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Aristo
A44
Service manual
0740 800 208 101102
SERVICE INSTRUCTIONS What is ESD?
Rights reserved to alter specifications without notice.
TOCe - 2 -
READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards are divided into numbered blocks, which are described individually in more detail in the description of operation.
This manual contains details of design changes that have been made up to and including September 2010.
ESD CAUTION !
STATIC ELECTRICITY can damage circuit boards and electronic components.
S Observe precautions for handling electrostatic sensitive devices.
S Use proper static-proof bags and boxes.
INTRODUCTION
Control panel A44 is intended for MMA-welding and TIG-welding with “Live TIG-start”. It is also intended for MIG/MAG-welding with an Arc Voltage Controlled (AVC) feeder, both with gas shielded welding and self-shielded flux cored wire welding (FCAW-S). A44 can also be used for arc-air gouging.
The control panel consists of an operator's control panel, a display board and a welding data board.
The power source, the wire feed unit and control panel, each have their own microprocessor for control. The control panel is the central unit in the system: in addition to setting and controlling welding data, it also has overall control of the entire system.
Control panel A44 Pushbuttons are used for parameter selection and the knob for parameter settings (voltage, welding current, time etc.).
More control panel information is found in chapter Instructions, see page 19.
ci25_00 - 3 -
WIRING DIAGRAM
The MMC module consists of three main units: S S S 1AP1 Welding data board - Processor and CAN communication board 1AP2 Display board - Display and encoder board 1AP3 Front panel - Front panel with pushbuttons and LEDs Wiring diagram for control panel A44 ci25_00 - 4 -
DESCRIPTION OF OPERATION
This description of operation describes the function of circuit boards and other components in the equipment. It is divided into sections, numbered to correspond to the circuit board numbers and divisions into function blocks.
Self-test
When mains power is switched on, the welding data unit runs a self diagnostic program test.
1.
The program memory of the welding data unit is checked by a check-sum test.
If the test detects a fault, fault code E1 will be logged.
2.
LED test, display test and software version indication are enabled by visual inspection.
S The LED test starts with all LEDs dark, then the diodes are turned on and off, one at a time, until all diodes have been tested. If the test detects a fault, no fault code will be logged.
S Then the display test is made in the same way as the LED test but for each segment of the digits in the display. If the test detects a fault, no fault code will be logged.
S Finally the software version of the welding data unit is displayed, in this example the version is 0.18
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1AP1 Welding data board Circuit board identity
The welding data board has a machine ID, a hardware ID, a unit type and a unit number. To read them you need the ESAT service kit, see page 18.
S S S The machine ID determines which type of control panel the board is intended for.
The hardware ID shows the design and type of circuit board.
The unit type and unit number are used for identification on the CAN bus.
The identification numbers of this board are: Machine ID Hardware ID Unit type Unit number 31 4 0 1 Note!
If more than one welding data unit is connected to the CAN bus, the welding data unit with the lowest unit number is then in command of the system. The other unit is inactive.
Example: A power source with control panel A44 (unit number = 1) is connected to a wire feeder with control panel MA44 (unit number = 0). The MA44 welding data board will then control the system.
1AP1:1 Power supply
Circuit board 1AP1 receives a 12 V power supply from the control board in the power source. This is regulated to 5 V, which supplies all the circuits of the control panel. The 12 V and 5 V supplies are monitored by a reset circuit: tolerance values are 12 V +2/-3 V and 5 V
$
0.25 V.
Monitoring the voltages makes sure that, in the event of loss of power, the processor has time to save the current data and to shut down the current processes in a controlled manner.
Loss of power supply does not generate a fault code on the display. If the 12 V supply drops below 9 V, either momentarily or indefinitely, but does not fail entirely, the display will show fault code 4. The machine must be turned off, and then on again, to reset the system.
To store data which need to be saved even if the power supply is switched off, there is a persistent flash memory area included in the processor. Data are saved in this memory when the mains power supply is turned off or lost.
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Circuit diagram for power supply and CAN bus
1AP1:2 Communication
Communication between the control panel and other units is via the system's CAN bus.
Note! The welding data board in the A44 control panel does not have a terminating resistor.
Read more about the CAN bus in the service manual for the power source.
Starting sequence
At power-up, the board's micro processor sets the bus speed for the CAN controller to 400 kbit/s.
The welding data board displays the starting sequence from power-up.
First LED1 lights red, then LED1, LED2 and LED3 lights green.
When the board has been initiated, and is running the application program, LED1 flashes continuously with a green light.
LEDs on welding data board 1AP1 ci25_01 - 7 S0740 800 208/E101102/P26
1AP1:3 LED and display control
The front panel, 1AP3, includes LEDs for visual indication. The display board, 1AP2, has a three digit LED-display (DY1). Display contrast cannot be adjusted. Both the LEDs and the display are matrix connected and multiplexed by the welding data board. They are function tested at power on.
ci25_01 Circuit diagram for LEDs and display - 8 S0740 800 208/E101102/P26
Component positions for 1AP3 front panel A44
The component positions diagram for display board 1AP2 is on page 13.
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1AP1:4 Pushbutton monitoring
The front panel includes matrix connected pushbuttons. It also includes a smart panel feature that makes the welding data board recognize the type of panel attached.
The pushbuttons and the smart panel feature are multiplexed by the welding data board.
Circuit diagram for pushbutton monitoring and control panel identification ci25_01 - 10 S0740 800 208/E101102/P26
Component positions for 1AP3 front panel A44
The component positions diagram for display board 1AP2 is on page 13.
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1AP1:5 Encoder monitoring
The panel has a pulse generator (encoder) for setting the welding current.
Turning the encoder (SW1) briefly connects pin 2 (0 V) to pins 1 and 3, but with a slight time difference between them. This generates an A pulse and a B pulse that are displaced by about 90 ° relative to each other.
One square wave pulse train is used as clock frequency and the other square wave pulse train defines the knob-turning direction by comparing the phase position (positive or negative) compared to the clock frequency.
Circuit diagram for encoder monitoring.
1AP1 Component positions
ci25_01 Component positions for the welding data board - 12 S0740 800 208/E101102/P26
1AP2 Component positions
Component positions for the display board ci25_01 - 13 S0740 800 208/E101102/P26
FAULT CODES
Fault log
All faults that occur when using the welding equipment are documented as error messages in the fault log. When the fault log is full, the oldest message will automatically erase when the next fault occurs.
Only the most recent fault message is displayed on the control panel. To read the entire fault log, the machine must be connected to the ESAT: see service tools on page 18.
Faults are monitored/detected in two ways: by test routines that are run on initiation and by functions that can detect a fault when it occurs.
Fault codes
The control panel displays a unit type to indicate which unit has generated the fault. The following unit types are used: U0 U3 = welding data unit (MMC) = wire feed unit U1 = cooling unit U4 = remote control unit U2 = power source U5 = pre reg unit (multivoltage) Fault codes are used to indicate that a fault has occurred in the equipment. They are displayed with an E followed by a code number.
A unit type number is displayed to indicate which unit has generated the fault. Fault code numbers and unit type numbers are shown alternately.
Example: Fault indication indicates that the welding data unit (U 0) has lost contact with the power source (E18).
If several faults have been detected only the code for the last occurring fault is displayed. Press any function button or turn any knob to remove the fault indication from the display.
Note!
If the remote control is activated, you must press (deactivating the remote control) to erase the fault indication.
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Fault code description
This manual describes the fault codes for the welding data unit of control panel A44. The fault codes for the other units are described in the manuals for these units.
Fault code *1 *2 4 12 14 15 Description EPROM check sum error - program memory error This indicates a fault in the check sum test of the program memory, which is run only when initiating the unit after power-up. This fault does not disable any functions.
The program memory is damaged. This is a serious fault, that can have unforeseen effects.
Action: Restart the machine. If the fault persists, load new software via ESAT. If the fault still persists, replace circuit board 1AP1.
Microprocessor RAM error The microprocessor is unable to read/write from/to a particular memory address in its internal memory. This test is performed only as part of initiation after power-up. This fault does not disable any functions.
Action: Restart the machine. If the fault persists, replace circuit board 1AP1.
5 V power supply too low The unregulated power supply voltage for the processor is too low: the smoothing capacitors cannot keep the voltage up enough for the processor to continue to operate. The processor stops all normal activities, expecting to be shut down.
Action: Turn off the mains power supply to reset the unit. If the fault persists, check the power supply to circuit board 1AP1.
Communication error (warning) The systems CAN bus is temporarily overloaded, or there is electric noise on the bus.
Action: Check the equipment to ensure that only one wire feed unit and/or remote control unit is connected.
Communication error (bus off) The system's CAN bus has temporarily ceased to work due to excessive load. The current welding process is stopped.
Action: Check the equipment to ensure that only one wire feed unit and/or remote control unit is connected. Turn off the mains power supply to reset the unit.
Lost messages The CAN bus circuit indicates that a message has been lost. No functions are disabled by this fault.
17 18 Action: Check that all units are correctly connected to the CAN bus.
Lost contact with the wire feed unit Current activities will be stopped.
This fault can be caused by a break in the connection (i.e. the CAN cable) between the wire feed unit and the control panel.
Action: Check the CAN cabling.
Lost contact with the power source Current activities will be stopped and welding start is prevented.
This fault can be caused by a break in the connection between the welding data unit in the control panel and the control unit in the power source.
Action: Check the CAN cabling.
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Fault code Description 19 Memory error in data memory Information in persistent data memory is incorrect. Basic data will be used.
*22 *23 26 Action: This fault corrects itself. Turn off the mains power supply to reset the unit. Stored data in the current memory section will be lost. If the fault recurs each time the unit is started, there is a fault in the persistent memory.
Replace the welding data board, 1AP1.
Transmitter buffer overflow The welding data unit is unable to transmit information to the other units at a sufficiently high speed.
Action: A break in the bus line can cause this fault. Check the CAN cabling. Turn off the mains power supply to reset the unit.
Receiver buffer overflow The welding data unit is unable to process information from the other units at a sufficiently high speed. This fault is caused by abnormal loading of the microprocessor in the welding data unit.
Action: Turn off the mains power supply to reset the unit.
Program operating fault Something has prevented the processor from performing its normal program duties. The program restarts automatically. The current welding process will be stopped. This fault does not disable any functions.
*28 29 40 Action: Contact ESAB if the fault occurs.
Stack overflow The program execution does not work.
This fault code is intended as an aid during development work. Contact ESAB if the fault occurs.
No cooling water flow The flow monitor has tripped.
The current welding process is stopped and starting is prevented Action: Check the cooling water circuit and the pump.
Incompatible units Incorrect wire feed unit is connected. Start is prevented Action: Connect the correct wire feed unit.
Fault codes marked with an asterisk ( * ) are page 18.
not displayed by the control panel. but they are stored in the fault log. To get access to the fault log use the ESAT service tool. See ci25f1 - 16 S0740 800 208/E101102/P26
SERVICE INSTRUCTIONS ESD CAUTION !
STATIC ELECTRICITY can damage circuit boards and electronic components.
S Observe precautions for handling electrostatic sensitive devices.
S Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to people.
ESD damage occurs when an ungrounded person or object with a static charge comes into contact with a component or assembly that is grounded. A rapid discharge can occur, causing damage. This damage can take the form of immediate failure, but it is more likely that system performance will be affected and the component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from building up on you or on anything at your work station, then there cannot be any static discharges.
Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static charge, so you should not bring unnecessary nonconductive items into the work area. It is obviously difficult to avoid all such items, so various means are used to drain off any static discharge from persons to prevent the risk of ESD damage. This is done by simple devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only antistatic packaging materials. Overall, handling of ESD-sensitive devices should be minimized to prevent damage.
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Service aid
We can offer a number of service tools that will simplify the service.
Antistatic service kit
Ordering no. 0740 511 001 The kit makes it easier to protect sensitve components from electrostatic discharge.
Contents: S S A conductive mat (size 610 x 610 mm) A 1.5 metre long ground cable with a crocodile clip S An adjustable wrist strap and cable with an inbuilt protective resistor Antistatic service kit
ESAT service kit
The software update is made from a PC, it has to be managed by a trained serviceman. For this a PC program called ESAT, ESAB Software Administration Tool, is needed. The PC is connected to the welding equipment by a cable connector and a CAN reader. From the ESAT it is possible to update the software. ESAT also contains service functions by which it is possible to control, change or read the different functions of the equipment.
For the installation and use of the ESAT you need a PC with operating system Windows.
The ESAT service kit contents: S CAN adapter with connection cables S CD with software S Instruction manual for ESAT Ordering no: 0458 847 880 0458 847 881 PPCAN for connection to the print port of the PC USB2CAN for connection to the USB port of the PC ci25f2 - 18 S0740 800 208/E101102/P26
INSTRUCTIONS
This chapter is an extract from the instruction manual for the A44 control panel.
SAFETY CAUTION!
Read and understand the instruction manual before installing or operating.
INSTALLATION Control panel A44
4 5 6 1 2 3 Display Indication of selected parameter in the display (current, voltage or percent) Pushbutton for selection of display indication during welding (current or voltage) Knob for setting the current (A) or percentage (%) Pushbuttons for selection and storage of the welding data program sets, 1--2 Pushbutton for selection of “Hot start” or “Arc force“ when MMA welding or inductance when MIG/MAG welding. Button is also used for hidden functions 7 8 9 Pushbutton for selection of welding method MMA or TIG Pushbutton for selection of electrode type “Basic“, “Rutile“ or “Cellulose“ when MMA welding Pushbutton for parameter setting from panel or from a remote control unit 10 Indication of VRD function (reduced open-circuit voltage). LED lights when VRD is active ci25i1 - 19 S0740 800 208/E101102/P26
Remote control unit
Using a remote control unit, the primary parameters of the welding process can be controlled from a device other than the control panel.
When the remote control unit is connected, everything is controlled from the remote control unit, and the knob on the control panel is out of operation.
MMA WELDING Settings
Function Current Active panel Remote control unit Hot start Arc force Drop welding 2) Welding data memory 3) Setting range 4 A - max 1 ) 0 = Off 1 = On 0 = Off 1 = On 0 - 99% 0 - 99% 0 = Off 1 = On 1 and 2 1) The setting range is dependent on the power source used.
2) Hidden function 3)
Default value 100 A On Off 0 5 0
Symbol and Function explanations MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the arc melts the electrode, and its coating forms protective slag.
Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the machine before activation. When the remote control unit is activated the panel is inactive.
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Hot Start ”Hot start” increases the welding current during a fixed period at the start of the welding process. Set the start current at a % of the set welding current using the knob. This reduces the risk of incomplete fusion at the start of the weld.
Arc force
The arc force is important in determining how the current changes in response to a change in the arc length. A lower value gives a calmer arc with less spatter.
Arc-air gouging
When arc gouging, choose the FCAW-S icon on the panel and adjust with the knob to achieve the recommended current value for the choosen carbon electrode.
Hidden function MMA welding
To access or leave the function, use the parameter selection button depressed for 5 seconds. The display shows a letter and a value. The knob is used to change the value of the function.
Function d = Drop welding Settings 0 = Off 1 = On 0 . Hold the button Default value
Drop welding
Drop welding can be used when welding with stainless electrodes. The function involves alternately striking and extinguishing the arc in order to achieve better control of the supply of heat. The electrode needs only to be raised slightly to extinguish the arc.
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MIG/MAG WELDING Settings
Function Inductance Active panel Remote control unit Welding data memory 1) 1)
Setting range 0 - 100 0 = Off 1 = On 0 = Off 1 = On 1 and 2
Symbol and Function explanations MIG/MAG and FCAW-S welding
Default value 70 On Off During MIG/MAG welding, an arc melts a continuously supplied wire. The weld pool is protected by shielding gas.
During FCAW-S a powder filled cored wire is used instead of gas to protect the weld pool.
The power source provides a Constant Voltage (CV), where the open-circuit voltage of 16.5
- 60 V DC manages to drive the Mobile wire feed units. When welding with these wire feed units, the wire feed speed is set on the wire feed unit and the voltage on the power source panel.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance pro duces a harsher sound but a stable, concentrated arc. Control of the inductance is especially important when short arc welding.
Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the machine before activation. When the remote control unit is activated the panel is inactive.
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TIG WELDING Settings
Function Current Active panel Remote control unit Min current 2) Welding data memory 3) Setting range 3 A - max 0 = Off 1 = On 0 = Off 1 = On 0 - 99% 1 and 2 1 ) 1) The setting range is dependent on the power source used.
2) Hidden function 3)
Default value 60 A On Off 30%
Symbol and Function explanations TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten electrode, which does not melt itself. The weld pool and the electrode are protected by shielding gas.
”Live TIG-start”
At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When the electrode is then lifted away from the workpiece, the arc is struck at a limited current level (12 - 15 A).
Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the machine before activation. When the remote control unit is activated the panel is inactive.
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Hidden function TIG welding
Function I = Min current Settings 0 - 99% Default value 30 To access or leave the function, use the parameter selection button depressed for 5 seconds. The display shows a letter and a value. The knob is used to change the value of the function.
Min current
. Hold the button Used to set the minimum current for the remote control T1 Foot CAN.
Examples: If the max current is 100 A and the min current is to be 50 A, set the hidden function min current to 50%.
If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.
ci25i1 - 24 S0740 800 208/E101102/P26
VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit, this is indicated by an error message (16) appearing in the display and welding cannot be started whilst the error message is displayed.
The VRD function is not active (LED is off) on delivery. To activate the VRD function use the ESAT service tool.
Note!
The VRD function works for power sources where it is implemented.
WELDING DATA MEMORY
Two different welding data programs can be stored in the A44 control panel memory.
Press button or for 5 seconds to store the welding data in the memory.
The welding data is stored when the green indicator lamp starts to flash.
To switch between the different welding data memories press button or The welding data memory has a back-up so that the settings remain even if the mains supply has been switched off.
.
SPARE PARTS
The spare parts list is published in a separate document that can be downloaded from the internet: www.esab.com
Product A44 Filename 0459 839 051 ci25i1 - 25 S0740 800 208/E101102/P26
Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218 GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186 ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44
ESAB subsidiaries and representative offices
NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03 POLAND ESAB Sp.zo.o.
Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277 SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41 SPAIN ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55 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 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 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 ESAB AB SE-695 81 LAXÅ SWEDEN Phone +46 584 81 000 www.esab.com
Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88 EGYPT ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74 RUSSIA LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280 LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060 Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.com
081016
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