A2- A6 Process Controller

Transcription

1 A2- A6 Process Controller PEH Bruksanvisning Brugsanvisning Bruksanvisning Käyttöohjeet Instruction manual Betriebsanweisung Valid for machine no 220 -xxx -xxxx Valid for program version PEH4.0, PEH4.01 and PEH4.2

2 VENKA... 4 DANK NORK UOMI ENGLIH DEUTCH Rätt till ändring av specifikationer utan avisering förbehålles. Ret til ændring af specifikationer uden varsel forbeholdes. Rett til å endre spesifikasjoner uten varsel forbeholdes. Oikeudet muutoksiin pidätetään. Rights reserved to alter specifications without notice. Änderungen vorbehalten

3 FÖRÄKRAN OM ÖVERENTÄMMELE Esab Welding Equipment AB, Laxå, weden, försäkrar under eget ansvar att manöverlåda A2--A6 Process Controller från serienummer 220 är i överensstämmelse med standard EN enligt villkoren i direktiv (73/23/EEG) med tillägg (93/68/EEG) OVERENTEMMELEERKLÆRING Esab Welding Equipment AB, Laxå, weden garanterer under eget ansvar, at styreboks A2--A6 Process Controller fra serienummer 220 er i overensstemmelse med standard EN ifølge betingelserne i direktiv (73/23/EEC) med tillægg (93/68/EEC) FORIKRING OM OVERENTEMMELE Esab Welding Equipment AB, Laxå, weden, forsikrer på eget ansvar at bryterskap A2--A6 Process Controller fra serienummer 220 er i samsvar med standard EN i overensstemmelse med bestemmelsene i direktiv (73/23/EØF) med tillegg (93/68/EØF) VAATIMUTENMUKAIUUVAKUUTU Esab Welding Equipment AB, Laxå, weden, vakuuttaa omalla vastuullaan, että ohjausyksikkö A2--A6 Process Controller sarjanumerosta 220 täyttää standardin EN vaatimukset direktiivin (73/23/EEC) ja sen lisäyksen (93/68/EEC) mukaisesti DECLARATION OF CONFORMITY Esab Welding Equipment AB, Laxå, weden, gives its unreserved guarantee that control unit A2--A6 Process Controller from serial number 220 complies with standard EN , in accordance with the requirements of directive (73/23/EEA) and addendum (93/68/EEA) KONFORMITÄTERKLÄRUNG Esab Welding Equipment AB, Laxå, weden, versichert hiermit auf eigene Verantwortung, daß die Bedieneinheit A2--A6 Process Controller ab erien--nr 220 mit der Norm EN gemäß den Bedingungen der Richtlinien (73/23/EWG) mit der Ergänzung (93/68/EWG) in Übereinstimmung steht Göteborg Greger Jacobson enior Vice President EAB AB E Göteborg weden Tel: Fax:

4 ENGLIH 1AFETY INTRODUCTION General Welding power sources Technical data INTALLATION General Connection of the welding power source Connection of the welding head OPERATIONAL DECRIPTION General Control panel MANUAL OPERATION Travel and wire feed Controlling valves MENU Menu overview MAINMENU General Entering welding parameters Adjusting parameter values (during welding) Choosing a new set of parameters during welding electing the display language WELDING ETUP General Changing settings Available settings Definitions Preset indicators ERROR LIT Error codes MAINTENANCE General ORDERING PARE PART DIAGRAM ACCEORIE PARE PART LIT TOCe

5 1 AFETY Users of EAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. afety precautions must meet the requirements that apply to this type of welding equipment. The following recommendations 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: its operation location of emergency stops its function relevant safety precautions welding 2. The operator must ensure that: no unauthorised person is stationed within the working area of the equipment when it is started up. no--one is unprotected when the arc is struck 3. The workplace must: be suitable for the purpose be free from draughts 4. Personal safety equipment Always wear recommended personal safety equipment, such as safety glasses, flame--proof clothing, safety gloves. Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5. General precautions Make sure the return cable is connected securely. Work on high voltage equipment may only be carried out by a qualified electrician. Appropriate fire extinquishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on the equipment during operation. fgb7safe

6 WARNING ARC WELDING AND CUTTING CAN BE INJURIOU TO YOURELF AND OTHER. TAKE PRECAU- TION WHEN WELDING. AK FOR YOUR EMPLOYER AFETY PRACTICE WHICH HOULD BE BAED ON MANUFACTURER HAZARD DATA. ELECTRIC HOCK - Can kill Install and earth the welding unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. Insulate yourself from earth and the workpiece. Ensure your working stance is safe. FUME AND GAE - Can be dangerous to health Keep your head out of the fumes. Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAY - Can injure eyes and burn skin. Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. Protect bystanders with suitable screens or curtains. FIRE HAZARD parks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOIE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERTAND THE INTRUCTION MANUAL BEFORE INTALLING OR OPERATING. PROTECT YOURELF AND OTHER! 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. fgb7safe

7 2 INTRODUCTION 2.1 General EAB s A2--A6 Process Controller (PEH) is a control unit which, when combined with A2--A6 automatic welding equipment can be used for submerged--arc or MIG/MAG welding. The process controller is designed for use with EAB s LAF and TAF welding power sources. Close integration of the control system with the welding power source makes it possible to ensure very precise process reliability. All the controls that are needed to control welding travel and the entire welding process are situated on the control panel. Incoming cables from various system components are connected to sockets at the rear of the process controller or to the circuit board terminals inside the controller. 2.2 Welding power sources The welding power sources are specially adapted to work with the A2--A6 Process Controller. The welding power source and process controller are connected by a twin wire bus that allows the welding process to be controlled and monitored much more precisely than previously possible. The power source settings can be adjusted from the control panel on the process controller. EAB s earlier generation of welding power sources, such as the LAH, LAE and TAE can be adapted for use with the new process controller with the aid of a conversion kit. The new welding power sources are already prepared for straightforward connection to the A2--A6 Process Controller (PEH). The welding power sources also supply the correct current to the process controller, thus eliminating the need for any external power supply. 2.3 Technical data A2 -A6 Process Controller (PEH) Nominal voltage from power source: 42V AC 50/60 Hz Nominal load: Max. 900 VA Motor connections adapted for EAB s A2 - or A6 - motors: Motor current 5 A continuous, max. 10 A Wire speed regulation: Internal EMK control or with AC tacho, 6 pulses per rev Welding speed: m/min (depending on travel unit)) Max. manual travel speed: 2.0 m/min Filler wire, wire feed speed: m/min (depending on wire feed unit) Ambient temperature: Max. 45_ C, Min. --15_ C Relative humidity: Max. 98 % Weight: Dimensions L x B x H: 5.5 kg Enclosure class: IP x 210 x 164 mm Enclosure class The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water. Equipment marked IP 23 is designed for indoor and outdoor use. fgb7d1ea

8 3 INTALLATION 3.1 General The installation must be executed by a professional. 3.2 Connection of the welding power source Connect control cable (1) from the welding power source to connector X Connection of the welding head Arc voltage to terminal X2.1 As to all other connections, contact EAB. Connection of welding power source Connection of the welding head fgb7i1ea

9 4 OPERATIONAL DECRIPTION 4.1 General witch on welding power source The process controller can be used in manual or automatic mode. In manual mode the wire feed speed and travel speed are controlled manually and you can preset all other essential welding parameters for the current weld. In automatic mode you can choose a preset group of welding parameters and fine--tune the actual welding parameters. Other settings made previously in manual mode cannot be adjusted in automatic mode. The process controller is ready for manual operation as soon as the mains power is switched on. When welding begins the controller switches to automatic mode. When welding stops, or if there is a fault, the controller switches back to manual mode. 4.2 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. HIFT key 10. top welding. Return to manual mode 11. tart welding. witch to automatic mode 12. Fast, wire feed or travel 13. croll 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. fgb7fb1e

10 5 MANUAL OPERATION 5.1 Travel and wire feed Travel and wire feed commands can be given when not welding, as follows: witch on welding power source The direction of travel is as shown by the square symbol on the welding equipment. Normal speed. The direction of travel is as shown by the triangular symbol on the welding equipment. Normal speed. To stop travel described above, press the same key again. Retract wire. Normal speed. Wire continues to retract until you release the key. Advance wire. Normal speed. Wire continues to advance until you release the key. After switching on, you can select maximum speed by pressing the fast key. The LED in the key lights up. To return to normal speed press the fast key again. To stop immediately, press, or even at max. speed. Normal speed and max. speed can be adjusted under PREET YTEM MENU. 5.2 Controlling valves To operate a valve you must be in the MAIN MENU. Open the valve for flux or gas by pressing. Close an open valve by pressing the same key. Valve (Open/ Closed) fgb7o1ea

11 6 MENU 6.1 Menu overview The A2--A6 Process Controller (PEH) software is divided into several menus. The program structure is described in the overview below. MAIN MENU Direction tart TOP WELDING WIRE DATA Regulation PREET YTEM MENU Y Direct CA WELDING ETUP MAIN MENU ET Heat input per cm Welding current Wire feed speed Arc voltage Travel speed Preset indicators electing the display language WELDING ETUP Arc start method Type of weld finish Welding direction Regulation method Wire type Wire material Wire size PREET YTEM MENU / DIPLAY MENU / ERROR LIT Menus that are not accessible by the user fgb7me1e

12 7 MAIN MENU 7.1 General In the MAIN MENU you choose the welding current, arc voltage and travel speed you want to use for welding. During welding you can adjust the welding parameters or choose a complete new set of parameters. witch on the power source. The main menu will appear as follows: Indicates that parameter set 1 of 10 available has been selected (can be hidden). Indicates the heat input in kj/cm that will result from the chosen values of welding current, arc voltage and travel speed (can be hidden). Indicates the type of start Travel direction Chosen arc voltage in volts. Chosen travel speed in centimetres per minute. Indicates if the valve output is open or closed. Example of display if constant current (CA) has been chosen. Example of display if welding with constant wire feed speed (CW) is chosen. Chosen welding current in amperes. Example of display during welding at constant wire feed speed (CW). Chosen wire feed speed. Resultingweldingcurrent after the welding start. For the selection of (CA) or (CW), see the menu WELDING ETUP on page 102. fgb7hm1e

13 Example of display in the event of a fault. Error code appears in bottom left section of display. Error message is cancelled by pressing Max. 20 messages saved in chronological order. tart welding by pressing. The LED in the key lights up. top welding by pressing fgb7hm1e

14 7.2 Entering welding parameters When the power source is switched on, the main menu appears on the display. In the Display menu you can choose how many sets of parameters you want to work with. If more than one set of parameters is used then the ET number appears in the top left corner. 1. Welding current or wire feed speed 2. ET no. 3. Arc voltage 4. Travel speed If you choose to work with just one set of parameters then start at step 3. Press + to mark the parameter set field. Type in the desired ET number and press. elect the field for welding current or wire feed speed by pressing. Type in the desired welding current or wire feed speed. Max. 4 numbers, press. elect the field for arc voltage by pressing. Type in the desired arc voltage, max. 3 numbers, press. elect the field for travel speed by pressing. Type in the desired travel speed, max. 3 numbers and press. Now the whole set has been marked and is ready to use. A further 9 additional sets can be stored. (Total 10 ETs). fgb7hm1e

15 7.3 Adjusting parameter values (during welding) Once welding has started the welding parameters can be fine--tuned using the arrowed numerical keys (over -ride function). Increase Decrease Welding current or wire feed speed Arc voltage Travel speed ave the values as follows: top welding with. ave the changed values with. To revert to the original values, press +. fgb7hm1e

16 7.4 Choosing a new set of parameters during welding (Only possible when you have chosen to work with several sets of parameters by programming the Display menu) Immediate selection uppose that while welding with parameter set 1 ( ET 1 ) you decide to change to parameter set 6 ( ET 6 ) without checking the parameters first. Press +. The field ET 1 is marked and parameter set 1 is active Press. The field ET 6 flashes. Press. The field ET 6 is marked and parameter set 6 is active Check before choosing uppose that while welding with parameter set 1 ( ET 1 ) you decide to change to parameter set 6 ( ET 6 ) after first checking the parameters. Mark the field ET 1 by pressing +. Press. The field ET 6 flashes. The new parameter set can be checked before being chosen by pressing +. The complete row displaying the welding parameters flashes and displays the values for parameter set 6 ( ET 6 ), although parameter set 1 ( ET1 ) remains in use during the current welding cycle. Press. The field ET 6 is marked and parameter set 6 is active. fgb7hm1e

17 7.5 electing the display language The selection is made in the MAIN MENU Display language Press. The current language is shown in the top right corner of the display. croll forward to the desired language with. Return with. The following languages can be selected: venska=wedish / Dansk=Danish / Norsk=Norwegian / oumi=finnish / English=English / Deutsch=German / Francaise=French / Nederlands=Dutch / Espanol=panish / Italiano=Italian / Portugues=Portuguese / Eesti=Estonian / Cesky=Czechoslovakian. N.B. The China version is only available in English and Chinese. fgb7hm1e

18 8 WELDING ETUP 8.1 General In WELDING ETUP you can choose a variety of settings including start method, welding direction, wire diameter and similar variables in order to carry out a specific welding task. These settings cannot be changed during welding. GB witch from the MAIN MENU to WELDING ETUP. Direction Y tart Direct TOP WELDING WIRE DATA Regulation CA PREET YTEM MENU 8.2 Changing settings Direction tart TOP WELDING WIRE DATA Regulation PREET YTEM MENU Y Direct CA General croll between the alternatives in the left column with or +. When all settings have been done return to the MAIN MENU with +. For available settings see on page 103. To change the settings for Direction, tart and Regulation: Mark menu Direction, tart or Regulation and press. croll forward to the chosen option with. Return with +. To change the settings for TOP WELDING and WIRE DATA: Mark menu TOP WELDING or WIRE DATA and press. elect the alternative that is to be changed with. Press. croll forward to the chosen option with or type in your own values. Return with + Explanations of terms: When is indicated in combination with another key you should press first and hold it down while pressing the second key. fgb7fs1e

19 8.3 Available settings Press Press Direction Y, J tart Direct cratch TOP WELDING WIRE DATA Regulation Crater fill (ms) Burnback time (ms) Wire type Wire diameter if olid wire is chosen if Flux cored is chosen if trip is chosen if Gauging is chosen Wire material Number of wires 1, 2 CA, CW olid wire, Flux cored, trip, Gauging x0.5 60x x Fe, Al, PREET YTEM MENU N.B! The menu PREET YTEM MENU is not accessible to the user fgb7fs1e

20 8.4 Definitions 1. Direction Two alternatives can be chosen Y repeated on all units) (triangle) and J (square) (these symbols are Y (triangle) indicates travel in one direction. J (square) indicate 2. tart Two alternatives can be chosen: Direct start or cratch start. Direct start means that travel starts when the arc ignites. cratch start means that travel starts at the same time as wire feed. crape start is used when welding rusty or dirty material. 3. TOP WELDING Crater fill and Burnback time canbeset. Crater fill times between 10 and 3000 ms ( sec.) can be selected. The crater fill function is used to finish the weld without leaving a crater. Crater fill starts when the welding stop key is pressed, and continues for the preset crater fill time. This function is most useful when MIG/MAG welding. Burnback times between 10 and 3000 ms ( sec.) can be selected. The burnback time starts after the crater fill sequence has ended. Correct choice of the burnback time prevents: the wire sticking to the work piece the wire sticking to the nozzle fgb7fs1e

21 4. WIRE DATA Wire type The equipment can be preset for the wire you intend to weld with. The control system must be given information about the wire shape in order to achieve optimum start/stop characteristics. solid wire cored wire strip gauging Wire diameter The chosen wire diameter has a big effect on the start cycle and crater filling. When welding with a wire diameter that is not given in the options table, choose the nearest diameter from the menu. Note! For certain wire materials a better welding result can be achieved, if a value deviating from the real wire dimension by 1 step is set (normally 1 step from the real value). When metric units are used the following alternatives are available: olid wire: Cored wire: trip: Gauging: olid: Cored wire: When inch units are used the following alternatives are available trip: 0.8 mm 0.8 mm 30x0.5 mm 8.0 mm x /2 1.0 mm 1.0 mm 60x0.5 mm 9.5 mm x /6 1.2 mm 1.2 mm 100x0.5 mm 13.0 mm x /8 1.6 mm 1.6 mm 1/16 1/ mm 2.0 mm 5/64 5/ mm 2.4 mm 3/32 3/ mm 3.0 mm 7/64 7/ mm 3.2 mm 1/8 1/8 4.0 mm 4.0 mm 5/32 5/ mm 3/ mm 1/4 Gauging: Wire composition When welding with different filler materials the start and stop method is affected by the choice of materials. It is therefore important that the settings show whether you are welding with steel--based or aluminium--based filler wires. Fe teel filler wire Al Aluminium filler wire tainless steel filler wire Number of wires Values between can be entered. For example, if welding with two wires (Twin Arc) enter the value 2. fgb7fs1e

22 5. Regulation Two different operating modes can be used for welding, either constant current, CA, or constant wire feed speed, CW. CA, constant current. Normally used for submerged arc welding, which involves working with large welds, large currents and large weld pools. The wire feed speed is controlled by the power source to maintain a constant current. CW, constant wire feed speed. Normally used for MIG/MAG welding, for small weld pools, thin sheet metal and thin filler wire. It is easier to achieve a constant throat thickness when welding with this method. Welding is controlled by selecting a fixed wire feed speed and the current is adjusted to achieve this speed. The resulting current is displayed above the selected wire feed speed (see display shot on page 106). 8.5 Preset indicators The numbers and symbols on the display show the chosen preset values, see table below. hown in display MAIN MENU as Y J hown in plain English (e.g. 3.0) tart Direction Wire diameter: olid wire Flux cored trip gauging WELDING ETUP options Direct cratch TRIANGLE QUARE x0.5 60x x OUTPUT Open/Closed Valve fgb7fs1e

23 9 ERROR LIT 9.1 Error codes Analogue board Communication error with Analogue card top Check cables and connections I/O board Communication error with Digital I/O top Check cables and connections Wire feed motor (Motor 1) Current too high top Check wire feed Overheating (Motor 1) top Wait until temperature has fallen 201:5 Communication error ** top Check the cabling. Travel motor (Motor 2) Current too high top Check travel motor / gearbox Overheating (Motor 2) top Wait until temperature has fallen 202:5 Communication error ** top Check the cabling. Drive unit (PEH4.2) hort--circuit, drive unit ** top Replace the PC board Overheating, drive unit ** top Wait for a while and then check the heat dissipating element Welding power source (T1) Communication error top Check cables and connections Unsuccessful start top Check stick--out and welding parameters Current limit/ Arc extinguished *** top Welding short--circuited, Cure short--circuit / Check wire feed Current limit ** top Welding short--circuited, Cure short--circuit Thermostat / overheating top Wait until temperature has fallen Arc extinguished ** top Check wire feed Inputs / outputs Display No cooling water top Check if the gas is flowing or if the limit (Flashing) (inlet K22 open) * switch is open. (Flashing) No gas flow (inlet K23 open) * top Check gas pressure or if the limit switch is open. * Inputs are activated by using settings in menu PREET YTEM MENU. ** Only valid for control box with program version PEH4.2. *** Only valid for control box with program version PEH4.0 and PEH4.01. fgb7f1ea

24 10 MAINTENANCE 10.1 General Note: All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period. In the event of malfunction: Contact your nearest EAB representative, see last page. 11 ORDERING PARE PART pare parts are ordered through your nearest EAB representative, see back cover. When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 135. This will simplify dispatch and ensure you get the right part. fgb7f1ea

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26 EAB subsidiaries and representative offices Europe AUTRIA EAB Ges.m.b.H Vienna -Liesing Tel: Fax: BELGIUM.A. EAB N.V. Brussels Tel: Fax: THE CZECH REPUBLIC EAB VAMBERK s.r.o. Prague Tel: Fax: DENMARK Aktieselskabet EAB Copenhagen -Valby Tel: Fax: FINLAND EAB Oy Helsinki Tel: Fax: FRANCE EAB France.A. Cergy Pontoise Tel: Fax: GERMANY EAB GmbH olingen Tel: Fax: GREAT BRITAIN EAB Group (UK) Ltd Waltham Cross Tel: Fax: EAB Automation Ltd Andover Tel: Fax: NORWAY A EAB Larvik Tel: Fax: POLAND EAB p.z.o.o Warszaw Tel: Fax: PORTUGAL EAB Lda Lisbon Tel: Fax: LOVAKIA EAB lovakia s.r.o. Bratislava Tel: Fax: PAIN EAB Ibérica.A. Alcobendas (Madrid) Tel: Fax: WEDEN EAB verige AB Gothenburg Tel: Fax: EAB International AB Gothenburg Tel: Fax: WITZERLAND EAB AG Dietikon Tel: Fax: North and outh America ARGENTINA CONARCO Buenos Aires Tel: Fax: BRAZIL EAB.A. Contagem -MG Tel: Fax: Asia/Pacific CHINA hanghai EAB A/P hanghai Tel: Fax: INDIA EAB India Ltd Calcutta Tel: Fax: INDONEIA P.T. Esabindo Pratama Jakarta Tel: Fax: MALAYIA EAB (Malaysia) nd Bhd elangor Tel: Fax: INGAPORE EAB ingapore Pte Ltd ingapore Tel: Fax: EAB Asia/Pacific Pte Ltd ingapore Tel: Fax: OUTH KOREA EAB eah Corporation Kyung -Nam Tel: Fax: UNITED ARAB EMIRATE EAB Middle East Dubai Tel: Fax: Representative offices BULGARIA EAB Representative Office ofia Tel/Fax: EGYPT EAB Egypt Dokki -Cairo Tel: Fax: ROMANIA EAB Representative Office Bucharest Tel/Fax: RUIA -CI EAB Representative Office Moscow Tel: Fax: EAB Representative Office t Petersburg Tel: Fax: Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page HUNGARY EAB Kft Budapest Tel: Fax: ITALY EAB aldatura.p.a. Mesero (Mi) Tel: Fax: THE NETHERLAND EAB Nederland B.V. Utrecht Tel: Fax: CANADA EAB Group Canada Inc. Missisauga, Ontario Tel: Fax: MEXICO EAB Mexico.A. Monterrey Tel: Fax: UA EAB Welding & Cutting Products Florence, C Tel: Fax: EAB AB E LAXÅ WEDEN Phone