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
0740 801 106
A2- A6
Process Controller
PEH
104
Service manual
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TOCe
1 READ THIS FIRST 4..................................................
1.1 General 4..................................................................
1.2 Software versions 5.........................................................
2SAFETY 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 OVER VIEW 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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TOCe
Rights reserved to alter specifications without notice.
SPARE PARTS LIST 65...................................................
ALPHABETICAL LIST OF CONTENTS 73..................................
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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.
GB
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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 program (Flash, IC 15) 486471880
PEH 1.1
DCDUO program (Prom, IC304) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 1.1
DCDUO program (Prom, IC304) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 1.2
DCDUO program (Prom, IC304) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 2.0
DCDUO program (Prom, IC304) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 2.1 and PEH 2.2
DCDUO program (Prom, IC304) 68S07001A02
CHKSUM 0221
Dat. 1998.04.04
Improved motor regulator data for better performance at low speed.
GB
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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) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 4.01
PEH program, China (Flash, IC 15) 486471881
PEH 4.01C
DCDUO program (Prom, IC304) 68S07001A02
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 program (Flash, IC 15) 486471880
PEH 4.2
PEH program China (Flash, IC 15) 486471881
PEH 4.2C
DCDUO program (Prom, IC304) 68S07001A02
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
.
The following software version (or higher) must be used LAF/TAF 4.0, digio 4.0 and Analogue Motor
node 4.0.
GB
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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.
From 06.10.01
PEH program (Flash, IC 15) 486471880
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 program (Flash, IC 15) 486471880
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
GB
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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.
Inch conversion.
From 00.02.29
LAF/TAF program (Flash, IC 6) 486525880
LAF/TAF 2.1
Improved wire creep speed LAF 1000ES
From 00.10.04
LAF/TAF program (Flash, IC 6) 486525880
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 program (Flash, IC 6) 486525880
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 program (Flash, IC 6) 486525880
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 program (Flash, IC 6) 486525880
LAF/TAF 4.2
Added new alarm.
Improved regulation.
Program version from PEH 4.0, PEH 4.0C is needed.
From 05.01.01
LAF/TAF program (Flash, IC 6) 486525880
LAF/TAF 4.3
Improved welding, analogue Interface.
From 06.10.01
LAF/TAF program (Flash, IC 6) 486525880
LAF 5.0
Changed regulation, improved with dynamic characteristic.
Program version from PEH 5.0, PEH 5.0C is needed.
New hardware is needed, for LAF 486367008 and 486376005 for TAF.
GB
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PEH in C&B
From 99.04.01
PEH program (Flash, IC 15) 486471880
PEH 2.3
DCDUO program (Prom, IC304) 68S07001A02
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
DIGIO1.0
From 99.06.01
Digital I/O -- node 486592882
DIGIO1.1
Safer readings of push buttons preventing unrequested stop during welding.
From 02.11.15
Digital I/O -- node 486592882
DIGIO4.0
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
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.
Programversion PEH4.0 or PEH4.0C is needed.
GB
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2SAFETY
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.
GB
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
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.
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.
GB
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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)
GB
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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 comm unication 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 addr ess.
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 m easuring 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.
GB
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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 V
AC
± U
AC
± 46,2 V
AC
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 V
DC
± U ± 65 V
DC
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 V
switch
11 V ± U ± 13V
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