ESAB A2 / A6 SAW → MIG/MAG welding conversion kit enables users to convert their existing SAW welding head or tractor to MIG/MAG welding. With permissible load of 600A AC/DC and wire dimensions ranging from 0.8-2.5mm for solid single wire and 1.2-3.2mm for flux cored wire, this conversion kit is suitable for a variety of welding applications. It features adjustable wire feed speed from 0.2-15m/min, a 1.5Nm brake hub braking torque, and can handle a maximum wire weight of 30kg.
ESAB A2 / A6 SAW → MIG/MAG welding conversion kit enables users to convert their existing SAW welding head or tractor to MIG/MAG welding. With permissible load of 600A AC/DC and wire dimensions ranging from 0.8-2.5mm for solid single wire and 1.2-3.2mm for flux cored wire, this conversion kit is suitable for a variety of welding applications. It features adjustable wire feed speed from 0.2-15m/min, a 1.5Nm brake hub braking torque, and can handle a maximum wire weight of 30kg.
Valid from Serial NO 740 XXX--XXXX0456 756 001 2001--03--09
A2/A6
SAW → MIG/MAG
101103105107109111102021110025108024042106023061104022041100020040060001
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 ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner 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 especifi caciones sin previo aviso.
Specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
SVENSKA 3..............................................
DANSK 9................................................
NORSK 15................................................
SUOMI 21................................................
ENGLISH 27..............................................
DEUTSCH 33.............................................
FRANÇAIS 39.............................................
NEDERLANDS 46.........................................
ESPAÑOL 53..............................................
ITALIANO 59..............................................
PORTUGUÊS 65..........................................
ÅËËÇÍÉÊÁ 72.............................................
ENGLISH
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TOCe
1 DIRECTIVE 28........................................................
2SAFETY 28...........................................................
3 INTRODUCTION 29...................................................
3.1 General 29..................................................................
3.2 Technical data 29............................................................
4 INSTALLATION 29....................................................
4.1 General 29..................................................................
4.2 Mounting instructions 30......................................................
4.3 Connections 31..............................................................
5 OPERATION 32.......................................................
5.1 General 32..................................................................
6 ORDERING OF SPARE PARTS 32......................................
SPARE PARTS LIST 75...................................................
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1 DIRECTIVE
DECLARATI ON OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that automatic welding machine A2/A6 SAW → MIG/MAG from serial number 740
complies with standard EN 60292, in accordance with the requirements of directive
(89/392/EEA) and addendum.
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 97--09--29
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
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3 INTRODUCTION
3.1 General
By way of the conversion kit an A2 SFE / A6 SFE welding head or an A2 TFE / A6 TFE
tractor can be converted from SAW to MIG/MAG welding.
All parts necessary for the conversion of the welding head are included in the kit.
Before using the system for MIG/MAG welding, cooling water and shielding gas must
be connected to the welding head, and some adjustments must be m ade in the control
system as well.
Instructions regarding these adjustments can be found in the instruction and service
manuals for the A2--A6 Process Controller.
3.2 Technical data
A2 SGE1 / A6 SGE1
MIG/MAG
Permissible load 100% 600 A AC/DC
Wire dimensions:
solid single wire
flux cored wire
0.8--2.5 mm
1.2--3.2 mm
Wire feed speed 0.2--15 m/min
Brake hub braking torque 1.5 Nm
Max. weight of wire 30 kg
Weight (without wire) 15 kg
Max. tilt sideways 25_
Slide, setting length *
hand--operated
motor--driven (journalled in ball bearings)
210 mm
300 mm
Continuous A--weighted noise pressure 68 dB
*) N.B. Other lengths on request.
4 INSTALLATION
4.1 General
The installation shall be e xecuted by authorized personnel.
WARNING!
Rotating parts can cause injury, take great care.
GB
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4.2 Mounting instructions
Before conversion After conversion
S Dismount the motor (1), contact equipment (2), flux hopper (3) and flux tube (4).
S Dismount the lower straightening roller (5).
S Dismount the motor (6), intended for M IG/MAG welding.
S Fit the guide tube (7) using clamp (8) and an M12 screw in the hole ( 9) where
the lower straightening roller was fitted previously.
S Fit the contact device (10) using clamp (12) with two M8 screws (11) against the
straightener (13).
For welding with fine wire a fine--wire straightener (14) is fitted on top of the
straightener (13) and a guide spiral is inserted into the guide tube (7).
S Fit a solenoid valve for shielding gas on the arm (A2T) using a mounting plate
and two screws, or on the motor with gear (A6S and A6T).
As to A2S the solenoid valve is fitted on a suitable place.
S Connect the cooling water hoses and the gas hose by way of hose clamps to the
MIG/MAG contact device and to the solenoid valve supplied. See figure on page
31.
GB
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4.3 Connections
A2
A6
Electrical connectio n s to the A2--A6 Process Cont roller
S Connect the gas solenoid valve to terminal K12.
S Connect the shielding gas flow guard to terminal K23. (Not included in the con-
version kit.)
S Connect the water flow guard to terminal K22. (Not included in the conversion
kit.)
Check that the arc voltage cable is connected to the clamp of the contact device and
to the A2 --A6 Process Controller (connection block X2).
GB
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Settings, A2--A6 Process Controller
S Product code Select A2TG, A6TG, A2SG or A6SG.
S Welding process Select MIG/MAG
S Gas preflow Indicate the desired time in seconds.
S Gas postflow Indicate the desired time in seconds.
Detailed instructions regarding the A2--A6 Process Controller settings can b e found
in the service manual.
Instructions for PEG 1, see instruction m anual 0443 392 xxx.
5 OPERATION
5.1 General
General safety regulations for the handling of the equipment appear from page 28.
Read through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
6 ORDERING OF SPARE PARTS
When ordering spare parts, please state the machine number and number of the
spare part as shown in the spare parts list on page 75.
This will facilitate our service and ensure you get the right parts.
GB
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ESAB A2 / A6 SAW → MIG/MAG welding conversion kit enables users to convert their existing SAW welding head or tractor to MIG/MAG welding. With permissible load of 600A AC/DC and wire dimensions ranging from 0.8-2.5mm for solid single wire and 1.2-3.2mm for flux cored wire, this conversion kit is suitable for a variety of welding applications. It features adjustable wire feed speed from 0.2-15m/min, a 1.5Nm brake hub braking torque, and can handle a maximum wire weight of 30kg.
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