A2 Tractoras

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Valid for serial no. 136--xxx--xxxx 0449 165 001 2005--09--06

A2 Automaticwelding machines A2 TF/ A2 TF (Twin)/ A2 TG/ A2 TG 4WD

101103105107109111102021110025108024042106023061104022041100020040060001

BruksanvisningBrugsanvisningBruksanvisningKäyttöohjeetInstruction manualBetriebsanweisung

Manuel d’instructionsGebruiksaanwijzingInstrucciones de usoIstruzioni per l’usoManual de instruçõesÏäçãßåò ÷ñÞóåùò



-- 2 --

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 especificaciones sin previo 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 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NORSK 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUOMI 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGLISH 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEUTSCH 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRANÇAIS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEDERLANDS 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESPAÑOL 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ITALIANO 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PORTUGUÊS 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ÅËËÇÍÉÊÁ 234. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



ENGLISH

-- 87 --TOCe

1 DIRECTIVE 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 SAFETY 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 General 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Welding Method 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Definitions 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Technical data 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Main components A2 TF (SAW) 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 Main Components A2 TG, A2 TG 4WD (MIG/MAG) 92. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 Description of Main Components 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Mounting 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Adjusting the brake hub 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Connections 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 General 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Loading the welding wire (A2 TF, A2 TG) 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Loading the welding wire (A2 TG 4WD) 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Changing the feed roller (A2 TF, A2 TG) 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Changing the feed rollers (A2 TG 4WD) 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 Contact equipment for Submerged arc welding 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7 Contact equipment for MIG/MAG welding 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8 Refilling with flux powder (Submerged arc welding) 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 Transportation of the Automatic Welding Machine 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10 Conversion of A2 TF (Submerged--arc) to MIG/MAG welding 105. . . . . . . . . . . . . . . . . . . .5.11 Conversion of A2 TF (submerged--arc welding) to Twin--arc 105. . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 General 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Daily 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Periodic 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 TROUBLESHOOTING 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 General 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 POSSIBLE FAULTS 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIMENSION DRAWING 255. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 257. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



-- 88 --fha9safe

1 DIRECTIVE

DECLARATION OF CONFORMITY Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreservedguarantee that welding equipment A2 TF/ A2 TG / A2 TG 4WD from serial number

136 complies withstandard EN 60292 and EN 60204, in accordance with the requirements of directive(89/392/EEC) and addendum (93/68/EEC).--------------------------------------------------------------------------------------------------------------------------------------

Göran PalmqvistDesign Manager, Automation & EngineeringESAB AB, Welding Automation

695 81 LAXÅSWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

Laxå 2001--11--23

2 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safety precautionsmust 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 weldingequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS 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 struck3. The workplace must:

S be suitable for the purposeS be free from draughts

4. Personal safety equipmentS 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 precautionsS 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



-- 89 --fha9safe

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 BEBASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can killS 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 healthS 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 HAZARDS Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearingS 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!

GB



-- 90 --fha9d1ea

3 INTRODUCTION

3.1 General

The A2 TF automatic welding machine is designed for Submerged Arc Welding ofbutt and fillet joints.

The A2 TG/ A2 TG 4WD automatic welding machines are designed for MIG/MAGwelding of butt and fillet joints.

All other applications are prohibited.

They are intended for use in combination with A2--A6 Process Controller ( PEH ) andESAB’s welding power sources LAF or TAF .

3.2 Welding Method

3.2.1 Submerged Arc Welding (SAW)

For submerged arc welding the A2 TF automatic welding machine is always to beused.

S Submerged arc Light Duty.

Submerged arc light duty with a Ø 20 mm connector permits a load up to 800 A(100%).

This version can be equipped with feed rollers for single or twin wire welding

(twin--arc). A special knurled feed roller is available for flux--cored wire, whichguarantees even wire feed without the risk of deformation due to high feed pressure.

3.2.2 MIG/MAG Welding

For MIG/MAG welding use either automatic welding machine A2 TG or A2 TG 4WD(the A2 TG 4WD consists of a four wheel drive wire feed unit).

In MIG/MAG welding the welding bead is shielded by way of shielding gas.

The welding head is water--cooled. The cooling water is supplied by hoses from

connections intended for the purpose.

3.3 Definitions

SAW welding The weld bead is protected by a cover of flux during thewelding.

SAW Light duty Permits welding with lower current load and thin wire.

MIG/MAG welding The weld bead is protected by shielding gas during

welding.Twin--arc welding Welding with two wires in one welding head.

GB



-- 91 --fha9d1ea

3.4 Technical data

3.4.1 A2 TF and A2 TG

A2 TF (UP) A2 TG (MIG/MAG)

Supply voltage 42 V AC 42 V ACPermissible load at 100 %: 800 A DC 600 A DC

Wire dimensions:

solid single wire 1.6--4.0 mm 0.8--2.5 mm

hollow wire

twin wire

1.6--4.0 mm

2x1.2--2.0 mm

1.2--3.2 mm

----

Wire feed speed, max 9 m/min 16 m/min

Brake hub braking torque 1.5 Nm 1.5 Nm

Travel speed 0.1--2.0 m/min 0.1--2.0 m/min

Turning radius for circumferential welding, min 1500 mm 1500 mm

Pipe diameter for internal joint welding, min 1100 mm 1100 mm

Max. weight of wire 30 kg 30 kg

Flux container volume(Not to be filled with preheated flux) 6 l ----

Weight (excl. wire and flux) 46 kg 46 kg

Max. lateral inclination (whole unit) 25_ 25_

3.4.2 A2 TG 4WD

A2 TG 4WD (MIG/MAG)

Type of gas: Mix/Ar CO2

Supply voltage 42 V AC 42 V AC

Permissible load at 100 %: 600 A DC 650 A DC

Wire dimensions:

Non--alloy / Low--alloyStainless steel

Cored wire Aluminium

1.0--1.6 mm1.0--1.6 mm

1.0--2.4 mm1.0 -- 2.0 mm

1.0--1.6 mm

1.0--2.4 mm

Wire feed speed, max 25 m/min 25 m/min

Brake hub braking torque 1.5 Nm 1.5 Nm

Travel speed 0.1--2.0 m/min 0.1--2.0 m/min

Turning radius for circumferential welding,min 1500 mm 1500 mm

Pipe diameter for internal joint welding, min 1100 mm 1100 mm

Setting range, contact device ±45˚ ±45˚

Max. weight of wire 30 kg 30 kg

Weight (wire excluded): 46 kg 46 kgMax. lateral inclination (whole unit) 25˚ 25˚

GB



-- 92 --fha9d1ea

3.5 Main components A2 TF (SAW)

1. Carriage

2. Carrier

3. Wire feed unit

4. Slide kit, manual

5. Contact tube

6. Connector (Twin)

7. Wire feed motor

8. Guide pin

9. Flux hopper

10. Flux tube

11. Fine--wire straightener

3.6 Main Components A2 TG, A2 TG 4WD (MIG/MAG)

1. Carriage

2. Carrier

3. Wire feed unit

4. Wire feed unit with four--wheel drive

5. Slide kit, manual

6. Connector ( A2 TG )

7. Connector ( A2 TG 4WD )

8. Wire feed motor

See on page 93 for a description of the main components.

GB



-- 93 --fha9d1ea

3.7 Description of Main Components

3.7.1 Carriage

The carriage is provided with 4--wheel drive.The carriage can be secured by way of the

locking lever (1).

3.7.2 Carrier

The control box, wire feed unit and flux hopper,among other things, are to be fitted on the carrier.

3.7.3 Wire Feed Unit / Wire Feed Unit with four--wheel Drive

The unit is used for guiding and feeding the welding wire down into the contacttube/connector.

3.7.4 Manual Slides

The horizontal and vertical position of the welding head is adjusted by way of linearslides. The angular motion can be freely adjusted using the rotary slide.

3.7.5 Contact Tube / Connector

Transfers welding current to the wire during welding.

3.7.6 Wire Feed Motor

The wire feed motor is used for feeding the welding wire.

3.7.7 Guide Pin

The guide pin is used to help positioning the welding head in the joint.

3.7.8 Flux Hopper / Flux Tube

The flux is filled into the flux hopper and is then transferred to the workpiece throughthe flux tube.

The amount of flux to be dropped down is controlled by way of the flux valve fitted tothe flux hopper.

See “Refilling with flux on page 105.

3.7.9 Fine--wire straightenerThe unit is used for the straightening of fine wire.

GB



-- 94 --fha9i1ea

4 INSTALLATION

4.1 General

The installation must be executed by a professional.

WARNING

Rotating parts can cause injury, take great care.

4.2 Mounting

4.2.1 Wire drum (Accessories)

Wire drum (1) is mounted on the brake hub ( 2).

S Check that the carrier (3) is pointing upwards.

NOTE! The maximum angle for the wire bobbin is 25°. At extreme angles, wear will occur on the brake hublocking mechanism and the wire bobbin will slide offthe brake hub.

WARNING

To prevent the reel sliding off the hub:S Lock the reel in place by turning the red knob as shown

on the warning label attached next to the hub.

4.3 Adjusting the brake hub

The brake hub is adjusted when delivered, if readjustmentis required, follow the instructions below. Adjust the brakehub so that wire is slightly slack when wire feed stops.

S Adjusting the braking torque:

S Turn the red handle to the lockedposition.

S Insert a screwdriver into the springs in the hub.

Turn the springs clockwise to reduce the braking torque

Turn the springs anticlockwise to increase the braking torque.NB: Turn both springs through the same amount.

GB



-- 95 --fha9i1ea

4.4 Connections

4.4.1 General

S The A2--A6 Process Controller ( PEH ) is to be connected by a qualified person.

S

For the connection of welding power source LAF/ TAF, see separate instructionmanual.

4.4.2 Automatic welding machine A2 TF (Submerged arc welding, SAW)

1. Connect the control cable (7 ) between the power source ( 8) and the control box A2--A6 Process Controller ( 2).

2. Connect the return cable (11) between the power source ( 8) and work piece ( 9).

3. Connect the welding cable (10) between the power source ( 8) and the automaticwelding machine (1).

4. Connect the measurement cable (12) between the power source ( 8) andworkpiece ( 9).

GB



-- 96 --fha9i1ea

4.4.3 Automatic welding machine A2 TG (Gas metal arc welding, MIG/MAG)

1. Connect the control cable (7 ) between the power source ( 8) and control box A2--A6 Process Controller ( 2).

2. Connect the return cable (11) between the power source ( 8) and work piece ( 9).

3. Connect the welding cable (10) between the power source ( 8) and the automaticwelding machine (1).

4. Connect the gas hose ( 5) between the reducer valve (6) and the gas connection(13) on the welding machine.

5. Connect the cooling water hoses ( 3) between the cooling unit ( 4) and theautomatic welding machine (1).

6. Connect the measurement cable (12) between the power source ( 8) andworkpiece ( 9).

GB



-- 97 --fha9i1ea

4.4.4 Automatic welding machine A2 TG 4WD (Gas metal arc welding,MIG/MAG)

1. Connect the control cable (7 ) between the welding power source ( 8) and the A2--A6 Process Controller ( 2).

2. Connect the return cable (11) between the welding power source ( 8) and thework piece ( 9).

3. Connect the welding cable (10) between the welding power source ( 8) and theautomatic welding machine (1).

4. Connect the gas hose ( 5) between the reduction valve (6) and the gas valve onthe automatic welding machine (13).

5. Connect the hoses for cooling water ( 3) between the cooling unit ( 4) and theautomatic welding machine (1).

6. Connect the measuring cable (12) between the welding power source ( 8) and

the work piece ( 9).

GB



-- 98 --fha9o1ea

5 OPERATION

5.1 General

Caution:Have you read and understood the safety information ?

You must not operate the machine before then !

General safety regulations for the handling of the equipment can be found on page 88. Read through before you start using the equipment!

S Select electrode type and flux powder or shielding gas so that the weld materialis as close as possible to the analysis of the base metal.

S Select electrode size and welding data in accordance with the valuesrecommended by the welding materials supplier.

S Thorough preparation of the weld surfaces is necessary to achieve a good weld.NOTE! The width of the weld joint gap must be uniform.

S To minimise the risk of heat crack formation, the width of the weld must begreater than the penetration depth.

S

Always carry out a test weld with the same joint type and sheet thickness as theproduction work piece.

S For control and adjustment of the automatic welding machine and welding powersupply, see the instruction manual for the A2--A6 Process Controller (PEH).

GB



-- 99 --fha9o1ea

5.2 Loading the welding wire (A2 TF, A2 TG)

A2 TF (UP) A2 TF (UP, Twin) A2 TG (MIG/MAG)

1. Mount the wire drum according to the instructions on page 94.

2. Check that feed roller (1) and contact jaw or contact tip ( 3) are of the correctdimension for the selected wire size.

3. For A2 TF (Twin) and A2 TG:

S Feed the wire through the wire guide ( 8).

4. When welding with fine wire:

S Feed the wire through the fine Wire feed unit (6).Ensure that the straightener is correctly adjusted so that the wire emergesstraight out through the contact jaws or contact tip ( 3).

5. Pull the end of the wire through the straightener ( 2).

S For a wire diameter greater than 2 mm; straighten out 0.5 m of wire and feedit by hand down through the straightener.

6. Locate the end of the wire in the feed roller (1) groove.

7. Set the wire tension on the feed roller with the knob ( 4).

S Note! Do not tension more than is required to achieve an even feed.

8. Feed the wire forward 30 mm by pressing on the control box A2--A6 Process Controller ( PEH ).

9. Direct the wire by adjusting the knob ( 5).

S Always use a guide tube (7 ) to ensure even feed of fine wire (1.6 -- 2.5 mm).

S For MIG/MAG welding with wire sizes < 1.6 mm, use a guide spiral, which isinserted in the guide tube (7 ).

GB



-- 100 --fha9o1ea

5.3 Loading the welding wire (A2 TG 4WD)

1. Check that the feed rollers (1, 4) and the contact nozzle (7) are of the correctdimension for the wire size selected.

NOTE!The feed rollers are marked with their respective groove diameter (D) on theopposite side of the roller.

2. Undo the pressure devices (10) and put up the pressure arms (11).

3. Put the end of the wire through the wire guide nipple (12).

4. Locate the end of the wire in the groove of the feed roller (1) and feed it throughthe intermediate nozzle (3).

5. Locate the end of the wire in the groove of the other feed roller (4) and feed itthrough the outlet nozzle (9).

6. Put down the pressure arms (11) and adjust the wire tension on thefeed rollers (1, 4) by way of the pressure devices (10).

NOTE! Do not tighten down too hard.

7. Feed the wire forward 30 mm by pressing on the control box A2--A6 Process Controller ( PEH ).

GB



-- 101 --fha9o1ea

5.4 Changing the feed roller (A2 TF, A2 TG)

Single wire

S Release the knobs (3) and (4).

S

Release the hand wheel (2).S Change the feed roller (1).

They are marked with their respective wire sizes.

Twin wire (Twin--arc)

S Change the feed roller (1) with twin grooves in the same way as for single wire.

S NOTE! The pressure roller (5) must also be changed. A special curved pressureroller for twin wire replaces the standard pressure roller for single wire.

S

Assemble the pressure roller with special stub shaft(order no. 0146 253 001).

Flux--cored wire for knurled rollers (Accessories)

S Change the feed roller (1) and pressure roller (5) as a pair for the wire size to beused.

NOTE! A special stub shaft is required for the pressure roller(order no. 0212 901 101).

S Tighten the pressure screw (4) with moderate pressure to ensure that the

flux--cored wire does not deform.

5.5 Changing the feed rollers (A2 TG 4WD)

S Undo the pressure devices (10).

S Put up the pressure arms (11).

S Undo the mounting screws (2) of thefeed rollers.

S Replace the feed rollers (1, 4).S Adjust the wire tension on the new feed rollers.

GB



-- 102 --fha9o1ea

5.6 Contact equipment for Submerged arc welding

5.6.1 For single wire 1.6 -- 4.0 mm. Light duty (D20)

Use automatic welding machine A2 TF (UP) wherethe following are included:

S Wire feed unit (1),

S Connector D20 ( 2)

S Contact tip ( 3) (M12 thread).

Tighten the contact tip ( 3) with a key in order toensure that a good contact is achieved.

5.6.2 For twin wires 2 x 1.2 -- 2.0 mm, Light Twin (D35)

Use automatic welding machine A2 TF (UP, Twin)where the following are included:


S Connector Twin D35 ( 2)S Contact tip ( 3) (M6 thread).

S Fine--Wire feed unit ( 5)

S Guide tubes ( 4, 6).


Adjustment of the wires for Twin--arc welding:

S Position the wires in the joint so as to achieve optimal weld quality by rotating the

connector. The two wires can be rotated so that they are positioned one after theother along the line of the joint, or in any position up to 90° across the joint, i.e.one wire on each side of the joint.

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5.7 Contact equipment for MIG/MAG welding

5.7.1 For single wire 1.6 -- 2.5 mm (D35)

Use automatic welding machine A2 TG (MIG/MAG)where the following are included:


S Connector D35 ( 2)

S Contact tip ( 3) (M10 thread).


5.7.2 For single wire < 1.6 mm (D35)

Use automatic welding machine A2 TG (MIG/MAG)where the following are included:


S Connector D35 ( 2)S Contact tip ( 3) (M12 thread).

S Guide tubes ( 4).


Use the following accessories:

S Fine--wire straightener (5) to be fitted on top ofthe clamp of the wire feed unit (1).

S Guide spiral to be inserted into the guide tube (4).

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5.7.3 For single wire 1.0 -- 2.4 mm (wire feed unit with four--wheel drive)

Use automatic welding machine A2 TG 4WD(MIG/MAG) where the following are included:


S Contact device D35 (6)

Tighten the contact device (6) usingthe Allen screw (8).

S Contact nozzle (7).

Tighten the contact nozzle in order toensure that good contact is achieved.

Select a wire guide insert of the correct dimension

for the type of wire to be used. See the instructionmanual for contact device MTW 600 (0449 006 xxx).

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5.8 Refilling with flux powder (Submerged arc welding)

1. Close the flux valve (1) on the flux hopper.

2. Remove the cyclone on the flux recovery unit, if fitted.

3. Fill with flux powder.NOTE! The flux powder must be dry. Where possibleavoid using agglomerating flux powder outdoors andin damp environments.

4. Position the flux tube so that it does not becomekinked.

5. Adjust the height of the flux nozzle above the weld sothat the correct amount of flux is delivered.

Flux coverage should be sufficient so that penetrationof the arc does not occur.

5.9 Transportation of the Automatic Welding Machine

S Disengage the wheels by turning the locking lever (1).

S Make sure the safety chain ( 2) is properly

fastened; this to prevent an accident happening,if for example the carrier is not adequatelylocked to the foot clamp of the carriage.

For transportation through a manholethe chain can be removed.

5.10 Conversion of A2 TF (Submerged--arc) to MIG/MAG welding Assemble in accordance with the instructions accompanying the conversion kit.

5.11 Conversion of A2 TF (submerged--arc welding) to Twin--arc Assemble in accordance with the instructions accompanying the conversion kit.

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6 MAINTENANCE

6.1 General

Note: All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period.

NB! Before doing any kind of maintenance work, make sure the mains isdisconnected.

For the maintenance of the A2--A6 Process Controller ( PEH ), see the instructionmanual 0443 745 xxx.

6.2 Daily

S Clean flux and dirt off moving parts of the welding machine.S Check that the contact tip and all electrical cables are connected.

S Check that all bolted joints are tight and that guides and drive rollers are notworn or damaged.

S Check the brake hub braking torque. It should not be so low, that the wire reelcontinues to rotate when wire feed is stopped and it should not be so great thatthe feed rollers slip. As a guide, the braking torque for a 30 kg wire reel shouldbe 1,5 Nm.To adjust the braking torque see on page 94.

6.3 Periodic

S Inspect the electrode feed unit’s electrode control, drive rollers and contact tip.

S Replace worn or damaged components.

S Inspect the slides, lubricate them if they are binding.

S Lubricate the chain.

S Tensioning the chain between the trolley’s front and back axles.

S Dismantle the trolley wheels and blanks. Remove the Y flange bearing bolts.

S Tension the chain by moving the trolley’s rear axle parallel in relation to thefront axle.

S Reassemble in the reverse order.

S Tensioning the chain from the trolley’s front axle to the drive motor andgearbox.

S Tension the chain by moving the drive motor and gearbox.

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7 TROUBLESHOOTING

7.1 General

Equipment

S Instruction manual control box A2--A6 Process Controller ( PEH ).

Check

S that the power supply is connected for the correct mains supply

S that all three phases are supplying the correct voltage (phase sequence is notimportant)

S that welding cables and connections are not damaged

S that the controls are correctly set

S that the mains supply is disconnected before starting repairs

7.2 POSSIBLE FAULTS

1. Symptom Current and voltage readings show large fluctuations.

Cause 1.1 Contact jaws or nozzle are worn or wrong size.

Action Replace contact jaws or nozzle.

Cause 1.2 Feed roller pressure is inadequate.

Action Increase pressure on feed rollers.

2. Symptom Wire feed is irregular.

Cause 2.1 Pressure on feed rollers incorrectly set.

Action Adjust pressure on feed rollers.

Cause 2.2 Feed rollers wrong size.

Action Replace feed rollers.

Cause 2.3 Grooves in feed rollers are worn.

Action Replace feed rollers.

3. Symptom Welding cables overheating.

Cause 3.1 Poor electrical connection.Action Clean and tighten all electrical connections.

Cause 3.2 Cross--sectional area of welding cables too small.

Action Use cables with a larger cross--section or use parallel cables.

8 ORDERING OF SPARE PARTSSpare 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 257.This will simplify dispatch and ensure you get the right part.

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ESAB ABSE--695 81 LAXÅSWEDENPhone +46 584 81 000

ESAB subsidiaries and representative offices

EuropeAUSTRIAESAB Ges.m.b.HVienna--LiesingTel: +43 1 888 25 11Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.BrusselsTel: +32 2 745 11 00Fax: +32 2 745 11 28

THE CZECH REPUBLICESAB VAMBERK s.r.o.PragueTel: +420 2 819 40 885Fax: +420 2 819 40 120

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GREAT BRITAINESAB Group (UK) LtdWaltham CrossTel: +44 1992 76 85 15Fax: +44 1992 71 58 03

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HUNGARY ESAB KftBudapestTel: +36 1 20 44 182Fax: +36 1 20 44 186

ITALY ESAB Saldatura S.p.A.Mesero (Mi)Tel: +39 02 97 96 81Fax: +39 02 97 28 91 81

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SPAINESAB Ibérica S.A.

Alcalá de Henares (MADRID)Tel: +34 91 878 3600Fax: +34 91 802 3461

SWEDENESAB Sverige ABGothenburgTel: +46 31 50 95 00Fax: +46 31 50 92 22

ESAB International ABGothenburgTel: +46 31 50 90 00Fax: +46 31 50 93 60

SWITZERLANDESAB AGDietikonTel: +41 1 741 25 25Fax: +41 1 740 30 55

North and South AmericaARGENTINACONARCOBuenos AiresTel: +54 11 4 753 4039Fax: +54 11 4 753 6313

BRAZILESAB S.A.Contagem--MGTel: +55 31 2191 4333Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.Missisauga, OntarioTel: +1 905 670 02 20Fax: +1 905 670 48 79

MEXICOESAB Mexico S.A.MonterreyTel: +52 8 350 5959Fax: +52 8 350 7554

USAESAB Welding & Cutting ProductsFlorence, SCTel: +1 843 669 44 11Fax: +1 843 664 57 48

Asia/PacificCHINAShanghai ESAB A/PShanghaiTel: +86 21 5308 9922Fax: +86 21 6566 6622

INDIA

ESAB India LtdCalcuttaTel: +91 33 478 45 17Fax: +91 33 468 18 80

INDONESIAP.T. ESABindo PratamaJakartaTel: +62 21 460 0188Fax: +62 21 461 2929

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ESAB (Malaysia) Snd BhdShah Alam SelangorTel: +60 3 5511 3615Fax: +60 3 5512 3552

SINGAPOREESAB Asia/Pacific Pte LtdSingaporeTel: +65 6861 43 22Fax: +65 6861 31 95

SOUTH KOREAESAB SeAH CorporationKyungnamTel: +82 55 269 8170Fax: +82 55 289 8864

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Representative officesBULGARIAESAB Representative OfficeSofiaTel/Fax: +359 2 974 42 88

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Dokki--CairoTel: +20 2 390 96 69Fax: +20 2 393 32 13

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RUSSIA--CISESAB Representative OfficeMoscowTel: +7 095 937 98 20Fax: +7 095 937 95 80

ESAB Representative OfficeSt PetersburgTel: +7 812 325 43 62

Fax: +7 812 325 66 85

DistributorsFor addresses and phone numbers to our distributors inother countries, please visit our home page

www.esab.com

A2 Tractoras

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