ESAB A2SF J1 User manual

Valid for serial no. 940-xxx-xxxx
A2 Welding heads
A2SF J1 / A2SF J1 Twin
A2SG J1 / A2SG J1 4WD
Instruction manual
0449 175 260 20130-6-17

  
Rights reserved to alter specifications without notice.
ENGLISH 4. . . . ..........................................

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ENGLISH
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 
1 SAFETY 5...........................................................
2 INTRODUCTION 8...................................................
2.1 General 8..................................................................
2.2 Welding Method 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Definitions 8................................................................
2.4 Technical Data 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Main components A2SF J1 (SAW) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Main components A2SF J1 Twin (SAW) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Main Components A2SG J1 (MIG/MAG) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Main Components A2SG J1 4WD (MIG/MAG) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Description of Main Components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INSTALLATION 13. . . .................................................
3.1 General 13..................................................................
3.2 Mounting 13.................................................................
3.3 Adjusting the brake hub 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 OPERATION 18.......................................................
4.1 General 18..................................................................
4.2 Loading the welding wire (A2SF J1/ A2SF J1 Twin, A2SG J1) 19. . . . . . . . . . . . . . . . . . .
4.3 Loading the welding wire (A2SG J1 4WD) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Changing the feed roller (A2SF J1/ A2SF J1 Twin, A2 SG J1) 21. . . . . . . . . . . . . . . . . . .
4.5 Changing the feed rollers (A2SG J1 4WD) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Contact equipment for Submerged arc welding 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Contact equipment for MIG/MAG welding 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Refilling with flux powder (Submerged arc welding) 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Conversion of A2SF J1/ A2SF J1 Twin
(Submerged arc welding) to MIG/MAG welding 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Conversion of A2SF J1 (Submerged arc welding) to Twin-arc 24. . . . . . . . . . . . . . . . . . . .
5 MAINTENANCE 25. . . .................................................
5.1 General 25..................................................................
5.2 Daily 25.....................................................................
5.3 Regularly 25.................................................................
6 FAULTTRACING 26..................................................
6.1 General 26..................................................................
6.2 Possible faults 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ACCESSORIES 27....................................................
8 ORDERING OF SPARE PARTS 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSIONDRAWING 28................................................
SPAREPARTSLIST 35..................................................

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SafeArcS GB
1 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. 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 oper-
ation 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:
its operation
location of emergency stops
its function
relevant safety precautions
welding
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
3. The workplace must:
be suitable for the purpose
be free from draughts
4. Personal safety equipment
Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves. Note! Do not use safety
gloves when replacing wire.
Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns.
5. Protection against other risks
Dust particles of a certain size can be harmful to man. A ventilation system
and extractor should therefore be provided to eliminate this risk.
6. 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 extinquishing equipment must be clearly marked and close
at hand.
Lubrication and maintenance must not be carried out on the equipment
during operation.
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SafeArcS GB
WARNING, RISK OF CRUSHING!
Do not use safety gloves when replacing wire, feed rollers and wire bobbins.
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
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.
Insulate yourself from earth and the workpiece.
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
Keep your head out of the fumes.
Use 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
Protect your eyes and body. Use the correct welding screen and filter lens and
wear protective clothing.
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
Sparks (spatter) can cause fire. Make sure therefore that there are no inflam-
mable materials nearby.
NOISE - Excessive noise can damage hearing
Protect your ears. Use ear defenders or other hearing protection.
Warn bystanders of the risk.
MALFUNCTION
Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
READ AND UNDERSTAND THE INSTRUCTION MAN-
UAL BEFORE INSTALLING OR OPERATING.
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SafeArcS GB
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2 INTRODUCTION
2.1 General
All the welding heads included in this instruction manual are designed for SAW and
MIG/MAG welding of butt and fillet joints.
They are intended for use in combination with PEK and ESAB's welding power
sources LAF or TAF.
2.2 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%).
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 either the A2SG J1 or A2SG J1 4WD welding heads are to
be used.
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.
2.3 Definitions
SAW welding 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.
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2.4 Technical Data
A2SF J1/
A2SF J1 Twin (SAW)
A2SG J1
(MIG/MAG)
Rated load 100% 800A 600A
Wire dimensions:
solid single wire
flux-cored wire
solid twin wire
1.6-4.0 mm
1.6-4.0 mm
2x1.2-2.0 mm
0.8-2.5 mm
1.2-3.2 mm
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Wire feed speed 0.2-9.0 m/min 0.2-16 m/min
Brake drum braking torque 1.5 Nm 1.5 Nm
Max weight, wire 2x30 kg 2x30 kg
Flux hopper (Not to be filled with preheated flux)
Capacity:
Max. temperature plastic flux hopper:
6 l
80C
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Weight (flux and wire excluded)
with hand-operated linear slides
with motor-driven linear slides
23 kg
45 kg
23 kg
44 kg
Sideways tilt, max. 2525
Setting length of the slide*
hand-operated
motor-driven
90 mm
180 mm
90 mm
180 mm
Enclosure class IP10 IP10
*) NB. Available in other lengths on request.
A2SG J1 4WD (MIG/MAG)
Type of gas: Mix/Ar CO2
Permissible load at 100 %: 600 A 650 A
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 (wire excluded):
with hand-operated linear slides
with motor-driven linear slides
23 kg
45 kg
23 kg
45 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
Enclosure class IP10 IP10
*) NB. Available in other lengths on request.
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2.5 Main components A2SF J1 (SAW)
1. Wire feed unit
2. Slide kit, manual
3. Slide kit, motorized
4. Contact tube
5. Wire feed motor
6. Guide pin
7. Flux hopper
8. Flux tube
9. Carrier for wire drum
2.6 Main components A2SF J1 Twin (SAW)
1. Wire feed unit
2. Slide kit, manual
3. Slide kit, motorized
4. Connector (Twin)
5. Wire feed motor
6. Fine-Wire feed unit
7. Flux hopper
8. Flux tube
9. Carrier for wire drum
See on page 12 for a description of the main components.
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2.7 Main Components A2SG J1 (MIG/MAG)
1. Wire feed unit
2. Slide kit, manual
3. Slide kit, motorized
4. Connector (MIG/MAG)
5. Wire feed motor
6. Carrier for wire drum
2.8 Main Components A2SG J1 4WD (MIG/MAG)
1. Wire feed unit with four-wheel drive
2. Slide kit, manual
3. Slide kit, motorized
4. Connector (MIG/MAG)
5. Wire feed motor
6. Carrier for wire drum
See on page 12 for a description of the main components.
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2.9 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. The angular motion can be freely adjusted using the rotary slide.
For the motorized slide (A6 Slide), see instruction manual 0443 394 xxx.
2.9.3 Contact Tube / Connector
Transfers welding current to the wire during welding.
2.9.4 Wire Feed Motor
The wire feed motor is used for feeding the welding wire.
2.9.5 Guide Pin
The guide pin is used to help positioning the welding head in the joint.
2.9.6 Fine-wire straightener
The unit is used for the straightening of fine wire.
2.9.7 Flux Hopper / Flux Tube
The flux is filled into the flux hopper and 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.
See “Refilling with flux on page 24.
2.9.8 Carrier for Wire Drum
The carrier is provided with a brake hub on which one the wire drum is to be fitted.
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3 INSTALLATION
3.1 General
The installation must be executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
3.2 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.
Make sure the bolts do not touch the bottom of the insulator, which has a thread
depth of 14 mm.
3.2.2 A6 Slide
For mounting/ dismounting of A6 Slide, see instruction manual 443 394 xxx.
        
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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.
WARNING
To prevent the reel 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.
3.3 Adjusting the brake hub
The brake hub is adjusted when delivered, if
readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly
slack when wire feed stops.
Adjusting the braking torque:
Turn the red handle to the locked position.
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.
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3.4 Connections
3.4.1 General
PEK is to be connected by a qualified person.
See instruction manual 0460 948 xxx, 0460 949 xxx, 0459 839 036.
For the connection of A6 GMH, see instruction manual 0460 671 xxx.
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).
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
welding head (1).
4. Connect the measuring cable (12) between the welding power source (8) and
the work piece (9).
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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).
3. Connect the welding cable (10) between the welding power source (8) and the
welding head (1).
4. Connect the gas hose (5) between the reduction valve (6) and the gas valve on
the welding head (13).
5. Connect the hoses for cooling water (3) between the cooling unit (4) and the
welding head (1).
6. Connect the measuring cable (12) 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).
3. Connect the welding cable (10) between the welding power source (8) and the
welding head (1).
4. Connect the gas hose (5) between the reduction valve (6) and the gas valve on
the welding head (13).
5. Connect the hoses for cooling water (3) between the cooling unit (4) and the
welding head (1).
6. Connect the measuring cable (12) between the welding power source (8) and
the work piece (9).
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4 OPERATION
4.1 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. See page 15- 17.
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4.2 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.
3. For A2SF J1Twin and A2SG 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).
Setting the wire feed pressure:
Start by making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder's pressure rollers. It is important that the
pressure is not too great.
To check that the feed pressure is set correctly, you can feed out the wire
against an insulated object, e.g. a piece of wood.
When you hold the contact tip approx. 20 mm from the piece of wood the feed
rollers should slip.
Never tension the feed rollers more than is required to achieve an even feed.
Overtensioning reduces the life of the equipment. Never use any tool to tension
the feed rollers.
IMPORTANT!
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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 < 1.6 mm, use a guide spiral, which is
inserted in the guide tube (7).
4.3 Loading the welding wire (A2SG J1 4WD)
1. Check that the feed rollers (1, 4) and the contact nozzle (7) are of the correct
dimension for the wire size selected.
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) 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 through
the intermediate nozzle (3).
5. Locate the end of the wire in the groove of the other feed roller (4) and feed it
through the outlet nozzle (9).
6. 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.
7. Feed the wire forward 30 mm below the contact nozzle by pressing on
the control box PEK.
GB