ESAB A6 Mastertrac Manual Download Page 1

Page: 1 / 50

Valid for serial no. 940-xxx-xxxx

0449 265

2009-10-05

460

A6 Mastertrac

A6TF F1/ A6TF F1 Twin

Instruction manual

Summary of Contents for A6 Mastertrac

Page 1: ...Valid for serial no 940 xxx xxxx 0449 265 2009 10 05 460 A6 Mastertrac A6TF F1 A6TF F1 Twin Instruction manual ...

Page 2: ... 2 Rights reserved to alter specifications without notice ENGLISH 4 ...

Page 3: ...3 ...

Page 4: ...re 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...

Page 5: ...stops S its function S relevant safety precautions S welding 2 The operator must ensure that S no unauthorised person is stationed within the working area of the equipment when it is started up S no one is unprotected when the arc is struck S the working area working range is free from objects 3 The workplace must S be suitable for the purpose S be free from draughts 4 Personal safety equipment S ...

Page 6: ... position S That 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 S Make sure that the automatic welding machine is not unstable before start S That 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 weldi...

Page 7: ...S Use 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 S Protect your eyes and body Use the correct welding screen and filter lens and wear protective clothing S Protect bystanders with suitable screens or curtains FIRE HAZARD S Sparks spatter can cause fire Make sure therefore that there are no i...

Page 8: ...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...

Page 9: ...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 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 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 GB ...

Page 10: ...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 GB ...

Page 11: ...he 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 i...

Page 12: ...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 S Adjusting the braking torque S Turn the red handle to the locked position S Insert a screwdriver into the springs in the hub Turn the springs clockwise ...

Page 13: ...6 PAV see instruction manual 0460 670 xxx 3 4 2 Automatic welding machine A6TF F1 A6TF F1 Twin Submerged arc welding SAW 1 Connect the control cable 5 between the power source 3 and the control box 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 machine 1 4 Connect the measurement cabl...

Page 14: ...ty information You must not operate the machine before then General safety regulations for the handling of the equipment can be found on page 5 Read through before you start using the equipment Return cable Before welding start check that the return cable is connected See page 13 GB ...

Page 15: ... 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 S 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 S Note Do not tension more than is...

Page 16: ...er 5 must also be changed A special curved pressure roller for twin wire replaces the standard pressure roller for single wire S Assemble the pressure roller with special stub shaft order no 0146 253 001 Flux cored wire for knurled rollers Accessories S 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 rolle...

Page 17: ...ontact jaw 3 Ensure that good contact is achieved between the contact jaws and the wire S Guide tubes 4 6 Accessories S Fine wire straightener 5 to be fitted on top of the clamp of the wire feed unit 1 N B When mounting the fine wire straightener remove the plate 7 if it s exists N B The protection plate 8 shall not be removed Adjustment of the wires for Twin arc welding S Position the wires in th...

Page 18: ... the flux recovery unit if fitted 3 Fill with flux powder NOTE The flux powder must be dry 4 Position the flux tube so that it does not become kinked 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 GB ...

Page 19: ... automatic welding machine the lifting eye 2 shall be used 4 7 Conversion of A6TF F1 A6TF F1 Twin Submerged arc to MIG MAG welding Assemble in accordance with the instructions accompanying the conversion kit 4 8 Conversion of A6TF F1 submerged arc welding to Twin arc Assemble in accordance with the instructions accompanying the conversion kit GB ...

Page 20: ...orn or damaged S Check the brake hub braking torque It should not be so low that the wire reel continues to rotate when wire feed is stopped and it should not be so great that 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 on page 12 5 3 Periodic S Check the wire feed motor brushes once every three months Replace when the...

Page 21: ...e Cause 1 2 Feed roller pressure is inadequate Action Increase pressure on feed rollers 2 Symptom Wire feed is irregular Cause 2 1 Pressure on feed rollers incorrectly set Action Adjust pressure on feed rollers Cause 2 2 Feed rollers wrong size Action Replace feed rollers Cause 2 3 Grooves in feed rollers are worn Action Replace feed rollers 3 Symptom Welding cables overheating Cause 3 1 Poor elec...

Page 22: ...8 510 288 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 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 D mm 148 772 880 2 0 3 0 ...

Page 23: ... 0146 253 001 Stub shaft 0144 953 001 Sperical 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 ...

Page 24: ... 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 M 10 ...

Page 25: ...DIMENSION DRAWING 25 dimdoc ...

Page 26: ... 26 dimdoc ...

Page 27: ...TF F1 A6TF F1 Twin Edition 2009 10 05 Ordering no Denomination Notes 0461 235 880 A6 Mastertrac A6TF F1 SAW 0461 235 881 A6 Mastertrac A6TF F1 SAW Twin 0461 235 890 A6 Mastertrac A6TF F1 SAW 0461 235 891 A6 Mastertrac A6TF F1 SAW Twin ...

Page 28: ...1 0449490881 Carriage 2 1 0449254880 Carrier 3 1 0449252880 Slide travel kit manual 90 mm 4 1 0449250880 Wire feed unit right 156 1 5 1 0460504880 Control box PEK 6 1 0449253900 Cable set L 1 6 m 6 2 1 0460907891 Motor cable 1 5 m 6 3 1 0461239881 Arc welding cable 1 7 m 6 4 1 0460908880 Pulse transducer cable 2 m ...

Page 29: ...1 0449490881 Carriage 2 1 0449254880 Carrier 3 1 0449252880 Slide travel kit manual 90 mm 4 1 0449250890 Wire feed unit right 74 1 5 1 0460504880 Control box PEK 6 1 0449253900 Cable set L 1 6 m 6 2 1 0460907891 Motor cable 1 6 m 6 3 1 0461239881 Arc welding cable 1 7 m 6 4 1 0460908880 Pulse transducer cable 2 m ...

Page 30: ... 1 1 0449490881 Carriage 2 1 0449254880 Carrier 3 1 0449252880 Slide travel kit manual 90 mm 4 1 0449250881 Wire feed unit Twin 156 1 5 1 0460504880 Control box PEK 6 1 0449253900 Cable set L 1 6m 6 2 1 0460907891 Motor cable 1 6 m 6 3 1 0461239881 Arc welding cable 1 7 m 6 4 1 0460908880 Pulse transducer cable 2 m ...

Page 31: ...n 1 1 0449490881 Carriage 2 1 0449254880 Carrier 3 1 0449252880 Slide travel kit manual 90mm 4 1 0449250891 Wire feed unit Twin 74 1 5 1 0460504880 Control box PEK 6 1 0449253900 Cable set L 1 6m 6 2 1 0460907891 Motor cable 1 6 m 6 3 1 0461239881 Arc welding cable 1 7 m 6 4 1 0460908880 Pulse transducer cable 2 m ...

Page 32: ...25 1 0449485881 Drive unit 30 1 0334167001 Bottom plate 31 2 0215701019 Circlip D25x1 2 32 1 0334189001 Gear wheel 35 1 0215701243 Wedge 5x5x65 36 1 0461242880 Pulse transducer cable 1 25m 38 1 0461241880 Motor cable 43 1 0333630001 Locking arm adjustable 44 1 0211102940 Roll pin D 3x28 45 1 0215701016 Circlip D20 46 1 0334196001 Bushing 48 1 0334192880 Excenter 52 1 0221307001 Steel ball 7 94 mm ...

Page 33: ... 33 h449490s ...

Page 34: ...olumn 5 1 0334170001 Clamping ring 7 6 0219504307 Cup spring d20 10 2 8 3 0193571106 Locking plate steel 26 10 5x22 9 1 0193570129 Locking arm m10x32 12 1 0334176880 Reel holder 14 1 0146967880 Brake hub 17 1 0334297880 Box holder 21 1 0334185886 Box girder beam 30 1 0334707883 Thread steerer ...

Page 35: ...5 f449252s Item no Qty Ordering no Denomination Notes 0449252880 Slide travel kit manual 90mm 1 2 0154465880 Slide manual L 90 2 1 0334171001 Plate 4 1 0334170001 Clamping ring 5 1 0334172001 Gear bracket ...

Page 36: ...rame 6 1 0154463880 Carriage with slide rails 7 6 0190509485 Stop screw M10x10 8 1 0154458001 End piece 10 2 0211102957 Roll pin D5x20 11 1 0154461001 Lead screw 16 1 0190531201 Ball bearing SKF 3201 17 1 0154456001 Lock nut 18 1 0154457001 Ball bearing cap 22 1 0334537001 Handle crank 23 1 0211102938 Roll pin D3x20 ...

Page 37: ...h gear A6 VEC 156 1 see separate manual 2 1 0147639880 Wire straightener right mounted D35 3 1 0218810183 Insulated hand wheel 4 1 0334290882 Contact equipment D35 L275 6 1 0148487880 Bracket for flux hopper 7 1 0147649881 Flux hopper 10 l 10 1 0457713001 Bar 20 1 0148493001 Cable holder 22 1 0334294001 Attachment 29 1 0449528001 Protection plate ...

Page 38: ...right mounted D35 Twin 3 1 0218810183 Insulated hand wheel 4 1 0334290882 Contact equipment D35 L275 6 1 0148487880 Bracket for flux hopper 7 1 0147649881 Flux hopper 10 l 10 1 0457713001 Bar 20 1 0148493001 Cable holder 22 1 0334294001 Attachment 29 1 0449528001 Protection plate 30 1 0155300001 Plate 32 2 0156800002 Wire liner D 8 4 35 1 0146967880 Brake hub 36 2 0154734001 Brake hub clamp Not sh...

Page 39: ...h gear A6 VEC 74 1 see separate manual 2 1 0147639880 Wire straightener right mounted D35 3 1 0218810183 Insulated hand wheel 4 1 0334290882 Contact equipment D35 L275 6 1 0148487880 Bracket for flux hopper 7 1 0147649881 Flux hopper 10 l 10 1 0457713001 Bar 20 1 0148493001 Cable holder 22 1 0334294001 Attachment 29 1 0449528001 Protection plate ...

Page 40: ...ulated hand wheel 4 1 0334290882 Contact equipment D35 L275 6 1 0148487880 Bracket for flux hopper 7 1 0147649881 Flux hopper 10 l 10 1 0457713001 Bar 20 1 0148493001 Cable holder 22 1 0334294001 Attachment 29 1 0449528001 Protection plate 30 1 0155300001 Plate 32 2 0156800002 Wire liner D8 4 35 1 0146967880 Brake hub 36 2 0154734001 Brake hub clamp 40 1 0145787880 Fine wire straightener 42 1 0334...

Page 41: ... 7 4 0215201209 Sealing O ring D11 3x2 4 8 2 0218400801 Pressure roller arm 9 1 0218810181 Handwheel insulated 10 1 0218810182 Handwheel insulated 11 3 0332408001 Stub shaft 13 3 0153148880 Pressure roller 14 1 0415498001 Pressure roller upper 15 2 0212902601 Spacer screw 16 1 0415499001 Pressure roller lower 19 2 0219501013 Spring washer D18 1 10 2 28 1 0156531001 Clamp half D35 30 1 0212 601110 ...

Page 42: ...209 Sealing O ring 11 3x2 4 8 2 0218400801 Pressure roller arm 9 1 0218810181 Handwheel insulated 10 1 0218810182 Handwheel insulated 11 2 0332408001 Stub shaft 12 1 0218524580 Pressure roller twin 13 2 0153148880 Pressure roller 14 1 0415498001 Pressure roller upper 15 2 0212902601 Spacer screw 16 1 0415499001 Pressure roller lower 19 2 0219501013 Spring washer d18 1 10 2 28 1 0156531001 Clamp ha...

Page 43: ...e 5 1 0156530001 Clamp half D35 6 1 0212900001 Spacer screw 7 2 0215201209 Sealing O ring D11 3x2 4 8 1 0218400801 Pressure roller arm 9 1 0218810181 Handwheel insulated 12 1 0218524580 Pressure roller twin 14 1 0415498001 Pressure roller upper 15 1 0212902601 Spacer screw 19 2 0219501013 Spring washer D18 1 10 2 28 1 0156531001 Clamp half 30 1 0212601110 Nut M10 ...

Page 44: ... 44 f334290s Item Qty Orderingno Denomination Remarks 0334290882 Contact equipment single wire D35 2 1 0417959881 Contact jaw tube L 275 11 1 0153299880 Flux nozzle complete ...

Page 45: ...959s Item no Qty Ordering no Denomination Notes 0417959881 Contact jaw tube L 275 mm 4 1 0443372001 Fitting bolt 5 4 0219504307 Cup spring d20 10 2 T 1 1 6 1 0417979001 Ring 8 1 0443344881 Contact tube L 275 mm ...

Page 46: ... 46 f153299s Item no Qty Ordering no Denomination Notes 0153299880 Flux nozzle complete 1 1 0153290002 Holder for flux pipe 2 1 0153296001 Flux pipe bent 3 1 0153425001 Wheel ...

Page 47: ...n Notes 0147649881 Flux Hopper 10l 1 1 0154007001 Flux hopper 2 1 0148837001 Window a6 flux hopper 3 1 0147645001 Mounting 6 1 0153347880 Flux valve 7 1 0215201232 Sealing O ring 69 2x5 7 13 1 0020301780 Flux strainer 14 1 0443383002 Flux hose L 500 ...

Page 48: ... 48 h153347s Item no Qty Ordering no Denomination Notes 0153347880 Flux valve 1 1 0153348001 Outlet 2 1 0153349001 Shaft 3 1 0211102938 Roll pin d 3x20 ...

Page 49: ...5787880 Fine wire straightener for twin wire 1 1 0145788001 Case 2 2 0145789001 Roller 3 2 0145790001 Roller 4 2 0145791001 Searing bushing 5 2 0190240103 Bearing bushing D12 10 9 2 0145793001 Runner 11 2 0145794001 Knob 13 1 0145795001 Link 15 0151287001 Hose ...

Page 50: ... 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48...

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