ESAB A6 OPC User manual

Instruction manual
0333 125 001 GB 20190219
A6 OPC Flux recovery unit

TABLE OF CONTENTS
0333 125 001 © ESAB AB 2019
1SAFETY ....................................................................................................... 3
2TECHNICAL DESCRIPTION ....................................................................... 5
3OPERATION ................................................................................................ 7
4MAINTENANCE........................................................................................... 8
DIMENSION DRAWING....................................................................................... 9
SPARE PARTS .................................................................................................... 10
Rights reserved to alter specifications without notice.

1 SAFETY
0333 125 001 -3- © ESAB AB 2019
1 SAFETY
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should be
based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the 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 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
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection.
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
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 SAFETY
0333 125 001 -4- © ESAB AB 2019
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
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

2 TECHNICAL DESCRIPTION
0333 125 001 -5- © ESAB AB 2019
2 TECHNICAL DESCRIPTION
The OPC flux recovery unit is intended for use on stationary and transportable welding units,
where a small, compact flux recovery unit is needed,
Maximum permissible air pressure: 6 kp/cm2
Air consumption at various pressures:
kp/cm² 4 5 6
liter/min 175 225 250
Rubber parts in the flux recovery unit can withstand temperatures encountered when using
preheated flux at up to 220 °C and with workpiece temperatures not exceeding 350 °C.
NOTE!
A metal flux hopper must be used.
Suction capacity data can be found in chapter "MAINTENANCE" of this manual.
The OPC flux recovery unit consists of:
1. Ejector, powered by compressed
air.
The side of the ejector intended
for connection to the cyclone is
fitted with a flange.
Connections are provided on the
other side of the ejector for the
suction hose and compressed air
hose 1/4 ".
2. Suction hose, connects the
recovery unit to the suction nozzle.
3. Suction nozzle, available in four
versions:
○ for normal butt welds
○ for larger butt welds
○ for fillet welds, left
○ for fillet welds, right
4. Nozzle bracket, holds the flux
recovery nozzle in position above
the weld.
5. Flux hopper, optional accessories.
6. Cyclone, for separating the
recovered flux from the air and
returning it to the flux hopper.
Fitted above the flux hopper.
7. Securing strap
8. Filter bag

2 TECHNICAL DESCRIPTION
0333 125 001 -6- © ESAB AB 2019
The flux hopper consists of:
1. Flux strainer, separates slag from flux
2. Flux hopper (10 l)
3. Flux hose, 1"×500 mm
4. Inspection window, for checking flux level
5. Manual flux valve
6. Adjustable flux outlet nozzle, for fitting to the welding head

3 OPERATION
0333 125 001 -7- © ESAB AB 2019
3 OPERATION
1. Check that the equipment is properly installed and that all hoses are secured.
2. Check that the flux valve is closed.
3. Fill the flux hopper with flux.
4. Open the flux valve, allowing the flux to run down on to the weld joint through the
supply nozzle.
5. Start welding and the suction unit at the same time. Unused flux will be sucked up
through the suction nozzle and hose into the cyclone, where the flux will be separated
from the slag. The flux falls through the strainer into the flux hopper, while the
dust-laden air is cleaned by the filter bag before being discharged.
6. Dimension drawing can be found in chapter "DIMENSION DRAWING" of this manual.

4 MAINTENANCE
0333 125 001 -8- © ESAB AB 2019
4 MAINTENANCE
1. Check that the rubber lining of the cyclone is undamaged, and replace it if necessary.
2. Check that all gaskets and joints are sealing properly.
3. Replace the filter bag when indicated by suction effect falling off after about 3-5
working hours. Performance can be improved by shaking the filter bag clean between
replacements.
*1 Air pressure (bar)
*2 Welding speed (m/min)
*3 Flux area (mm)
*4 H=Height of lift in m
At a suction height of 0.8 m, welding speed is not affected by the type of flux used.
Air pressure (kp/cm2)Suction height (m) Max welding speed (m/h)
6 0.8 70
5 0.8 60
4 0.8 45

DIMENSION DRAWING
0333 125 001 -9- © ESAB AB 2019
DIMENSION DRAWING
Flux recovery unit
1. Hose length 1000 mm
2. Nozzle length 210 mm
Flux hopper

SPARE PARTS
0333 125 001 - 10 - © ESAB AB 2019
SPARE PARTS
Spare parts may be ordered through your nearest ESAB dealer, see esab.com. When
ordering, please state product type, serial number, denominations and ordering numbers
according to the spare parts list. This facilitates dispatch and ensures correct delivery.
Maintenance and repair work should be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended spare parts.
C = Component designation in the circuit diagram