A2/A6 SAW

Single Twin
101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning Brugsanvisning Bruksanvisning Kyttohjeet Instruction manual Betriebsanweisung

Manuel dinstructions Gebruiksaanwijzing Instrucciones de uso Istruzioni per luso Manual de instrues

0456 757 001

2001-03-09

Valid for Serial NO 740 XXX-XXXX

SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 11

NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 FRANAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ESPAOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 PORTUGUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Rtt till ndring av specifikationer utan avisering frbehlles. Ret til ndring af specifikationer uden varsel forbeholdes. Rett til endre spesifikasjoner uten varsel forbeholdes. Oikeudet muutoksiin pidtetn. Rights reserved to alter specifications without notice. nderungen vorbehalten. Sous rserve de modifications sans avis pralable. 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 especificaes sem aviso prvio. .

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ENGLISH

1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 36 37
37 37

4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 4.2 4.3 4.4 4.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly instructions -- Heavy Duty A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly instructions -- Light Duty A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly instructions -- Light Duty A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37
37 38 39 40 41

5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42
42

6 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

TOCe

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GB 1 DIRECTIVE

DECLARATION OF CONFORMITY Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee that automatic welding machine A2/A6 SAW SingleTwin from serial number 740 complies with standard EN 60292, in accordance with the requirements of directive (89/392/EEA) and addendum and standard EN 50199 in accordance with the requirements of directive 89/336/ EEA and addendum 93/68/ EEA . -------------------------------------------------------------------------------------------------------------------------------------Lax 98--02--16

Paul Karlsson Managing Director Esab Welding Equipment AB 695 81 LAX SWEDEN

Tel: + 46 584 81000

Fax: + 46 584 12336

SAFETY

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 work place. All work must be carried out by trained personnel well familiar 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 The operator must ensure that: S no unauthorized person is stationed within the working area of the equipment when it is started up. S that no--one is unprotected when the arc is struck The work place must: S be suitable for the purpose S be free from draughts 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. General precautions S Make sure the return cable is connected securely. S Work on high voltage equipment shall 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.

2.

3.

4.

5.

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GB 3
3.1

INTRODUCTION
General

A welding head of type A2 SFE / A6 SFE or a tractor of type A2 TFE / A6 TFE can be converted from SAW welding with single wire to twin wires by way of a conversion kit (Twin design). The conversion kit contains all parts necessary for the conversion of the welding head. Before using the system certain adjustments must be made in the PEH control system (A2--A6 Process Controller). Instructions regarding these adjustments can be found in the instruction manual for the control system.

3.2

Technical data
A6 TFE1 UP LD D20 A6 TFE1 UP HD D35 1500 A -AC/DC 2x2.0--3.0mm 0.2--4.0 m/min 1.5 Nm 2x30 kg 10 l 50 kg 25_ 210 mm 300 mm 68 dB A2 TFE1 UP LD D20 800 A AC/DC 2x1.2--2.0 mm 0.2--9.0 m/min 1.5 Nm 2x30 kg 6l 50 kg 25_ 90 mm

Permissible load 100 % 60 % Wire dimensions: twin wires Wire feed speed Brake hub braking torque Max. weight of wire Flux hopper capacity (must not be filled with preheated flux) Weight (without flux and wire) Lateral inclination, max. Setting length of the slide * hand--operated motor--driven (ball bushings) Continuously A--weighted noise pressure
*) NB. Other lengths can be supplied.

800 A 1000 A AC/DC 2x1.2--2.0 mm 0.2--4.0 m/min 1.5 Nm 2x30 kg 10 l 50 kg 25_ 210 mm 300 mm 68 dB

4
4.1

INSTALLATION
General

The installation shall be executed by a professional.

WARNING!
Rotating parts can cause injury, take great care.

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GB
4.2 Assembly instructions - Heavy Duty A6

For the change of welding method from single wire to twin wires, follow the instructions below. S S S S S S To loosen the contact jaws, draw the wire out of the wire straightener (1). Stop the flux flow by closing the flux valve. Loosen the flux tube (2) and dismount the flux nozzle with an Allen key. Dismount the existing SAW contact device. Undo the four screws on the contact jaws and remove the jaws. Mount contact device D35 (3) fitted with two contact jaws for twin wires. Mount one of the contact jaws in the fixed part of the contact device (4) using the screws supplied. Mount the other jaw under screw (5) in the loose half of the two--piece contact device (6). Tighten up the screws to achieve good contact between the jaws and the contact device. To exchange feed roller (10) for a roller with twin grooves (not contained in the conversion kit), release the knobs (7) and (8) and the hand wheel (9). Change to a pressure roller with spherical bearing (11) for twin wires. Mount the plate with two wire liners (12). Fit an extra reel holder. Fit the brake hub and the bobbin on the outside of the reel holder. Lead the wires down through the contact tip to the wire feed unit. NB. The wires must not be crossed in the contact device! Re--mount the flux nozzle and fit the flux tube. Open the flux valve.

S S S S S S S S S

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GB
4.3 Assembly instructions - Light Duty A6

For the change of welding method from single wire to twin wires, follow the instructions below. S S S S S S S S S S S Stop the flux flow by closing the flux valve. Loosen the flux tube (1) and dismount the flux nozzle. Dismount the contact jaws and the loose half of the contact device. Keep the Heavy Duty guide tubes and fit guide tubes for Light Duty inside the Heavy Duty tubes. Exchange pressure roller (2) for a pressure roller with spherical bearing. Assemble the fine wire straightener (3) with two guide tubes (4) for twin wires < 1.6 mm. Fit an extra reel holder. Fit the brake hub and the bobbin on the outside of the reel holder. Fit contact device D35 (5). Assemble the twin adapter (6) for M6 contact tips with M5 bolts in the fixed part of the two--piece contact device and fit two contact tips (7). Replace the support roller by the clamp (8) with holes for two tubes. Fit the clamp in the M12 hole on the wire straightener. The clamp is to clasp the guide tubes which shall bottom on the twin adapter and the contact tips. Tighten the contact tips with a key to ensure that a good contact is achieved.. If necessary, cut the guide tubes to length so that the feed roller runs freely.. Re--mount the flux nozzle and fit the flux tube. Open the flux valve.

S S S S

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GB
4.4 Assembly instructions - Light Duty A2

For the change of welding method from single wire to twin wires, follow the instructions below. S S S S S S S S S S S S S S S S Stop the flux flow by closing the flux valve. Loosen the flux tube (1) and dismount the flux nozzle with an Allen key. Keep the Heavy Duty guide tubes and fit guide tubes for Light Duty inside the Heavy Duty tubes. For twin wires < 1.6 mm a guide spiral, inserted into each guide tube, is used to help straightening the wire. Dismount the existing SAW contact device and the clamp (9). Fit fine wire straightener (3) with two guide tubes (4). Exchange the pressure roller (2) for a pressure roller with spherical bearing. Fit an extra reel holder. Fit the brake hub, the support and the bobbin on the outside of the reel holder. Assemble the contact device D35 (5) with twin adapter (6) the two contact tips (7) and the clamp. Assemble the twin adapter for M6 contact tips with M5 bolts in the fixed part of the two--piece contact device and fit two contact tips (7). Fit the clamp (8) in the M12 hole on the wire straightener. The clamp is to clasp the guide tubes which shall bottom on the twin adapter and the contact tips. Tighten up the contact tips with a key to achieve good contact. If necessary, cut the guide tubes to length so that the feed roller runs freely. Re--mount the supplied flux nozzle and fit the flux tube. Open the flux valve.
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GB
4.5 Connections
A2/A6

Electrical connections to the A2- A6 Process Controller S Make sure the arc voltage cable is connected to the contact device clamp and to the A2--A6 Process Controller box (terminal block X2). Go to the submenu PRESET WELDING and select WIRE DATA.

Adjustments in the A2- A6 Process Controller S S Set Number of Wires to 2. For more detailed instructions, see instruction manual 0443 745 001 for A2--A6 Process Controler. Instructions for PEG 1, see instruction manual 0443 392 xxx.

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GB 5
5.1

OPERATION
General

General safety regulations for the handling of the equipment appear from page 36. Read through before you start using the equipment!

WARNING!
Rotating parts can cause injury, take great care.

ORDERING 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 101. This will simplify dispatch and ensure you get the right part.

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