ESAB Mastertrac A6, A6 TFE1, A6 TFE2, A6 TGE1 Instruction Manual

A6 Mastertrac

A6 TFE1/A6 TFE2/A6 TGE1

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Manuel d’instructions
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ПдзгЯет чсЮуещт

Valid for serial no. 725--xxx--xxxx0456 503 001 2004--12--02

SVENSKA 5..............................................

DANSK 22................................................

NORSK 39................................................

SUOMI 56................................................

ENGLISH 73..............................................

DEUTSCH 90.............................................

FRANÇAIS 107.............................................

NEDERLANDS 124.........................................

ESPAÑOL 141..............................................

ITALIANO 158..............................................

PORTUGUÊS 175..........................................

ЕЛЛЗНЙКБ 192.............................................

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.

ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.

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FÖRSÄKRAN OM ÖVERENSST ÄMMELSE

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.

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OVERENSSTEMMELSEERKLÆRING

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.

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FORSIKRING OM OVERENSSTEMMELSE

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.

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VAATIMUSTENMUKAISUUSVAKUUTUS

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.

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DECLARATION OF CONFORMITY

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.

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KONFORMITÄTSERKLÄRUNG

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.

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CERTIFICAT DE CONFORMITÉ

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.

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OVEREENKOMSTIGHEIDSVERKLARING

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.

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DECLARACIÓN DE CONFORMIDAD

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.

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3

DICHIARAZIONE DI CONFORMITA

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.

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DECLARAÇÃO DE CONFORMIDADE

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.

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ВЕВБЙЩУЗ УШМЦЩНЙБУ

Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, вевбйюней ме дйкЮ фзт ехиэнз
oфй з бхфьмбфт ухгкпллзфЮт A6 TFE1/TFE2/TGE1 брь фпн бсйимь уейсЬт 725
всЯукефбй уе ухмцщнЯб ме фп уфбнфбсф ЕН 60292 уэмцщнб ме фпх ьспхт фзт
пдзгЯбт 89/392/ЕЕC кбй фзн рспуиЮкз.

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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81176 Fax: + 46 584 12336

4

ENGLISH

1SAFETY 74...........................................................

2 INTRODUCTION 76...................................................

2.1 General 76..................................................................

2.2 Technical data 76............................................................

2.3 Welding method 77...........................................................

2.4 Horizontal Welding or Welding on an Inclined Plane 77............................

2.5 Equipment 78................................................................

3 INSTALLATION 80....................................................

3.1 General 80..................................................................

3.2 Connections 80..............................................................

4 OPERATION 82.......................................................

4.1 General 82..................................................................

4.2 Starting work 82..............................................................

4.3 Refilling with flux powder (submerged--arc welding) 87............................

4.4 Conversion of A6 TFE1 (Submerged-- arc welding) to MIG/MAG welding 87..........

4.5 Conversion of A6 TFE1 / A6 SFE2 (Submerged--arc welding) to Twin--arc 87.........

5 MAINTENANCE 88....................................................

5.1 General 88..................................................................

5.2 Daily 88.....................................................................

5.3 Regularly 88.................................................................

6 TROUBLESHOOTING 89..............................................

6.1 General 89..................................................................

6.2 Possible faults 89............................................................

7 ORDERING OF SPARE PARTS 89......................................

WEAR COMPONENTS 211..............................................

SPARE PARTS LIST 215................................................

TOCe

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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:

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.

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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

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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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2 INTRODUCTION

2.1 General

The A6 TFE1 automatic welding machine is mounted on a self--propelled trolley

and is designed for submerged--arc welding of butt and fillet welds.
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.
The A6 TGE1 automatic welding machine is mounted on a self--propelled trolley

and is designed for M IG/MAG welding of butt and fillet welds.

All other uses are prohibited.

The automatic welding machines are used in conjunction with ESABÕs control box
A2--A6 Process Controller (PEH).

The supply voltage to the control box and to the welding machine motors is provided
by ESAB’s welding power sources LAF and TAF.

The position of welding head can be set horizontally and vertically with the linear
slides. Angular movement is adjusted with the angular slide.

2.2 Technical data

6 Mastertrac

Supply voltage 42 V AC 42 V AC 42 V AC
Rated load 100 % 1500 A DC/AC 1500 A DC/AC 600 A DC
Electrode dimensions:

solid single wire 3.0--6.0 mm 3.0--6.0 mm 1.0--2.4 mm
flux--cored wire 3.0--4.0 mm 3.0--4.0 mm 1.6--3.2 mm

twin wire 2x2.0--3.0 2x2.0--3.0mm -- -­Electrode feed rate, max. 4m/min 4m/min 16 m/min
Brake drum braking torque 1.5 Nm 1.5 Nm 1.5 Nm
Speed of travel 0.1--2.0 m/min 0.1--2.0 m/min 0.1--2.0 m/min
Electrode weight, max. 30 kg 2x15kg 30 kg
Flux hopper capacity

(Must not be filled with preheated flux)
Weight (excluding electrode and flux) 110 kg 158 kg 100 kg
Continuous A weighted sound pressu-

re

A6 TFE1 A6 TFE2 A6 TGE1

Submerged--arc MIG/MAG

10 l 10 l -- --

68 dB 68 dB 83 dB

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2.3 Welding method

Submerged--arc welding

For submerged--arc welding, an A6 Mastertrac of type A6 TF is used, which is
available in several different versions:

S Submerged --arc Light duty

Submerged-- arc light duty, with a ∅ 20 mm connector, which permits a load of up
to 800 A (100%) or 1000 A (60%).

S Submerged--arc Heavy duty

Submerged-- arc heavy duty, with a ∅ 35 mm connector, which permits a load of
up to 1500 A.

Both versions 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.

For work in confined spaces, (smaller than 50 cm), a special welding head of type

A6 SFE1C is available, which can be installed on the Mastertrac as required.

Tandem 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.

MIG/MAG welding

For MIG/MAG welding, an A6 Mastertrac A6 TGE1 is used, which has a maximum
rated load of 600 A. The welding head is water cooled, with the cooling water
supplied by hoses from connections intended for the purpose.

2.4 Horizontal Welding or Welding on an Inclined Plane

The automatic welding machines are designed for horizontal welding in the first
place.

Read the section Welding on an Inclined Plane - In the Travel Direction o r
Sideways, on page 74.

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2.5 Equipment

Included in a complete welding head are a feed motor (A6 VEC) to feed in the wire
and contact equipment which supplies current to the wire and provides a good
contact.

Contact equipment is available in several different versions.

S A6 TF is used for submerged--arc welding.
S A6 TG is used for MIG/MAG welding.

Main components of the A6 TFE1 and A6 TFE2

1. Straightener.

2. Contact equipment which
consists of a contact tip,
connector and flux tube.

3. Angular slide

4. Slide (motor or handdriven)

5. Motor and gearbox (A6 VEC)

6. Wire drum

7. Flux hopper (may be
fitted with a cyclone)

8. --

9. Trolley

10. Column

11. Disengagement lever

Main components of the A6 TGE1

1. Straightener.

2. Contact equipment which
consists of a connector, gas
nozzle and water hoses.

3. Angular slide.

4. Slide (motor or hand driven).

5. Motor and gearbox (A6 VEC).

6. Wire drum.

7. Fine wire straightener.

8. Wire guide.

9. Trolley.

10. Column.

11. Disengagement lever.

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Example of the A6 SFE1C, which can be mounted on an A6 Mastertrac

1. Straightener.

2. Contact equipment, which consists of a contact tip, connector and flux tube.

3. Slide (motor driven).

4. Motor and gearbox (A6 VEC).

5. Flux hopper (1 l).

For connection instructions for submerged--arc and MIG/MAG welding, see page 80.

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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 Connections

3.2.1 General

S Connection of the control box A2--A6 Process Controller (PEH) to the automatic

welding machine is carried out prior to delivery.
For further information, see instruction manual for the A2--A6 Process Controller

(PEH).

S Connect the A6 Mastertrac in accordance with the following diagrams.

3.2.2 Submerged--Arc Welding (SAW)

S Connect the control cable (7) between the welding power source (8) and the

control box PEH (2).

S Connect the return cable (11) between the welding power source (8) and the

work piece (9).

S Connect the welding cable (10) between the welding power source (8) and the

automatic welding machine (1).

S Connect the measuring cable (12) between the welding power source (8) and

the work piece (9).

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3.2.3 Gas Metal Arc Welding (MIG/MAG)

S Connect the control cable (7) between the welding power source (8) and the

control box A2--A6 Process Controller (PEH) (2).

S Connect the return cable (11) between the welding power source (8) and the

work piece (9).

S Connect the welding cable (10) between the welding power source (8) and the

automatic welding machine (1).

S Connect the gas pipe (5) between the reduction valve (6) and the gas valve on

the automatic welding machine (13).

S Connect the hoses for cooling water (3) between the cooling unit (4) and the

automatic welding machine (1).

S Connect the measuring cable (12) between the welding power source (8) and

the work piece (9).

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4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on
page 74. Read through before you start using the equipment!

S Select 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.

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 m achine and welding power

supply, see the instruction manual for the A2--A6 Process Controller (PEH).

S The trolley can be moved manually after disengaging the disengagement lever,

see the diagram on page 78.

S When changing consumables, see table on page 211.

4.2 Starting work

Loading the welding wire

S Remove the wire drum (1) from the brake hub (2)

and take off the side plate (3).

S Locate the wire reel on the wire drum (1).
S Cut off the binding wires from around the

wire reel.

S Replace the side plate (3).
S Replace the wire drum (1) on the brake hub (2).

Check that the carrier (4) is in the correct position.

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.

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SAW MIG/MAG

S Check that the feed roller (1) and contact jaw or contact tip (3) are of the correct

dimension for the selected wire size.

S Pull the end of the wire through the straightener (2). For a wire diameter greater

than 2 mm; straighten out 0.5 m of wire and feed it by hand down through the
straightener.

S Locate the end of the wire in the feed roller (1) groove.
S Set the wire tension on the feed roller with the knob (7). Note! Do not tension

more than is required to achieve an even feed.

S The pressure screw (8) must not be dismantled. (Applies to Submerged --arc

Heavy duty).

S Feed the wire forward 30 mm by pressing on the control box

A2--A6 Process Controller.

S Direct the wire by adjusting the knob (6).

For fine wire, the special fine wire straightener (4) is used for both single and
twin wire.

Ensure that the straightener is correctly adjusted so that the wire emerges
straight out through the contact jaws or contact tip.

Always use a guide tube (5) to ensure even feeding of fine wire (1.6 -- 2.5 mm).
For MIG/MAG welding with wire sizes < 1.6 mm, use a guide spiral, which is

inserted in the guide tube (5).

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Changing the feed roller

S Single wire

S Release the knobs (3) and (4).
S Release the hand wheel (2).
S Change the feed roller (1). They are marked with their

respective wire sizes.

S Twin wire (Twin--arc)

S Change the feed roller (1) with twin grooves in the same way as

for single wire.

S 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.

S Assemble the pressure roller with special stub shaft

(order no. 146 253--001).

S Flux--cored wire (for knurled rollers)

S Change 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. 2129 011--01).

S Tighten the pressure screw (4) with moderate pressure to ensure that the

flux-- cored wire does not deform.

Contact equipment for submerged--arc welding
S For single wire 3.0 -- 4.0 mm. Light duty (D20)

Use the straightener (3), connector (1) D20 with contact tip
(2) (M12 thread).

S Tighten the contact tip (2) with a key in order to ensure

that a good contact is achieved.

S For single wire 1.6 -- 2.5 mm Submerged--arc.

Light duty (D20)

Use the straightener (3), connector (1) D20 with contact
tip (2) (M12 thread) and separate fine wire straightener (4)
with guide tube (6).

S Assemble the clamp (7) with guide tube (6) in the M12

hole on the straightener (3). The guide tube (6) should
bottom on the contact tip (2).

S If necessary, cut the guide tube (6) to length so that the

feed roller (5) runs freely.

S Assemble the fine wire straightener (4) on the upper

side of the clamp for the straightener (3).

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S For single wire 3.0 -- 6.0 mm. Heavy duty (D35)

Use the straightener (3), connector (1) D35 with contact
jaws (2).

S Assemble one contact jaw with the M5 bolts provided, in

the fixed contact tip (a).

S Assemble 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.

S 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. Ensure that good
contact is a chieved with the wire.

S Adjustment of the wire for tandem welding

S The distance between the first and second wires must not be so great that

the slag has time to solidify between the wires.

S Ensure that good flux coverage is achieved between the first and second

wires.

S Fortwinwires2x2.0--3.0Heavy Twin (D35) (Accessories)

Use the straightener (3), connector (1) D35 with contact
jaws (2).

S Assemble the first contact jaw with the M5 bolts

supplied, in the fixed connector ( a).

S Assemble 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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S Fortwinwires2x1.2--2.0mm,LightTwin(D35)(Accessories)

Use 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.

S Assemble the twin adapter (9) for M6 contact tips (2) with

the M5 bolts in the fixed half of the two --piece connector
(1).

S Assemble 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).

S Tighten the contact tip (2) with a key to ensure that a good

contact is achieved.

S If necessary, cut the guide tube (6) to length so that the

feed roller (5) runs freely.

S Adjustment of the wires for Twin--arc welding:

S Position 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.

Contact equipment for MIG/MAG welding.
S For single wire 1.6 -- 2.5 mm (D35)

Use the straightener (3), connector (1) D35 with contact
tip (2) (M10 thread).

S Tighten the contact tip (2) with a key to ensure that a

good contact is achieved.

S Assemble the clamp (7) with guide tube (6) in the M12

hole on the standard straightener (3). The guide tube (6)
should bottom on the contact tip (2).

S If necessary, cut the guide tube (6) to length so that the

feed roller (5) runs freely.

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-- 8 6 --

GB

S For single wire < 1.6 mm (D35)

Use the straightener (3), connector (1) D35 with contact tip
(2) (M12 thread), fine wire straightener (4) with guide tube
(6) and guide spiral, which is inserted in the guide tube (6).

S Assemble the clamp (7) with guide tube (6) in the M12

hole on the standard straightener (3). The guide tube (6)
should bottom on the contact tip (2).

S If necessary, cut the guide tube (6) to length so that the

feed roller (5) runs freely.

S Assemble the fine wire straightener (4) on the upper side

of the clamp for the straightener (3).

S Connect the cooling water and gas (MIG/MAG welding).

4.3 Refilling with flux powder (submerged--arc welding)

S Close the flux valve on the flux hopper.
S Remove the cyclone on the flux recovery unit, if fitted.
S Fill with flux powder. NOTE! The flux powder must be dry. Where possible

avoid using agglomerating flux powder outdoors and in damp environments.

S Position the flux tube so that it does not become kinked.
S 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.

4.4 Conversion of A6 TFE1 (Submerged--arc welding) to MIG/MAG

welding

Assemble in accordance with the instructions accompanying the conversion
kit.

4.5 Conversion of A6 TFE1 / A6 SFE2 (Submerged--arc welding) to

Twin--arc

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Assemble in accordance with the instructions accompanying the conversion
kit.

-- 8 7 --

GB

5 MAINTENANCE

5.1 General

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.

5.2 Daily

S Clean flux and dirt off moving parts of the welding machine.
S Check that the contact tip and all electrical cables are connected.
S Check that all bolted joints are tight and that guides and drive rollers are not

worn or damaged.

S Check 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.

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.

5.3 Regularly

S Check the wire feed motor brushes

once every three months.
Replace when they are worn
downto6mm.

S Eximine the slides and lubricate if

they bind.

S Inspect the wire guides, drive

rollers and contact tip on the wire
feed unit. Replace any worn or damaged
components, (see spare parts list o n page 215).

S If the carriage travel becomes

jerky, check that hte chain is correctly tensioned. Tension the chain if necessary.

S To tension the chain undo the nut (*1) and turn the cam, then tighten the nut.

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GB

6 TROUBLESHOOTING

6.1 General

Equipment

S Instruction manual for control box A2--A6 Process Controller.
S Operating manual for motor with gear A6 VEC, best nr 443 393.

Check

S that the power supply is connected for the correct mains supply
S that all three phases are supplying the correct voltage (phase sequence is not

important)

S that welding cables and connections are not damaged
S that the controls are correctly set
S that 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 desig­nation and spare part number as shown in the spare parts list on page 215.
This will simplify dispatch and ensure you get the right part.

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-- 8 9 --

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V .
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.z.o.o
Warszaw
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB International AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. Esabindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Singapore Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyung--Nam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA--CIS

ESAB Representative Office
Moscow
Tel:[phone]
Fax: [phone]

ESAB Representative Office
St Petersburg
Tel:[phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

031021