ESAB Welding Control Unit PEI User manual
- Category
- Welding System
- Type
- User manual
Valid for serial no. 5380449 331 001 110214
Welding Control Unit
PEI
104
Instruction manual
-- 2 --
Rights reserved to alter specifications without notice.
ENGLISH 5..............................................
3
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
Esab Welding Equipment AB, 695 81 Laxå, Sweden, försäkrar under eget ansvar att
manöverlåda Welding Control Unit PEI från serienummer 2433100016 är i överens-
stämmelse m ed standard EN 60974--1 enligt villkor en i direktiv (73/23/EEG) med til-
lägg (93/68/EEG) och standard EN 50199 enligt villkoren i dir ektiv (89/336/EEG)
med tillägg (93/68/EEG).
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OVERENSSTEMMELSEERKLÆRING
Esab Welding Equipment AB, 695 81 Laxå, Sweden garanterer under eget ansvar,
at styreboks Welding Control Unit PEI fra serienummer 2433100016 er i overens-
stemmelse med standard EN 60974--1 ifølge betingelserne i direktiv (73/23/EEC)
med tillægg (93/68/EEC) og standarden EN 50199 ifølge betingelserne i dir e ktiv
(89/336/EØF) med tillæg ( 93/68/EØF) .
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VAATIMUSTENMUKAISUUSVAKUUTUS
Esab Welding Equipment AB, 695 81 Laxå, Sweden, vakuuttaa omalla vastuullaan,
että ohjausyksikkö Welding Control Unit PEI sar janumer osta 2433100016 täyttää
standardin EN 60974--1 vaatim ukset direktiivin (73/23/EEC) ja sen lisäyksen
(93/68/EEC) mukaisesti ehtojen mukaisesti sekä standardin EN 50199 vaatimukset
direktiivin (89/336/ETY) ja sen lisäysten (93/68/ETY) ehtojen mukaisesti.
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DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that control unit Welding Control Unit PEI from serial number 2433100016 complies
with standard EN 60974--1, in accordance with the requirements of directive
(73/23/EEC) and addendum (93/68/EEC), and with standard EN 50199, in accord -
ance with the requirements of directive (89/336/EEC) and addendum (93/68/EEC).
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KONFORMITÄTSERKLÄRUNG
Esab Welding Equipment AB, 695 81 Laxå, Sweden, versichert hiermit auf eigene
Verantwortung, daß die Bedieneinheit Welding Control Unit PEI ab Serien--Nr
2433100016 mit der Norm EN 60974--1 gemäß den Bedingungen der Richtlinien
(73/23/EWG) mit der Ergänzung (93/68/EWG) in Übereinstimmung steht und dem
Standard EN 50199 gemäß den Bedingungen der Direktive (89/336/EEG) mit Zusatz
(93/68/EEG) entspricht.
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CERTIFICAT DE CONFORMITÉ
Esab Welding Equipment AB, 695 81 Laxå Sweden, certifie sous sa propre respon-
sabilité que le boîtier de commande Welding Contro l Unit PEI à partir du numéro de
serie 2433100016 répond aux normes de qualité EN 60974--1 conformément aux
directives (73/23/EEC) avec annexe (93/68/EEC) et à la norme EN 50199 selon les
conditions de la directive (89/336/CEE) avec additif (93/68/CEE).
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OVEREENKOMSTIGHEIDSVERKLARING
Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart op eigen verantwoor-
delijkheid dat bedieningsbox Welding Control Unit PEI van serienummer
2433100016 overeenkomt met norm EN 60974--1 volgens richtlijn (73/23/EEG) van
de Raad met toevoeging (93/68/EEG) en met norm EN 50199 conform de bespalin -
gen in richtlijn (89/336/EEG) met annex (93/68/EEG).
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4
DECLARACIÓN DE CONFORMIDAD
Esab Welding Equipment AB, 695 81 Laxå, Sweden, declara, asumiendo toda res-
ponsabilidad, que la caja de m andos Welding Control Unit PEI desde el número de
serie 2433100016 está fabricada de conformidad con la normativa EN 60974--1 se-
gún los requisitos de la directiva (73/23/EEC) con el suplemento (93/68/EEC) y con
la norma EN 50199 según los requisitos de la directiva (89/336/CEE) con el suple-
mento (93/68/CEE).
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DICHIARAZIONE DI CONFORMITA
Esab Welding Equipment AB, 695 81 Laxå, Sweden, dichiara sotto la propria re-
sponsabilità che la centralina di controllo Welding Contr o l Unit PEI dal numero di se-
rie 2433100016 è conforme alla norma EN 60974--1 ai sensi dei requisiti previsti dal -
la direttiva (73/23/CEE) e successive integrazioni nella direttiva (93/68/CEE) ed alla
norma EN 50199 come previsto dalla direttiva (89/336/CEE) e successive integra-
zioni (93/68/CEE).
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DECLARAÇÃO DE CONFORMIDADE
Esab Welding Equipment AB, 695 81 Laxå, Sweden, certifica, sob a sua própria res -
ponsabilidade que, a caixa de contr olo Welding Control Unit PEI desde núm ero de
série 2433100016 está em conformidade com a norma EN 60974--1, segundo os
requisitos constantes na directiva (73/23/EEC) e com o suplemento (93/68/EEC) e
com a norma EN 50199 segundo os requisitos da directiva (89/336/CEE) com o su-
plemento ( 93/68/CEE).
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ÂÅÂÁÉÙÓÇ ÓØÌÖÙÍÉÁÓ
Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, âåâáéþíåé ìå äéêÞ ôçò åõèýíç
oôé ç ðçãÞ êéâþôéï ÷åéñéóìïý Welding Control Unit PEI áðü ôïí áñéèìü óåéñÜò
2433100016 âñßóêåôáé óå óõìöùíßá ìå ôï óôáíôáñô ÅÍ 60974 -1 óýìöùíá ìå ôïõ
üñïõò ôçò ïäçãßáò (73/23/ÅÅC) êáé ôçí ð ñïóèÞêç (93/68/ÅÅC) êáé ôï ðñüôõðï
EN 50199 óýìöùíá ìå ôéò áðáéôÞóåéò ôçò ïäçãßáò (89/336/EEG) êáé ôïõ
ðáñáñôÞìáôïò (93/68/EEG).
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Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2003--03--13
ENGLISH
-- 5 --
TOCe
1SAFETY 6...........................................................
2 INTRODUCTION 9...................................................
2.1 General 9..................................................................
2.2 Welding power sources 9.....................................................
2.3 Technical data 9............................................................
3 TECHNICAL DESCRIPTION 10.........................................
3.1 Controls on the front panel 10..................................................
3.2 Controls on the rear panel 13..................................................
4 INSTALLATION 14....................................................
4.1 General 14..................................................................
4.2 Voltage adjustment 15........................................................
5 OPERATION 16.......................................................
5.1 General 16..................................................................
DIMENSION DRAWING 17................................................
SPARE PARTS LIST 19..................................................
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SafeArcS GB
1SAFETY
Users of ESAB welding equipm ent have the ultimate r e sponsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety pre-
cautions. Safety 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 m ust be carried out by trained personnel well-acquainted with the oper-
ation 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. Note! Do not use safety
gloves when replacing wire.
S Do not wear loose-fitting items, such as scarves, bracelets, r ings, etc.,
which could become trapped or cause burns.
5. Protection against other risks
S Dust particles of a certain size can be harmful to man. A ventilation system
and extractor should therefore be provided to eliminate this r isk.
6. 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
-7-
SafeArcS GB
WARNING, RISK OF CRUSHING!
Do not use safety gloves when replacing wire, feed rollers and wire bobbins.
GB
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR
EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU-
FACTURER'S HAZARD DATA.
ELECTRIC SHOCK - Can k ill
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 keep fumes and gases 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 inflam-
mable m aterials nearby.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
READ AND UNDERSTAND THE INSTRUCTION MAN-
UAL BEFORE INSTALLING OR OPERATING.
-8-
SafeArcS GB
GB
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fgc6d1ea
2 INTRODUCTION
2.1 General
The welding control unit PEI is used together with A2 automatic welding equipment
for adjusting welding parameters and controlling the welding process.
It is intended for SAW or MIG/MAG welding with DC.
(N.B. PEI is set for SAW at delivery, if you want to change to MIG/MAG welding
contact ESAB)
2.2 Welding power sources
The welding power sources are specially adapted to work with the welding control
unit PEI.
2.3 Technical data
Welding control unit PEI
Supply voltage (tolerans ±10%): 42 V, 50/60 Hz
Fuse: 16 A delayed
No-load power: 25 VA
Permissible load:
at 100 % duty cycle
at 60 % duty cycle
40 V DC max
3.5 A
4.5 A (KSV5035/603)
Voltage setting reference signal: 0-10,0V
Burn-back time: 0-2,0s
Pre-flow / post flow time: 0.5 s /1.0 s
Power source output: 30 V DC, 100 mA max - NPN-OC
Gas/ auxiliary valve: 42 V 50/60 Hz - 1A max
Voltmeter range: 10 - 99.9 V (3 digits)
Ammeter range: 30 - 1999 A (3½ digits)
External current shunts permissible: 1000 A / 60 mV (factory setting)
1500 A / 60 mV
750 A / 100 mV
600 A / 60 mV
Wire feed speed - SAW : 0,5 - 9.0 m/min, 20 - 355 IPM (KSV5035/375)
Wire feed speed - MIG/MAG: 0,9 - 16.2 m/min, 35 - 640 IPM (KSV5035/374)
Travel speed: 0.1 - 2.0 m/min, 4.0 - 80.0 IPM (KSV5035/603)
Embedded supply for external sensors: 24V 300mA
Embedded supply for laser pointer lamp: 3.3V/ 5V DC 50 mA
Temperature range: -10 - 40_C (14 - 104_F)
Weight: 6.2 kg
Dimensions: 197 x 227 x 220 mm
Enclosure class: IP 23
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.
GB
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fgc6d2ea
3 TECHNICAL DESCRIPTION
3.1 Controls on the front panel
S4 (Red) Emergency Switch
S1 (Green) Welding process - ON
S2 (Red) Welding process - OFF
Travel - OF F
S3 (White) Travel - ON
S5 Inching (toggle switch)
S6 Travel direction (toggle switch)
R1 Voltage adjustment
R2 Wire speed adjustment
R3 Travel speed adjustment
GB
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fgc6d2ea
Emergency switch, S4 (Red)
The Emergency switch is connected directly to the
welding power sources control circuit.
Push-button, S1 (Green) – welding process start.
Push-button with lamp.
The lamp is on for 2 seconds after the welding power source
has been switched on .
If, after this time, the lamp starts to flash, it means that the unit
is not ready due to some false signal during the initial period.
For instance, if, for some reason, the welding power source was
switched on during the initial period, the controller is blocked until
there is no voltage on the rectifier output. The same if current is
present, or inching switch, or any of the push-buttons are pressed
during the initial period after powering.
Start is disabled if:
S inching is performed,
S tractor is already switched on (by means of Push-button S3),
S there is a signal from the proximity switch, corresponding to the travel direction,
S there is no water-flow signal (only when a coolant flow guard is used for gas
shielded welding).
The control of the welding process is performed according to the required sequence,
including gas pre-flow, direct or scratch start, burn-back time, and gas post-flow.
The lamp is on during welding.
The welding process is switched off if:
S Push-button S2 is pressed,
S a signal from appropriate proximity switch is present,
S travel direction was changed
(by means of toggle switch S6)
S water-flow guard signal disappeared,
S more then 1s long short circuit is sensed
(voltage less then 10V and current still present)
Push-button, S2 (Red) – switches off the welding process and travel.
Push-button, S3 (White) - switches on the travel
Operation of this button is disabled during the welding.
The travel is switched off if:
S Push-button “0” is pressed,
S a signal from appropriate proximity switch is present,
S travel direction was changed (by means of toggle switch S6).
GB
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fgc6d2ea
Voltage setting knob, R1
Intended for setting the voltage of the welding
power source.
The 0-10 V reference signal is produced by
positioning the knob.
Voltage meter
It shows an average value of the arc voltage. The m eter doesn't show any voltage
less than 10V.
The reading is frozen at the moment of switching the welding process off.
Wire feed speed setting knob, R2
Intended for setting the wire speed.
Inching toggle switch, S5
Operation of this switch is disabled during the
welding. The control system doesn't allow for
quick switching from one to opposite direction to
protect the drive.
Ammeter
It shows the average value of the welding current. The meter doesn't show any
current below 10A.
The reading is frozen at the moment of switching the welding process off.
The ammeter is intended for different types of shunts. The unit is set to 1000A,
60mV before leaving the factory.
Wire speed d isp lay
The display shows the set wire speed. The r ange is changed according to setting the
SAW or MIG/MAG mode. The speed can be displayed in m/min or in inch-per-min
(IPM). N.B. T he display is set to m/min at delivery, if you want to change to IPM
contact ESAB.
S T he range for SAW is 0,5 - 9.0 m/min, (20-355 IPM),
S T he range for MIG/MAG is 0,9 - 16.2 m/min, (35-640 IPM).
Travel speed setting knob, R3
Intended for setting the travel speed.
Travel sp eed display
Intended for showing the travel speed.
The maximum displayed value is 200cm/min (80IPM).
N.B. The display is set to cm/min at delivery,
if you want to change to IPM contact ESAB.
Travel direction toggle switch, S6
For setting the direction of travel.
Welding stops if the direction of travel is changed during the welding process.
GB
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fgc6d2ea
3.2 Controls on the rear panel
DIRECT
START
SCRATCH
START
BURN BACK
1,6
0
0,4
0,8
1,2
6
EXT.
2,0s
Mode setting (1)
Intended for setting DIRECT START or SCRATCH START modes.
S DIRECT START
The feeder motor starts at minimal speed. The tractor is stopped. At the
moment of sensing the welding current, both motors start to operate with
pre-adjusted speeds.
S SCRATCH START
Both the feeder motor and the tractor start at m inimal speed. At the moment of
sensing the welding current both motors start to operate with pre-adjusted
speeds.
S EXT.
Extension, which is not currently supported.
Burn-Back time ad ju stment (2)
Intended for setting the burn-back time (maximum 2 seconds).
Adjustment is not active during welding. Setting is refreshed once per second.
GB
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fgc6i1ea
4 INSTALLATION
4.1 General
The installatio n must be executed by a profession al.
1. Dismantle the rear panel as follows:
a. Unscrew the four screws ( 1) placed at the rear of the upper cover.
b. Unscrew the screw (2 ) that is placed under the lower cover.
c. If necessary losen the screws ( 3).
d. The rear panel can now be moved.
2. If the trimmers need adjusting contact ESAB.
GB
-15-
fgc6i1ea
3. Connect the welding head to the terminal 1 on X2.
Use the appropriate hole and the r ubber gland for the cable output.
N.B. Do not remove any jumpers.
*1 Welding head
*2 Welding power source
4. Put the rear panel back into place and screw in the screws (see on page 14).
5. Connect the power source and the controller by m eans of the control cable to the
socket X1 placed on the rear panel of the unit.
6. By means of a screwdriver, select an appropriate start mode (DIRECT/
SCRATCH), see on page 13. External mode is not supported.
7. Adjust the approximate value of the burn-back time.
Make further adjustments after welding tests. See on page 13.
8. Connect the current cables to the welding head and the workpiece.
4.2 Voltage adjustment
If the voltage adjustment is not working, take contact to the nearest ESAB
representative, see back cover.
GB
-16-
fgc6o1ea
5OPERATION
5.1 General
General safety regulations for the handling of the equipment can be found on
page 6. Read through before you start using the equipment!
1. Position the automatic welding head at the starting point of the weld joint.
2. Position the wire near the work piece by means of toggle switch S5.
3. Cut the wire at an angle.
4. Adjust the approximate, anticipated values of welding voltage, wire speed, and
tractor speed by means of the respective knob.
5. Select the start mode and the travel direction.
6. Start welding by pushing the knob S1.
7. Make fine adjustments of the welding parameters according to the read-outs and
the quality of the weld using the respective knob.
8. Press pushbutton S2 to stop welding.
9. If necessary adjust the value of burn-back time, see on page 13.
GB
DIMENSION DRAWING
-17-
diagdoc
-18-
sida
SPARE PARTS LIST
-19-
sparefram.ildoc
Edition 070427
Ordering no. Denomination Notes
0449 330 880 Welding control unit PEI
-20-
f449330s.ildoc
Item ref.
Qty Ordering no. Denomination Notes
0449330880 We lding Control Unit PEI
1)
A1 1 0349302904 Control module TS11
R1, R2, R3 3 0349302093 Knob FI 23 E103-3-1611-343
R1, R2, R3 3 0349303030 Potentiometer PC-16 S H 10 C P11 222 A 2020 MTA
S1 1 0349484300 Pushbutton FT22-KLZ-11-N
S2 1 0349484302 Pushbutton FT22-WC-01-N
S3 1 0349484297 Pushbutton FT22-KB-10-N
S4 1 0349303239 Pushbutton FT22-B-02-N
S5 1 0349303236 Toggle switch 100-SP4-T8-B13-M1 RE / 7105TZBE / A127T1TZBP
S6 1 0349303235 Toggle switch 100-SP1-T8-B13-M1 RE / 7101TZBE / A123T1TZBP
1 0349303238 Front panel foil PEI
1)
Calibration may be needed after replacement of A1 or it's “A” subpart. Please
contact supplier or nearest service shop for help/guidance.
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ESAB Welding Control Unit PEI User manual
- Category
- Welding System
- Type
- User manual
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