ESAB A6TF F1 Bedienungsanleitung

Valid for serial no. 940-xxx-xxxx0449 265 2009-10-05460

A6 Mastertrac

A6TF F1/ A6TF F1 Twin

Instruction manual

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Rights reserved to alter specifications without notice.

ENGLISH 4..............................................

ENGLISH

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TOCe

1SAFETY 5...........................................................

2 INTRODUCTION 8...................................................

2.1 General 8..................................................................

2.2 Welding Method 8...........................................................

2.3 Definitions 8................................................................

2.4 Horizontal Welding 8.........................................................

2.5 Technical data 9............................................................

2.6 Main components A6TF F1 (SAW), A6TF F1 Twin (SAW) 10......................

2.7 Description of Main Components 11............................................

3 INSTALLATION 12....................................................

3.1 General 12..................................................................

3.2 Mounting 12.................................................................

3.3 Adjusting the brake hub 12....................................................

3.4 Connections 13..............................................................

4 OPERATION 14.......................................................

4.1 General 14..................................................................

4.2 Loading the welding wire (A6TF F1/ A6TF F1 Twin) 15............................

4.3 Changing the feed roller (A6TF F1/ A6TF F1 Twin) 16.............................

4.4 Contact equipment for Submerged arc welding 17................................

4.5 Refilling with flux powder (Submerged arc welding) 18.............................

4.6 Transportation of the Automatic Welding Machine 19..............................

4.7 Conversion of A6TF F1/ A6TF F1 Twin

(Submerged-arc) to MIG/MAG welding 19.......................................

4.8 Conversion of A6TF F1 (submerged-arc welding) to Twin-arc 19....................

5 MAINTENANCE 20....................................................

5.1 General 20..................................................................

5.2 Daily 20.....................................................................

5.3 Periodic 20..................................................................

6 TROUBLESHOOTING 21..............................................

6.1 General 21..................................................................

6.2 POSSIBLE FAULTS 21.......................................................

7 ORDERING OF SPARE PARTS 21......................................

WEAR COMPONENTS 22.................................................

DIMENSION DRAWING 25................................................

SPARE PARTS LIST 27..................................................

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SafeArcT GB

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 precau-

tions. Safety precautions must meet the requirements that apply to this type of weld-

ing 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 hazar-

dous situations which can result in injury to the operator and damage to the equip-

ment.

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

Sthe working area/working range is free from objects.

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. Note! Do not use safety gloves

when replacing wire.

SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns.

5. Protection against other risks

SDust particles of a certain size can be harmful to man.

A ventilation system and extractor should therefore be provided to eliminate

this risk.

SWhen replacing the wire drum, exercise the greatest caution as the end of

the wire could cause personal injury.

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SafeArcT GB

6. 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.

WARNING, RISK OF CRUSHING!

Do not use safety gloves when replacing wire, feed rollers and wire bobbins.

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 inflam-

mable 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.

PROTECT YOURSELF AND OTHERS!

READ AND UNDERSTAND THE INSTRUCTION MAN-

UAL BEFORE INSTALLING OR OPERATING.

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SafeArcT GB

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hfa8d1ea

2 INTRODUCTION

2.1 General

The A6TF F1/ A6TF F1 Twin 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 the control box, PEK and ESAB's

welding power sources LAF or TAF.

2.2 Welding Method

2.2.1 Submerged Arc Welding (SAW)

SSubmerged arc Light Duty.

Submerged arc light duty with a Ø 20 mm connector permits a load up to

800 A (100%).

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 Light duty This version permits a load up to 800 A (100%) and

welding with a thin wire.

SAW Heavy duty This version permits a load up to 1500 A (100%) and

welding 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.

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2.5 Technical data

A6TF F1 A6TF F1 Twin

Supply voltage 42 V AC 42 V AC

Permissible load at 100 %: 1500 A 1500 A

Wire dimensions:

solid single wire

hollow wire

solid twin wire

3.0-6.0 mm

3.0-4.0 mm

2x2.0-3.0 mm

3.0-6.0 mm

3.0-4.0 mm

2x2.0-3.0 mm

Wire feed speed, max 4m/min 4m/min

Brake hub braking torque 1.5 Nm 1.5 Nm

Travel speed 0.1-2.0 m/min 0.1-2.0 m/min

Max. weight of wire 30 kg 30 kg

Flux container volume (Not to be filled with preheated

flux) 10 l 10 l

Weight (excl. wire and flux) 110 kg 140 kg

Enclosure class IP10 IP10

EMC classification Class A Class A

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2.6 Main components A6TF F1 (SAW), A6TF F1 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

10. Wire guide

See on page 11 for a description of the main components.

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