ESAB TAF 800, TAF 1250 Instruction manual

TAF 800/ TAF 1250
AC

101103105107109 111102021110025108024042106023061104022041100020040060001

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Instruction manual
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Manuel d’instructions

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Istruzioni per l’uso
Manual de instruções

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Instrukcja obs³ugi

Valid for Serial NO 6060456 513 2006--05--10301

SVENSKA 5..............................................

DANSK 13................................................

NORSK 21................................................

SUOMI 29................................................

ENGLISH 37..............................................

DEUTSCH 45.............................................

FRANÇAIS 54.............................................

NEDERLANDS 63.........................................

ESPAÑOL 72..............................................

ITALIANO 81..............................................

PORTUGUÊS 90..........................................

ЕЛЛЗНЙКБ 99.............................................

POLSKI 110.................................................

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.

Zastrzegamy sobie prawo do wprowadzenia zmian.

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ESAB AB, Welding Equipment, 695 81 Laxå, Sverige, försäkrar under eget ansvar att svetsströmkälla
TAF 800/ TAF 1250 från serienummer 606 är i överensstämmelse med standard EN 60974--1 enligt
villkoren i direktiv (73/23/EEG) med tillägg (93/68/EEG) och standard EN 60974--10 enligt villkoren i
direktiv (89/336/EEG) med tillägg (93/68/EEG).

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FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

ESAB AB, Welding Equipment, S--695 81 Laxå, Sverige, erklærer på eget ansvar, at svejsestrømkilde
TAF 800/ TAF 1250 fra serienummer 606 er i overensstemmelse med standarden EN 60974--1 ifølge
betingelserne i direktiv (73/23/EØF) med tillæg (93/68/EØF) og standarden EN 60974--10 ifølge betin­gelserne i direktiv (89/336/EØF) med tillæg (93/68/EØF).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Sverige, forsikrer på eget ansvar at sveisestrømkilde
TAF 800/ TAF 1250 fra serienummer 606 er i overensstemmelse med standard EN 60974--1 i følge
vilkårene i direktiv (73/23/EF) med tillegg (93/68/EF) og standard EN 60974--10 i følge vilkårene i di­rektiv (89/336/EF) med tillegg (93/68/EF).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Ruotsi, vakuuttaa omalla vastuullaan, että hitsausvir­talähde TAF 800/ TAF 1250 alkaen sarjanumerosta 606 täyttää standardin EN 60974--1 vaatimukset
direktiivin (73/23/ETY) ja sen lisäysten (93/68/ETY) ehtojen mukaisesti sekä standardin EN 60974--10
vaatimukset direktiivin (89/336/ETY) ja sen lisäysten (93/68/ETY) ehtojen mukaisesti.

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ESAB AB, Welding Equipment, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source TAF 800/ TAF 1250 from serial number 606 complies with standard EN 60974--1, in
accordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with
standard EN 60974--10 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Schweden, bestätigt hiermit in Eigenverantwortung,
daß die Schweißstromquelle T AF 800/ TAF 1250 ab Seriennummer 606 dem Standard EN 60974--1
gemäß den Bedingungen der Direktive (73/23/EEG) mit Zusats (93/68/EEG) und dem Standard EN
60974--10 gemäß den Bedingungen der Direktive (89/336/EEG) mit Zusatz (93/68/EEG) entspricht.

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OVERENSSTEMMELSEERKLÆRING

FORSIKRING OM SAMSVAR

VAATIMUSTENMUKAISUUSVAKUUTUS

DECLARATION OF CONFORMITY

ZULASSUNGSNACHWEIS

ESAB AB, Welding Equipment, S--695 81 Laxå Suède, certifie que la source de courant de soudage
TAF 800/ TAF 1250 à partir du numéro de série 606 est conforme à la norme EN 60974--1 selon les
cinditions de la directive (73/23/CEE) avec additif (93/68/CEE) et à la norme EN 60974--10 selon les
conditions de la directive (89/336/CEE) avec additif (93/68/CEE).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Zweden, verklaart geheel onder eigen verantwoorde­lijkheid dat lasstroombron TAF 800/ TAF 1250 van het serienummer 606 in overeenstemming is met
norm EN 60974--1 conform de bepalingen in richtlijn (73/23/EEG) met de annex (93/68/EEG) en met
norm EN 60974--10 conform de bespalingen in richtlijn (89/336/EEG) met annex (93/68/EEG).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Suecia, garantiza bajo propia responsabilidad que la
fuente de corriente para soldadura TAF 800/ TAF 1250 a partir del número de serie 606 concuerda
con la norma EN 60974--1 conforme a la directiva (73/23/CEE) con el suplemento (93/68/CEE) y con
la norma EN 60974--10 según los requisitos de la directiva (89/336/CEE) con el suplemento
(93/68/CEE).

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ESAB AB, Welding Equipment, S--695 81 Laxå, Svezia, dichiara sotto la propria responsabilità che il
generatore per saldatura TAF 800/ TAF 1250 con numero di serie a partire da 606 è conforme alla
norma EN 60974--1 come previsto dalla direttiva (73/23/CEE) e successive integrazioni (93/68/CEE)
ed alla norma EN 60974--10 come previsto dalla direttiva (89/336/CEE) e successive integrazioni
(93/68/CEE).

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CERTIFICAT DE CONFORMITÉ

VERKLARING VAN OVEREENSTEMMING

DECLARACIÓN DE CONFORMIDAD

DICHIARAZIONE DI CONFORMITA

3

ESAB AB, Welding Equipment, S--695 81 Laxå, Suécia, garante sob responsabilidade de própria que

L

a fonte de corrente para soldadura TAF 800/ TAF 1250 a partir do número de série 606 está em
conformidade com a norma EN 60974--1 segundo os requisitos da directiva (73/23/CEE) com o su­plemento (93/68/CEE) e com a norma EN 60974--10 segundo os requisitos da directiva (89/336/CEE)
com o suplemento (93/68/CEE).

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DECLARAÇÃO DE CONFORMIDADE

ЗефбйсеЯбESAB AB, Welding Equipment, 695 81 Laxе, УпхздЯб, дзлюней ьфй пй рзгЭт сеэмбфпт
ухгкьллзузт TAF 800/ TAF 1250 брь фпн бсйимь уейсЬт 606 кбй Эрейфб, ухммпсцюнпнфбй ме фп
рсьфхрп EN 60974–1 уэмцщнб ме фйт брбйфЮуейт фзт пдзгЯбт (73/23/EEG) кбй фпх
рбсбсфЮмбфпт (93/68/EEG) кбй фп рсьфхрп EN 60974--10 уэмцщнб ме фйт брбйфЮуейт фзт
пдзгЯбт (89/336/EEG) кбй фпх рбсбсфЮмбфпт (93/68/EEG).

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Firma ESAB AB, Welding Equipment, 69581 Laxaa, Szwecja, gwarantuje pod rygorem odpowiedzialno¶ci, ¿e
¼ród³a pr±du spawania TAF 800/ TAF 1250 od numeru seryjnego 606 spe³niaj± wymagania normy
EN60974-1 wed³ug dyrektywy (73/23/EEC) z poprawkami (93/68/EEG) oraz normy EN 60974-10
wed³ug dyrektywy (89/336/EEG) z poprawkami (93/68/EEG)..

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Kent Eimbrodt
Global Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

ДЗЛЩУЗ УХММПСЦЩУЗУ

DEKLARACJA ZGODNO¦CI

4

ENGLISH

1SAFETY 38...........................................................

2 INTRODUCTION 40...................................................

2.1 General 40..................................................................

2.2 Technical data 40............................................................

3 INSTALLATION 41....................................................

3.1 General 41..................................................................

3.2 Unpacking and location 41.....................................................

3.3 Connections 41..............................................................

3.4 PC board 42.................................................................

4 OPERATION 43.......................................................

4.1 General 43..................................................................

4.2 Controls 43..................................................................

4.3 Start--up 43..................................................................

5 MAINTENANCE 44....................................................

5.1 General 44..................................................................

5.2 Cleaning 44.................................................................

6 ORDERING OF SPARE PARTS 44......................................

DIAGRAM 118............................................................

LIST OF COMPONENTS 119...............................................

CONNECTION INSTRUCTION 120..........................................

SPARE PARTS LIST 121...................................................

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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GB

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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GB

3 INSTALLATION

3.1 General

The in stallatio n 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 120.

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 42).

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) mar ked on

the front of the power source.

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GB

Mains con n ectio 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 “ OF F ” 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 “ OF F “ position and all other poles to “ON“.

S TAF 1250

Set pole 2 to “ OF F ” 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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GB

4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on
page 38. Read through before you start using the equipment!

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 a ctivated.

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 resetting 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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GB

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.

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 121.
This will simplify dispatch and ensure you get the right part.

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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.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
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]

NORWA Y

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

051118