A2-A6 Peh PDF

A2- A6
Process Controller
PEH
104
Service manual
0740 801 106 2007--02--20 Valid from machine no 220 XXX--XXXX

Valid for program version PEH4.0, PEH4.0C, PEH4.01,
PEH4.01C, PEH4.2, PEH4.2C, PEH4.3, PEH4.3C, PEH 5.0,
PEH5.0C, PEH 5.1 and PEH 5.1C
1 READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Software versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 COMPONENT POSITIONS ON CIRCUIT BOARD AP2 . . . . . . . . . . . . . . . . . . 16
6 COMPONENT POSITIONS ON CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . 17
7 FUNCTION DESCRIPTION (CIRCUIT BOARD) . . . . . . . . . . . . . . . . . . . . . . . . 18
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2 NME (AP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3 DC DUO (AP1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 TEST POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.1 Testing the external power supply (from the welding power source) . . . . . . . . . . . . . . . 20
8.2 Testing the internal power supply voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.3 Checking that the program is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.4 Checking NO. 1 output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5 Checking NO. 2 output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.6 Gas valve output control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.7 Measuring the motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.2 Internal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.3 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.4 Adjusting the DC DUO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.5 NME connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.6 Connection between the DC DUO and the NME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 USING THE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10.2 Using the keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11 PRESET SYSTEM MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.2 System function settings available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
12 DEFINITIONS (PRESET SYSTEM MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.1 Product code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.2 Weld process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
12.3 POWER SOURCE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
12.4 Gas preflow (s) (only for GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12.5 Gas postflow (s) (only for GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
12.6 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12.7 Cable length (m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.8 Cable area (mm2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
12.9 Weldhead offset, mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12.10 START SEQUENCE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.11 STOP SEQUENCE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.12 CALIBRATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.13 DISPLAY MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
12.14 ERROR LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.15 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13 PRESET SYSTEM MENU OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
14 CHANGE OF PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
14.2 Storing trimming data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
14.3 Changing the program in the PEH electronics: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
14.4 Changing programs in the PEH electronics and the welding power source: . . . . . . . . 64
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SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
ALPHABETICAL LIST OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Rights reserved to alter specifications without notice.
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1 READ THIS FIRST
1.1 General
This service manual is intended for use by technicians with electrical/electronic
training, for help in connection with fault--tracing and/or repair.
This manual contains details of all design changes that have been made up to and
including October 2006.
This manual is valid for program version PEH4.0, PEH4.01, PEH4.2, PEH 4.3 and
PEH 5.0. (Includes the chinese versions)
For older versions see service manual 0740 801 006.
For further information see the A2--A6 Process controller (PEH) instruction manual
0443 745 xxx.
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1.2 Software versions
PEH
From production start 97.07.04
PEH program (Flash, IC 15) 486471880
PEH 1.00 A
DCDUO program (Prom, IC304) 68S07001A02
CHKSUM 0210
Dat. 1997.07.04
From 97.12.12
PEH 1.1
CHKSUM 0211
Dat. 1997.12.12
VEC 8000RPM motor (A6G) can be used.
MEK 4 motor with tacho can be used.
Product code for ”A2TFF1” (Weldtrac) added.
Calibration menu deleted.
From 98.04.04
PEH 1.1
CHKSUM 0221
Dat. 1998.04.04
DCDUO software 68S07001A02, CHKSUM 0221 compatible with hardware 971029 and all later
versions.
Upgraded DCDUO program, preventing unsafe usage of tacho function.
From 98.05.20
PEH 1.2
CHKSUM 0221
Dat. 1998.04.04
External start/stop function
Strip welding
Stainless steel setting. If this function is needed the power source board 486367001A in the LAF must
be used and LAF program version LAF 2.0
ESW welding added (new function added).
From 98.09.30
PEH 2.0
CHKSUM 0221
Dat. 1998.04.04
For access to all new features program version LAF 2.0 (part no 486525880) must be used together
with PEH 2.0.
Inch conversion.
New manual programmable start method added.
From 99.03.20
PEH 2.1 and PEH 2.2
CHKSUM 0221
Dat. 1998.04.04
Improved motor regulator data for better performance at low speed.
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From 00.04.04
PEH 3.1
CHKSUM 0221
Dat. 1998.04.04
One software version for all applications (Tractors and C&B).
From 02.11.15
PEH 4.0
PEH program, China (Flash, IC 15) 486471881
PEH 4.0C
CHKSUM 0221
Dat. 1998.04.04
Gauging process added.
Complete support for Weldoc. (Not in the Chinese version)
Added new languages. (In the Chinese version only English and Chinese can be selected)
Safer bus communication.
Calibration function. (Not in the Chinese version)
The following must be used: LAF/TAF version 4.0, digio 4.0, and Analogue Motor node 4.0.
From 03.04.14
PEH 4.01
PEH program, China (Flash, IC 15) 486471881
PEH 4.01C
CHKSUM 0221
Dat. 1998.04.04
Bug fixes, for example tandem welding.
The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor
node 4.0.
From 04.01.01
PEH 4.2
PEH program China (Flash, IC 15) 486471881
PEH 4.2C
CHKSUM 0221
Dat. 1998.04.04
Added wire creep speed menu.
New product code.
Added Russian language (Not in China version).
New motor selection for parallel driving.
New alarm codes.
Increased maximum speed for motor vec4000.
Bug fixes.
node 4.0.
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From 05.01.01
PEH 4.3
PEH program China (Flash, IC 15) 486471881
PEH 4.3C
CHKSUM 0221
Dat. 1998.04.04
Added wire creep speed menu. (Valid for the chinese version)
Added Polish language (Not in China version).
Error log, permanent memory.
node 4.0.
From 06.10.01
PEH 5.0
PEH program china (Flash, IC 15) 486471881
PEH 5.0C
DCDUO program (Prom, IC304) **************
CHKSUM 0221
Dat. 1998.04.04
Improved functions for tandem welding. Possible to restart master.
Possible to use craterfill and stopsequense together.
From 07.02.19
PEH 5.1
PEH program china (Flash, IC 15) 486471881
PEH 5.1C
DCDUO program (Prom, IC304) **************
CHKSUM 0221
Dat. 1998.04.04
Bug fix Limit switch
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Welding Power Source

From production start 97.07.04
LAF/TAF program (Flash, IC 6) 486525880
LAF/TAF 1.00A
From 99.01.01
LAF/TAF 2.0
Strip welding and ESW welding.
Stainless steel setting. If this function is needed the power source board 486367001A in the LAF must
be used.
Inch conversion.
From 00.02.29
LAF/TAF 2.1
Improved wire creep speed LAF 1000ES
From 00.10.04
LAF/TAF 2.4
Improved welding starts and welding
Safer detection of arc strike.
Changed sequence of weld start.
Faster engagement of the regulators.
Modified voltage regulation.
From 02.11.15
LAF/TAF 4.0
Improved welding performance, better regulators.
Improved arc--ignition.
Parallel connection of LAF
TAF 800 60% duty factor
Complete support for Weldoc. (Not in the Chinese version)
Gauging process added.
Calibration function. (Not in the Chinese version)
Program version 4.0 or 4.0C is needed.
From 03.04.14
LAF/TAF 4.01
Increased wire creep speed.
Voltage regulations for analogue interface (PEI).
Program version from PEH 4.0, PEH 4.0C is needed.
From 04.01.01
LAF/TAF 4.2
Added new alarm.
Improved regulation.
From 05.01.01
LAF/TAF 4.3
Improved welding, analogue Interface.
From 06.10.01
LAF 5.0
Changed regulation, improved with dynamic characteristic.
New hardware is needed, for LAF 486367008 and 486376005 for TAF.
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PEH in C&B
From 99.04.01
PEH 2.3
CHKSUM 0221
Dat. 1998.04.04
PEH program for use in stations with a Roller bed/ Positioner (Analogue Motor node) and an
RCC--unit (Digital I/O node).
Note! This program version cannot handle a Roller bed/positioner without an RCC--unit.
Contact ESAB for custom--made program.
From 99.01.15
Digital I/O -- node 486592880
DIG IO 1.0
From 99.06.01
DIG IO 1.1
Safer readings of push buttons preventing unrequested stop during welding.
From 02.11.15
DIG IO 4.0
Safer bus communication with PEH.
Programversion PEH4.0 or PEH4.0C is needed.
From 99.01.15
Analogue Motor node 486569880
RB 1.1
From 99.06.20
RB 1.2
Roller bed / Positioner can be controlled from PEH (using SHIFT + 9), RCC unit not necessary.
For PEH program, contact ESAB for custom--made program.
From 02.11.15
RB 4.0
Returns actual speed for external travel axis.
Programversion PEH4.0 or PEH4.0C is needed.
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2 SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interference. It is the user’s responsibility to take
adequate precautions.
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3 COMPONENT DESCRIPTION
The component description refers to the component names in the connection

diagram.
AP1 DC DUO circuit board: see the function description on page 19.
AP2 NME circuit board: see the function description on page 18.
DY1 Display
HL1 Pilot lamp (accessory)
KB1 Control panel (see page 27)
K1 Connector for the graphic display.
K2 Keyboard connector
K3 Connector between the DC DUO circuit board and the NME board.
K5 Circuit board contact
K5:1 is normally closed
K5:2 is connected to the display control voltage supply
K5:3 is connected to + 5 V
K5:4 is connected to + 5 V
K5:5 is connected to 0 V
K5:6 is connected to 0 V
K7 Bus termination (on NME circuit board)
K9 Connection of the serial bus connection
K10 Connector for the wire feed motor (M1)
K11 Connector for the travel motor (M2)
K12 Connector for the gas valve
K13 42 V AC (input from power source)
K14 42 V AC (Pilot lamp)
K17 60 V DC
K22 Connector for the water flow guard, limit switch or external start function.
K23 Connector for the gas flow guard, limit switch or external stop function.
M1 Wire feed motor.
M2 Travel motor
ST1 Emergency stop (see page 27 and 59).
XS1 Connector 12--pin (connector for the control cable from the welding power
source).
X2 Terminal block (emergency stop, arc voltage)
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4 CONNECTION DIAGRAM
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5 COMPONENT POSITIONS ON CIRCUIT BOARD AP2
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6 COMPONENT POSITIONS ON CIRCUIT BOARD AP1
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7 FUNCTION DESCRIPTION (CIRCUIT BOARD)
Serial
buss
7.1 General
The drive unit consists of two circuit boards, named NME (AP2) and DC DUO (AP1).
(See Page 16 and Page 17 for component positions on the circuit boards.)
The NME board deals with all communication with the higher level system via a
two--wire serial bus. It also manages the control panel (KB1) and the display (DY1),
as well as communication with the DC DUO circuit board processor (IC300).
The DC DUO board controls the speed of two DC motors, which may be separately
excited or of permanent magnet type. Speed control is effected either by
measurement of the armature voltage or by tachometer control.
7.2 NME (AP2)

This board is built up around an MC 143150
Neuron processor (IC1), with associated memory,
working memory and program memory (IC15) and
necessary address decoding.
An 8--pole DIP switch (SW1) on the board is
used to set the board’s system address.
As immunity to interference is particularly important,
communication is galvanically isolated through
transformer TR1.
The communication is disconnected by a
single--pole relay, when the board is not powered
but still connected to the system.
Communication with the DC DUO circuit board is via
a parallel bus.
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7.3 DC DUO (AP1)

The DC DUO circuit board can be divided into five function blocks:
1. Internal power supply
Generates the necessary power supplies for the electronic circuitry.
2. The processor (IC300)
Controls the motors and communication with the NME circuit board.
The microprocessor controls the motors by measuring their armature voltages,
the available DC bus voltage and the motor currents.
3. Analogue part
Converts the measured quantities from the power section to voltage levels that
allow A/D conversion.
4. Power section
Consists of two full--wave MOSFET transistor bridges and associated drive
circuits and current shunts.
5. Inputs and outputs
For connection of the gas valve, guards, limit switch and the external start/stop
function.
In the interests of a robust system, the heat sinks on which the power
semiconductors are mounted, also carry a thermistor that monitors the temperature
of the heat sinks.
Protection against short circuits is provided by a high--speed overload protection
circuit that shuts down the power section if a short circuit occurs.
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8 TEST POINTS
8.1 Testing the external power supply (from the welding power
source)
Measure the voltage at contact K13.
The approved value range for the voltage is 37,8 VAC ± UAC ± 46,2 VAC
8.2 Testing the internal power supply voltages

The following test measurements can be made when the motor is not running.
Connect a voltmeter across the following components (negative to GND) :
Set value Approved value range

Positive connected to K17:1 +60 V 53 VDC ± U ± 65 VDC
Positive connected to K1:1 +5 V 4,8 V ± U ± 5,2 V
Positive connected to cathode D206 +12 V 10,5 V ± U ± 13,5V
Positive connected to anode D207 --12 V --13,5 V ± U ± --10,5V
Positive connected to cathode Z402 +15 A 13 V ± U ± 16V
Positive connected to cathode Z401 +15 B 13 V ± U ± 16V
Positive connected to cathode Z403 +15 C 13 V ± U ± 16V
Positive connected to cathode Z404 +15 D 13 V ± U ± 16V
Positive connected to cathode Z1 +12 Vswitch 11 V ± U ± 13V
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8.3 Checking that the program is running

Measure the signal on K3:12 using an oscilloscope, and make sure that it is constant
at +5V. If the program is not running normally, the signal will go low.
The software will then perform a reset and the signal will again go high.
8.4 Checking NO. 1 output stage

S Issue a RUN command.
S Check the voltage on IC407:11. It should normally be low, at 0V.
S Check the waveform on IC407:5. It must be a square wave with 50 % pulse
width and an amplitude close to +60 V.
8.5 Checking NO. 2 output stage
S Issue a RUN command.
S Check the voltage on IC407:11. It should normally be low, at 0V.
S Check the waveform on IC409:5. It must be a square wave with 50 % pulse
width and an amplitude close to +60 V.
8.6 Gas valve output control
Press and measure the voltage over K12.1 and K12.2 (42 V AC). If there is no
voltage available, either T201 is defective or the current path on the card is
burnt--off.
8.7 Measuring the motor current

The current through motor M1 (the wire feed motor) can be measured at IC402: 7,
while the current through motor M2 (the travel motor) can be measured at IC405:7
(1 V is equivalent to 5 A).
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9 INSTALLATION
9.1 General
The incoming power supply (42 V AC) to the A2--A6 Process Controller (PEH) is
obtained from the welding power source via the control cable, which also carries the
bus communication between the two units.
See the connection diagram on page 14.
9.2 Internal connections

S Connect incoming cables to the 12--pole connector (XS1) and the circuit board
contacts on the inside of the control unit. All the cables are screened, and the
screens must be connected to the earth points intended for them.
The 12--pole connector, XS1, is connected internally to circuit board connectors
K13 and K9 and to terminal block X2.
One conductor (emergency stop) is connected to emergency stop switch ST1.

One conductor (emergency stop) is connected to terminal block X2.2
One conductor (arc voltage) is connected to terminal block X2.1
Two conductors (bus communication) are

connected to K9.1 and K9.2 (0,5 mm 2) on
Draw counter balancing for incoming cable. the NME circuit board (AP2).
Two conductors (x3) (42 AC)

are connected to K13.1 and
K13.2 (2,5 mm 2).
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9.3 External connections

Motor connections for the wire feed motor, M1
A2 motor
Motor cable, two conductors and screen, connected to connectors K10.1 and K10.2.
AC--Tachometer cable (accessory), two conductors and screen, connected to connectors K10.5
and K10.6.
A6 motor
Motor cable, four conductors and screen, connected to connectors K10.1 and K10.2, with the field
connections made to K10.3 and K10.4.
The AC tachometer cable (accessory), is connected to connectors K10.5 and K10.6.
Motor connections for travel motor M2 (travel motion)

Motor cable, two conductors with screen, connected to connectors
K11.1 and K11.2.
The motor field winding is connected to K11.3 and K11.4 (with screen).
The AC tachometer cable (accessory): two conductors and screen, con-
nected to K11.5 and K11.6.
Connection of the welding head

Arc voltage to terminal X2.1
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Input for connection of a gas flow guard (NC), limit switch or external stop function.
Screened 2--wire 2 x 0,75 mm2, connected to K23.1 and K23.2.
Input for connection of a water flow guard (NC), limit switch or external start function.
Output for connecting a flux or gas valve, 42 V AC max. 0,5 A

Connection of an external emergency stop (accessory)

Remove the internal emergency stop connection and connect
the external emergency stop circuit to X2.2.
Connection of a Pilot lamp (accessory)

Connect the transformer primary (42V) to K14.1 and K14.2.
The transformer and pilot lamp are included in a complete set of compo-
nents for incorporation in the unit and must be ordered separately.
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9.4 Adjusting the DC DUO

Adjusting the display contrast
As delivered, the lighting is set for the
best contrast. If necessary, it can be
adjusted by potentiometer P101
Connection of jumper J1:

For the green display place the jumper on 1 and
2.
For the blue display place the jumper on 2 and 3.
Motor control software

The motor control program is stored in an
EPROM, IC 304. It is marked to show the
version number of the software supplied.
9.5 NME connection

The graphic display is to be connected to connector K1.
The keyboard is to be connected to connector K2.
The bus connection in the control cable (from the
welding power source) is to be connected to
connector K9.
DIP switch
The NME circuit board carries a DlP switch (SW1) which
is preset on delivery for use with A2--A6 units, and its
settings must not be altered in the field. When supplied
as a spare part, the settings of the switch must be
checked, and adjusted if necessary, before the board is
fitted in the control box.
Setting the DIP switch SW1:

DIP switch SW1 must be set to Closed position,
i.e. all eight poles must be set to Closed position.
Communications software
The communications software, the keyboard controller, display driver and the trim
parameters for the DCDUO circuit board are stored in flash memory IC15.
The chip is mounted in a socket and can be changed.
Diagnostics
There is one LED (L02 RED) on the circuit board that can be used for system fault
tracing:
S The LED lights to indicate failure of communication to the DC DUO board, or in

the event of a microprocessor fault.
S The LED flashes to indicate that there is a fault in the program.
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Bus termination/connection
When the NME circuit board
is the first or last board in a
network, a short--circuiting link
must be fitted in socket K7.
9.6 Connection between the DC DUO and the NME

The NME circuit board (AP2) is a separate unit that is secured above the DC DUO
circuit board (AP1) by means of four screws.
Connectors K3 (communication between the boards), K4 (guard inputs and gas
valve output) and K5 (supply voltage for the NME circuit board) provide the electrical
link between the two boards.
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10 USING THE CONTROL PANEL
10.1 Control panel

1. Emergency stop
2. The direction of travel is as shown
by the triangular symbol on the
welding equipment.
3. The direction of travel is as shown
by the square symbol on the welding
equipment.
4. Advance wire
5. Retract wire
6. Change menu
7. Numerical key, number entry
8. ENTER key, Change row
9. SHIFT key
10. Stop welding. Return to manual mode
11. Start welding. Switch to automatic mode
12. Fast, wire feed or travel
13. Scroll page (welding setup menu) or close valve (main menu)
The arrowed keys are used during welding to increase or

decrease the current, voltage and speed.
By pressing either , , + or + it is possible to browse.
N.B.
When an I/O board is connected the keys 2, 3, 4, 5, 10, 11 and 12 can no longer be
used.
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10.2 Using the keys

To explain how to use the keys the WELDING SETUP menu has been used as an
example. Note that the keys are used in the same way in all of the menus.
For a detailed description of the MAIN MENU and the WELDING SETUP, read the
instruction manual for PEH (0443 745 xxx).
S Switch from the MAIN MENU to WELDING SETUP.

Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU
WELDING SETUP
A B
1 Direction Y, J
2 Start Direct, Scratch
3 STOP WELDING
4 WIRE DATA
5 Regulation CA, CW
6 PRESET SYSTEM MENU
S To change a setting, move from Column A to Column B with .
S Find the required alternative with or with + .

Note that for certain rows you have to enter your own values.
S Return to Column A with

+ .
S Move forward to the next row with .
S Move back to the previous row with + .

(This also provides a direct move from row 1 to row 6.)
S To reach the respective sub--menus on rows 3, 4 and 6 select the required menu
and press .
N.B. If the PRESET SYSTEM MENU is password--protected, enter the password
while the menu is selected and then press .
S Return to the previous menu with .

+
Jump forward a whole page by pressing and jump backwards with .
Explanation of symbols:
shown in combination with another key means that must be pressed first,
and then held while the second key is pressed.
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11 PRESET SYSTEM MENU
11.1 General
The PRESET SYSTEM MENU is used to configure the equipment connected to
the A2--A6 Process Controller (PEH) to give the correct performance of the
complete system.
The control unit variables are set to their optimum settings before the equipment is
delivered from ESAB, and should not normally need to be changed when the
equipment has been supplied to the customer.
If changing any of the variables, use the product codes for ESAB’s A2--A6 automatic
welding machines or for other systems that can be directly connected to the control
system.
The product code includes information on gear ratios, motor types, drive rollers,
diameters etc.
For information about the Control panel and information about how to use the keys,
see pages 27 --28.
11.2 System function settings available

PRESET SYSTEM MENU
A B
12:1 Product code (see page 30) A2TFE / A2TGE / A2TFH / A2TGH /
A6TFE / A6TGE / FREE2AX / FREE3AX
12:2 Weld process (see page 41) SAW / GMAW / ESW / Gauging
12:3 POWER SOURCE MENU (see page 42) X
12:4 Gas preflow (s) (see page 47) 1--99
12:5 Gas postflow (s) (see page 47) 1--99
12:6 Password (see page 48) XXXXX
12:7 Cable length (m) (see page 49) X
12:8 Cable area (mm2) (see page 49) X
12:9 Weldhead offset, mm (see page 50) X
12:10 START SEQUENCE MENU (see page 51)
12:11 STOP SEQUENCE MENU (see page 53)
12:12 CALIBRATION MENU (see page 55)
12:13 DISPLAY MENU (see page 57)
12:14 ERROR LIST (see page 59)
12:15 Test (see page 61) 0/1/2
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12 DEFINITIONS (PRESET SYSTEM MENU)
12.1 Product code
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Gas preflow (s) 1--99
Gas postflow (s) 1--99
Password XXXXX
Cable length (m) X
Cable area (mm2) X
System configuration uses product codes that are explained below.

Selection of the appropriate product codes automatically also selects the correct
details of the motor types and gear ratios used in the particular product.
N.B. This is not the case for “FREE2AX” and “FREE3AX”.
12.1.1 Alternatives:
For program version 4.0 and 4.01:
S A2TFE A2 SAW automatic welding machine
S A2TGE A2 MIG/MAG automatic welding machine
S A2TFH A2 SAW automatic welding machine
S A2TGH A2 MIG/MAG automatic welding machine
S A6TFE A6 SAW automatic welding machine
S A6TGE A6 MIG/MAG automatic welding machine
S FREE2AX Optional configuration for connection of two motors to the drive board.
S FREE3AX Optional configuration for connection of external Roller bed,
Positioner or Linear axis.
Also for connection of two motors to the drive board.
For program version 4.2, 4.3 and 5.0:
S FREE2AX Optional configuration for connection of two motors to the drive board.
S FREE3AX Optional configuration for connection of external Roller bed,
Positioner or Linear axis.
Also for connection of two motors to the drive board.
For A2TFE, A2TGE, A2TFH, A2TGH, A6TFE, A6TGE, A6TFH and A6TGH see on
page 31.
To select “FREE2AX / FREE3AX”, select it and press .

Available settings for “FREE2AX” see on page 32.
Available settings for “FREE3AX” see on page 37.
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The wire feed motor and wire feed axis are automatically set when either A2TFE,
A2TGE, A2TFH, A2TGH, A6TFE, A6 TGE, A6TFH or A6TGH have been selected.
Table for program version 4.0 and 4.01:

Wire feed axis (wire feed motor):
A2TFE A2TGE A2TFH A2TGH A6TFE (*1) A6TGE
Motor FHP36 FHP68 FHP36 FHP68 VEC4000 VEC8000
Gear1 49:1 49:1 49:1 49:1 156:1 74:1
Gear2 1:1 1:1 1:1 1:1 1:1 1:1
P.D.mm 49 49 49 49 49 49
Encoder ppr 6 0 6 0 0 0
Low manual speed 150 150 150 150 150 150
High manual speed 300 300 300 300 300 300
Travel axis (travel motor):

A2TFE A2TGE A2TFH A2TGH A6TFE (*2) A6TGE
Motor DUNKER2 DUNKER2 FHP258 FHP258 DUNKER1 DUNKER1
Gear1 750:1 750:1 24:1 24:1 375:2 375:2
Gear2 158:100 158:100 51:1 51:1 427:100 427:100
P.D.mm 158 158 158 158 180 180
Encoder ppr 0 0 6 6 0 0
Low manual speed 100 100 100 100 100 100
High manual speed 200 200 200 200 200 200
Table for program version 4.2, 4.3, 5.0 and 5.1:

N.B.
For A6 Mastertrac with serial number 232 or earlier use motor data (*1) and (*2).
Wire feed axis (wire feed motor):

A2TFH A2TGH A6TFH A6TGH
Motor FHP36 FHP68 VEC4000 VEC8000
Gear1 49:1 49:1 156:1 74:1
Gear2 1:1 1:1 1:1 1:1
P.D.mm 49 49 49 49
Encoder ppr 6 0 0 0
Low manual speed 150 150 150 150
High manual speed 300 300 300 300
Travel axis (travel motor):

A2TFH A2TGH A6TFH A6TGH
Motor FHP258 FHP258 FHP258 FHP258
Gear1 24:1 24:1 24:1 24:1
Gear2 51:1 51:1 51:1 51:1
P.D.mm 158 158 180 180
Encoder ppr 6 6 6 6
Low manual speed 100 100 100 100
High manual speed 200 200 200 200
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12.1.2 Function settings available for FREE2AX:

The following menu is shown when FREE2AX has been selected:
See on page 32 WIRE FEED AXIS

See on page 32 PEH TRAVEL AXIS
See on page 34 Binary inputs Not used, Guards, Limit sw, Start/stop
See on page 35 DRIVE TRIM MENU
1. WIRE FEED AXIS / PEH TRAVEL AXIS

WIRE FEED AXIS is used to adjust the wire feed motor.
PEH TRAVEL AXIS is used to adjust the travel motor.
The following menu is shown when either WIRE FEED AXIS or
PEH TRAVEL AXIS has been selected:
Motor FHP36/ FHP68/ FHP258/ VEC8000/ VEC4000/

DUNKER1/ DUNKER2/
MET3B (PEH 4.0, PEH4.01), VEC4000Par (PEH 4.2, PEH4.3)
GEAR 1
GEAR 2
P.D. mm 1--10000
Encoder ppr 0--10000
Low manual speed 1--1000
High manual speed 1--5000
GEAR1 and GEAR2 see on page 33.

P.D. mm is the feed roller diameter (effective diameter of the gearwheel).
Encoder ppr is the number of pulses per revolution or tacho pulses per
revolution. The default value is 6.
“Low manual speed”, the default value is 100
N.B Only for Wire feed motor.
The travel motor follows the value entered into the MAIN MENU.
“High manual speed”, the default value is 150.
Note that in the rows for P.D. mm, Encoder ppr, “Low manual speed” and
“High manual speed” you enter your own values if necessary.
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The following menu is shown when either “GEAR1”, “GEAR2” or “GEAR3” has been
selected:
N1 X
N2 X
By entering values for N1 and N2 any gear ratio located after the motor gears (for
example FHP 36) can be selected.
N1 = the number of teeth of the gear wheel of the motor shaft.
N2 = the number of teeth of the gear wheel of the outgoing shaft.
Example:
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2. Binary inputs
WIRE FEED AXIS
PEH TRAVEL AXIS
Binary inputs Not used, Guards, Limit sw, Start/stop
DRIVE TRIM MENU
Adjusting and using the inputs are only possible if product code “FREE2AX“ or
“FREE3AX” have been selected.
If other product codes (fixed ones) are selected the inputs will not be active.
The following alternatives are available:
S Not used
The inputs are not active.
S Guards
2 transducers (water and gas flow guards with normally closed (NC) contact
function) can be connected.
Note. If only one transducer is connected the other input must be bridged.
S Limit switch
Limit switches (normally with closed (NC) contact function) are to be
connected to the inputs. When one of the limit switches is activated (opened)
the motion of the motor ceases, and only the motion in the opposite direction
is possible.
S Start/stop
The function is used when external start and stop of the welding is desired. A
starting contact (closing NO) is to be connected to input K22. The stop
function is to be connected to K23.
The contact function of a transducer connected to
(Flashing)
the inputs shall normally be closed (NC). When the
switch (Guards or Limit switch) is opened this will be
indicated in the bottom right part of the display by a
flashing contact symbol.
Inlet K22 or K23 is open.
The inputs K22 and K23 on the

DCDUO board can be assigned
different functions on this
sub--menu.
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3. DRIVE TRIM MENU
WIRE FEED AXIS

PEH TRAVEL AXIS
Binary inputs Not used, Guards, Limit sw, Start/stop
DRIVE TRIM MENU
Use this menu to set up the required parameter and setting values for the PEH
electronics.
Data settings are stored in the IC15 flash memory chip (see page 25).
The settings are therefore unique for each electronic unit and are shown in this
menu.
The preset values for an untrimmed electronics card are shown in the table on
page 36. The values for a trimmed electronics card will differ from those of the
Preset Values.
Set your own offset values for the wire feed motor (M1) VXPoffset 32768, and for
the travel motor (M2) VYPoffset 32768.
Example:
How to adjust the offset error of the travel motor:
S Select DRIVE TRIM MENU and press .
S Select VXPoffset and press .

S Enter the desired value, for example 32868.
+
S Return to the MAIN MENU by holding down.
The value of the VXP offset is now 32868.
Proceed in the same way to adjust the offset error VYPoffset 32768 of the travel
motor.
If necessary, trimming data for the respective electronics card can be ordered
from ESAB.
When ordering trimming data, the manufacturing number must be indicated (to
be found on the DC DUO card, capacitor C201).
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The preset values for an untrimmed electronics card are shown in the
following table:
Name Trimming Explanation
Trim menu Default values (meaning)
VNscale 20480 Power supply to DC bus
VXPoffset 32768 Positive voltage offset, wire feed motor
VXNoffset 32768 Negative voltage offset, wire feed motor
CXPoffset 32768 Positive current offset, wire feed motor
CXNoffset 32768 Negative current offset, wire feed motor
VYPoffset 32768 Positive voltage offset, travel motor
VYNoffset 32768 Negative voltage offset, travel motor
CYPoffset 32768 Positive current offset, travel motor
CYNoffset 32768 Negative current offset, travel motor
VXPscale 19200 Positive armature voltage measurement / speed--con-
trolled wire feed
VXNscale 19200 Negative armature voltage measurement / speed--con-
trolled wire feed
CXPscale 3200 Positive armature current measurement
CXNscale 3200 Negative armature current measurement
VYPscale 19200 Positive armature voltage measurement / speed--con-
trolled travel motor
VYNscale 19200 Negative armature voltage measurement / speed--con-
trolled travel motor
CYPscale 3200 Positive armature current measurement
CYNscale 3200 Negative armature current measurement
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12.1.3 Function settings available for FREE3AX:

The following menu is shown when “FREE3AX” has been selected:
See on page 37 PEH AXES

See on page 32 EXTERNAL AXIS ROL, POS, LIN
When welding demands connection of an external Roller bed (ROL),

Positioner (POS) or Linear axis (LIN) settings must be made in “FREE3AX”.
To steer ROL, POS or LIN the analogue PCB card must be connected.
The PCB gives a reference signal of 0--10V and two direction signals (right and left).
1. PEH AXES
The following menu is shown when “PEH AXES” has been selected:
See on page 32 WIRE FEED AXIS

See on page 32 PEH TRAVEL AXIS
See on page 34 Binary inputs Not used, Guards, Limit sw, Start/stop
See on page 35 DRIVE TRIM MENU
For available settings, see on page 32 -- 36.
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2. EXTERNAL AXIS
PEH AXES
EXTERNAL AXIS ROL, POS, LIN
The following alternatives are available:

S ROL when using external Roller bed
S POS when using external Positioner
S LIN when using external Linear axis
Available settings for ROL and LIN:
GEAR 1
GEAR 2
GEAR 3
P.D. mm 1--10000
Motor rpm
Frequency ratio
Available settings for POS:
GEAR 1
GEAR 2
GEAR 3
Motor rpm
Frequency ratio
“GEAR1”, “GEAR2” and “GEAR3”, see on page 33.

P.D. mm is the effective diameter of the gearwheel.
Encoder ppr is the number of pulses per revolution or tacho pulses per
revolution. The default value is 6.
“Motor rpm” is the maximum rpm for the motor.
“Frequency ratio” N1, setting frequency converter values
N2, power supply frequency in Hz
“High manual speed”, is manual travel motion with high speed.
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MAIN MENU settings for Roller bed, Positioner and Linear axis
Roller bed (ROL)
When the Roller bed settings have been made, the active motion is displayed on
the MAIN MENU (see figure below).
Select an axis by pressing the Axis selection key on the remote control unit
RCC.
In systems without an RCC unit, press + to select an axis.
PEH 4.0 PEH 4.0

LINEAR CIRCULAR
The axis activated is presented here:
LINEAR = Boom or carriage (LINEAR1 = Boom, LINEAR2 = Carriage)

CIRCULAR = Roller bed
Positioner (POS)
To select active axis, proceed in the same way as for the Roller bed.
PEH 4.0 PEH 4.0

LINEAR POS
LINEAR AXIS (LIN)

To select active axis, proceed in the same way as for the Roller bed.
PEH 4.0 PEH 4.0

LINEAR 1 LINEAR 2
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“PRESET SYSTEM MENU” when setting Roller bed
Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU
Weld_diameter
Roller_diameter
Weld joint
Roller diameter Weld diameter
Roller bed
“PRESET SYSTEM MENU” when setting Positioner
Direction Y
Start Direct
STOP WELDING
WIRE DATA
Regulation CA
PRESET SYSTEM MENU
Weld_diameter
Weld joint
Weld diameter
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12.2 Weld process
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXX
Cable length (m) X
Cable area (mm2) X
The following alternatives can be selected:

S SAW for submerged arc welding
S GMAW for gas metal arc welding
S ESW for electro--slag welding (cladding)
S Gauging for arc--air gouging
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12.3 POWER SOURCE MENU

This menu is used for configuration of the welding power source.
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
The following menu is shown when POWER SOURCE MENU has been selected:
For program version 4.0 and 4.01:
See on page 42 Power source type LAF, TAF / Other / None

See on page 43 Max weld voltage, dv
See on page 43 Min weld voltage, dv
See on page 43 Max ref voltage, mV
See on page 44 Power source #
For program version 4.2, 4.3 and 5.0:
See on page 42 Power source type LAF, TAF / Other / None

See on page 44 Power source #
See on page 43 Wire Creep Speed
See on page 43 Max weld voltage, dv
See on page 43 Min weld voltage, dv
See on page 43 Max ref voltage, mV
1. Power source type:

LAF, TAF -- Welding power sources that are specially adapted to work with the
A2--A6 Process Controller.
Other -- Welding power source other than LAF/TAF, that is used together
with an analogue PCB card to get a voltage reference and
start/stop signal.
If Other has been selected it’s only possible to weld with a constant
wire feed speed (CW),
N.B This alternative is not available in the Chinese version.
None -- Control box PEH is used only to steer the travel direction.
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2. Max weld voltage, dv (valid when Other has been selected)

Max weld voltage that is allowed to be entered into the control box (20.0--60.0 V).
Note that this affects the resolution.
3. Min weld voltage, dv (valid when Other has been selected)

Min weld voltage that is allowed to be entered into the control box (0.0--30.0 V).
Note that this affects the resolution.
4. Max ref voltage, dv (valid when Other has been selected)

Max reference voltage out (1.000--10.000 V).
Reference voltage out from the PCB depends on which welding power source that is
being used.
Welding power
source
bus Analogue PCB
C15 Reference (not LAF/TAF)
PEH C16
Start/ Stop
C12
C13
Example:
Max requested reference voltage is 0--5 V, write 5000 in the menu.
The lowest requested weld voltage is 15 V, write 150 in the menu.
Max requested weld voltage is 50 V, write 500 in the menu.
Program version 4.0, 4.01: Program version 4.2, 4.3, 5.0, 5.1:
Power source type Other Power source type Other
Max weld voltage, dv 500 Power source #
Min weld voltage, dv 150 Wire Creep Speed
Max ref voltage, mV 5000 Max weld voltage, dv 500
Power source # Min weld voltage, dv 150
Max ref voltage, mV 5000
5. Wire creep speed (Valid for PEH4.2, PEH4.3, PEH4.3C)

Used for setting the desired wire creep speed of the feed motor at the start.
Entering for example the value 10 into the Wire Creep Speed menu will result in a
creep speed of 10 cm/min.
The preset value 0 will result in a creep speed calculated according to the set
welding data.
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6. Power source #
General
Used for Tandem welding to get both Systems to start welding at the same point.
This is only possible if the function “Weldhead offset” has been set (see on page 50).
N.B. Make sure that both control boxes have the same settings for “Weldhead offset”
and that they have the same welding speed.
The “Master” control box is number 1 (PEH1) and the “Slave” control box is
number 2 (PEH2).
Travel motion is always steered from PEH1.
System1
(PEH1 and Welding power source no. 1)
System2
(PEH2 and Welding power source no.2)
Weldhead offset
Start sequence/ Stop sequence

S The function start sequence can be used for both System1 and System2.
N.B. The speed must be the same for both Systems.
The function stop sequence can only be used for System2.
Gas metal arc welding (GMAW)

S To use GMAW, set “Gas postflow (s)” to 1 second, see on page 47.
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Example 1
System1
(PEH1 and Welding power source no. 1)
System2
(PEH2 and Welding power source no.2)
Weldhead offset
S Press start for both PEH1 and PEH2 at the same time.
S System1 starts welding.
System2 doesn’t start welding until it has reached the starting point for System1
(the distance is set in “Weldhead offset”).
S Press stop for both PEH1 and PEH2 at the same time.
S System1 stops welding while the travel motion continues.
System2 stops welding when it has reached the point where System1 stopped
welding (the distance is set in “Weldhead offset”).
S The weld is finished.
Example 2
When using a remote control box (RCC) the two systems must be connected to each
other (see manual A2- A6 Process Control System article no. 0458 081 074).
System 1 System 2
bus bus
DIG I/O 1 DIG I/O 2
D7 C2
When using an RCC one can when necessary use only Welding power source 2.
S Set “Weldhead offset” to 0 in the menu for PEH2.
S Press start for Welding power source 2 on the RCC.
System1 starts to move and System2 starts to weld
S Press stop for Welding power source 2 on the RCC to finish.
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Example 3
S Set “Weldhead offset” to 0 in the menu for PEH2.
S Press start for Welding power source 2 on the RCC.
System1 starts to move and System2 starts to weld
S Press stop for Welding power source 1, system2 continues welding, start
welding power source 1 and both systems weld.
Both systems can be stopped and started independently of each other.
-- 46 --
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12.4 Gas preflow (s) (only for GMAW)
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
The protective gas must start to flow before the arc is struck in order to provide time
for it to cover the weld position. A suitable preflow time must therefore be loaded
into the system, and this is done by entering the required time, in seconds, into the
selected field.
Times between 1 and 99 seconds can be entered. The default value is 1 second.
12.5 Gas postflow (s) (only for GMAW)
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
The protective gas must continue to flow after the arc is extinguished in order to
protect the weld while it cools. A suitable postflow time must therefore be loaded
into the system, and this is done by entering the required time, in seconds, into the
selected field.
Times between 1 and 99 seconds can be entered. The default value is 2 seconds.
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12.6 Password
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
Access to the PRESET SYSTEM MENU can be protected by entering a password in

the Password field.
The password must consist of not more than five numerals, XXXXX.
If no password is required, enter the numerical value 0. If the password consists of
more than one numeral, press a few times until there is only one 0.
The password that has been entered can be shown in the MAIN MENU display by
entering +
For example if the password is

12345 the display will show:
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12.7 Cable length (m)
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
The arc voltage is noticeably affected by the impedance of the welding cables. The
impedance is affected by such factors as the length, the cross--sectional area and
the laying of the cables. This effect is particularly marked when using AC welding
current sources.
The volt drop that occurs in long cables can be compensated for by entering the
exact length of the cable being used.
The total length of the cable in metres (welding current and return current cables
together) must be entered.
The value can be set between 10--1000 m. The default value is 10 m.
12.8 Cable area (mm2)
Product code A2TFH

Weld process SAW
POWER SOURCE MENU
Password XXXXX
Cable length (m) X
Cable area (mm2) X
Enter the cross--sectional area of the cable in mm2.

The value can be set between 25--1000 mm2. The default value is 95 mm2.
N.B.
When using two cables the cross--sectional area for both cables must be added
together.
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12.9 Weldhead offset, mm
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
Weldhead offset is the distance between the welding heads.

Used for Tandem welding so that both Systems start welding at the same point, see
on page 44.
IMPORTANT!
When setting the distance, “Offset” between welding head no.1 and welding head
no.2, the distance is converted by the PEH to a time between the start of welding
head no.1 and the start of welding head no.2.
The time that PEH can calculate for the distance between start/stop of the welding
power sources is max. 65 seconds.
This means that if for example a welding speed of 50 cm/min is set, it is only
possible to add max. 540 mm as an “Offset”. This is to prevent the time from
elapsing before welding head no.2 has come to the start point.
-- 50 --
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12.10 START SEQUENCE MENU
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
The following menu is shown when START SEQUENCE MENU has been selected:
START PHASE 1
START PHASE 2
Max OCV Off / On
On some occasions, for example when welding with special electrodes or materials,
it can be necessary to make up a special start sequence. The start method can also
influence the appearance of the weld bead.
The start sequence is divided into two phases (PHASE1 and PHASE2). The time
and percentage values of the two phases can be adjusted.
N.B. PHASE2 is not available in the Chinese version.
PHASE2 has no effect if t = 0 in PHASE1.
t = the durability of the sequence, indicated in intervals of 0.1 s (max. 99.9 s).
Max OCV (Max open circuit voltage)

On -- 50 V at start, after weld arc it returns to set value.
Off -- Set value at start.
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Example:
START PHASE 1 START PHASE 2
Time 0,1s 20 Time 0,1s 30

Speed % 100 Speed % 100
Voltage % 50 Voltage % 70
Current % 100 Current % 100
Wire feed % 100 Wire feed % 100
voltage
100 %
70 %
50 %
Phase 1 = 2,0 s Phase 2 = 3,0 s
Current, voltage and speed are adjusted by

indicating a percentage value of the welding
parameters on the main menu.
Max. adjustable value is 150% as long as the
capacity of the welding power source and the
max. possible welding speed are not exceeded.
Preset value is 100.
When the welding parameters are changed through the over--ride function, the
values in the start sequence are changed correspondingly, see the Instruction
manual.
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12.11 STOP SEQUENCE MENU
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
The following menu is shown when STOP SEQUENCE MENU has been selected:
STOP PHASE 1
STOP PHASE 2
The stop sequence menu is mainly used for programming the crater filling. It
is programmed in the same way as the start sequence menu.
In the stop sequence menu a phase can be interrupted by pressing the stop key .
PHASE2 has no effect if t = 0 in PHASE1.
t = the durability of the sequence, indicated in intervals of 0.1 s (max. 99.9 s).
N.B. PHASE2 is not available in the Chinese version.
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Example:
STOP PHASE 1 STOP PHASE 2
Time 0,1s 30 Time 0,1s 20

Speed % 100 Speed % 100
Voltage % 70 Voltage % 50
Current % 100 Current % 100
Wire feed % 100 Wire feed % 100
voltage
100 %
70 %
50 %
Phase 1 = 3,0 s Phase 2 = 2,0 s
Current, voltage and speed are adjusted by

indicating a percentage value of the welding
parameters on the main menu.
Max. adjustable value is 150% as long as the
capacity of the welding power source and the
max. possible welding speed are not
exceeded.
Preset value is 100.
When the welding parameters are changed through the over--ride function, the
values in the start sequence are changed correspondingly, see the Instruction
manual.
-- 54 --
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12.12 CALIBRATION MENU
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
Choosing the CALIBRATION MENU the following menu comes up:
Current at PEH % 100

Voltage at PEH % 100
Current at head % 100
Voltage at head % 100
Travel speed % 100
Wire speed % 100
Current at PEH %
Shows the real value in the PEH display expressed as a percentage of the desired
current reference value.
Voltage at PEH %
Shows the real value in the PEH display expressed as a percentage of the desired
voltage reference value.
Current at head %
Shows how many per cent the set reference value constitutes of the measured
current value at the welding head. This also affects the real value in the PEH display.
Voltage at head %
Shows how many per cent the set reference value constitutes of the measured
voltage value at the welding head. This also affects the real value in the PEH display.
Travel speed %
Adjustment as a percentage of the measured speed of the travel motor in relation to
the speed desired (valid for LINEAR 1).
Wire speed %
Adjustment as a percentage of the measured speed of the wire feed motor in relation
to the speed desired.
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Example
PEH
30 V
Welding head
LAF / TAF
{
+ -- 28 V
The value shown in the PEH is 30V. The measured value at the welding head is 28V.
The value for Voltage at head % will in this case be 107% (30/28 = 1,07⇒ 107).
Adjusting the Voltage at head % results in an increase of the value shown in the
PEH. The Voltage at PEH % must therefore be adjusted.
In order to reduce the value shown on the screen, indicate for
instance 30/32 = 0,94% 94%.
Current at PEH % 100

Voltage at PEH % 94
Current at head % 100
Voltage at head % 107
Travel speed % 100
Wire speed % 100
Before changing the CALIBRATION MENU, make sure all connectors are properly
fitted.
IMPORTANT!
S In order not to affect the voltage answer through inductance, the voltage
reference cable shall not be laid together with the current cable.
S The calibration shall be carried out by way of the existing cables at a known
load.
In order to get reliable measurement test results a measuring device in accordance
with the British standard BS 7570:2000 must be used.
Note that the system need not be linear within its working range.
The linearity is affected by induction and other disturbing factors coming up when
using different welding parameters.
The same adjustment in per cent within the whole range signifies that high values
are more affected than low ones.
-- 56 --
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12.13 DISPLAY MENU

This menu controls how the information on the display is presented.
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
The following menu is shown when DISPLAY MENU has been selected:
Unit Metric/ Inches

Current display Real value/ Set value
Heat input On/ Off
Parameter set 1
Units
Metric, Inches
Speeds, lengths or wire sizes in the MAIN MENU can be displayed in either metric
units or inches.
Current display
Set value, Real value
The welding parameters can be displayed as either set values or real values. The
set values are stable and are not subject to rapid fluctuations. On the other hand, if
information on the actual welding current is required, select real value and the
current will be shown in figures on the MAIN MENU display.
Heat input
On, Off
This shows how much energy is supplied to the weld, calculated from the set values
of voltage and current. It is displayed on the MAIN MENU as kJ/cm.
Parameter set
This specifies the number of parameter sets to be used: a maximum of ten is
allowed.
Enter a numerical for the number of sets in Column B. The default value is 1.
-- 57 --
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Example:
How to select the unit Metric:
S Select Unit and press .
S Find Metric by pressing .
S Return to the MAIN MENU with +
The unit has now been set to Metric.
-- 58 --
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12.14 ERROR LIST
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0/1/2
Error messages are displayed on the bottom row of the MAIN MENU.
Error messages that may occur are shown here:

Error codes, see on page 60.
Error categories
Emergency stop (see page 27)
A special emergency stop function that is activated by pressing the emergency stop
pushbutton in dangerous situations (e.g. risk of injury etc.).
When the reason for the emergency stop has been corrected, the emergency stop
function can be reset by deactivating the emergency stop pushbutton.
Incorrect entry of numerical values

If incorrect numerical values are entered (e.g. for voltage, current or speed), a
message is generated indicating the values that are allowed.
Error messages shown on the bottom line of the display.

Alarm
Conditions that could result in unacceptable defects in the process and which
automatically generate an emergency stop. When such a fault occurs, the error
message must be acknowledged by pressing after the fault has been corrected.
Error messages are displayed in sequence by the system and can be inspected in
the ERROR LIST menu. The system can store up to 20 messages, after which the
oldest messages are erased as new messages are added at the top of the list.
S Select ERROR LIST and press .
S Step through the list with .
To erase the errors press + .
S Return to the PRESET SYSTEM MENU with + .
-- 59 --
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Error codes
The following codes generated by the DC DUO board can be shown on the display:
Analogue board
203.01 Communication error with Stop Check cables and connections
Analogue card
I/O board
301.01 Communication error with Stop Check cables and connections
Digital I/O
Wire feed motor (Motor 1)

201.2 Current too high Stop Check wire feed
201.3 Overheating (Motor 1) Stop Wait until temperature has fallen
201:5 Communication error ** Stop Check the cabling.
Travel motor (Motor 2)

202.2 Current too high Stop Check travel motor / gearbox
202.3 Overheating (Motor 2) Stop Wait until temperature has fallen
202:5 Communication error ** Stop Check the cabling.
Drive unit (PEH4.2)

204.2 Short--circuit, drive unit ** Stop Replace the PC board
204.3 Overheating, drive unit ** Stop Wait for a while and then check the heat dissi-
pating element
Welding power source (T1)

111.01 Communication error Stop Check cables and connections
111.53 Unsuccessful start Stop Check stick--out and welding parameters
111.54 Current limit/ Stop Welding short--circuited, Cure short--circuit /
Arc extinguished*** Check wire feed
111.54 Current limit ** Stop Welding short--circuited, Cure short--circuit
111.55 Thermostat / overheating Stop Wait until temperature has fallen
111.57 Arc extinguished ** Stop Check wire feed
Inputs / outputs
Display No cooling water Stop Check if the gas is flowing or if the limit switch
(Flashing)
(inlet K22 open) * is open.
No gas flow Stop Check gas pressure or if the limit switch is

(Flashing)
(inlet K23 open) * open.
* These inputs are activated by entries in the menu “Binary inputs” (see page 34).
** Only valid for control box with program version PEH4.2, PEH4.2C, PEH4.3,
PEH4.3C, PEH5.0, PEH5.0C, PEH5.1 and PEH 5.1 C.
*** Only valid for control box with program version PEH4.0, PEH4.0C, PEH4.01 and
PEH 4.01C.
-- 60 --
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12.15 Test
Cable area (mm2) X

Weldhead offset, mm
START SEQUENCE MENU
STOP SEQUENCE MENU
CALIBRATION MENU
DISPLAY MENU
ERROR LIST
Test 0 /1 /2
When this menu is active, the main menu displays information that is normally
hidden
Test = 0
The function is not active.
Test = 1
Wire feed speed is shown in the MAIN MENU according to the figure below.
This is Not deactivated when the power is off.
Wire feed speed

(cm/ min)
Test = 2
Speed and motor current for both motors are shown in the MAIN MENU according to
the figure below. This is deactivated when the power is off.
Wire feed speed (cm/ min) Travel speed (cm/ min)

Motor current for wire feed Motor current for travel
-- 61 --
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13 PRESET SYSTEM MENU OVERVIEW
MAIN MENU
Direction Start
STOP WELDING WIRE DATA
Crater fill Burnback time Wire type Wire size
Regulation Wire material Number of wires
CA CW
Weld diameter *1 PRESET SYSTEM MENU
Roller diameter *2
Product code Weld process
WIRE FEED/TRAVEL AXIS Binary inputs

SAW GMAW ESW GAUG
Motor GEAR 1 Not used Guards
GEAR 2 GEAR 3 *
Limit sw Start/Stop
P.D. mm Encoder ppr
Motor rpm * Frequency ratio*
Low manual speed High manual speed
DRIVE TRIM MENU
POWER SOURCE MENU Gas preflow (s)

Power source type Power source #
Wire Creep Speed *3 Max weld voltage, dV
Min weld voltage, dV Max ref voltage, mV
Gas postflow (s) Password
Cable length (m) Cable area (mm2)
Weldhead offset, mm START SEQUENCE MENU
START PHASE 1 START PHASE 2
Max ocv
STOP SEQUENCE MENU CALIBRATION MENU

Current at PEH % Voltage at PEH %
STOP PHASE 1 STOP PHASE 2
Current at head % Voltage at head %
Travel speed % Wire speed %

DISPLAY MENU
Unit Current display
* FREE3AX
*1 Setting, Roller bed/ Positioner Heat input Parameter set
*2 Setting, Roller bed
*3 Valid from PEH4.2 ERROR LIST Test
-- 62 --
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14 CHANGE OF PROGRAM
14.1 General
When changing programs, the flash memory (IC15)
must be replaced. In doing this, the trimming data set
will be replaced by the preset values of the new flash
memory, see page 35.
To keep the set trimming data, the data must first be
stored in the welding power source and then be sent
back to the PEH electronics when the new flash
memory is installed.
Store trimming data for future upgradings of the
program if the complete PEH electronics are to be
replaced.
N.B. When changing the flash memory (IC15) make
sure that the program versions are compatible between
for example the PEH and the welding power source.
14.2 Storing trimming data

Trimming data to the welding power source:
+
S Press .
Trimming data are sent from the PEH electronics to
the welding power source where they are stored.
Trimming data back to the PEH electronics:
+
S Press .
Trimming data are sent from the welding power source to the PEH electronics.
Existing trimming data will be overwritten.
NOTE! After the trimming data have been recalled, the voltage supply to the
PEH electronics must be switched off, in order to activate the new trimming data.
NOTE!
To be sure that the trimming data of the PEH electronics are stored in the welding
power source, the data should always be stored before changing the program.
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14.3 Changing the program in the PEH electronics:

S Store trimming data in the welding power source
(see “Trimming data to the welding power source” on page 63).
S Replace the flash memory (IC15) on the NME card (AP2).
S Recall trimming data from the welding power source
(see “Trimming data back to the PEH electronics” on page 63).
14.4 Changing programs in the PEH electronics and the welding

power source:
S Store trimming data in the welding power source
(see “Trimming data to the welding power source” on page 63).
S Replace the flash memory (IC15) on the NME card (AP2).
S Recall trimming data from the welding power source
(see “Trimming data back to the PEH electronics” on page 63).
The right trimming data for the PEH electronics are now available in the new
electronics program.
S Replace the flash memory (IC6) in the welding power source.
S Switch on the welding power source.
In the event error code 111.01 should come up, the power source must be
switched off and then on again for correct initiation.
-- 64 --
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Spare parts list
A2- A6 Process Controller (PEH)

Edition 2004--12--17
Ordering no. Denomination Notes

0443 741 880 Control box A2--A6 Process Controller (PEH)
Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram
-- 65 --
pehspare
Item
Qty Ordering no. Denomination Notes C
no.
0443741880 CONTROL BOX PEH

3 1 0443638880 Control panel KB1
4 1 0443740001 Emergency stop ST1
8 2 0457278001 Rail
9 1 0443748880 Cable complete XS1
10 0443730880 Circuit board AP1 + AP2
14 1 0443849001 Insulation
20 1 0449130001 Display, ccfl backlight DY1
21 0192526003 Sealing strip 530 mm
23 10 0192645002 Bushing
26 2 0467911884 Capacitor Valid from programversion PEH1.2
41 1 0449137880 Inverter with screen box
-- 66 --
f443741r
Item
Qty Ordering no. Denomination Notes
no.
0443 748 880 Cable with connectors

1 1 0368 543 003 Pin socket, Burndy
4 1 0443 841 880 Cable set
6 1 0456 489 005 Circuit board connection
7 1 0456 489 004 Circuit board connection
8 1 0193 275 002 Connection block 3 pole
9 0190 209 109 Hose
10 2 0192 541 003 Pin cable clip 2,5 mm2
-- 67 --
f443748s
Item Ordering no.
Qty Denomination Notes C
no.
0443 730 880 Circuit board AP1 + AP2

2 0456 489 002 Connection terminal 6 poles K10, K11
3 0456 489 001 Connection terminal 2 poles K12, K17, K22, K23
4 0456 489 004 Connection terminal 2 poles K13, K14
5 1 0486 471 880 Flash memory IC15
7 0456 489 005 Connection terminal 4 poles K9, K9X
-- 68 --
s443730r
Item
no.
0456500880 Control cable L = 15 m, Accessories

1 1 0449449880 Control cable 15m, 12--28 pole (LAF/TAF--PEH)
2 1 0449448880 Adapter 28--12pol. (PEH--LAF 12p)



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


-- 69 --
f456500s
Item
no.
0449449880 Control cable 15m, 12-- 28 pole (LAF/TAF-- PEH)

1 1 0368541106 Pin plug, burndy 28 pol.
2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
4 1 0368542303 Sleeve plug, burndy 12 pol.
5 5 0323945002 Contact sleeve 0,32--0,52
6 3 0323945003 Connector sleeve 0,52--1,50
7 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2
8 4 0323945008 Contact pin max 2.5mm2
9 4 0323945007 Contact sleeve max 2.5mm2

2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
5 5 0323945002 Contact sleeve 0,32--0,52
9 4 0323945007 contact sleeve max 2.5mm2

2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
5 5 0323945002 Contact sleeve 0,32--0,52
-- 70 --
f449449s
Item
no.

2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
5 5 0323945002 Contact sleeve 0,32--0,52

2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
5 5 0323945002 Contact sleeve 0,32--0,52

2 3 0323945004 Connector pin 0,52--1,50
3 5 0323945001 Connector pin 0,32--0,52
5 5 0323945002 Contact sleeve 0,32--0,52
-- 71 --
f449449s
Item
no.
0449448880 Adapter 28-- 12POL(PEH-- LAF12P)

1 1 0368546106 Sleeve cable socket 28--pol
3 5 0323945002 Contact sleeve 0,32--0,52
4 1 0368541303 Pin plug burndy 12 pol.
5 5 0323945001 Connector pin 0,32--0,52
6 3 0323945004 Connector pin 0,52--1,50 0,52--1,50
7 1 0193963001 Cable, screened 5x0.5mm2 3x1.5mm2 4x2.5mm2
-- 72 --
f449448s
ALPHABETICAL LIST OF CONTENTS
A L
AC--Tachometer cable, 23 LED (L02 RED), 25
Adjusting the display contrast, 25 Linear axis, 39
Alarm, 59
M
Arc voltage, 23
Arc--air gouging (Gouging), 41 MENU OVERVIEW, 62
MIG/MAG welding, 41
B Motor cable, 23
Binary inputs, 34 Motor control software, 25
Bus termination, 13 , 26 Motor current, 21
C Motor field winding, 23
Cable area, 49 N
Cable length, 49 NME, 13 , 18 , 25 , 26
Cable, complete, 22
O
CALIBRATION MENU, 55
Change of program, 63 Offset error, 35
Communications software, 25 P
Control panel, 27
P.D. mm, 32 , 38
Current display, 57
Parameter set, 57
D Password, 48
DC DUO, 13 , 18 , 19 , 25 , 26 PEH AXES, 37
Diagnostics (NME), 25 PEH TRAVEL AXIS, 32
DIP switch (SW1), 18 , 25 Pilot lamp, 24
DISPLAY MENU, 57 Positioner, 39
DRIVE TRIM MENU, 35 POWER SOURCE MENU, 42
Power supply voltages, 20
E
PRESET SYSTEM MENU, 29
Electro--slag welding (ESW), 41 Product code, 30
Emergency stop, 13 , 59
Encoder ppr, 32 , 38 R
Error categories, 59 Roller bed, 39
Error codes: S
Arc extinguished, 60
Current limit, 60 Safety, 11
Overheating, 60 START SEQUENCE MENU, 51
Thermostat / overheating, 60 STOP SEQUENCE MENU, 53
Unsuccessful start, 60 Storing trimming data, 63
ERROR LIST, 59 Submerged arc welding, 41
Error message, 59 T
EXTERNAL AXIS, 38
Test menu, 61
External emergency stop, 24
Travel motor (M2), 13 , 21 , 23
F Trimming data, 35
Flash memory (IC15), 25 U
G Unit, 57
Gas flow guard, 13 , 24 W
Gas postflow, 47
Water flow guard, 13 , 24
Gas preflow, 47
Weld process, 41
Gas valve, 13 , 24
Weldhead offset, 50
H WIRE FEED AXIS, 32
Heat input, 57 Wire feed motor (M1), 13 , 21 , 23
IndexE -- 73 --
ESAB subsidiaries and representative offices
Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
CHINA
ESAB Ges.m.b.H Larvik ESAB Representative Office
Tel: +47 33 12 10 00 Shanghai ESAB A/P
Vienna--Liesing Shanghai Sofia
Tel: +43 1 888 25 11 Fax: +47 33 11 52 03 Tel/Fax: +359 2 974 42 88
Tel: +86 21 5308 9922
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ESAB France S.A. Gothenburg ESAB Asia/Pacific Pte Ltd other countries, please visit our
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Dietikon
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ESAB Welding & Cutting Products
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Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
061127

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A2- A6

0740 801 106 2007--02--20 Valid from machine no 220 XXX--XXXX

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

1.2 Software versions

Welding Power Source

ELECTRIC SHOCK -- Can kill

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

The component description refers to the component names in the connection

5 COMPONENT POSITIONS ON CIRCUIT BOARD AP2

6 COMPONENT POSITIONS ON CIRCUIT BOARD AP1

7 FUNCTION DESCRIPTION (CIRCUIT BOARD)

7.2 NME (AP2)

7.3 DC DUO (AP1)

8.2 Testing the internal power supply voltages

Set value Approved value range

8.3 Checking that the program is running

8.4 Checking NO. 1 output stage

8.7 Measuring the motor current

9.2 Internal connections

One conductor (emergency stop) is connected to emergency stop switch ST1.

Two conductors (bus communication) are

Two conductors (x3) (42 AC)

9.3 External connections

Motor connections for travel motor M2 (travel motion)

Connection of the welding head

Output for connecting a flux or gas valve, 42 V AC max. 0,5 A

Connection of an external emergency stop (accessory)

Connection of a Pilot lamp (accessory)

9.4 Adjusting the DC DUO

Connection of jumper J1:

Motor control software

9.5 NME connection

Setting the DIP switch SW1:

S The LED lights to indicate failure of communication to the DC DUO board, or in

9.6 Connection between the DC DUO and the NME

10 USING THE CONTROL PANEL

10.1 Control panel

The arrowed keys are used during welding to increase or

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

10.2 Using the keys

S Switch from the MAIN MENU to WELDING SETUP.

S To change a setting, move from Column A to Column B with .

S Find the required alternative with or with + .

S Return to Column A with

S Move forward to the next row with .

S Move back to the previous row with + .

S Return to the previous menu with .

11 PRESET SYSTEM MENU

11.2 System function settings available

12 DEFINITIONS (PRESET SYSTEM MENU)

12.1 Product code

Product code A2TFH

System configuration uses product codes that are explained below.

To select “FREE2AX / FREE3AX”, select it and press .

Table for program version 4.0 and 4.01:

Travel axis (travel motor):

Table for program version 4.2, 4.3, 5.0 and 5.1:

Wire feed axis (wire feed motor):

Travel axis (travel motor):

12.1.2 Function settings available for FREE2AX:

See on page 32 WIRE FEED AXIS