ESAB A2 SF Bedienungsanleitung

Valid for serial no. 2400449 375 101 GB 2009--03--11

A2 Welding heads with

Welding Control Unit PEI

A2 SF / A2 SF (Twin)/ A2 SG

Instruction manual

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved

guarantee that welding head A2 SF / A2 SG / A2 SG 4WD from serial number 136

complies with standard EN 60292 and EN 60204, in accordance with the require-

ments of directive (89/392/EEC) and addendum (93/68/EEC).

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Göran Palmqvist

Design Manager, Automation & Engineering

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

Laxå 2001--11--01

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TOCe

Rights reserved to alter specifications without notice.

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

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

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

2.2 Welding Method 6...........................................................

2.3 Definitions 6................................................................

2.4 Technical Data 7............................................................

2.5 Main components A2 SF (SAW) 8.............................................

2.6 Main components A2 SF (SAW, Twin) 8........................................

2.7 Main Components A2 SG (MIG/MAG) 9........................................

2.8 Description of Main Components 10............................................

3 INSTALLATION 11....................................................

3.1 General 11..................................................................

3.2 Mounting 11.................................................................

3.3 Adjusting the brake hub 12....................................................

3.4 Connections 13..............................................................

4 OPERATION 15.......................................................

4.1 General 15..................................................................

4.2 Loading the welding wire (A2 SF, A2 SG) 16.....................................

4.3 Changing the feed roller (A2 SF, A2 SG) 18......................................

4.4 Contact equipment for Submerged arc welding 19................................

4.5 Contact equipment for MIG/MAG welding 20.....................................

4.6 Refilling with flux powder (Submerged arc welding) 21.............................

4.7 Conversion of A2 SF (Submerged arc welding) to MIG/MAG welding 21.............

4.8 Conversion of A2 SF (Submerged arc welding) to Twin--arc 21.....................

5 MAINTENANCE 22....................................................

5.1 General 22..................................................................

5.2 Daily 22.....................................................................

5.3 Regularly 22.................................................................

6 FAULT TRACING 23...................................................

6.1 General 23..................................................................

6.2 Possible faults 23............................................................

7 ACCESSORIES 24....................................................

8 ORDERING OF SPARE PARTS 24......................................

DIMENSION DRAWING 25................................................

SPARE PARTS LIST 29...................................................

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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 recommen-

dations 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

4. Personal safety equipment

SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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 MANU--

FACTURER’S 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 keep fumes and gases 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 ear defenders or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION

SCall for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

READ AND UNDERSTAND THE INSTRUCTION MANUAL

BEFORE INSTALLING OR OPERATING.

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2 INTRODUCTION

2.1 General

All the welding heads included in this instruction manual are designed for SAW and

MIG/MAG welding of butt and fillet joints.

They are intended for use in combination with A2 Welding Control Unit (PEI)and

ESAB’s welding power source LAF.

2.2 Welding Method

2.2.1 Submerged Arc Welding (SAW)

For submerged arc welding the A2 SF welding head 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.

2.2.2 MIG/MAG Welding

For MIG/MAG welding the A2 SG welding head is to be used.

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.

2.3 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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2.4 Technical Data

2.4.1 Welding head A2 SF and A2 SG

A2 SF (SAW) A2 SG (MIG/MAG)

Rated load 100% 800A AC/DC 600A AC/DC

Wire dimensions:

solid single wire

flux--cored wire

twin wire

1.6--4.0 mm

2x1.2--2.0 mm

0.8--2.5 mm

1.2--3.2 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

(Not to be filled with preheated flux)

Capacity:

Max. temperature plastic flux hopper:

80°C

Weight (flux and wire excluded)

with hand--operated linear slides

with motor--driven linear slides

23 kg

45 kg 23 kg

44 kg

Sideways tilt, max. 25°25°

Setting length of the slide*

hand--operated

motor--driven 90 mm

180 mm 90 mm

180 mm

*) NB. Available in other lengths on request.

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2.5 Main components A2 SF (SAW)

1. Wire feed unit

2. Slide kit, manual

3. Slide kit, motorized

4. Contact tube

5. Wire feed motor

6. Guide pin

7. Flux hopper

8. Flux tube

9. Carrier for wire drum

2.6 Main components A2 SF (SAW, Twin)

1. Wire feed unit

2. Slide kit, manual

3. Slide kit, motorized

4. Connector (Twin)

5. Wire feed motor

6. Fine--Wire feed unit

7. Flux hopper

8. Flux tube

9. Carrier for wire drum

See on page 10 for a description of the main components.

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2.7 Main Components A2 SG (MIG/MAG)

1. Wire feed unit

2. Slide kit, manual

3. Slide kit, motorized

4. Connector (MIG/MAG)

5. Wire feed motor

6. Carrier for wire drum

See on page 10 for a description of the main components.

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2.8 Description of Main Components

2.8.1 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.

2.8.2 Manual and Motorized 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.

For the motorized slide (A6 Slide), see instruction manual 0443 394 xxx.

2.8.3 Contact Tube / Connector

Transfers welding current to the wire during welding.

2.8.4 Wire Feed Motor

The wire feed motor is used for feeding the welding wire.

2.8.5 Guide Pin

The guide pin is used to help positioning the welding head in the joint.

2.8.6 Fine--wire straightener

The unit is used for the straightening of fine wire.

2.8.7 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 21.

2.8.8 Carrier for Wire Drum

The carrier is provided with a brake hub on which one the wire drum is to be fitted.

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