伊萨LAF焊机PEH维修手册

A2-A6

ProcessController

PEH

104专业维修伊萨焊接设备及线路板伊萨中国区域维修中心周工：ｅｓａｂ＿ｃｎ＠１６３．ｃｏｍ

Servicemanual

2005--04--12

Validformachineno220XXX--XXXX

ValidforprogramversionPEH4.0,PEH4.01andPEH4.2,PEH4.3

0740801106

1READTHISFIRST..................................................

1.1General..................................................................1.2Softwareversions.........................................................

2SAFETY...........................................................3COMPONENTDESCRIPTION.......................................4CONNECTIONDIAGRAM...........................................5COMPONENTPOSITIONSONCIRCUITBOARDAP2..................6COMPONENTPOSITIONSONCIRCUITBOARDAP1..................7FUNCTIONDESCRIPTION(CIRCUITBOARD)........................

7.1General..................................................................7.2NME(AP2)..............................................................7.3DCDUO(AP1)...........................................................8TESTPOINTS......................................................8.1Testingtheexternalpowersupply(fromtheweldingpowersource)...............8.2Testingtheinternalpowersupplyvoltages....................................8.3Checkingthattheprogramisrunning.........................................8.4CheckingNO.1outputstage................................................8.5CheckingNO.2outputstage................................................8.6Gasvalveoutputcontrol....................................................8.7Measuringthemotorcurrent................................................9INSTALLATION....................................................9.1General..................................................................9.2Internalconnections.......................................................9.3Externalconnections.......................................................9.4AdjustingtheDCDUO.....................................................9.5NMEconnection...........................................................9.6

ConnectionbetweentheDCDUOandtheNME...............................

10USINGTHECONTROLPANEL......................................10.1Controlpanel.............................................................10.2Usingthekeys............................................................11PRESETSYSTEMMENU............................................11.1General..................................................................11.2Systemfunctionsettingsavailable...........................................12DEFINITIONS(PRESETSYSTEMMENU).............................12.1Productcode.............................................................12.2Weldprocess.............................................................12.3POWERSOURCEMENU..................................................12.4Gaspreflow(s)(onlyforGMAW)............................................12.5Gaspostflow(s)(onlyforGMAW)...........................................12.6Password................................................................12.7Cablelength(m)..........................................................12.8Cablearea(mm2).........................................................12.9Weldheadoffset,mm......................................................12.10STARTSEQUENCEMENU.................................................12.11STOPSEQUENCEMENU..................................................12.12CALIBRATIONMENU......................................................12.13DISPLAYMENU..........................................................12.14ERRORLIST.............................................................12.15

Test.....................................................................

13PRESETSYSTEMMENUOVERVIEW................................14CHANGEOFPROGRAM............................................14.1General..................................................................14.2Storingtrimmingdata......................................................14.3ChangingtheprograminthePEHelectronics:.................................14.4

ChangingprogramsinthePEHelectronicsandtheweldingpowersource:........

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SPAREPARTSLIST...................................................63ALPHABETICALLISTOFCONTENTS..................................71

Rightsreservedtoalterspecificationswithoutnotice.TOCe

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GB11.1

READTHISFIRSTGeneral

Thisservicemanualisintendedforusebytechnicianswithelectrical/electronictraining,forhelpinconnectionwithfault--tracingand/orrepair.

ThismanualcontainsdetailsofalldesignchangesthathavebeenmadeuptoandincludingDecember2004.

ThismanualisvalidforprogramversionPEH4.0,PEH4.01,PEH4.2andPEH4.3.(Includesthechineseversions)

Forolderversionsseeservicemanual0740801006.

ForfurtherinformationseetheA2--A6Processcontroller(PEH)instructionmanual0443745xxx.

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GB1.2

PEH

Fromproductionstart97.07.04PEHprogram(Flash,IC15)DCDUOprogram(Prom,IC304)

486471880PEH1.00A68S07001A02CHKSUM0210Dat.1997.07.04

Softwareversions

From97.12.12

PEHprogram(Flash,IC15)

486471880PEH1.1

DCDUOprogram(Prom,IC304)68S07001A02

CHKSUM0211Dat.1997.12.12

VEC8000RPMmotor(A6G)canbeused.MEK4motorwithtachocanbeused.

Productcodefor”A2TFF1”(Weldtrac)added.Calibrationmenudeleted.From98.04.04

PEHprogram(Flash,IC15)486471880

PEH1.1

DCDUOprogram(Prom,IC304)68S07001A02

CHKSUM0221Dat.1998.04.04

DCDUOsoftware68S07001A02,CHKSUM0221compatiblewithhardware971029andalllaterversions.

UpgradedDCDUOprogram,preventingunsafeusageoftachofunction.From98.05.20

PEHprogram(Flash,IC15)486471880

PEH1.2

DCDUOprogram(Prom,IC304)68S07001A02

CHKSUM0221Dat.1998.04.04

Externalstart/stopfunctionStripwelding

Stainlesssteelsetting.Ifthisfunctionisneededthepowersourceboard486367001AintheLAFmustbeusedandLAFprogramversionLAF2.0ESWweldingadded(newfunctionadded).From98.09.30

PEHprogram(Flash,IC15)486471880

PEH2.0

DCDUOprogram(Prom,IC304)68S07001A02

CHKSUM0221Dat.1998.04.04

ForaccesstoallnewfeaturesprogramversionLAF2.0(partno486525880)mustbeusedtogetherwithPEH2.0.Inchconversion.

Newmanualprogrammablestartmethodadded.

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GB9.3

Externalconnections

Motorconnectionsforthewirefeedmotor,M1A2motor

Motorcable,twoconductorsandscreen,connectedtoconnectorsK10.1andK10.2.

AC--Tachometercable(accessory),twoconductorsandscreen,connectedtoconnectorsK10.5andK10.6.A6motor

Motorcable,fourconductorsandscreen,connectedtoconnectorsK10.1andK10.2,withthefieldconnectionsmadetoK10.3andK10.4.

TheACtachometercable(accessory),isconnectedtoconnectorsK10.5andK10.6.

MotorconnectionsfortravelmotorM2(travelmotion)Motorcable,twoconductorswithscreen,connectedtoconnectorsK11.1andK11.2.ThemotorfieldwindingisconnectedtoK11.3andK11.4(withscreen).TheACtachometercable(accessory):twoconductorsandscreen,con-nectedtoK11.5andK11.6.ConnectionoftheweldingheadArcvoltagetoterminalX2.1

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GBInputforconnectionofagasflowguard(NC),limitswitchorexternalstopfunction.Screened2--wire2x0,75mm2,connectedtoK23.1andK23.2.Inputforconnectionofawaterflowguard(NC),limitswitchorexternalstartfunction.Screened2--wire2x0,75mm2,connectedtoK22.1andK22.2.Outputforconnectingafluxorgasvalve,42VACmax.0,5AScreened2--wire2x0,75mm2,connectedtoK12.1andK12.2.Connectionofanexternalemergencystop(accessory)RemovetheinternalemergencystopconnectionandconnecttheexternalemergencystopcircuittoX2.2.ConnectionofaPilotlamp(accessory)

Connectthetransformerprimary(42V)toK14.1andK14.2.

Thetransformerandpilotlampareincludedinacompletesetofcompo-nentsforincorporationintheunitandmustbeorderedseparately.

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GB9.4

AdjustingtheDCDUO

AdjustingthedisplaycontrastAsdelivered,thelightingissetforthebestcontrast.Ifnecessary,itcanbeadjustedbypotentiometerP101ConnectionofjumperJ1:Forthegreendisplayplacethejumperon1and2.

Forthebluedisplayplacethejumperon2and3.MotorcontrolsoftwareThemotorcontrolprogramisstoredinanEPROM,IC304.Itismarkedtoshowtheversionnumberofthesoftwaresupplied.

9.5NMEconnection

ThegraphicdisplayistobeconnectedtoconnectorK1.ThekeyboardistobeconnectedtoconnectorK2.Thebusconnectioninthecontrolcable(fromtheweldingpowersource)istobeconnectedtoconnectorK9.DIPswitchTheNMEcircuitboardcarriesaDlPswitch(SW1)whichispresetondeliveryforusewithA2--A6units,anditssettingsmustnotbealteredinthefield.Whensuppliedasasparepart,thesettingsoftheswitchmustbe

checked,andadjustedifnecessary,beforetheboardisfittedinthecontrolbox.SettingtheDIPswitchSW1:

DIPswitchSW1mustbesettoClosedposition,i.e.alleightpolesmustbesettoClosedposition.CommunicationssoftwareThecommunicationssoftware,thekeyboardcontroller,displaydriverandthetrimparametersfortheDCDUOcircuitboardarestoredinflashmemoryIC15.Thechipismountedinasocketandcanbechanged.DiagnosticsThereisoneLED(L02RED)onthecircuitboardthatcanbeusedforsystemfaulttracing:SS

TheLEDlightstoindicatefailureofcommunicationtotheDCDUOboard,orintheeventofamicroprocessorfault.

TheLEDflashestoindicatethatthereisafaultintheprogram.

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GBBustermination/connectionWhentheNMEcircuitboardisthefirstorlastboardinanetwork,ashort--circuitinglinkmustbefittedinsocketK7.

9.6ConnectionbetweentheDCDUOandtheNME

TheNMEcircuitboard(AP2)isaseparateunitthatissecuredabovetheDCDUOcircuitboard(AP1)bymeansoffourscrews.

ConnectorsK3(communicationbetweentheboards),K4(guardinputsandgas

valveoutput)andK5(supplyvoltagefortheNMEcircuitboard)providetheelectricallinkbetweenthetwoboards.

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GB1010.1

USINGTHECONTROLPANELControlpanel

1.Emergencystop

2.Thedirectionoftravelisasshown

bythetriangularsymbolontheweldingequipment.3.Thedirectionoftravelisasshown

bythesquaresymbolontheweldingequipment.4.Advancewire5.Retractwire6.Changemenu

7.Numericalkey,numberentry8.ENTERkey,Changerow9.SHIFTkey

10.Stopwelding.Returntomanualmode11.Startwelding.Switchtoautomaticmode12.Fast,wirefeedortravel

13.Scrollpage(weldingsetupmenu)orclosevalve(mainmenu)

Thearrowedkeysareusedduringweldingtoincreaseordecreasethecurrent,voltageandspeed.

Bypressingeither,,

+or

+itispossibletobrowse.

N.B.

WhenanI/Oboardisconnectedthekeys2,3,4,5,10,11and12cannolongerbeused.

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GBThefollowingmenuisshownwheneither“GEAR1”,“GEAR2”or“GEAR3”hasbeenselected:

N1N2XXByenteringvaluesforN1andN2anygearratiolocatedafterthemotorgears(forexampleFHP36)canbeselected.

N1=thenumberofteethofthegearwheelofthemotorshaft.N2=thenumberofteethofthegearwheeloftheoutgoingshaft.Example:fzb2d3ea

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GB2.BinaryinputsWIREFEEDAXISPEHTRAVELAXISBinaryinputsDRIVETRIMMENUNotused,Guards,Limitsw,Start/stopAdjustingandusingtheinputsareonlypossibleifproductcode“FREE2AX“or“FREE3AX”havebeenselected.

Ifotherproductcodes(fixedones)areselectedtheinputswillnotbeactive.Thefollowingalternativesareavailable:SS

Notused

Theinputsarenotactive.Guards

2transducers(waterandgasflowguardswithnormallyclosed(NC)contactfunction)canbeconnected.

Note.Ifonlyonetransducerisconnectedtheotherinputmustbebridged.S

Limitswitch

Limitswitches(normallywithclosed(NC)contactfunction)aretobe

connectedtotheinputs.Whenoneofthelimitswitchesisactivated(opened)themotionofthemotorceases,andonlythemotionintheoppositedirectionispossible.S

Start/stop

Thefunctionisusedwhenexternalstartandstopoftheweldingisdesired.Astartingcontact(closingNO)istobeconnectedtoinputK22.ThestopfunctionistobeconnectedtoK23.

Thecontactfunctionofatransducerconnectedtotheinputsshallnormallybeclosed(NC).Whentheswitch(GuardsorLimitswitch)isopenedthiswillbeindicatedinthebottomrightpartofthedisplaybyaflashingcontactsymbol.

(Flashing)

InletK22orK23isopen.

TheinputsK22andK23ontheDCDUOboardcanbeassigneddifferentfunctionsonthissub--menu.

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GB3.DRIVETRIMMENU

WIREFEEDAXISPEHTRAVELAXISBinaryinputsNotused,Guards,Limitsw,Start/stopDRIVETRIMMENUUsethismenutosetuptherequiredparameterandsettingvaluesforthePEHelectronics.

DatasettingsarestoredintheIC15flashmemorychip(seepage23).

Thesettingsarethereforeuniqueforeachelectronicunitandareshowninthismenu.

Thepresetvaluesforanuntrimmedelectronicscardareshowninthetableonpage34.ThevaluesforatrimmedelectronicscardwilldifferfromthoseofthePresetValues.

Setyourownoffsetvaluesforthewirefeedmotor(M1)VXPoffset32768,andforthetravelmotor(M2)VYPoffset32768.Example:Howtoadjusttheoffseterrorofthetravelmotor:SSS

SelectDRIVETRIMMENUandpress

.

SelectVXPoffsetandpress.

Enterthedesiredvalue,forexample32868.

+

SReturntotheMAINMENUbyholdingdown.ThevalueoftheVXPoffsetisnow32868.

ProceedinthesamewaytoadjusttheoffseterrorVYPoffset32768ofthetravelmotor.

Ifnecessary,trimmingdatafortherespectiveelectronicscardcanbeorderedfromESAB.

Whenorderingtrimmingdata,themanufacturingnumbermustbeindicated(tobefoundontheDCDUOcard,capacitorC201).

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GBThepresetvaluesforanuntrimmedelectronicscardareshowninthefollowingtable:

NameTrimmenuVNscaleVXPoffsetVXNoffsetCXPoffsetCXNoffsetVYPoffsetVYNoffsetCYPoffsetCYNoffsetVXPscaleVXNscaleCXPscaleCXNscaleVYPscaleVYNscaleCYPscaleCYNscaleTrimmingDefaultvalues204803276832768327683276832768327683276832768192001920032003200192001920032003200Explanation(meaning)

PowersupplytoDCbusPositivevoltageoffset,wirefeedmotorNegativevoltageoffset,wirefeedmotorPositivecurrentoffset,wirefeedmotorNegativecurrentoffset,wirefeedmotorPositivevoltageoffset,travelmotorNegativevoltageoffset,travelmotorPositivecurrentoffset,travelmotorNegativecurrentoffset,travelmotorPositivearmaturevoltagemeasurement/speed--con-trolledwirefeed

Negativearmaturevoltagemeasurement/speed--con-trolledwirefeed

PositivearmaturecurrentmeasurementNegativearmaturecurrentmeasurementPositivearmaturevoltagemeasurement/speed--con-trolledtravelmotor

Negativearmaturevoltagemeasurement/speed--con-trolledtravelmotor

PositivearmaturecurrentmeasurementNegativearmaturecurrentmeasurementfzb2d3ea

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GB12.1.3FunctionsettingsavailableforFREE3AX:

Thefollowingmenuisshownwhen“FREE3AX”hasbeenselected:

Seeonpage35Seeonpage30

PEHAXESEXTERNALAXISROL,POS,LINWhenweldingdemandsconnectionofanexternalRollerbed(ROL),

Positioner(POS)orLinearaxis(LIN)settingsmustbemadein“FREE3AX”.TosteerROL,POSorLINtheanaloguePCBcardmustbeconnected.

ThePCBgivesareferencesignalof0--10Vandtwodirectionsignals(rightandleft).

1.PEHAXES

Thefollowingmenuisshownwhen“PEHAXES”hasbeenselected:

Seeonpage30Seeonpage30Seeonpage32Seeonpage33

WIREFEEDAXISPEHTRAVELAXISBinaryinputsDRIVETRIMMENUNotused,Guards,Limitsw,Start/stopForavailablesettings,seeonpage30--34.

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GB2.EXTERNALAXIS

PEHAXESEXTERNALAXISROL,POS,LINThefollowingalternativesareavailable:SSS

ROLwhenusingexternalRollerbedPOSwhenusingexternalPositionerLINwhenusingexternalLinearaxis

AvailablesettingsforROLandLIN:

GEAR1GEAR2GEAR3P.D.mmEncoderpprMotorrpmFrequencyratioHighmanualspeed1--100000--100001--5000AvailablesettingsforPOS:

GEAR1GEAR2GEAR3EncoderpprMotorrpmFrequencyratioHighmanualspeed0--100001--5000“GEAR1”,“GEAR2”and“GEAR3”,seeonpage31.P.D.mmistheeffectivediameterofthegearwheel.

Encoderppristhenumberofpulsesperrevolutionortachopulsesperrevolution.Thedefaultvalueis6.

“Motorrpm”isthemaximumrpmforthemotor.“Frequencyratio”

N1,settingfrequencyconvertervaluesN2,powersupplyfrequencyinHz

“Highmanualspeed”,ismanualtravelmotionwithhighspeed.

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GBMAINMENUsettingsforRollerbed,PositionerandLinearaxisRollerbed(ROL)

WhentheRollerbedsettingshavebeenmade,theactivemotionisdisplayedontheMAINMENU(seefigurebelow).

SelectanaxisbypressingtheAxisselectionkeyontheremotecontrolunitRCC.

InsystemswithoutanRCCunit,press

+

toselectanaxis.

PEH4.0LINEARPEH4.0CIRCULARTheaxisactivatedispresentedhere:LINEAR=Boomorcarriage(LINEAR1=Boom,LINEAR2=Carriage)CIRCULAR=RollerbedPositioner(POS)

Toselectactiveaxis,proceedinthesamewayasfortheRollerbed.

PEH4.0LINEARPEH4.0POSTheaxisactivatedispresentedhere:LINEARAXIS(LIN)

Toselectactiveaxis,proceedinthesamewayasfortheRollerbed.

PEH4.0LINEAR1PEH4.0LINEAR2Theaxisactivatedispresentedhere:fzb2d3ea

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GB“PRESETSYSTEMMENU”whensettingRollerbed

DirectionStartSTOPWELDINGWIREDATARegulationPRESETSYSTEMMENUWeld_diameterRoller_diameterYDirectCAWeldjointRollerdiameterWelddiameter

Rollerbed“PRESETSYSTEMMENU”whensettingPositioner

DirectionStartSTOPWELDINGWIREDATARegulationPRESETSYSTEMMENUWeld_diameterYDirectCAWeldjointWelddiameter

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GB12.2

Weldprocess

A2TFHProductcodeWeldprocessPOWERSOURCEMENUGaspreflow(s)Gaspostflow(s)PasswordCablelength(m)Cablearea(mm2)SAW1--991--99XXXXXThefollowingalternativescanbeselected:SSSS

SAWforsubmergedarcweldingGMAWforgasmetalarcweldingESWforelectro--slagwelding(cladding)Gaugingforarc--airgouging

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GB12.3

POWERSOURCEMENU

Thismenuisusedforconfigurationoftheweldingpowersource.

ProductcodeWeldprocessA2TFHSAW1--991--99XXXXXXXPOWERSOURCEMENUGaspreflow(s)Gaspostflow(s)PasswordCablelength(m)Cablearea(mm2)ThefollowingmenuisshownwhenPOWERSOURCEMENUhasbeenselected:Forprogramversion4.0and4.01:

Seeonpage40Seeonpage41Seeonpage41Seeonpage41Seeonpage42

PowersourcetypeMaxweldvoltage,dvMinweldvoltage,dvMaxrefvoltage,mVPowersource#LAF,TAF/Other/NoneForprogramversion4.2and4.3:

Seeonpage40Seeonpage42Seeonpage41Seeonpage41Seeonpage41Seeonpage41

PowersourcetypePowersource#WireCreepSpeedMaxweldvoltage,dvMinweldvoltage,dvMaxrefvoltage,mVLAF,TAF/Other/None1.Powersourcetype:

LAF,TAF--Weldingpowersourcesthatarespeciallyadaptedtoworkwiththe

A2--A6ProcessController.Other

--WeldingpowersourceotherthanLAF/TAF,thatisusedtogetherwithananaloguePCBcardtogetavoltagereferenceandstart/stopsignal.

IfOtherhasbeenselectedit’sonlypossibletoweldwithaconstantwirefeedspeed(CW),

N.BThisalternativeisnotavailableintheChineseversion.--ControlboxPEHisusedonlytosteerthetraveldirection.

None

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