ESAB | A2 Automatic welding machines | Instruction manual | ESAB A2 Automatic welding machines User manual

ESAB A2 Automatic welding machines User manual
A2 Automatic
welding machines
A2 TF/ A2 TF (Twin)/ A2 TG/
A2 TG 4WD
101103105107109111102021110025108024042106023061104022041100020040060001
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Instruction manual
Betriebsanweisung
0449 165 001 2005--09--06
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Valid for serial no. 136--xxx--xxxx
SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
ÅËËÇÍÉÊÁ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
-- 2 --
ENGLISH
1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1
3.2
3.3
3.4
3.5
3.6
3.7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main components A2 TF (SAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Components A2 TG, A2 TG 4WD (MIG/MAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90
90
90
91
92
92
93
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.1
4.2
4.3
4.4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the brake hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
94
94
95
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the welding wire (A2 TF, A2 TG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the welding wire (A2 TG 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the feed roller (A2 TF, A2 TG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the feed rollers (A2 TG 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact equipment for Submerged arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact equipment for MIG/MAG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refilling with flux powder (Submerged arc welding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transportation of the Automatic Welding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion of A2 TF (Submerged--arc) to MIG/MAG welding . . . . . . . . . . . . . . . . . . . .
Conversion of A2 TF (submerged--arc welding) to Twin--arc . . . . . . . . . . . . . . . . . . . . .
98
99
100
101
101
102
103
105
105
105
105
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.2 Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3 Periodic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.2 POSSIBLE FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DIMENSION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
TOCe
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GB
1
DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved
guarantee that welding equipment A2 TF/ A2 TG / A2 TG 4WD from serial number
136 complies with
standard EN 60292 and EN 60204, in accordance with the requirements of directive
(89/392/EEC) and addendum (93/68/EEC).
-------------------------------------------------------------------------------------------------------------------------------------Laxå 2001--11--23
Göran Palmqvist
Design Manager, Automation & Engineering
ESAB AB, Welding Automation
695 81 LAXÅ
SWEDEN
Tel: + 46 584 81000
2
Fax: + 46 584 411721
SAFETY
Users of ESAB welding 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 welding 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 welding
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 welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from draughts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
fha9safe
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GB
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S
Install and earth the welding unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
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.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
fha9safe
-- 89 --
GB
3
INTRODUCTION
3.1
General
The A2 TF automatic welding machine is designed for Submerged Arc Welding of
butt and fillet joints.
The A2 TG/ A2 TG 4WD automatic welding machines are designed for MIG/MAG
welding of butt and fillet joints.
All other applications are prohibited.
They are intended for use in combination with A2--A6 Process Controller (PEH) and
ESAB’s welding power sources LAF or TAF.
3.2
Welding Method
3.2.1
Submerged Arc Welding (SAW)
For submerged arc welding the A2 TF automatic welding machine is always to be
used.
S
Submerged arc Light Duty.
Submerged arc light duty with a Ø 20 mm connector permits a load up to 800 A
(100%).
This version can be equipped with feed rollers for single or twin wire welding
(twin--arc). A special knurled feed roller is available for flux--cored wire, which
guarantees even wire feed without the risk of deformation due to high feed pressure.
3.2.2
MIG/MAG Welding
For MIG/MAG welding use either automatic welding machine A2 TG or A2 TG 4WD
(the A2 TG 4WD consists of a four wheel drive wire feed unit).
In MIG/MAG welding the welding bead is shielded by way of shielding gas.
The welding head is water--cooled. The cooling water is supplied by hoses from
connections intended for the purpose.
3.3
Definitions
SAW welding
The weld bead is protected by a cover of flux during the
welding.
SAW Light duty
Permits welding with lower current load and thin wire.
MIG/MAG welding
The weld bead is protected by shielding gas during
welding.
Twin--arc welding
Welding with two wires in one welding head.
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GB
3.4
Technical data
3.4.1
A2 TF and A2 TG
A2 TF (UP)
A2 TG (MIG/MAG)
Supply voltage
42 V AC
42 V AC
Permissible load at 100 %:
800 A DC
600 A DC
solid single
g wire
1.6--4.0 mm
0.8--2.5 mm
hollow wire
1.6--4.0 mm
1.2--3.2 mm
twin wire
2x1.2--2.0 mm
----
Wire feed speed, max
9 m/min
16 m/min
Brake hub braking torque
1.5 Nm
1.5 Nm
Travel speed
0.1--2.0 m/min
0.1--2.0 m/min
Turning radius for circumferential welding, min
1500 mm
1500 mm
Pipe diameter for internal joint welding, min
1100 mm
1100 mm
Max. weight of wire
30 kg
30 kg
Flux container volume
(Not to be filled with preheated flux)
6l
----
Weight (excl. wire and flux)
46 kg
46 kg
Max. lateral inclination (whole unit)
25_
25_
Wire dimensions:
3.4.2
A2 TG 4WD
A2 TG 4WD (MIG/MAG)
Type of gas:
Mix/Ar
CO2
Supply voltage
42 V AC
42 V AC
Permissible load at 100 %:
600 A DC
650 A DC
1.0--1.6 mm
1.0--1.6 mm
1.0--2.4 mm
1.0 -- 2.0 mm
1.0--1.6 mm
Wire feed speed, max
25 m/min
25 m/min
Brake hub braking torque
1.5 Nm
1.5 Nm
Travel speed
0.1--2.0 m/min
0.1--2.0 m/min
Turning radius for circumferential welding,
min
1500 mm
1500 mm
Pipe diameter for internal joint welding, min
1100 mm
1100 mm
Setting range, contact device
±45˚
±45˚
Max. weight of wire
30 kg
30 kg
Weight (wire excluded):
46 kg
46 kg
Max. lateral inclination (whole unit)
25˚
25˚
Wire dimensions:
Non--alloy / Low--alloy
Stainless steel
Cored wire
Aluminium
fha9d1ea
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1.0--2.4 mm
GB
3.5
Main components A2 TF (SAW)
1.
Carriage
5.
Contact tube
9.
2.
Carrier
6.
Connector (Twin)
10. Flux tube
3.
Wire feed unit
7.
Wire feed motor
11. Fine--wire straightener
4.
Slide kit, manual
8.
Guide pin
3.6
Flux hopper
Main Components A2 TG, A2 TG 4WD (MIG/MAG)
1.
Carriage
4.
Wire feed unit with four--wheel drive
7.
Connector (A2 TG 4WD)
2.
Carrier
5.
Slide kit, manual
8.
Wire feed motor
3.
Wire feed unit
6.
Connector (A2 TG)
See on page 93 for a description of the main components.
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GB
3.7
Description of Main Components
3.7.1
Carriage
The carriage is provided with 4--wheel drive.
The carriage can be secured by way of the
locking lever (1).
3.7.2
Carrier
The control box, wire feed unit and flux hopper,
among other things, are to be fitted on the carrier.
3.7.3
Wire Feed Unit / Wire Feed Unit with four--wheel Drive
The unit is used for guiding and feeding the welding wire down into the contact
tube/connector.
3.7.4
Manual Slides
The horizontal and vertical position of the welding head is adjusted by way of linear
slides. The angular motion can be freely adjusted using the rotary slide.
3.7.5
Contact Tube / Connector
Transfers welding current to the wire during welding.
3.7.6
Wire Feed Motor
The wire feed motor is used for feeding the welding wire.
3.7.7
Guide Pin
The guide pin is used to help positioning the welding head in the joint.
3.7.8
Flux Hopper / Flux Tube
The flux is filled into the flux hopper and is then transferred to the workpiece through
the flux tube.
The amount of flux to be dropped down is controlled by way of the flux valve fitted to
the flux hopper.
See “Refilling with flux on page 105.
3.7.9
Fine-- wire straightener
The unit is used for the straightening of fine wire.
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GB
4
INSTALLATION
4.1
General
The installation must be executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
4.2
Mounting
4.2.1
Wire drum (Accessories)
Wire drum (1) is mounted on the brake hub (2).
Check that the carrier (3) is pointing upwards.
S
NOTE! The maximum angle for the wire bobbin is 25°.
At extreme angles, wear will occur on the brake hub
locking mechanism and the wire bobbin will slide off
the brake hub.
WARNING
To prevent the reel sliding off the hub:
S Lock the reel in place by turning the red knob as shown
on the warning label attached next to the hub.
4.3
Adjusting the brake hub
The brake hub is adjusted when delivered, if readjustment
is required, follow the instructions below. Adjust the brake
hub so that wire is slightly slack when wire feed stops.
S
Adjusting the braking torque:
S
Turn the red handle to the locked
position.
S
Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs anticlockwise to increase the braking torque.
NB: Turn both springs through the same amount.
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GB
4.4
Connections
4.4.1
General
S
The A2--A6 Process Controller (PEH) is to be connected by a qualified person.
S
For the connection of welding power source LAF/ TAF, see separate instruction
manual.
4.4.2
Automatic welding machine A2 TF (Submerged arc welding, SAW)
1. Connect the control cable (7) between the power source (8) and the control box
A2--A6 Process Controller (2).
2. Connect the return cable (11) between the power source (8) and work piece (9).
3. Connect the welding cable (10) between the power source (8) and the automatic
welding machine (1).
4. Connect the measurement cable (12) between the power source (8) and
workpiece (9).
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GB
4.4.3
Automatic welding machine A2 TG (Gas metal arc welding, MIG/MAG)
1. Connect the control cable (7) between the power source (8) and control box
A2--A6 Process Controller (2).
2. Connect the return cable (11) between the power source (8) and work piece (9).
3. Connect the welding cable (10) between the power source (8) and the automatic
welding machine (1).
4. Connect the gas hose (5) between the reducer valve (6) and the gas connection
(13) on the welding machine.
5. Connect the cooling water hoses (3) between the cooling unit (4) and the
automatic welding machine (1).
6. Connect the measurement cable (12) between the power source (8) and
workpiece (9).
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GB
4.4.4
Automatic welding machine A2 TG 4WD (Gas metal arc welding,
MIG/MAG)
1. Connect the control cable (7) between the welding power source (8) and the
A2--A6 Process Controller (2).
2. Connect the return cable (11) between the welding power source (8) and the
work piece (9).
3. Connect the welding cable (10) between the welding power source (8) and the
automatic welding machine (1).
4. Connect the gas hose (5) between the reduction valve (6) and the gas valve on
the automatic welding machine (13).
5. Connect the hoses for cooling water (3) between the cooling unit (4) and the
automatic welding machine (1).
6. Connect the measuring cable (12) between the welding power source (8) and
the work piece (9).
fha9i1ea
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GB
5
OPERATION
5.1
General
Caution:
Have you read and understood the safety information ?
You must not operate the machine before then !
General safety regulations for the handling of the equipment can be found on
page 88. Read through before you start using the equipment!
S
Select electrode type and flux powder or shielding gas so that the weld material
is as close as possible to the analysis of the base metal.
S
Select electrode size and welding data in accordance with the values
recommended by the welding materials supplier.
S
Thorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE! The width of the weld joint gap must be uniform.
S
To minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
S
Always carry out a test weld with the same joint type and sheet thickness as the
production work piece.
S
For control and adjustment of the automatic welding machine and welding power
supply, see the instruction manual for the A2--A6 Process Controller (PEH).
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GB
5.2
Loading the welding wire (A2 TF, A2 TG)
A2 TF (UP)
A2 TF (UP, Twin)
A2 TG (MIG/MAG)
1. Mount the wire drum according to the instructions on page 94.
2. Check that feed roller (1) and contact jaw or contact tip (3) are of the correct
dimension for the selected wire size.
3. For A2 TF (Twin) and A2 TG:
S
Feed the wire through the wire guide (8).
4. When welding with fine wire:
S
Feed the wire through the fine Wire feed unit (6).
Ensure that the straightener is correctly adjusted so that the wire emerges
straight out through the contact jaws or contact tip (3).
5. Pull the end of the wire through the straightener (2).
S
For a wire diameter greater than 2 mm; straighten out 0.5 m of wire and feed
it by hand down through the straightener.
6. Locate the end of the wire in the feed roller (1) groove.
7. Set the wire tension on the feed roller with the knob (4).
S
Note! Do not tension more than is required to achieve an even feed.
8. Feed the wire forward 30 mm by pressing
A2--A6 Process Controller (PEH).
on the control box
9. Direct the wire by adjusting the knob (5).
S
Always use a guide tube (7) to ensure even feed of fine wire (1.6 -- 2.5 mm).
S
For MIG/MAG welding with wire sizes < 1.6 mm, use a guide spiral, which is
inserted in the guide tube (7).
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GB
5.3
Loading the welding wire (A2 TG 4WD)
1. Check that the feed rollers (1, 4) and the contact nozzle (7) are of the correct
dimension for the wire size selected.
NOTE!
The feed rollers are marked with their respective groove diameter (D) on the
opposite side of the roller.
2. Undo the pressure devices (10) and put up the pressure arms (11).
3. Put the end of the wire through the wire guide nipple (12).
4. Locate the end of the wire in the groove of the feed roller (1) and feed it through
the intermediate nozzle (3).
5. Locate the end of the wire in the groove of the other feed roller (4) and feed it
through the outlet nozzle (9).
6. Put down the pressure arms (11) and adjust the wire tension on the
feed rollers (1, 4) by way of the pressure devices (10).
NOTE! Do not tighten down too hard.
7. Feed the wire forward 30 mm by pressing
A2--A6 Process Controller (PEH).
fha9o1ea
-- 100 --
on the control box
GB
5.4
Changing the feed roller (A2 TF, A2 TG)
Single wire
S
Release the knobs (3) and (4).
S
Release the hand wheel (2).
S
Change the feed roller (1).
They are marked with their respective wire sizes.
Twin wire (Twin--arc)
S
Change the feed roller (1) with twin grooves in the same way as for single wire.
S
NOTE! The pressure roller (5) must also be changed. A special curved pressure
roller for twin wire replaces the standard pressure roller for single wire.
S
Assemble the pressure roller with special stub shaft
(order no. 0146 253 001).
Flux--cored wire for knurled rollers (Accessories)
S
Change the feed roller (1) and pressure roller (5) as a pair for the wire size to be
used.
NOTE! A special stub shaft is required for the pressure roller
(order no. 0212 901 101).
S
Tighten the pressure screw (4) with moderate pressure to ensure that the
flux--cored wire does not deform.
5.5
Changing the feed rollers (A2 TG 4WD)
S
Undo the pressure devices (10).
S
Put up the pressure arms (11).
S
Undo the mounting screws (2) of the
feed rollers.
S
Replace the feed rollers (1, 4).
S
Adjust the wire tension on the new feed rollers.
fha9o1ea
-- 101 --
GB
5.6
Contact equipment for Submerged arc welding
5.6.1
For single wire 1.6 -- 4.0 mm. Light duty (D20)
Use automatic welding machine A2 TF (UP) where
the following are included:
S
Wire feed unit (1),
S
Connector D20 (2)
S
Contact tip (3) (M12 thread).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
5.6.2
For twin wires 2 x 1.2 -- 2.0 mm, Light Twin (D35)
Use automatic welding machine A2 TF (UP, Twin)
where the following are included:
S
Wire feed unit (1),
S
Connector Twin D35 (2)
S
Contact tip (3) (M6 thread).
S
Fine--Wire feed unit (5)
S
Guide tubes (4, 6).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
Adjustment of the wires for Twin-- arc welding:
S
Position the wires in the joint so as to achieve optimal weld quality by rotating the
connector. The two wires can be rotated so that they are positioned one after the
other along the line of the joint, or in any position up to 90° across the joint, i.e.
one wire on each side of the joint.
fha9o1ea
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GB
5.7
Contact equipment for MIG/MAG welding
5.7.1
For single wire 1.6 - 2.5 mm (D35)
Use automatic welding machine A2 TG (MIG/MAG)
where the following are included:
S
Wire feed unit (1),
S
Connector D35 (2)
S
Contact tip (3) (M10 thread).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
5.7.2
For single wire < 1.6 mm (D35)
Use automatic welding machine A2 TG (MIG/MAG)
where the following are included:
S
Wire feed unit (1),
S
Connector D35 (2)
S
Contact tip (3) (M12 thread).
S
Guide tubes (4).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
Use the following accessories:
S
Fine--wire straightener (5) to be fitted on top of
the clamp of the wire feed unit (1).
S
Guide spiral to be inserted into the guide tube (4).
fha9o1ea
-- 103 --
GB
5.7.3
For single wire 1.0 -- 2.4 mm (wire feed unit with four-- wheel drive)
Use automatic welding machine A2 TG 4WD
(MIG/MAG) where the following are included:
S
Wire feed unit (5),
S
Contact device D35 (6)
Tighten the contact device (6) using
the Allen screw (8).
S
Contact nozzle (7).
Tighten the contact nozzle in order to
ensure that good contact is achieved.
Select a wire guide insert of the correct dimension
for the type of wire to be used. See the instruction
manual for contact device MTW 600 (0449 006 xxx).
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-- 104 --
GB
5.8
Refilling with flux powder (Submerged arc welding)
1. Close the flux valve (1) on the flux hopper.
2. Remove the cyclone on the flux recovery unit, if fitted.
3. Fill with flux powder.
NOTE! The flux powder must be dry. Where possible
avoid using agglomerating flux powder outdoors and
in damp environments.
4. Position the flux tube so that it does not become
kinked.
5. Adjust the height of the flux nozzle above the weld so
that the correct amount of flux is delivered.
Flux coverage should be sufficient so that penetration
of the arc does not occur.
5.9
Transportation of the Automatic Welding Machine
S
Disengage the wheels by turning the locking lever (1).
S
Make sure the safety chain (2) is properly
fastened; this to prevent an accident happening,
if for example the carrier is not adequately
locked to the foot clamp of the carriage.
For transportation through a manhole
the chain can be removed.
5.10
Conversion of A2 TF (Submerged--arc) to MIG/MAG welding
Assemble in accordance with the instructions accompanying the conversion kit.
5.11
Conversion of A2 TF (submerged--arc welding) to Twin--arc
Assemble in accordance with the instructions accompanying the conversion kit.
fha9o1ea
-- 105 --
GB
6
MAINTENANCE
6.1
General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
NB! Before doing any kind of maintenance work, make sure the mains is
disconnected.
For the maintenance of the A2--A6 Process Controller (PEH), see the instruction
manual 0443 745 xxx.
6.2
Daily
S
Clean flux and dirt off moving parts of the welding machine.
S
Check that the contact tip and all electrical cables are connected.
S
Check that all bolted joints are tight and that guides and drive rollers are not
worn or damaged.
S
Check the brake hub braking torque. It should not be so low, that the wire reel
continues to rotate when wire feed is stopped and it should not be so great that
the feed rollers slip. As a guide, the braking torque for a 30 kg wire reel should
be 1,5 Nm.
To adjust the braking torque see on page 94.
6.3
Periodic
S
Inspect the electrode feed unit’s electrode control, drive rollers and contact tip.
S
Replace worn or damaged components.
S
Inspect the slides, lubricate them if they are binding.
S
Lubricate the chain.
S
Tensioning the chain between the trolley’s front and back axles.
S
S
Dismantle the trolley wheels and blanks. Remove the Y flange bearing bolts.
S
Tension the chain by moving the trolley’s rear axle parallel in relation to the
front axle.
S
Reassemble in the reverse order.
Tensioning the chain from the trolley’s front axle to the drive motor and
gearbox.
S
fha9m1ea
Tension the chain by moving the drive motor and gearbox.
-- 106 --
GB
7
TROUBLESHOOTING
7.1
General
Equipment
S Instruction manual control box A2--A6 Process Controller (PEH).
Check
S
that the power supply is connected for the correct mains supply
that all three phases are supplying the correct voltage (phase sequence is not
important)
that welding cables and connections are not damaged
S
that the controls are correctly set
S
that the mains supply is disconnected before starting repairs
S
S
7.2
POSSIBLE FAULTS
1. Symptom
Current and voltage readings show large fluctuations.
Cause 1.1
Contact jaws or nozzle are worn or wrong size.
Action
Replace contact jaws or nozzle.
Cause 1.2
Feed roller pressure is inadequate.
Action
Increase pressure on feed rollers.
2. Symptom
Wire feed is irregular.
Cause 2.1
Pressure on feed rollers incorrectly set.
Action
Adjust pressure on feed rollers.
Cause 2.2
Feed rollers wrong size.
Action
Replace feed rollers.
Cause 2.3
Grooves in feed rollers are worn.
Action
Replace feed rollers.
3. Symptom
Welding cables overheating.
Cause 3.1
Poor electrical connection.
Action
Clean and tighten all electrical connections.
Cause 3.2
Cross--sectional area of welding cables too small.
Action
Use cables with a larger cross--section or use parallel cables.
8
ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list on page 257.
This will simplify dispatch and ensure you get the right part.
fha9f1ea
-- 107 --
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.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
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: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 2485 377
Fax: +31 30 2485 260
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
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: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
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: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
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
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: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Shah Alam Selangor
Tel: +60 3 5511 3615
Fax: +60 3 5512 3552
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
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-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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
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
041227
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