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
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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.
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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.
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Example of the A6 SFE1C
!5
.1 1
%5 34
0 3%# 784
&2 3 4
Connection instructions for SAW and MIG/MAG welding appear from the system dia-
gram on page 12.
3 INSTALLATION
3.1 General
Installation shall only be performed by qualified personnel.
WARNING
Rotating parts can cause injury, take great care.
3.2 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.
3.3 Connections
1. The connection of the PEK to the welding machine shall be done according to
the connection instructions in the PEK service manual.
For further information, see instruction manual for the PEH,
0460 948 xxx, 0460 949 xxx, 0459 839 036.
GB
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2. Connect the A6 welding heads as follows:
SUBMERGED ARC WELDING (SAW)
Connect the control cable (7) between the welding power source (8) and the
PEK (2).
Connect the return cable (11) between the welding power source (8) and the
work piece (9).
Connect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
Connect the measuring cable (12) between the welding power source (8)
and the work piece (9).
GAS METAL ARC WELDING (MIG/MAG)
Connect the control cable (7) between the welding power source (8) and the
PEK (2).
Connect the return cable (11) between the welding power source (8) and the
work piece (9).
Connect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
Connect the gas hose (5) between the reduction valve (6) and the gas valve
on the automatic welding machine (13).
Connect the hoses for cooling water (3) between the cooling unit (4) and the
automatic welding machine (1).
Connect the measuring cable (12) between the welding power source (8)
and the work piece (9).
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4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 5. Read through before you start using the equipment!
4.2 Starting work
Loading the welding wire
Remove the wire drum (1) from the brake hub (2)
and take off the side plate (3).
Locate the wire reel on the wire drum (1).
Cut off the binding wires from around the
wire reel.
Fit the side plate (3).
Fit 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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Check that the feed roller (1) and contact jaw or contact tip
(3) are of the correct dimension for the selected wire size.
Pull the end of the wire through the straightener (2). For a
wire diameter greater than 2 mm; straighten out 0.5 m of
wire and feed it by hand down through the straightener.
Locate the end of the wire in the feed roller (1) groove.
Set the wire tension on the feed roller with the knob (7).
Note! Do not tension more than is required to achieve an
even feed.
The pressure screw (8) must not be dismantled. (Applies to
Submerged-arc Heavy duty).
Feed the wire forward 30 mm below the contact tip by
pressing on the control box PEK.
Direct the wire by adjusting the knob (6).
For fine wire, the special fine wire straightener (4) is used
for both single and twin wire.
Ensure that the straightener is correctly adjusted so that the
wire emerges straight out through the contact jaws or
contact tip.
Always use a guide tube (5) to ensure even feeding of fine
wire (1.6 - 2.5 mm).
For MIG/MAG welding with wire sizes < 1.6 mm, use a
guide spiral, which is inserted in the guide tube (5).
Changing the feed roller
Single wire
Release the knobs (3) and (4).
Release the hand wheel (2).
Change the feed roller (1). The rollers are marked with
their respective wire sizes.
Twin wire (Twin-arc)
Change the feed roller (1) with twin grooves in the same way as for single
wire.
NOTE! The pressure roller (5) must also be changed. A special spherical
pressure roller for twin wire replaces the standard pressure roller for single
wire.
Assemble the pressure roller with special stub shaft
(order no. 146 253-001).
Flux-cored wire (for knurled rollers)
Change the feed roller (1) and pressure roller (5) in pairs for the wire size to
be used. NOTE! A special stub shaft is required for the pressure roller
(order no. 0212 901 101).
Tighten the pressure screw (4) with moderate pressure to ensure that the
flux-cored wire does not deform.
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Contact equipment for submerged-arc welding
For single wire 3.0 - 4.0 mm. Light duty (D20)
Use the straightener (3), connector (1) D20 with contact tip (2)
(M12 thread).
Tighten the contact tip (2) with a key in order to ensure
that a good contact is achieved.
For single wire 1.6 - 2.5 mm Submerged-arc.
Light duty (D20)
Use the straightener (3), connector (1) D20 with contact
tip (2) (M12 thread) and separate fine wire straightener (4)
with guide tube (6).
Fit the clamp (7) with guide tube (6) in the M12 hole on
the straightener (3). The guide tube (6) should bottom
on the contact tip (2).
If necessary, cut the guide tube (6) to length so that the
feed roller (5) runs freely.
Fit the fine wire straightener (4) on the upper side of the
clamp for the straightener (3).
For single wire 3.0 - 6.0 mm. Heavy duty (D35)
Use the straightener (3), connector (1) D35 with contact
jaws (2).
Fit one of the contact jaws with the M5 bolts provided, in
the fixed contact tip (a).
Fit the other contact jaw in the free half of the two-piece
connector (b) under the bolt (8) and tighten down hard to
ensure that a good contact is achieved between the
contact jaws and the wire.
For flux-cored wire 1.6 mm - 4.0 mm (D20 and D35) (Accessories)
If contact jaws (D35) are used, the contact jaws must not be tightened too hard
in order that the flux-cored wire is not deformed. Ensure that good contact is
achieved with the wire.
Adjustment of the wire for tandem welding
The distance between the first and second wire must not be so great that the
slag gets time to solidify between the wires.
Ensure that good flux coverage is achieved between the first and second
wires.
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For twin wires 2 x 2.0 - 3.0 Heavy Twin (D35) (Accessories)
Use the straightener (3), connector (1) D35 with contact
jaws (2).
Fit the first contact jaw with the M5 bolts supplied, in the
fixed connector (a).
Fit the other contact jaw in the free half of the two-piece
connector (b) under the bolt (8) and tighten down hard to
ensure that a good contact is achieved between the
contact jaws and the wire.
For twin wire 2 x 1.2 - 2.0 mm, Light Twin (D35) (Accessories)
Use the straightener (3), connector (1) D35 with twin
adapter (9) and 2 contact tips (2) (M6 threads) and separate
fine wire straightener (4) with two guide tubes (6). For twin
wire < 1.6 mm, insert a guide spiral into each guide tube.
Fit the twin adapter (9) for M6 contact tips (2) with the
M5 bolts in the fixed half of the two-piece connector
(1).
Fit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube should
bottom on the twin adapter (9) for the contact tip (2).
Tighten the contact tip (2) with a key to ensure that a
good contact is achieved.
If necessary, cut the guide tube (6) to length so that the
feed roller (5) runs freely.
Adjustment of the wires for Twin-arc welding:
Position the wires in the joint so as to achieve optimal weld quality by
rotating the connector. The two wires can be rotated so that they are
positioned one after the other along the line of the joint, or in any position
up to 90across the joint, i.e. one wire on each side of the joint.
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Contact equipment for MIG/MAG welding.
For single wire 1.6 - 2.5 mm (D35)
Use the straightener (3), connector (1) D35 with contact
tip (2) (M10 thread).
Tighten the contact tip (2) with a key to ensure that a
good contact is achieved.
Fit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube (6) should
bottom on the contact tip (2).
If necessary, cut the guide tube (6) to length so that the
feed roller (5) runs freely.
For single wire < 1.6 mm (D35)
Use the straightener (3), connector (1) D35 with contact tip (2)
(M12 thread), fine wire straightener (4) with guide tube (6)
and guide spiral, which is inserted in the guide tube (6).
Fit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube (6) should
bottom on the contact tip (2).
If necessary, cut the guide tube (6) to length so that the
feed roller (5) runs freely.
Fit the fine wire straightener (4) on the upper side of the
clamp for the straightener (3).
Connect the cooling water and gas (MIG/MAG welding).
Filling of flux (Submerged arc welding)
Close the flux valve on the flux hopper.
Remove the cyclone on the flux recovery unit, if fitted.
Fill with flux .
NOTE! The flux powder must be dry.
Position the flux tube so that the flux hose does not become kinked.
Adjust the height of the flux nozzle above the weld so that the correct amount of
flux is delivered.
The flux coverage should be high enough to prevent the arc from burning
through.
4.3 Conversion of A6 SFE1 (Submerged arc welding) to MIG/MAG
welding
Assemble the conversion kit according to the instructions provided.
4.4 Conversion of A6 SFE1 / A6 SFE2 (Submerged arc welding) to
Twin-arc
Assemble the conversion kit according to the instructions provided.
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5 MAINTENANCE
5.1 General
NB! Before doing any kind of maintenance work, make sure the mains is discon-
nected.
For the maintenance of the PEK, see the instruction manual,
0460 948 xxx, 0460 949 xxx, 0459 839 036.
5.2 Daily
Clean flux and dirt off moving parts of the welding machine.
Check that the contact tip and all electric cables are connected.
Check that all bolted joints are tight and that guides and drive rollers are not
worn or damaged.
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.
Adjusting the braking torque:
Set the locking button (2) to the
locked position.
Insert a screwdriver into the hub
springs.
Turning the springs (1) clockwise
reduces the braking torque.
Turning the springs anticlockwise increases the torque.
NOTE! Turn the springs by the same amount.
5.3 Regularly
Check the carbon brushes of the wire feed motor every three months. Replace
when they are worn down to 6 mm.
Check the slides and lubricate if they bind.
Check the wire guides, drive rollers and contact tip of the wire feed unit.
Replace any worn or damaged components, (see spare parts list on page 25).
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6 FAULT TRACING
'( 9 8:1
0460 948 xxx, 0460 949 xxx, 0459 839 036
%# 781
0443 393 xxx
" )
3 . 4
POSSIBLE FAULTS
!* (+ Current and voltage readings show large fluctuations
" , !*! Contact jaws or nozzle are worn or wrong size.
+ Replace contact jaws or nozzle.
" , !* Feed roller pressure is too low.
+ Increase pressure on feed rollers.
* (+ Wire feed is irregular
" , *! Feed roller pressure not correct.
+ Change the feed roller pressure.
" , * Feed rollers wrong size.
+ Replace feed rollers.
" , *% Grooves in feed rollers are worn.
+ Replace feed rollers.
%* (+ Welding cables overheating
" , %*! Poor electrical connection.
+ Clean and tighten all electrical connections.
" , %* Cross-section of welding cables too small.
+ Use cables with a larger cross-section or use parallel cables.
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7 ACCESSORIES
0 ! (**#(
0 !++*+++
% !#; ; ($!
. , , ,,! < !+++ $(, $$
. ,,! ,,(+! = !* ; >(> $$
2 !++, (#( $$!
%# 528 09? &0%? !*# ,*# $$!
%# 528 &%# 528, 3<' 4 !* + (* $$,
%# 528 &%# 528, 3='4 !$!> >+* $$,
3',!4 ! (+ *+$$(
%0#&0 ! ! *;+++!!
8 ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list on page 25.
This will simplify dispatch and ensure you get the right part.
GB
This manual suits for next models
2
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