ESAB A6 Mastertrac Tandem User manual

Valid for serial no. 940-xxx-xxxx0449 468 360 2010-10-08
A6 Mastertrac
Tandem
A6TF F2
Instruction manual

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

3

ENGLISH
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TOCe
1SAFETY 5...........................................................
2 INTRODUCTION 8...................................................
2.1 General 8..................................................................
2.2 Welding method 8...........................................................
2.3 Horizontal Welding 8.........................................................
2.4 Technical data 9............................................................
2.5 Main components A6TF F2 (SAW) 9...........................................
2.6 Description of Main Components 10............................................
3 INSTALLATION 11....................................................
3.1 General 11..................................................................
3.2 Mounting 11.................................................................
3.3 Adjusting the brake hub 11....................................................
3.4 Connections 12..............................................................
4 OPERATION 13.......................................................
4.1 General 13..................................................................
4.2 Loading the welding wire 14...................................................
4.3 Changing the feed roller 15...................................................
4.4 Contact equipment for submerged-arc welding 16................................
4.5 Refilling with flux powder 16...................................................
4.6 Transportation of the Automatic Welding Machine 17..............................
5 MAINTENANCE 18....................................................
5.1 General 18..................................................................
5.2 Daily 18.....................................................................
5.3 Regularly 18.................................................................
6 TROUBLESHOOTING 19..............................................
6.1 General 19..................................................................
6.2 Possible faults 19............................................................
7 ORDERING OF SPARE PARTS 19......................................
WEAR COMPONENTS 20.................................................
DIMENSION DRAWING 21................................................
SPARE PARTS LIST 23..................................................

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SafeArcT GB
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 precau-
tions. Safety precautions must meet the requirements that apply to this type of weld-
ing 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 welding equipment. Incorrect operation of the equipment may lead to hazar-
dous situations which can result in injury to the operator and damage to the equip-
ment.
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
Sthe working area/working range is free from objects.
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. Note! Do not use safety gloves
when replacing wire.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. Protection against other risks
SDust particles of a certain size can be harmful to man.
A ventilation system and extractor should therefore be provided to eliminate
this risk.
SWhen replacing the wire drum, exercise the greatest caution as the end of
the wire could cause personal injury.
GB

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SafeArcT GB
6. 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.
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
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 keep fumes and gases 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 inflam-
mable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use ear defenders or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION
SCall 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
The A6TF F2 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 PEK 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 wire welding . 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 A6SF is always used, which must
be connected to 2 welding power sources and 2 control boxes of type PEK.
The tandem welding head includes 2 single welding heads (A6SF), each with its
own contact tip. Each contact tip has a maximum rated load of 1500 A.
2.3 Horizontal Welding
The automatic welding machine is designed for horizontal welding.
A6TF F2 is not to be used for welding on inclined planes.
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2.4 Technical data
A6TF F2 (SAW)
Supply voltage 42 V AC
Ratedload100% 1500 A
Electrode dimensions:
solid single wire
flux-cored wire
3,0-6,0 mm
3,0-4,0 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. 2x30kg
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
Enclosure class IP10
EMC classification Class A
2.5 Main components A6TF F2 (SAW)
1. Carriage
2. Carrier
3. Wire feed unit
4. Slide, manual
5. Connector
6. Motor with gear (A6 VEC)
7. Flux hopper
8. Flux nozzle
See on page 10 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 Carrier
The control boxes, among other things, are to be fitted on the carrier.
2.6.3 Wire Feed Unit
The unit is used for guiding and feeding the welding wire down into the connector.
2.6.4 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.
2.6.5 Connector
Transfers welding current to the wire during welding.
2.6.6 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.
2.6.7 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 16.
GB

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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).
WARNING
To prevent the reel sliding off the hub:
S 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
SThe PEK is to be connected by a qualified person. See instruction manual
0460 948 xxx, 0460 949 xxx, 0459 839 036.
SFor the connection of A6 GMH, see instruction manual 0460 671 001.
SFor the connection of A6 PAV, see instruction manual 0460 670 001.
3.4.2 Automatic welding machine A6TF F2 (Submerged arc welding. SAW)
1. Connect the control cable (5) between the power source (3) and the control box
PEK (2).
2. Connect the return cable (6) between the power source (3) and work piece (4).
3. Connect the welding cable (7) between the power source (3) and the automatic
welding machine (1).
4. Connect the measurement cable (8) between the power source (3) and
workpiece (4).
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4OPERATION
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 12.
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4.2 Loading the welding wire
1. Mount the wire drum according to the instructions on page 11.
2. Check that feed roller (1) and contact jaw or contact tip (3) are of the correct
dimension for the selected wire size.
3. When welding with fine wire:
SFeed 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).
4. Pull the end of the wire through the straightener (2).
SFor a wire diameter greater than 2 mm; straighten out 0.5 m of wire and feed
it by hand down through the straightener.
5. Locate the end of the wire in the feed roller (1) groove.
6. Set the wire tension on the feed roller with the knob (4).
SNote! Do not tension more than is required to achieve an even feed.
7. Feed the wire forward 30 mm below the contact tip by pressing on the
control box PEK.
8. Direct the wire by adjusting the knob (5).
SAlways use a guide tube (7) to ensure even feed of fine wire (1.6 - 2.5 mm).
Accessories:
SFine-wire straightener (6)tobefittedontopof
the clamp of the wire feed unit (2).
N.B. When mounting the fine-wire straightener,
remove the plate (9) if it's exists.
N.B. Theprotectionplate(8) shall not be removed
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4.3 Changing the feed roller
Single wire
SRelease the knobs (3) and (4).
SRelease the hand wheel (2).
SChange the feed roller (1).
They are marked with their respective wire sizes.
Flux-cored wire for knurled rollers (Accessories)
SChange 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).
STighten 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
For single wire 3.0 - 6.0 mm. Heavy duty (D35)
SUse the straightener (3), connector (1) D35 with
contact jaws (2).
SAssemble one contact jaw with the M5 bolts provided,
in the fixed contact tip (a).
SAssemble the other contact jaw in the free half of the
two-piece connector (b) under the bolt (8) and tighten
down hard to ensure that a good contact is achieved between
the contact jaws and the wire.
For flux-cored wire 1.6 mm - 4.0 mm (D20 and D35) (Accessories)
If contact jaws (D35) are used, the contact jaws must not be tightened down to
hard in order to ensure that the flux-cored wire is not distorted.
SEnsure that good contact is achieved with the wire.
Adjustment of the wire for tandem welding
The distance between the first and second wires must not be so great that the
slag has time to solidify between the wires.
SEnsure that good flux coverage is achieved between the first and second
wires.
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 shall 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.
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4.6 Transportation of the Automatic Welding Machine
SDisengage the wheels by turning the locking lever (1).
N.B. In case of lifting the automatic welding machine, the lifting eye (2) shall be
used.
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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
SClean flux and dirt off moving parts of the welding machine.
SCheck that the contact tip and all electrical cables are connected.
SCheck that all bolted joints are tight and that guides and drive rollers are not
worn or damaged.
SCheck 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 11.
5.3 Regularly
SCheck the wire feed motor brushes
once every three months.
Replace when they are worn
downto6mm.
SEximine the slides and lubricate if
they bind.
SInspect the wire guides, drive
rollers and contact tip on the wire
feed unit. Replace any worn or damaged
components, (see wear components on page 20).
SIf the carriage travel becomes
jerky, check that hte chain is correctly tensioned. Tension the chain if necessary.
STo tension the chain undo the nut (*1) and turn the cam, then tighten the nut.
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6 TROUBLESHOOTING
6.1 General
Equipment
SInstruction manual for control box PEK, ordering number 0460 948 xxx,
0460 949 xxx, 0459 839 036.
SInstruction manual for motor with gear A6 VEC, ordering number 0443 393 xxx.
Check
Sthat the power supply is connected for the correct mains supply
Sthat all three phases are supplying the correct voltage (phase sequence is not
important)
Sthat welding cables and connections are not damaged
Sthat the controls are correctly set
Sthat the mains supply is disconnected before starting repairs
6.2 Possible faults
1. Symptom Current and voltage readings show large fluctuations.
Cause 1.1 Contact jaws or nozzle are worn or wrong size.
Action Replace contact jaws or nozzle.
Cause 1.2 Feed roller pressure is inadequate.
Action Increase pressure on feed rollers.
2. Symptom Wire feed is irregular.
Cause 2.1 Pressure on feed rollers incorrectly set.
Action Pressure on feed rollers incorrectly set.
Cause 2.2 Feed rollers wrong size.
Action Replace feed rollers.
Cause 2.3 Grooves in feed rollers are worn.
Action Replace feed rollers.
3. Symptom Welding cables overheating.
Cause 3.1 Poor electrical connection.
Action Clean and tighten all electrical connections.
Cause 3.2 Cross-sectional area of welding cables too small.
Action Use cables with a larger cross-section or use parallel cables.
7 ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list on page 23.
This will simplify dispatch and ensure you get the right part.
GB

WEAR COMPONENTS
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Feed rollers
SAW tubular wire
Part no D (mm)
0146 024 880 0,8--1,6
0146 024 881 2,0--4,0
Pressure rollers
SAW tubular wire
Part no D (mm)
0146 025 880 0,8--1,6
0146 025 881 2,0--4,0
Contact jaws
SAW HD (D35)
Part no D (mm)
0265 900 880 3,0
0265 900 882 4,0
0265 900 883 5,0
0265 900 884 6,0