ESAB TAE → TAF conversion kit enables you to upgrade your TAE 800/1250 welding power source to resemble TAF 800/1250, making it compatible with the A2--A6 Process Controller (PEH) control box. Experience enhanced welding capabilities and seamless integration with your existing equipment.
ESAB TAE → TAF conversion kit enables you to upgrade your TAE 800/1250 welding power source to resemble TAF 800/1250, making it compatible with the A2--A6 Process Controller (PEH) control box. Experience enhanced welding capabilities and seamless integration with your existing equipment.
0457 567 026 2002--06--1 1
TAE 800/1250 → TAF 800/1250
Conversion kit
104100
Monteringsanvisning Assembly instruction
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Rätt till ändring av specifikationer utan avisering förbehålles.
Rights reserved to alter specifications without notice.
SVENSKA 3..............................................
ENGLISH 14..............................................
ENGLISH
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TOCe
1SAFETY 15...........................................................
2 INTRODUCTION 17...................................................
2.1 General 17..................................................................
2.2 Technical data 17............................................................
3 INSTALLATION 18....................................................
3.1 General 18..................................................................
3.2 Assembly instructions 18......................................................
3.3 Testing 21...................................................................
3.4 Connections 22..............................................................
4 OPERATION 24.......................................................
4.1 General 24..................................................................
5 ORDERING OF SPARE PARTS 24......................................
LIST OF COMPONENTS 25...............................................
DIAGRAM 26............................................................
SPARE PARTS LIST 27...................................................
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foe2safe
1SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevan t safety precautions.
The following recommendations should be observed in a ddition 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
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS 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 y our 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 y our ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
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 r esponsibility to take
adequate precautions.
GB
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2 INTRODUCTION
2.1 General
The welding power sources TAE 800/1250 (adapted to fit control equipment PEG 1)
can be converted to resemble TAF 800/ 1250 by way of a conversion kit, and by that
be adapted to fit the control box A2--A6 Process Controller (PEH).
For rational conversion all components necessary for the work are contained in the
conversion kit.
2.2 Technical data
The conversion of the power sources does not result in any divergencies with regard
to the technical data, compared to previously issued documentation.
See instruction manual for welding power source TAF 800/1250
(order no. 0456 513 xxx).
GB
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3 INSTALLATION
3.1 General
The installation must be execu ted by a professional.
3.2 Assembly instructions
Follow the instructions below for th e conversion of TAE 800:
1. Dismount the cable stem, excluding the
cables 034 and 035 for the power supply of the
control transformer.
2. Dismount all electronics boards and their fittings.
3. Dismount the control panel.
4. Remove the support with the attached fuse--bases.
5. Remove the lower fuse (K21.2 = fuse for 42 V AC
from the control transformer K9).
The other two fuses are to be r e--used together
with the rubber spacers, but fitted elsewhere in
the power source.
6. Remove the multi--pole contact devices on the
bottom plate and cover the holes by way of two
plastic plugs from the kit.
7. Remove the signs (a sticker and a screwed sign
marked 42 V) from the bottom plate.
8. Dismount the terminal block on the control
transformer.
9. Cover the contactor and the contr ol transformer before drilling new mounting
holes.
10. Drill the holes according to the drilling diagram for the attachment of
S the fuse--bases (FU1)
S the electronics board ( AP1)
S the contactor (KM2)
S the discharging board with the 12--pole contact device (XS4).
11. Fit a new ( AP1) circuit board with box on the plate, using the insulating washers
and self--tapping screws which form part of the conversion kit.
12. Connect the discharge capacitor to earth.
13. Set the two DIP switches (SW1 and SW2) on the board according to the
instructions in the TAF manual.
14. Fit the 12--pole contact (XS4) and the discharging board on the medium plate.
15. Connect a new cable stem according to the connection diagram.
16. Mount the cables for the emergency stop on the control panel. T hen connect the
control panel to the cable stem.
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17. Remove (cut off) the conductor 077 between the board K45.3 and the collector
rail.
18. Only remount the RC filter fitted in the old power source.
19. Remove the old connection diagram on the inside of the cover plate.
GB
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Follow the instructions below for th e conversion of TAE 1250:
1. Dismount the cable stem, excluding the
cables 034 and 035 (for the connection to the
control transformer).
2. Cut off the connection to the synchronising
transformers (cables marked 001, 002, 003)
inthecablestem.
3. Dismount all electronics boards and their fittings.
4. Dismount the control panel.
5. Remove the fuse holder K21.2 fitted above the
control transformer to the right. The lower fuse
(K21.2 = fuse for 42 V AC from the control
transformer K9) is replaced by an automatic
fuse on the new control panel.
6. Remove the multi--pole contact devices on the
bottom plate and cover the holes by way of two
plastic plugs from the kit.
7. Remove the signs (a sticker and a screwed sign
marked 42 V) from the bottom plate.
8. Dismount the terminal block on the control transformer.
9. Cover the contactor and the contr ol transformer before drilling new mounting holes.
10. Drill the holes according to the drilling diagram for the attachment of
S the electronics board ( AP1)
S the contactor (KM2)
S the discharging board with the 12--pole contact device (XS4).
11. Fit a new (AP1) circuit board with box on the plate, using the insulating washers
and self--tapping screws which form part of the conversion kit.
12. Connect the discharge capacitor to earth.
13. Set the two DIP switches (SW1 and SW2) on the board according to the
instructions in the TAF manual.
14. Fit the 12--pole contact (XS4) and the discharging board on the medium plate
and connect the discharge capacitor to earth.
15. Connect a new cable stem according to the connection diagram.
16. Re--use the conductors 034 and 035 for the connection to the control
transformer (TC1).
17. Connect (by soldering) the conductors 001, 002 and 003 in the cable stem to the
three synchronising transformers ( TC2).
18. Mount the cables for the emergency stop on the control panel. T hen connect the
control panel to the cable stem.
19. Remove (cut off) the conductor 077 between the board K45.3 and the collector
rail.
20. Only remount the RC filter fitted in the old power source.
21. Remove the old connection diagram on the inside of the cover plate.
GB
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3.3 Testing
S Connect the welding power source to the mains.
S Before switching on the welding power source, check that the power supply to
the board is 19 V.
S Connect the PEH control box to the 12--pole contact (XS4) in the welding power
source by way of the control cable.
S Switch on the power supply for the welding power source using the
rotary switch (QF) on the front panel.
S Make sure the power supply is interrupted when the emergency stop (QS)is
activated.
S Set the welding parameters over the PEH control box.
S Start welding by pressing the START key.
S Make sure the r elay in the welding power source is activated when the welding
starts.
S Check that different current and voltage values can be set over the PEH control
box.
S Mount the protective shields after finished work.
GB
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3.4 Connections
S The connection of the control box to the automatic welding machine is to be
done according to the instruction m anual for control box PEH
(order no. 0443 745 xxx).
S T h e welding machine is connected according to the following figures.
Submerged arc welding (SAW)
S Connect the control cable (4) between power source (3) and control box A2--A6
Process Controller (PEH) (2).
S Connect return cable (7) between power source (3) and workpiece (8).
S Connect welding cable (6) between power source (3) and welding machine (1).
S Connect measuring cable (5) between power source (3) and workpiece (8).
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GB
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Gas metal arc weld ing (MIG/MAG)
S Connect control cable (4) between power source (3) and control box
A2--A6 Process Controller (PEH) (2).
S Connect return cable (7) between power source (3) and workpiece (8).
S Connect welding cable (6) between power source (3) and welding machine (1).
S Connect gas hose (9) between reducing valve (10) and gas valve (11) on the
welding machine.
S Connect the cooling water hoses (12) between cooling unit (13) and welding
machine (1).
S Connect measuring cable (5) between power source (3) and workpiece (8).
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in
out
GB
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4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 15. Read through before you start using the equipment!
Caution:
Have you read and understood the safety information ?
You must not operate the machine beforehand !
For more information read the instruction manual for control box PEH
(order no. 0443 745 xxx) and the instruction manual for welding power source
TAF 800/1250 (order no. 0456 513 xxx).
5 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 27.
This will simplify dispatch and ensure you get the right part.
GB
ESAB AB
SE--695 81 L AXÅ
SWEDEN
Phone +46 584 81 000
Fax + 46 584 123 08
www.esab.com
020314
ESAB subsidiaries and representative offices
Europe
AUSTRIA
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Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
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Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
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Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
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Tel:+4536300111
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Tel: +49 212 298 0
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Tel: +44 1992 76 85 15
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AS ESAB
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Tel: +351 1 837 1527
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Tel:+421744882426
Fax:+421744888741
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Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
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ESAB Sverige AB
Gothenburg
Tel:+4631509500
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Tel:+4631509000
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Contagem-- MG
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Tel: +1 843 669 44 11
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AUSTRALIA
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Tel: +61 2 9647 1232
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Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
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Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
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Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
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Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
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Tel: +65 861 43 22
Fax: +65 861 31 95
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Tel: +65 861 74 42
Fax: +65 863 08 39
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Representative offices
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ESAB Representative Of fice
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Tel/Fax: +40 1 322 36 74
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ESAB Representative Of fice
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Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Of fice
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Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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ESAB TAE → TAF conversion kit enables you to upgrade your TAE 800/1250 welding power source to resemble TAF 800/1250, making it compatible with the A2--A6 Process Controller (PEH) control box. Experience enhanced welding capabilities and seamless integration with your existing equipment.
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