ESAB A6 Mastertrac User manual

Valid for serial no. 916-xxx-xxxx0449 275 260 2009-11-09
A6 Welding heads
A6SF F1 / A6SF F1 Twin
Instruction manual

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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 WeldingMethod 8...........................................................
2.3 Definitions 8................................................................
2.4 TechnicalData 9............................................................
2.5 MainComponentsA6SFF1 10.................................................
2.6 MainComponentsA6SFF1Twin 10............................................
2.7 DescriptionofMainComponents 11............................................
3 INSTALLATION 12....................................................
3.1 General 12..................................................................
3.2 Mounting 12.................................................................
3.3 AdjustingtheBrakeHub 13....................................................
3.4 Connections 14..............................................................
4 OPERATION 15.......................................................
4.1 General 15..................................................................
4.2 LoadingtheWeldingWire 16..................................................
4.3 ChangingtheFeedRoller 17...................................................
4.4 Contact Equipment for Submerged Arc Welding 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 RefillingwithFluxPowder 19..................................................
4.6 Conversion of A6SF F1 / A6SF F1 Twin (Submerged Arc Welding) to MIG/MAG welding .
19
4.7 Conversion of A6SF F1 (Submerged Arc Welding) to Twin-arc 19. . . . . . . . . . . . . . . . . . .
5 MAINTENANCE 20....................................................
5.1 General 20..................................................................
5.2 Daily 20.....................................................................
5.3 Regularly 20.................................................................
6 FAULTTRACING 21..................................................
6.1 General 21..................................................................
6.2 Possiblefaults 21............................................................
7 ACCESSORIES 22....................................................
8 ORDERINGOFSPAREPARTS 22......................................
DIMENSIONDRAWING 23................................................
SPAREPARTSLIST 25..................................................

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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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2 INTRODUCTION
2.1 General
All the welding heads included in this instruction manual are designed for SAW
welding of butt and fillet joints.
They are intended for use in combination with PEK and ESAB's welding power
source LAF or TAF.
2.2 Welding Method
Submerged Arc Welding (SAW)
Submerged arc Light Duty.
Submerged arc light duty with a Ø 20 mm connector permits a load up to 800 A
(100%).
Submerged 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.
2.3 Definitions
            

             ! " 
   
            #   ! " 
  $ 
  %       
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2.4 Technical Data
A6SF F1 / A6SF F1 Twin
Rated load 100% 1500 A
Wire dimensions:
solid single wire
flux-cored wire
twin wire
3,0-6,0 mm
3,0-4,0 mm
2x2,0-3,0mm
Wire feed speed 0,2-4,0 m/min
Brake drum braking torque 1,5 Nm
Max weight, wire 2x30 kg
Flux hopper capacity (Not to be filled with preheated flux) 10 l
Weight (flux and wire excluded)
with hand-operated linear slides
with motor-driven linear slides
58 kg
75 kg
Sideways tilt, max. 25
Setting length of the slide*
hand-operated
motor-driven 210 mm 300 mm
Enclosure class IP10
*) NB! Other lengths on request.
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2.5 Main Components A6SF F1
1. Wire feed unit
2. Slide kit, manual
3. Slide kit, motorised
4. Contact tube
5. Motor with gear (A6 VEC)
6. Carrier for wire drum
7. Flux hopper
8. Flux tube
9. Flux nozzle
2.6 Main Components A6SF F1 Twin
1. Wire feed unit
2. Slide kit, manual
3. Slide kit, motorised
4. Connector (Twin)
5. Motor with gear (A6 VEC)
6. Carrier for wire drum
7. Flux hopper
8. Flux tube
9. Flux nozzle
See on page 11 for a description of the main components.
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2.7 Description of Main Components
2.7.1 Wire Feed Unit
The unit is used for guiding and feeding the welding wire down into the contact
tube/connector.
2.7.2 Manual and Motorised 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 motorised slide (A6 Slide), see instruction manual 0443 394 xxx.
2.7.3 Contact Tube / Connector
Transfers welding current to the wire during welding.
2.7.4 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.
2.7.5 Carrier for Wire Drum
The carrier is provided with a brake hub on which one the wire drum is to be fitted.
2.7.6 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 19.
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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 be mounted on a beam-travelling carriage or on a welding col-
umn 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 0443 394 xxx.
This safety sign is placed on the cover of the vertical slide.
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3.2.3 Wire reel (Accessories)
The wire reel (1) is mounted on the brake hub (2).
Check that the carrier (3) is pointing upwards.
NOTE! The maximum angle for the wire reel is 25.
At extreme angles, wear will occur on the brake hub
locking mechanism and the wire reel 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 the 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 A6SF F1 / A6SF F1 Twin
1. Connect the control cable (3) between the welding power source (4) and the (2).
2. Connect the return cable (7) between the welding power source (4) and the work
piece (5).
3. Connect the welding cable (6) between the welding power source (4) and the
welding head (1).
4. Connect the measuring cable (8) between the welding power source (4) and the
work piece (5).
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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 14.
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4.2 Loading the Welding Wire
1. Mount the wire drum according to the instructions on page 13.
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 A6SF F1 Twin:
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.
8. Feed the wire forward 30 mm below the contact tip by pressing on control
box PEK.
9. Straighten 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).
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4.3 Changing the Feed Roller
Single wire
Release the knobs (3) and (4).
Release the hand wheel (2).
Change the feed roller (1).
The rollers are marked with their respective wire
sizes.
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 a special stub shaft
(order no. 0146 253 001).
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.
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4.4 Contact Equipment for Submerged Arc Welding
4.4.1 For Single Wire 3,0 - 6,0 mm
Use automatic welding machine A6SF F1 where
the following units units are included:
Wire feed unit (1)
Connector D35 (2)
Contact jaw (3)
Ensure that good contact is achieved between the
contact jaws and the wire.
4.4.2 For Twin Wires 2 x 2,0 - 3,0 mm
Use automatic welding machine A6SF F1 Twin
where the following are included:
Wire feed unit (1)
Connector Twin D35 (2)
Contact jaw (3)
Ensure that good contact is achieved between the
contact jaws and the wire.
Guide tubes (4, 6)
Accessories:
Fine-wire straightener (5) to be fitted on top of
the clamp of the wire feed unit (1).
N.B. When mounting the fine-wire straightener,
remove the existing plate (7).
N.B. The protection plate (8) shall not be removed
Adjustment of the Wires for Twin-arc Welding:
Position the wires in the joint so as to achieve optimal weld quality by rotating the
connector. The two wires can be rotated so that they are positioned one after the
other along the line of the joint, or in any position up to 90across the joint, i.e.
one wire on each side of the joint.
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4.5 Refilling with Flux Powder
1. Close the flux valve (1) on the flux hopper.
2. Remove the cyclone on the flux recovery unit, if fitted.
3. Fill with flux powder.
NOTE! The flux powder must be dry.
4. Position the flux tube so that it does not become
kinked.
5. Adjust the height of the flux nozzle above the weld so
that the correct amount of flux is delivered.
Flux coverage should be sufficient so that penetration
of the arc does not occur.
4.6 Conversion of A6SF F1 / A6SF F1 Twin (Submerged Arc
Welding) to MIG/MAG welding
For the conversion kit see instruction manual 0456 756 xxx.
4.7 Conversion of A6SF F1 (Submerged Arc Welding) to Twin-arc
For the conversion kit see instruction manual 0456 757 xxx.
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5 MAINTENANCE
5.1 General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
NB! Before doing any kind of maintenance work, make sure the mains is
disconnected.
For the maintenance of the PEK, see the instruction manual 0460 948 xxx,
0460 949 xxx, 0459 839 036.
5.2 Daily
Keep the moving parts of the welding head clean.
Make sure contact nozzles, hoses and electric cables are properly connected.
Make sure all bolted joints are tightened and that the conduit and the feed rollers
are not worn or damaged.
Check the brake hub braking torque. It should not be so low, that the wire reel
continues to rotate when wire feed is stopped and it should not be so great that
the feed rollers slip. As a guide, the braking torque for a 30 kg wire reel should
be 1.5 Nm.
To adjust the braking torque see on page 13.
5.3 Regularly
Check the wire feed motor brushes once every three months. Replace when
they are worn down to 6 mm.
Examine the slides and lubricate if they bind.
Inspect the wire guides, drive rollers and contact tip on the wire feed unit.
Replace any worn or damaged components, (see spare parts list on page 25).
Inspect the gas nozzle and clear it regularly of welding spatter.
Blow the wire conduit clean at regular intervals.
For trouble-free wire feed the wear parts of the feed mechanism should be
cleaned and replaced at regular intervals.
NOTE that too hard pre-tensioning can lead to abnormal wear of the pressure
roller, feed roller and wire conduit.
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