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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4 OPERATION
4.1 General
Caution:
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 4. Read through before you start using the equipment!
SSelect wire type and flux powder or shielding gas so that the weld material is as
close as possible to the analysis of the base metal.
Select wire size and welding data in accordance with the values recommended
by the welding materials supplier.
SThorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE! The width of the weld joint gap must be uniform.
STo minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
SAlways carry out a test weld with the same joint type and sheet thickness as the
production work piece.
SFor control and adjustment of the automatic welding machine and welding power
supply, see the instruction manual for the A2--A6 Process Controller (PEH).
SThe trolley can be moved manually after disengaging the disengagement lever,
see the diagram on page 8.
SWhen changing consumables, see table on page 18.
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4.2 Loading the welding wire
1. Mount the wire drum according to the instructions on page 9.
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 A6 TF (Twin):
SFeed the wire through the wire guide (8).
4. 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).
5. 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.
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).
SNote! Do not tension more than is required to achieve an even feed.
8. Feed the wire forward 30 mm by pressing on the control box
A2--A6 Process Controller (PEH).
9. 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).
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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.
Twin wire (Twin--arc)
SChange 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.
SAssemble the pressure roller with special stub shaft
(order no. 0146 253 001).
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.
Fortwinwires2x2.0--3.0Heavy Twin (D35) (Accessories)
SUse the straightener (3), connector (1) D35 with
contact jaws (2).
SAssemble the first contact jaw with the M5 bolts supplied,
in the fixed connector (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.
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Fortwinwires2x1.2--2.0mm,LightTwin(D35)(Accessories)
SUse the straightener (3), connector (1) D35 with twin
adapter (9) and 2 contact tips (2) (M6 threads) and
separate fine wire straightener (4) with two guide tubes (6).
For twin wires < 1.6 mm, a guide spiral, inserted into each
guide tube, is used.
SAssemble the twin adapter (9) for M6 contact tips (2) with the
M5 bolts in the fixed half of the two--piece connector (1).
SAssemble the clamp (7) with guide tube (6) in the M12 hole
on the standard straightener (3). The guide tube should bottom
on the twin adapter (9) for the contact tip (2).
STighten the contact tip (2) with a key to ensure that a good
contact is achieved.
SIf necessary, cut the guide tube (6) to length so that the feed
roller (5) runs freely.
Adjustment of the wires for Twin--arc welding:
SPosition 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.
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. Where possible
avoid using agglomerating flux powder outdoors and
in damp environments.
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 A6 TF (submerged--arc welding) to Twin--arc
SAssemble in accordance with the instructions accompanying the conversion kit.
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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 A2--A6 Process Controller (PEH), see the instruction
manual 0443 745 xxx.
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 9.
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 spare parts list on page 21).
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 A2--A6 Process Controller (PEH),
ordering number 0443 745 xxx.
SOperating 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 21.
This will simplify dispatch and ensure you get the right part.
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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

Dimension drawing
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