ESAB A6 DK User manual

Instruction manual
0819 301 101 GB 20200827 Valid for: serial no. 942-xxx-xxxx
A6 DK
Automatic welding machine

TABLE OF CONTENTS
0819 301 101 © ESAB AB 2020
1SAFETY ....................................................................................................... 5
1.1 Meaning of symbols ............................................................................... 5
1.2 Safety precautions ................................................................................. 5
2INTRODUCTION.......................................................................................... 9
2.1 General .................................................................................................... 9
2.2 Definitions ............................................................................................... 9
3TECHNICAL DATA ...................................................................................... 10
3.1 Main components A6DK ....................................................................... 11
3.2 Description of main components.......................................................... 12
3.2.1 Carriage................................................................................................ 12
3.2.2 Wire feed unit ....................................................................................... 12
3.2.3 Connector............................................................................................. 12
3.2.4 Guide wheel ......................................................................................... 12
3.2.5 Motor with gear (A6VEC) .................................................................... 12
3.2.6 Control box (PEK) ................................................................................ 12
3.2.7 Flux recovery unit (A6OPC) ................................................................ 12
3.2.8 Flux hopper / Flux tube / Flux nozzle ................................................... 13
4INSTALLATION............................................................................................ 14
4.1 General .................................................................................................... 14
4.2 Mounting ................................................................................................. 14
4.2.1 Wire drum (Accessories) ...................................................................... 14
4.3 Adjusting the brake hub ........................................................................ 15
4.4 Connections............................................................................................ 15
4.4.1 General................................................................................................. 15
4.4.2 Automatic welding machine A6DK (Submerged-arc Welding, SAW) .. 16
5OPERATION ................................................................................................ 17
5.1 General .................................................................................................... 17
5.2 Loading the welding wire....................................................................... 17
5.3 Changing the feed roller ........................................................................ 18
5.3.1 Single wire............................................................................................ 18
5.4 Refilling with flux powder ...................................................................... 18
5.5 Transportation of the Automatic Welding Machine............................. 19
6MAINTENANCE........................................................................................... 20
6.1 General .................................................................................................... 20
6.2 Daily......................................................................................................... 20
6.3 Periodic ................................................................................................... 20
7TROUBLESHOOTING ................................................................................. 21
7.1 General .................................................................................................... 21
7.2 Possible errors ....................................................................................... 21
8ORDERING SPARE PARTS ........................................................................ 22

TABLE OF CONTENTS
0819 301 101 © ESAB AB 2020
DIMENSION DRAWING....................................................................................... 23
ORDERING NUMBERS ...................................................................................... 24
ACCESSORIES ................................................................................................... 25
Rights reserved to alter specifications without notice.

1 SAFETY
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1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
1.2 Safety precautions
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. 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

1 SAFETY
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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
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
• Install and ground the unit in accordance with instruction manual.
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
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.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY
0819 301 101 -7- © ESAB AB 2020
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.

1 SAFETY
0819 301 101 -8- © ESAB AB 2020
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.

2 INTRODUCTION
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2 INTRODUCTION
2.1 General
The A6DK automatic welding machine is designed for Submerged-arc Welding (SAW) of
butt and fillet joints.
All other applications are prohibited.
They are intended for use in combination with PEK and ESAB's welding power sources LAF
or TAF and Aristo1000.
NOTE!
For use with Aristo1000 only together PEK with serial no. 747-xxx-xxxx or later.
2.2 Definitions
SAW welding The weld bead is protected by a cover of flux during the welding.

3 TECHNICAL DATA
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3 TECHNICAL DATA
A6DK
Supply voltage 42VAC
Permissible load at 100% 1500ADC
Wire dimensions 3.0–6.0mm
Wire feed speed 0.2–4.0m/min
Brake hub braking torque 1.5Nm
Travel speed 0.15–2.0m/min
Maximum weight of wire 30kg
Flux container volume
(Not to be filled with preheated flux)
10l
Weight
(Excluding wire and flux)
150kg

3 TECHNICAL DATA
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3.1 Main components A6DK
1. Carriage 6. Control box PEK
2. Wire feed unit 7. Flux recovery unit (A6OPC)
3. Connector 8. Flux hopper
4. Guide wheel 9. Flux nozzle
5. Motor with gear (A6VEC) 10. Flux tube (not shown)
For more information on the main components, see section "Description of main
components".

3 TECHNICAL DATA
0819 301 101 - 12 - © ESAB AB 2020
3.2 Description of main components
3.2.1 Carriage
The carriage is powered by A6VEC motors (1).
It is equipped with handles (2) and two support wheels (3).
Use the handle bars to tilt the welding machine backwards, the support wheels will now take
the weight and the welding machine can be moved.
3.2.2 Wire feed unit
The unit is used for guiding and feeding the welding wire down into the connector.
3.2.3 Connector
Transfers welding current to the wire during welding.
3.2.4 Guide wheel
The guide wheel is attached to the connector and guides the welding machine along the weld
joint.
3.2.5 Motor with gear (A6VEC)
The motor is used for feeding the welding wire.
For more information regarding the A6VEC see Instruction manual 0443393xxx.
3.2.6 Control box (PEK)
See Instruction manual 0460948xxx, 0460949xxx, 0459839036.
3.2.7 Flux recovery unit (A6OPC)
The A6OPC is used to recover the surplus flux.
For more information regarding the A6OPC, see Instruction manual 0443407xxx.

3 TECHNICAL DATA
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3.2.8 Flux hopper / Flux tube / Flux nozzle
The flux is filled into the flux hopper and is then transferred to the workpiece through the flux
tube and the flux nozzle.
The amount of flux to be dropped down is controlled by way of the flux valve fitted to the flux
hopper.
For more information, see section "Refilling with flux powder".

4 INSTALLATION
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4 INSTALLATION
4.1 General
The installation must be carried out by a professional.
WARNING!
Rotating parts can cause injury, take great care.
4.2 Mounting
4.2.1 Wire drum (Accessories)
• The wire drum (1) is mounted on the brake hub (2).
• Check that the carrier (3) is pointing upwards.
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 from 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.

4 INSTALLATION
0819 301 101 - 15 - © ESAB AB 2020
4.3 Adjusting the brake hub
The brake hub is adjusted when delivered, if readjustment is required, follow the instructions
below. Adjust the brake hub so that wire is slightly slack when wire feed stops.
Adjusting the braking torque:
1. Turn the red handle to the locked
position.
2. Insert a screwdriver into the springs
in the hub.
○ Turn the springs clockwise to
reduce the braking torque.
○ Turn the springs
counter-clockwise to increase
the braking torque.
NOTE!
Make sure you turn both springs the same amount.
4.4 Connections
4.4.1 General
• The PEK is to be connected by a qualified person. See Instruction manual
0460948xxx, 0460949xxx, 0459839036.
• For the connection of A6OPC, see Instruction manual 0443407xxx.
• For the connection of welding power source LAF/ TAF, see separate instruction
manuals.

4 INSTALLATION
0819 301 101 - 16 - © ESAB AB 2020
4.4.2 Automatic welding machine A6DK (Submerged-arc Welding, SAW)
1. Connect the control cable (5) between the power source (3) and the control box PEK
(2).
2. Connect the return cable (6) between the power source (3) and work piece (4).
3. Connect the welding cable (7) between the power source (3) and the automatic
welding machine (1).
4. Connect the measurement cable (8) between the power source (3) and workpiece (4).

5 OPERATION
0819 301 101 - 17 - © ESAB AB 2020
5 OPERATION
5.1 General
CAUTION!
Read and understand the instruction manual before
installing or operating.
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
• Select electrode type and flux powder so that the weld material is as close as possible
to the analysis of the base metal.
• Select electrode size and welding data in accordance with the values recommended by
the welding materials supplier.
• Thorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE!
The width of the weld joint gap must be uniform.
• To minimize the risk of hot cracking the width of the weld should be larger than the
penetration.
• Always weld a test piece with the same joint preparation and plate thickness as the
intended production piece.
NOTE!
Never make a trial weld on a production workpiece.
• For control and adjustment of the automatic welding machine and welding power
supply, see the Instruction manual for the PEK.
5.2 Loading the welding wire
1. Mount the wire drum according to the
instructions in section "Mounting".
2. Check that feed roller (1) and contact jaw or
contact tip (3) are of the correct dimension for
the selected wire size.
3. Straighten out 0.5m of wire and feed it by hand
down through the straightener (2).
4. Locate the end of the wire in the feed roller (1)
groove.
5. Set the wire tension on the feed roller with the
knob (4).
NOTE!
Do not tension more than is required
to achieve an even feed.
6. Feed the wire forward 30mm below the contact
tip by pressing on the control box PEK.
7. Direct the wire by adjusting the knob (5).

5 OPERATION
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5.3 Changing the feed roller
5.3.1 Single wire
• Release the knobs (3) and (4).
• Release the hand wheel (2).
• Change the feed roller (1).
They are marked with their respective wire sizes.
5.4 Refilling with flux powder
1. Close the flux valve (1) on the flux hopper.
2. Remove the cyclone on the flux recovery unit, if fitted.
3. Fill with flux powder.
NOTE!
The flux powder must be dry. Where possible
avoid using agglomerating flux powder outdoors
and in damp environments.
4. Position the flux tube so that it does not become kinked.
5. Adjust the height of the flux nozzle above the weld so that
the correct amount of flux is delivered.
Flux coverage should be sufficient so that penetration of the
arc does not occur.

5 OPERATION
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5.5 Transportation of the Automatic Welding Machine
• Tip the welding machine backwards with the handles (1).
• The weight has now been moved to the support wheels (2) and the welding machine
can be moved.

6 MAINTENANCE
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6 MAINTENANCE
6.1 General
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
NOTE!
Before doing any kind of maintenance work, make sure the mains cable is
disconnected.
For the maintenance of the control box PEK, see the Instruction manual 0460948xxx,
0460949xxx, 0459839036.
6.2 Daily
• Clean flux and dirt off moving parts of the welding machine.
• Check that the contact tip and all electrical 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 the 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.
To adjust the braking torque see section "Adjusting the brake hub".
6.3 Periodic
• Inspect the electrode feed unit's electrode control, drive rollers and contact tip.
• Replace worn or damaged components.
• Inspect the slides, lubricate them if they are binding.