ESAB A6S Arc Master User manual

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..................................................

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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.
GB

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SafeArcS GB
WARNING, RISK OF CRUSHING!
Do not use safety gloves when replacing wire, feed rollers and wire bobbins.
GB

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.
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SafeArcS GB
GB

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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.
GB

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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.
GB

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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.
GB