ESAB A6 Mastertrac Tandem User manual

Instruction manual
0449 468 460 GB 20230626 Valid for: serial no. 940-xxx-xxxx
A6 Mastertrac Tandem
A6TF F2

TABLE OF CONTENTS
0449 468 460 © 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 Horizontal welding.................................................................................. 9
3TECHNICAL DATA ...................................................................................... 10
4INSTALLATION............................................................................................ 11
4.1 General .................................................................................................... 11
4.2 Main components A6TF F2 (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 Connections............................................................................................ 13
4.5.1 General................................................................................................. 13
4.5.2 Automatic welding equipment A6TF F2 (Submerged Arc Welding,
SAW) ....................................................................................................
14
5OPERATION ................................................................................................ 15
5.1 General .................................................................................................... 15
5.2 Loading the welding wire....................................................................... 15
5.2.1 Accessories .......................................................................................... 16
5.3 Changing the feed roller ........................................................................ 16
5.3.1 Single wire............................................................................................ 16
5.3.2 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. Heavy duty (D35) .................................... 17
5.4.2 For flux-cored wire 1.6–4.0mm (D20 and D35) (Accessories) ............ 17
5.4.3 Adjustment of the wire for tandem welding .......................................... 17
5.5 Refilling with flux powder ...................................................................... 18
5.6 Transportation ........................................................................................ 19
6MAINTENANCE........................................................................................... 20
6.1 General .................................................................................................... 20

TABLE OF CONTENTS
0449 468 460 © ESAB AB 2023
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 468 460 -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 468 460 -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 468 460 -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 468 460 -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 468 460 -9- © ESAB AB 2023
2 INTRODUCTION
2.1 General
The A6TF F2 automatic welding equipment with two welding heads, is mounted on a
self-propelled trolley. It is designed for Submerged Arc Welding (SAW) of butt welds.
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)
The weld bead is protected by a cover of flux during the welding.
• 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 wire welding. A special knurled feed
roller is available for flux-cored wire, which guarantees even feed without the risk of
deformation due to high feed pressure.
• Tandem welding (Submerged Arc)
For tandem welding, a welding head of type A6SF is always used, which must be connected
to 2 welding power sources and 2 control units of type PEK.
The tandem welding head includes 2 single welding heads (A6SF), each with its own contact
tip. Each contact tip has a maximum rated load of 1500A.
2.3 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 468 460 - 10 - © ESAB AB 2023
3 TECHNICAL DATA
A6TF F2 (SAW)
Supply voltage 42VAC
Permissible load at 100% 1500A
Wire dimensions
Solid single wire
Flux-cored wire
3.0–6.0mm
3.0–4.0mm
Maximum wire feed speed 4m/min
Brake hub braking torque 1.5Nm
Travel speed 0.1–2.0m/min
Maximum weight of wire 2×30kg
Flux hopper volume 10l
Weight
(Excluding wire and flux)
158kg
Continuous A weighted sound pressure 68dB
Enclosure class IP10
EMC classification ClassA

4 INSTALLATION
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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 F2 (SAW)
1. Carriage 5. Connector
2. Carrier 6. Motor with gear (A6 VEC)
3. Wire feed unit 7. Flux hopper
4. Slide kit, manual 8. Flux nozzle

4 INSTALLATION
0449 468 460 - 12 - © ESAB AB 2023
4.3 Description of main components
4.3.1 Carriage
The carriage is provided with 4-wheel drive. 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".

4 INSTALLATION
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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.
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 Connections
4.5.1 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.

4 INSTALLATION
0449 468 460 - 14 - © ESAB AB 2023
4.5.2 Automatic welding equipment A6TF F2 (Submerged Arc Welding, SAW)
1. Connect the control cable between the power source and the PEK.
2. Connect the return cable between the power source and work piece.
3. Connect the welding cable between the power source and the automatic welding
equipment.
4. Connect the measurement cable between the power source and workpiece.
1. Automatic welding equipment 5. Control cable
2. PEK 6. Return cable
3. Power source 7. Welding cable
4. Work piece 8. Measurement cable

5 OPERATION
0449 468 460 - 15 - © ESAB AB 2023
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. 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).
4. 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.
5. Locate the end of the wire in the feed roller (1) groove.
6. 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.
7.
Feed the wire forward 30mm below the contact tip by pressing on the PEK.
8. Direct the wire by adjusting the knob (5).

5 OPERATION
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NOTE!
Always use a guide tube (7) to ensure even feed of fine wire (1.6–2.5mm).
5.2.1 Accessories
• Fine-wire straightener (6) to be fitted on top of the clamp of the
wire feed unit (2).
NOTE!
When mounting the fine-wire straightener, remove the
plate(9) if it exists.
NOTE!
Do not remove the protection plate (8).
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 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.

5 OPERATION
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5.4 Contact equipment for Submerged Arc Welding
5.4.1 For single wire 3.0–6.0mm. Heavy duty (D35)
• Use the straightener (3), connector (1) D35 with contact
jaws(2).
• Assemble one contact jaw with the M5 bolts provided, in the
fixed contact tip (a).
• Assemble the other contact jaw in the free half of the two-piece
connector (b) under the bolt (8). Tighten hard to ensure that a
good contact is achieved between the contact jaws and the
wire.
5.4.2 For flux-cored wire 1.6–4.0mm (D20 and D35) (Accessories)
NOTE!
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 a good contact is achieved with the wire.
5.4.3 Adjustment of the wire for tandem welding
NOTE!
The distance between the first and second wires must not be so great that the slag
has time to solidify between the wires.
Ensure that good flux coverage is achieved between the first and second wires.

5 OPERATION
0449 468 460 - 18 - © ESAB AB 2023
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 OPERATION
0449 468 460 - 19 - © ESAB AB 2023
5.6 Transportation
Disengage the wheels by turning the locking lever (1).
NOTE!
Use the lifting eye bolt (2) when lifting the equipment.

6 MAINTENANCE
0449 468 460 - 20 - © ESAB AB 2023
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.