ESAB A6 Mastertrac A6TF User manual

Instruction manual
0449 265 560 GB 20230626 Valid for: serial no. 940-xxx-xxxx
A6 Mastertrac
A6TF F1 / A6TF F1 Twin

TABLE OF CONTENTS
0449 265 560 © ESAB AB 2023
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 9
2.1 General .................................................................................................... 9
2.2 Welding method...................................................................................... 9
2.2.1 Submerged Arc Welding (SAW) ........................................................... 9
2.3 Definitions ............................................................................................... 9
2.4 Horizontal welding.................................................................................. 9
3TECHNICAL DATA ...................................................................................... 10
4INSTALLATION............................................................................................ 11
4.1 General .................................................................................................... 11
4.2 Main components A6TF F1 (SAW), A6TF F1 Twin (SAW) ................... 11
4.3 Description of main components.......................................................... 12
4.3.1 Carriage................................................................................................ 12
4.3.2 Carrier................................................................................................... 12
4.3.3 Wire feed unit ....................................................................................... 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 ................................................................................................. 13
4.4.1 Wire drum (Accessories) ...................................................................... 13
4.5 Adjusting the brake hub ........................................................................ 13
4.6 Connections............................................................................................ 13
4.6.1 General................................................................................................. 13
4.6.2 Automatic welding equipment A6TF F1 / A6TF F1 Twin (Submerged
Arc Welding, SAW)...............................................................................
14
5OPERATION ................................................................................................ 15
5.1 General .................................................................................................... 15
5.2 Loading the welding wire....................................................................... 15
5.3 Changing the feed roller ........................................................................ 16
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 ................................ 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 ...................................................................... 18

TABLE OF CONTENTS
0449 265 560 © ESAB AB 2023
5.6 Transportation ........................................................................................ 18
5.7 Conversion of A6TF F1 / A6TF F1 Twin (Submerged Arc Welding)
to MIG/MAG welding...............................................................................
19
5.8 Conversion of A6TF F1 (Submerged Arc Welding) to Twin-arc ......... 19
6MAINTENANCE........................................................................................... 20
6.1 General .................................................................................................... 20
6.2 Daily......................................................................................................... 20
6.3 Periodic ................................................................................................... 20
7TROUBLESHOOTING ................................................................................. 21
7.1 General .................................................................................................... 21
7.2 Possible errors ....................................................................................... 21
8ORDERING SPARE PARTS ........................................................................ 22
DIMENSION DRAWING....................................................................................... 23
ORDERING NUMBERS....................................................................................... 25
WEAR PARTS...................................................................................................... 26
Rights reserved to alter specifications without notice.

1 SAFETY
0449 265 560 -5- © ESAB AB 2023
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

1 SAFETY
0449 265 560 -6- © ESAB AB 2023
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0449 265 560 -7- © ESAB AB 2023
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.

1 SAFETY
0449 265 560 -8- © ESAB AB 2023
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.

2 INTRODUCTION
0449 265 560 -9- © ESAB AB 2023
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.

3 TECHNICAL DATA
0449 265 560 - 10 - © ESAB AB 2023
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
(Excluding wire and flux)
110kg 140kg
Enclosure class IP10 IP10
EMC classification ClassA ClassA