ESAB A6 SFD1 Series User manual

443 398 --002 9703 Valid from Machine no 452 XXX--XXXX
A6 SFD1
Automatic welding machine
Schweißautomat
Appareil de soudage automatique
Lasautomaat
Operating manual
Bedienungsanleitung
Manuel de l’opérateur
Gebruikershandboek

SAFETY 2..............................................
TECHNICAL DESCRIPTION 3.............................
INSTALLATION 4........................................
OPERATION 9..........................................
MAINTENANCE 10........................................
TROUBLESHOOTING 11..................................
CONNECTION INSTRUCTIONS FOR PEG1 AND A6 VEC 12..
SICHERHEIT 14..........................................
TECHNISCHE BESCHREIBUNG 15.........................
INSTALLATION 16........................................
BETRIEB 21..............................................
WARTUNG 22............................................
FEHLERSUCHE 23.......................................
ANSCHLUSSANLEITUNG FÜR PEG1 UND A6 VEC 24.......
SECURITE 26............................................
DESCRIPTION TECHNIQUE 27............................
INSTALLATION 28........................................
MISE EN SERVICE 33.....................................
ENTRETIEN 34...........................................
RECHERCHE DE PANNES 35..............................
INSTRUCTIONS DE BRANCHEMENT POUR PEG1 ET A6 VEC 36
VEILIGHEID 38...........................................
TECHNISCHE BESCHRIJVING 39..........................
INSTALLATIE 40..........................................
GEBRUIK 45.............................................
ONDERHOUD 46.........................................
STORINGZOEKEN 47.....................................
INSCHAKELINSTRUCTIES VOOR PEG1 EN A6 VEC 48......
DIMENSION DRAWING - MASSBILD -
COTES D’ENCOMBREMENT - MAATSCHETS 49......
DIAGRAM - SCHALTPLAN - SCHÉMA - SCHEMA 51.........
WEAR COMPONENTS - VERSCHLEISSTEILE -
PIÈCES D’USURE - SLIJTAGEONDERDELEN 52......
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande medeleling voorbehouden.

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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
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse 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
SProtect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
SProtect your ears. Use ear defenders or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

SAFETY
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SAFETY
Users of ESAB automatic welding machines have ultimate responsibility for ensuring
that anyone who works on or near the equipment observes all the relevant safety
precautions.
The following recommendations should be observed in addition to the standard re-
gulations that apply to the work place.
All work must be carried out according to the specified instructions by personnel who
are thoroughly familiar with the operation of the welding machine.
Incorrect or unintentional operation of the equipment may lead to a hazardous situ-
ation which can result in injury to the operator and damage to the equipment.
1. Anyone who uses the automatic welding machine must be familiar with:
Sits operation
Sthe location of emergency stops
Sits function
Srelevant safety precautions
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the machine
when it is started up.
Sthat no--one is in a hazardous position when the carriage or slide mechan-
isms are operated.
3. The work place must:
Sbe clear of mechanical components, tools, or other obstructions that could
prevent the operator from moving freely within the working area.
Sbe organized so that there is free access to the emergency stop.
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety
glasses, flame--proof clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, etc., which could
become trapped.
5. General precautions
Live electrical components are normally shielded from accidental contact.
SMake sure the return cable is connected securely.
SWork on high voltage components may only be carried out by a qualified
electrician.
SAppropriate fire extinguishing equipment must be clearly marked and close
at hand.
SLubrication and maintenance must not be carried out on the equipment dur-
ing its operation.

TECHNICAL DESCRIPTION
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TECHNICAL DESCRIPTION
The A6 SFD1 automatic welding machine is designed for submerged arc welding of
butt and fillet joints. It can be installed on a carrier arrangement such as a column
and boom or a carriage running on a beam.
All other applications are prohibited.
The welding machine should be installed using bolts. (Make sure the bolts do not
touch the bottom of the insulator, which has a thread depth of 14 mm). The machine
must be mounted on a rigid base so that it is securely attached and there is no risk
of it working loose.
TECHNICAL DATA
A6 SFD1 LD (Light Duty) D20 HD (Heavy Duty) D35
Permissible load AC/DC
continuous 800 A 1500 A
60% 1000 A --
Electrode size
solid single wire 1,6--4,0 mm 3,0--6,0 mm
twin wire 2x1,2--2,5 mm 2x2,0--3,0 mm
hollow wire 1,6--4,0 mm 3,0--4,0 mm
Wire feed speed 0,5--9 m/min 0,2--4,5 m/min
Electrode weight, max.,mounted on welding
head 2x30 kg 2x30 kg
Slide adjustment range *
manual 210 mm 210 mm
motor--driven (with ball bearings) 300 mm 300 mm
Weight (excl. electrode and flux) 110 kg 110 kg
Flux container volume 10 l 10 l
Brake hub braking torque 1,5 Nm 1,5 Nm
Supply voltage (AC) 42 V 42 V
Continuous A--weighted noise pressure 68 dB 68 dB
*NOTEother lengths are available!
See the dimensional sketch for the heavy duty version of the manually operated slide
on page 49 and the light duty version of the motor--driven slide on page 50.

INSTALLATION
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INSTALLATION
1. Motor with gear A6 VEC, see manual 443 393.
2. Control box PEG1, see manual 443 392.
3. Connect the welding machine as shown in the diagram on page 51.
SRectifier:
GConnect the control cable (08) between the welding power source (01)
and control box PEG1.
GConnect the cable lugs on the cable (07) between the welding power
source and the shunt.
GConnect the electrode to the positive terminal.
SAlternating current:
GConnect the control cable (08) between the welding power source (01)
and the control box PEG1 (02).
GConnect the welding cable (07) between the welding power source (10)
and the shunt.
SConnect the return cable between the welding power source (01, 10) and the
workpiece.
SConnect the measuring cable (09) between the workpiece and the welding
power source (01, 10) or between the workpiece and the control box PEG1
(02) (e.g. if a welding power source of a different make is used).
SConnect the motor and gears A6 VEC to the control box PEG1 (02).
SConnect the projector lamp, if used, to the control box PEG1 (02).
4. Check that the control box PEG1 is connected as shown in the table on page 12
and that the gear ratio and rotor speed are as specified there.
5. If a motor--driven slide is used, see manual 443 394.
6. If joint following equipment A6 GMD is used, see manual 443 403.
7. Choose the electrode type and flux to give a weld metal analysis that roughly
matches the base material. Choose the size of electrode and welding para-
meters according to the recommendations of the consumable manufacturer.

INSTALLATION
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8. Loading the welding electrode.
SRemovethewirereelfromthebrakehub(2)
and remove the backing plate (3).
SPlace the coil of wire (1) on the reel and refit the
backing plate (3).
SFit the wire reel and disposable bobbin on the
brake hub (2). CHECK the position of the carrier.
IMPORTANT!
To prevent the wire bobbin slipping
off the brake hub:
Lock the bobbin in place using the red knob,
as shown on the label (see drawing on right)
positioned next to the brake hub.
SCheck that the feed roller (1) and contact jaws (4) are the right size.
SWhen using heavy wire (3 -- 6 mm):
a. Cut off the ties around the
electrode coil.
b. Pull out the end of the electrode.
c. Straighten out the electrode.
SPosition the end of the electrode in
the groove in the feed rollers.
SAdjustthepressureexertedonthe
electrode by the roller (6).
NOTE! Only tighten it enough to
ensure reliable feeding.
Do not tighten the pressure screw all the
way, leave some movement in the spring.
SThe spacer bolt (3) must not be removed.
SFeed the electrode forward using switch
A02onthePEG1box.
SWhile the electrode is being fed forwards,
straighten it out using the knob (5) on the wire
straightener, or using a special straightener for thin wire or twin wire.
When the wire straightener is correctly set the wire should come out
straight through the contact jaws and contact tip.

INSTALLATION
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9. Changing the wire feed roller (see wear components on page 52).
SSingle wire:
GUnscrew the knob (5) and pressure screw (6).
GUnscrew the handwheel (2).
GReplace the feed roller. The wire size is marked on the roller.
STwin wire:
GReplace twin wire feed rollers in the same way as for single wire rollers.
GNOTE! Replace the pressure roller at the same time. The special spheri-
cal rollers for twin wire replace the standard pressure roller for single
wire.
GFit the pressure roller with the special shaft stud
(order no. 146 253--001).
STube wire (for knurled rollers):
GReplace the feed roller and pressure in pairs for the chosen wire size.
NOTE! A special shaft stud is required for the pressure roller (order no.
2129 011--01).
GTighten the pressure screw to a moderate pressure so that the tube wire
is not deformed.
WARNING!
Rotating parts can cause injury, take great care.

INSTALLATION
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10. Contact equipment
SSingle wire 1,6 -- 2,5 mm (4,0 mm). Light duty (D20)
Supplied as standard with A6 SFD1 (LD version) and used as necessary,
e.g. in restricted spaces, wire sizes up to 4,0 mm.
Use contact tube D20 with contact tip (M12 thread), see table on page 54.
GTighten the contact tip using spanner no. 10 to ensure a good contact.
For thinner wires, e.g. ø1,6 -- 2,5 mm, use a guide tube and separate thin
wire straightener.
GFit the clamp for the guide tube in the M12 hole for the fixed straighten-
ing roller on the standard wire straightener. The guide tube should bot-
tom against the contact tip. Trim the length so that the distance to the
feed roller is about 5 mm.
GInstall the thin wire straightener above the clamp for the wire straigh-
tener.
SSingle wire 3,0 -- 6,0 mm. Heavy duty (D35)
Included as standard with A6 SFD1.
Use contact tube D35 with contact jaws. See also the remarks about contact
tube D20 for wires up to 4 mm in restricted spaces.
GUse a standard straightener with the A6, consisting of one fixed and one
adjustable roller.
GAssemble the contact jaws using the M5 bolts supplied, one part of the
contact jaws on the fixed part of the contact tube and the other part on
the loose half of the split contact tube.
GInstall the loose half with the contact jaw in place using the M8 hex head
bolts and tighten fully to ensure good contact between the contact jaws
and the electrode.
STube electrodes.
Contact tubes D20 och D35 can be used for tube electrode. If contact jaws
(D35) are used they should be tightened to a moderate pressure only to
avoid deforming the tube electrode. Make sure that good electrical contact is
achieved with the electrode.
STwin wire.
Always use contact tube D35 for twin wire with a guide tube and separate
straightener.
GFit the clamp for the guide tube in the M12 hole for the fixed straighten-
ing rollers on the standard wire straightener. The guide tubes should bot-
tom against the contact jaws (Heavy Twin) or against the adapter for the
contact tip (Light Twin).
GTrim the length of the guide tubes so that the distance to the feed rollers
is around 5 mm.

INSTALLATION
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STwin wire 2x1,2 -- 2x2,0 mm, Light Twin:
Use two contact tips with M6 threads. For the correct wire sizes see the table
on page 54.
GTighten the contact tips well, to ensure a good electrical contact.
GFit the adapter for the M6 contact tip to the fixed half of the split contact
tube using M5 bolts. The pressure screw and loose half of the contact
tube are not required for this application.
STwin wire 2x2,0 -- 2x3,0 mm, Heavy Twin:
GUse Twin contact jaws, for heavy electrodes (2x2,0 mm), see also Light
Twin.
GFit the contact jaws using the M5 bolts provided. NOTE! Fit the half of the
contact jaws with the projection in the fixed half of the contact tube.
GRemove the loose half of the contact tube when fitting new wire by undo-
ing the pressure screw.
GFeed the wire down and guide it into the groove in the fixed half of the
contact jaws (with projection).
GUndo the M5 bolts that hold the contact jaws and fit the loose half using
the M8 Allen bolt, so that both halves of the contact jaws surround the
electrode. Tighten the loose half of the contact jaws in place using the
M5 bolts to ensure good electrical contact.
SAdjusting the wires during Twin--arc welding:
Adjust the positions of the wires in the joint by rotating the contact tip. Both
wires can be rotated so that they are in line with the joint, or up to 90_across
the joint, i.e. one wire either side of the joint.
11. Filling up with flux
SClose the flux valve on the flux container.
SRemove the separator for the flux pump, if fitted. Fill with flux.
NOTE! The flux must be dry. If possible, avoid using agglomerated flux out-
side or in humid environments.
SAdjust the height of the flux nozzle above the weld to give the correct amount
of flux. The flux cover should be thick enough so that the arc cannot pen-
etrate it.