ESAB A6 Mastertrac User manual

GB
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
L
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:
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
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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