Autotransformer TUA 1, Autotransformer TUA 2

Instruction manual

0459 302 101 GB 20180627 Valid for: serial no. 808-xxx-xxxx

TABLE OF CONTENTS

1 2

SAFETY

.......................................................................................................

1.1

Meaning of symbols

...............................................................................

1.2

Safety precautions

.................................................................................

INTRODUCTION

..........................................................................................

2.1

Equipment

...............................................................................................

3 4

TECHNICAL DATA

......................................................................................

INSTALLATION

............................................................................................

4.1

Mains power supply

...............................................................................

5

MAINTENANCE

...........................................................................................

5.1

Cleaning the air filter

..............................................................................

6

ORDERING SPARE PARTS

........................................................................

ASSEMBLY INSTRUCTION

................................................................................

DIAGRAM

............................................................................................................

CONNECTION INSTRUCTION

............................................................................

ORDERING NUMBERS

.......................................................................................

WEAR PARTS

......................................................................................................

ACCESSORIES

...................................................................................................

4

4 4

7

7

11

11

12

13

14

15

17

18

19

8

9

9

Rights reserved to alter specifications without notice.

0459 302 101 © ESAB AB 2018

1 SAFETY

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.

2.

3.

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 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 The workplace must: ○ be suitable for the purpose ○ be free from drafts 0459 302 101

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© ESAB AB 2018

1 SAFETY 4.

5.

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 General precautions: ○ Make sure the return cable is connected securely ○ Work on high voltage equipment

may only be carried out by a qualified electrician

○ 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!

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• 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.

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1 SAFETY

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 that there are no inflammable materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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.

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© ESAB AB 2018

2 INTRODUCTION

2 INTRODUCTION

Autotransformer TUA 1

and

TUA 2

are two autotransformers which can be used together with the most of ESAB welding power sources.

The autotransformer is available in two versions: • TUA 1 narrow • TUA 2 wide

Accessories for the product can be found in the "ACCESSORIES" chapter of this manual.

2.1

Equipment

Autotransformer TUA 1 and Autotransformer TUA 2 are delivered with: • Instruction manual 0459 302 101

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© ESAB AB 2018

3 TECHNICAL DATA

3 TECHNICAL DATA

NOTE!

When the autotransformer is connected to a power source, the technical data of the autotransformer applies.

Autotransformer TUA 1

< 70 db

Autotransformer TUA 2 Mains voltage Primary current

I max 1)

No-load power (idle state)

208/230/400/460/475/500/575V, ±10%, 3~ 50/60 Hz 208/230/400/460/475/500/575V, ±10%, 3~ 50/60 Hz 78 A 125 W

Values of the conventional load (MMA)

1) 78 A 125 W 60% duty cycle 100% duty cycle 500 A 400 A

Power factor at maximum current (I 2 )

1) MMA 0.93

500 A 400 A 0.93

Efficiency at maximum current (I 2 )

1) MMA

Apparent power at maximum current (I 2 )

1)

Active power at maximum current (I 2 )

1)

Working temperature

82.7

26.0 kVA 24.2 kW -10 to +40 °C (+14 to +104 °F) 82.7

26.0 kVA 24.2 kW -10 to +40 °C (+14 to +104 °F) < 70 db

Continual A-weighted sound pressure Dimensions l×w×h Weight Insulaion class Enclosure class Application class

614×289×266 mm 67 kg H IP 23 621×389×266 mm 80 kg H IP 23

Restrictive use

Class A Class A 1) Based on autotransformer connected to ESAB Mig 5000i power source

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.

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© ESAB AB 2018

4 INSTALLATION

4 INSTALLATION

The installation must be carried out by a professional.

For instructions regarding assembly and connection, see separate appendices to this manual.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions.

4.1

Mains power supply

A. Mains connection B. Mains cable from the welding power source Check that the autotransformer is connected to the correct mains power supply voltage, and that it is protected by the correct fuse size. A protective earth connection must be made, in accordance with regulations.

A. Rating plate with supply connection data

Recommended fuse sizes and minimum cable areas Autotransformer Mains voltage Mains cable area

(mm 2 )

Primary current

, I max

Phase current

, I 1eff

Fuse

Anti-surge Type C MCB

60 Hz 50/60 Hz 50 Hz 60 Hz 60 Hz 50 Hz 60 Hz

208 V 4×10 78 A 60 A 63 A 63 A 230 V 4×10 74 A 56 A 63 A 63 A 400 V 460 V 475 V 500 V 575 V 4×6 4×4 4×4 47 A 40 A 38 A 38 A 32 A 30 A 50 A 35 A 35 A 40 A 40 A 32 A 4×4 33 A 27 A 35 A 32 A 4×2.5

27 A 20 A 25 A 25 A The fuse sizes and cable areas specified above are based on autotransformer connected to ESAB Mig 5000i power source.

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4 INSTALLATION

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with Swedish regulations. They may not be applicable in other countries: make sure that the cable area and fuse sizes comply with the relevant national regulations.

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© ESAB AB 2018

5 MAINTENANCE

5 MAINTENANCE

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!

NOTE!

Regular maintenance is important for safe and reliable operation.

Only those persons who have appropriate electrical knowledge (authorised personnel) may remove the safety plates to connect or carry out service, maintenance or repair work on welding equipment.

CAUTION!

All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults.

5.1

Cleaning the air filter

• Release the cover plate with the dust filter (1).

• Swing out the cover plate (2).

• Remove the dust filter (3).

• Blow it clean with compressed air at reduced pressure.

• Replace the filter the finer mesh on the side against the cover plate (2).

• Refit the cover plate with the filter.

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© ESAB AB 2018

6 ORDERING SPARE PARTS

6 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.

Autotransformer TUA 1 / Autotransformer TUA 2 is designed and tested in accordance with the international and European standards

IEC/EN 60974-1

that the product still conforms to the said standard.

and

IEC/EN 60974-10

. It is the obligation of the service unit which has carried out the service or repair work to make sure Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.

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© ESAB AB 2018

ASSEMBLY INSTRUCTION

ASSEMBLY INSTRUCTION

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© ESAB AB 2018

DIAGRAM

DIAGRAM

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© ESAB AB 2018

CONNECTION INSTRUCTION

CONNECTION INSTRUCTION

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© ESAB AB 2018

CONNECTION INSTRUCTION 0459 302 101

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© ESAB AB 2018

ORDERING NUMBERS

ORDERING NUMBERS

Ordering no.

0459 144 880 0459 145 880 0459 302 990

Denomination

Autotransformer TUA 1 Narrow Autotransformer TUA 2 Wide Spare part list The spare parts list is available on the Internet at

www.esab.com

.

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© ESAB AB 2018

WEAR PARTS

WEAR PARTS

Item Ordering no.

1 2 0458 398 001 0458 383 001

Denomination

Filter Front grill 0459 302 101

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© ESAB AB 2018

ACCESSORIES

ACCESSORIES

Handle (1 piece) with mounting screws

0459 307 880 Narrow 0459 307 881 Wide 0459 302 101

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© ESAB AB 2018

For contact information visit esab.com

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com