ESAB TAE → TAF User manual

Brand: ESAB

Model: TAE → TAF

Category: Welding System

Type: User manual

ESAB TAE → TAF conversion kit enables you to rebuild your existing TAE 800/1250 welding power source into a TAF 800/1250, making it compatible with ESAB's A2--A6 Process Controller (PEH). This conversion kit includes all the necessary components for a quick and efficient transformation. Once rebuilt, you'll have access to features like 0--10 V control, KM2 feedback, current shunt signal, and U+ and U-- contacts. Upgrade your welding setup and benefit from enhanced control and functionality with the ESAB TAE → TAF conversion kit.

0457 567 126 2004--04--16

TAE 800/1250 → TAF 800/1250

Conversion kit

104100

Monteringsanvisning Assembly instruction

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ENGLISH

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TOCe

1SAFETY 16...........................................................

2 INTRODUCTION 18...................................................

2.1 General 18..................................................................

2.2 Technical data 18............................................................

3 INSTALLATION 19....................................................

3.1 General 19..................................................................

3.2 Assembly instructions 19......................................................

3.3 Testing 23...................................................................

3.4 Connections 24..............................................................

4 OPERATION 26.......................................................

4.1 General 26..................................................................

5 ORDERING OF SPARE PARTS 26......................................

DIAGRAM 27............................................................

LIST OF COMPONENTS 28...............................................

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

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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 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.

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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 s tandards.

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.

PROTECT YOURSELF AND OTHERS!

WARNING

This product is intended for industrial use. In a domestic environment this

product may cause r adio interference. It is the user’s responsibility to take

adequate precautions.

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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 ESAB’s control box A2--A6 Process Controller (PEH).

For rational conversion all components necessary for the work are contained in the

conversion kit.

S Instruction manual for A2--A6 Process Controller (PEH), order no. 0443 745 xxx

2.2 Technical data

The conversion of the power sources r esults in the following divergencies with

regard to the technical data, compared to previously issued documentation.

S The Emergency stop has been removed

S 0--10 V steering in contact XS4

S Reconnection of KM2 to connection block X3

S Current shunt signal in contact XS4

S U+ , U-- contact XS4

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3 INSTALLATION

3.1 General

The installation must be executed by a professional.

WARNING

Rotating parts can cause injury, take great care.

3.2 Assembly instructions

3.2.1 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 re--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.

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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 control transformer befor e drilling new m ounting

holes.

10. Drill the holes according to the drilling diagram for the attachment of

S the fuse--bases (FU1)

S the e lectronics board (AP1)

S the contactor ( KM2)

11. Fit a new (AP1) circuit board with box on the plate, using the insulating washers

and self--tapping screws which form part o f 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. Mount the new terminal plate.

15. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate.

16. Connect a new cable stem according to the connection diagram.

17. Mount the cables for the control panel. Then connect the control panel to the

cable stem.

18. Remove (cut off) the conductor 077 between the board K45.3 and the collector

rail.

19. Only remount the RC filter fitted in the old power source.

20. Remove the old connection diagram on the inside of the cover plate.

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3.2.2 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) in the cable stem.

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 control transformer befor e drilling new m ounting

holes.

10. Drill the holes according to the drilling diagram for the attachment of

S the e lectronics board (AP1)

S the contactor ( KM2)

11. Fit a new (AP1) circuit board with box on the plate, using the insulating washers

and self--tapping screws which form part o f 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.

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14. Mount the new terminal plate.

15. Fit the 28--pole contact (XS4) and the discharging board on the terminal plate

and connect the discharge capacitor to earth.

16. Connect a new cable stem according to the connection diagram.

17. Re--use the conductors 034 and 035 for the connection to the control

transformer ( TC1).

18. Dismount the transformer (K76)

19. Connect (by soldering) the conductors in the cable stem to the two synchronising

transformers (TC2).

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.

-- 2 3 --

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3.3 Testing

1. Connect the welding power source to the mains.

2. Before switching on the welding power source, check that the power supply to

the board is 19 V.

3. Connect control box PEH to the 28--pole contact ( XS4) in the welding power

source by way of the control cable.

4. Switch on the power supply for the welding power source using the

rotary switch (QF) on the front panel.

5. Make sure the power supply is interrupted when the emergency stop (QS)is

activated.

6. Set the welding parameters over the PEH control box.

7. Start welding by pressing the START key.

8. Make sure the relay in the welding power source is activated when the welding

starts.

9. Check that different current and voltage values can be set from control box PEH.

10. Mount the protective shields after finished work.

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3.4 Connections

3.4.1 General

S The connection of the control box to the automatic welding machine is to be

done according to the A2--A6 Process Controller ( PEH) instruction manual.

3.4.2 Automatic weld ing machine (Submerged Arc Welding, SAW)

S Connect the control cable (4) between power source (3) and

control box 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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3.4.3 Automatic welding machine (Gas Metal Arc Welding, MIG/MAG)

S Connect control cable (4) between power source (3) and control box 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)onthe

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).

out

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4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on

page 16. 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 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 29.

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

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Komponentförteckning List of components

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compdok

C = Component designation in the circuit diagram

Denomination

TAE/TAF

800

TAE/TAF

1250

Remarks

AP1 (K70.1) Circuit board X X

AP2 Circuit board EMC--filter X X

C1 Capacitor X X

C2 Capacitor X X

C4 Capacitor X X

FU1 (K.35) Fuse X X

FU2 (K21.2) Fuse X X 20 A

HL1 Indicator lamp, white X X 42--48 V

HL2 Indicator lamp yellow X X 28 V

KM1 (K8) Contactor X X

KM2 Contactor X X

L1 Inductor X X

M1 Fan X X

QF (K6) Main switch (black) X X

R1 Power resistor X X

R2 Power resistor X X

R3 Power resistor X

RS1 (K18) Shunt X X

ST1 Thermal relay X X

TC1 Control transformer X X

TC2 Control transformer X

TM1 Transformer X X

V1 Thyristor X X

V2 Thyristor X X

V3 Thyristor X

V4 Thyristor X X

XS4 Burndy socket X X 28--pole

XT1 Connection block X X

XT2 Connection block X X

XT3 Connection block X X

XT4 Connection block X X

Z1, Z2 Contact protection X X

Z3, Z4 Contact protection X X

Reservdelsförteckning Spare parts list

-- 2 9 --

foe2spare

Conversion kit

Edition 2003--08--20

Ordering no. Denomination Notes

0456 797 880 TAE 800

0456 797 881 TAE 1250

Abbreviations used in the spare parts list:

C = Component designation in the circuit diagram

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f456797s

Item

no.

Qty

Ordering no.

TAE 800

Ordering no.

TAE 1250

Denomination Notes C

0456797880 0456797881 Conversion kit

1 0456531883 0456531883 Cable harness conversion kit TAF 800

2 1 0805586131 0805586131 Contactor KM2

3 1 0805586113 0805586113 Contact block

5 0456374882 0456374882 Cable set

6 1 0193260155 0193260155 Connector 7--pole AP1.H

7 1 0193260152 0193260152 Connector 4--pole

8 1 0193260150 0193260150 Connector 2--pole

9 1 0368544003 0368544003 Sleeve socket Burndy 28--pole XS4

10 0456 374 886

0456374880

0456 374 886

0456374880

Cable set

11 1 0193260154 0193260154 Connector 6--pole

12 1 0193260151 0193260151 Connector 3--pole

13 1 0486466880 0486466880 Circuit board, insulation card

14 0456322882 0456322883 Front panel, complete

15 1 0320746002 0320746001 Main switch QF

16 1 0192576004 0192576004 Indicating lamp white 42--48 V HL1

17 1 0192576303 0192576303 Indicating lamp yellow 28 V HL2

18 2 0567200610 0567200610 Fuse 16 A 500 V FU1

19 1 0193586104 0193586104 Automatic fuse 20 A FU2

20 1 0486376880 0486376880 Circuit board AP1

21 1 0486178880 0486178880 Circuit board EMC--filter AP2

22 1 0442849880 0442849881 Contactor KM1

23 1 0319470016 0319470016 Control, transformer 42 V 900 V A TC1

24 2 0319828001 0319828001 Transformer TC2

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Phone +46 584 81 000

www.esab.com

031021

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ESAB TAE → TAF User manual

Brand: ESAB

Model: TAE → TAF

Category: Welding System

Type: User manual

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