ESAB A6 Mastertrac Instruction Manual
GB
Valid for serial no. 709--xxx--xxxx0449 265 201 GB 2007--07--12
A6 Mastertrac
A6 TF/ A6 TF (Twin)
Instruction manual
-- 2 --
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, declares under sole responsibility that the automatic welding machine A6 Mastertrac (A6 TF/A6 TF Twin) 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).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
L
axå 2007--02--21
-- 3 --
TOCe
Rights reserved to alter specifications without notice.
1SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 General 6..................................................................
2.2 Welding Method 6...........................................................
2.3 Definitions 6................................................................
2.4 Horizontal Welding or Welding on an Inclined Plane 6............................
2.5 Technical data 7............................................................
2.6 Main components A6 TF (SAW), A6 TF Twin (SAW) 8...........................
2.7 Description of Main Components 9............................................
3 INSTALLATION 10....................................................
3.1 General 10..................................................................
3.2 Mounting 10.................................................................
3.3 Adjusting the brake hub 10....................................................
3.4 Connections 11..............................................................
4 OPERATION 12.......................................................
4.1 General 12..................................................................
4.2 Loading the welding wire (A6 TF) 13............................................
4.3 Changing the feed roller (A6 TF) 14.............................................
4.4 Contact equipment for Submerged arc welding 15................................
4.5 Refilling with flux powder (Submerged arc welding) 16.............................
4.6 Conversion of A6 TF (Submerged--arc) to MIG/MAG welding 16....................
4.7 Conversion of A6 TF (submerged--arc welding) to Twin--arc 16.....................
5 MAINTENANCE 17....................................................
5.1 General 17..................................................................
5.2 Daily 17.....................................................................
5.3 Periodic 17..................................................................
6 TROUBLESHOOTING 18..............................................
6.1 General 18..................................................................
6.2 POSSIBLE FAULTS 18.......................................................
7 ORDERING OF SPARE PARTS 18......................................
WEAR COMPONENTS 19.................................................
DIMENSION DRAWING 22................................................
SPARE PARTS LIST 23...................................................
-- 4 --
safetyE
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 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 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:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
Mind the following:
S That the freewheel clutch of the gear shall be in locked position.
S That, 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.
S Make sure that the automatic welding machine is not unstable before start.
S That 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.
S That the consumption of wire and flux results in displacement of the weight distribution during
the welding.
GB
-- 5 --
safetyE
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
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
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB
-- 6 --
fhb3d1ea
2 INTRODUCTION
2.1 General
The A6 TF automatic welding machines are designed for Submerged--arc welding
(SAW) of butt and fillet joints.
All other applications are prohibited.
They are intended for use in combination with A2--A6 Process Controller (PEH) and
ESAB’s welding power sources LAF or TAF.
2.2 Welding Method
2.2.1 Submerged Arc Welding (SAW)
S Submerged--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.
2.3 Definitions
SAW welding The weld bead is protected by a cover of flux during the
welding.
SAW Heavy duty This version permits a load up to 1500 A (100%) and weld-
ing with a thick wire.
Twin--arc welding Welding with two wires in one welding head.
2.4 Horizontal Welding
The automatic welding machines are designed for horizontal welding.
They are not to be used for welding on inclined planes.
The following exception can be made, if special precautionary measures and
settings on the automatic welding machines are applied:
S at inclinations up to 20 degrees sideways.
Read section 5, on page 4.
GB
-- 7 --
fhb3d1ea
2.5 Technical data
A6 TF
Supply voltage 42 V AC
Permissible load at 100 %: 1500 A DC
Wire dimensions:
3.0--6.0 mm
solidsinglewire
hollow wire
twin wire
3.0--
6.0mm
3.0--4.0 mm
2x2.0--3.0 mm
Wire feed speed, max 4m/min
Brake hub braking torque 1.5 Nm
Travel speed 0.1--2.0 m/min
Max. weight of wire 30 kg
Flux container volume (Not to be filled with preheated flux) 10 l
Weight (excl. wire and flux) ¶137 kg
Max. inclination *
*See point 2.4 on page 6.
GB
-- 8 --
fhb3d1ea
2.6 Main components A6 TF (SAW), A6 TF Twin (SAW)
1. Carriage
2. Carrier
3. Wire feed unit
4. Slide kit, manual
5. Connector
6. Motor with gear (A6 VEC)
7. Flux hopper
8. Flux tube
9. Flux nozzle
See on page 9 for a description of the main components.
GB
-- 9 --
fhb3d1ea
2.7 Description of Main Components
2.7.1 Carriage
The carriage is provided with 4--wheel drive.
The carriage can be secured by way of the
locking lever (1).
2.7.2 Carrier
The control box, wire feed unit and flux
hopper, among other things, are to be fitted
on the carrier.
2.7.3 Wire Feed Unit
The unit is used for guiding and feeding the welding wire down into the connector.
2.7.4 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.
2.7.5 Connector
Transfers welding current to the wire during welding.
2.7.6 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.
2.7.7 Flux Hopper / Flux Tube / Flux nozzle
The flux is filled into the flux hopper and is then transferred to the wor kpiece 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
-- 1 0 --
fhb3i1ea
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).
S Check 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.
S Adjusting the braking torque:
S Turn the red handle to the locked
position.
S Insert 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.
GB
-- 1 1 --
fhb3i1ea
3.4 Connections
3.4.1 General
S TheA2--A6ProcessController(PEH) is to be connected by a qualified person.
S For the connection of A6 GMD, see instruction manual 0443 403 xxx.
S For the connection of A6 PAK, see instruction manual 0443 405 xxx.
3.4.2 Automatic welding machine A6 TF (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).
GB
-- 1 2 --
fhb3o1ea
4 OPERATION
4.1 General
Caution:
Have you r ead 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!
S Select electrode type and flux powder or shielding gas so that the weld material
is as close as possible to the analysis of the base metal.
S Select electrode size and welding data in accordance with the values
recommended by the welding materials supplier.
S Thorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE! The width of the weld joint gap must be uniform.
S To minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
S Always carry out a test weld with the same joint type and sheet thickness as the
production work piece.
S For control and adjustment of the automatic welding machine and welding power
supply, see the instruction manual for the A2--A6 Process Controller (PEH).
GB
-- 1 3 --
fhb3o1ea
4.2 Loading the welding wire (A6 TF)
1. Mount the wire drum according to the instructions on page 10.
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):
S Feed the wire through the wire guide (8).
4. When welding with fine wire:
S Feed 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).
S For 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).
S Note! 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).
S Always use a guide tube (7) to ensure even feed of fine wire (1.6 -- 2.5 mm).
GB