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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SafeArcT GB
GB

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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.
GB

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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