ESAB TAF 800, TAF 1250 Instruction manual / Spare parts list (Replacement parts)

GB

TAF 800/ TAF 1250
AC

Instruction manual

Valid for serial no. 7120456 513 601 GB 2007--04--20

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, declares under sole responsibility that

L

welding power source TAF 800 / TAF 1250AC from serial number 712 (2007 w.12) is designed and
tested in conformity with standard EN 60974--1 and EN 60974--10 in accordance with the conditions in
the directives (2006/95/EC) and (2004/108/EC).

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axå 2007--03--30

Kent Eimbrodt
Global Director
Equipment and Automation

DECLARATION OF CONFORMITY

2

1SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 General 6..................................................................

2.2 Technical data 6............................................................

3 INSTALLATION 7....................................................

3.1 General 7..................................................................

3.2 Unpacking and location 7.....................................................

3.3 Connections 7..............................................................

3.4 PC board 8.................................................................

4 OPERATION 9.......................................................

4.1 General 9..................................................................

4.2 Controls 9..................................................................

4.3 Start--up 9..................................................................

5 MAINTENANCE 10....................................................

5.1 General 10..................................................................

5.2 Cleaning 10.................................................................

6 ORDERING OF SP ARE P ARTS 10......................................

DIAGRAM 11............................................................

LIST OF COMPONENTS 12...............................................

CONNECTION INSTRUCTION 13..........................................

SPARE PARTS LIST 15...................................................

Rights reserved to alter specifications without notice.

TOCe

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GB

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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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!

WARNING

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.

WARNING!

Read and understand the instruction manual
before installing or operating.

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.

By applying this European Directive you will improve the environment and human health!

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2 INTRODUCTION

2.1 General

TAF 800/1250 are remote--controlled, two-- phase AC welding power sources

designed for high--throughput, mechanised submerged --arc welding (SAW).
They should always be used in conjunction with ESAB’s control box
A2--A6 Process Controller (PEH).

The welding power source converts, via a thyristor bridge--rectifier, the secondary
voltage’s sine wave to a square wave with excellent arc ignition and welding
characteristics. They are fan cooled and are overload protected by a thermal
cut--out. Re-- setting takes place automatically as soon as the temperature has
reduced to an acceptable level.

The welding power source and control box are connected together via a two--wire
bus, which makes it possible to control the welding process very precisely.

Adjustment of the welding power source can be carried out from the front panel of
the control box, where all the welding parameters can be adjusted by the operator.
The operation of the welding power source is controlled and monitored completely
by the control box, from which the start and stop characteristics can be set.
The pre--set welding parameters can be monitored while welding is in progress.

For more detailed information regarding the settings and the working mode of the
welding power source, please refer to the A2--A6 Process Controller (PEH)
instruction manual.

2.2 Technical data

TAF 800 TAF 1250

Voltage 346/400/415/ 500 V, 1μ50 Hz

400/440/550 V, 1μ60 Hz

Permissible load at:

100 % duty cycle
60 % duty cycle

Setting range 300 A/32 V -- 800 A/44 V 400 A/36 V -- 1250 A/44 V
No--load voltage 71 V 71 V
No--load power 230 W 230 W
Effiency 0,86 0.86
Power factor 0,75 0,76
Weight 495 kg 608 kg
Dimensions L x W x H 774 x 598 x 1228 774 x 598 x 1228
Enclosure class IP 23 IP 23

800 A/44 V
1000 A/44 V

346/400/415/500 V, 1μ50 Hz
400/440/550 V, 1μ60 Hz

1250 A /44 V
1500 A/44 V

Application class

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

Application class

The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.

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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

3.2 Unpacking and location

WARNING -- TIPPING RISK!

Fasten the equipment -- particularly if the ground is uneven or sloping.

S Place the welding power source on a level foundation.
S Make sure there is nothing to prevent the cooling.

Lifting instructions

3.3 Connections

S On delivery the welding power source is connected

for 400 V. For other supply voltage, switch over to
the desired voltage on the main transformer and the
control transformer according to the connection
instructions on page 13.

S Make sure the mains cable has the right sectional area

and fuse it with an adequate fuse according to
applicable local directions (see table on page 8).

S Connect the earth cable to the screw marked .
S Tighten the cable support (1).
S Connect the mains cable to the main terminal

blocks L1 and L3.

S Connect the control cable between the TAF

welding power source and the control unit to the
28--pole contact (2) inside the welding power
source.

S Connect 1--pin socket measure cable (4)tothe

work piece.

S Connect a suitable welding and return cable to the contacts (3) marked on

the front of the power source.

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Mains connectio n

TAF 800 50 Hz
Voltage (V) 346 400 / 415 500 400/ 440 550

Current (A)

I

max

1

I

eff

1

Cablearea(mm2) 2x70+35 2x70+35 2x50+35 2x70+35 2x50+35
Fuse, slow (A) 160 160 125 160 125

TAF 1250
Voltage (V) 346 400 / 415 500 400 / 440 550

Current (A)

I

max

1

I

eff

1

Cablearea(mm2) 2x(2x70+35) 2x(2x70+35) 2x95+50 2x(2x70+35) 2x95+50
Fuse, slow (A) 250 200 200 200 200

184
145

299
249

160
127

50 Hz 60 Hz

254
212

129
104

205
170

160
127

254
212

60 Hz

129
104

205
170

3.4 PC board

The PC board (AP1) has two DIP switches (SW1 and SW2) which are preset on
delivery. The settings are not to be changed.

When spare parts are installed the settings of the DIP switches must be checked
(and set, if necessary) before fitting the PC board into the welding power source.

3.4.1 DIP switch SW1

To make the communication with the
A2--A6 Process Controller work,
DIP switch 1 (SW1) must be set.

Setting of DIP switch SW1:

S Set pole 6 to “OFF” position and all

other poles to “ON”.

3.4.2 DIP switch SW2

DIP switch 2 (SW2) must be set in order to
inform the A2--A6 process controller about the
rating of the power source that is connected.

Setting of DIP switch SW2:

S TAF 800

Set pole 1 to “OFF“ position and all other poles to “ON“.

S TAF 1250

Set pole 2 to “OFF” position and all other poles
to “ON”.

Welding power source program

The welding power source program is stored in the flash memory IC 6.
The capsule is fitted in a holder and is replaceable.

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4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!

Note! Never use the welding power source without side plates.

4.2 Controls

The front panel contains:

S Main switch (1) breaking the incoming mains

voltage for the welding power source.

S White Indicating lamp (2) showing that the

main switch is activated.

S Yellow indicating lamp (3) showing that the

thermal protection has entered into action due to
overheating in the transformer. The lamp is reset
when the temperature has gone down to an
acceptable level.

S Pushbutton (4) for the r esetting of automatic fuse FU1 for 42 V supply voltage.

4.3 Start--up

S Connect the return cable to the work piece.

S Set the main switch (1) to position “I“.

The white indicating lamp (2) goes on and the fan starts.

S Set the welding parameters and start welding by way of the control box

(see the A2--A6 Process Controller 0443 745 xxx instruction manual).

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5 MAINTENANCE

5.1 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.

5.2 Cleaning

S Clean the welding power source as necessary.

Dry compressed air is recommended for the purpose.

WARNING! Blocked air inlets or outlets will lead to overheating.

Note:

In order to ensure safe operation of the contactor, keep the magnetic parts clean.
If the contactor has to be cleaned it must be taken apart, and all the pieces be
cleaned.
Alternatively, the contactor can be replaced.

WARNING!

Never use compressed air to clean the contactor without first taking it apart

completely.

6 ORDERING OF SP ARE PARTS

TAF 800/ TAF 1250 is designed and tested in accordance with the international and Eu­ropean standards IEC/EN 60974--1 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 that the product still conforms to the said standard.

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 15.
This will simplify dispatch and ensure you get the right part.

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Diagram

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List of components

C = Component designation in the circuit diagram

C Denomination C Denomination

AP1 Circuit board
AP2 Circuit board EMC--filter
AP3 Circuit board (disturbance elimin-

ation)

C1 Capacitor
C2 Capacitor
C4 Capacitor
C5 Capacitor
EO1 Ferrite core
FU1 Fuse
FU2 Fuse
HL1 Indicator lamp, white
HL2 Indicator lamp yellow
KM1 Contactor
KM2 Contactor
L1 Inductor
M1 Fan

QF Main switch (black)
R1 Power resistor
R2 Power resistor
RS1 Shunt
ST1 Thermal relay
TC1 Control transformer
TC2 Control transformer
TM1 Transformer
V1 Thyristor
XS3 Screw terminal
XS4 Burndy socket
XT1 Connection block
XT2 Connection block
XT3 Connection block
XT4 Connection block
Z1, Z2 Contact protection
Z3 Contact protection

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Connection instruction

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sida

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Spare parts list

TAF 800/ TAF 1250 AC

Edition 2007--04--02

Ordering no. Denomination Notes

0456 325 880 Welding power source TAF 800

0456 326 880 Welding power source TAF 1250

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

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Item

Qty

no.

TAF 800

1 2 2 0442 719 880 Connection block

3 1 1 0318 042 882 Inductor coil

4 1

5 1 0442 763 880 Inductor L1

6 1 1 0460 004 880 Fan complete

6:1 1 1 0460 294 880 Fan M1

7 6 6 0041 051 606 Contact protection Z1--Z3

8 2

9 4

10 1 1 0486 178 880 Circuit board EMC--filter AP2

11 2 2 0567 200 610 Fuse 16 A FU1

12 1 1 0320 746 002 Main switch Black QF

13 1 1 0192 576 004 Lamp On/Off HL1

14 1 1 0192 576 303 Indicator lamp Yellow HL2

15 1 1 0193 586 104 Automatic fuse 20 A FU2

17 2 2 0156 388 001 Handle

18 1 1 0486 376 880 Circuit board AP1

19 1 1 0805 586 131 Contactor KM2

20 1

21 2 2 0319 828 001 Control transformer TC2

22 1 1 0460 092 001 Control transformer TC1

23 1 1 0158 115 880 Cable inlet

24 1 1 0319 445 001 Thermal relay ST1

25 1 1 0551 203 080 Shunt RS1

26 1 1 0442 846 001 Capacitor C5

27 1

28 1

35 1 1 0523300201 Positive terminal

36 1 1 0319445001 Thermostat

37 0191 085 104 Capacitor C4

Qty
TAF 1250

Ordering no. Denomination Notes C

0456 325 880 Welding power source TAF 800

0456 326 880 Welding power source TAF 1250

0442 906 880
0442 906 881

1

1 0442 945 880 Inductor L1

0442 972 001
0321 427 001

2

0442 993 880
0443 065 880

4

0442 849 880
0442 849 881

1

0457 934 880
0457 935 880

1

0442 717 884
0442 717 885

1

Inductor coil
Inductor coil

Thyristor
Thyristor

Thyristor bridge
Thyristor bridge

Contactor
Contactor

Transformer coil
Transformer coil

Transformer
Transformer

V1
V1

KM1
KM1

TM1

f456325s

1 1 0486178880 Circuit board (disturb-

ance eliminator)

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AP3

TAF 800/1250 AC

f456325s

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax:[phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax:[phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

061127