ESAB A6 TFD1 User manual

443 401 --002 9510 Valid from Machine no 452 XXX--XXXX
A6 TFD1/TFD2/
TGD1
Automatic welding machine
Schweißautomat
Appareil de soudage automatique
Lasautomaat
Operating manual
Bedienungsanleitung
Manuel de l’opérateur
Gebruikershandboek

SAFETY 2..............................................
TECHNICAL DESCRIPTION 3.............................
INSTALLATION 4........................................
OPERATION 7..........................................
MAINTENANCE 10........................................
TROUBLESHOOTING 11..................................
CONNECTION INSTRUCTIONS FOR PEG1 AND A6 VEC 12..
SICHERHEIT 14..........................................
TECHNISCHE BESCHREIBUNG 15.........................
INSTALLATION 16........................................
BETRIEB 19..............................................
WARTUNG 22............................................
FEHLERSUCHE 23.......................................
ANSCHLUSSANLEITUNG FÜR PEG1 UND A6 VEC 24.......
SÉCURITÉ 26............................................
DESCRIPTION TECHNIQUE 27............................
INSTALLATION 28........................................
FONCTIONNEMENT 31...................................
ENTRETIEN 34...........................................
RECHERCHE DE PANNES 35..............................
INSTRUCTIONS DE BRANCHEMENT POUR PEG1 ET A6 VEC 36
VEILIGHEID 38...........................................
TECHNISCHE BESCHRIJVING 39..........................
INSTALLATIE 40..........................................
GEBRUIK 43.............................................
ONDERHOUD 46.........................................
STORINGZOEKEN 47.....................................
INSCHAKELINSTRUCTIES VOOR PEG1 EN A6 VEC 48......
DIMENSION DRAWING - MASSBILD - COTES
D’ENCOMBREMENT - MAATSCHETS 49..............
DIAGRAM - SCHALTPLAN - SCHÉMA - SCHEMA 51.........
WEAR COMPONENTS - VERSCHLEISSTEILE -
PIÈCES D’USURE - SLIJTAGEONDERDELEN 53......
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

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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 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
inflammable 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.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

SAFETY
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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 re-
gulations 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 situ-
ation 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.

TECHNICAL DESCRIPTION
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TECHNICAL DESCRIPTION
The A6 TFD1 automatic welding machine is mounted on a tractor carriage and is de-
signed for submerged arc welding of butt and fillet joints (using AC or DC).
The A6 TFD2 automatic welding machinewith its twin welding heads is mounted on a
tractor carriage and is designed for submerged arc welding of butt joints (using AC
or DC).
The A6 TGD1 automatic welding machineis mounted on a tractor carriage and is de-
signed for MIG/MAG welding of butt and fillet joints (using DC).
The horizontal and vertical positions of the welding head can be adjusted using a
cross slide. The angular position is adjusted using a rotary slide.
All other applications are prohibited.
TECHNICAL DATA
A6 TFD1 A6 TFD2 A6 TGD1
Rating 1500 A DC/AC 1500 A DC/AC 600 A DC
Electrode size
solid single wire 3,0--6,0 mm 3,0--6,0 mm 1,0--2,4 mm
tube wire 1,6--3,2 mm
twin wire 2x2,0--2x3,0
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
Electrode weight, max 30 kg 30 kg 30 kg
Flux container volume
(Must not be filled with preheated flux) 10 l 10 l
Weight (excl. wire and flux) 110 kg 158 kg 100 kg
Brake hub braking torque 1,5 Nm 1,5 Nm 1,5 Nm
Transverse inclination, max 25_25_25_
Supply voltage 42 V AC 42 V AC 42 V AC
Continuous A--weighted noise pressure 68 dB 68 dB 83 dB
See dimension drawing on page 49 and on page 50.

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INSTALLATION
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INSTALLATION
Connecting the automatic welding machine welding power source
1. Set the machine for butt or fillet welding as shown on the dimension drawing on
page 49.
2. A6 VEC wire feed motor, see operators’ manual 443 393.
3. Control unit PEG1, see operators’ manual 443 392.
4. Connect the cables according to the diagram on page 51 and page 52.
SRectifier:
SConnect control cable (08) for the A6 TFD1 or (15) for the A6 TGD1 be-
tween the power source (01) and the control unit PEG1 (02).
SConnect the cable with the connecting lugs (07) or (08) between the
power source (01) and the shunt.
SAlternating current:
SConnect control cable (08) between the filler wire unit (11) and the PEG1
control unit (02).
SConnect the filler wire unit (11) to the power source (10).
SConnect the welding cable (07) between the power source (10) and
shunt.
SConnect the return cable between the power source (01, 10) and the work--
piece.
SConnect the measuring cable (09) or (16) between the work piece and power
source (01,10) or between the work piece and the PEG1 control unit (02)
(e.g. if a power source of a different make is used).
SConnect the A6 VEC motor and gearbox to the PEG1 control unit (02).
Check that the PEG1 control unit is connected as shown in the table on page 12
and that the gear ratio and motor speed match the values given there.
Installing filler wire.
Replacing a wire reel.
SRemovethewirereelfromthebrakehub(2)
and remove the end plate (3).
SPlace the coil of wire (1) on the reel and fit
the end plate (3).
SFit the wire reel or disposable reel on the
brake hub (2).
NOTE the position of the locking stud.

INSTALLATION
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IMPORTANT!
To prevent the wire bobbin slipping
off the brake hub:
Lock the bobbin in place using the red knob,
as shown on the label (see drawing on right)
positioned next to the brake hub.
5. Contact tip equipment
SSingle wire 1.6 -- 2.5 mm (4.0 mm). Light duty (D20)
For use in restricted spaces, etc., with wire diameters up to 4.0 mm.
Use contact tube D20 with contact tip (M12 thread), see table on page 55.
STighten the contact tip using a no. 10 spanner to ensure good electrical
contact.
For smaller wire diameters, 1.6 -- 2.5 mm, use a guide tube and separate fine
wire straightener.
SFit the clamp for the guide tube to the M12 hole normally used for the
fixed straightening roller on the standard wire straightener. The guide
tube should bottom against the contact tip. Trim the length so that there
is about a 5 mm gap between the wire feed roller and the end of the
tube.
SInstall the fine wire straightener on top of the clamp for the wire straigh-
tener unit.
SSingle wire 3.0 -- 6.0 mm. Heavy duty (D35)
Use contact tube D35 with contact jaws. See also the remarks concerning
the use of contact tube D20 for wires up to 4.0 mm in diameter in restricted
spaces.
SUse the standard wire straightener unit for the A6, consisting of one fixed
and one adjustable roller.
SInstall the contact jaws using the M5 bolts supplied, fitting one half of the
contact jaws in the fixed contact tube and the other in the loose half of
the split contact tube.
SInstall the loose half and contact jaw in position and tighten the pressure
screw to ensure good electrical contact between the contact jaw and the
electrode.
STube wire
Either the D20 or D35 contact tubes can be used for tube electrode.
If contact jaws (D35) are used only moderate pressure should be applied to
them to prevent deforming the tube wire. Make sure that good contact is ob-
tained with the wire.

INSTALLATION
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STwin wire
Always use the D35 contact tube for twin wire, with a guide tube and separ-
ate wire straightener.
SFit the clamp for the guide tube to the M12 hole normally used for the
fixed straightening roller on the standard wire straightener. The guide
tube should bottom against the contact jaw (Heavy Twin) or against the
adapter for the contact tip (Light Twin).
STrim the length so that there is about a 5 mm gap between the wire feed
roller and the end of the tube.
Twin wire 2x1.2 -- 2x2.0 mm, Light Twin:
Use (2) contact tips with M6 threads. For wire diameters see table on page
55.
STighten the contact tips well to ensure good electrical contact.
SFit the M5 adapter for the M6 contact tips in the fixed half of the split
contact tube. The pressure screw and the loose half of the contact tube
are not necessary for this application.
Twin wire 2x2.0 -- 2x3.0 mm, Heavy Twin:
SUse Twin contact jaws for large diameter wires
(2x2,0 mm, see also Light Twin).
SFit the contact jaws using the M5 bolts supplied for the purpose.
NOTE! Fit the contact jaw half with the projection in the fixed section of
the contact tube.
SRemove the loose half of the contact tube when installing new wire by
undoing the pressure screw.
SFeed out the wire and guide it through the groove in the fixed half of the
contact jaws (projection).
SUnscrew the M5 bolt for the contact jaw and fit the loose half using an
M8 allen bolt, so that the half of the contact jaw with the projection and
the opposing half surround the wires. The loose section of the contact
tube is then bolted in place using the M5 bolts to provide good contact.
SAdjustment of wires for Twinarc welding:
Adjust the wires in the joint to give the optimum weld results by twisting the
contact tube. The wires can be rotated so that they are in line with the joint or
at any angle up to 90_to the joint, i.e., one wire each side of the joint.
STandem welding
SThe distance between the first wire and the second must not be so large
that the slag solidifies before the following wire reaches it.
SMake sure there is a good covering of flux between the first and second
wire.

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OPERATION
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OPERATION
1. Adjusting the braking torque:
STurn the locking knob (006) to
the locked position.
SInsert a screwdriver in the
hub springs.
STurning the springs (002) clock-
wise increases the braking torque.
STurning them anticlockwise reduces the torque.
NOTE! Turn the springs the same amount.
2. Check that the feed roller (1) and
contact jaws (4) are the correct size.
3. Changing the feed roller
(see wear components on page 53).
SSingle wire
SUndo knobs (5) and (6).
SUndo the hand wheel (2).
SReplace the feed roller.
Thewirediameterismarkedonthe
feed rollers.
STwin wire
SThe procedure for replacing twin wire
rollers is the same as for single wire
rollers.
SNOTE! Replace the pressure roller at the
same time. The special spherical pres-
sure roller for twin wire replaces the standard
roller for single wire.
SFit the pressure roller using the special shaft stud
(order no. 146 253--001).
STube wire
SReplace the feed roller and pressure roller as a pair for the required wire
size.
SNOTE! A special shaft stud is required for the pressure roller
(order no. 2129 011--01).
SDo not overtighten the pressure roller to avoid deforming the tube wire.
SInsert the end of the wire in the groove in the feed roller.
4. If the wire diameter is larger than 2 mm:
straighten out the first 0.5 m of the wire and feed it by hand through the wire
straightener.

OPERATION
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5. Adjust the wire pressure on the feed roller using knob (6).
NOTE: Do not tighten more than necessary to ensure uniform feeding. Do not
tighten the knob (6) all the way, there should be some travel left in the spring.
6. Connect the power supply to the mains.
Feed the wire out about 30 mm using switch A 02 on control unit PEG1.
7. Straighten the wire by adjusting knob (5). Fine wire should be straight about
25 mm after it leaves the contact tip and heavy wire about 45 mm after the con-
tact tip.
The securing bolt (3) must not be removed.
WARNING!
Rotating parts can cause injury, take great care.
8. Select the wire and flux (or gas) so that the weld metal analysis roughly matches
that of the plate. Select the wire diameter and welding parameters as recom-
mended by the consumable manufacturer.
9. Connect the cooling water and gas (MIG/MAG welding).
10. Adjust the flux nozzle so that it does not bend and gives a good covering of flux
(submerged arc welding).
11. Make sure the distance between the carriage wheels and the weld joint is not
less than 50 mm during welding.
12. If the control handles are moved make sure they are screwed all the way in so
that the tapered surfaces meet. Use the holes in the guide handles to help
tighten them thoroughly. Clean the threads if necessary.