ESAB Conversion kit A2 / A6 SAW SINGEL → TWIN User manual
- Category
- Welding System
- Type
- User manual
GB
0456 757 101 GB 2007--12--13
Conversion kit
A2/A6 SAW Single
→
Twin
Instruction manual
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TOCe
Rights reserved to al ter specifications without notice.
1SAFETY 3...........................................................
2 INTRODUCTION 5...................................................
2.1 General 5..................................................................
2.2 Technical data 5............................................................
3 INSTALLATION 6....................................................
3.1 General 6..................................................................
3.2 Assembly instructions A6 (D20) 7.............................................
3.3 Assembly instructions A6 (D35) 8.............................................
3.4 Assembly instructions A2 (D20) 9.............................................
3.5 Connections 10..............................................................
4 OPERATION 11.......................................................
4.1 General 11..................................................................
5 ORDERING OF SPARE PARTS 11......................................
SPARE PARTS LIST 13...................................................
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SafE
1SAFETY
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 workplace.
All work must be carried out by trained personnel well--acquainted 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 unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace 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 Work on high voltage equipment may 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.
GB
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SafE
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 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!
These conversion kits (0413 541 881 and 0809 934 882) are no machines.
The components are intended for replacement of parts in existing machines of
type A2 SFE/ A6 SFE and A2 TFE/ A6 TFE.
GB
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2 INTRODUCTION
2.1 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 adjustm ents 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 contr ol system.
2.2 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
1000 A
AC/DC
Wire dimensions:
twin wires 2x1.6--2.5 mm 2x2.0--3.0mm 2x1.2--2.5 mm
Wire feed speed 0.2--8.0 m/min 0.2--4.0 m/min 0.2--9.0 m/min
GB
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3 INSTALLATION
3.1 General
The installation must b e executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
GB
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3.2 Assembly instructions A6 (D20)
Order number 0413541881.
Follow the instructions below when converting the welding head A6 (D20) from
single to double wire design (twin).
S Dismount the flux nozzle ( 4) from the contact device ( 1 ).
S Dismount the contact device D20 from the welding head, and fit contact device
D35 instead.
S Fit contact jaws for twin wire (not included in the conversion kit). M ake sure that
good contact is obtained between the contact jaws and the contact device (1).
S Loosen the hand wheels (5, 7) for the pressure roller and the feed roller.
S Remove the pressure roller (2), and fit the spherical pressure roller instead.
S Replace the feed roller (3) by a feed roller with two grooves for twin wire (not in-
cluded in the conversion kit).
S Remove the straightening roller ( 8 ) with associated arm (6).
S Dismount the support roller (14) fitted on the lower part of the wire feed unit, and
fit the guide tube clamp ( 9) instead.
S Adjust the length of the guide tubes (10) to fit in between the upper edge of the
contact jaws and the lower edge of the feed roller. Make sure the feed roller (3)
runs freely.
S Fit the fine--wire straightener (11) and adjust the length of the wire conduit (13).
S Fit the brake hub (12) on the outside of the wire r eel holder.
S Fit the flux nozzle (4) on the contact device (1).
GB
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3.3 Assembly instructions A6 (D35)
Order number 0809934882.
Follow the instructions below when converting the welding head A6 (D35) from
single to double wire design (twin).
S Dismount the flux nozzle ( 4) from the contact device ( 1 ).
S Dismount existing contact jaws.
S Fit contact jaws for twin wire (not included in the conversion kit). M ake sure that
good contact is obtained between the contact jaws and the contact device (1).
S Loosen the hand wheels (5, 7) for the pressure roller and the feed roller.
S Remove the pressure roller (2), and fit the spherical pressure roller instead.
S Replace the feed roller (3) by a feed roller with two grooves for twin wire (not in-
cluded in the conversion kit).
S Remove the straightening roller ( 8 ) with associated arm (6).
S Dismount the support roller (14) fitted on the lower part of the wire feed unit, and
fit the guide tube clamp ( 9) instead.
S Adjust the length of the guide tubes (10) to fit in between the upper edge of the
contact jaws and the lower edge of the feed roller. Make sure the feed roller (3)
runs freely.
S Fit the fine--wire straightener (11) and adjust the length of the wire conduit (13).
S Fit the brake hub (12) on the outside of the wire r eel holder.
S Fit the flux nozzle (4) on the contact device (1).
GB
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3.4 Assembly instructions A2 (D20)
Order number 0413541881.
Follow the instructions below when converting the welding head A6 (D20) from
single to double wire design (twin).
S Dismount the flux nozzle ( 4) from the contact device ( 1 ).
S Dismount the contact device D20 from the welding head, and fit contact device
D35 instead.
S Fit contact tips for twin wire (not included in the conversion kit).
S Loosen the hand wheels (5, 7) for the pressure roller and the feed roller.
S Remove the pressure roller (2), and fit the spherical pressure roller instead.
S Replace the feed roller (3) by a feed roller with two grooves for twin wire (not in-
cluded in the conversion kit).
S Remove the straightening roller ( 8 ) with associated arm (6).
S Dismount the support roller (14) fitted on the lower part of the wire feed unit, and
fit the guide tube clamp ( 9) instead.
S Adjust the length of the guide tubes (10) to fit in between the nozzle holder
and the lower edge of the feed roller. Make sure the feed roller (3) runs freely.
S Fit the fine--wire straightener (11) and adjust the length of the wire conduit (13).
S Fit the brake hub (12) on the outside of the wire r eel holder.
S Fit the flux nozzle (4) on the contact device (1).
GB
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3.5 Connections
A2/A6
Electrical conn ectio n s to the A2--A6 Process Controller
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 th e A2--A6 Process Controller
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 xxx for
A2--A6 Process Controler.
GB
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4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING
Rotating parts can cause injury, take great care.
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 13.
This will simplify dispatch and ensure you get the right part.
GB
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sida
Spare p arts list
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sparefram
Edition 2007--01--22
Ordering no. Denomination Notes
0413541881 Conversion kit A6 (D20) / A2 (D20)
0809934882 Conversion kit A6 (D35)
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f413541s
Item
no.
Qty Ordering no. Denomination Notes
0413541881 Conversion kit A6 (D20) / A2 (D20)
1 1 0333852881 Conatct device, Twin L=275
2 1 0156530001 Clamp half D35
3 1 0156531001 Clamp half D35
12 1 0146967880 Brake hub
13 1 0218524580 Pressure roller, T win
15 2 0156800002 Wire liner D8/4
17 1 0153299880 Flux nozzle
19 1 0145787880 Fine wire straightener
A2 (D20)
A6 (D20)
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f333852s
Item
no.
Qty Ordering no. Denomination Notes
333 852--881 Contact device, twin Tw in L=275 A6 UP
2 1 333 772--001 Nozzle holder
7 1 417 959--881 Contact equipment L=275
8 2 415 032--001 Guide pipe
9 2 334 279--001 Spiral to connector L=366
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f417959s
Item
no.
Qty Ordering no. Denomination Notes
0417959881 Contact equipment L=275mm
4 1 0443372001 Fitting bolt
5 4 0219504307 Beleville washer d20/10.2
6 1 0417979001 Ring
8 1 0443344881 Contact device D35
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f153299s
Item
no.
Qty Ordering no. Denomination Notes
0153299880 Flux nozzle
1 1 0153290002 Pipe holder
2 1 0153296001 Pipe bend
3 1 0153425001 Wheel
-- 1 8 --
f809934s
Item
no.
Qty Ordering no. Denomination Notes
0809934882 Conversion kit A6 (D35)
1 1 0218524580 Pressure roller, T win
2 1 0146967880 Brake hub
3 2 0156800002 Wire liner
8 1 0334278890 Guide insert single --twin
9 1 0145787880 Fine wire straightener
13 1 0155300001 Plate
14 2 0192238449 Screw M8x16
-- 1 9 --
f334278s
Item
no.
Qty Ordering no. Denomination Notes
0334278890 Guide Insert single--twin
2 1 0218518201 Clamp
3 2 0415032002 Guide tube L=750 mm
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f145787s
Item
no.
Qty Ordering no. Denomination Notes
0145787880 Fine wire straightener for twin wire
1 1 0145788001 Case
2 2 0145789001 Roller
3 2 0145790001 Roller
4 2 0145791001 Searing bushing
5 2 0190240103 Bearing bushing D12/10
9 2 0145793001 Runner
11 2 0145794001 Knob
13 1 0145795001 Link
15 1 0151287001 Hose L=600
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ESAB Conversion kit A2 / A6 SAW SINGEL → TWIN User manual
- Category
- Welding System
- Type
- User manual
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