ESAB A6 TFD1 Instructions for use

Automatic welding machine
333 534--003 9612
A6 TFD1/TFD2/
TGD1
Simplified ser
v
ice manual

LIST OF CONTENTS Sida
SAFETY 4.....................................................
TECHNICAL DESCRIPTION 5...................................
INSTALLATION 10...............................................
OPERATION 11.................................................
MAINTENANCE 13..............................................
TROUBLESHOOTING 14.........................................
DIMENSION DRAWING 15........................................
DIAGRAM 17....................................................
SPARE PARTS LIST A6 TFD1/TFD2/TGD1 19.......................
Rights reserved to alter specifications without notice.

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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 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 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
inflammable materials nearby.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE
INSTALLING OR OPERATING THE EQUIPMENT
PROTECT YOURSELF AND OTHERS!

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SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring
that anyone who works on or near the equipment observes all the relevant safety
precautions.
The following recommendations should be observed in addition to the standard
regulations that apply to the work place.
All work must be carried out according to the specified instructions by personnel who
are thoroughly familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous
situation which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the automatic welding machine must be familiar with:
Sits operation
Sthe location of emergency stops
Sits function
Srelevant safety precautions
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the machine
when it is started up.
Sthat no--one is in a hazardous position when the carriage or slide mechan-
isms are operated.
3. The work place must:
Sbe clear of mechanical components, tools, or other obstructions that could
prevent the operator from moving freely within the working area.
Sbe organized so that there is free access to the emergency stop.
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, etc., which could
become trapped.
5. General precautions
Live electrical components are normally shielded from accidental contact.
SMake sure the return cable is connected securely.
SWork on high voltage components may only be carried out by a qualified
electrician.
SAppropriate fire extinguishing equipment must be clearly marked and close
at hand.
SLubrication and maintenance must not be carried out on the equipment dur-
ing its operation.

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TECHNICAL DESCRIPTION
The A6 TFD1 automatik welding machine is mounted on a tractor unit and intended for DC
or AC submerged--arc welding of butt and fillet welds.
The A6 TFD2 automatik welding machine with two welding heads is mounted on a tractor
unit and intended for DC or AC submerged--arc welding of butt and fillet welds.
The A6 TGD1 automatik welding machine is mounted on a tractor unit and intended for DC
MIG/MAG--welding of butt and fillet welds.
Welding head position is adjustable by means of vertical and horisontal crossslides, with an
angular slide for angular adjustment.
A6 TFD1 A6 TFD2 A6 TGD1
Permissible load 1500 A DC/AC 1500 A DC/AC 600 A DC
Wire diameter
solid wire
hollow wire
3,0--6,0 mm 3,0--6,0 mm 1,0--2,4 mm
1,6--3,2 mm
Wire feed speed, max. 4,2 m/min 4,2 m/min 17,5 m/min
Travel speed, max. 2,5 m/min 2,5 m/min 2,5 m/min
Wire weight, max. 30 kg 30 kg 30 kg
Flux hopper volume 10 l 10 l
Weight (excl. wire and flux) 110 kg 158 kg 100 kg
Brake hub torque 1,5 Nm 1,5 Nm 1,5 Nm
Sideways tipping angle, max. 25_25_25_
Control voltage 42 V AC 42 V AC 42 V AC

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TheA6Tautomaticweldingmachineconsistsof: (See the pictures on page 7)
1. Brake hub
2. Wire straightener
for feeding and straightening the filler wire before it enters the contact device and contact
jaws or contact tip, and to carry weld ing current from the shunt to the contact device.
The straightener clamp can be rotated around the wire drive unit gearbox, e,g. when
welding with leading or trailing wire and when fillet welding.
3. Handle
for adjusting the position of the tractor, manual transport or adjustment while welding is
in progress.
4. Slide, hand--operated for transverse adjustment of the welding head
5. Slide, hand--operated for vertical adjustment of the welding head
6. Insulator, for galvanic insulation of live parts, e.g. the welding head and the carriage
7. Tractor unit
with four wheels, of which two are grooved for use on rails. The tractor is powered by a
geared motor with chain drive to the two axles, so that all four wheels are driven.
Motor supply voltage 42 V
Motor speed 3220 rpm
Motor torque 27 Ncm (0.27 Nm)
Gear ratio 187.5:1
Gearbox output torque 22.5 Nm
Final reduction ratio 64:15
Sprocket ratio 1:1
8. Wire feed motor, A6 VEC (see instructions 333 533--003)
Wire feed motor with reduction gear 42 V (A6 TFD1/A6 TFD2)
Motor speed 4000 rpm
Gear ratio 156,1
Wire feed motor with reduction gear 42 V (A6 TGD1)
Motor speed 8000 rpm
Gear ratio 74:1
9. Control lever, for disengaging the drive for manual transport
10. PEG 1 control box
Additional parts:
11. Wire reel, for max. 30 kg of filler wire
12. Flux hopper
13. D35 contact equipment, intended for use with 3.0 -- 6.0 mm wire
Additional parts for the A6 TGD1:
14. Hoses, for gas and cooling water (14/6.3 mm)
15. Solenoid valve, 42 V

A6 TGD1
A6 TFD1
A6 TFD2
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Extra accessories for the A6 TFD1 A6 TFD2 and A6 TGD1 Ordering no.
Fine wire straightener (not for the A6 TFD2)
when accurate wire straightening is required for single wire
not exceeding 2.5 mm diameter
332 565--880
Guide wheel bogey (not for the A6 TFD2) 6711 257--80
Rail set (2 m) 6715 039--80
Guide rail with magnets (3 m), (several lengths of guide rail can be used together) 154 203--880
Extra accessories for the A6 TFD1 (submerqed-arc welding)
Fine wire straightener
when accurate wire straightening is required for twin wire not
exceeding 2.5 mm diameter
145 787--880
D20 contact equipment for single wire:
without contact tip and feed roller
with contact tip and feed rollers for 1.6 -- 3.0 mm
wire with contact tip and feed rollers for 3.0 -- 5.0 mm wire
334 289--880
--881
--882
D35 contact equipment for single wire (L=Length of the contact device)
without contact jaws and feed rollers (L=220 mm)
with contact jaws and feed rollers for 3.0 -- 6.0 mm (L=220 mm)
without contact jaws and feed rollers (L=275 mm)
with contact jaws and feed rollers for 3.0 -- 6.0 mm (L=275 mm)
334 290--880
--881
--882
--883
D35 contact equipment for twin wire, with fine wire straightener and flux nozzle
without contact tip and feed rollers (L=220 mm)
without contact tip and feed rollers (L=275 mm)
without contact jaws and feed rollers (L=220 mm)
without contact jaws and feed rollers (L=275 mm)
with contact tip and feed rollers 1.2-- 2.5 mm (L=220 mm)
with contact tip and feed rollers 1.2-- 2.5 mm (L=275 mm)
with contact jaws and feed rollerc3 2.5-3,0 mm (L=220 mm)
with contact jaws and feed rollers 2.5-3,0 mm (L=275 mm)
with flux tube
334 291--880
--881
--882
--883
--884
--885
--886
--887
153 299--880
Contact tube curved, D20, for use in fillet welding 155 197--001
Flux funnel, for D20 contact equipment with insulating sleeve 145 221--881
Flux funnel
for D35 contact equipment, including
Insert, height 18 mm
Insert, height 30 mm
2549 008--80
2549 003--02
2549 003--01
OPC flux recovery unit, (see instruction manual 333 125--001) 148 140--880
Wire reel, steel 416 492--880

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Guide lamp
for D35 contact equipment
for D20 contact equipment
153 143--880
--882
Strip cladding head, for welding 30--100 mm strip 155 972--880
Accessory set for air/arc gouging 153 592--880
Conversion set
consisting of a wire feed unit for an A6 SFD1 for conversion of an existing
A6 TFD1 automatic welding machine to MIG/MAG--welding
(wire diameter 1.0 -- 3.2 mm)
334 299--880
Extra accessories for the A6 TFD2 (submerged--arc welding)
OPC flux recovery unit, (see instruction manual 333 125--001) 148 140--880
Guide lamp (for D35 contact equipment) 153 143--880
Extra accessories for the A6 TGD1 (MIG/MAG welding)
Wire reel, plastic, for 30 kg of wire 153 872--880

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INSTALLATION
Connecting the automatic welding machine to the welding Power source
1. Dimension drawing: see fig. on page 15 and on page 16.
2. Adjust the automatic welding machine for butt or fillet welding as shown on page 15.
3. A6 VEC wire feed motor: see instruction manual 333 533--003
4. PEG1 control box: see instruction manual 333 470--001
5. Connection instructions, see page 17.
SDC welding:
Connect control cable (08) for A6 TFD1 resp. (15) for A6 TGD1 between the weld-
ing power source and the PEG1 control box.
Connect the welding current lead carrying a cable lug (07) resp. (08) between the
welding power source and the current shunt
SAC welding:
Connect control cable (08) between the auxiliary control box (11) and the PEG1 con-
trol box. Connect the auxiliary control box (11) to the welding power source.
Connect the welding current lead (07) between the welding power source and the
current shunt.
SConnect the return cable between the welding power source and the workpiece
SConnect the measurement cable (09) resp. (16) between the workpiece and the
welding power source, or between the workpiece and the PEG1 control box
(e.g. as might be required when a power source from another manufacturer is being
used)
SConnect the A6 VEC geared motor to the PEG1 control box
SConnect the guide lamp, if used, to the PEG1 control box
Loading with wire
1. Replacement of the coil
SRemove the wire reel from the brake hub (2) and take off one end (3).
SPlace the coil (1) of wire on the reel and replace the end (3)
SFit the wire reel or disposable reel on the brake hub (2):
Note the position of the carrier
IMPORTANT!
To prevent the wire drum from slipping off the
brake hub; Secure the drum with the red retaining knob,
as shown on the warning lable (right) by the brake hub.