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.
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FÖRSÄKRAN OM ÖVERENSST ÄMMELSE
Esab Welding Equipment AB, 695 81 Laxå, Sverige, försäkrar under eget ansvar att
svetsutrustning A2 TF / A2 TG från serienummer 136 är i överensstämmelse med
standard EN 60292 och EN 60204 enligt villkoren i direktiv (89/392/EEG) med tillägg
(93/68/EEG).
Esab Welding Equipment AB, S-- 695 81 Laxå, Sverige, erklærer på eget ansvar, at
svejseudstyr A2 TF / A2 TG fra serienummer 136 er i overensstemmelse med standarden EN 60292 og EN 60204 ifølge betingelserne i direktiv (89/392/EØF) med til læg (93/68/EØF).
Esab Welding Equipment AB, S --695 81 Laxå, Sverige, forsikrer på eget ansvar at
sveiseutstyr A2 TF / A2 TG fra serienummer 136 er i overensstemmelse med standard EN 60292 og EN 60204 i følge vilkårene i dir ektiv (89/392/EF) med tillegg
(93/68/EF).
Esab Welding Equipment AB, S--695 81 Laxå, Ruotsi, vakuuttaa omalla vastuullaan,
että hitsauslaitteisto A2 TF/ A2 TG alkaen sarjanumerosta 136 täyttää standardin EN
60292 ja EN 60204 vaatimukset direktiivin (89/392/ETY) ja sen lisäysten
(93/68/ETY).
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved
guarantee that welding equipment A2 TF/ A2 TG 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).
Esab Welding Equipment AB, S --695 81 Laxå Schweden, bestätigt hiermit in Eigenverantwortung, daß der Schweißausrüstung A2 TF/ A2 TG ab Seriennummer 136
dem Standard EN 60292 und EN 60204 gemäß den Bedingungen der Direktive
(89/392/EEG) mit Zusatz (93/68/EEG).
SPARE PARTS LIST113...................................................
TOCe
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1SAFETY
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.
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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
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn 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!
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2INTRODUCTION
2.1General
The A2 TF automatic welding machine is designed for Submerged Arc Welding of
butt and fillet joints.
The A2 TG automatic welding machine is designed for MIG/MAG welding of butt and
fillet joints.
All other applications are prohibited.
They are intended for use in combination with A2 Welding Control Unit (PEI) and
ESAB’s welding power source LAF.
2.2Welding Method
2.2.1Submerged Arc Welding (SAW)
For submerged arc welding the A2 TF automatic welding machine is always to be
used.
SSubmerged 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.
2.2.2MIG/MAG Welding
For MIG/MAG welding use either automatic welding machine A2 TG.
In MIG/MAG welding the welding bead is shielded by way of shielding gas.
The welding head is water--cooled. T he cooling water is supplied by hoses from
connections intended for the purpose.
2.3Definitions
SAW weldingThe weld bead is protected by a cover of flux during the
welding.
SAW Light dutyPermits welding with lower current load and thin wire.
MIG/MAG weldingThe weld bead is protected by shielding gas during
welding.
Twin--arc weldingWelding with two wires in one welding head.
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2.4Technical data
2.4.1A2 TF and A2 TG
A2 TF (UP)A2 TG (MIG/MAG)
Supply voltage42 V AC42 V AC
Permissible load at 100 %:800 A DC600 A DC
Wire dimensions:
solid single wire
hollow wire
twin wire
Wire feed speed, max9m/min16 m/min
Brake hub braking torque1.5 Nm1.5 Nm
Travel speed0.1--2.0 m/min0.1--2.0 m/min
Turning radius for circumferential welding, min1500 mm1500 mm
Pipe diameter for internal joint welding, min1100 mm1 100 mm
Max. weight of wire30 kg30 kg
Flux container volume
(Not to be filled with preheated flux)
Weight (excl. wire and flux)46 kg46 kg
Max. lateral inclination (whole unit)
1.6--4.0 mm0.8--2.5 mm
1.6--4.0 mm
2x1.2--2.0 mm
6l-- --
25_25_
1.2--3.2 mm
-- --
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2.5Main components A2 TF (SAW)
1.Carriage
2.Carrier
3.Wire feed unit
4.Slide kit, manual
5.Contact tube
6.Connector (Twin)
7.Wire feed motor
8.Guide pin
2.6Main Components A2 TG (MIG/MAG)
9.Flux hopper
10. Flux tube
1 1. Fine--wire straightener
1.Carriage
2.Carrier
3.Wire feed unit
4.Slide kit, manual
See on page 82 for a description of the main components.
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5.Connector
6.Wire feed motor
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2.7Description of Main Components
2.7.1Carriage
The carriage is provided with 4--wheel drive.
The carriage can be secured by way of the
locking lever (1).
2.7.2Carrier
The control box, wire feed unit and flux hopper,
among other things, are to be fitted on the carrier.
2.7.3Wire Feed Unit / Wire F eed Unit with four--wheel Drive
The unit is used for guiding and feeding the welding wire down into the contact
tube/connector.
2.7.4Manual 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.
2.7.5Contact Tube / Connector
Transfers welding current to the wire during welding.
2.7.6Wire Feed Moto r
The wire feed motor is used for feeding the welding wire.
2.7.7Guide Pin
The guide pin is used to help positioning the welding head in the joint.
2.7.8Flux 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 91.
2.7.9Fine--wire straightener
The unit is used for the straightening of fine wire.
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3INSTALLATION
3.1General
The installation must be executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
3.2Mounting
3.2.1Wire drum (Accessories)
Wire drum (1) is mounted on the brake hub (2).
SCheck that the carrier (3) is pointing upwards.
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 r eel 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.
3.3Adjusting 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.
SAdjusting the braking torque:
STurn the r ed handle to the locked
position.
SInsert 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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3.4Connections
3.4.1General
SThe A2 Welding Control Unit (PEI) is to be connected by a qualified person.
SFor the connection of welding power source LAF, see separate instruction
1.Connect the control cable (7) between the power source (8) and the control box
A2 Welding Control Unit (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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3.4.3Automatic welding machine A2 T G (Gas metal arc welding, MIG/MAG)
1.Connect the control cable (7) between the power source (8) and control box
A2 Welding Control Unit (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 r educer 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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4OPERATION
4.1General
Caution:
Have you read and understood the safety information ?
You must not operate the machine beforehand !
General safety regulations for the handling of the equipment can be found on
page 77. Read through before you start using the equipment!
SSelect 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.
SSelect electrode size and welding data in accordance with the values
recommended by the welding materials supplier.
SThorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE! The width of the weld joint gap must be uniform.
STo minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
SAlways carry out a test weld with the same joint type and sheet thickness as the
production work piece.
SFor control and adjustment of the automatic welding machine and welding power
supply, see the instruction manual for the A2 Welding Control Unit (PEI).
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4.2Loading 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 83.
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:
SFeed the wire through the wire guide (8).
4.When welding with fine wire:
SFeed 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).
SFor 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).
SNote! Do not tension more than is required to achieve an even feed.
8.Feed the wire forward 30 mm withon the control box
A2 Welding Control Unit (PEI).
9.Direct the wire by adjusting the knob (5).
SAlways use a guide tube (7) to ensure even feed of fine wire (1.6 -- 2.5 mm).
SF or 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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4.3Changing the feed roller (A2 TF, A2 TG)
Single wire
SRelease the knobs (3) and (4).
SRelease the hand wheel (2).
SChange the feed roller (1).
They are marked with their respective wire sizes.
Twin wire (Twin--arc)
SChange the feed roller (1) with twin grooves in the same way as for single wire.
SNOTE! The pressure roller (5) must also be changed. A special curved pressure
roller for twin wire replaces the standard pressure roller for single wire.
SAssemble the pressure roller with special stub shaft
(order no. 0146 253 001).
Flux--cored wire for knurled rollers (Accessories)
SChange 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).
STighten the pressure screw (4) with moderate pressure to ensure that the
flux--cored wire does not deform.
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4.4Contact equipment for Submerged arc welding
4.4.1For single wire 1.6 -- 4.0 mm. Light duty (D20)
Use automatic welding m achine A2 TF (UP) where
the following are included:
SWire feed unit (1),
SConnector D20 (2)
SContact tip (3) (M12 thread).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
4.4.2Fortwinwires2x1.2--2.0mm,LightTwin(D35)
Use automatic welding m achine A2 TF (UP, Twin)
where the following are included:
SWire feed unit (1),
SConnector Twin D35 (2)
SContact tip (3) (M6 thread).
SFine--Wire feed unit (5)
SGuide 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 :
SPosition 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.
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4.5Contact equipment for MIG/MAG welding
4.5.1For single wire 1.6 -- 2.5 mm (D35)
Use automatic welding machine A2 TG (MIG/MAG)
where the following are included:
SWire feed unit (1),
SConnector D35 (2)
SContact tip (3) (M10 thread).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
4.5.2For single wire < 1.6 mm (D35)
Use automatic welding machine A2 TG (MIG/MAG)
where the following are included:
SWire feed unit (1),
SConnector D35 (2)
SContact tip (3) (M12 thread).
SGuide tubes (4).
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
Use the following accessories:
SFine--wire straightener (5) to be fitted on top of
the clamp of the wire feed unit (1).
SGuide spiral to be inserted into the guide tube (4).
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4.6Refilling 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.
4.7Transportation of the Automatic Welding Machine
SDisengage the wheels by turning the locking lever (1).
SMake 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.
4.8Conversion of A2 TF (Submerged--arc) to MIG/MAG welding
Assemble in accordance with the instructions accompanying the conversion kit.
4.9Conversion of A2 TF (submerged--arc welding) to Twin--arc
Assemble in accordance with the instructions accompanying the conversion kit.
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5MAINTENANCE
5.1General
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 Welding Control Unit (PEI), see the instruction
manual 0449 331 xxx.
5.2Daily
SClean flux and dirt off moving parts of the welding machine.
SCheck that the contact tip and all electrical cables are connected.
SCheck that all bolted joints are tight and that guides and drive rollers are not
worn or damaged.
SCheck 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 83.
5.3Periodic
SInspect the electrode feed unit’s electrode control, drive rollers and contact tip.
SReplace worn or damaged components.
SInspect the slides, lubricate them if they are binding.
SLubricate the chain.
STensioning the chain between the trolley’s front and back axles.
SDismantle the trolley wheels and blanks. Remove the Y flange bearing bolts.
STension the chain by moving the trolley’s rear axle parallel in r elation to the
front axle.
SReassemble in the reverse order.
STensioning the chain from the trolley’s front axle to the drive motor and
gearbox.
STension the chain by moving the drive motor and gearbox.
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6TROUBLESHOOTING
6.1General
Equipment
SInstruction manual control box A2 Welding Control Unit (PEI).
Check
Sthat the power supply is connected for the correct mains supply
Sthat all three phases are supplying the correct voltage (phase sequence is not
important)
Sthat welding cables and connections are not damaged
Sthat the controls are correctly set
SSSS
that the mains supply is disconnected before starting repairs
6.2POSSIBLE FAULTS
1. SymptomCurrent and voltage readings show large fluctuations.
Cause 1 .1Contact jaws or nozzle are worn or wrong size.
ActionReplace contact jaws or nozzle.
Cause 1 .2Feed roller pressure is inadequate.
ActionIncrease pressure on feed rollers.
2. SymptomWire feed is irregular.
Cause 2 .1Pressure on feed rollers incorrectly set.
ActionAdjust pressure on feed rollers.
Cause 2 .2Feed rollers wrong size.
ActionReplace feed rollers.
Cause 2 .3Grooves in feed rollers are worn.
ActionReplace feed rollers.
3. SymptomWelding cab les overheating.
Cause 3 .1Poor electrical connection.
ActionClean and tighten all electrical connections.
Cause 3 .2Cross--sectional area of welding cables too small.
ActionUse cables with a larger cross--section or use parallel cables.
7ORDERING 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 113.
This will simplify dispatch and ensure you get the right part.