SAFETY 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 pre- cautions. Safety precautions must meet the requirements that apply to this type of welding equipment.
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WARNING, RISK OF CRUSHING! Do not use safety gloves when replacing wire, feed rollers and wire bobbins. - 6 - SafeArcS GB...
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WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU- FACTURER'S HAZARD DATA. ELECTRIC SHOCK - Can kill Install and earth the welding unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
Welding Method 2.2.1 Submerged Arc Welding (SAW) For submerged arc welding the A2SF J1/ A2SF J1 Twin welding head is always to be used. Submerged arc Light Duty. Submerged arc light duty with a Ø 20 mm connector permits a load up to 800 A (100%).
Description of Main Components 2.9.1 Wire Feed Unit / Wire Feed Unit with four-wheel Drive The unit is used for guiding and feeding the welding wire down into the contact tube/connector. 2.9.2 Manual and Motorized Slides The horizontal and vertical position of the welding head is adjusted by way of linear slides.
INSTALLATION General The installation must be executed by a professional. WARNING Rotating parts can cause injury, take great care. Mounting 3.2.1 Welding head The welding head can easily be mounted on a beam-travelling carriage or on a weld- ing column and boom unit by way of four M12 screws. N.B.
3.2.3 Wire drum (Accessories) Wire drum (1) is mounted on the brake hub (2). 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 hub locking mechanism and the wire bobbin will slide off the brake hub.
For the connection of A6 PAV, see instruction manual 0460 670 xxx. 3.4.2 Welding head A2SF J1/ A2SF J1 Twin (Submerged arc welding, SAW) 1. Connect the control cable (7) between the welding power source (8) and the PEK (2).
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3.4.3 Welding head A2SG J1 (Gas metal arc welding, MIG/MAG) 1. Connect the control cable (7) between the welding power source (8) and the PEK (2). 2. Connect the return cable (11) between the welding power source (8) and the work piece (9).
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3.4.4 Welding head A2SG J1 4WD (Gas metal arc welding, MIG/MAG) 1. Connect the control cable (7) between the welding power source (8) and the PEK (2). 2. Connect the return cable (11) between the welding power source (8) and the work piece (9).
OPERATION General WARNING: 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 5. Read through before you start using the equipment! Return cable Before welding start, check that the return cable is connected.
Loading the welding wire (A2SF J1/ A2SF J1 Twin, A2SG J1) A2SF J1 (SAW) A2SF J1 Twin (SAW) A2SG J1 (MIG/MAG) 1. Mount the wire drum according to the instructions on page 14. 2. Check that feed roller (1) and contact jaw or contact tip (3) are of the correct dimension for the selected wire size.
8. Feed the wire forward 30 mm below the contact tip by pressing on the control box PEK. 9. Direct the wire by adjusting the knob (5). Always use a guide tube (7) to ensure even feed of fine wire (1.6 - 2.5 mm). For MIG/MAG welding with wire sizes <...
Changing the feed roller (A2SF J1/ A2SF J1 Twin, A2 SG J1) Single wire Release the knobs (3) and (4). Release the hand wheel (2). Change the feed roller (1). They are marked with their respective wire sizes. Twin wire (Twin-arc) Change the feed roller (1) with twin grooves in the same way as for single wire.
4.6.2 For twin wires 2 x 1.2 - 2.0 mm, Light Twin (D35) Use welding head A2SF J1 Twin (SAW) where the following are included: Wire feed unit (1), Connector Twin D35 (2) Contact tip (3) (M6 thread).
Contact equipment for MIG/MAG welding 4.7.1 For single wire 1.6 - 2.5 mm (D35) Use welding head A2SG J1 (MIG/MAG) where the following are included: Wire feed unit (1), Connector D35 (2) Contact tip (3) (M10 thread). Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved.
(Submerged arc welding) to MIG/MAG welding For the conversion kit see instruction manual 0456 756 xxx. 4.10 Conversion of A2SF J1 (Submerged arc welding) to Twin-arc For the conversion kit see instruction manual 0456 757 xxx. - 24 - hha2o1ea...
MAINTENANCE 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 is disconnected.
FAULT TRACING General Equipment Instruction manual for PEK, 0460 948 xxx, 0460 949 xxx, 0459 839 036. Check that the power supply is connected for the correct mains supply that all three phases are supplying the correct voltage (phase sequence is not important) that welding cables and connections are not damaged that the controls are correctly set that the mains supply is disconnected before starting repairs...
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