ESAB A6 Mastertrac Manuel utilisateur

Valid for serial no. 709--xxx--xxxx0449 265 201 GB 2007--07--12

A6 Mastertrac

A6 TF/ A6 TF (Twin)

Instruction manual

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DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, declares under sole responsibility that the au-

tomatic 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).

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Kent Eimbrodt

Global Director

Equipment and Automation

axå 2007--02--21

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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...................................................

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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 recommen-

dations 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:

Sits operation

Slocation of emergency stops

Sits function

Srelevant safety precautions

Swelding

2. The operator must ensure that:

Sno unauthorised person is stationed within the working area of the equipment when it is

started up.

Sno--one is unprotected when the arc is struck

3. The workplace must:

Sbe suitable for the purpose

Sbe free from draughts

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, rings, etc., which could become

trapped or cause burns.

5. General precautions

SMake sure the return cable is connected securely.

SWork on high voltage equipment may only be carried out by a qualified electrician.

SAppropriate fire extinquishing equipment must be clearly marked and close at hand.

SLubrication and maintenance must not be carried out on the equipment during operation.

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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safetyE

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS 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.

PROTECT YOURSELF AND OTHERS!

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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)

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.

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:

Sat inclinations up to 20 degrees sideways.

Read section 5, on page 4.

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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

hollow wire

twin wire

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.

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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.

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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 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 16.

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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 Mounting

3.2.1 Wire 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:

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.

SAdjusting the braking torque:

STurn the red 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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