ESAB PAV User manual

PAV
Instruction manual
0460 670 101  GB  20220211
Valid for: serial no. 845-, 936-, 049-,
941-xxx-xxxx

TABLE OF CONTENTS
0460 670 101 -3- © ESAB AB 2022
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols .................................................................................................... 4
1.2 Safety precautions ...................................................................................................... 4
2 INTRODUCTION ......................................................................................................................... 7
2.1 General ......................................................................................................................... 7
2.2 Variants ........................................................................................................................ 7
2.3 Main parts .................................................................................................................... 7
3 TECHNICAL DATA ..................................................................................................................... 9
4 INSTALLATION........................................................................................................................... 10
4.1 General ......................................................................................................................... 10
4.2 Installation and connection ........................................................................................ 10
5 OPERATION ............................................................................................................................... 11
5.1 General ......................................................................................................................... 11
5.2 Joint-tracking unit with control panel ....................................................................... 11
5.3 Joint-tracking unit (rear section) ............................................................................... 12
5.4 Portable control box.................................................................................................... 14
5.5 Positioning before welding start................................................................................ 15
6 MAINTENANCE.......................................................................................................................... 16
7 ACCESSORIES .......................................................................................................................... 17
8 DIAGRAM ................................................................................................................................... 18
9 DIMENSION DRAWING.............................................................................................................. 22
10 ORDERING NUMBERS .............................................................................................................. 23
11 SPARE PARTS LIST................................................................................................................... 24

1  SAFETY
0460 670 101 -4- © ESAB AB 2022
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and follow
all labels, employer´s safety practices and Safety Data Sheets
(SDSs).
1.2 Safety precautions
Users of ESAB 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 equipment. The following recommendations 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 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 equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2 The operator must ensure that:
• no unauthorised person is stationed within the working area of the
equipment when it is started up
• no-one is unprotected when the arc is struck or work is started with the
equipment
3 The workplace must:
• be suitable for the purpose
• be free from drafts
4 Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns
5 General precautions:
• Make sure the return cable is connected securely
• Work on high voltage equipment may only be carried out by a
qualified electrician

1  SAFETY
0460 670 101 -5- © ESAB AB 2022
• Appropriate fire extinguishing equipment must be clearly marked and
close at hand
• Lubrication and maintenance must not be carried out on the equipment
during operation
WARNING!
Wire feeders are intended to be used with power sources in MIG/MAG mode only.
If used in any other welding mode, such as MMA, the welding cable between wire feeder and
power source must be disconnected, or else the wire feeder becomes live or energized.
If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.
Recommended ESAB coolant ordering number: 0465720002.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves
or wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side
of your body. Secure them with tape when possible. Do not
place your body between the torch and work cables. Never coil
the torch or work cable around your body. Keep welding power
source and cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible
to the area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1  SAFETY
0460 670 101 -6- © ESAB AB 2022
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those
locations, due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic equipment
that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment for
purchase. For ordering information contact your local ESAB dealer or visit us on our website.

2  INTRODUCTION
0460 670 101 -7- © ESAB AB 2022
2 INTRODUCTION
2.1 General
PAV is a control system for motorised slides. The system is available in several variants, see below.
2.2 Variants
• Joint-tracking unit with control panel
• Joint-tracking unit with portable control box
• Built-in components for columns and booms
2.3 Main parts
1 Joint-tracking unit (with or without control panel)
2 Portable control box
3 Motor cable
For more information, see OPERATION chapter.

2  INTRODUCTION
0460 670 101 -8- © ESAB AB 2022

3  TECHNICAL DATA
0460 670 101 -9- © ESAB AB 2022
3 TECHNICAL DATA
PAV
Supply voltage 42VAC, 50-60Hz
Current output 450VA
Ambient temperature -15°C ± 45°C
Relative atmospheric humidity Max. 98%
Maximum motor current 6A,100%
Enclosure class IP23
Current limits 15A (hardware current limit)
Power supply fusing 10Aslow
Motor regulator, type Switched four quadrant reg.
Rotor voltage 40VDC
Field voltage, separate magnetised motor 60VDC
Weight 58.5 kg
Joint-tracking unit 6.2kg
Portable control box 2.7kg (complete with 4m cable and
protection)
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water.
Equipment marked IP23 is intended for indoor and outdoor use.

4  INSTALLATION
0460 670 101 - 10 - © ESAB AB 2022
4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
4.2 Installation and connection
1 Measurement information, see DIMENSION DRAWING.
2 Connection, see DIAGRAM.
3 Check that the required output and voltage is available for complete installation.

5  OPERATION
0460 670 101 - 11 - © ESAB AB 2022
5 OPERATION
5.1 General
General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!
5.2 Joint-tracking unit with control panel
Emergency stop (1)
• One press on the button activates EMERGENCY STOP.
NOTE!
An emergency stop must never be reset before the cause of the abnormal function or signal
has been established and rectified.
Signal lamp
• Illuminates when the power has been switched on.
Control lever
• Manual control of the servo slides Up/Down and Left/Right.
Lamp pushbutton (rapid speed)

5  OPERATION
0460 670 101 - 12 - © ESAB AB 2022
Selection of low or high speed during manual positioning with the control lever.
• One press on the button activates rapid speed.
A lamp in the button illuminates when the function is activated.
• Return to low speed by pressing the button again.
Check that the lamp has gone out before carrying out further commands.
5.3 Joint-tracking unit (rear section)
1Connection, power supply 42V
2Switch
Power supply On/Off
3Socket, for connecting the vertical slide motor
4Socket, for connecting the horizontal slide motor
5Control fuse, 10A slow
6Socket (23-pin), for connecting the portable control box
7Sockets, for connecting the limit position switch
8Extra sockets
9Service contacts

5  OPERATION
0460 670 101 - 13 - © ESAB AB 2022

5  OPERATION
0460 670 101 - 14 - © ESAB AB 2022
5.4 Portable control box
Emergency stop (1)
• One press on the button activates EMERGENCY STOP.
NOTE!
An emergency stop must never be reset before the cause of the abnormal function or signal
has been established and rectified.
Signal lamp
• Illuminates when the power has been switched on.
Control lever
• Manual control of the servo slides Up/Down and Left/Right.
Lamp pushbutton (rapid speed)
Selection of low or high speed during manual positioning with the control lever.
• One press on the button activates rapid speed.
A lamp in the button illuminates when the function is activated.
• Return to low speed by pressing the button again.
Check that the lamp has gone out before carrying out further commands.

5  OPERATION
0460 670 101 - 15 - © ESAB AB 2022
5.5 Positioning before welding start
1 Align the welding equipment into position in relation to the weld joint with the control
lever.
2
For rough settings, press the lamp pushbutton .
The lamp illuminates.
3 For precise settings and during welding, check that the lamp pushbutton
is not depressed. The lamp should be switched off.

6  MAINTENANCE
0460 670 101 - 16 - © ESAB AB 2022
6 MAINTENANCE
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts any work
to rectify any faults in the product during the warranty period.
• Check that the cables are intact and that they are correctly connected.
• Clean the equipment with compressed air regularly.
• Follow the instructions for the internal components.

7  ACCESSORIES
0460 670 101 - 17 - © ESAB AB 2022
7 ACCESSORIES
Ordering number
0148636002 Intermediate transformer for separate power supply, from mains power
190, 220, 380, 415, 440, 500V50Hz
200, 230, 380, 415, 440, 500V60Hz to secondary 42V, 660VA
0262613404 Cable 3×2.5mm2, connection, transformer
0334333xxx A6 servo slide ball bushing type with permanent magnetised motor
42VDC
0334426xxx A6 motor driven slide, slide bearing mounted long runner, with A6 VEC
motor 42V - 4000rom ratio 74:1
0460745xxx Motor cable.
The cable is available in different lengths, see the appropriate sales
brochure for the servo slide. (Contact ESAB's sales office.)

8  DIAGRAM
0460 670 101 - 18 - © ESAB AB 2022
8 DIAGRAM

8  DIAGRAM
0460 670 101 - 19 - © ESAB AB 2022
PAV with control panel

8  DIAGRAM
0460 670 101 - 20 - © ESAB AB 2022
PAV with remote control box