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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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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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

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3.2.1 Wire reel (Accessories)
Wire reel (1) is mounted on the brake hub (2).
Check that the carrier (3) is pointing upwards.
NOTE! The maximum angle for the wire reel is 25.
At extreme angles, wear will occur on the brake hub
locking mechanism and the wire reel 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.
3.3 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:
Turn the red handle to the locked position.
Insert a screwdriver into the springs in the hub.
Turn the springs clockwise to reduce the braking torque
Turn the springs anticlockwise to increase the braking torque.
NB: Turn both springs through the same amount.
GB

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3.4 Connections
3.4.1 General
The PEH/ PEK is to be connected by a qualified person.
For the connection of A6 GMH, see instruction manual 0460 671 xxx.
For the connection of A6 PAV, see instruction manual 0460 670 xxx.
For the connection of A6 VEC, see instruction manual 0443 393 xxx.
3.4.2 Welding Head A6S Compact 300
1. Connect the control cable (7) between the welding power source (8) and
PEH/ PEK (2)
2. Connect the return cable (11) between the welding power source (8) and the
work piece (9).
3. Connect the welding cable (10) between the welding power source (8) and the
welding head (1).
4. Connect the measuring cable (12) between the welding power source (8) and
the work piece (9).
5. Connect the measuring cable (13) between PEH/ PEK (2) and
the welding head (1).
GB

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4 OPERATION
4.1 General
WARNING:
Have you read and understood the safety
information ?
You must not operate the machine before then !
General safety regulations for the handling of the equipment can be found on
page 5. Read through before you start using the equipment!
Select wire type and flux powder so that the weld material is as close as possible
to the analysis of the base metal.
Select wire 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 minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
Always carry out a test weld with the same joint type and sheet thickness as the
production work piece.
NOTE! NEVER make a trial weld on a production work piece.
Operating instructions for control box A2-A6 Process Controller (PEH)
See instruction manual 0443 745 xxx.
Operating instructions for PEK
See instruction manual 0460 948 xxx, 0460 949 xxx, 0459 839 036.
GB

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4.2 Loading the welding wire
1. Mount the wire drum according to the instructions on page 11.
2. Check that the feed roller (1) and nozzle (2) are the correct size.
If using large wire (3-4 mm):
Remove the ties from the coil of wire.
Feed out the end of the wire.
Note that for 4 mm wire, pliers may need to be used to pull the wire through.
Straighten the wire.
3. Guide the wire through the groove in the feed roller (1). Make sure the wire runs
under the guide roller (3).
4. Adjust the feed roller pressure on the wire using the pressure screw (4).
NB! Do not tighten more than necessary to ensure smooth feeding.
5. Feed the wire forward using the PEH/ PEK.
6. At the same time adjust the screws (5) on the wire guide (6).
When the wire guide is correctly adjusted the wire should be straight when it
leaves the nozzle (2).
N.B. Do not tighten the screws (5) more than necessesary as this will result in an
uneven wire feed.
GB

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4.3 Changing the feed roller
1. Release the knob (3).
2. Release the hand wheel (2).
3. Change the feed roller (1).
They are marked with their respective wire sizes.
4.4 Filling with flux
The flux container should be filled by connecting it
to a pressurised flux tank (type TPC 75).
The flow of flux into the flux container is
automatically regulated at the inlet pipe.
When the flux level falls below the inlet pipe
new powder is supplied from the pressurised
flux tank.
NOTE! The flux powder must be dry. Where
possible avoid using agglomerating flux powder
outdoors and in damp environments.
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.
GB

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5 MAINTENANCE
5.1 General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
A2-A6 Process Controller (PEH), see instruction manual 0443 745 xxx.
PEK, see instruction manual 0460 948 xxx, 0460 949 xxx, 0459 839 036.
Wire feed motor A6 VEC, see instruction manual 0443 393 xxx.
5.2 Daily
Keep moving parts of the welding machine free from dust and flux.
Make sure all electrical cables and hoses are properly connected and
undamaged.
Make sure all bolted joints are tight.
Check the braking torque of the brake hub. It should be sufficient to stop the wire
reel rotating when wire feed stops but not so high that the feed rollers slip. The
recommended braking torque for a 30 kg wire reel is 1.5 Nm.
Adjusting the braking torque:
a. Turn the red handle to the locked position.
b. Insert a screwdriver into the springs in
the hub.
Turn the springs clockwise to
reduce the braking torque
Turn the springs anticlockwise to
increase the braking torque.
NB: Turn both springs through the same amount.
5.3 Regularly
Once every three months check the wire feed motor brushes, replace them when
they are worn down to 6 mm.
Check the cross-slides and lubricate if stiff.
Check the wire guides and drive rollers on the wire feed unit. Replace any
components that are worn or damaged.
GB

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hfc1f1ea
6 FAULT TRACING
6.1 General
Equipment
A2-A6 Process Controller (PEH), see instruction manual 0443 745 xxx.
PEK, see instruction manual 0460 948 xxx, 0460 949 xxx, 0459 839 036.
Wire feed motor A6 VEC, see instruction manual 0443 393 xxx.
Check
that the welding power supply is connected for the correct mains voltage
that all three phases are giving the correct voltage
(phase sequence not important)
that the welding cables and connections to them are not damaged
that the controls are in the right positions
that the mains supply is disconnected before starting repairs
6.2 Possible faults
1. Symptom Current and voltage show fluctuating values on digital display.
Cause 1.1 Contact jaws or contact tip are worn or wrong size.
Action Replace contact jaws or contact tip.
Cause 1.2 Pressure on feed rollers is inadequate.
Action Increase pressure on feed rollers.
2. Symptom Wire feed is irregular.
Cause 2.1 Pressure on feed rollers is incorrectly adjusted.
Action Adjust pressure on feed rollers.
Cause 2.2 Feed rollers wrong size.
Action Change feed rollers.
Cause 2.3 Groove in feed rollers is worn.
Action Replace feed rollers.
3. Symptom Welding cables overheat.
Cause 3.1 Poor electrical connection.
Action Clean and tighten all electrical connections.
Cause 3.2 Welding cables too small.
Action Increase dimension of cables or use parallel cables.
GB

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hfc1a1ea
7 ACCESSORIES
TV monitoring equipment (Option 10)
The TV monitoring equipment enables the operator to supervise and adjust the
welding heads position from outside, via the screen.
See separate manual.
Laser lamp (Option 20)
The laser lamp is used together with the TV monitoring equipment, when positioning
the torch to the weld joint.
See separate manual.
Note the following when welding using a laser lamp
The laser radiation can injure your eyes.
Do not look straight at the laser diode or the laser beam when it is activated.
Do not direct the laser beam towards another person.
&  ' ! (
)  ! *  +'  , 0811176880
$  +'  , 0811177880
  %-  +'  , 0813620880
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 21.
This will simplify dispatch and ensure you get the right part.
GB

DIMENSION DRAWING
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
*Welding head complete with camera, laser lamp and inductive joint tracking system.
Minimum diameter for longitudinal welding 300 mm.
Minimum diameter for circumreferential welding 500mm.

WEAR COMPONENTS
- 20 -

Feed rollers
  . /0 1. 0
  & +  ,
   
     
Contact tip
 $& +&,
  & +  ,
   
   
   