Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Esab Welding Equipment AB, 695 81 Laxå, Sweden, försäkrar under eget ansvar att
svetsautomat A6 T F E1/TFE2/TGE1 från serienummer 725 är i överensstämmelse
med standard EN 60292 enligt villkoren i direktiv 89/392/EEG med tillägg.
Esab Welding Equipment AB, 695 81 Laxå, Sweden garanterer under eget ansvar,
at svejseautomat A6 TFE1/TFE2/TGE1 fra serienummer 725 er i overensstemmelse
med standard EN 60292 ifølge betingelserne i direktiv 89/392/EEC med tillægg.
Esab Welding Equipment AB, 695 81 Laxå, Sweden, forsikrer på eget ansvar at
sveiseautomat A6 TFE1/TFE2/TGE1 med serienummer 725 er i samsvar med standard EN 60292 i overensstemmelse med bestemmelsene i direktiv 89/392/EØF med
tillegg.
Esab Welding Equipment AB, 695 81 Laxå, Sweden, vakuuttaa omalla vastuullaan,
että hitsausautomaatti A6 TFE1/TFE2/TGE1 sarjanumerosta 725 täyttää standardin
EN 60292 vaatimukset direktiivin 89/392/EEC ja sen lisäyksen mukaisesti.
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that automatic welding machine A6 TFE1/TFE2/TGE1 from serial number 725 complies with standard EN 60292, in accordance with the requirements of directive
89/392/EEA and addendum.
Esab Welding Equipment AB, 695 81 Laxå Sweden, versichert hiermit auf eigene
Verantwortung, daß der Schweißautomat A6 TFE1/TFE2/TGE1 ab Serien--Nr 725
mit der norm EN 60292 gemäß den Bedingungen der Richtlinien 89/392/EWG mit
der Ergänzung in Übereinstimmung steht.
Esab Welding Equipment AB, 695 81 Laxå Sweden, certifie sous sa propre responsabilité que la appareil de soudage automatique A6 TFE1/TFE2/TGE1 à partir du
numéro de serié 725 répond aux normes de qualité EN 60292 conformément aux
directives 89/392/EEC avec annexe.
Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart op eigen verantwoordelijkheid dat lasautomaat A6 TF E1/TF E2/TGE1 van serienummer 725 overeenkomt
met norm EN 60292 volgens richtlijn 89/392/EEG van de Raad m e t toevoeging.
Esab Welding Equipment AB, 695 81 Laxå, Sweden, declara, asumiendo toda responsabilidad, que la equipo para soldadura automática A6 TFE1/TFE2/TGE1 desde
el número de serie 725 está fabricada de conformidad con la normativa EN 60292
según los requisitos de la directiva 89/392/EEC con el suplemento.
Esab Welding Equipment AB, 695 81 Laxå Sweden, dichiara sotto la propria responsabilità che la saldatrice automatica A6 TFE1/TFE2/TGE1 dal numero di serie 725 è
conforme alla norma EN 60292 ai sensi dei requisiti previsti dalla direttiva
89/392/CEE e successive integrazioni nella direttiva.
Esab Welding Equipment AB, 695 81 Laxå Sweden, certifica, sob a sua própria responsabilidade que, a equipamento autom ático para soldadura A6 TFE1/TFE2/TGE1
desde número de série 725 está em conformidade com a norma EN 60292, segundo os requisitos constantes na directiva 89/392/EEC e com o suplemento.
SPARE PARTS LIST187................................................
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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 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.
Welding on an Inclined Plane -- In the Travel Direction or Sideways
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
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 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.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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2INTRODUCTION
2.1General
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.
2.2Welding method
2.2.1Submerged--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.
2.3Horizontal 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 the section Welding on an Inclined Plane - In the Travel Direction o r
Sideways, on page 66.
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2.4Technical data
A6 TFE2
Supply voltage42 V AC
Rated load 100 %1500 A DC/AC
Electrode dimensions:
solid single wire3,0--6,0 mm
flux--cored wire3,0--4,0 mm
twin wire2x2,0--3,0 mm
Electrode feed rate, max.4m/min
Brake drum braking torque1,5 Nm
Speed of travel0,1--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 pressure68 dB
2.5Main components
1.Carriage
2.Wire feed unit
3.Slide, manual
4.Connector
5.Motor with gear (A6 VEC)
See on page 70 for a description of the main components.
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6.Flux hopper
7.Flux nozzle
GB
2.6Description of Main Components
2.6.1Carriage
The carriage is provided with 4--wheel drive.
The carriage can be secured by way of the
locking lever (1).
2.6.2Wire Feed Unit
The unit is used for guiding and feeding the welding wire down into the connector.
2.6.3Manual 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.
2.6.4Connector
Transfers welding current to the wire during welding.
2.6.5Motor 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.
2.6.6Flux 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 77.
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3INSTALLATION
3.1General
The installation must be executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
3.2Mounting
3.2.1Wire 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.
3.3Adjusting 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 r ed 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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3.4Connections
3.4.1General
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.
3.4.2Submerged arc weldin g (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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4OPERATION
4.1General
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 66. 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 70.
SWhen changing consumables, see table on page 186.
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4.2Loading the welding wire
1.Mount the wire drum according to the instructions on page 71.
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 pressingon 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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4.3Changing 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) m ust 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)asapairforthewiresizetobe
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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4.4Contact 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
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)intheM12hole
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.
4.5Refilling 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.
4.6Conversion of A6 TF (submerged--arc welding) to Twin--arc
SAssemble in accordance with the instructions accompanying the conversion kit.
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5MAINTENANCE
5.1General
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.
5.2Daily
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 71.
5.3Regularly
SCheck the wire feed motor brushes once every three months.
Replace when they are worn down to 6 mm.
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 187).
SIf the carriage travel becomes jerky, check that the chain is correctly tensioned.
If the chain is not tense, check the chain tensioner.
Replace the tensioner as necessary.
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6TROUBLESHOOTING
6.1General
Equipment
SInstruction manual for control box A2 --A6 Process Controller (PEH),
ordering number 0443 745 xxx.
SOperating manual for m otor 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
6.2Possible faults
1. SymptomCurrent and voltage readings show large fluctuations.
Cause 1 .1Contact jaws or nozzle are worn or wrong size.
ActionReplace contact jaws or nozzle.
Cause 1 .2Feed roller pressure is inadequate.
ActionIncrease pressure on feed rollers.
2. SymptomWire feed is irregular.
Cause 2 .1Pressure on feed rollers incorrectly set.
ActionPressure on feed rollers incorrectly set.
Cause 2 .2Feed rollers wrong size.
ActionReplace feed rollers.
Cause 2 .3Grooves in feed rollers are worn.
ActionReplace feed rollers.
3. SymptomWelding cables overheating.
Cause 3 .1Poor electrical connection.
ActionClean and tighten all electrical connections.
Cause 3 .2Cross--sectional area of welding cables too small.
ActionUse cables with a larger cross--section or use parallel cables.
7ORDERING 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 designation and spare part number as shown in the spare parts list on page 187.
This will simplify dispatch and ensure you get the right part.