WO 100 2 - ESAB

GB 

WO1002 

Aristot 

Instruction manual 

0444 534 074 GB 071107 

Valid for program version 1.6

1 INTRODUCTION ................................................... 3 

1.1 Selection of language ...................................................... 3 

1.2 Control panel ............................................................. 4 

2 SETTING RANGE .................................................. 5 

3 WELDING PARAMETERS ........................................... 6 

3.1 Sectors .................................................................. 6 

3.2 Welding current ........................................................... 7 

3.2.1 Pulsed current/continuous current ....................................... 7 

3.3 Wire feed ................................................................. 7 

3.4 Rotation .................................................................. 8 

3.5 Gas ..................................................................... 8 

3.6 Preheating ................................................................ 8 

3.7 Slope .................................................................... 9 

4 MENU STRUCTURE ................................................ 10 

5 MENUS ........................................................... 11 

5.1 Weld area ................................................................ 11 

5.1.1 Parameters .......................................................... 11 

5.1.2 File manager ......................................................... 16 

5.1.3 Information ........................................................... 16 

5.1.4 Joint information ...................................................... 17 

5.1.5 Settings ............................................................. 19 

5.1.6 Limits ............................................................... 20 

5.2 Design area .............................................................. 20 

5.3 Settings .................................................................. 21 

5.3.1 Appearance .......................................................... 21 

5.3.2 Users settings ........................................................ 22 

5.4 Login .................................................................... 24 

5.5 Library ................................................................... 24 

5.5.1 Weld programs ....................................................... 25 

5.5.2 Search filter .......................................................... 25 

5.6 Manual mode ............................................................. 26 

5.6.1 Motor selection ....................................................... 26 

5.6.2 Gas valve control ..................................................... 27 

5.6.3 Run motor ........................................................... 27 

5.7 Tool editor ................................................................ 27 

5.7.1 Load/save ........................................................... 28 

5.7.2 Edit settings .......................................................... 29 

5.7.3 Edit motor data ....................................................... 29 

5.8 Logs ..................................................................... 30 

5.8.1 Event log ............................................................ 30 

5.8.2 Quality data .......................................................... 33 

5.9 Manual welding ........................................................... 34 

5.10 Generate ................................................................. 37 

6 TECHNICAL TERMS ................................................ 38 

ORDERING NUMBER ................................................. 

39 

Rights reserved to alter specifications without notice. 

TOCe 

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1 INTRODUCTION 

The manual describes the use of a control panel. WO1002 

For general information about operation, see the instruction manual for the power 

source and control unit. 

The text displayed in the panel is available in the following languages: Swedish, 

Norwegian, Danish, Finnish, English, German, French, Dutch, Spanish, Italian, 

Portuguese, Greek, Polish, Czech, Hungarian, Slovenian and Russian. 

1.1 Selection of language 

The first time you start up the machine, the following is displayed. 

On delivery the system is set to English. To select your preferred language: 

S Press the ”Menu” button 

so that the menu is 

activated and shows the 

options available at this 

level. 

S Turn the knob until 

”Settings” is highlighted, 

then press the knob. 

S ”Appearance” is 

highlighted, press the knob. 

S ”General” is highlighted, 

press the knob. The 

”Language” field with the 

word ”English” is framed. 

Turn the knob to select 

your preferred language. 

S Activate your preferred language by pressing the knob. 

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1.2 Control panel 

1 Knob 

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For moving, activating and setting parameter values. 

There are three knob functions: 

S Turn to the left 

S Turn to the right 

S Press the knob, activate 

2 Display 

There are four view fields in the 

display: 

Upper status field (A) 

Information about the weld area’s 

program name, user, which type of tool 

is connected and the tube dimension. 

Main menu field (B) 

Different menus, see chapter 5 ”Menu 

Structure”. 

View field (C) 

For editing weld programs, saving programs, information, appearance, etc. 

Status field (D) 

Shows general information, error messages and current welding data (position, 

voltage, current) 

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3 Quick stop/Restart 

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Immediate stop of the welding process. Gas postflow occurs according 

to information from end sector. 

Pressing the button again initiates restart with parameters from start 

sector; the welding process continues from the point in the weld 

program at which the interruption occurred. 

4 Left arrow 

Moving to the left in the menus and back in the main menus 

5 Right arrow 

Moving to the right in the menus and forward in the main menus 

6 Main menu 

Moving to the main menu field 

2 SETTING RANGE 

Parameter Setting range 

Sector 

Breakpoints 

Degrees 

Welding current 1) 

Peak current 

Background current 

Pulse time 

Background time 

Wire feed 

Peak wire feed speed 

Background wire feed speed 

Rotation 

Rotation speed 

Rotation direction 

Pulsed rotation 

Gas 

Weld gas preflow time 

Weld gas postflow time 

Start gas 

Root gas 

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0--50 

0.000 -- 9.999 

0 -- 3599˚ 

3 -- 400 A 2) 

3 -- 400 A 2) 

0.01 -- 25 s 

0.01 -- 25 s 

15 -- 250 cm/min 

15 -- 250 cm/min 

5 -- 100 % of the welding tool’s maximum speed 

Forwards and Backwards 

0.05 -- 25 s 

0 -- 6000 s 

0 -- 6000 s 

0 -- 6000 s 

0 -- 6000 s 

Preheating 

Preheating time 0 -- 600 s 

Slope 

Slope up time 

Slope down time 

0.1 -- 25 s 

0.1 -- 25 s

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1) The maximum welding current for air--cooled tube welding tools is 100 A. 

The maximum welding current for water--cooled tube welding tools is 400 A. 

See also the instruction manual for the tube welding tool in question. 

2) Depends on power source 

3 WELDING PARAMETERS 

3.1 Sectors 

A program for tube welding can be divided into different sections: sectors. Each 

sector corresponds to one section of the tube’s circumference. The maximum 

number of sectors for one program is 50. 

A sector can be assigned g its own set of values 

ffor diff different welding ldi parameters, suchh as 

current current, rotation speed and wire feed speed speed, etc etc. 

This allows the welding to be performed using 

different weldingg parameter p settings g for different 

Sector 4 Sector 1 

sections of the tube joint. Sector 3 Sector 2 

The division into sectors is done by 

indicating different breakpoints or degrees 

around the circumference of the tube. Each 

breakpoint or degree constitutes the starting 

point for a new sector. In the figure, 

breakpoint 0.000, 0 degrees, is the starting 

point for sector 1, breakpoint 0.250, 90 

degrees, the starting point for sector 2, and 

so on on. 

The power source allows welding of up to 

10 turns t in i the th same weld ld jjoint. i t (Th (The 

welding tool can be rotated 10 times around 

the tube.) 

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0.000 


0.750 0.250 


0.500 

Note: A sector may not be less than 10 thousandths, or 3.6 degrees, of a turn. 

S Turn 1 = 

breakpoints 0.000 -- 0.999 

0 -- 359 degrees 

S Turn 3 = 


720 -- 1079 degrees 

S Turn 5= 


1440 -- 1799 degrees 

S Turn 7= 


2160 -- 2519 degrees 

S Turn 9= 


2880 -- 3239 degrees 

S Turn 2 = 


360 -- 719 degrees 

S Turn 4 = 


1080 -- 1439 degrees 

S Turn 6= 


1800 -- 2159 degrees 

S Turn 8 = 


2520 -- 2879 degrees 

S Turn 10 = 


3240 -- 3599 degrees

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To conclude a weld program, a so--called end sector is indicated. 

For a sector to be counted as an end sector the following two conditions must be 

fulfilled: 

S There is no subsequent sector. 

S The welding current value for the sector is 0 ampere. 

3.2 Welding current 

Six parameters are represented in the parameter group for welding current: 

S Peak current 

S Background current 

S Pulse time 

S Background time 

S Special pulsing 

S Slope, see point 3.7. 

TIG welding with pulsed current 

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Pulse time 



Welding current can be pulsed or continuous (not pulsed). 

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Peak current 

3.2.1 Pulsed current/continuous current 

When welding using a pulsed current, peak current, background current, pulse 

time and background time must be given a value. 

When welding using a continuous current, however, you need only enter a 

parameter value for peak current. Entering a value for background current will result 

in a pulsed current. 

3.3 Wire feed 

Wire feed speed is used to indicate the feed speed for the filler wire in cm/minute. 

Speed can be pulsed or continuous (not pulsed). 

Three parameters are represented in the parameter group for wire feed: 

S Peak wire feed 

S Background wire feed 


For welding using a continuous (not pulsed) wire feed, only the peak wire feed 

parameter needs to be entered.

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For welding with a pulsed wire feed speed, both the peak wire feed and the 

background wire feed parameters need to be entered. 

The pulsed wire feed speed is always automatically synchronized with the welding 

current so that the wire feed speed is high when using peak current and low when 

using background current. 

3.4 Rotation 

Used to indicate the rotation speed of the electrode around the workpiece. It is 

indicated in mm/min. 

The rotation speed can be pulsed or continuous (not pulsed). 

Four parameters are represented in the parameter group for rotation: 

S Rotation speed 

S Rotation direction 

S Pulsed rotation 


Pulsed rotation is automatically synchronized with the welding current so that the 

welding tool is stationary at peak current and rotates at background current. 

3.5 Gas 

Three parameters are represented in the parameter group for shielding gas: 

S Weld gas 

S Start gas 

S Root gas 

Weld gas refers to the shielding gas on the upper side of the weld joint. The weld 

gas parameter indicates how long the shielding gas is to flow on the upper side of 

the joint before and after welding. The weld gas is monitored by a flow guard min. 

4.5 l/min. 

Some shielding gases, for example, helium (He), can cause problems with regard to 

igniting the arc. If this type of shielding gas is to be used as weld gas, it may be 

advisable to use a different gas mixture at the actual instance of starting, a so--called 

start gas. 

Root gas refers to the shielding gas on the underside of the weld joint. The root gas 

parameter indicates how long the shielding gas is to flow on the underside of the 

joint before and after welding. 

If one value is entered for weld gas and another for start gas in sector 1, only the 

start gas will flow. The weld gas starts flowing once the arc is ignited. 

3.6 Preheating 

Preheating is used to heat the workpiece at the starting point in order to ensure 

correct penetration of the molten pool and is defined as the time elapsing between 

arc ignition and the start of the rotary motion. If no value has been entered for 

preheating, rotation will start as soon as the arc ignites. 

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3.7 Slope 

A slope may be indicated for certain parameters. A slope is the time during which the 

value of the parameter gradually changes from the value in the preceding sector to 

the value entered for the current sector. 

Slope up = gradual increase, if the preceding value is lower than the entered value. 

Slope down = gradual decrease, if the preceding value is higher than the entered 

value. 

The maximum period a slope can run depends on the duration of a particular sector. 

If the slope time is of the same duration as the sector, this is called a ‘sector slope’. 

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4 MENU STRUCTURE 

Table 

· Edit table 

· Show/hide 

· Weld 

control 

· Edit 

Table 

· Edit table 

· Show/hide 

· Edit 

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Weld area 

Parameters File manager Information Joint info. Settings Limits 

Graphical 

· Current 

· Wire feed 

· Rotation 

· Gas 

· General 

· Description 

· Tube 

· Electrode 

· Wire 

· Gas 

Design area 

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· Visualization 

· Parameter 

values 

· Tool 

settings 

· Tube 

settings 

Parameters File manager Information Joint info. Settings Limits 

Graphical 

· Current 

· Wire feed 

· Rotation 

· Gas 

· General 

· Description 

· Tube 

· Electrode 

· Wire 

· Gas 

· Visualization 

· Parameter 

values 

· Tool 

settings 

· Tube 

settings

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Settings Login Library Manual 

mode 

Appearance User · Weld 

program 

· General 

· Quality 

data 

Load/ 

save 

· Tool 

selection 

· Tool 

action 

Tool 

editor 

Change 

settings 

· General 

· Parameter 

limits 

5 MENUS 

Change 

motor data 

· Change 

parameter 

· Show para 

meters 

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· Motor selection 

· Gas valve control 

· Search filter · Run motor 

Event 

log 

Logs Manual 

welding 

Quality data 

· Quality data 

files 

· Contents 

Generate 

There are two work areas where you can view and edit welding parameters, Weld 

area (see chapter 5.1) and Design area (see chapter 5.2). 

5.1 Weld area 

In this view, you can view and edit parameters in a weld program and control the 

welding process. The weld program in the weld area controls the welding process. 

You can enter the weld area’s parameters by loading a weld program from the 

library, generating a basic weld program or editing the parameters manually. 

5.1.1 Parameters 

This menu option is solely an archive for other menu options. 

Weld area - -> Parameters - -> Table 

Here you can view and edit welding parameters in table form and start and stop the 

welding process.

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Each parameter in a parameter group is highlighted in the group’s colour. 

A selected welding parameter in the table is indicated by a blue box with two arrows. 

S To move through the table, turn the knob. 

S To change direction, press the knob. 

S To change a parameter value, click on the right arrow and change the parameter 

values using the knob. 

Menu shortcuts: 

S Edit table 

Highlights the table with welding parameters 

S Show/hide 

Shows or hides groups of welding parameters in the table. 

Here you can choose which parameters are to be shown in the table by selecting 

groups of parameters. 

S Weld control 

Highlights the start button in the weld control box. 

The buttons in this box control the welding process. You can start, stop, direct 

stop, continue or simulate the start of the welding process. 

S Edit sectors 

Highlights the button ’Add sector after’ in the Edit sectors box. 

The number of sectors can be increased or decreased using this box. It is 

possible to add new sectors before or after an existing sector and remove 

sectors in the weld program. 

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Weld area - -> Parameters - -> Graphical - -> Current 

In this view, you can view and edit welding parameters for current in a graphical 

representation. 

The current’s peak and background values are represented in a coordinate system. 

The Y--axis represents the current’s value in ampere, while the X--axis represents 

time. 

The current’s various values per sector are connected and form a line. 

Green indicates the peak current value per sector, while blue indicates the 

background current value per sector. 

Slope is represented as an angled line from the start of the sector, which ends where 

the slope time stops on the X--axis. 

S Zoom 

Here you can adjust the scale of the X--axis in the coordinate system. 

S Weld control 

The buttons in this box control the welding process. You can start, stop, direct 

stop, continue or simulate the start of the welding process. 

S Sector information 

The figures in this field show the other parameters concerned with the parameter 

group for current. The sector’s breakpoint is represented by a dash in a circle 

(cross--section of a tube). 

If the weld program extends over more than one turn, these turns are shown as 

a sequence of slightly smaller circles. 

The preheating time is shown in tenths of a second under the breakpoint 

information. 

Special pulsing on or off is shown as an image, where a red cross indicates that 

special pulsing is not being used. 

The relationship between pulse times is shown as a pulse cycle. Separate times 

for peak and background pulse. 

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S Figure for breakpoints 

It is possible to move, add or remove breakpoints using the knob in the figure for 

breakpoints. By skipping forward to the figure and highlighting it, you can turn the 

knob and move a white dash or ‘cursor’. 

Moving a breakpoint: 

S Press the knob once the cursor is on or directly next to the breakpoint cursor 

(black) to be moved. 

The breakpoint is ‘collected’ by the cursor and follows this when it is turned 

around in the circle. 

S To confirm the new breakpoint, press the knob. 

Creating a new breakpoint 

S Move the cursor by turning the knob and press the knob once at the point 

where you want the new breakpoint to be created. 

Removing a breakpoint: 

S Press the knob once the cursor is on or directly next to the breakpoint cursor 

to be removed. 

The breakpoint is ‘collected’ by the cursor and follows this when it is turned 

around in the circle. 

S Turn the knob to the previous or next breakpoint and press the knob once. 

Weld area - -> Parameters - -> Graphical - -> Wire feed 

Here you can view and edit parameters that control wire feed per sector. 

The coordinate system shows the speed at which the wire will be fed out at the peak 

and background value per sector. 

Slope is represented as an angled line from the start of the sector for the duration 

entered for the slope. 

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Weld area - -> Parameters - -> Graphical - -> Rotation 

Rotation speed is viewed and edited in a coordinate system with one line for each 

value and time slope. The coordinate system shows breakpoints as dashed lines. 

If pulsed rotation is off, this is shown by a pulse that is crossed out. 

Weld area - -> Parameters - -> Graphical - -> Gas 

Times for weld, start and root gas are viewed and edited in this view. 

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5.1.2 File manager 

This view is used to save, copy, clear and verify weld programs. 

S Save weld program 

To save a weld program, select where you want the program to be saved, either 

on the control unit (User defined programs) or on a USB memory device 

(External memory). 

Specify a file name and click the ’Save weld program’ button using the knob. 

S Copy weld program to another area 

Depending on which work area is active, it is possible to copy the contents of 

one area to another area by clicking the ’Copy this wld program to design area’ 

button or ’Copy this weld program to weld area’ button. 

S Clear, reset weld program 

If you want to begin a brand new weld program, click the ’Clear weld area’ 

button or ’Clear design area’ button. 

S Verify 

This function is used to check whether the weld program in the current work area 

fulfils the system’s requirements as follows: 

S A tool is selected for the weld program. 

S The connected tool is the same as the one the program is designed for (only 

applies to weld area). 

S The program has at least two sectors (start and stop sector). 

S The final sector in the program is a stop sector (the welding current is zero). 

S Selected tube diameter is supported by the selected tool. 

S The welding parameters in each sector are within the limits (min. and max. 

values) for the selected tool. 

5.1.3 Information 

Used to enter information about the weld program. This information does not affect 

the welding process, but is an aid for describing the program in words. 

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S General 

Program name is shown at the top of the list. This is not the same as file name in 

file manager. If a program name is assigned, this is the suggestion offered for 

the file name. 

S Description 

S Tube 

S Electrode 

S Wire 

S Gas 

5.1.4 Joint information 

In this view, you can view and change how the joint will look to suit the weld 

program. This is only information about the weld program. It does not affect the 

welding process. 

In the ”Visualization, Visualization” field, it is possible to view a graphical 

representation of the joint. In the ”Parameters” field, you can view those values 

relevant to the joint. Values that affect the joint can be changed in both fields. 

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Visualization 

S Turn the knob and a blue line will indicate which parameter has been selected. 

S Press the knob and the line will turn red. The value can be changed by turning 

the knob. 

Parameter 

S Use the arrows to move between the various parameters. 

S Turn the knob to change the value. 

Gap 

Nose 

Nose length 

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Radius 

Bevel angle 

Material thickness 

5.1.5 Settings 

This view allows you to select tools and the external tube dimension for which the 

weld program has been created. In the ”Tool settings” field, you can scroll through 

the tools and look at an overview of the tools under ”Tool illustration”. To select a 

tool, press the knob and then select the type of tool by turning and pressing the 

knob. 

The external tube dimension is selected by turning the knob. To confirm, press the 

knob. The selected tool (”Tool ”) and dimension (”Ø:”) are visible in the top status 

field, when using views from a work area. 

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5.1.6 Limits 

This view can be used to limit how much a user can change preset parameter values 

in a weld program. 

In order for the restrictions to be activated, the check box ”Limits activated” must be 

checked. 

5.2 Design area 

Weld programs can be created in the design area for use in the weld area or saved 

in the library for subsequent use. To see how the design area works, refer to chapter 

5.1Weld Area. The design area works in a similar way to the weld area. 

The greatest difference between the two areas is that you cannot control the welding 

process from the design area. 

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5.3 Settings 

You can change the appearance of the panel and manage users in the system via 

the Settings menu. 

5.3.1 Appearance 

Settings - -> Appearance - -> General 

S Language 

Choose from Swedish, Norwegian, Danish, Finnish, English, German, French, 

Dutch, Spanish, Italian, Portuguese, Greek, Polish, Czech, Hungarian, Slovenian 

and Russian. 

S Angle system 

Choose between thousandth points or degrees. 

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S Start view 

Choose between starting the panel with the login menu or last viewed menu. 

Settin g s - - > Ap p earan ce - - > QData 

S Post weld function 

Choose from: 

S None 

S Print 

S Save 

S Print + save 

The values that are saved and printed out are set values and the measurement 

values from the concluded welding process. Printing uses the integral printer in 

the control unit. 

The values are saved in the control panel under the ”quality data” menu, see 

chapter 5.8. 

Settings - -> Appearance - -> Date and time 

Here you can view and enter the 

date and time used in the system. 

5.3.2 Users settings 

In this view, you can add, change and delete users. 

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”Default user” appears the first time this menu is accessed. 

To add a new user: 

S Press the right or left arrow until ”New user” is 

highlighted. 

S Press the knob. 

S Turn the knob until a suitable ID appears. 

S Press the knob. The next box will be 

highlighted. 

S Turn the knob until a suitable letter appears, 

press the knob, and so on. 

S Once the name is ready, press the right 

arrow until ”ok” is highlighted. 

S Press the knob. 

A new user appears in the list. 

To change a user: 

S Highlight the user list (by pressing the arrow keys). 

S Turn the knob to select the user you want to change and press the knob. 

A new field appears at the side of the user list, which allows you to change the 

selected user’s name or ID. Confirm the changes using ”OK”. 

To delete a user: 

S Highlight the user. 

S Press the knob, move to the ”Delete user” button and click on the button. 

The user disappears from the list. 

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5.4 Login 

The login menu is used to select users and view which program version applies for 

the panel and which units are connected. It is also possible to view version 

information on the connected units/nodes. 

The user name is shown in the top status field, see chapter Control Panel 1.2. 

5.5 Library 

Programs can be erased and retrieved for the weld area or the design area using the 

library menu. 

Please note that each program stored in the library is 4 -- 6 Kb. The control unit’s 

internal memory is 1 Gb, so there is only a very small risk of the library becoming full. 

NOTE! Predefined programs that begin with ESAB cannot be erased. These 

programs are tested and are intended to serve as start data for similar dimensions. 

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5.5.1 Weld programs 

5.5.2 Search filter 

Using the search filter menu it is possible to search by the following criteria in the 

programs stored in the library: 

S Nothing 

S Name 

S Project 

S Material 

S External tube diameter 

S Tube wall thickness 

If there are programs that match the criteria, these programs are displayed in the 

”Weld programs” menu. 

If there are no programs that match the selected criteria, continue on to ”Go to 

Generate”, see chapter Generate 5.10. 

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5.6 Manual mode 

All motors can be checked using this menu. 

5.6.1 Motor selection 

Here you can choose which motor to run and also enter the motor speed. 

Note: This view only shows those motors available in the system. The tool selected 

in ”Weld area ----> Settings” affects the information shown. 

S Wire inching 

Used when loading a new wire bobbin, for example. 

S Rotation/Transport 

Used to move the welding tool around the workpiece. 

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5.6.2 Gas valve control 

Used when measuring the gas flow or to flush any air or moisture from the gas 

hoses before welding begins. 

Starts and stops the flow of gas. 

If you exit this view, the gas valves close automatically. 

5.6.3 Run motor 

Used to view the current value of the motors. 

Note! Hold in the knob to activate motor drive. 

Run selected motor forwards ”+” or 

backwards ”--”, and view current 

speed for selected motor. 

5.7 Tool editor 

This menu is used for viewing and editing tool parameters. You can create new tools 

from scratch or use predefined tools. Tools that are created by a user can be 

removed, changed and saved. Predefined tools supplied with the system cannot be 

changed or removed. 

Please note that the tool currently being used is designated a specific work area, a 

tool area. All changes performed in the views described below only affect the tool 

area and are not saved until this is requested by the user. 

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5.7.1 Load/save 

In this view, you can load a tool to work from when creating a new tool, clear 

user--defined tools and save tools. 

Select a tool to use (enter parameters in the tool area) by moving to the list of tools 

using the left or right arrow. Turn the knob to select (highlight) a tool. 

Move to the button ”Load tool”, press the knob and confirm that this is the tool you 

want to use. 

It is also possible to use a tool specification (tool type), for example, a tool with a 

particular diameter range. 

Delete a created tool by selecting it in the list, press the knob on ”Delete tool, Delete 

tool” and confirm that you want to delete it using ”Yes”. It is not possible to delete any 

tools supplied with the system. 

You can save the created tool as a new tool or in place of an existing tool (you 

cannot replace tools supplied with the system). 

To save the tool as a new tool (or new tool type): 

S Move to the list of tools (or tool types) using the arrow keys. 

S Turn the knob to highlight ”New.... ” in the list. 

S Click the menu button and select ”Tool action”. 

S Move to the ”Save tooll” button. 

S Press the knob and confirm that you want to save the tool as a new tool using 

the ”Yes” button. 

To replace an existing tool, use the same procedure as above but instead select an 

existing tool from the list of tools. 

You can upload tools to the system from a USB memory device, if you have a 

”MechTIG_Tools.xml” tool file at the root of the file structure. 

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Proceed as follows: 

S Connect a USB memory device to the panel’s USB terminal, where the 

”MechTIG_Tools.xml” file is at the very root of the file structure. 

S Move to the ”Load tools from usb--memory” button using the arrow keys. 

S Press the knob and confirm using ”Yes” to invalidate all the changes made to the 

tool. 

Clear or reset all parameters in the tool area by moving to the ”Clear tooll” button 

and pressing the knob. Confirm using ”Yes” to invalidate any changes made in the 

tool area. 

To save all your tools to a USB memory device: 

S Connect a USB memory device to the panel’s USB terminal. 

S Move to the ”Save tools to usb--memory” button and press the knob. 

S Confirm using ”Yes” to save the tools and overwrite any tools stored on the USB 

memory device. 

5.7.2 Edit settings 

This view is used once you have loaded a tool or when you want to create a brand 

new tool. Here you can view and edit all parameter values for a tool. 

The ”General settings” field contains general settings for the tool, while the 

”Parameter limits” field defines the highest and lowest values for a parameter. 

For min. values the value 0 means that the minimum value has not been set, while 

for max. values 65535 means that the maximum value has not been set. (In some 

instances, where decimals are used, 655,30 or 6553,5 may indicate not set). 

5.7.3 Edit motor data 

In this view, you can view and edit specific motor settings. There are motor settings 

for each motor (rotation, wire feed, weaving and AVC). There are currently three 

parameters per motor. The parameters are ”Setting parameter”, ”Scalefactor 

position” (”numerator” and ”denominator”) and ”Scalefactor speed” (”numerator” and 

”denominator”). 

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GB 

Add the value 100 for the parameter ”Scalefactor position (numerator)” for the motor 

that controls rotation. 


S Move to the text field under ”Motor parameter” using the arrow keys. 

S Turn the knob until ”Scalefactor position (numerator)” is visible in the text field 

and press the knob. 

S Change the value to 100 by turning the knob. Press the knob to continue. 

S Turn the knob so that ”Rotation” appears in the text field. Confirm by pressing 

the knob. 

S Press the knob to add (or edit) the value in the list of parameters for the rotation 

motor. 

You can remove motor parameters by highlighting a parameter in the list of motor 

parameters, pressing the knob, moving to the ”Delete” button and pressing the knob 

to delete the selected parameter from the list. 

5.8 Logs 

This menu allows you to view logs compiled by the system. 

5.8.1 Event log 

Event log 

When a fault occurs, this is indicated by the symbol , which is displayed to the 

right of the ESAB logo. When you go into the Event log menu, the symbol 

disappears. 

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GB 

Used to display operating messages 

In order to clear or remove all operating messages from the log, move the focus to 

the ”Clear log” button with the arrow keys and press the knob. Confirm that you want 

to remove all events by pressing ”Yes” with the knob. The event log is reloaded and 

is now empty. 

It is also possible to save the event log onto an external USB memory. 


S Insert a USB memory in the panel’s USB contact, move the focus with the arrow 

keys to the ”Save” button. 

S Press the knob. The text ”Event log saved” appears in the lower status bar if the 

log was saved correctly. 

Operating messages 

Unit Unit 

1 = cooling unit 6 = motor control 1, rotation, wire feed 

2 = power source 8 = weld data unit 

4 = remote control 17 = I/O node 

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GB 

Below describes event codes which the user can take action by him self. Is any other 

code shown, send for a service technician. 

Code Description 

5 Intermediate DC voltage outside limits 

The voltage is too high or too low. Too high a voltage can be due to severe transients on 

the mains power supply or to a weak power supply (high inductance of the supply or a 

phase missing). 

The power unit is stopped and cannot be started. 

Action: Turn off the mains power supply to reset the unit. If the fault persists, send for a 

service technician. 

6 High temperature 

The thermal overload cut--out has tripped. 

The current welding process is stopped and cannot be restarted until the cut--out has 

reset. 

Action: Check that the cooling air inlets or outlets are not blocked or clogged with dirt. 

Check the duty cycle being used, to make sure that the equipment is not being overloaded. 

If the fault is repeated, send for a service technician. 

11 Motor servo fault, (rotation, wire feed) 

When a motor cannot maintain its speed. Welding stops. 

Action: Check that the tool / wire feed unit has not become trapped or is moving too 

slowly. If the fault persists, send for a service technician. 

11 Current servo fault, (power source) 

The voltage is too high or too low. Too high a voltage can be due to severe transients on 

the mains power supply or to a weak power supply (high inductance of the supply or a 

phase missing). 

The power unit is stopped and cannot be started. 

Action:Turn off the mains power supply to reset the unit. If the fault persists, send for a 

service technician. 

12 Internal communication error (warning) 

The load on the system’s CAN--bus is temporarily too high. 

The power unit may have lost contact with the panel. 

Action: Check that all the equipment is correctly connected. 

If the fault persists, send for a service technician. 

14 Communication error 

The system’s CAN--bus has temporarily stopped working due to the load being too high. 

The current welding process stops. 

Action: Check that all the equipment is correctly connected. Turn off the mains power 

supply to reset the unit. If the fault persists, send for a service technician. 

17 Lost contact with unit 

Lost contact with unit. The gas is not turned off; it must be turned off manually. 

Start is prevented 

Action: Check the cables. If the fault persists, send for a service technician. 

19 Battery voltage low 

Battery voltage too low. If the battery is not replaced, all stored data will be lost. 

This fault does not disable any functions. 

Action: Send for a service technician to replace the battery. 

20 Incorrect set values stored in welding program 

Non--permitted values have been discovered at start--up. 

Action: Change parameters in the welding program. If the fault persists, send for a service 

technician. 

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GB 

Code Description 

29 No cooling water flow 

The flow monitor switch has tripped. 

The current welding process is stopped and starting is prevented. 

Action: Check cooling water circuit, pump and hoses. 

32 No gas flow 

The gas flow is less than 3.5 l/min. Start prevented. 

Action: Check the gas valve, hoses and connectors. 

41 Failed welding start 

The power source does not manage to light the welding arc. 

Action: Check welding cables and tool. 

5.8.2 Quality data 

Here you can view data saved 

under the post weld function, see 

chapter 5.3. 

Logs - -> QData - -> QData files 

The QData file is saved with the 

date and a serial number. 

ThefilescanbesavedtoaUSB 

memory device using ”Save”. 

Logs - -> QData - -> QData content 

The QData file’s set values and 

measurement values are visible in 

this field. 

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GB 

5.9 Manual welding 

This menu is used for welding performed with a manual TIG torch. 

Trigger mode 

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2stroke 

Gas preflow Slope 

up 

Functions when using 2 -stroke control of the welding torch. 

- 34 - 

Slope down Gas postflow 

In 2--stroke control mode, pressing the TIG torch trigger switch (1) starts gas preflow 

(if used) and ignites the arc. The current rises to the set value (as controlled by the 

slope up function, if in operation). Releasing the trigger switch (2) reduces the 

current (as controlled by the slope down function, if in operation) and extinguishes 

the arc. Gas postflow follows, if in operation.

GB 

bi16d1ea 

4stroke 

Gas preflow Slope 

up 

Functions when using 4 -stroke control of the welding torch. 

- 35 - 

Slope down Gas postflow 

In 4--stroke control mode, pressing the trigger switch (1) starts gas preflow (if used). 

At the end of the gas preflow time, the current rises to the pilot level (a few 

amperes), and the arc is ignited. Releasing the trigger switch (2) increases the 

current to the set value (as controlled by the slope up function, if in operation). When 

the trigger switch is next pressed (3), the current is reduced to pilot level again (as 

controlled by the slope down function, if in operation). Releasing the switch again (4) 

extinguishes the arc and starts gas postflow. 

Start method 

HF 

The HF function ignites the arc by means of a spark produced when the electrode is 

brought closer to the workpiece. 

LiftArct 

The LiftArct function ignites the arc when the electrode is brought into contact with 

the workpiece and then lifted away from it. 

Igniting the arc using the LiftArc functiont. Step 1: the electrode is held against the workpiece. Step 

2: the trigger switch is pressed, and a low current starts to flow. Step 3: the welder lifts the electrode 

from the workpiece; the arc ignites, and the current rises automatically to the set value.

GB 

Peak current 

The higher of two current values in the event of pulsed current. 


The lower of two current values in the event of pulsed current. 

Peak time 

The time the pulse current is on during a pulse period. 


Background current time that together with the pulse current time produces the pulse 

period. 

TIG welding with pulsed current 

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Pulse time 



- 36 - 

Peak current 

Slope up 

The slope up function means that when the TIG arc ignites the current rises slowly to 

the set value. This provides ‘gentler’ heating of the electrode, and gives the welder a 

chance to position the electrode properly before the full current value is reached. 

Slope down 

TIG welding uses ”slope down”, where the current falls slowly over a controlled time, 

to avoid craters and/or cracks in a completed weld. 

Gas preflow 

This controls the time during which shielding gas flows before the arc is ignited. Also 

see information under chapter 3.5. 

Gas postflow 

This controls the time during which shielding gas flows after the arc is extinguished. 

Also see information under chapter 3.5.

GB 

5.10 Generate 

A complete basic weld program can be generated here that can be added to the 

design area or directly to the weld area. The program can be used as the basis for 

creating your own program. 

Specify: 

S Tube material 

S Tube wall thickness 

Max. 3 mm for stainless steel and max. 2.7 mm for carbon steel. 

S External tube diameter 

S Tool and tool type 

Activate by pressing ”Generate in weld area” or ”Generate in design area”. 

Automatically opens the weld area or design area menu. 

It is now possible to continue working on the program in the weld area or design 

area. See chapter ”Weld Area” 5.1 or ”Design Area” 5.2. 

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- 37 -

6 TECHNICAL TERMS 

2stroke 2--stroke control of the welding torch. 

4stroke 4--stroke control of the welding torch. 

Amplitude Weave. 

Background current The lower of two current values when using pulsed current. 

Background time Background current time that together with the peak current time produces 

the pulse period. 

Background voltage Arc voltage control when using background current. 

Background wire feed 

speed 

Wire feed speed during specified background time. 

Breakpoint Starting point for a new sector. 

Delay time The time it takes for the arc voltage to stabilize before arc voltage control 

begins. 

Design area Weld programs are created in this menu. 

End sector Last welding sector in a welding sequence. 

Generate Search for a complete basic weld program. 

Library Memory for storing weld programs. 

Peak current The higher of two current values when using pulsed current, or the current 

value when using continuous current. 

Peak voltage Arc voltage control at peak current. 

Peak wire feed speed Wire feed speed at peak current. 

Preheating time Delay time for welding movement when preheating the workpiece. 

Pulse time The time the current is ”on” during a pulse period. 

Root gas Shielding gas for the underside of the weld joint (root side). 

Rotation speed The rotation speed of the electrode around the workpiece. 

Sector A specific section of tube. 

Sector system How the division into sectors is displayed, by degrees or breakpoints. 

Slope down Gradual reduction of a value. 

Slope up Gradual increase in a value. 

Special pulsing Welding current synchronizes with the weaving motion. 

Square -wave pulsing Special pulsing with pulsed rotation. 

Start gas Special shielding gas with high ionizing qualities, which facilitates arc 

ignition. 

Start sector First welding sector in a welding sequence. 

Verify Check whether the program stays within the limit values. 

Weld area Programs in the weld area control the welding process. 

Weld gas Shielding gas for the upper side of the weld joint. 

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- 38 -

Ordering number 

Ordering no. Denomination 

0444 534 070 Instruction manual SE 

0444 534 071 Instruction manual DK 

0444 534 072 Instruction manual NO 

0444 534 073 Instruction manual FI 

0444 534 074 Instruction manual GB 

0444 534 075 Instruction manual DE 

0444 534 076 Instruction manual FR 

0444 534 077 Instruction manual NL 

0444 534 078 Instruction manual ES 

0444 534 079 Instruction manual IT 

0444 534 080 Instruction manual PT 

0444 534 081 Instruction manual GR 

0444 534 082 Instruction manual PL 

0444 534 083 Instruction manual HU 

0444 534 084 Instruction manual CZ 

0444 534 027 Instruction manual GB, RU 

Instruction manuals and the spare parts list are available on the Internet at www.esab.com 

bi16o2 

- 39 - 

Edition 071107

ESAB subsidiaries and representative offices 

Europe 

AUSTRIA 

ESAB Ges.m.b.H 

Vienna -Liesing 

Tel: +43 1 888 25 11 

Fax: +43 1 888 25 11 85 

BELGIUM 

S.A. ESAB N.V. 

Brussels 

Tel: +32 2 745 11 00 

Fax: +32 2 745 11 28 

THE CZECH REPUBLIC 

ESAB VAMBERK s.r.o. 

Vamberk 

Tel: +420 2 819 40 885 

Fax: +420 2 819 40 120 

DENMARK 

Aktieselskabet ESAB 

Herlev 

Tel:+4536300111 

Fax:+4536304003 

FINLAND 

ESAB Oy 

Helsinki 

Tel: +358 9 547 761 

Fax: +358 9 547 77 71 

FRANCE 

ESAB France S.A. 

Cergy Pontoise 

Tel:+33130755500 

Fax:+33130755524 

GERMANY 

ESAB GmbH 

Solingen 

Tel: +49 212 298 0 

Fax: +49 212 298 218 

GREAT BRITAIN 

ESAB Group (UK) Ltd 

Waltham Cross 

Tel: +44 1992 76 85 15 

Fax: +44 1992 71 58 03 

ESAB Automation Ltd 

Andover 

Tel: +44 1264 33 22 33 

Fax: +44 1264 33 20 74 

HUNGARY 

ESAB Kft 

Budapest 

Tel:+3612044182 

Fax:+3612044186 

ITALY 

ESAB Saldatura S.p.A. 

Mesero (Mi) 

Tel:+3902979681 

Fax:+390297289181 

THE NETHERLANDS 

ESAB Nederland B.V. 

Amersfoort 

Tel: +31 33 422 35 55 

Fax: +31 33 422 35 44 

NORWAY 

AS ESAB 

Larvik 

Tel:+4733121000 

Fax:+4733115203 

POLAND 

ESAB Sp.zo.o. 

Katowice 

Tel: +48 32 351 11 00 

Fax: +48 32 351 11 20 

PORTUGAL 

ESAB Lda 

Lisbon 

Tel: +351 8 310 960 

Fax: +351 1 859 1277 

SLOVAKIA 

ESAB Slovakia s.r.o. 

Bratislava 

Tel:+421744882426 

Fax:+421744888741 

SPAIN 

ESAB Ibérica S.A. 

Alcalá de Henares (MADRID) 

Tel: +34 91 878 3600 

Fax: +34 91 802 3461 

SWEDEN 

ESAB Sverige AB 

Gothenburg 

Tel:+4631509500 

Fax:+4631509222 

ESAB international AB 

Gothenburg 

Tel:+4631509000 

Fax:+4631509360 

SWITZERLAND 

ESAB AG 

Dietikon 

Tel: +41 1 741 25 25 

Fax: +41 1 740 30 55 

North and South America 

ARGENTINA 

CONARCO 

Buenos Aires 

Tel: +54 11 4 753 4039 

Fax: +54 11 4 753 6313 

BRAZIL 

ESAB S.A. 

Contagem -MG 

Tel: +55 31 2191 4333 

Fax: +55 31 2191 4440 

CANADA 

ESAB Group Canada Inc. 

Missisauga, Ontario 

Tel: +1 905 670 02 20 

Fax: +1 905 670 48 79 

MEXICO 

ESAB Mexico S.A. 

Monterrey 

Tel: +52 8 350 5959 

Fax: +52 8 350 7554 

USA 

ESAB Welding & Cutting Products 

Florence, SC 

Tel: +1 843 669 44 11 

Fax: +1 843 664 57 48 

ESAB AB 

SE -695 81 LAXÅ 

SWEDEN 

Phone +46 584 81 000 

www.esab.com 

Asia/Pacific 

CHINA 

Shanghai ESAB A/P 

Shanghai 

Tel: +86 21 5308 9922 

Fax: +86 21 6566 6622 

INDIA 

ESAB India Ltd 

Calcutta 

Tel: +91 33 478 45 17 

Fax: +91 33 468 18 80 

INDONESIA 

P.T. ESABindo Pratama 

Jakarta 

Tel: +62 21 460 0188 

Fax: +62 21 461 2929 

JAPAN 

ESAB Japan 

Tokyo 

Tel: +81 3 5296 7371 

Fax:+81352968080 

MALAYSIA 

ESAB (Malaysia) Snd Bhd 

Selangor 

Tel: +60 3 8027 9869 

Fax:+60380274754 

SINGAPORE 

ESAB Asia/Pacific Pte Ltd 

Singapore 

Tel:+6568614322 

Fax: +65 6861 31 95 

SOUTH KOREA 

ESAB SeAH Corporation 

Kyungnam 

Tel: +82 55 269 8170 

Fax: +82 55 289 8864 

UNITED ARAB EMIRATES 

ESAB Middle East FZE 

Dubai 

Tel: +971 4 887 21 11 

Fax: +971 4 887 22 63 

Representative offices 

BULGARIA 

ESAB Representative Office 

Sofia 

Tel/Fax: +359 2 974 42 88 

EGYPT 

ESAB Egypt 

Dokki -Cairo 

Tel: +20 2 390 96 69 

Fax: +20 2 393 32 13 

ROMANIA 

ESAB Representative Office 

Bucharest 

Tel/Fax: +40 1 322 36 74 

RUSSIA 

LLC ESAB 

Moscow 

Tel: +7 095 543 9281 

Fax: +7 095 543 9280 

LLC ESAB 

St Petersburg 

Tel: +7 812 336 7080 

Fax: +7 812 336 7060 

Distributors 

For addresses and phone 

numbers to our distributors in 

other countries, please visit our 

home page 

www.esab.com 

070514

WO 100 2 - ESAB

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