ESAB A2 / A6 SAW SINGEL → TWIN User manual

Brand: ESAB

Model: A2 / A6 SAW SINGEL → TWIN

Category: Welding System

Type: User manual

The ESAB A2 / A6 SAW SINGEL → TWIN is a versatile welding machine capable of converting A2/A6 SAW welding heads or tractors from single wire to twin wire welding with the use of a conversion kit. It offers precise control over the welding process, allowing for efficient and high-quality welds. The system's adaptability makes it suitable for a variety of welding applications.

Valid for Serial NO 740 XXX--XXXX0456 757 001 2001--03--09

A2/A6 SAW

Single → Twin

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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 11................................................

NORSK 19................................................

SUOMI 27................................................

ENGLISH 35..............................................

DEUTSCH 43.............................................

FRANÇAIS 51.............................................

NEDERLANDS 59.........................................

ESPAÑOL 67..............................................

ITALIANO 75..............................................

PORTUGUÊS 83..........................................

ÅËËÇÍÉÊÁ 92.............................................

ENGLISH

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TOCe

1 DIRECTIVE 36........................................................

2SAFETY 36...........................................................

3 INTRODUCTION 37...................................................

3.1 General 37..................................................................

3.2 Technical data 37............................................................

4 INSTALLATION 37....................................................

4.1 General 37..................................................................

4.2 Assembly instructions -- Heavy Duty A6 38......................................

4.3 Assembly instructions -- Light Duty A6 39........................................

4.4 Assembly instructions -- Light Duty A2 40........................................

4.5 Connections 41..............................................................

5 OPERATION 42.......................................................

5.1 General 42..................................................................

6 ORDERING OF SPARE PARTS 42......................................

SPARE PARTS LIST 101...................................................

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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 Single→Twin 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 re-

quirements of directive 89/336/ EEA and addendum 93/68/ EEA .

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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 98--02--16

2SAFETY

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 recommen-

dations 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

2. 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

3. The work place must:

S be suitable for the purpose

S be free from draughts

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, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S W ork 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.

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3 INTRODUCTION

3.1 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 contr o l

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 A6 TFE1 A2 TFE1

UP UP UP

LD D20 HD D35 LD D20

Permissible load 100 %

60 %

800 A

1000 A

AC/DC

1500 A

AC/DC

800 A

AC/DC

Wire dimensions:

twin wires 2x1.2--2.0 mm 2x2.0--3.0mm 2x1.2--2.0 mm

Wire feed speed 0.2--4.0 m/min 0.2--4.0 m/min 0.2--9.0 m/min

Brake hub braking torque 1.5 Nm 1.5 Nm 1.5 Nm

Max. weight of wire 2x30 kg 2x30 kg 2x30 kg

Flux hopper capacity

(must not be filled with preheated flux)

10 l 10 l 6l

Weight (without flux and wire) 50 kg 50 kg 50 kg

Lateral inclination, max. 25_ 25_ 25_

Setting length of the slide *

hand--operated

motor--driven (ball bushings)

210 mm

300 mm

210 mm

300 mm

90 mm

Continuously A--weighted noise pressure 68 dB 68 dB

*) NB. Other lengths can be supplied.

4 INSTALLATION

4.1 General

The in stallatio n shall b e executed b y a professional.

WARNING!

Rotating parts can cause injury, take great care.

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4.2 Assembly instructions -- Heavy Duty A6

For the change of welding m ethod from single wire to twin wires, follow the

instructions below.

S To loosen the contact jaws, draw the wire out of the wire straightener (1).

S Stop the flux flow by closing the flux valve .

S Loosen the flux tube (2) and dismount the flux nozzle with an Allen key.

S Dismount the existing SAW contact device.

S Undo the four screws on the contact jaws and remove the jaws.

S 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).

S Tighten up the screws to achieve good contact between the jaws and the contact

device.

S To exchange feed roller (10) for a roller with twin grooves (not contained in the

conversion kit), r elease the knobs (7) and (8) and the hand wheel (9).

S Change to a pressure roller with spherical bearing (11) for twin wires.

S Mount the plate with two wire liners (12).

S Fit an extra reel holder.

S Fit the brake hub and the bobbin on the outside of the reel holder.

S Lead the wires down through the contact tip to the wire feed unit. NB. The wires

must not be crossed in the contact device!

S Re--mount the flux nozzle and fit the flux tube.

S Open the flux valve.

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4.3 Assembly instructions -- Light Duty A6

For the change of welding m ethod from single wire to twin wires, follow the

instructions below.

S Stop the flux flow by closing the flux valve .

S Loosen the flux tube (1) and dismount the flux nozzle.

S Dismount the contact jaws and the loose half of the contact device.

S Keep the Heavy Duty guide tubes and fit guide tubes for Light Duty inside the

Heavy Duty tubes.

S Exchange pressure roller (2) for a pressure roller with spherical bearing.

S Assemble the fine wire straightener (3) with two guide tubes (4) for twin wires <

1.6 mm.

S Fit an extra reel holder.

S Fit the brake hub and the bobbin on the outside of the reel holder.

S Fit contact device D35 (5).

S 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).

S 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.

S Tighten the contact tips with a key to ensure that a good contact is achieved..

S If necessary, cut the guide tubes to length so that the feed roller runs freely..

S Re--mount the flux nozzle and fit the flux tube.

S Open the flux valve.

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4.4 Assembly instructions -- Light Duty A2

For the change of welding m ethod from single wire to twin wires, follow the

instructions below.

S Stop the flux flow by closing the flux valve .

S Loosen the flux tube (1) and dismount the flux nozzle with an Allen key.

S Keep the Heavy Duty guide tubes and fit guide tubes for Light Duty inside the

Heavy Duty tubes.

S For twin wires < 1.6 mm a guide spiral, inserted into each guide tube, is used to

help straightening the wire.

S Dismount the e xisting SAW contact device and the clamp (9).

S Fit fine wire straightener (3) with two guide tubes (4).

S Exchange the pressure roller (2) for a pressure roller with spherical bearing.

S Fit an extra reel holder.

S Fit the brake hub, the support and the bobbin on the outside of the reel holder.

S Assemble the contact device D35 (5) with twin adapter (6) the two contact tips

(7) and the clamp.

S 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).

S 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.

S Tighten up the contact tips with a key to achieve good contact.

S If necessary, cut the guide tubes to length so that the feed roller runs freely.

S Re--mount the supplied flux nozzle and fit the flux tube.

S Open the flux valve.

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4.5 Connections

A2/A6

Electrical con n ectio ns to the A2--A6 Pro cess Con troller

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).

Adjustments in t h e A2--A6 Process Con t roller

S Go to the submenu PRESET WELDING and select WIRE DATA.

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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5 OPERATION

5.1 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.

6 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 101.

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

ESAB A2 / A6 SAW SINGEL → TWIN User manual

Brand: ESAB

Model: A2 / A6 SAW SINGEL → TWIN

Category: Welding System

Type: User manual

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ESAB A2 / A6 SAW SINGEL → TWIN User manual

ESAB A2 / A6 SAW SINGEL → TWIN User manual

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