ESAB A6 S Arc Master Bedienungsanleitung

Valid for serial no. 3210456 562 101 2009--03--09

A6 S Arc Master

A6 S G Master

A6 S Compact 500

A6 SFE1 / A6 SFE2 / A6 SGE1/

A6 SFE1C

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Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

Instrukcja obs³ugi

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Rätt till ändring av specifikationer utan avisering förbehålles.

Ret til ændring af specifikationer uden varsel forbeholdes.

Rett til å endre spesifikasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préalable.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

Reservamo--nos o direito de alterar as especificações sem aviso prévio.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

Zastrzegamy sobie prawo do wprowadzenia zmian.

SVENSKA 3..............................................

DANSK 18................................................

NORSK 33................................................

SUOMI 48................................................

ENGLISH 63..............................................

DEUTSCH 78.............................................

FRANÇAIS 94.............................................

NEDERLANDS 109.........................................

ESPAÑOL 124..............................................

ITALIANO 140..............................................

PORTUGUÊS 155..........................................

ÅËËÇÍÉÊÁ 172.............................................

POLSKI 189.................................................

ENGLISH

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TOCe

1 DIRECTIVE 64........................................................

2SAFETY 64...........................................................

3 INTRODUCTION 65...................................................

3.1 General 65..................................................................

3.2 Definitions 65................................................................

3.3 Technical data 66............................................................

3.4 Welding method 66...........................................................

3.5 Equipment 67................................................................

4 INSTALLATION 68....................................................

4.1 General 68..................................................................

4.2 Mounting 68.................................................................

4.3 Connections 68..............................................................

5 OPERATION 70.......................................................

5.1 General 70..................................................................

5.2 Starting work 70..............................................................

5.3 Conversion of A6 SFE1 (Submerged arc welding) to MIG/MAG welding 74...........

5.4 Conversion of A6 SFE1 / A6 SFE2 (Submerged arc welding) to Twin--arc 74.........

6 MAINTENANCE 75....................................................

6.1 General 75..................................................................

6.2 Daily 75.....................................................................

6.3 Regularly 75.................................................................

7 FAULT TRACING 76...................................................

8 ACCESSORIES 77....................................................

9 ORDERING OF SPARE PARTS 77......................................

WEAR COMPONENTS 204.................................................

SPARE PARTS LIST 207...................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee

that automatic welding machine A6 SFE1 / A6 SFE2 / A6 SGE1/ A6 SFE1C from

serial number 740 complies with standard EN 60292, in accordance with the require-

ments of directive (89/392/EEA) and addendum.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Laxå 97--11--19

2SAFETY

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 precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations 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 hazardous situations which can result

in injury to the operator and damage to the equipment.

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

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.

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

trapped or cause burns.

5. 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.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ 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 take fumes and gases away 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 inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

3 INTRODUCTION

3.1 General

All the automatic welding machines included in this instruction manual are designed

for SAW and MIG/MAG welding of butt and fillet joints.

ESAB’s welding heads are of the A6 S type and are intended for use in combination

with A2--A6 Process Controller and ESAB’s welding power sources LAF and TAF.

The welding head can be positioned horizontally and vertically with the linear slides.

The angular position is adjusted with the angular slide.

3.2 Definitions

SAW welding The weld bead is protected by a cover of flux during the

welding.

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

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

MIG/MAG welding The weld bead is protected by shielding gas during wel-

ding.

Tandem welding Welding with two welding heads.

Twinarc welding Welding with two wires in the same welding head.

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3.3 Technical data

A6 SFE1 A6 SFE1 A6 SFE2 A6 SGE1 A6 SFE1C

UP UP UP MIG/MAG UP

LD D20 HD D35 HD D35

Rated load 100%

60 %

800 A

1000 A

AC/DC

1500 A

AC/DC

1500 A

AC/DC

600 A

AC/DC

1500 A

AC/DC

Wire dimensions:

solid single wire 1.6--4.0 mm 3.0--6.0 mm 3.0--6.0 mm 0.8--2.5 mm -- 4 . 0 m m

flux--cored wire 1.6--4.0 mm 3.0--4.0 mm -- 1.2--3.2 mm --

twin wire 2x1.2--2.0 mm 2x2.0--3.0mm 2x2.0--3.0mm -- --

Wire feed speed 0.2--4.0 m/min 0.2--4.0 m/min 0.2--4.0 m/min 0.2--15 m/min 0.2--4.0 m/min

Brake drum braking torque 1.5 Nm 1.5 Nm 1.5 Nm 1.5 Nm 1.5 Nm

Max weight, wire 2x30 kg 2x30 kg 4x30 kg 30 kg 2x30 kg

Flux hopper capacity

(Must not be filled with preheated

flux) 10 l 10 l 10 l -- 1l

Weight (flux and wire excluded) 50 kg 50 kg 100 kg 15 kg 50 kg

Sideways tilt, max. 25_25_25_25_25_

Setting length of slide *

manual

motor--driven (with ball bearings) 210 mm

300 mm 210 mm

300 mm 60 mm

Continuous A--weighted noise pres-

sure 68 dB 68 dB 68 dB 83 dB 68 dB

*) NB! Other lengths on request.

3.4 Welding method

Submerged arc welding (SAW)

For SAW welding the A6 SF welding head is always used. It is available in the

following designs:

SSubmerged--arc Light duty

Submerged--arc light duty, with a ∅20 mm connector, which permits a load of up

to 800 A (100%) or 1000 A (60%).

SSubmerged--arc Heavy duty

Submerged--arc heavy duty, with a ∅35 mm connector, which permits a load of

up to 1500 A.

Both versions 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.

For work in confined spaces, (smaller than 50 cm), a special welding head of type

A6 SFE1C is available, which can be installed on the Mastertrac as required.

Tandem welding (submerged--arc)

For tandem welding, a welding head of type A6 SFE2 is always used, which must be

connected to 2 welding power sources and 2 control boxes of type A2--A6 Process

Controller.

The tandem welding head includes 2 single welding heads (A6 SF), each with its

own contact tip. Each contact tip has a maximum rated load of 1500 A.

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MIG/MAG welding

For MIG/MAG welding the A6 SG welding head is always used, permitting a max.

load of 600 A. The welding head is water--cooled, with the cooling water supplied by

hoses from connections intended for the purpose.

3.5 Equipment

Included in a complete welding head are a feed motor (A6 VEC) to feed in the wire

and contact equipment which supplies current to the wire and provides a good con-

tact.

Contact equipment is available in several different versions.

SA6 SF is used for submerged--arc welding.

SA6 SG is used for MIG/MAG welding.

Example -- A6 SFE1 and A6 SFE2

1Straightener.

2Contact equipment which consists of a

contact tip, connector and flux tube.

3Angular slide

4Slide (motor--driven or manually operated)

5Motor and gearbox (A6 VEC)

6Wire drum

7Flux hopper (may be fitted with a cyclone)

Example -- A6 SGE1

1Straightener.

2Contact equipment which consists of a

connector, gas nozzle and water hoses.

3Angular slide.

4Slide (motor--driven or manually operated)

5Motor and gearbox (A6 VEC).

6Wire drum.

7Fine--wire straightener (Accessories).

8Wire guide.

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Example of the A6 SFE1C

1Straightener.

2Contact equipment, which consists of a contact tip, connector and flux tube.

3Slide (motor--driven).

4Motor and gearbox (A6 VEC).

5Flux hopper (1 l).

Connection instructions for SAW and MIG/MAG welding appear from the system dia-

gram on page 69.

4 INSTALLATION

4.1 General

Installation shall only be performed by qualified personnel.

WARNING

Rotating parts can cause injury, take great care.

4.2 Mounting

The automatic welding machines can easily be fitted with 4 screws M10x40 on a

rail--borne carriage or on a column and boom unit.

4.3 Connections

1. The connection of the A2--A6 Process Controller (PEH) to the welding machine

shall be done according to the connection instructions in the A2--A6 Process

Controller (PEH) service manual.

For further information, see instruction manual for the A2--A6 Process Controller

(PEH).

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2. Connect the A6 welding heads as follows:

SUBMERGED ARC WELDING (SAW)

SConnect the control cable (7) between the welding power source (8) and the

A2--A6 Process Controller (PEH) (2).

SConnect the return cable (11) between the welding power source (8) and the

work piece (9).

SConnect the welding cable (10) between the welding power source (8) and

the automatic welding machine (1).

SConnect the measuring cable (12) between the welding power source (8)

and the work piece (9).

GAS METAL ARC WELDING (MIG/MAG)

SConnect the control cable (7) between the welding power source (8) and the

A2--A6 Process Controller (PEH) (2).

SConnect the return cable (11) between the welding power source (8) and the

work piece (9).

SConnect the welding cable (10) between the welding power source (8) and

the automatic welding machine (1).

SConnect the gas hose (5) between the reduction valve (6) and the gas valve

on the automatic welding machine (13).

SConnect the hoses for cooling water (3) between the cooling unit (4) and the

automatic welding machine (1).

SConnect the measuring cable (12) between the welding power source (8)

and the work piece (9).

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5 OPERATION

5.1 General

General safety regulations for the handling of the equipment can be found on

page 64. Read through before you start using the equipment!

SSelect wire type and flux or shielding gas so that the weld material is as close as

possible to the analysis of the base metal. Select wire size and welding data in

accordance with the values recommended by the welding materials supplier.

SThorough preparation of the weld surfaces is necessary to achieve a good weld.

NOTE! The width of the weld joint gap must be uniform.

STo minimise the risk of heat crack formation, the width of the weld must be

greater than the penetration depth.

SAlways carry out a test weld with the same joint type and sheet thickness as the

production work piece.

SFor control and adjustment of the automatic welding machine and welding power

supply, see the instruction manual for the A2--A6 Process Controller (PEH).

SFor replacement of wear parts, see table on page 204.

5.2 Starting work

Loading the welding wire

SRemove the wire drum (1) from the brake hub (2)

and take off the side plate (3).

SLocate the wire reel on the wire drum (1).

SCut off the binding wires from around the

wire reel.

SFit the side plate (3).

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

Check that the carrier (4) is in the correct position.

NOTE! The maximum angle for the wire bobbin is 25°.

At extreme angles, wear will occur on the brake hub locking

mechanism and the wire bobbin will slide off the brake hub.

WARNING

To prevent the reel 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.

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