ESAB | MA23 | Instruction manual | ESAB MA23 User manual

ESAB MA23 User manual
US
Origo™
MA23
MA24
Instruction manual
0460 454 087 US 090818
Valid from program version 1.05
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
3
Control panel MA23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel MA24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
2 MIG/MAG WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2.1
2.2
2.3
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and function explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden MIG/MAG functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
8
3 MMA WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
3.1
3.2
3.3
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol and Function explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hidden MMA functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
11
4 WELDING DATA MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
5.1
5.2
List of fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault code descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
6 ORDERING SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRE AND GAS DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
15
Rights reserved to alter specifications without notice.
TOCa
-2-
US
1
INTRODUCTION
The manual describes use of MA23 and MA24 control panels.
For general information about operation see user's instructions for the power source
respectively wire feed unit.
When mains power is supplied the unit runs a self diagnosis of the
LEDs and the display, the program version is displayed and in this
example the program version is 0.17A
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
1.1
Control panel MA23
Setting voltage
Setting the wire feed speed,
current, (ampere, m/minute or
percent)
Display
Choice of welding method
MIG/MAG
or MMA
Choice of 2-stroke
Setting from panel
or 4-stroke
, program change with welding gun trigger switch
or connecting remote control unit
Display of VRD function (reduced open-circuit voltage) is active or inactive.
Note! The VRD function works for power sources where it is implemented.
Gas flushing
Wire inching
Indication of which parameter is shown in the display. Volts, amperes, m/min, or
percent.
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Setting the inductance
Buttons for weld data memory. See page 12.
1.2
Control panel MA24
Setting voltage / QSet
Setting the wire feed speed,
current, (ampere, m/minute
percent or seconds)
Display
Choice of welding method
MIG/MAG
or MMA
Choice of QSet
Selection of creep start
, manual setting
or synergy
or crater filling
Choice of 2-stroke
or 4-stroke
Setting from panel
, program change with welding gun trigger switch
or connecting remote control unit
Display of VRD function (reduced open-circuit voltage) is active or inactive.
Note! The VRD function works for power sources where it is implemented.
Gas flushing
Wire inching
Indication of which parameter is shown in the display. Volts, synergy, QSet,
amperes, m/min, seconds or percent.
Setting the inductance
or crater filling time
synergy selection
Buttons for weld data memory. See page 12.
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2
MIG/MAG WELDING
2.1
Settings
Functions
Setting range
Voltage
8 - 60 V
x
x
Wire feed speed
31.6 - 986.3 inch/min
x
x
Synergy
OFF or ON
-
x
Synergic lines
15 pcs
-
x
QSet
OFF or ON
-
x
Manual setting
OFF or ON
-
x
Creep start
OFF or ON
-
x
Creep start 1)
0=OFF or 1=ON
x
-
Crater filling
OFF or ON
-
x
Crater filling time
0-5s
-
x
2 stroke or 4 stroke
x
x
Active panel
OFF or ON
x
x
Changing trigger data
OFF or ON
x
x
Remote control unit
OFF or ON
x
x
-
x
x
Wire inching
-
x
x
Inductance
0 - 100
x
x
Welding data memory
1, 2, 3
x
x
Gas pre flow time 1)
0.1 - 9.9 s
x
x
Unit of measurement 1)
0 = inch, 1 = mm
x
x
Burnback time 1)
50 - 250 ms
x
x
0.1 - 9.9 s
x
x
2/4-stroke
2)
Gas flushing
2)
Gas post flow time
1)
MA23
1)
These functions are hidden functions, see description point 2.3.
2)
These functions cannot be changed while welding is in progress
2.2
MA24
Symbol and function explanation
MIG/MAG welding
MIG/MAG welding melts a continuously supplied filler wire, with the weld pool being
protected by shielding gas.
Wire feed speed
This sets the required feed speed of the filler wire in inches per minute.
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Synergy
Each combination of wire type, wire diameter and gas mixture requires a unique
relationship between wire feed speed and voltage (arc length) to obtain a stable
functioning arc. The voltage (arc length) automatically conforms in accordance with
the pre-programmed synergic line you selected, which makes it much easier to find
the correct welding parameters. The connection between the wire feed speed and
the other parameters is called the synergic line. See the different synergic lines on
page 14.
It is also possible to order other synergy lines, but these must be installed by an
authorised ESAB service engineer.
When activating synergy
also select synergy option
using the setting
knob.
QSett
QSet , is used to facilitate setting welding parameters.
Turning the knob clockwise increases (+) the arc length.
Turning the knob anti-clockwise reduces (-) the arc length.
SHORT ARC
When first starting welding with a wire type / gas type QSetautomatically sets all
the necessary welding parameters. After that QSetstores all the data to produce
a good weld. The voltage then automatically conforms to changes in the wire feed
speed.
SPRAY ARC
When approaching the spray arc area the value for QSet must be increased.
Disengage the QSet function when welding with pure spray arc, All settings are
inherited from QSet, with the exception of the voltage which must be set.
Recommendation: Make the first weld (6 seconds) with QSet on a test piece to
obtain all the correct data.
Manual
Manual operation. The operator must set appropriate values for the wire feed and
voltage.
Slow run in
Slow run in starting feeds out the wire at 50% of the set speed until it makes
electrical contact with the workpiece.
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Crater filling
Crater filling time
Crater filling helps to avoid pores, thermal cracking and crater formation in the weld
when welding stops.
When activating crater filling
also select crater filling time
using the
setting knob.
This function cannot be used with QSet.
2-stroke
With 2-stroke gas pre-flow (if used) starts when the welding gun trigger switch is
pressed. The welding process then starts. Releasing the trigger switch stops weld­
ing entirely and starts gas post-flow (if selected).
4-stroke
With 4 stroke, the gas pre-flow starts when the welding gun trigger switch is
pressed in and the wire feed starts when it is released. The welding process
continues until the switch is pressed in again, the wire feed then stops and when
the switch is released the gas post-flow starts (if selected).
Active panel
Settings are made from the control panel.
Changing welding data
This function permits changing between different welding data memories by a press
on the trigger of the welding gun.
To change without ongoing welding press quickly. If the trigger is held depressed for
too long, the program interprets this as a welding start.
Changing welding data during welding with 2-stroke
During ongoing welding the welding gun's trigger is depressed, to change welding
data memory, release the trigger and depress it quickly.
Changing welding data during welding with 4-stroke
During ongoing welding with 4-stroke the welding gun's trigger is released, to change
welding data memory, depress the trigger and release it quickly.
When activating welding data
select welding data memory
or
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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.
With the remote control unit function activated one can change between different
welding data memories using a welding gun with program selector (RS3).
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.
Note! The VRD function works for power sources where it is implemented.
Gas purging
Gas purging is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas purging occurs for as long as the
button is held depressed and occurs without voltage or wire feed starting.
Wire inching
Wire inching is used when one needs to feed wire without welding voltage being
applied. The wire is fed as long as the button is depressed.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance
produces a harsher sound but a stable, concentrated arc.
2.3
Hidden MIG/MAG functions
There are hidden functions in the control panel.
depressed for 5 seconds. The
To access these hidden functions hold the button
display will show a letter and a value. The knob for wire feed is used to change the
value of the selected function.
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MA23
Function letter
Function
A
Gas pre-flow
I
Burnback time
L
Gas post-flow
J
Creep start
MA24
Function letter
Function
A
Gas pre-flow
C
Unit of measurement
I
Burnback time
L
Gas post-flow
To leave the function hold the button
depressed for 5 seconds.
Gas pre-flow
This controls the time during which shielding gas flows before the arc is struck.
Unit of measurement
0 = inch, 1 = mm, Default value = 1
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 welding 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.
Gas post-flow
This controls the time during which shielding gas flows after the arc is extinguished.
Slow run in
Slow run in starting feeds out the wire at 50% of the set speed until it makes
electrical contact with the workpiece.
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3
MMA WELDING
3.1
Settings
Functions
Setting range
Current
16- max A
Active panel
MA23
2)
MA24
x
x
OFF or ON
x
x
Remote control unit
OFF or ON
x
x
Arc force 1)
0 - 99
x
x
Drop welding 1)
0=OFF or 1=ON
x
x
0 - 99
x
x
1=ArcPlus II or 0=ArcPlus
x
x
Hotstart
1)
Weld regulator
1)
1)
These functions are hidden functions, see description point 3.3.
2)
The setting range is dependent on the power source.
3.2
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.
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.
Note! The VRD function works for power sources where it is implemented.
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3.3
Hidden MMA functions
There are hidden functions in the control panel.
To access these hidden functions hold the button
depressed for 5 seconds. The
display will show a letter and a value. The knob for voltage is used to change the
value of the selected function.
MA23 and MA24
Function letter
Function
C
Arc Force
d
Drop welding
H
Hotstart
F
Regulator type
To leave the function hold the button
depressed for 5 seconds.
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.
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.
Hot start
Hot start increases the weld current for an adjustable time at the start of welding,
thus reducing the risk of poor fusion at the beginning of the joint.
Welding regulator
Welding regulator is a type of control that produces a more intense, more
concentrated and calmer arc. It recovers more quickly after a spot short-circuit,
which reduces the risk of the electrode becoming stuck.
ArcPlus (0) is recommended with basic type of electrode
ArcPlusll (1) is recommended with rutile and cellulosic type of electrode
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4
WELDING DATA MEMORY
Three different welding data programs can be stored in the control panel memory.
Hold button
,
or
pressed in for 5 seconds to store 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 battery so that the settings remain even if
the machine has been switched off.
5
FAULT CODES
Fault codes are used to indicate that a fault has occurred in the
equipment. They are given in the lower part of the display with an E
followed by a fault code number.
A unit number is displayed to indicate which unit has generated the
fault.
Fault code numbers and unit numbers are shown alternately.
Fault indication indicates that the control panel (U 0) has lost
contact with the power source.
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, deactivate the remote control by pressing
to remove the fault indication.
5.1
List of fault codes
U 0 = welding data unit
U 2 = power source
U 1 = cooling unit
U 4 = remote control unit
5.2
Fault code descriptions
The fault codes that the user can correct themselves are given below. If a different
code appears, call a service technician.
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Fault
code
E6
Description
High temperature
The thermal overload cut-out has tripped.
The current welding process is stopped and cannot be restarted until the temperature has
fallen.
E 12
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.
Communication error (warning)
The load on the system's CAN-bus is temporarily too high.
The power unit / wire feed unit has lost contact with the control panel.
E 17
Action: Check the equipment and ensure that only one wire feed unit or remote control
unit is installed. If the fault persists, send for a service technician.
Lost contact
The control panel has lost contact with the wire feed unit.
The current welding process stops.
E 18
Action: Check the cables. If the fault persists, send for a service technician.
Lost contact
The control panel has lost contact with the power source.
The current welding process stops.
E 27
Action: Check the cables. If the fault persists, send for a service technician.
Out of wire
The wire feed unit is not feeding out any wire. The current welding process will be stopped
and prevents welding start.
E 29
Action: Load a new wire.
No cooling water flow
The flow monitor switch has tripped.
The current welding process is stopped and starting is prevented.
E 32
Action: Check the cooling water circuit and the pump.
No gas flow
The gas flow is less than 6 l/min. Start prevented.
E 40
Action: Check the gas valve, hoses and connectors.
Incompatible units
Incorrect wire feed unit is connected. Start is prevented
E 41
Action: Connect the correct wire feed unit.
Lost contact with the cooling unit
The control panel has lost contact with the cooling unit. Switch off the power source!
Action: Check the wiring. If the fault persists, send for a service technician.
6
ORDERING SPARE PARTS
When ordering replacement parts, order by part number and part name, as
illustrated on the figure. Always provide the series or serial number on the unit on
which the parts will be used. The serial number is stamped on the rating plate.
- 13 bi21d1aa
Wire and gas dimensions
Syn no
Material
ESAB designation
Wire diameter
(inch)
Shielding gas
1
Fe
OK AristoRod 12.50
.040
82% Ar+18%CO2
2
Fe
OK AristoRod 12.50
.045
82% Ar+18%CO2
3
Al 4043
OK Autrod 4043
.045
100% Ar
4
Al 4043
OK Autrod 4043
1/16
100% Ar
5
Al 5356
OK Autrod 5356
.045
100% Ar
6
Al 5356
OK Autrod 5356
1/16
100% Ar
7
SS
OK Autrod
.040
98% Ar+2%CO2
8
SS
OK Autrod
.045
98% Ar+2%CO2
9
Fe RCW
OK Tubrod
.045
82% Ar+18%CO2
10
Fe RCW
OK Tubrod
.052
82% Ar+18%CO2
11
Fe RCW
OK Tubrod
1/16
82% Ar+18%CO2
12
Fe BCW
OK Tubrod
.045
82% Ar+18%CO2
13
Fe MCW
OK Tubrod
.045
82% Ar+18%CO2
14
Fe MCW
OK Tubrod
.052
82% Ar+18%CO2
15
Fe MCW
OK Tubrod
1/16
82% Ar+18%CO2
- 14 bi21syna
MA23, MA24
Ordering number
Ordering no.
Denomination
0459 773 889 Origo MA23
0459 773 886 Origo MA24
0460 454 070
0460 454 071
0460 454 072
0460 454 073
0460 454 074
0460 454 075
0460 454 076
0460 454 077
0460 454 078
0460 454 079
0460 454 080
0460 454 081
0460 454 082
0460 454 083
0460 454 084
0460 454 085
0460 454 086
0460 454 087
0460 454 089
0460 454 090
0460 454 091
0460 454 092
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 US
Instruction manual EE
Instruction manual LV
Instruction manual SL
Instruction manual LT
0459 839 024 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
- 15 bi21o
Edition 090818
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A
B
C
CUSTOMER SERVICE QUESTIONS:
Telephone: (800) 362-7080 / Fax: (800) 634-7548
Order Entry Product Availability
Pricing
Order Information
ENGINEERING SERVICE:
Telephone: (834) 664-4416 / Fax: (800) 446-5693
Warranty Returns
Authorized Repair Stations
Hours: 7.30 AM to 5:00 PM EST
Welding Equipment Troubleshooting
TECHNICAL SERVICE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
Hours: 8.00 AM to 7:00 PM EST
Returns
Hours: 8.00 AM to 5:00 PM EST
Equipment Recommendations
D
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
E
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7.30 AM to 3:30 PM EST
WELDING EQUIPMENT TRAINING:
Telephone: (843) 664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7.30 AM to 4:00 PM EST
F
Hours: 7.30 AM to 4:00 PM EST
G
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
Hours: 7.30 AM to 4:00 PM EST
H
TECHNICAL ASST. CONSUMABLES:
Telephone: (800) 933-7070
Hours: 7.30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers:
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products
090818
PO BOX 100545, Florence SC 29501-0545
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