ESAB A2 PEK User manual

Instruction manual
0460 949 474 GB 20210203 Valid for: From software version 5.00
A2, A6 PEK Control Panel

TABLE OF CONTENTS
0460 949 474 © ESAB AB 2021
1INTRODUCTION.......................................................................................... 5
1.1 Control panel .......................................................................................... 5
1.1.1 Keys and knobs.................................................................................... 5
1.2 First step ................................................................................................. 6
1.2.1 Choice of language .............................................................................. 6
1.2.2 Unit of measurements .......................................................................... 8
1.3 Display..................................................................................................... 9
1.3.1 Symbols in the display.......................................................................... 9
1.4 General information about settings...................................................... 10
1.4.1 Setting of numerical values .................................................................. 10
1.4.2 Setting with given alternatives.............................................................. 10
1.5 QUIT and ENTER .................................................................................... 10
2MENUS ........................................................................................................ 11
2.1 Main Menu............................................................................................... 11
2.1.1 Configuration menu .............................................................................. 11
2.1.2 Tools menu ........................................................................................... 12
2.1.3 Weld data setting menu........................................................................ 12
2.1.4 Measurements menu............................................................................ 14
2.1.5 Weld data memory menu ..................................................................... 15
2.1.6 Fast mode menu .................................................................................. 15
3SUBMERGED ARC WELDING ................................................................... 17
3.1 Settings for submerged arc welding .................................................... 17
4GAS METAL ARC WELDING...................................................................... 19
4.1 Settings for gas metal arc welding ....................................................... 19
5ELECTRO SLAG WELDING ....................................................................... 21
5.1 Settings for electro slag welding .......................................................... 21
6GOUGING .................................................................................................... 23
6.1 Settings for gouging .............................................................................. 24
7FUNCTION EXPLANATIONS ...................................................................... 25
7.1 CA, constant amperage ......................................................................... 25
7.2 CW, constant wire feed .......................................................................... 25
7.3 CC, constant current .............................................................................. 25
7.4 Wire / electrode dimension.................................................................... 25
7.5 Arc voltage.............................................................................................. 25
7.6 Wire feed speed...................................................................................... 25
7.7 ICE wire feed speed ............................................................................... 25
7.8 ICE wire start delay ................................................................................ 26
7.9 Travel speed............................................................................................ 26
7.10 Welding direction ................................................................................... 26
7.11 AC frequency .......................................................................................... 26

TABLE OF CONTENTS
0460 949 474 © ESAB AB 2021
7.12 AC balance.............................................................................................. 26
7.13 AC offset.................................................................................................. 26
7.14 Flux pre-flow (SAW)................................................................................ 26
7.15 Gas pre-flow (GMAW)............................................................................. 26
7.16 Start adjust.............................................................................................. 26
7.17 Air pre-flow (Gouging) ........................................................................... 27
7.18 Start type................................................................................................. 27
7.19 Wire creep start ...................................................................................... 27
7.20 Start phases............................................................................................ 27
7.21 Max Open Circuit Voltage (OCV) ........................................................... 27
7.22 Flux post-flow (SAW).............................................................................. 27
7.23 Gas post-flow (GMAW)........................................................................... 28
7.24 Air post-flow (Gouging) ......................................................................... 28
7.25 Crater filling ............................................................................................ 28
7.26 Burnback time ........................................................................................ 28
7.27 Stop phases ............................................................................................ 28
7.28 Dynamic regulation ................................................................................ 28
7.29 Control parameters ................................................................................ 29
7.30 Setting limits ........................................................................................... 29
7.31 Measure limits ........................................................................................ 29
7.32 PEK control unit as separate motor control ........................................ 29
8MEMORY MANAGEMENT .......................................................................... 33
8.1 Control panel working method.............................................................. 33
8.2 Store ........................................................................................................ 33
8.3 Recall....................................................................................................... 34
8.4 Delete....................................................................................................... 35
8.5 Copy......................................................................................................... 36
8.6 Name........................................................................................................ 37
8.7 Edit........................................................................................................... 37
9CONFIGURATION MENU............................................................................ 39
9.1 Code lock ................................................................................................ 39
9.1.1 Lock code status .................................................................................. 39
9.1.2 Specify/edit lock code........................................................................... 40
9.2 General configuration ............................................................................ 40
9.2.1 Fast mode soft keys ............................................................................. 40
9.2.2 Quality data log to file........................................................................... 41
9.2.3 Soft key configuration........................................................................... 41
9.2.4 Auto save mode ................................................................................... 43
9.3 Machine configuration ........................................................................... 43
9.3.1 Product code ........................................................................................ 44
9.3.2 Wire feed axis....................................................................................... 45
9.3.3 Cold wire axis (ICE).............................................................................. 46

TABLE OF CONTENTS
0460 949 474 © ESAB AB 2021
9.3.4 Travel axis ............................................................................................ 46
9.3.5 External axis......................................................................................... 46
9.3.6 Tandem for LAF and TAF power sources............................................. 47
9.3.7 Tandem for Aristo® 1000 power source ............................................... 50
9.3.8 Parallel power sources (applies only to Aristo® 1000 power sources) 52
9.3.9 ICE wire feed........................................................................................ 53
9.3.10 Step function ........................................................................................ 54
9.3.11 Intermittent welding ............................................................................. 56
9.3.12 Polarity (applies only to Aristo® 1000 power source)........................... 56
9.3.13 Node id settings (applies only to Aristo® 1000 power source)............. 56
9.3.14 System information (applies only to Aristo® 1000 power source)........ 56
9.4 Cable lengths (applies only to LAF and TAF power sources)............ 57
9.5 Maintenance............................................................................................ 57
9.6 Measure–values filter factor.................................................................. 57
10 TOOLS ......................................................................................................... 59
10.1 Event handling........................................................................................ 59
10.1.1 Event log .............................................................................................. 59
10.1.2 Active errors ......................................................................................... 60
10.1.3 Unit IDs................................................................................................. 60
10.1.4 Description of fault management codes ............................................... 60
10.2 Export/Import .......................................................................................... 63
10.3 File manager ........................................................................................... 63
10.3.1 Delete a file/folder ................................................................................ 64
10.3.2 Rename a file/folder ............................................................................. 65
10.3.3 Create new folder ................................................................................. 65
10.3.4 Copy and paste files............................................................................. 65
10.4 Setting limit editor .................................................................................. 66
10.5 Measure limits editor ............................................................................. 67
10.6 Production statistics .............................................................................. 67
10.7 Quality functions .................................................................................... 68
10.7.1 Store quality data ................................................................................. 69
10.7.2 Import system settings ......................................................................... 69
10.8 Calendar .................................................................................................. 70
10.9 User accounts......................................................................................... 70
10.10 Unit information...................................................................................... 71
ORDERING NUMBERS....................................................................................... 73
Rights reserved to alter specifications without notice.

1 INTRODUCTION
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1 INTRODUCTION
To benefit as much as possible from your welding equipment, we recommend that you read
this instruction manual.
For general information about operation, see the instruction manual for the control unit,
automatic welding machine, column and boom or power source.
The text presented in the display is available in the following languages: English, US English,
Swedish, Finnish, Norwegian, Danish, German, French, Italian, Dutch, Spanish, Portuguese,
Hungarian, Polish, Czech, Turkish, Chinese, Korean and Russian.
Instruction manuals in other languages can be downloaded from the Internet: www.esab.com
1.1 Control panel
1. Menu 10. Arc voltage / Setting knob
2. Positioning knob, for moving cursor 11. Fast motion
3. Enter 12. Manual travel motion
4. Green indication lamp, illuminates
when the function is active
13. Welding current / Wire feed speed /
Setting knob
5. Welding start 14. Emergency stop
6. Welding stop 15. Manual wire feed upwards
7. Travel speed / Setting knob 16. Soft keys
8. Manual travel motion 17. Display
9. Manual wire feed downwards
1.1.1 Keys and knobs
Menu
The Menu key always takes you back to the main menu in the relevant process.

1 INTRODUCTION
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Enter
Use the ENTER key to confirm a selection.
Soft keys
The five keys (S1 - S5) under the display have different functions. They are called soft keys,
i.e. they can have different functions depending on which menu you are in. The current
function for these keys can be seen from the text in the bottom row of the display. When the
function is active, this is indicated by the field with the text box turning white.
Wire feed upwards
Key for reversing the wire without arc voltage, when replacing wire bobbin for
example. The wire is fed as long as the button is depressed.
Wire feed downwards
Menu
Key for feeding wire without arc voltage. The wire is fed as long as the button is
depressed.
Travel motion
Key for travel motion in the direction of welding where the symbol is indicated on
the weld equipment. To stop travel motion press , or .
The LED illuminates during travel motion.
Welding start
Key for welding start.
Welding stop
Key for welding stop for all travel motions and all motors.
Positioning knob
The uppermost right-hand knob is the positioning knob and is used to position the cursor.
Settings knob
The three settings knobs are used to change the set values in the panel.
1.2 First step
1.2.1 Choice of language
This menu appears at first start:

1 INTRODUCTION
0460 949 474 -7- © ESAB AB 2021
SAW: CA
NONE NONE GAS / FLUX NONE 2ND FUNCT
The control panel is set to English on delivery. To select your language, proceed as follows:
Press Menu to access the main menu.
Position the cursor on the CONFIGURATION row, using the positioning knob.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
DC
CA
Fe SOLID
3.0 mm
SET MEASURE MEMORY FAST MODE
Press ENTER to confirm the selection.
Position the cursor on the LANGUAGE row. Press ENTER to bring up a list of the languages
that are available in the control panel.
CONFIGURATION
LANGUAGE
CODE LOCK►
GENERAL CONFIGURATION►
MACHINE CONFIGURATION►
CABLE LENGTHS►
MAINTENANCE►
MEASURE-VALUES FILTER FACTOR
ENGLISH





ONE
QUIT
Position the cursor on the row for your language and press ENTER.

1 INTRODUCTION
0460 949 474 -8- © ESAB AB 2021
NORSK
POLSKI
PORTUGUES
SUOMI
SVENSKA
CHINESE
1.2.2 Unit of measurements
The control panel is set to metric measurement on delivery. To change measurement unit,
proceed as follows:
Press Menu to access the main menu.
Position the cursor on the CONFIGURATION row, using the positioning knob.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
DC
CA
Fe SOLID
3.0 mm
SET MEASURE MEMORY FAST MODE
Press ENTER to confirm the selection.
Position the cursor on the GENERAL CONFIGURATION row.
CONFIGURATION
LANGUAGE
CODE LOCK
GENERAL CONFIGURATION►
MACHINE CONFIGURATION►
CABLE LENGTHS►
MAINTENACE►
MEASURE-VALUES FILTER FACTOR
ENGLISH





ONE
QUIT
Press ENTER to confirm the selection.
Position the cursor on the UNIT OF LENGTH row. Press ENTER to bring up a list of the
measurements that are available in the control panel.

1 INTRODUCTION
0460 949 474 -9- © ESAB AB 2021
GENERAL CONFIGURATION
FAST MODE SOFT BUTTONS
QUALITY DATA LOG TO FILE
SOFT KEYS SETUP►
AUTO SAVE MODE
UNIT OF LENGTH

1
ON

OFF
METRIC
QUIT
Position the cursor on the row for correct measurement and press ENTER.
METRIC
INCH.
1.3 Display
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
DC
CA
Fe SOLID
3.0 mm
SET MEASURE MEMORY FAST MODE
Cursor
The control panel's cursor is presented as a black field around the text, with the selected text
turning white. The cursor is displayed in the instruction manual with bold text
Text boxes
At the bottom of the display are five boxes containing text that describes the current function
of the five soft keys below the display.
1.3.1 Symbols in the display
AThe selected weld data set
BWelding direction
CA fault has occurred, see
section "Event handling".
DRecalled memory position
number
EScroll bar. Further information
can be found in this menu

1 INTRODUCTION
0460 949 474 - 10 - © ESAB AB 2021
Arrows
Where there is more information behind a row, this is indicated with a black arrow behind
the text.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
AC
CC
Fe SOLID
0.8 mm
SET MEASURE MEMORY FAST MODE
1.4 General information about settings
There are three types of setting:
• Setting of numerical values
• Setting of given alternatives
• Setting of ON/OFF mode
1.4.1 Setting of numerical values
The settings knobs are used to increase or decrease the set values when setting numerical
values. In the measurements menu, the knobs for welding current / wire feed speed, arc
voltage or travel speed are used.
1.4.2 Setting with given alternatives
Some settings are made by selecting an option from a list. This is an example of the list:
SAW
GMAW
GOUGING
The cursor is positioned on the row for SAW. By pressing ENTER in this position, the SAW
option is selected. If you want to choose another option instead, position the cursor on the
correct row by scrolling up or down using the positioning knob. Then press ENTER. If you
want to exit the list without making a selection, press QUIT.
1.5 QUIT and ENTER
The soft key farthest to the right is used primarily for QUIT, although it is occasionally used
for other functions.
•QUIT returns you to the previous menu or image.
• Pressing ENTER entails the execution of a selected choice in a menu or a list.
The key is called ENTER in this manual.

2 MENUS
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2 MENUS
The control panel uses several different menus:
• Main menu
• Configuration menu
• Tools menu
• Weld data settings menu SET
• Measurments menu MEASURE
• Weld data memory menu MEMORY
• Fast mode menu FAST MODE
During start-up, a start-up screen containing information about the current program version
is displayed briefly.
Start-up screen
2.1 Main Menu
In the MAIN MENU, you can change welding process, method, wire type, control method,
wire dimension etc.
You can access other sub menus from this menu.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
DC
CA
Fe SOLID
3.0 mm
SET MEASURE MEMORY FAST MODE
2.1.1 Configuration menu
MAIN MENU » CONFIGURATION
In the CONFIGURATIONmenu it is possible to change language, change password, make
general configuration, make machine adjustments etc. The menu has different appearances
depending on which power source type is selected under MACHINE CONFIGURATION.

2 MENUS
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CONFIGURATION
LANGUAGE
CODE LOCK►
GENERAL CONFIGURATION►
MACHINE CONFIGURATION►
CABLE LENGTHS►
MAINTENANCE►
NETWORK SETTINGS
MEASURE-VALUES FILTER FACTOR
ENGLISH






ONE
QUIT
2.1.2 Tools menu
MAIN MENU » TOOLS
In the TOOLS menu you can transfer files, view quality and production statistics, event logs,
etc.
TOOLS
EVENT HANDLING►
EXPORT / IMPORT►
FILE MANAGER►
SETTING LIMIT EDITOR►
MEASURE LIMIT EDITOR►
PRODUCT STATISTICS►
QUALITY FUNCTIONS►
CALENDAR►
USER ACCOUNTS►
UNIT INFORMATION►
QUIT
2.1.3 Weld data setting menu
MAIN MENU » SET
In the weld data setting menu, SET, it is possible to change different welding parameters.
The menu has different appearances depending on which welding process is selected.

2 MENUS
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SAW WELD DATA SETTING
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
START DATA►
STOP DATA►
REGULATION PAR.►
SETTING LIMITS►
MEASURE LIMITS►
POLARITY
20.5 V
395 A
0 cm/min
■


AUTO


DC+
QUIT
Another example of the menu with Aristo® 1000:
SAW WELD DATA SETTING
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
AC FREQUENCY
AC BALANCE
AC OFFSET
START DATA►
STOP DATA►
REGULATION PAR.►
24.0 V
3200 A
30 cm/min
■
50 HZ
50%
0 V
QUIT
Example of the menu with LAF/ TAF power source

2 MENUS
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SAW WELD DATA SETTING
VOLTAGE
CURRENT
TRAVEL SPEED
DIRECTION
START DATA►
STOP DATA►
REGULATION PAR.►
SETTING LIMITS►
MEASURE LIMITS►
POLARITY
30.0 A
500 A
30 cm/min
■





DC +
MEASURE QUIT
2.1.4 Measurements menu
MAIN MANU » MEASURE
In MEASURE menu, you can view measured values for various welding parameters while
welding is in progress.
SAW: CA
EXT. AXIS DIR. SQUARE NONE SET VALUES 2ND FUNCT
•450 Amp - Measured welding current
•30.0 Volt - Measured arc voltage
•50 cm/min - Measured travel speed
SAW: CA
NONE NONE ICE WF NONE 2ND FUNCT
•cm/min - Measured wire speed
•kJ/cm - Indicates energy per unit length, which is obtained using the values selected
for welding current, arc voltage and travel speed

2 MENUS
0460 949 474 - 15 - © ESAB AB 2021
•cm/min - Measured ICE wire feed speed
•kg/h - Indicates used material per / hour
The measured values remain in the display even after welding has been completed.
You can move to different menus without losing the measurement values.
The settings knobs can be used to change the welding parameters in the measurement
display.
If the set value is changed when welding is not in progress, the measurement value changes
to zero.
For activating ICE wire feed, a soft key, ICE WF, is activated, see section "Soft key
configuration". When the key is depressed, the ICE wire speed is changed using the left
settings knob A. If the soft key is not depressed, the settings knob affects the A current.
In the measurement display one can also see the set values if the soft key SET VALUES is
activated. If both soft keys, ICE WF and SET VALUES are activated, the set feed speed for
cold wire can be changed. For activating see section "Soft key configuration".
SAW: CW
NONE DIR: SQUARE NONE SET VALUES 2ND FUNCT
•300 cm/min - Set wire feed speed
•20.0 Volt - Set arc voltage
•30 cm/min - Set travel speed
2.1.5 Weld data memory menu
MAIN MENU » MEMORY
In the WELD DATA MEMORY menu you can store, recall, delete and copy various set weld
data. The weld data sets can be stored in 255 different memory positions.
WELD DATA MEMORY
1 (SAW)
7 (GMAW)


STORE 2ND FUNCT QUIT
For further information, see section "MEMORY MANAGEMENT".
2.1.6 Fast mode menu
MAIN MENU » FAST MODE

2 MENUS
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In the FAST MODE menu, you can link soft keys to weld data memory positions. These
settings are carried out in the CONFIGURATION menu. The number of the selected memory
position is displayed in the top right corner.
16
WELD DATA 1 WELD DATA 2 WELD DATA 3 WELD DATA 4 2ND FUNCT
For further information, see section "Fast mode soft keys".

3 SUBMERGED ARC WELDING
0460 949 474 - 17 - © ESAB AB 2021
3 SUBMERGED ARC WELDING
MAIN MENU » PROCESS
During Submerged Arc Welding (SAW), an arc melts a continuously supplied wire. The weld
pool is protected by flux.
Aristo® 1000: When the SAW process is selected, choose METHOD with the positioning
knob and press ENTER. Choose AC or DC.
SAW
PROCESS
METHOD
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
SAW
AC
CC
Fe SOLID
0.8 mm
SET MEASURE MEMORY FAST MODE
Aristo® 1000: When the SAW process is selected, you can choose between three control
methods by marking REGULATION TYPE using the positioning knob and pressing ENTER.
Choose between constant welding current CA or constant wire feed CW or constant current
CC.
LAF/TAF: When the SAW process is selected, you can choose between three control
methods by marking REGULATION TYPE using the positioning knob and pressing ENTER.
Choose between constant welding current CA or constant wire feed CW.
See explanations in "CA, constant amperage", "CW, constant wire feed" and "CC, constant
current".
If ICE wire feed is selected, see "ICE wire feed", page53, only regulation type CW can be
selected.
3.1 Settings for submerged arc welding
Settings Setting range In steps of Value after
resetting
Arc voltage 1)
For Aristo® 1000 14 -50 V 0.1 V (1V) 30 V
For LAF/TAF 8 - 60 V 0.1 V (1V) 30 V
Welding current 1) (CA) 0 - 3200 A 1 A 400 A
Wire feed speed 1) (CW) 0 - 2500 cm/min 1 cm/min 100 cm/min
Constant current 1) 3) (CC) 0 - 3200 A 1 A 500 A
ICE wire feed speed 1) 0 - 200% 1% 100%
ICE wire start delay 1) 0 - 99,0 s 0,1 s 2,5 s
Travel speed *0 - 200 cm/min 1 cm/min 30 cm/min
Welding direction ▲-■ - ■
AC frequency 3) 10 - 100 Hz 1 50 Hz

3 SUBMERGED ARC WELDING
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Settings Setting range In steps of Value after
resetting
AC balance 3) 25 - 75% 1 50%
AC offset 3) -300-+ A/-10 +10V 1 A / 0.1 V 0
Start data 2)
Flux pre-flow 0 - 99.0 s 0.1 s 0 s
Start adjust Min = 50% 1% 100%
Start type Direct orScratch - Direct
Wire creep start Auto orSet speed - Auto
Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min
Start phases OFF orON - OFF
Open-circuit voltage OFF orON - OFF
Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V
Stop data 2)
Flux post-flow 0 - 99.0 s 0.1 s 0 s
Crater filling OFF orON - OFF
Crater filling time 0 - 10 s 0.01 s 0.0 s
Burnback time 0- 10 s 0.01 s 0.65 s
Stop phases OFF orON - OFF
Control parameters
Dynamics Auto orSet values - Auto
Inductance Auto orSet values - Auto
Setting limits - - -
Measure limits - - -
1) The setting range is dependent on the product used.
2) The menu shows the settings that belong to the selected regulation type.
3) Applies only to Aristo®1000 power sources

4 GAS METAL ARC WELDING
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4 GAS METAL ARC WELDING
The process is available for certain machine types.
MAIN MENU » PROCESS
During Gas Metal Arc Welding (GMAW), an arc melts a continuously supplied wire. The weld
pool is protected by shielding gas.
When the Gas Metal Arc Welding GMAW process is selected, you can choose between two
control methods by marking REGULATION TYPE using the positioning knob and pressing
ENTER. Choose between constant amperage CA or constant wire feed CW, see explanation
in "CA, constant amperage" and "CW, constant wire feed".
GMAW
PROCESS
REGULATION TYPE
WIRE TYPE
WIRE DIMENSION
CONFIGURATION►
TOOLS►
GMAW
CA
Fe SOLID
0.8 mm
QUIT
CA
CW
4.1 Settings for gas metal arc welding
Settings Setting range In steps of Value after
resetting
Arc voltage *14 -50 V 0.1 V (1V) 30 V
Welding current *(CA) 0 - 3200 A 1 A 500 A
Wire feed speed *(CW) 0 - 2500 cm/min 1 cm/min 100 cm/min
Travel speed *0 - 200 cm/min 1 cm/min 30 cm/min
Welding direction ▲-■ - ■
Start data 2)
Gas pre/flow 0 - 99.0 s 0.1 s 0.2 s
Start adjust Min = 50% 1% 100%
Start type Direct orScratch - Direct
Wire creep start Auto orSet speed - Auto
Wire creep start speed 0 - 1000 cm/min 1 cm/min 20 cm/min
Start phases OFF orON - OFF
Open-circuit voltage OFF orON - OFF
Maximum open-circuit voltage 5 - 60 V 0.1 V 50 V
Stop data
Gas post-flow 0 - 99.0 s 0.1 s 0.2 s
Crater filling OFF orON - OFF

4 GAS METAL ARC WELDING
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Settings Setting range In steps of Value after
resetting
Crater filling time 0 - 10 s 0.01 s 0.0 s
Burnback time 0- 10 s 0.01 s 0.20 s
Stop phases OFF orON - OFF
Dynamic regulation Auto orSet values - Auto
Setting limits - - -
Measure limits - - -
*) The setting range is dependent on the product used.