ESAB Origo A44 User manual

GB
Valid from program version 1.14
0463 009 074 GB 20150306
OrigoTM
A44
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 INTRODUCTION 3...................................................
1.1 Control panel A44 3.........................................................
2 MMA WELDING 4....................................................
2.1 Settings 4..................................................................
2.2 Symbol and Function explanations 4...........................................
2.3 Hidden functions MMA welding 6..............................................
3 MIG/MAG / FCAW-S WELDING 7......................................
3.1 Settings 7..................................................................
3.2 Symbol and Function explanations 7...........................................
4 TIG WELDING 8.....................................................
4.1 Settings 8..................................................................
4.2 Symbol and Function explanations 8...........................................
4.3 Hidden function TIG welding 9................................................
5 WELDING DATA MEMORY 10..........................................
6 FAULT CODES 10....................................................
6.1 List of fault codes 10..........................................................
6.2 Fault code descriptions 11.....................................................
7 ORDERING SPARE PARTS 11.........................................
ORDER NUMBER 13.....................................................

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1 INTRODUCTION
The manual describes use of the A44 control panel.
NOTE! Differences in the panel function may occur, depending on in which product it
is installed.
For general information about operation see user's instructions for the power source.
When mains power is supplied the unit runs a self diagnosis of the
LEDs and the display, the soft ware version is displayed and in this
example the soft ware version is 0.18.
Instruction manuals in other languages can be downloaded from the website,
www.esab.com.
1.1 Control panel A44
Display
Indication of which parameter is shown in the display (current, voltage or
percent)
Display of measurement value for current (A) or voltage (V) during welding.
Knob for setting data (current, voltage or percent)
Buttons for weld data memory settings. See section 5.
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Button for choosing parameters ”Hot start” or arc pressure ”Arc force”
when MMA welding or inductance when MIG/MAG welding
Selection of welding method
MMA , MIG/MAG, FCAW-S or TIG
Choice of electrode type ”Basic”, ”Rutile” or ”Cellulose” when MMA welding
Setting from panel and connecting remote control unit
Display of VRD function (reduced open-circuit voltage)
Measured value in the display for arc voltage V, and welding current A, is arithmetic
average value = rectified average value.
2 MMA WELDING
2.1 Settings
Function Setting range Default value
Current 4 A - max 1)100 A
Active panel 0 = Off 1 = On ON
Remote control unit 0 = Off 1 = On OFF
Hot start 0 - 99% 0
Arc force 0 - 99% 5
Welding data memory 2) 1 and 2 -
Drop welding 3) 0 = Off 1 = On OFF
Min current 3) 0 - 99% -
VRD - -
1) The setting range is dependent on the power source used.
2) See chapter 5
3) Hidden function
2.2 Symbol and Function explanations
MMA welding
MMA welding may also be referred to as welding with coated electrodes. Striking the
arc melts the electrode, and its coating forms protective slag.
Setting current
A higher current produces a wider weld pool, with better penetration into the
workpiece.
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Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the
machine before activation. When the remote control unit is activated the panel is
inactive.
Hot Start
”Hot start” increases the welding current during a fixed period at the start of the
welding process. Set the start current at a % of the set welding current using the
knob. This reduces the risk of incomplete fusion at the start of the weld.
Arc force
The arc force is important in determining how the current changes in response to a
change in the arc length. A lower value gives a calmer arc with less spatter.
VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when
welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit,
this is indicated by an error message (16) appearing in the display and welding
cannot be started whilst the error message is displayed.
Contact an authorised ESAB service technician to activate the function.
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Air carbon arc gouging
When arc gouging, choose the FCAW-S icon on the panel and adjust with the
knob to achieve the recommended voltage value for the choosen carbon electrode.
Air-gouging reference table
Recommended arc voltage by
carbon electrode dimension
Set voltage in MIG/MAG AVC
mode for air-gouging.
Inductance setting = default
Ø4 mm 37 V 70%
Ø5 mm 39 V 70%
Ø6 mm 41 V 70%
Ø8 mm 43 V 70%
2.3 Hidden functions MMA welding
Function Settings
d= Drop welding 0 = Off 1 = On
I= Min current 0 - 99%
To access the function in A44, use button . Keep the button depressed for 5
seconds. The display shows a letter and a value. The knob is used to change the
value of the function.
To leave hidden functions, press for 5 seconds.
Drop welding
Drop welding can be used when welding with stainless electrodes. The function
involves alternately striking and extinguishing the arc in order to achieve better
control of the supply of heat. The electrode needs only to be raised slightly to
extinguish the arc.
Min current
Used to set the minimum current for the remote control unit.
If the max current is 100 A and the min current is to be 50 A, set the hidden function
min current to 50%.
If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.
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3 MIG/MAG / FCAW-S WELDING
3.1 Settings
Function Setting range Default value
Inductance 0 - 100 70%
Active panel 0 = Off 1 = On ON
Remote control unit 0 = Off 1 = On OFF
Welding data memory 1) 1 and 2 -
VRD - -
1) See chapter 5
3.2 Symbol and Function explanations
MIG/MAG / FCAW-S welding
When this function is activated it is possible to use an Arc Voltage Controlled or
(Mobile Feed), where the arc voltage from the power source is used to power the
feed unit.
During MIG/MAG welding, an arc melts a continuously supplied wire. The weld pool
is protected by shielding gas.
During FCAW-S a powder filled cored wire is used instead of gas to protect the weld
pool. The power source provides a Constant Voltage (CV), where the open-circuit
voltage of 16.5 - 60 V DC manages to drive the Mobile Feed. When welding with
these wire feed units, the wire feed is set on the wire feed unit and the voltage on the
power source panel.
Inductance
Higher inductance results in a wider weld pool and less spatter. Lower inductance
produces a harsher sound but a stable, concentrated arc.
Control of the inductance is especially important when short arc welding.
Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the
machine before activation. When the remote control unit is activated the panel is
inactive.
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VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when
welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit,
this is indicated by an error message (16) appearing in the display and welding
cannot be started whilst the error message is displayed.
Contact an authorised ESAB service technician to activate the function.
4 TIG WELDING
4.1 Settings
Function Setting range Default value
Current 3 A - max 1)60 A
Active panel 0 = OFF 1 = ON ON
Remote control unit 0 = OFF 1 = ON OFF
Welding data memory 2) 1 and 2 -
Min current 3) 0 - 99% -
VRD - -
1) The setting range is dependent on the power source used.
2) See chapter 5
3) Hidden function
4.2 Symbol and Function explanations
TIG welding
TIG welding melts the metal of the workpiece, using an arc struck from a tungsten elec
trode, which does not melt itself. The weld pool and the electrode are protected by
shielding gas.
”Live TIG-start”
At a ”Live TIG-start” the tungsten electrode is placed against the workpiece. When
the electrode is then lifted away from workpiece, the arc is struck at a limited current
level (12 - 15 A).
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Active panel
Settings are made from the control panel.
Remote control unit
Settings are made from the remote control unit.
The remote control unit must be connected to the remote control unit socket on the
machine before activation. When the remote control unit is activated the panel is
inactive.
VRD (Voltage Reducing Device)
The VRD function ensures that the open-circuit voltage does not exceed 35 V when
welding is not being carried out. This is indicated by a lit VRD LED.
The VRD function is blocked when the system senses that welding has started.
If the VRD function is activated and the open-circuit voltage exceeds the 35 V limit,
this is indicated by an error message (16) appearing in the display and welding
cannot be started whilst the error message is displayed.
Contact an authorised ESAB service technician to activate the function.
4.3 Hidden function TIG welding
Function Settings
I = Min current 0 - 99%
To access the function in A44, use button . Keep the button depressed for 5
seconds. The display shows a letter and a value. The knob is used to change the
value of the selected function.
To leave hidden function, press for 5 seconds.
Min current
Used to set the minimum current for the remote control.
If the max current is 100 A and the min current is to be 50 A, set the hidden function
min current to 50%.
If the max current is 100 A and the min current is to be 90 A, set the min current to 90%.
This function also applies when setting background current with pulsed TIG.
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5 WELDING DATA MEMORY
Two different welding data programs can be stored in the A44 control panel memory.
Press button or for 5 seconds to store the welding data in the memory.
The welding data is stored when the green indicator lamp starts to flash.
To switch between the different welding data memories press button or
.
The welding data memory has a back-up so that the settings remain even if the
mains supply has been switched off.
6 FAULT CODES
Fault codes are used to indicate that a fault has occurred in the equipment. It is
indicated in the display by an E followed by a fault code number.
A unit number is displayed to indicate which unit has generated the fault, for example
U 0.
If several faults have been detected only the code for the last occurring fault is
displayed. Press any function button or turn the knob to remove the fault indication
from the display.
NOTE! If the remote control unit is activated, deactivate the remote control unit by
pressing to remove the fault indication.
6.1 List of fault codes
Unit number:
U 0 = welding data unit
U 3 = wire feed unit
U 1 = cooling unit
U 4 = remote control
U 2 = power source
U 5 = multivoltage,
Program version 1.25
GB