ESAB A6S Compact 300 User manual

Valid for serial no. 440-xxx-xxxx0449 458 001 10-03-11
A6S Compact 300
Instruction manual

  
Rights reserved to alter specifications without notice.
ENGLISH 4..............................................

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,

ENGLISH
  
  
1 SAFETY 5...........................................................
2 INTRODUCTION 8...................................................
2.1 General 8..................................................................
2.2 TechnicalData 8............................................................
2.3 Maincomponents 9.........................................................
3 INSTALLATION 10....................................................
3.1 General 10..................................................................
3.2 Mounting 10.................................................................
3.3 Adjustingthebrakehub 11....................................................
3.4 Connections 12..............................................................
4 OPERATION 13.......................................................
4.1 General 13..................................................................
4.2 Loadingtheweldingwire 14...................................................
4.3 Changingthefeedroller 15....................................................
4.4 Fillingwithflux 15............................................................
5 MAINTENANCE 16....................................................
5.1 General 16..................................................................
5.2 Daily 16.....................................................................
5.3 Regularly 16.................................................................
6 FAULTTRACING 17..................................................
6.1 General 17..................................................................
6.2 Possiblefaults 17............................................................
8 ORDERINGOFSPAREPARTS 18......................................
DIMENSIONDRAWING 19................................................
WEARCOMPONENTS 20.................................................
SPAREPARTSLIST 21..................................................

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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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hfc1d1ea
2 INTRODUCTION
2.1 General
The A6S Compact 300 welding head is designed for submerged arc welding (SAW)
of butt and fillet joints.
It's intended for use in combination with PEH/ PEK and ESAB's welding power
sources LAF or TAF.
It can be mounted on a beam-travelling carriage or on a welding column and boom
unit.
The welding head can be used inside pipes having a minimum diameter
of 300 mm for longitudinal welding and 500 mm for circumreferential welding.
2.2 Technical Data
    
     800 A
  
Steel
Stainless 3-4 mm
3.2 mm
 0.1-1.7 m/min
 ! 42 V
 "!#   68 dB
$ ! ! 50 mm
! ! ! 360
 % 
Standard
High speed 0,2-4.0 m/min
0.4-8.0 m/min
GB

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hfc1d1ea
2.3 Main components
1. Motor with gear (A6 VEC)
See instruction manual 0443 393 xxx.
2. Wire straightener
Used for guiding and feeding the welding wire down into the wire guider.
3. Slide
Vertical alignment 25 mm
Horizontal alignment 25 mm
4. Contact tube
Transfers welding current to the wire during welding.
5. Wire guider
Used to guide the wire into the contact tube.
6. Flux hopper
The flux is filled into the flux hopper and is then transferred to the workpiece
through the flux nozzle.
See “Filling with flux on page 15.
7. Flux nozzle
8. Flux suction pipe
Used for recovering surplus flux.
GB

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hfc1i1ea
3 INSTALLATION
3.1 General
The installation must be executed by a professional.
WARNING
Rotating parts can cause injury, take great care.
3.2 Mounting
The welding head should be installed using M12 bolts. It must be firmly secured to
prevent it working loose.
N.B.
Make sure the bolts do not touch the bottom of the insulator, which has a thread
depth of 14 mm.
See the dimension drawing on page 19.
GB