A2 S Mini Master
A2 S G Master
A2 SFE1 / A2 SGE1
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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
0456 552 981111001
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
ПдзгЯет чсЮуещт
Valid from Serial NO 740 XXX--XXXX
SVENSKA 3..............................................
DANSK 17................................................
NORSK 31................................................
SUOMI 45................................................
ENGLISH 59..............................................
DEUTSCH 73.............................................
FRANÇAIS 88.............................................
NEDERLANDS 103.........................................
ESPAÑOL 118..............................................
ITALIANO 133..............................................
PORTUGUÊS 148..........................................
ЕЛЛЗНЙКБ 163.............................................
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.
ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.
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ENGLISH
1 DIRECTIVE 60........................................................
2SAFETY 60...........................................................
3 INTRODUCTION 61...................................................
3.1 General 61..................................................................
3.2 Definitions 61................................................................
3.3 Technical data 62............................................................
3.4 Welding method 62...........................................................
3.5 Equipment 63................................................................
4 INSTALLATION 64....................................................
4.1 General 64..................................................................
4.2 Mounting 64.................................................................
4.3 Connections 64..............................................................
5 OPERATION 66.......................................................
5.1 General 66..................................................................
5.2 Starting work 66..............................................................
5.3 Conversion of A2 SFE1 (Submerged arc welding) to MIG/MAG welding 70...........
5.4 Conversion of A2 SFE1 (Submerged arc welding) to Twin--arc 70...................
6 MAINTENANCE 70....................................................
6.1 General 70..................................................................
6.2 Daily 70.....................................................................
6.3 Regularly 71.................................................................
7 FAULT TRACING 71...................................................
8 ACCESSORIES 72....................................................
9 ORDERING OF SPARE PARTS 72......................................
WEAR COMPONENTS 178.................................................
SPARE PARTS LIST 179...................................................
TOCe
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that automatic welding machine A2 SFE1 / A2 SGE1 from serial number 740 complies with standard EN 60292, in accordance with the requirements of directive
(89/392/EEA) and addendum.
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Laxå 97--09--29
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584
12336
2SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions.
The following recommendations should be observed in addition to the standard regulations that apply
to the work place.
All work must be carried out according to the specified instructions by personnel who are thoroughly
familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous situation which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the automatic welding machine must be familiar with:
S its operation
S the location of emergency stops
S its function
S relevant safety precautions
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the machine when it is started
up.
S that no--one is in a hazardous position when the carriage or slide mechanisms are operated.
3. The work place must:
S be clear of mechanical components, tools, or other obstructions that could prevent the oper-
ator from moving freely within the working area.
S be organized so that there is free access to the emergency stop.
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, etc., which could become
trapped.
5. General precautions
Live electrical components are normally shielded from accidental contact.
S Make sure the return cable is connected securely.
S Work on high voltage components may only be carried out by a qualified electrician.
S Appropriate fire extinguishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during its operation.
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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 keep fumes and gases 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 ear defenders 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!
3 INTRODUCTION
3.1 General
All the automatic welding machines included in this instruction manual are designed
for SAW and MIG/MAG welding of butt and fillet joints.
ESAB’s welding heads are of the A2 S type and are intended for use in combination
with A2--A6 Process Controller and ESAB’s welding power sources LAF and TAF.
The welding head can be positioned horizontally and vertically with the linear slides.
The angular position is adjusted with the angular slide.
3.2 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 thinner wire.
MIG/MAG welding The weld bead is protected by shielding gas during wel-
ding.
Tandem welding Welding with two welding heads.
Twinarc weldin g Welding with two wires in the same welding head.
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3.3 Technical data
A2 SFE1 A2 SGE1
Submerged--arc MIG/MAG
LD D20
Rated load 100% 800 AAC/DC 600 A AC/DC
Wire dimensions:
solid single wire 1.6--4.0 mm 0.8--2.5 mm
flux--cored wire 1.6--4.0 mm 1.2--3.2 mm
twin wire 2x1.2--2.0 mm --
Wire feed speed 0.2--9.0 m/min 0.2--16 m/min
Brake drum braking torque 1.5 Nm 1.5 Nm
Max weight, wire 2x30 kg 2x30 kg
Flux hopper capacity
(Must not be filled with preheated flux)
Weight (flux and wire excluded) 50 kg 15 kg
Sideways tilt, max. 25_ 25_
6l --
Setting length of slide *
manual drive
*) NB! Other lengths on request.
90 mm 90 mm
3.4 Welding method
Submerged arc welding (SAW)
For submerged arc welding, the A2 SF welding head is always to be used.
S Submerged arc Light duty
Submerged arc light duty, with a 20 mm connector, which permits a load of 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.
MIG/MAG welding
For MIG/MAG welding the A2 SG welding head is always used, permitting a max.
load of 600 A. The welding head is water--cooled, with the cooling water supplied by
hoses from connections intended for the purpose.
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3.5 Equipment
The complete welding head includes a feed motor for the wire feed and contact
equipment supplying current to the wire and ensuring good contact.
The contact equipment is available in different versions.
S A2 SF is used for Submerged arc welding.
S A2 SG is used for MIG/MAG welding.
Example -- A2 SFE1
1. Wire straightener
2. Contact equipment consisting of
contact tip, connector and flux tube
3. Angular slide
4. Slide
5. Feed motor
6. Wire drum
7. Flux hopper (may be fitted with a cyclone)
Example -- A2 SGE1
1. Wire straightener
2. Contact equipment consisting of
connector, gas nozzle and water
hoses.
3. Angular slide
4. Slide
5. Feed motor
6. Wire drum.
7. Fine--wire straightener
8. Wire guide
Connection instructions for SAW and MIG/MAG welding appear from the system
diagram on page 64.
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4 INSTALLATION
4.1 General
Installation shall only be performed by qualified personnel.
WARNING!
Rotating parts can cause injury, take great care.
4.2 Mounting
The automatic welding machines can easily be fitted on a rail--borne carriage or on a
column and boom unit with 4 screws.
4.3 Connections
1. The connection of the A2--A6 Process Controller (PEH) to the welding machine
shall be done according to the connection instructions in the A2--A6 Process
Controller (PEH) service manual.
For further information, see instruction manual for the A2--A6 Process Controller
(PEH).
2. Connect the A2 welding heads as follows:
SUBMERGED ARC WELDING (SAW)
S Connect the control cable (7) between the welding power source (8) and the
A2--A6 Process Controller (PEH) (2).
S Connect the return cable (11) between the welding power source (8) and the
work piece (9).
S Connect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
S Connect the measuring cable (12) between the welding power source (8)
and the work piece (9).
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GAS METAL ARC WELDING (MIG/MAG)
S Connect the control cable (7) between the welding power source (8) and the
A2--A6 Process Controller (PEH) (2).
S Connect the return cable (11) between the welding power source (8) and the
work piece (9).
S Connect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
S Connect the gas hose (5) between the reduction valve (6) and the gas valve
on the automatic welding machine (13).
S Connect the hoses for cooling water (3) between the cooling unit (4) and the
automatic welding machine (1).
S Connect the measuring cable (12) between the welding power source (8)
and the work piece (9).
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