Valid for Serial NO 930 XXX--XXXX0449 002 001 2001--03--12
A2 S GMAW Mini
Master
A2 SGF1
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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
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Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændri ng af specifikationer uden varsel forbeholdes.
Rett til å endre spesifi kasjoner 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 previ o aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
SVENSKA 3..............................................
DANSK 18................................................
NORSK 33................................................
SUOMI 48................................................
ENGLISH 63..............................................
DEUTSCH 78.............................................
FRANÇAIS 93.............................................
NEDERLANDS 109.........................................
ESPAÑOL 125..............................................
ITALIANO 141..............................................
PORTUGUÊS 156..........................................
ÅËËÇÍÉÊÁ 172.............................................
ENGLISH
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TOCe
1 DIRECTIVE 64........................................................
2SAFETY 64...........................................................
3 INTRODUCTION 66...................................................
3.1 General 66..................................................................
3.2 Technical data 66............................................................
3.3 Welding method 66...........................................................
3.4 Equipment 67................................................................
4 INSTALLATION 68....................................................
4.1 General 68..................................................................
4.2 Mounting 68.................................................................
4.3 Connections 69..............................................................
5 OPERATION 70.......................................................
5.1 General 70..................................................................
5.2 Start--up 70..................................................................
6 MAINTENANCE 74....................................................
6.1 General 74..................................................................
6.2 Daily 74.....................................................................
6.3 Periodic 74..................................................................
7 TROUBLE SHOOTING 75..............................................
8 ACCESSORIES 76....................................................
9 ORDERING OF SPARE PARTS 76......................................
10 WEAR COMPONENTS 77..............................................
DIMENSION DRAWING 188................................................
SPARE PARTS LIST 191...................................................
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1 DIRECTIVE
DECLARATI ON OF CONFORM ITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved
guarantee that welding head A2 SGF1 from serial number 930 complies with
standard EN 60292 and EN 60204, in accordance with the requirements of directive
(89/392/EEC) and addendum (93/68/EEC).
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Johnny Sundin
Design Manager, Div Engineering
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721
Laxå 1999--11--12
2SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions.
The following recommendations should be observed in addition to the standard regulations that apply
to the work place.
All work must be carried out according to the specified instructions by personnel who are thoroughly
familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous situation which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the automatic welding machine must be familiar with:
S its operation
S the location of emergency stops
S its function
S relevant safety precautions
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the machine when it is started
up.
S that no--one is in a hazardous position when the carriage or slide mechanisms are operated.
3. The work place must:
S be clear of mechanical components, tools, or other obstructions that could prevent the oper-
ator from moving freely within the working area.
S be organized so that there is free access to the emergency stop.
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, etc., which could become
trapped.
5. General precautions
Live electrical components are normally shielded from accidental contact.
S Make sure the return cable is connected securely.
S Work on high voltage components may only be carried out by a qualified electrician.
S Appropriate fire extinguishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during its operation.
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 MANU--
FACTURER’S 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 keep fumes and gases from
your breathing zone and the general area.
ARC RAYS -- Can injure eyes an d 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 ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call 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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3 INTRODUCTION
3.1 General
The A2 SGF1 welding head is designed for MIG/MAG welding of butt and fillet joints.
A2 SGF1 is intended for use together with control box A2--A6 Process Controller and
ESAB’s LAF welding power source.
The welding head can be horisontally or vertically positioned by way of linear slides.
The angular motion can be freely adjusted by way of an angle slide.
Push angle for forehand welding or drag angle for backhand welding can be set
using the rotary attachment.
3.2 Technical data
A2 SGF1
Type of gas: Mix/Ar CO
2
Permissible load at 100 %: 600 A DC 650 A DC
Wire dimensions:
Non--alloy / Low--alloy
Stainless steel
Cored wire
Aluminium
1.0--1.6 mm
1.0--1.6 mm
1.0--2.4 mm
1.0 -- 2.0 mm
1.0--1.6 mm
1.0--2.4 mm
Wire feed speed 2.0--25 m/min 2.0--25 m/min
Setting range, contact device ±45˚ ± 45˚
Brake hub braking torque 1.5 Nm 1.5 Nm
Max. weight of wire 30 kg 30 kg
Weight (without wire):
with hand operated linear slides
with motor driven linear slides
15 kg
43 kg
15 kg
43 kg
Max. lateral inclination (whole unit) 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.
3.3 Welding method
MIG/MAG welding
In MIG/MAG welding the welding bead is shielded by way of shielding gas.
The welding head is water--cooled. The cooling water is connected to the respective
connection by way of hoses.
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3.4 Equipment
The complete welding head consists of a motor for the feed of the wire and contact
equipment supplying current to the wire.
Examp le o f an A2 SGF1 with hand o p erated linear slides:
1. Wire feed unit with
four--wheel drive
2. Contact equipment containing
gas nozzle, contact device and
water hose
3. Angle slide
4. Linear slide (hand operated)
5. Wire feed motor
6. Wire drum
7. Wire conduit
8. Rotary attachment
Examp le o f an A2 SGF1 with motor d riven linear slides:
1. Wire feed unit with
four--wheel drive
2. Contact equipment containing
gas nozzle, contact device and
water hose
3. Angle slide
4. Linear slide (motor driven)
5. Wire feed motor
6. Wire drum
7. Wire conduit
8. Rotary attachment
Connection instructions for MIG/MAG welding, see the system diagram on page 69.
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4 INSTALLATION
4.1 General
The installatio n shall be executed b y a p rofession al.
WARNING!
Rotating parts can cause injury, take great care.
4.2 Mounting
The automatic welding m achine can easily be mounted on a beam--travelling
carriage or on a welding column and boom unit by way of four M12 screws.
Make sure the bolts do not touch the bottom of the insulator, which has a thread
depth of 14 mm.
For mounting/ dism ounting o f A6 Slide, see instruction manual 443 394 xxx.
This safety sign is placed on the cover of the vertical slide.
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4.3 Connections
1. The A2-- A6 Process Controller is to be connected by a qualified person.
2. For the connection of A6 GMD, see instruction manual 0443 403 xxx.
3. For the connection of A6 PAK, see instruction manual 0443 405 xxx.
4. Connect the welding head as follows:
S The control cable (7) between the welding power source (8) and the A2--A6
Process Controller (2).
S The return cable (11) between the welding power source (8) and the
workpiece (9).
S The welding cable (10) between the welding power source (8) and the
welding head (1).
S The gas hose (5) between the pressure reducing valve (6) and the gas valve
of the welding head (13).
S The hoses for cooling water (3) between the cooling unit (4) and the welding
head (1).
S The measuring cable (12) between the welding power source (8) and the
workpiece (9).
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5 OPERATION
5.1 General
General safety regulations for the handling of the equipment appear from
page 64. Read through before you start using the equipment!
S Select wire type and shielding gas so that the weld material is as close as
possible to the analysis of the base material. Select wire size and welding data in
accordance with the values recommended by the consumables supplier.
S T horough joint preparation is necessary to achieve a good weld result.
NOTE! The width of the joint gap must be uniform.
S To minimise the risk of heat crack formation the width of the weld must be
greater than the penetration depth.
S Always carry out a test weld with the same joint type and plate thickness as the
workpiece to be produced.
S F or control and adjustment of the welding head and welding power source, see
the instruction manual for the A2--A6 Process Controller.
S F or the replacement of wear parts, see table on page 77.
5.2 Start--up
NOTE!
The wire drum is not included in the delivery of the welding head in MIG design.
Fitting the wire drum
S F it the wire drum (1) on the brake hub (2).
Check that the carrier (3) is in the correct position.
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.
IMPORTANT!
To prevent the reel sliding off the hub: Lock the reel in place
by turning the red knob as shown on the warning label atta -
ched next to the hub.
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S Check that the feed rollers (1, 4) and the contact nozzle (7) are of the correct
dimension for the wire size selected.
NOTE!
The feed rollers are marked with their respective groove diameter (D) on the
opposite side of the roller.
S Undo the pressure devices (10) and put up the pressure arms (11).
S Put the end of the wire through the wire guide nipple (12).
S Locate the end of the wire in the groove of the feed roller (1) and feed it through
the intermediate nozzle (3).
S Locate the end of the wire in the groove of the other feed roller ( 4) and feed it
through the outlet nozzle (9).
S Put down the pressure arms (11) and adjust the wire tension on the feed rollers
(1, 4) by way of the pressure devices (10).
Do not tighten down too hard.
S F eed the wire forward 30 mm by pressing on the control box A2--A6
Process Controller.
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Replacing the feed rollers
S Undo the pressure devices (10).
S Put up the pressure arms (11).
S Undo the mounting screws (2) of the feed rollers.
S Replace the feed rollers.
S Adjust the wire tension on the new feed rollers.
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Contact equipment for MIG/MAG welding
Use the straightener (5), the contact device D35 (6) and the contact nozzle (7).
Select a wire guide insert of the correct dimension for the type of wire to be used.
See the instruction manual for contact device M T W 600 (0449 006 XXX).
S Tighten the contact device ( 6) using the Allen screw (8).
S Tighten the contact nozzle in order to ensure that good contact is achieved.
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6 MAINTENANCE
6.1 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.
N.B. Before starting any repairs the mains voltage must be disconnected.
For the maintenance of A2--A6 Process Controller, see instruction manual
0443 745 XXX.
6.2 Daily
S Keep the moving parts of the welding head clean.
S Make sure contact nozzles, hoses and electric cables are properly connected.
S Make sure all bolted joints are tightened and that the conduit and the feed rollers
are not worn or damaged.
S Check the braking torque of the brake hub. It should not be so low that the drum
continues to rotate when the wire feed is stopped, and not so high that the feed
rollers slip. As a guide, the braking torque of a 30 kg wire drum should be 1.5
Nm.
Adjusting the braking torque:
S Set the locking button (2) in locked
position.
S Adjust the springs of the
hub by way of a
screwdriver.
S Turning the springs (1) clockwise
reduces the braking torque.
S Turning the springs anticlockwise increases the braking torque.
NOTE! Turn the springs by the same amount.
6.3 Periodic
S Inspect the gas nozzle and clear it regularly of welding spatter.
S Inspect the slides and lubricate if the they are binding.
S Inspect the wire conduit, the feed rollers and the contact nozzle of the wire feed
unit. Replace worn or damaged parts (for spare parts, see page 191).
S Blow the wire conduit clean at regular intervals and clean the gas nozzle.
S F o r trouble--free wire feed the wear parts of the feed mechanism should be clea-
ned and replaced at regular intervals.
NOTE that too hard pre--tensioning can lead to abnormal wear of the pressure
roller, feed roller and wire conduit.
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7 TROUBLE SHOOTING
Equipment S Instruction manual for A2--A6 Process Controller.
Check S that the welding power source is connected for the correct mains
voltage
S that all 3 phases are live (phase sequence not important)
S that the welding cables and their connections are intact
S that the controls are in the desired position
S th at th e mains voltage is disco n nected before starting an y
repairs.
POSSIBLE FAULTS
1. Symptom Current and voltage readings show large fluctuations
Cause 1.1 The contact nozzle is worn or of the wrong dimension.
Action Replace the contact nozzle.
Cause 1.2 The gas nozzle is choked up.
Action Clear of welding spatter.
2. Symp to m Wire feed is irregular
Cause 2.1 The pressure on the feed rollers is not correct.
Action Correct the pressure.
Cause 2.2 The feed rollers are of the wrong dimension.
Action Replace the feed rollers.
Cause 2.3 The grooves in the feed rollers are worn.
Action Replace the feed rollers.
3. Sympto m Weld in g cables overheating
Cause 3.1 Improper electric connections.
Action Clean and tighten all electric connections.
Cause 3.2 The area of the welding cables is not sufficient.
Action Use cables of greater area or parallel cables.
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8 ACCESSORIES
Linear slide (hand operated) 0413 518 xxx...................................
Linear slide (motor driven) 0334 333 xxx.....................................
Angular slide 0413 506 880................................................
9 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 desig-
nation and spare part number as shown in the spare parts list on page 191.
This will simplify dispatch and ensure you get the right part.
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10 WEAR COMPONENTS
Design. Order no. Wire Ø Type
1 Feed roller 369 557--001 0,6--0,8 Fe, Ss
Feed roller 369 557--002 0,8--1,0 Fe, Ss
Feed roller 369 557--003 1,0--1,2 Fe, Ss
Feed roller 369 557--007 1,2--1,6 Fe, Ss, Tube wire
Feed roller 369 557--004 1,0--1,2/1,4--1,6 T ube wire
Feed roller 369 557--005 1,4--1,6 (2,0--2,4) T ube wire
Feed roller 369 557--006 1,0--1,2 Al
Feed roller 369 557--008 1,6 Al
2 Pressure roller 369 728--001 Fe,Ss,Al,Tubewire
Pressure roller (knurled) 466 262--001 T ube wire
3 Adapter 367 907--013
4 Inlet nozzle 380 351--001
5 Adapter nozzle 455 072--001 Fe, Ss, Tube wire
Adapter nozzle 456 615--001 Al
6 Outlet nozzle 469 837--880 Fe, Ss, Al
Outlet nozzle 469 837--881 Al
7 Pinion 455 052--001
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