ESAB A6S Arc Master Bedienungsanleitung

Valid for serial no. 935-xxx-xxxx0456 562 201 2009-11-09

A6S Arc Master

A6S G Master

A6S Compact 500

A6 SFE1/ A6 SFE2/ A6 SGE1/

A6 SFE1C

Instruction manual

  

Rights reserved to alter specifications without notice.

ENGLISH 4..............................................



ENGLISH

  

 

1 SAFETY 5...........................................................

2 INTRODUCTION 8...................................................

2.1 General 8..................................................................

2.2 Definitions 8................................................................

2.3 Technicaldata 8............................................................

2.4 Weldingmethod 9...........................................................

2.5 Equipment 10................................................................

3 INSTALLATION 11....................................................

3.1 General 11..................................................................

3.2 Mounting 11.................................................................

3.3 Connections 11..............................................................

4 OPERATION 13.......................................................

4.1 General 13..................................................................

4.2 Startingwork 13..............................................................

4.3 Conversion of A6 SFE1 (Submerged arc welding) to MIG/MAG welding 17. . . . . . . . . . .

4.4 Conversion of A6 SFE1 / A6 SFE2 (Submerged arc welding) to Twin-arc 17. . . . . . . . .

5 MAINTENANCE 18....................................................

5.1 General 18..................................................................

5.2 Daily 18.....................................................................

5.3 Regularly 18.................................................................

6 FAULTTRACING 19..................................................

7 ACCESSORIES 20....................................................

8 ORDERINGOFSPAREPARTS 20......................................

WEARCOMPONENTS 21.................................................

SPAREPARTSLIST 25..................................................

- 5 -

SafeArcS GB

1 SAFETY

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 pre-

cautions. Safety precautions must meet the requirements that apply to this type of

welding 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 oper-

ation 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:

its operation

location of emergency stops

its function

relevant safety precautions

welding

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

3. The workplace must:

be suitable for the purpose

be free from draughts

4. Personal safety equipment

Always wear recommended personal safety equipment, such as safety

glasses, flame-proof clothing, safety gloves. Note! Do not use safety

gloves when replacing wire.

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

which could become trapped or cause burns.

5. Protection against other risks

Dust particles of a certain size can be harmful to man. A ventilation system

and extractor should therefore be provided to eliminate this risk.

6. 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 extinquishing equipment must be clearly marked and close

at hand.

Lubrication and maintenance must not be carried out on the equipment

during operation.

- 6 -

SafeArcS GB

WARNING, RISK OF CRUSHING!

Do not use safety gloves when replacing wire, feed rollers and wire bobbins.

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR

EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU-

FACTURER'S HAZARD DATA.

ELECTRIC SHOCK - Can kill

Install and earth the welding unit in accordance with applicable standards.

Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet

clothing.

Insulate yourself from earth and the workpiece.

Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

Keep your head out of the fumes.

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

Protect your eyes and body. Use the correct welding screen and filter lens and

wear protective clothing.

Protect bystanders with suitable screens or curtains.

FIRE HAZARD

Sparks (spatter) can cause fire. Make sure therefore that there are no inflam-

mable materials nearby.

NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

Warn bystanders of the risk.

MALFUNCTION

Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

READ AND UNDERSTAND THE INSTRUCTION MAN-

UAL BEFORE INSTALLING OR OPERATING.

- 7 -

SafeArcS GB

- 8 -

hfb6d1ea

2 INTRODUCTION

2.1 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 PEK 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.

2.2 Definitions

              



            

          

                



       

            

2.3 Technical data

   !    !        !    !"

        

# #$  # #%&  # #%&

   !!"

#! "

$!! %

!!! %

%&' 

(!! %



%&' 

(!! %



%&' 

#!! %



%&' 

(!! %



%&' 

 )

   #*!  +!#!  +!#!  !$,(   *! 

  #*!  +!*!   ,+,  

  , ,,!  ,,!+! ,,!+!  

   !,*! & !,*! & !,*! & !, ( & !,*! &

-   . ( / ( /  ( /  ( /  ( / 

0 1  ,+!  ,+!  *+!  +!  ,+! 

2  

30     

4

!  !  !   

 3   4 (!  (!  !!  (  (! 

5 1  ,(,(,(,(,(

5    6



 3  4

, ! 

+!! 

, ! 

+!! 

, ! 

+!! 

, ! 

+!!  #! 

 %  

 #$ - #$ - #$ - $+ - #$ -

*) NB! Other lengths on request.

- 9 -

hfb6d1ea

2.4 Welding method

Submerged arc welding (SAW)

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

following designs:

Submerged-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%).

Submerged-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 PEK.

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.

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.

- 10 -

hfb6d1ea

2.5 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.

A6 SF is used for submerged-arc welding.

A6 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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