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.
Software versions 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 program (Flash, IC 15) 486471880 PEH 1.1 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0211 Dat.
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From 00.04.04 PEH program (Flash, IC 15) 486471880 PEH 3.1 DCDUO program (Prom, IC304) 68S07001A02 CHKSUM 0221 Dat. 1998.04.04 One software version for all applications (Tractors and C&B). From 02.11.15 PEH program (Flash, IC 15) 486471880 PEH 4.0 PEH program, China (Flash, IC 15) 486471881 PEH 4.0C DCDUO program (Prom, IC304)
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From 05.01.01 PEH program (Flash, IC 15) 486471880 PEH 4.3 PEH program China (Flash, IC 15) 486471881 PEH 4.3C DCDUO program (Prom, IC304) 68S07001A02 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 The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor node 4.0.
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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 program (Flash, IC 6) 486525880 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.
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From 99.06.20 Analogue Motor node 486569880 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 Analogue Motor node 486569880 RB 4.0 Returns actual speed for external travel axis.
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.
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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 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.
COMPONENT DESCRIPTION The component description refers to the component names in the connection diagram. DC DUO circuit board: see the function description on page 19. NME circuit board: see the function description on page 18. Display Pilot lamp (accessory) Control panel (see page 27) Connector for the graphic display.
FUNCTION DESCRIPTION (CIRCUIT BOARD) Serial buss 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.
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.
TEST POINTS 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 V 46,2 V ± ± 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...
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. Checking NO.
INSTALLATION 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. Internal connections Connect incoming cables to the 12--pole connector (XS1) and the circuit board contacts on the inside of the control unit.
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.
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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 mm , connected to K23.1 and K23.2. Input for connection of a water flow guard (NC), limit switch or external start function. Screened 2--wire 2 x 0,75 mm , connected to K22.1 and K22.2.
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 For the blue display place the jumper on 2 and 3.
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. 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.
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.
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).
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.
DEFINITIONS (PRESET SYSTEM MENU) 12.1 Product code Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1- -99 Gas postflow (s) 1- -99 Password XXXXX Cable length (m) Cable area (mm2) 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.
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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...
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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 DRIVE TRIM MENU See on page 35 1.
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The following menu is shown when either “GEAR1”, “GEAR2” or “GEAR3” has been selected: 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.
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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: Not used The inputs are not active.
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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...
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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”.
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2. EXTERNAL AXIS PEH AXES EXTERNAL AXIS ROL, POS, LIN The following alternatives are available: ROL when using external Roller bed POS when using external Positioner LIN when using external Linear axis Available settings for ROL and LIN: GEAR 1 GEAR 2 GEAR 3 P.D.
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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.
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“PRESET SYSTEM MENU” when setting Roller bed Direction Start Direct STOP WELDING WIRE DATA Regulation PRESET SYSTEM MENU Weld_diameter Roller_diameter Weld joint Weld diameter Roller diameter Roller bed “PRESET SYSTEM MENU” when setting Positioner Direction Start Direct STOP WELDING WIRE DATA Regulation PRESET SYSTEM MENU Weld_diameter...
12.2 Weld process Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1- -99 Gas postflow (s) 1- -99 Password Cable length (m) Cable area (mm2) The following alternatives can be selected: SAW for submerged arc welding GMAW for gas metal arc welding ESW for electro--slag welding (cladding) Gauging for arc--air gouging - - 41 - -...
12.3 POWER SOURCE MENU This menu is used for configuration of the welding power source. Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1- -99 Gas postflow (s) 1- -99 Password XXXXX Cable length (m) Cable area (mm2) The following menu is shown when POWER SOURCE MENU has been selected: For program version 4.0 and 4.01: See on page 42...
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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).
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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.
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Example 1 System1 (PEH1 and Welding power source no. 1) System2 (PEH2 and Welding power source no.2) Weldhead offset Press start for both PEH1 and PEH2 at the same time. System1 starts welding. System2 doesn’t start welding until it has reached the starting point for System1 (the distance is set in “Weldhead offset”).
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Example 3 Set “Weldhead offset” to 0 in the menu for PEH2. Press start for Welding power source 2 on the RCC. System1 starts to move and System2 starts to weld Press stop for Welding power source 1, system2 continues welding, start welding power source 1 and both systems weld.
12.4 Gas preflow (s) (only for GMAW) Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1--99 Gas postflow (s) 1- -99 Password XXXXX Cable length (m) Cable area (mm2) The protective gas must start to flow before the arc is struck in order to provide time for it to cover the weld position.
12.6 Password Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1- -99 Gas postflow (s) 1- -99 Password XXXXX Cable length (m) Cable area (mm2) Access to the PRESET SYSTEM MENU can be protected by entering a password in the Password field.
12.7 Cable length (m) Product code A2TFH Weld process POWER SOURCE MENU Gas preflow (s) 1- -99 Gas postflow (s) 1- -99 Password XXXXX Cable length (m) Cable area (mm2) 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.
12.9 Weldhead offset, mm Cable area (mm2) 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.
12.10 START SEQUENCE MENU Cable area (mm2) 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...
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Example: START PHASE 1 START PHASE 2 Time 0,1s Time 0,1s Speed Speed Voltage Voltage Current Current Wire feed Wire feed 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.
12.11 STOP SEQUENCE MENU Cable area (mm2) 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.
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Example: STOP PHASE 1 STOP PHASE 2 Time 0,1s Time 0,1s Speed Speed Voltage Voltage Current Current Wire feed Wire feed 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.
12.12 CALIBRATION MENU Cable area (mm2) 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 % Voltage at PEH % Current at head % Voltage at head %...
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Example 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.
12.13 DISPLAY MENU This menu controls how the information on the display is presented. Cable area (mm2) 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...
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Example: How to select the unit Metric: Select Unit and press Find Metric by pressing Return to the MAIN MENU with The unit has now been set to Metric. - - 58 - - fzb2d3ea...
12.14 ERROR LIST Cable area (mm2) 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.
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** 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 - -...
12.15 Test Cable area (mm2) 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.
PRESET SYSTEM MENU OVERVIEW MAIN MENU Direction Start STOP WELDING WIRE DATA Crater fill Burnback time Wire type Wire size Wire material Number of wires Regulation PRESET SYSTEM MENU Weld diameter *1 Roller diameter *2 Product code Weld process Binary inputs WIRE FEED/TRAVEL AXIS GMAW GAUG...
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.
14.3 Changing the program in the PEH electronics: Store trimming data in the welding power source (see “Trimming data to the welding power source” on page 63). Replace the flash memory (IC15) on the NME card (AP2). Recall trimming data from the welding power source (see “Trimming data back to the PEH electronics”...
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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...
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Item Ordering no. Denomination Notes 0456500880 Control cable L = 15 m, Accessories 0449449880 Control cable 15m, 12- -28 pole (LAF/TAF- -PEH) 0449448880 Adapter 28- -12pol. (PEH- -LAF 12p) 0456500881 Control cable L = 25 m, Accessories 0449449881 Control cable 25m, 12- -28 pole (LAF/TAF- -PEH) 0449448880 Adapter...
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ALPHABETICAL LIST OF CONTENTS AC--Tachometer cable, 23 LED (L02 RED), 25 Adjusting the display contrast, 25 Linear axis, 39 Alarm, 59 Arc voltage, 23 MENU OVERVIEW, 62 Arc--air gouging (Gouging), 41 MIG/MAG welding, 41 Motor cable, 23 Binary inputs, 34 Motor control software, 25 Bus termination, 13 , 26 Motor current, 21...
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ESAB subsidiaries and representative offices Europe Asia/Pacific Representative offices NORWAY AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna- -Liesing Sofia Shanghai Fax: +47 33 11 52 03...
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