ESAB A6 Mastertrac User manual

Valid for serial no. 7090449 468 101 GB 2007--07--12

A6 Mastertrac

A6 TFE2

Instruction manual

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DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, declares under sole responsibility that the au-

tomatic welding machine A6 Mastertrac (A6 TFE2) from serial number 709 xxx xxxx (2007 week 09)

is designed and tested in conformity with the published standards in accordance with the conditions in

the directives (98/37/EC) and (2004/108/EC).

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Kent Eimbrodt

Global Director

Equipment and Automation

axå 2007--02--21

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TOCe

Rights reserved to alter specifications without notice.

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

2 INTRODUCTION 6...................................................

2.1 General 6..................................................................

2.2 Welding method 6...........................................................

2.3 Horizontal Welding or Welding on an Inclined Plane 6............................

2.4 Technical data 7............................................................

2.5 Main components 7.........................................................

2.6 Description of Main Components 8............................................

3 INSTALLATION 9....................................................

3.1 General 9..................................................................

3.2 Mounting 9.................................................................

3.3 Adjusting the brake hub 9....................................................

3.4 Connections 10..............................................................

4 OPERATION 11.......................................................

4.1 General 11..................................................................

4.2 Loading the welding wire 12...................................................

4.3 Changing the feed roller 13...................................................

4.4 Contact equipment for submerged--arc welding 14................................

4.5 Refilling with flux powder 15...................................................

4.6 Conversion of A6 TF (submerged--arc welding) to Twin--arc 15.....................

5 MAINTENANCE 16....................................................

5.1 General 16..................................................................

5.2 Daily 16.....................................................................

5.3 Regularly 16.................................................................

6 TROUBLESHOOTING 17..............................................

6.1 General 17..................................................................

6.2 Possible faults 17............................................................

7 ORDERING OF SPARE PARTS 17......................................

WEAR COMPONENTS 18.................................................

DIMENSION DRAWING 19................................................

SPARE PARTS LIST 21...................................................

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1SAFETY

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 precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations 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 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

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, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

Mind the following:

SThat the freewheel clutch of the gear shall be in locked position.

SThat, if the operator leaves the machine, it shall be parked with blocks in front of the wheels,

in order to prevent the machine from moving unintentionally.

SMake sure that the automatic welding machine is not unstable before start.

SThat the placement of the welding head and the wire reel influence the centre of gravity of

the machine.

Too high a centre of gravity means an unstable welding machine.

SThat the consumption of wire and flux results in displacement of the weight distribution during

the welding.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ 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 take fumes and gases away 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 earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

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2 INTRODUCTION

2.1 General

The A6 TFE2 automatic welding machine, with two welding heads, is mounted on

a self--propelled trolley and is designed for submerged--arc welding of butt welds.

All other uses are prohibited

The position of welding head can be set horizontally and vertically with the linear

slides. Angular movement is adjusted with the angular slide.

The automatic welding machine is intended for use in combination with the

A2--A6 Process Controller (PEH) and ESAB’s welding power sources LAF or TAF.

2.2 Welding method

2.2.1 Submerged--arc welding

The weld bead is protected by a cover of flux during the welding.

SSubmerged--arc Heavy duty

Submerged--arc heavy duty, with a ∅35 mm connector, which permits a load of

up to 1500 A.

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.

STandem welding (submerged--arc)

For tandem welding, a welding head of type A6 TFE2 is always used, which

must be connected to 2 welding power sources and 2 control boxes of type

(A2--A6 Process Controller).

The tandem welding head includes 2 single welding heads (A6 SF), each with its

own contact tip. Each contact tip has a maximum rated load of 1500 A.

2.3 Horizontal Welding or Welding on an Inclined Plane

The automatic welding machine is designed for horizontal welding.

A6 TFE2 is not to be used for welding on inclined planes.

Read section 5, on page 4.

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2.4 Technical data

A6 TFE2

Supply voltage 42 V AC

Rated load 100 % 1500 A DC/AC

Electrode dimensions:

solid single wire 3,0--6,0 mm

flux--cored wire 3,0--4,0 mm

twin wire 2x2,0--3,0 mm

Electrode feed rate, max. 4m/min

Brake drum braking torque 1,5 Nm

Speed of travel 0,1--2,0 m/min

Electrode weight, max. 2x15kg

Flux hopper capacity (Must not be filled with preheated flux) 10 l

Weight (excluding electrode and flux) 158 kg

Continuous A weighted sound pressure 68 dB

2.5 Main components

1. Carriage

2. Wire feed unit

3. Slide, manual

4. Connector

5. Motor with gear (A6 VEC)

6. Flux hopper

7. Flux nozzle

See on page 8 for a description of the main components.

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2.6 Description of Main Components

2.6.1 Carriage

The carriage is provided with 4--wheel drive.

The carriage can be secured by way of the

locking lever (1).

2.6.2 Wire Feed Unit

The unit is used for guiding and feeding the welding wire down into the connector.

2.6.3 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.

2.6.4 Connector

Transfers welding current to the wire during welding.

2.6.5 Motor with gear (A6 VEC)

The motor is used for feeding the welding wire.

For more information regarding the A6 VEC see instruction manual 0443 393 xxx.

2.6.6 Flux Hopper / Flux Tube / Flux nozzle

The flux is filled into the flux hopper and is then transferred to the workpiece through

the flux tube and the flux nozzle.

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 15.

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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 Wire drum (Accessories)

Wire drum (1) is mounted on the brake hub (2).

SCheck 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.

SAdjusting the braking torque:

STurn the red handle to the locked

position.

SInsert 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

STheA2--A6ProcessController(PEH) is to be connected by a qualified person.

SFor the connection of A6 GMD, see instruction manual 0443 403 xxx.

SFor the connection of A6 PAK, see instruction manual 0443 405 xxx.

3.4.2 Submerged arc welding (SAW)

1. Connect the control cable (7) between the power source (8) and the control box

A2--A6 Process Controller (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 machine (1).

4. Connect the measurement cable (12) between the power source (8) and

workpiece (9).

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