voltage too low. If the battery is not replaced, all stored data will be lost.
This error does not disable any functions.
Action: Send for a service technician to replace the battery.
11
Speed error on a motor, (wire feed, travel motor)
A motor cannot maintain its speed. Welding stops.
Action: Check that the wire feed has not jammed or runs too fast. If the error persists,
send for a service technician.
12
Internal communication error (warning)
The load on the system's CAN-bus is temporarily too high.
The power source may have lost contact with the control unit.
Action: Check that all the equipment is correctly connected. If the error persists, send for
a service technician.
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Error
code
14
17
32
43
44
9.2
Description
Communication error
The system's CAN-bus has temporarily stopped working due to the load being too high.
The current welding process stops.
Action: Check that all the equipment is correctly connected. Turn off the mains power
supply to reset the unit. If the error persists, send for a service technician.
Lost contact with the unit
Lost contact with a unit.
Action: Check wiring and the connector between the control unit and power source. If the
error persists, send for a service technician.
No gas flow
Start prevented.
Action: Check the gas valve, hoses and connectors.
High welding current
Power source have switched off the welding process because the current has exceeded
the maximum current parameter for the power source.
Action: Is reset at next weld start. If the error persists, send for a service technician.
Start pause welding current
The welding process has stopped because it has not advanced within 10 seconds.
Action: Is reset at next weld start. If the error persists, send for a service technician.
Export/Import
Main menu Tools Export / Import
In the Export/Import menu, it is possible to transfer information to and from the
control panel via a USB memory.
The following information can be transferred:
S Weld data sets
Export/Import
S System setting
Export / Import
S Setting limits
Export / Import
S Measure limits
Export / Import
S Error log
Export
S Quality function log
Export
S Production statistics
Export
Carry out the following to save on a USB memory:
Insert the USB memory into the control unit.
Select the row with the
information that is to be
transferred. Press
EXPORT or IMPORT,
depending on whether
the information is to be
exported or imported.
EXPORT/IMPORT
WELD DATA SETS
SYSTEM SETTINGS
SETTING LIMITS
MEASURE LIMITS
ERROR LOG
QUALITY FUNCTION LOG
PRODUCTION STATISTICS
EXPORT
IMPORT
QUIT
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9.3
File manager
Main menu Tools File manager
In the file manager it is possible to manage information on a USB memory (C:\). File
manager makes it possible to delete and copy weld data and quality data manually.
When the USB memory is connected, the display shows the memory's default folder
if one is not previously selected.
The control panel remembers where you were the last time you used file manager,
so that you return to the same place in the file structure when you come back.
FILE MANAGER
..
NEW FOLDER
QData.xml
INFO
S
S
S
UPDATE
ALT.
QUIT
In order to ascertain how much storage space remains for the memory, use the
INFO function.
Update the information by pressing UPDATE.
When you want to delete, change name, create new folder, copy or paste, press
ALT. A list then appears from which you can choose. If (..) or a folder is selected,
you can only create a new folder or paste in a file that you have previously
copied. If you have selected a file, the options RENAME, COPY or PASTE will
be added if you have previously copied a file.
Select a folder or file
and press ALT.
FILE MANAGER
..
WeldData
NEW FOLDER
ErrorLog.xml
QData.xml
XWeldoffice.dat
INFO
UPDATE
This list is displayed when you have pressed ALT.
ALT.
QUIT
COPY
PASTE
DELETE
RENAME
NEW FOLDER
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9.3.1 Delete a file/folder
Select the file or folder that is to be deleted and press ALT.
DELETE
RENAME
NEW FOLDER
Select DELETE and press ENTER.
The file/folder is now removed. In order to delete a folder it must be empty, i.e. first
delete the files contained in the folder.
9.3.2 Rename a file/folder
Select the file or folder that is to be renamed and press ALT.
DELETE
RENAME
NEW FOLDER
Select RENAME and press ENTER.
A keyboard appears in the display. Use the positioning knob to change row and the
arrows to move left and right. Select the character/function that is to be used and
press ENTER.
9.3.3 Create new folder
Select where the new folder is to be located and press ALT.
Select NEW FOLDER and press ENTER.
DELETE
RENAME
NEW FOLDER
A keyboard then appears in the display. Use the positioning knob to change row and
the arrows to move left and right. Select the character/function that is to be used and
press ENTER.
9.3.4 Copy and paste files
Select the file that is to be copied and press ALT.
COPY
PASTE
DELETE
RENAME
NEW FOLDER
Select COPY and press ENTER.
Position the cursor in the folder in which the copied file is to be located and press
ALT.
COPY
PASTE
DELETE
RENAME
NEW FOLDER
Select PASTE and press ENTER.
The copy is saved as Copy of plus the original name, e.g. Copy of WeldData.awd.
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9.4
Setting limit editor
Main menu Tools Setting limit editor
In this menu you set your own max. and min. values for various welding methods.
The limits cannot be above or below the values for which the power source is
dimensioned. There are 50 storage points. Select the row for an empty storage point
and press ENTER. Select process by pressing ENTER and select the welding
process using the positioning knob and press ENTER.
The maximum and minimum values for arc voltage, wire feed speed, travel speed
and welding current can be selected for all processes.
EDIT LIMITS
PROCESS
VOLTAGE
VOLTAGE
WIRE SPEED
WIRE SPEED
TRAVEL SPEED
TRAVEL SPEED
CURRENT
CURRENT
SAW
MIN 17.0
MAX 47.0
MIN 50
MAX 970
MIN 100
MAX 2400
MIN 70
MAX 1500
STORE
DELETE
QUIT
When the values have been adjusted, press STORE. When asked if the limit value is
to be saved at the selected storage point, press NO or YES. The storage point's
values can be seen under the line at the bottom.
With the AUTO soft key, the parameters are set automatically according to the most
recently used parameters.
When asked if the limit settings are to be set automatically, press NO or YES and
then STORE if the setting is to be retained.
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9.5
Measure limits editor
Main menu Tools Measure limits editor
In this menu you set your own measurement values for the various welding methods.
There are 50 storage points. Select the row for an empty storage point and press
ENTER. Select process by pressing ENTER and select the welding process using
the positioning knob and press ENTER.
The following values can be selected:
S arc voltage: min, max
S wire feed speed: min, max
S welding current: min, max
S travel speed: min, max
S energy per unit length: min, max
Set the desired value using the setting knobs and press STORE.
In the dialogue box, you are asked if you want to store the selected storage point.
Press YES to save the value. The storage point's values can be seen under the line
at the bottom.
MEASURE LIMITS
1 - SAW
2 - GMAW
345670.0 - 46.9 Volt , 0 - 2495 cm/min
3 - 994 cm/min , 3 - 990 Amp
5 - 500 kJ/min
QUIT
With the AUTO soft key, the parameters are set automatically according to the most
recently used measurement values.
When asked if the measurement values are to be set automatically, press NO or
YES and then STORE if the setting is to be retained.
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9.6
Production statistics
Main menu Tools Production statistics
The production statistics will keep track of the total arc time, the total amount of
material and the number of welds since the most recent reset. They will also keep
track of the arc time and the amount of material used in the most recent weld. For
information purposes, the melted wire material per length unit that has been
calculated and when the most recent reset occurred are also displayed.
PRODUCTION STATISTICS
LAST WELD
ARCTIME
CONSUMED WIRE
BASED ON
NUMBER OF WELDS
LAST RESET
RESET
0s
0g
1g/m
0s
0g
0
081114
UPDATE
TOTAL
08:38:03
QUIT
When you press RESET, all counters are reset. Date and time show the most recent
reset.
If you do not reset the counters, these are all automatically reset when one of them
has reached its maximum value.
Maximum counter values
Time
Weight
Quantity
999 hours, 59 minutes, 59 seconds
13350000 grams
65535
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9.7
Quality functions
Main menu Tools Quality functions
Quality functions keep track of various interesting weld data for individual welds.
These functions are:
S Time of welding start.
S Duration of welding.
S Maximum, minimum and average current during welding.
S Maximum, minimum and average voltage during welding.
S Maximum, minimum and average energy per unit length during welding.
The number of welds since the most recent reset is displayed in the row at the
bottom. Information can be stored about a maximum of 100 welds. In the event of
more than 100 welds, the first one is overwritten.
The most recently noted weld is presented in the display, although it is also possible
to browse between other noted welds. All logs are deleted when you press RESET.
QUALITY FUNCTIONS
#WELD: 1 / 4
START 20090107 15:59:14
WELD TIME 00:00:20 WELD DATA:
HEAT INPUT: 3.12 kJ/mm
MAX
MIN
I (Amp)
293.00
243.00
U (V)
41.50
16.20
Q (kJ/min)
7.00
0.00
NUMBER OF WELDS SINCE RESET: 4
RESET
UPDATE
AVE.
289.00
39.40
2.00
QUIT
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9.7.1
Store quality data
Main menu Tools Export / Import
The files that are produced in the control panel are stored as xml files. The USB
memory must be formatted as FAT32 in order to work.
Insert a USB memory in the control panel, see chapter 9.3 “File manager”.
EXPORT/IMPORT
Select QUALITY
FUNCTION LOG, press
WELD DATA SETS
EXPORT.
SYSTEM SETTINGS
SETTING LIMITS
MEASURE LIMITS
ERROR LOG
QUALITY FUNCTION LOG
PRODUCTION STATISTICS
EXPORT
QUIT
The entire set of quality data (information about the 100 most recent welds) that is
stored in the control panel is now saved on the USB memory.
The file is in a folder called QData. QData is created automatically when you insert a
USB memory.
9.8
Calendar
Main menu ! Tools ! Calendar
Date and time are set here.
Select the row that is to
be set: year, month,
day, hour, minutes and
seconds. Set the
correct value using one
of the setting knobs.
Press SET.
DATE & TIME
YEAR
MONTH
DAY
HOUR
MINUTES
SECONDS
2008
NOV
21
10
45
55
20100115
10:48:59
SET
QUIT
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9.9
User accounts
Main menu ! Tools ! User accounts
Occasionally it is particularly important from a quality perspective that the product
cannot be used by unauthorised parties.
User name, account level and password are registered in this menu.
Select USER NAME
and press ENTER.
Step down to an empty
row and press ENTER.
Key in a new user
name on the keyboard
using the positioning
knob and the arrows
and ENTER.
USER ACCOUNTS
USER NAME
b ACCOUNT LEVEL
b PASSWORD
USER ACCOUNTS
STORE
DELETE
ADMINISTRATOR
ADMIN
OFF
QUIT
There is space for 16 user accounts. In the quality data files it will be evident which
users have executed a particular weld.
Under ACCOUNT LEVEL choose from:
S
Administrator
full access (can add new users)
S Senior user
can access everything except:
S machine configuration
S user accounts
S network settings
S Normal user
can access:
S In the Configuration menu:
S Maintenance
S In the Tools menu:
S Unit information
S In the Settings menu:
S Voltage
S Current / wire feed
S Travel speed
S Welding direction
In the PASSWORD row, key in a password using the keyboard. When the power
source is switched on and the control panel activated, you are asked in the display to
enter your password.
If you choose not to have this function, but instead want the power source and
control panel to be unlocked for all users, select USER ACCOUNTS OFF.
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9.10
Unit information
Main menu ! Tools ! Unit information
I this menu you can see the following information:
S
Machin ID
S
Node ID
2 = power source
6 = wire feed and travel motion (motor board)
8 = control panel
S
Software version
UNIT INFORMATION
Machine ID
Node ID
44
23
5
Software Version
8
2
6
1.00A
2.00A
1.18A
SETTING WELD DATA UNIT
QUIT
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PEK Control panel
Menu structure
NO TAG63
SAW
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION "
TOOLS "
SET
MEASURE
SAW
DC
CA
FE SOLID
0.8 MM
MEMORY
FAST
MODE
SET
Voltage
Welding current1) (CA)
Wire feed speed1) (CW)
Constant current1) (CC)
Ice wire feed speed1) (CW)
Ice wire start delay1) (CW)
Travel speed1)
Direction
AC frequency
AC balance
AC offset
Start data2)
- flux pre-flow
- start type
- wire creep start
- wire creep start speed
- start phases
- OCV
- max OCV
Stop data2)
- flux post-flow
- crater filling
- crater filling time
- burnback time
- stop phases
Regulation parameters
- dynamics
- inductance
Setting limits
Measure limits
1) The setting range is dependent on the product used.
2) The menu shows the settings that belong to the selected regulation type.
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PEK Control panel
GMAW
GMAW
PROCESS
REGULATION TYPE
WIRE TYPE
WIRE DIMENTION
CONFIGURATION "
TOOLS "
SET
MEASURE
GMAW
CA
FE SOLID
0.8 MM
MEMORY
FAST
MODE
SET
Arc voltage*
Welding current* (CA)
Wire feed speed* (CW)
Travel speed*
Direction
Start data
- gas pre-flow
- start type
- wire creep start
- wire creep start speed
- start phases
- OCV
- max OCV
Stop data
- gas post-flow
- crater filling
- crater filling time
- burnback time
- stop phases
Dynamic regulation
Setting limits
Measure limits
* The setting range is dependent on the product used.
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PEK Control panel
GOUGING
GOUGING
PROCESS
REGULATION TYPE
ELECTRODE DIMENSION
CONFIGURATION "
TOOLS "
SET
MEASURE
GOUGING
CA
8.0 MM
MEMORY
FAST
MODE
SET
Arc voltage*
Welding current* (CA)
Wire feed speed* (CW)
Travel speed*
Direction
Start data
- air pre-flow
- start type
- wire creep start
- wire creep start speed
- start phases
- OCV
- max OCV
Stop data
- air post-flow
- crater filling
- crater filling time
- burnback time
- stop phases
Dynamic regulation
Setting limits
Measure limits
* The setting range is dependent on the product used.
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PEK Control panel
CONFIGURATION
CONFIGURATION
LANGUAGE
CODE LOCK
GENERAL CONFIGURATION
MACHINE CONFIGURATION
MAINTENANCE
ENGLISH
QUIT
Configuration
Language
Code lock
General configuration
- fast mode soft buttons
- quality data log to file
- soft keys setup
- auto save mode
- unit of length
Machine configuration
- product code
- wire feed axis
- ice wire feed axis
- travel axis
- parallel power sources
- ice wire feed
- node ID settings
Maintenance
- contact tip change interval
- total running time limit
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PEK Control panel
TOOLS
TOOLS
ERROR LOG
EXPORT / IMPORT"
QUALITY FUNCTIONS"
CALENDAR"
USER ACCOUNTS"
UNIT INFORMATION"
QUIT
Tools
Error log
Export/import
-weld data sets
-system settings
-setting limits
-measure limits
-error log
-quality function log
-production statistics
Quality functions
Calendar
User accounts
Unit information
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Edition 111222
Wire dimension
Submerged arc welding with constant ampere (SAW CA)
Wire type
Wire diameter (mm)
Fe Solid
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0
Fe Solid Twin
2x0.8 2x1.0 2x1.2 2x1.6 2x2.0 2x2.4 2x3.0 2x4.0 2x5.0
Fe Flux Cored
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0
Fe Flux Cored Twin
2x0.8 2x1.0 2x1.2 2x1.6 2x2.0 2x2.4 2x3.0 2x4.0
SS Solid
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0
SS Solid Twin
2x0.8 2x1.0 2x1.2 2x1.6 2x2.0 2x2.4 2x3.0 2x3.2 2x4.0
SS Strip
30 x 0.5 60 x 0.5 90 x 0.5
SS Flux Cored
0.8 1.0 1.2 1.6 2.0 2.4 3.0 3.2 4.0 5.0 6.0
SS Flux Cored Twin
2x0.8 2x1.0 2x1.2 2x1.6 2x2.0 2x2.4 2x3.0 2x3.2 2x4.0
MIG/MAG welding with constant ampere (GMAW CA)
Wire type
Wire diameter (mm)
Fe Solid
0.8 1.0 1.2 1.6 2.0 2.4
Fe Flux Cored
0.8 1.0 1.2 1.6 2.0 2.4
SS Solid
0.8 1.0 1.2 1.6 2.0 2.4
SS Flux Cored
0.8 1.0 1.2 1.6 2.0 2.4
Al Solid
0.8 1.0 1.2 1.6 2.0 2.4
Al Flux Cored
0.8 1.0 1.2 1.6 2.0 2.4
Gouging with constant ampere (CA)
Electrode dimension (mm)
8.0 9.5 13.0
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© ESAB AB 2009
PEK Control panel
Order number
Ordering no.
Denomination
0460 504 880 Control unit PEK
0460 949 170
0460 949 171
0460 949 172
0460 949 173
0460 949 174
0460 949 175
0460 949 176
0460 949 177
0460 949 178
0460 949 179
0460 949 180
0460 949 181
0460 949 182
0460 949 183
0460 949 184
0460 949 185
0460 949 186
0460 949 189
0460 949 190
0460 949 191
0460 949 192
0460 949 193
Instruction manual SE
Instruction manual DK
Instruction manual NO
Instruction manual FI
Instruction manual GB
Instruction manual DE
Instruction manual FR
Instruction manual NL
Instruction manual ES
Instruction manual IT
Instruction manual PT
Instruction manual GR
Instruction manual PL
Instruction manual HU
Instruction manual CZ
Instruction manual SK
Instruction manual RU
Instruction manual EE
Instruction manual LV
Instruction manual SI
Instruction manual LT
Instruction manual CN
Instruction manuals are available on the Internet at www.esab.com
- 69 bi24o
© ESAB AB 2009
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
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
BULGARIA
ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
ROMANIA
ESAB Romania Trading SRL
Bucharest
Tel: +40 316 900 600
Fax: +40 316 900 601
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
RUSSIA
LLC ESAB
Moscow
Tel: +7 (495) 663 20 08
Fax: +7 (495) 663 20 09
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
UKRAINE
ESAB Ukraine LLC
Kiev
Tel: +38 (044) 501 23 24
Fax: +38 (044) 575 21 88
ITALY
ESAB Saldatura S.p.A.
Bareggio (Mi)
Tel: +39 02 97 96 8.1
Fax: +39 02 97 96 87 01
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
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
Africa
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
SOUTH AFRICA
ESAB Africa Welding & Cutting Ltd
Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
AUSTRALIA
ESAB South Pacific
Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
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 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
www.esab.com
© ESAB AB
110915

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