ESAB A2 Multitrac User manual

Instruction manual
0449 165 160 GB 20200827 Valid for: serial no. 940-xxx-xxxx
A2Multitrac
A2TFJ1/A2TFJ1Twin/
A2TGJ1/A2TGJ14WD

TABLE OF CONTENTS
0449 165 160 © ESAB AB 2020
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 9
2.1 General .................................................................................................... 9
2.2 Welding method...................................................................................... 9
2.2.1 Submerged Arc Welding (SAW) ........................................................... 9
2.2.2 MIG/MAG welding ................................................................................ 9
2.3 Definitions ............................................................................................... 9
2.4 Horizontal welding.................................................................................. 9
3INSTALLATION............................................................................................ 10
3.1 General .................................................................................................... 10
3.2 Main components A2TFJ1/A2TFJ1 Twin(SAW)............................... 10
3.3 Main components A2TGJ1/A2TGJ14WD(MIG/MAG) ..................... 11
3.4 Description of main components.......................................................... 11
3.4.1 Carriage................................................................................................ 11
3.4.2 Carrier................................................................................................... 11
3.4.3 Wire feed unit ....................................................................................... 11
3.4.4 Manual slides ....................................................................................... 11
3.4.5 Contact tube / Connector ..................................................................... 11
3.4.6 Wire feed motor.................................................................................... 12
3.4.7 Guide pin .............................................................................................. 12
3.4.8 Flux hopper / Flux tube......................................................................... 12
3.5 Mounting ................................................................................................. 12
3.5.1 Wire drum (Accessories) ...................................................................... 12
3.6 Adjusting the brake hub ........................................................................ 12
3.7 Connections............................................................................................ 13
3.7.1 General................................................................................................. 13
3.7.2 Automatic welding equipment A2TFJ1/A2TFJ1Twin (Submerged
Arc Welding, SAW)...............................................................................
14
3.7.3 Automatic welding equipment A2TGJ1 (Gas metal arc welding,
MIG/MAG) ............................................................................................
15
3.7.4 Automatic welding equipment A2TGJ14WD (Gas metal arc welding,
MIG/MAG) ............................................................................................
16
4OPERATION ................................................................................................ 17
4.1 General .................................................................................................... 17
4.2 Loading the welding wire (A2TFJ1/A2TFJ1Twin, A2TGJ1)........... 17
4.3 Loading the welding wire (A2TGJ14WD)............................................ 18
4.4 Changing the feed roller (A2TFJ1/ A2TFJ1Twin, A2TGJ1) ............ 19
4.4.1 Single wire............................................................................................ 19
4.4.1.1 Twin wire (Twin-arc)........................................................................... 19
4.4.1.2 Flux-cored wire for knurled rollers (Accessories) .............................. 19
4.5 Changing the feed rollers (A2TGJ14WD) ........................................... 20

TABLE OF CONTENTS
0449 165 160 © ESAB AB 2020
4.6 Contact equipment for Submerged Arc Welding ................................ 20
4.6.1 For single wire 1.6–4.0mm – Light duty (D20) .................................... 20
4.6.2 For twin wires 2×1.2–2.0mm – LightTwin (D35) ................................. 20
4.6.2.1 Accessories ....................................................................................... 21
4.6.2.2 Adjustment of the wires for twin-arc welding ..................................... 21
4.7 Contact equipment for MIG/MAG welding............................................ 21
4.7.1 For single wire 1.6–2.5mm(D35) ........................................................ 21
4.7.2 For single wire < 1.6mm (D35) ............................................................ 22
4.7.2.1 Accessories ....................................................................................... 22
4.7.3 For single wire 1.0–2.4mm (wire feed unit with four-wheel drive) ....... 22
4.8 Refilling with flux powder ...................................................................... 23
4.9 Transportation ........................................................................................ 23
4.10 Conversion of A2TFJ1/A2TFJ1Twin (Submerged Arc Welding) to
MIG/MAGwelding ...................................................................................
24
4.11 Conversion of A2TFJ1 (Submerged Arc Welding) to Twin-arc ......... 24
5MAINTENANCE........................................................................................... 25
5.1 General .................................................................................................... 25
5.2 Daily......................................................................................................... 25
5.3 Periodic ................................................................................................... 25
6TROUBLESHOOTING ................................................................................. 26
6.1 General .................................................................................................... 26
6.2 Possible errors ....................................................................................... 26
7ORDERING SPARE PARTS ........................................................................ 27
DIMENSION DRAWING....................................................................................... 28
SPARE PARTS LIST............................................................................................ 30
Rights reserved to alter specifications without notice.

1 SAFETY
0449 165 160 -5- © ESAB AB 2020
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
Users of ESAB 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 equipment. The following
recommendations 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

1 SAFETY
0449 165 160 -6- © ESAB AB 2020
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes.
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
• Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0449 165 160 -7- © ESAB AB 2020
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.

1 SAFETY
0449 165 160 -8- © ESAB AB 2020
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
0449 165 160 -9- © ESAB AB 2020
2 INTRODUCTION
2.1 General
The A2TFJ1/A2TFJ1Twin automatic welding equipment is designed for Submerged Arc
Welding (SAW) of butt and fillet joints.
The A2TGJ1/A2TGJ14WD automatic welding equipment is designed for MIG/MAG
welding of butt and fillet joints.
All other applications are prohibited.
Intended for use in combination with PEK and ESAB welding power sources LAF,TAF or
Aristo1000.
NOTE!
Aristo1000 only together with PEK with serial no. 747-xxx-xxxx or later.
2.2 Welding method
2.2.1 Submerged Arc Welding (SAW)
Use A2TFJ1/A2TFJ1Twin automatic welding equipment for Submerged Arc Welding.
• Submerged Arc Light duty
Submerged Arc Light duty with a Ø20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, which guarantees even wire feed
without the risk of deformation due to high feed pressure.
2.2.2 MIG/MAG welding
For MIG/MAG welding use either automatic welding equipment A2TGJ1 or A2TGJ14WD.
A2TGJ14WD consists of a four wheel drive wire feed unit.
The welding head is water-cooled. The cooling water is supplied by hoses from connections
intended for the purpose.
2.3 Definitions
SAW The weld bead is protected by a cover of flux during the welding.
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.
2.4 Horizontal welding
The products described in this manual are designed for horizontal welding.
NOTE!
Do not use A2 Multitrac when welding on inclined planes.

3 INSTALLATION
0449 165 160 - 10 - © ESAB AB 2020
3 INSTALLATION
3.1 General
The installation must be carried out by a professional.
WARNING!
Rotating parts can cause injury, take great care.
3.2 Main components A2TFJ1/A2TFJ1 Twin(SAW)
1. Carriage 6. Wire feed motor
2. Carrier 7. Wire guide
3. Wire feed unit 8. Flux hopper
4. Slide kit, manual 9. Flux tube
5. Contact tube 10. Guide pin

3 INSTALLATION
0449 165 160 - 11 - © ESAB AB 2020
3.3 Main components A2TGJ1/A2TGJ14WD(MIG/MAG)
1. Carriage 5. Connector
2. Carrier 6. Wire feed motor
3. Wire feed unit 7. Wire guide
4. Slide kit, manual
3.4 Description of main components
3.4.1 Carriage
The carriage is provided with 4-wheel drive. Secured the carriage with the locking lever (1).
3.4.2 Carrier
Fit the control unit, wire feed unit and flux hopper, among other things, on the carrier.
3.4.3 Wire feed unit
The wire feed unit guides and feeds the welding wire into the connector / contact tube.
3.4.4 Manual slides
The horizontal and vertical position of the welding head is adjusted by way of linear slides.
The angular motion can be freely adjusted using the rotary slide.
3.4.5 Contact tube / Connector
Transfers welding current to the wire during welding.

3 INSTALLATION
0449 165 160 - 12 - © ESAB AB 2020
3.4.6 Wire feed motor
The motor feeds the welding wire.
3.4.7 Guide pin
The guide pin is used to help positioning the welding head in the joint.
3.4.8 Flux hopper / Flux tube
The flux is filled into the flux hopper. It is then transferred to the workpiece through the flux
tube.
The amount of flux to be dropped down is controlled by way of the flux valve fitted to the flux
hopper.
For more information, see section "Refilling with flux powder".
3.5 Mounting
3.5.1 Wire drum (Accessories)
Mount the wire drum (1) on the brake hub (2).
WARNING!
To prevent the reel from sliding off
the hub: Lock the reel in place by
turning the red knob as shown on
the warning label attached next to
the hub.
3.6 Adjusting the brake hub
The brake hub is adjusted at delivery. If readjustment is required, follow the instructions
below. Adjust the brake hub so the wire is slightly slack when wire feed stops.

3 INSTALLATION
0449 165 160 - 13 - © ESAB AB 2020
Adjusting the braking torque:
1. Turn the red handle to the locked
position.
2. Insert a screwdriver into the springs
in the hub.
○ Turn the springs clockwise to
reduce the braking torque.
○ Turn the springs
counter-clockwise to increase
the braking torque.
NOTE!
Turn both springs the same amount.
3.7 Connections
3.7.1 General
• The PEK must be connected by a qualified person. See separate instruction manual.
• For connection of welding power source, see separate instruction manual.

3 INSTALLATION
0449 165 160 - 14 - © ESAB AB 2020
3.7.2 Automatic welding equipment A2TFJ1/A2TFJ1Twin (Submerged Arc
Welding, SAW)
1. Connect the control cable (7) between the power source (8) and the PEK (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 automatic
welding equipment (1).
4. Connect the measurement cable (12) between the power source (8) and workpiece
(9).
1. Automatic welding equipment 5. Control cable
2. PEK 6. Return cable
3. Power source 7. Welding cable
4. Work piece 8. Measurement cable

3 INSTALLATION
0449 165 160 - 15 - © ESAB AB 2020
3.7.3 Automatic welding equipment A2TGJ1 (Gas metal arc welding,
MIG/MAG)
1. Connect the control cable (7) between the power source (8) and the PEK (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 automatic
welding equipment (1).
4. Connect the gas hose (5) between the reducer valve (6) and the gas connection (13)
on the welding equipment.
5. Connect the cooling water hoses (3) between the cooling unit (4) and the automatic
welding equipment (1).
6. Connect the measurement cable (12) between the power source (8) and workpiece
(9).
1. Automatic welding equipment 5. Control cable
2. PEK 6. Return cable
3. Power source 7. Welding cable
4. Work piece 8. Measurement cable

3 INSTALLATION
0449 165 160 - 16 - © ESAB AB 2020
3.7.4 Automatic welding equipment A2TG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).
3. Connect the welding cable (10) between the welding power source (8) and the
automatic welding equipment (1).
4. Connect the gas hose (5) between the reduction valve (6) and the gas valve on the
automatic welding equipment (13).
5. Connect the hoses for cooling water (3) between the cooling unit (4) and the
automatic welding equipment (1).
6. Connect the measuring cable (12) between the welding power source (8) and the
work piece (9).
1. Automatic welding equipment 5. Control cable
2. PEK 6. Return cable
3. Power source 7. Welding cable
4. Work piece 8. Measurement cable

4 OPERATION
0449 165 160 - 17 - © ESAB AB 2020
4 OPERATION
4.1 General
CAUTION!
Read and understand the instruction manual before
installing or operating.
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
Return cable
Before starting the welding, check that the return cable is connected. See section
"Connections".
4.2 Loading the welding wire (A2TFJ1/A2TFJ1Twin, A2TGJ1)
A2TFJ1(SAW) A2TFJ1Twin(SAW) A2TGJ1(MIG/MAG)
1. Mount the wire drum according to the instructions in the "Installation" chapter.
2. Check that feed roller (1) and contact jaw or contact tip (3) has the correct dimension
for the selected wire size.
3. For A2TF J1 Twin and A2TG J1:
○ Feed the wire through the wire guide (8).
4. When welding with fine wire:
○ Feed the wire through the fine wire feed unit (6).
Ensure that the straightener is correctly adjusted so that the wire emerges
straight out through the contact jaws or contact tip (3).
5. Pull the end of the wire through the straightener (2).
○ For a wire diameter greater than 2 mm, straighten out 0.5 m of wire and feed it
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).
NOTE!
Do not tension more than is required to achieve an even feed.

4 OPERATION
0449 165 160 - 18 - © ESAB AB 2020
8.
Feed the wire forward 30 mm below the contact tip by pressing on the PEK.
9. Direct the wire by adjusting the knob (5).
NOTE!
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 < 1.6mm, use a guide spiral, which is
inserted in the guide tube (7).
4.3 Loading the welding wire (A2TGJ14WD)
1. Check that the feed rollers (1, 4) and the contact nozzle (7) has the correct dimension
for the selected wire size.
NOTE!
The feed rollers are marked with their respective groove diameter (D) on the
opposite side of the roller.
2. Undo the pressure devices (10).
3. Put up the pressure arms (11).
4. Put the end of the wire through the wire guide nipple (12).
5. Locate the end of the wire in the feed roller (1) groove. Feed the wire through the
intermediate nozzle (3).
6. Locate the end of the wire in the other feed roller (4) groove. Feed the wire through
the outlet nozzle (9).

4 OPERATION
0449 165 160 - 19 - © ESAB AB 2020
7. Put down the pressure arms (11) and adjust the wire tension on the feed rollers (1, 4)
by way of the pressure devices (10).
NOTE!
Do not tighten down too hard.
8.
Feed the wire forward 30mm below the contact nozzle by pressing on the PEK.
4.4 Changing the feed roller (A2TFJ1/ A2TFJ1Twin, A2TGJ1)
4.4.1 Single wire
• Release the knobs (3) and (4).
• Release the hand wheel (2).
• Change the feed roller (1).
The feed rollers are marked with their respective
wire sizes.
4.4.1.1 Twin wire (Twin-arc)
• Change the feed roller (1) with twin grooves in the same way as for single wire.
NOTE!
The pressure roller (5) must also be changed. A special curved pressure roller for
twin wire replaces the standard pressure roller for single wire.
• Assemble the pressure roller with special stub shaft (order no. 0146253001).
4.4.1.2 Flux-cored wire for knurled rollers (Accessories)
• Change the feed roller (1) and pressure roller (5) as a pair for the wire size to be used.
NOTE!
A special stub shaft is required for the pressure roller (order no. 0212 901 101).
• Tighten the pressure screw (4) with moderate pressure to ensure that the flux-cored
wire does not deform.

4 OPERATION
0449 165 160 - 20 - © ESAB AB 2020
4.5 Changing the feed rollers (A2TGJ14WD)
• Undo the pressure devices (10).
• Put up the pressure arms (11).
• Undo the mounting screws (2) of the
feed rollers.
• Replace the feed rollers (1, 4).
• Adjust the wire tension on the new feed
rollers.
4.6 Contact equipment for Submerged Arc Welding
4.6.1 For single wire 1.6–4.0mm – Light duty (D20)
The following are included:
• Wire feed unit (1)
• Connector D20 (2)
• Contact tip (3) (M12 thread)
Tighten the contact tip (3) with a key in order to
ensure that a good contact is achieved.
4.6.2 For twin wires 2×1.2–2.0mm – LightTwin (D35)
Use automatic welding equipment A2TFJ1Twin (SAW) where the
following are included:
• Wire feed unit (1)
• Connector Twin D35 (2)
• Contact tip (3) (M6 thread)
• Fine-wire feed unit (5)
• Guide tubes (4, 6)
Tighten the contact tip (3) with a key in order to ensure that a good contact is achieved.