ESAB A2 S GMAW Mini Master User manual

Valid for Serial NO 930 XXX--XXXX0449 002 001 2001--03--12
A2 S GMAW Mini
Master
A2 SGF1
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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 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 18................................................
NORSK 33................................................
SUOMI 48................................................
ENGLISH 63..............................................
DEUTSCH 78.............................................
FRANÇAIS 93.............................................
NEDERLANDS 109.........................................
ESPAÑOL 125..............................................
ITALIANO 141..............................................
PORTUGUÊS 156..........................................
ÅËËÇÍÉÊÁ 172.............................................

ENGLISH
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TOCe
1 DIRECTIVE 64........................................................
2SAFETY 64...........................................................
3 INTRODUCTION 66...................................................
3.1 General 66..................................................................
3.2 Technical data 66............................................................
3.3 Welding method 66...........................................................
3.4 Equipment 67................................................................
4 INSTALLATION 68....................................................
4.1 General 68..................................................................
4.2 Mounting 68.................................................................
4.3 Connections 69..............................................................
5 OPERATION 70.......................................................
5.1 General 70..................................................................
5.2 Start--up 70..................................................................
6 MAINTENANCE 74....................................................
6.1 General 74..................................................................
6.2 Daily 74.....................................................................
6.3 Periodic 74..................................................................
7 TROUBLE SHOOTING 75..............................................
8 ACCESSORIES 76....................................................
9 ORDERING OF SPARE PARTS 76......................................
10 WEAR COMPONENTS 77..............................................
DIMENSION DRAWING 188................................................
SPARE PARTS LIST 191...................................................

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fha8safe
1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved
guarantee that welding head A2 SGF1 from serial number 930 complies with
standard EN 60292 and EN 60204, in accordance with the requirements of directive
(89/392/EEC) and addendum (93/68/EEC).
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Johnny Sundin
Design Manager, Div Engineering
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721
Laxå 1999--11--12
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:
Sits operation
Sthe location of emergency stops
Sits function
Srelevant safety precautions
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the machine when it is started
up.
Sthat no--one is in a hazardous position when the carriage or slide mechanisms are operated.
3. The work place must:
Sbe clear of mechanical components, tools, or other obstructions that could prevent the oper-
ator from moving freely within the working area.
Sbe organized so that there is free access to the emergency stop.
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo 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.
SMake sure the return cable is connected securely.
SWork on high voltage components may only be carried out by a qualified electrician.
SAppropriate fire extinguishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during its operation.
GB

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
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to keep fumes and gases from
your breathing zone and the general area.
ARC RAYS -- Can injure eyes and burn skin
SProtect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
SProtect your ears. Use ear defenders or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
READ AND UNDERSTAND THE INSTRUCTION MANUAL
BEFORE INSTALLING OR OPERATING.
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GB

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3 INTRODUCTION
3.1 General
The A2 SGF1 welding head is designed for MIG/MAG welding of butt and fillet joints.
A2 SGF1 is intended for use together with control box A2--A6 Process Controller and
ESAB’s LAF welding power source.
The welding head can be horisontally or vertically positioned by way of linear slides.
The angular motion can be freely adjusted by way of an angle slide.
Push angle for forehand welding or drag angle for backhand welding can be set
using the rotary attachment.
3.2 Technical data
A2 SGF1
Type of gas: Mix/Ar CO
2
Permissible load at 100 %: 600 A DC 650 A DC
Wire dimensions:
Non--alloy / Low--alloy
Stainless steel
Cored wire
Aluminium
1.0--1.6 mm
1.0--1.6 mm
1.0--2.4 mm
1.0 -- 2.0 mm
1.0--1.6 mm
1.0--2.4 mm
Wire feed speed 2.0--25 m/min 2.0--25 m/min
Setting range, contact device ±45˚±45˚
Brake hub braking torque 1.5 Nm 1.5 Nm
Max. weight of wire 30 kg 30 kg
Weight (without wire):
with hand operated linear slides
with motor driven linear slides
15 kg
43 kg
15 kg
43 kg
Max. lateral inclination (whole unit) 25˚25˚
Setting length of the slide*
hand operated
motor driven
90 mm
180 mm
90 mm
180 mm
*) NB. Available in other lengths on request.
3.3 Welding method
MIG/MAG welding
In MIG/MAG welding the welding bead is shielded by way of shielding gas.
The welding head is water--cooled. The cooling water is connected to the respective
connection by way of hoses.
GB

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3.4 Equipment
The complete welding head consists of a motor for the feed of the wire and contact
equipment supplying current to the wire.
Example of an A2 SGF1 with hand operated linear slides:
1. Wire feed unit with
four--wheel drive
2. Contact equipment containing
gas nozzle, contact device and
water hose
3. Angle slide
4. Linear slide (hand operated)
5. Wire feed motor
6. Wire drum
7. Wire conduit
8. Rotary attachment
Example of an A2 SGF1 with motor driven linear slides:
1. Wire feed unit with
four--wheel drive
2. Contact equipment containing
gas nozzle, contact device and
water hose
3. Angle slide
4. Linear slide (motor driven)
5. Wire feed motor
6. Wire drum
7. Wire conduit
8. Rotary attachment
Connection instructions for MIG/MAG welding, see the system diagram on page 69.
GB

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4 INSTALLATION
4.1 General
The installation shall be executed by a professional.
WARNING!
Rotating parts can cause injury, take great care.
4.2 Mounting
The automatic welding machine can easily be mounted on a beam--travelling
carriage or on a welding column and boom unit by way of four M12 screws.
Make sure the bolts do not touch the bottom of the insulator, which has a thread
depth of 14 mm.
For mounting/ dismounting of A6 Slide, see instruction manual 443 394 xxx.
This safety sign is placed on the cover of the vertical slide.
GB

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4.3 Connections
1. The A2--A6 Process Controller is to be connected by a qualified person.
2. For the connection of A6 GMD, see instruction manual 0443 403 xxx.
3. For the connection of A6 PAK, see instruction manual 0443 405 xxx.
4. Connect the welding head as follows:
SThe control cable (7) between the welding power source (8) and the A2--A6
Process Controller (2).
SThe return cable (11) between the welding power source (8) and the
workpiece (9).
SThe welding cable (10) between the welding power source (8) and the
welding head (1).
SThe gas hose (5) between the pressure reducing valve (6) and the gas valve
of the welding head (13).
SThe hoses for cooling water (3) between the cooling unit (4) and the welding
head (1).
SThe measuring cable (12) between the welding power source (8) and the
workpiece (9).
GB

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5 OPERATION
5.1 General
General safety regulations for the handling of the equipment appear from
page 64. Read through before you start using the equipment!
SSelect wire type and shielding gas so that the weld material is as close as
possible to the analysis of the base material. Select wire size and welding data in
accordance with the values recommended by the consumables supplier.
SThorough joint preparation is necessary to achieve a good weld result.
NOTE! The width of the joint gap must be uniform.
STo minimise the risk of heat crack formation the width of the weld must be
greater than the penetration depth.
SAlways carry out a test weld with the same joint type and plate thickness as the
workpiece to be produced.
SFor control and adjustment of the welding head and welding power source, see
the instruction manual for the A2--A6 Process Controller.
SFor the replacement of wear parts, see table on page 77.
5.2 Start--up
NOTE!
The wire drum is not included in the delivery of the welding head in MIG design.
Fitting the wire drum
SFit the wire drum (1) on the brake hub (2).
Check that the carrier (3) is in the correct position.
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.
IMPORTANT!
To prevent the reel sliding off the hub: Lock the reel in place
by turning the red knob as shown on the warning label atta-
ched next to the hub.
GB