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Aristo
t U6
Service manual
0740 800 194 090707
SERVICE INSTRUCTIONS What is ESD?
Rights reserved to alter specifications without notice.
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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 board is divided into numbered blocks, which are described individually in more detail in the description of operation.
The spare parts list is published as a separate document, see page 27.
This manual contains details of design changes that have been made up to and including June 2009.
The manual is valid for: Control panel U6
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 U6 is intended for MMA-welding, TIG-welding, pulsed TIG-welding, MIG/MAG-welding and pulsed MIG/MAG-welding. U6 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.
The U6 panel has knobs for setting welding voltage and wire feed speed / current. Other settings are made by pushbuttons together with text in the display. More control panel information is found in chapter Instructions, see page 13.
Control panel A24 ci08_00 - 3 S0740 800 194/E090707/P28
WIRING DIAGRAM
The MMC module consists of three main units: 1AP1 Welding data board - Processor and CAN communication board 1AP2 Display board 1AP3 Operators control panel - Key pad with pushbuttons Wiring diagram for the U6 panel.
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DESCRIPTION OF OPERATION 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 this you need the ESAT service kit, see page 12.
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 = 36 Hardware ID = 1 Unit type = 0 Unit number = 0 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 A24 (unit number = 1) is connected to a wire feeder with control panel U6 (unit number = 0). The U6 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 in 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 manner.
$ 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 to RAM and to shut down the current processes in a controlled Loss of power supply does not generate a fault code. If the 12 V supply drops below 9 V, either momentarily or indefinitely, but does not fail entirely, the background lighting to the display will be dark, followed by display of fault code 4. The power source must be turned off, and then on again, to reset the system.
The RAM memory requires a power supply even when the power source is turned off. This is provided by battery BA1, see the component positions on
page 6. The battery is connected by the reset circuit when the mains power
supply is turned off or lost. The battery voltage is monitored by the processor: fault code 8 is displayed if it drops below 2.4 V.
Replacing the battery The battery is soldered to the circuit board. Removing it causes the RAM memory to lose all stored data, e.g. the fault log. When the new battery has been fitted, and the power source is restarted, the panel will be in its default state, i.e. as it originally left the factory.
It is possible to prevent data from being lost if a 12 V supply is maintained to the board while the battery is being changed.
CAUTION!
The circuit board is sensitive to ESD.
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1AP1:2 1AP1:5 1AP1:6 Communication
Communication between the MMC unit and other units is via the system's CAN bus.
Resistor R3 is the terminating resistor (120 Ω) for the bus. Read more about the CAN bus in the service manual for the power source.
Display panel U6
The U6 display panel is backlit by parallel-connected LEDs, controlled by transistor Q1. Display contrast can be adjusted by potentiometer R52: see the
component positions diagram on page 6.
Settings
The U6 panel has pulse generators (encoders) for setting the welding voltage and wire feed speed.Other functions are set by pushbuttons. Turning the voltage adjustment pulse generator briefly connects contact A3 (0 V) to contacts A1 and A2, but with a slight time difference between them. This generates pulses that are displaced by about 90 ° relative to each other. One square wave pulse is used as clock frequency and the other square wave pulse defines the knob-turning direction by comparing the phase position (positive or negative) compared to the clock frequency.
The wire feed speed pulse generator operates in a similar manner.
1AP1 Component positions
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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 be erased when the next fault occurs.
Only the most recent fault message is displayed on the control panel. To read the entire fault log, the equipment must be connected to the ESAT: see service tools on page 12.
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
Fault codes are updated every three seconds. They are shown on the display in the form of a symbol, as follows: The upper figure in the symbol is the number of the particular fault code. The lower figure indicates which unit type has generated the fault The following unit types are used: 0 = welding data unit 1 = cooling unit 2 = power source 3 = wire feed unit 4 = remote control unit The above symbol shows that the welding data unit (0) has lost contact with the power source.
Symbols may be steady or flashing, depending on the type of fault. Flashing symbols are indicaded with “o” in the table below.
Press any of the function keys in order to clear the symbol from the display.
Summary of fault codes
Fault code Description 10 11 12 14 15 1 2 3 4 5 6 8 9 Memory error, EPROM Memory error, RAM Memory error, external RAM +5 V power supply Intermediate DC voltage outside limits High temperature Power supply 1 Power supply 2 Power supply 3 Wire feed speed Communication error (warning) Communication error (bus off) Lost messages Welding data unit x x x x Cooling unit x x x Power source x x x x x x x x x x x Wire feed unit x x Remote control unit x x x x x x x x x x x x x x x x S0740 800 194/E090707/P28 ci08f1 - 7 -
16 17 18 19 20 22 23 26 27 28 29 31 32 40 41 Fault code Description High open-circuit voltage Lost contact with the wire feed unit Lost contact with the power source Incorrect setting values in external RAM High inductance in the welding circuit Transmitter buffer overflow Receiver buffer overflow Program operating fault Out of wire Stack overflow No cooling water flow No reply from the display unit No gas flow Incompatible units Lost contact with the cooling unit Welding data unit Cooling unit Power source x o o x x x x x x x x x x x o x x x x x Wire feed unit Remote control unit x x x o x x
Fault code description
This manual describes the fault codes for the welding data unit of control panel U6.
The fault codes for other units are described in the manuals for these units.
Code Description 1 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 equipment. If the fault persists, load new software via ESAT. If the fault still persists, replace the welding data board 1AP1.
2 3 Microprocessor RAM error The microprocessor is unable to read/write from/to a particular memory address in its internal memory. This test is preformed only as part of initiation at power on. This fault does not disable any functions.
Action: Restart the equipment. If the fault persists, replace the welding data board 1AP1.
Error in external RAM Read/write test of the processor's external RAM. This test is preformed only as part of initiation at power on.
The microprocessor is unable to read/write from/to a particular memory address in its external memory. This fault does not disable any functions.
Action: Restart the equipment. If the fault persists, replace the welding data board 1AP1.
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Code Description 4 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.
8 Low battery voltage +3 V This test is preformed only as part of initiation after power-up. This fault does not disable any functions.
Action: Replace the battery on circuit board 1AP1. If it is not replaced, the entire contents of the battery backed-up memory will be lost.
12 14 Communication error (warning) The load on the system CAN bus is temporarily too high.
Action: Check the equipment to ensure that only one wire feed unit and/or remote control unit is connected.
Communication error (bus off) Major interference on the system's CAN bus. The communication has temporarily ceased, due to excessive load on the bus. The current welding process is stopped.
Action: Check that there are no faulty units connected to the CAN bus. Check the cables.
Turn off the mains power supply to reset the unit.
15 17 18 19 22 Lost messages The bus CAN controller indicates that a message has been lost. No functions are disabled by this fault.
Action: Check that all units are correct connected to the CAN bus.
Lost contact with the wire feed unit Current activities will be stopped and welding start is prevented.
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 board in the MMC unit and the control board in the power source.
Action: Check the CAN cabling.
Memory error in data memory This fault will be detected if the information in the battery-backed-up memory has become corrupted.
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 battery voltage is correct, and if the fault recurs each time the unit is started, there is a fault in the persistent memory. Replace the welding data board, 1AP1, in the MMC unit.
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.
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Code Description 23 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.
26 Program operatiing fault Something has prevented the processor from performing its normal tasks in the program.
The program restarts automatically. The current welding process will be stopped. This fault does not disable any functions.
This fault should not happen. Contact ESAB if the fault yet occurs.
28 29 31 40 41 Stack overflow The program execution does not work.
This fault should not happen. The fault code is intended as an aid during development work.
Contact ESAB if the fault yet occurs.
No cooling water flow The flow monitor switch has tripped.
The current welding process is stopped and starting is prevented.
Action: Check the cooling water circuit and the pump.
No reply from the display unit The microprocessor has no contact with the display board.
Action: Check the ribbon cable and connectors between the welding data board (1AP1) and the display board (1AP2).
Incompatible units Incorrect wire feed unit is connected. Welding start is prevented.
Action: Connect the correct wire feed unit.
Lost contact with the cooling unit The welding data board has lost contact with the cooling unit. The welding process is stopped and starting is prevented.
Action: Check the wiring. Turn off the mains power supply to reset the unit.
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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: A conductive mat (size 610 x 610 mm) A 1.5 metre long ground cable with a crocodile clip 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: CAN adapter with connection cables CD with software 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 ci08f2 - 12 S0740 800 194/E090707/P28
INSTRUCTIONS
This chapter is an extract from the instruction manual for the U6 control panel. For detailed instructions, please see the instruction manual.
SAFETY
CAUTION!
Read and understand the instruction manual before installing or operating.
INTRODUCTION Control panel's working method
The control panel can be said to comprise two units: the primary memory and the welding data memory.
Primary memory Recall Store Welding data memory In the primary memory, a complete set of welding data settings are created which can be stored in the welding data memory.
When welding, it is always the content of the primary memory which controls the process. It is therefore also possible to recall welding data settings from the welding data memory to the primary memory.
Note that the primary memory always contains the most recently set welding data settings.
These can be recalled from the welding data memory or individually altered settings. In other words, the primary memory is never empty or “resetted” ci08i1 - 13 S0740 800 194/E090707/P28
Control panel
1 2 3 4 5 Display Knob for setting the voltage Knob for setting the wire feed speed or current Soft pushbuttons (function keys) MENU button
Soft pushbuttons
The functions of these buttons (i.e. what each one does) change, depending on the sub-menu shown on the display. The particular function for each button is shown by the text in the bottom line of the display, corresponding to the buttons. (A white dot beside the text indicates that the button is active.)
MENU pushbutton
This pushbutton brings you to the selection menu (see item <>) if you are in the main menu.
If you are in some other menu, it moves you back up one menu.
Symbols in the display
Back to the main menu.
Move the cursor down to a new setting parameter.
Change the function in the selected line.
Increase the value. Decrease the value.
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MENUS
The control panel uses several different menus: the main menu, the measurements menu, the selection menu, the process menu, the settings menu, the configuration menu and the memory menu. A startup display is also shown when starting, with information on the type of panel and the software version in use.
The main menu and the measurements menu
The main menu always appears immediately after starting, showing the values that are set. If you are in the main menu when you start to weld, the menu changes automatically to show the measured values (the measurements menu). The measured values remain on the display even after welding stops.
Other menus can be accessed without losing the measured values.
It is only when a knob is turned or the welding method changed that the setting values are displayed instead of the measured values.
The selection menu
Use the selection menu to select the next level of menu to which you want to go: process, settings, configuration or memory.
The process menu Use this menu to change the welding process, material type etc.
The configuration menu Use this menu to change the language, measurement units etc.
The settings menu Use this menu to set welding parameters, such as gas pre-flow, hot start time, crater fill time etc.
The memory menu Use this menu to store, recall and/or erase various stored welding data settings. There are ten storage positions for welding data.
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Menu structure
MIG/MAG 2/4 stroke Craterfill Hot start MIG/MAG Puls 2/4 stroke Craterfill Hot start Creep start Gas purge Wire inch Creep start Gas purge Wire inch TIG 2/4stroke Gas purg TIG Pulsed 2/4 stroke Gas purg MMA Hot start Air gouging MIG/MAG MIG/ MAG Puls QS/ Synergic Wire type Gas Wire diam Wire ty Gas Wire dia Process menu HF TIG TIG Puls Liftarc MMA E-type E-diam Air goug E-diam MIG/MAG MIG/MAG Puls Setting menu TIG TIG Puls MMA Configuration menu MIG/MAG MIG/MAG Puls TIG TIG Puls MMA Air goug Memory menu MIG/MAG TIG MMA Air goug Induktanc Gaspreflo Hot start Craterfill Burnback Gaspostfl Spot weld Gasprefl Hot start Craterfill Burnback Gaspostfl Spot weld Gasprefl.
Slope up Slope down Gaspostfl Puls curr.
Puls time Backgr. c.
Backgr. t.
Gasprefl.
Slope up Slope down Gaspostfl.
Arc force Hot start Lang.
Dimension Panel ena Trigger data Lang.
Dimensio Panalena Triggerd.
Min cur rent Lang Dimension Panel enable Lang Dimension Panel enable Store Recall Delete S0740 800 194/E090707/P28
MIG/MAG FUNCTIONS
2-stroke
Gas pre-flow Hot start Welding Crater fill Gas post-flow Functions when using 2-stroke control of the welding gun.
In the 2-stroke control mode, pressing the welding gun trigger switch starts gas pre-flow (if used) (1) and strikes the arc. Releasing the trigger switch (2) starts crater filling (if in operation), extinguishes the arc and starts gas post-flow (if in operation).
TIP: If the welding gun trigger switch is pressed again during the crater fill time, welding can be continued for as long as required (shown by the dotted line), using the crater fill data. Crater filling can also be interrupted by quickly pressing and releasing the trigger switch while crater filling is in progress.
- Activation of 2-stroke performed in the main menu.
4-stroke
Gas pre-flow Hot start Welding Crater fill Gas post-flow Function when using 4-stroke control of the welding gun.
In the 4-stroke control mode, pressing the welding gun trigger switch starts gas pre-flow (1).
Releasing the trigger switch (2) starts the welding process. At the end of welding, the welder presses the trigger switch again (3), which starts crater filling (if in operation) and reduces the welding data to a lower value. Releasing the trigger switch again (4) extinguishes the arc and starts gas post-flow (if used).
TIP: Crater filling stops when the trigger switch is released. Keeping the button pressed continues welding at the lower data of the crater filling function (dotted line).
- Activation of 4-stroke performed in the main menu.
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Crater filling
Crater filling helps to avoid pores, thermal cracking and crater formation in the workpiece at the end of the weld.
- Setting of crater filling time performed in the settings menu.
Hot start
The hot start function increases the welding current for an adjustable time at the start of welding, which reduces the risk of poor fusion at the start of the weld.
- Setting of hot start time performed in the settings menu.
Creep start
The creep start function reduces the initial feed speed of the wire to 50 % of the set speed until the wire contacts the workpiece.
- Activation of creep start performed in the main menu.
Gas purging
The gas purging function is used when measuring the gas flow rate, or to purge the gas hoses of any air or moisture before starting to weld. It continues as long as the button is held pressed, and prevents voltage from being applied and wire feed from starting.
- Activation of gas purging performed in the main menu.
Cold wire feed
Cold wire feed is used in order to feed out wire without energising the arc. The wire is fed out for as long as the button is held pressed.
- Activation of cold wire feed performed in the main menu.
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QSet
t 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 QSet automatically sets all the necessary welding parameters. After that QSet stores all the data to produce a good weld. The voltage then automatically conforms to changes in the wire feed speed.
The first weld must last for at least 6 seconds for the parameters to be correct.
SPRAY ARC When approaching the spray arc area the value for QSet Disengage the QSet must be increased. 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 all the correct data.
on a test piece to obtain The QSet function and the synergy function cannot be activated at the same time. - Activation of QSet performed in the process menu.
Synergy
Every combination of wire type, wire diameter and gas mixture requires a unique relationship between wire feed speed and voltage (arc length) in order to ensure a stable arc. The arc voltage (arc length) is automatically controlled in accordance with the preprogrammed synergy line that has been selected by the welder, which makes it much easier quickly to find the optimum welding parameters. The relationship between the wire feed speed and the other parameters is referred to as the synergy characteristic or synergy line.
Synergy ON: the main menu shows the set wire feed speed, as well as positive and negative deviation from the synergy line's voltage.
Positive deviation is displayed with a bar above SYN, negative is displayed below.
Synergy OFF: the main menu shows the set value for voltage and wire feed speed.
- Activation of synergy performed in the process menu.
Synergy line package The synergy line package supplied with the machine is called “ Standard synergic lines” and contains the 33 most frequently used synergy lines.
It is also possible to order other packages of synergy lines, but these must be installed by an authorised ESAB service engineer.
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Inductance
Higher inductance produces a more flowing weld and less spatter. Lower inductance produces a harsher sound and a stable, concentrated arc.
- Setting of inductance performed in the settings menu.
Gas pre-flow
The gas pre-flow time is the time during which the shielding gas flows before the arc is struck.
- Setting of gas pre-flow time performed in the settings menu.
Burnback time
The burnback time is a delay between when the wire feed unit starts to brake the wire until the power unit shuts off the welding current. Too short a burnback time leaves a long piece of filler wire projecting after welding has stopped, with resulting risk of the wire freezing into the solidifying weld pool. On the other hand, too long a burnback time reduces the stickout to such an extent that there is a risk of the arc striking from the welding gun contact tip when welding is next started.
- Setting of burnback time performed in the settings menu.
Gas post-flow
The gas post-flow function controls the time during which shielding gas continues to flow after the arc has been extinguished.
- Setting of gas post-flow time performed in the settings menu.
Change of trigger data
Using this function, it is possible to switch to various pre-set welding data alternatives by double-clicking on the welding gun's trigger.
Switching takes place between the memory positions 1, 2 and 3. If there is no data in memory position 2, switching takes place instead between positions 1 and 3.
ON - Switching between memory positions can take place before , after or during welding.
ARC OFF - Switching between memory positions can only take place before or after welding.
- Activation of trigger data switching performed in the configuration menu.
AVC feeder
When this function is activated it is possible to use an Arc Voltage Controlled (so-called “Off The Arc”) feeder, where the arc voltage from the power source is used to power the wire feed unit.
- Activation of AVC feeder is performed in the configuration menu.
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Spot welding
Select Spot welding when you want to “spot-weld” thin metal sheets.
- Activation and setting of Spot welding is performed in the settings menu.
Voltage
A higher voltage gives a longer arc, with a hotter and wider weld pool.
Irrespective of which menu is displayed, the setting value for the voltage can always be changed. The value is displayed in the main menu or selection menu.
Wire feed speed
The wire feed speed is the speed at which the filler wire is supplied, measured in m/min.
Irrespective of which menu is displayed, the setting value for the wire feed speed can always be changed. The value is displayed in the main menu or selection menu.
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TIG FUNCTIONS
2-stroke
Gas pre-flow Slope up Slope down Gas post-flow 2-stroke operation of the welding gun switch button.
In the 2-stroke control mode, pressing the welding gun switch button starts gas pre-flow (if used) and strikes the arc (1). The current rises to the set value (as controlled by the “slope up” function, if in operation). Releasing the switch button (2) reduces the current (or starts “slope down” if in operation) and extinguishes the arc. Gas post-flow follows if it is in operation.
- Activation of 2-stroke performed in the main menu.
4-stroke
Gas pre-flow Slope up Slope down Gas post-flow 4-stroke operation of the welding gun switch button.
In the 4 -stroke control mode, pressing the switch button starts gas pre-flow (if used) (1). At the end of the gas pre-flow time, the current rises to the pilot level (a few ampere), and the arc is struck. Releasing the switch button (2) increases the current to the set value (with “slope up”, if in use). At the end of welding, the welder presses the switch button again (3), which reduces the current to pilot level again (with “slope down”, if in use). Releasing the switch button again (4) extinguishes the arc and starts gas post-flow (if used).
- Activation of 4-stroke performed in the main menu.
HF
The HF function strikes the arc by a spark produced when the tungsten electrode is brought to within a certain distance from the workpiece.
- Activation of HF performed in the process menu.
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Lift Arc
The “Lift Arc” function strikes the arc when the electrode comes into contact with the workpiece and is then lifted off.
Striking the arc with the “Lift Arc” function. Step 1 shows the electrode in contact with the workpiece.
The button is then pressed (Step 2), and a low current flows. The arc strikes when the welder lifts the gun away from the workpiece (Step 3), which causes the current to rise automatically to the set value.
- Activation of “Lift-Arc” performed in the process menu.
Gas purging
Use the gas purging function to measure the gas flow or to purge the gas hoses of any air and/or moisture before starting to weld. Purging continues for as long as the switch button is held pressed, and prevents the current from flowing or the wire feed from starting.
- Gas purging performed in the main menu.
Gas pre-flow
The gas pre-flow setting controls the time during which the shielding gas flows before the arc is struck.
- Setting of gas pre-flow time performed in the settings menu.
Slope up
“Slope up” means that the initial TIG arc current is low and increases slowly to the set value.
This provides less harsh heating of the tungsten electrode and gives the welder time to position the electrode and arc before full welding current starts.
- The setting of “slope up” time performed in the settings menu.
Slope down
The “slope down” function in TIG welding is used to avoid the formation of crater cracking at the end of welding. It reduces the current slowly over an adjustable period of time.
- The setting of “slope down” time performed in the settings menu.
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Gas post-flow
Gas post-flow controls the time during which the shielding gas continues to flow after the arc is extinguished.
- Setting of gas post-flow time performed in the settings menu.
Pulse duration
This is the length of time during which the pulse current is on during a pulse cycle.
- Setting of pulse duration time performed in the settings menu.
Background time
This is the length of time during which the background current flows. With the pulse duration time, it gives the total pulse cycle time.
- Setting of background time performed in the settings menu.
Background current
This is the lower current value of the two currents used in pulsed current welding.
- Setting of background current performed in the settings menu.
Pulse current
This is the higher current value of the two currents used in pulsed current welding.
Irrespective of which menu is displayed, the setting value for the pulse current can always be changed. The value is displayed in the main menu, the selection menu or the settings menu.
Current Background time Pulse amp Background amp Pulse time Time TIG welding with pulsing.
Current
Higher current produces wider and deeper penetration into the workpiece.
Irrespective of which menu is displayed, the setting value for the current can always be changed. The value is displayed in the main menu or selection menu.
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Change of trigger data
Using this function, it is possible to switch to various pre-set welding data alternatives by double-clicking on the welding torch trigger.
Switching takes place between the memory positions 1, 2 and 3. If there is no data in memory position 2, switching takes place instead between positions 1 and 3.
ON - Switching between memory positions can take place before , after or during welding.
ARC OFF - Switching between memory positions can only take place before or after welding.
- Activation of trigger data switching performed in the configuration menu.
Min current
Used to set the minimum current for the remote control T1 Foot CAN.
If the max current is 100 A and the min current is to be 50 A, set the 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%.
- Activation of min current is performed in the configuration menu.
MMA FUNCTIONS
Hot start
The hot start function increases the welding current for an adjustable time at the start of welding. This reduces the risk of poor fusion defects at the start of the weld.
Setting of hot start time is performed in the settings menu.
Arc force
The arc force function controls how the current changes when the arc length changes. A lower value gives a less harsh arc with less spatter.
Setting of arc force is performed in the settings menu.
Current
Higher current produces wider and deeper penetration into the workpiece.
Irrespective of which menu is displayed, the setting value for the current can always be changed. The value is displayed in the main menu or selection menu.
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GENERAL FUNCTIONS Remote control unit
Power sources with intergrated control panels should have program version 1.21 or higher, in order for the remote control to function correctly.
Control panel's behaviour on connection of the remote control unit
The display freezes in the menu showing when the remote control unit is connected.
Measurement and setting values are updated, but only displayed in those menus in which the values can be shown.
If a fault code symbol is displayed, it cannot be removed until the remote control has been disconnected.
With 10-program remote control units, it is possible to switch between memory positions 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10. If memory position 2 is empty, the values from position 1 are retained. For further information, see chapter “memory management” in the instruction manual.
Settings
Panel enable
When a remote control unit is connected it is possible to set current or voltage and wire feed speed by the control panel or the remote control unit.
Note: this function must be activated before the remote control unit is connected.
- Activation of panel enable is performed in the configuration menu .
Auto save
If a welding data set is recalled from the welding data memory and the settings are adjusted, the changed settings will automatically be saved when a new welding data set is recalled from the memory.
- Activation of auto save performed in the configuration menu.
Limits
This function facilitates the assurance of a good welding quality by setting max. and min.
values for wire feed speed / current or voltage. The limits can be saved in the first 5 memory positions of the welding data memory.
- Activation of limits performed in the configuration menu.
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Lock code
By this function the settings menu can be locked, then it is only possible to select the main menu and the measurements menu, see chapter “Lock code” in the instruction manual.
- Activation of lock code is made in the configuration menu.
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 when the icon for VRD is visible, see picture.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and 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 on delivery. To activate the VRD function use the ESAT service tool.
Note!
The VRD function works for power sources where it is implemented.
The VRD icon
SPARE PARTS
The spare parts list is published in a separate document that can be downloaded from the internet: www.esab.com
Product U6 Filename 0458 818 990 ci08i7 - 27 S0740 800 194/E090707/P28
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.
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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
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