ESAB A6 Mastertrac A6TF F1 / A6TF F1 Twin Instruction manual

A6 Mastertrac

A6TF F1 / A6TF F1 Twin

Instruction manual

0449 265 560 GB 20200827

Valid for: serial no. 940-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY

1.1 Meaning of symbols

1.2 Safety precautions

2

INTRODUCTION

2.1 General

2.2 Welding method

2.2.1 Submerged Arc Welding (SAW)........................................................... 9

2.3 Definitions

2.4 Horizontal welding

3

TECHNICAL DATA

4

INSTALLATION

4.1 General

4.2 Main components A6TF F1 (SAW), A6TF F1 Twin (SAW)

4.3 Description of main components

4.3.1 Carriage................................................................................................ 12

4.3.2 Carrier................................................................................................... 12

4.3.3 Wire feed unit ....................................................................................... 12

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5

5

5

9

9

9

9

9

10

11

11

11

12

4.3.4 Manual slides ....................................................................................... 12

4.3.5 Connector............................................................................................. 12

4.3.6 Motor with gear (A6 VEC) .................................................................... 12

4.3.7 Flux hopper / Flux tube / Flux nozzle ................................................... 12

4.4 Mounting

4.4.1 Wire drum (Accessories) ...................................................................... 13

4.5 Adjusting the brake hub

4.6 Connections

4.6.1 General................................................................................................. 13

4.6.2 Automatic welding equipment A6TF F1 / A6TF F1 Twin (Submerged

Arc Welding, SAW)...............................................................................

5

OPERATION

5.1 General

5.2 Loading the welding wire

5.3 Changing the feed roller

5.3.1 Single wire............................................................................................ 16

5.3.2 Twin wire (Twin-arc).............................................................................. 16

5.3.3 Flux-cored wire for knurled rollers (Accessories) ................................. 16

5.4 Contact equipment for Submerged Arc Welding

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13

13

13

14

15

15

15

16

17

5.4.1 For single wire 3.0–6.0mm .................................................................. 17

5.4.2 For twin wires 2×2.0–3.0mm(D35) ..................................................... 17

5.4.2.1 Accessories ....................................................................................... 17

5.4.2.2 Adjustment of the wires for twin-arc welding ..................................... 17

5.5 Refilling with flux powder

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18

TABLE OF CONTENTS

5.6 Transportation

5.7 Conversion of A6TF F1 / A6TF F1 Twin (Submerged Arc Welding)

to MIG/MAG welding

5.8 Conversion of A6TF F1 (Submerged Arc Welding) to Twin-arc

6

MAINTENANCE

6.1 General

6.2 Daily

6.3 Periodic

7

TROUBLESHOOTING

7.1 General

7.2 Possible errors

8

ORDERING SPARE PARTS

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DIMENSION DRAWING
ORDERING NUMBERS
WEAR PARTS

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18

19

19

20

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20

21

21

21

22
23
25
26

Rights reserved to alter specifications without notice.

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1 SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB 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 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

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1 SAFETY

4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

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

could become trapped or cause burns

5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• 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

• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

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1 SAFETY

MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.

• Do not use on closed containers.

HOT SURFACE - Parts can burn

• Do not touch parts bare handed.

• Allow cooling period before working on equipment.

• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.

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1 SAFETY

NOTE!
Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

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2 INTRODUCTION

2 INTRODUCTION

2.1 General

The A6TF F1 / A6TF F1 Twin automatic welding equipment is designed for Submerged Arc
Welding (SAW) of butt and fillet joints.

All other applications are prohibited.

Intended for use in combination with PEK and ESAB welding power sources LAF, TAF or
Aristo1000.

NOTE!
Aristo1000 only together with PEK with serial no. 747-xxx-xxxx or later.

2.2 Welding method

2.2.1 Submerged Arc Welding (SAW)

• Submerged Arc Light duty

Submerged Arc Light duty with a Ø20mm connector permits a load up to 800A (100%).

• Submerged Arc Heavy duty

Submerged Arc Heavy duty with a Ø35mm connector 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 The weld bead is protected by a cover of flux during the welding.

SAW Light duty Permits welding with lower current load and thin wire.

SAW Heavy duty Permits welding with lower current load and thick wire.

Twin-arc welding Welding with two wires in one welding head.

2.4 Horizontal welding

The products described in this manual are designed for horizontal welding.

NOTE!

Do not use A6 Mastertrac Tandem when welding on inclined planes.

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3 TECHNICAL DATA

3 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

2×2.0–3.0mm

3.0–6.0mm

3.0–4.0mm

2×2.0–3.0mm

Maximum wire feed speed 4m/min 4m/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

Maximum weight of wire 30kg 30kg

Flux hopper volume 10l 10l

Weight

110kg 140kg

(Excluding wire and flux)

Enclosure class IP10 IP10

EMC classification ClassA ClassA

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4 INSTALLATION

4 INSTALLATION

4.1 General

The installation must be carried out by a professional.

WARNING!

Rotating parts can cause injury, take great care.

4.2 Main components A6TF F1 (SAW), A6TF F1 Twin (SAW)

1. Carriage 6. Motor with gear (A6 VEC)

2. Carrier 7. Flux hopper

3. Wire feed unit 8. Flux tube

4. Slide kit, manual 9. Flux nozzle

5. Connector 10. Wire guide

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4 INSTALLATION

4.3 Description of main components

4.3.1 Carriage

Secured the carriage with the locking lever (1).

4.3.2 Carrier

Fit the control unit, wire feed unit and flux hopper, among other things, on the carrier.

4.3.3 Wire feed unit

The wire feed unit guides and feeds the welding wire into the connector.

4.3.4 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.

4.3.5 Connector

Transfers welding current to the wire during welding.

4.3.6 Motor with gear (A6 VEC)

The motor feeds the welding wire.

For more information regarding A6 VEC see Instruction manual 0443 393 xxx.

4.3.7 Flux hopper / Flux tube / Flux nozzle

The flux is filled into the flux hopper. It 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.

For more information, see section "Refilling with flux powder".

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4 INSTALLATION

4.4 Mounting

4.4.1 Wire drum (Accessories)

Mount the wire drum (1) on the brake hub (2).

WARNING!

To prevent the reel from 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.

4.5 Adjusting the brake hub

The brake hub is adjusted at delivery. If readjustment is required, follow the instructions
below. Adjust the brake hub so the wire is slightly slack when wire feed stops.

Adjusting the braking torque:

1. Turn the red handle to the locked
position.

2. Insert a screwdriver into the springs
in the hub.

○ Turn the springs clockwise to

reduce the braking torque.

○ Turn the springs

counter-clockwise to increase
the braking torque.

NOTE!

Turn both springs the same amount.

4.6 Connections

4.6.1 General

• The PEK must be connected by a qualified person. See separate instruction manual.

• For connection of A6GMH, see separate instruction manual.

• For connection of A6PAV, see separate instruction manual.

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4 INSTALLATION

4.6.2 Automatic welding equipment A6TF F1 / A6TF F1 Twin (Submerged Arc Welding, SAW)

1. Connect the control cable (5) between the power source (3) and the PEK (2).

2. Connect the return cable (6) between the power source (3) and work piece (4).

3. Connect the welding cable (7) between the power source (3) and the automatic
welding equipment (1).

4. Connect the measurement cable (8) between the power source (3) and workpiece (4).

1. Automatic welding equipment 5. Control cable

2. PEK 6. Return cable

3. Power source 7. Welding cable

4. Work piece 8. Measurement cable

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5 OPERATION

5 OPERATION

5.1 General

CAUTION!

Read and understand the instruction manual before
installing or operating.

General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!

Return cable

Before starting the welding, check that the return cable is connected. See section
"Connections".

5.2 Loading the welding wire

1. Mount the wire drum according to the instructions in the "Installation" chapter.

2. Check that feed roller (1) and contact jaw or contact tip (3) has the correct dimension
for the selected wire size.

3. For A6TF F1 Twin:

○ Feed the wire through the wire guide (8).

4. When welding with fine wire:

○ 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).

○ 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).

NOTE!

Do not tension more than is required to achieve an even feed.

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5 OPERATION

8.

Feed the wire forward 30mm below the contact tip by pressing on the PEK.

9. Direct the wire by adjusting the knob (5).

NOTE!
Always use a guide tube (7) to ensure even feed of fine wire (1.6–2.5mm).

5.3 Changing the feed roller

5.3.1 Single wire

• Release the knobs (3) and (4).

• Release the hand wheel (2).

• Change the feed roller (1).
The feed rollers are marked with their respective wire sizes.

5.3.2 Twin wire (Twin-arc)

• Change the feed roller (1) with twin grooves in the same way as for single wire.

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.

• Assemble the pressure roller with special stub shaft (order no. 0146253001).

5.3.3 Flux-cored wire for knurled rollers (Accessories)

• 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. 0212901101).

• Tighten the pressure screw (4) with moderate pressure to ensure that the flux-cored
wire does not deform.

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5 OPERATION

5.4 Contact equipment for Submerged Arc Welding

5.4.1 For single wire 3.0–6.0mm

Use automatic welding equipment A6TFF1(SAW) where the
following are included:

• Wire feed unit (1)

• Connector D35 (2)

• Contact jaw (3)
Ensure that a good contact is achieved between the contact
jaws and the wire.

5.4.2 For twin wires 2×2.0–3.0mm(D35)

Use automatic welding equipment A6TFF1Twin(SAW) where the
following are included:

• Wire feed unit (1)

• Connector Twin D35 (2)

• Contact jaw (3)
Ensure that a good contact is achieved between the contact
jaws and the wire.

• Guide tubes (4, 6)

5.4.2.1 Accessories

• Fine-wire straightener (5) to be fitted on top of the clamp of the
wire feed unit (1).

NOTE!

When mounting the fine-wire straightener, remove the
plate(7) if it exists.

NOTE!
Do not remove the protection plate (8).

5.4.2.2 Adjustment of the wires for twin-arc welding

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.

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5 OPERATION

5.5 Refilling with flux powder

1. Close the flux valve (1) on the flux hopper.

2. Remove the optional cyclone on the flux recovery

unit, if fitted.

3. Fill with flux powder.

NOTE!

The flux powder must be dry. Use
preheated flux powder only when the
flux hopper is designed for that.

4. Position the flux tube without twisting it.

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.

5.6 Transportation

Disengage the wheels by turning the locking lever (1).

NOTE!

Use the lifting eye bolt (2) when lifting the equipment.

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5 OPERATION

5.7 Conversion of A6TF F1 / A6TF F1 Twin (Submerged Arc Welding) to MIG/MAG welding

Assemble in accordance with the instructions accompanying the conversion kit.

5.8 Conversion of A6TF F1 (Submerged Arc Welding) to Twin-arc

Assemble in accordance with the instructions accompanying the conversion kit.

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6 MAINTENANCE

6 MAINTENANCE

6.1 General

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.

NOTE!

Before doing any kind of maintenance work, make sure the mains cable is
disconnected.

For maintenance of the control unit, see separate instruction manual.

6.2 Daily

• Clean flux and dirt off moving parts.

• Check that the contact tip and all electrical cables are connected.

• Make sure all screwed joints are tightened.

• Check that guides and drive rollers are not worn or damaged.

• Check the brake hub braking torque. Tighten if the wire reel continues to rotate when
the wire feed is stopped. Loosen if 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 section "Adjusting the brake hub".

6.3 Periodic

• Check the wire feed motor brushes
once every three months. Replace
when they are worn down to 6mm.

• Inspect the slides, lubricate them if they
are binding.

• Inspect the wire guides, drive rollers
and contact tip on the wire feed unit.
Replace any worn or damaged
components, see section "WEAR
PARTS".

• If the carriage travel becomes jerky,
check that the chain is correctly
tensioned. Tension the chain if
necessary.

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

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7 TROUBLESHOOTING

7 TROUBLESHOOTING

7.1 General

Equipment

• Instruction manual for included parts.

Check

• That the power supply is connected for the correct mains supply.

• That all three phases are supplying the correct voltage (phase sequence is not
important).

• That welding cables and connections are not damaged.

• That the controls are correctly set.

• That the mains supply is disconnected before starting repairs.

7.2 Possible errors

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 Wire feed roller pressure is inadequate.

Action Increase pressure on wire feed rollers.

2. Symptom Wire feed is uneven

Cause 2.1 Pressure on wire feed rollers is incorrectly set.

Action Adjust pressure on wire feed rollers.

Cause 2.2 Wire feed rollers are of the wrong size.

Action Replace wire feed rollers.

Cause 2.3 Grooves in wire feed rollers are worn.

Action Replace wire feed rollers.

3. Symptom Welding cables are overheating

Cause 3.1 Poor electrical connection.

Action Clean and tighten all electrical connections.

Cause 3.2 Cross-sectional area of welding cables is too small.

Action Use cables with a larger cross-section or use parallel cables.

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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.

A6TFF1 and A6TFF1Twin are designed and tested in accordance with the international
and European standards EN60974-5, EN12100-2 and EN60974-10. On completion of
service or repair work, it is the responsibility of the person(s) performing the work to ensure
that the product still complies with the requirements of the above standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.

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DIMENSION DRAWING

DIMENSION DRAWING

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DIMENSION DRAWING

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ORDERING NUMBERS

ORDERING NUMBERS

Ordering

Denomination Type Notes

number

0461 235 880 A6 Mastertrac A6TF F1 SAW

0461 235 881 A6 Mastertrac A6TF F1 SAW Twin

0460 949 *74 Instruction manual PEK Control panel

0460 948 *01 Instruction manual PEK Control unit

0463 648 001 Spare parts list

Technical documentation is available on the Internet at: www.esab.com

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WEAR PARTS

WEAR PARTS

Feed rollers

SAW and MIG/MAG

Part no. D(mm)

0218 510 281 1.6

0218 510 282 2.0

0218 510 283 2.5

0218 510 286 4.0

0218 510 287 5.0

0218 510 288 6.0

0218 510 298 3.0–3.2

SAWTwin(D35)

Part no. D(mm)

0218 522 480 2.5

0218 522 481 3.0–3.2

0218 522 484 2.0

0218 522 486 1.2

0218 522 487 1.0

0218 522 488 1.6

SAW and MIG/MAG tubular wire

Part no. D(mm)

0146 024 880 0.8–1.6

0146 024 881 2.0–4.0

MIG/MAG

Part no. D(mm)

0145 538 880 0.6

0145 538 881 0.8

0145 538 882 1.0

0145 538 883 1.2

MIG/MAG

Part no. D(mm)

0148 772 880 2.0–3.0

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WEAR PARTS

Pressure rollers

SAW and MIG/MAG tubular wire

Part no. D(mm)

0146 025 880 0.8–1.6

0146 025 881 2.0–4.0

0146 025 882 5.0–7.0

SAWTwin

Part no.

0218 524 580

0146 253 001 Stub shaft

0144 953 001 Spherical ball bearing

0190 452 178 Washer

Stub shaft for pressure roller

SAW tubular wire

Part no.

0212 901 101

Contact jaws

SAWHD(D35)

Part no. D(mm)

0265 900 880 3.0

0265 900 881 3.2

0265 900 882 4.0

0265 900 883 5.0

0265 900 884 6.0

SAWTwinHD

Part no. D(mm)

0265 902 880 2.5–3.0

0265 902 881 2.0

0265 902 882 1.6

0265 902 883 4.0

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WEAR PARTS

Contact tip

MIG/MAG and SAWTwinLD(D35)

Part no. D(mm)

0153 501 002 0.8

0153 501 004 1.0

0153 501 005 1.2

0153 501 007 1.6

0153 501 009 2.0

0153 501 010 2.4–2.5

MIG/MAG(D35)

Part no. D(mm)

0258 000 908 1.2

0258 000 909 1.6

0258 000 910 2.0

0258 000 911 2.4

0258 000 913 1.0

0258 000 914 0.8

0258 000 915 3.2

Adapter for contact tip

SAW and MIG/MAG(D35)

Part no. D(mm)

0147 333 001 M6/M10

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WEAR PARTS

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© ESAB AB 2020

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