ESAB TAF 801 User manual

Instruction manual

0449 509 001 GB 20180426 Valid for: serial no. 935-, 126-xxx-xxxx

TAF 801

TABLE OF CONTENTS

0449 509 001 © ESAB AB 2018

1SAFETY ....................................................................................................... 4

1.1 Meaning of symbols ............................................................................... 4

1.2 Safety precautions ................................................................................. 4

2INTRODUCTION.......................................................................................... 7

3TECHNICAL DATA ...................................................................................... 8

4INSTALLATION............................................................................................ 9

4.1 Location................................................................................................... 9

4.2 Connections............................................................................................ 10

5OPERATION ................................................................................................ 11

5.1 Controls................................................................................................... 11

6MAINTENANCE........................................................................................... 12

6.1 Cleaning .................................................................................................. 12

6.1.1 Welding power source.......................................................................... 12

6.1.2 Contactor.............................................................................................. 12

7ORDERING SPARE PARTS ........................................................................ 13

DIAGRAM ............................................................................................................ 14

CONNECTION INSTRUCTION............................................................................ 18

ORDERING NUMBERS....................................................................................... 19

Rights reserved to alter specifications without notice.

1 SAFETY

0449 509 001 -4- © ESAB AB 2018

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 509 001 -5- © ESAB AB 2018

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 509 001 -6- © ESAB AB 2018

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.

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.

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 509 001 -7- © ESAB AB 2018

2 INTRODUCTION

TAF 801 is a remote-controlled, two-phase AC welding power source designed for

high-throughput, mechanised submerged-arc welding (SAW).

The welding power source converts, via a thyristor bridge-rectifier, the secondary voltage's

sine wave to a square wave with excellent arc ignition and welding characteristics.

The welding power source is fan cooled and is overload protected by a thermal cut-out.

Re-setting takes place automatically as soon as the temperature has reduced to a permitted

level.

3 TECHNICAL DATA

0449 509 001 -8- © ESAB AB 2018

3 TECHNICAL DATA

TAF 801

Voltage 346/380/400/415/500 V±10%, 1~50 Hz

440/550 V±10%, 1~60 Hz

Primary current Imax 147 A

Permissible load at:

100 % duty cycle 800 A / 44.0 V

Setting range 300 A/32.0 V - 800 A/44.0 V

No-load voltage 70 V

No-load power 214 W

Efficiency at maximum current 84%

Power factor at maximum current 0.83

Apparent power at maximum current 50.7 kVA

Active power at maximum current 42.2 kW

Operating temperature -10 °C to +40 °C (+14 °F to +104 °F)

Weight 495.0 kg (1091.3 lb)

Dimensions L x W x H 774×598×1228 mm (30.47×23.54×48.35

in.)

Insulation class (transformer) F

Enclosure class IP23

Application class

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP23 is intended for indoor and outdoor use.

4 INSTALLATION

0449 509 001 -9- © ESAB AB 2018

4 INSTALLATION

The installation must be carried out by a professional.

NOTE!

Mains supply requirements

High power equipment may, due to the primary current drawn from the mains

supply, influence the power quality of the grid. Therefore connection restrictions

or requirements regarding the maximum permissible mains impedance or the

required minimum supply capacity at the interface point to the public grid may

apply for some types of equipment (see "TECHNICAL DATA" chapter). In this

case it is the responsibility of the installer or user of the equipment to ensure, by

consultation with the distrubution network operator if necessary, that the

equipment may be connected.

4.1 Location

WARNING!

Secure the equipment - particularly if the ground is uneven or sloping.

• Place the welding power source on a level foundation.

• Make sure there is nothing to prevent the cooling.

Lifting instructions

4 INSTALLATION

0449 509 001 - 10 - © ESAB AB 2018

4.2 Connections

• On delivery the welding power source is connected for

400 V. For other supply voltage, switch over to the

desired voltage on the main transformer and the

control transformer according to the connection

instructions in "CONNECTION INSTRUCTION"

chapter.

• Make sure the mains cable has the right sectional

area and fuse it with an adequate fuse according to

applicable local directions (see table below in "Mains

connection" section).

•Connect the earth cable to the screw marked .

• Connect the mains cable to the main terminal blocks

L1 and L3.

• Tighten the cable support (1).

• Connect the control cable between the welding power

source and the control unit to the 28-pole contact (2)

inside the welding power source.

• Connect the 1-pin measuring cable (4) for measuring

the arc voltage to the return cable/welding head.

• Connect a suitable welding and return cable to the

contacts (3) marked on the front of the power

source.

Mains connection

TAF 801 50 Hz 60 Hz

Voltage (V) 346 ± 10% 380 ± 10% 400/415 ±

10%

500 ± 10% 440 ± 10% 550 ± 10%

Phase current

I1eff (A)

147 134 127 102 127 102

Cable area (mm2

)

2×70+35 2×70+35 2×70+35 2×50+35 2×70+35 2×50+

Fuse, slow (A) 160 160 160 125 160 125

NOTE!

The mains cable areas and fuse sizes as shown above are in accordance with

Swedish regulations. For other regions, supply cables must be suitable for the

application and meet local and national regulations.

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