ESAB A6 SFF1C Compact 500 User manual

Category
Welding System
Type
User manual
443 396 --002 9511 Valid from Machine no 452 XXX--XXXX
A6 - SFF1C
COMPACT 500
Automatic welding machine
Schweißautomat
Appareil de soudage automatique
Lasautomaat
Operating manual
Bedienungsanleitung
Manuel de l’opérateur
Gebruikershandboek
SAFETY 2..............................................
TECHNICAL DESCRIP TION 3.............................
INSTALLATION 4........................................
OPERATION 7..........................................
MAINTENANCE 8........................................
TROUBLESHOOTING 9..................................
CONNECTION INSTRUCTIONS FOR PEG1 AND A6 VEC 10..
SICHERHEIT 12..........................................
TECHNISCHE BESCHREIBUNG 13.........................
INSTALLATION 14........................................
BETRIEB 17..............................................
WARTUNG 18............................................
FEHLERSUCHE 19.......................................
ANSCHLUßANLEITUNG FÜR PEG1 UND A6 VEC 20.........
SÉCURITÉ 22............................................
DESCRIPTION TECHNIQUE 23............................
INSTALLATION 24........................................
MISE EN MARCHE 27.....................................
ENTRETIEN 28...........................................
RECHERCHE DE PANNES 29.............................
INSTRUCTIONS DE CONNEXI ON POUR PEG1 ET A6 VEC 30
VEILIGHEID 32...........................................
TECHNISCHE BESCHRIJVING 33..........................
INSTALLATIE 34..........................................
GEBRUIK 37.............................................
ONDERHOUD 38.........................................
STORINGZOEKEN 39.....................................
AANSLUITINSTRUCTIES VOOR PEG1 EN A6 VEC 40........
DIMENSION DRAWING - MASSBILD -
COTES D’ENCOMBREMENT - MAATSCHETS 41......
DIAGRAM - SCHALTPLAN - SCHÉMA - SCHEMA 42.........
WEAR COMPONENTS - VERSCHLEISSTEILE -
PIÈCES D’USURE - SLIJTAGEONDERDELEN 43......
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
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mmvarnea
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
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S 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
S Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use ear defenders or o ther hearing p rotection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPE RATING.
PROTECT YOURSELF AND OTHERS!
SAFETY
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SAFETY
Users o f 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 o f 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:
S its operation
S the location of emergency stops
S its function
S relevant 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:
S no unauthorized person is stationed within the working area of the machine
when it is started up.
S that no--one is in a hazardous position when the carriage or slide mechan-
isms are operated.
3. The work place must:
S be clear of mechanical components, tools, or other obstructions that could
prevent the operator from moving freely within the working area.
S be organized so that there is free access to the emergency stop.
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety
glasses, flame--proof clothing, safety gloves.
S Do 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.
S Make sure the return cable is connected securely.
S Work on high voltage components may only be carried out by a qualified
electrician.
S Appropriate fire extinguishing equipment must be clearly marked and close
at hand.
S Lubrication and maintenance must not be carried out on the equipment dur-
ing its operation.
TECHNICAL DESCRIPTION
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TECHNICAL DESCRIPTION
The A6 SFF1C automatic welding machine is designed for submerged arc welding of
butt and fillet joints. It can be mounted on a carrier such as a column and boom or
rail-- mounted carriage. The welding machine can also be used inside pipes having a
minimum diameter of 500 mm.
The automatic welding machine should be installed using M12 bolts. (Make sure the
bolts do not touch the bottom of the insulator, which has a thread depth of 14 mm).
It must be firmly secured to prevent it working loose.
TECHNICAL DATA
Maximum load AC/DC continuous 1500 A
Wire diameter, solid single wire max. 4,0 mm
Wire feed speed 0,2--4,5 m/min
Cross--slide adjustment range 60 mm
Weight (excl. flux) 50 kg
Flux container volume 1L
Brake hub braking torque 1,5 Nm
Supply voltage 42 V AC
Continuous A--weighted noise level 68 dB
See dimension drawing on page 41.
INSTALLATION
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INSTALLATION
1. Wire feed motor A6 VEC, see operators’ manual 443 393.
2. Control unit PEG1, see operators’ manual 443 392.
3. Connect the welding machine as shown in the schematic drawing on page 42.
S DC:
Connect control cable (008) between the power source (001) and control unit
PEG1 (002).
Connect the cable with lugs (007) between the power source (001) and
shunt.
Connect the wire to the positive terminal.
S AC:
Connect the control cable (008) between the filler wire unit (011) and control
unit PEG1.
Connect the filler wire unit (011) to the power source (010).
Connect the welding cable (007) from the power source transformer to the
shunt.
4. Connect the return cable between the power source (001, 010) and work piece.
5. Connect the meter lead (009) between the work piece and power source (001,
010) or between the work piece and control unit PEG1 (e.g. if a power source of
a different make is used).
6. Connect the motor (003) with gear A6 VEC to control unit PEG1 (002).
7. Check that the control unit PEG1 is connected as shown in the table on page 10
”Connection instructions for PEG1 and wire feed gearbox A6 VEC” and that the
gear ratio and rotor speed match the figures given.
8. If a motor driven cross --slide is fitted, see operating manual 443 394.
9. If A6 GMD joint tracking equipment is fitted, see operators’ manual 443 403.
10. Choose the wire and flux composition so that the final weld metal analysis will
closely match the base material. Use the wire diameter and welding parameters
recommended by your consumable supplier.
INSTALLATION
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11. Installation of welding wire.
S Remove the wire reel from the brake hub (2)
and remove the end plate (3).
S Place the wire coil (1) on the reel and refit
the end plate (3).
S Fit the wire reel or disposable reel on the
brake hub (2).
NOTE the position of the locating stud.
IMPORTANT
To prevent the wire reel slipping off the hub;
Lock it on the hub by turning the red knob,
as instructed in the directions placed next to
the hub.
See also diagram on right
S Check that the feed roller (1) and contact jaws (3) are the correct size.
If using large wire (3--4 mm):
S Remove the ties from the
coil of wire.
S Feed out the end of
the wire.
S Straighten the wire.
S Release the wire conduit from the
clamp (7) on the welding machine
and feed out the wire. About 0.5 m
of wire should project out of the wire
conduit.
S Benda90_ angle on the wire so it
can be fed down into the contact tip.
S Re--attach the wire conduit in the
clamp (7) on the welding ma-
chine.
S Guide the wire through the groove in the
feed roller (1). Make sure the wire runs
under the guide roller (6) just in front of
the wire conduit clamp.
S Adjust the feed roller (1) pressure on the wire using the pressure screw (4).
NOTE! Do not tighten more than necessary to ensure smooth feeding.
Do not tighten the pressure screw all the way, some travel should remain.
12. Feed the wire forward using switch A02 on the PEG unit.
13. At the same time adjust the knob (5) on the wire straightener. When the wire
straightener is correctly adjusted the wire should be straight when it leaves the
contact jaws (3).
INSTALLATION
-- 6 --
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14. Replacing the feed roller.
S Unscrew knob (5) and pressure screw (4)
S Unscrew the handwheel (2)
S Replace the feed roller. The wire size is marked on the rollers,
see the table on page 43.
15. Contact equipment
Single wire max. 4mm.
Use contact tip D35 with contact jaws
S Use standard wire straightener for A6 consisting of one fixed and one adjust-
able straightening roller.
S Fit the contact jaws using the M5 bolts that are supplied with it. Fit one part
of the jaws in the fixed contact tip and the other part in the loose half of the
split contact tip.
S Fit the loose half with the contact jaw in position under the pressure screw
and tighten fully to ensure good contact between the contact jaw and the
wire.
16. Filling with flux
S 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 p ressurised flux tank. NOTE ! Flux must be kept dry. Avoid using
agglomerated flux outdoors or in a wet environment.
S Adjust the height of the flux nozzle over the joint to produce a suitable flow of
flux. The flux coverage should be sufficient to prevent the arc showing
through.
WARNING!
Rotating parts can cause injury, take great care.
OPERATION
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OPERATION
1. Careful joint preparation is essential for good welding results.
NOTE! The gap in the weld joint must be uniform.
2. To minimize the risk of hot cracking the width of the weld should be larger than
the penetration.
3. Always weld a test p iece with the same joint preparation and plate thickness a s
the intended production piece.
NOTE! NEVER make a trial weld on a production work piece.
Operating i nstructions for control box PEG1
See operating manual PEG1 order no. 443 392.
aza5dp08
MAINTENANCE
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MAINTENANCE
Control unit PEG1, see operators’ manual 443 392.
Wire feed motor A6 VEC, see operators’ manual 443 393.
Daily
S Keep moving parts of the welding machine free from dust and flux.
S Make sure all electrical cables and hoses are properly connected and undam-
aged.
S Make sure all bolted joints are tight.
S 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 brake torque:
S Turn the locking button (006)
to the locked position
S Insert a screwdriver in the
hub springs. Turn the
springs (002) clockwise to re-
duce the torque.
S Turn the springs anticlockwise to increase the braking torque.
NOTE! Turn each spring the same distance.
Regularly
S Once every three months check the wire feed motor brushes, replace them when
they are worn down to 6 mm.
S Check the cross --slides and lubricate if stiff.
S Check the wire guides and drive rollers on the wire feed unit. Replace any com-
ponents that are worn or damaged. See Wear components on page 43.
TROUBLESHOOTING
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TROUBLESHOOTING
Equipment
S Manual for control box PEG1, order no. 443 392.
S Manual for motor with gear A6 VEC, order no. 443 393.
Check
S that the welding power supply is connected for the correct mains
voltage
S that all three phases are giving the correct voltage
(phase sequence not important)
S that the welding cables and connections to them are not damaged
S that the controls are in the right positions
S that the mains supply is disconnected before starting repairs
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.
10
CONNECTION INSTRUCTIONS FOR PEG1 AND A6 VEC
W
i
W
l
d
i
h
d
C
Switch
(
f
d
b
k
)
S
w
i
t
c
h
(
9
)
Control card
t
i
A6 VEC
Wire Welding method Current
(
feed--bac
k
)
Front PEG1 *
S
w
i
t
c
h
(
9
)
Sequence card *
connection
Control card *
Gear ratio
Rotor speed
r/min
Single wire
2,5--6 mm
Submerged arc
welding
DC Position1or2 Up
X--1
B--7
156:1 4000
Single wire
2,5--6 mm
Submerged arc
welding
AC Position 1 Up
X--1
B--7
156:1 4000
Twin wire
2x1,2 -- 3,0 mm
Submerged arc
welding
DC Position 1 Down
X--1
B--7
156:1
(74:1)
4000
Strip
0,5x30 -- 100 m
Submerged arc
welding
DC Position 1 Up
X--1
B--7
156:1 4000
Carbon electrode
8,0--12,7 mm
Arc--air gouging DC Position 2 Up
X--1
B--7
156:1 4000
* See operators’ manual PEG1 443 392.
-- 4 2 --
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DIAGRAM - SCHALTPLAN - SCHÉMA - SCHEMA
Denomination Bezeichnung Désignation Benaming
01 Welding power
source (DC)
Schweisstromquelle
(DC)
Source de courant de
soudage (c.c.)
Lasstroombron (DC)
02 Control box Bedienungskasten Coffret de commande Bedieningsbox
03 Motor with gear Motor mit Getriebe Moteur avec engrena-
ge
Motor met overbren-
ging
04 Straightener Drahtrichtwerk Dresse-- fil Richtrolinrichting
05 Connector Stecker Connecteur Connector
06 Contact tube Kontaktrohr Tube de contact Contactbuis
07 Welding cable Schweisskabel Câble de soudage Laskabel
08 Control cable Steuerkabel Câble de commande Bedieningskabel
09 Cable Leitung Câble Leiding
10 Welding power
source (AC)
Schweisstromquelle
(AC)
Source de courant de
soudage (c.a.)
Lasstroombron (AC)
11 Filler wire unit Zusatzdrahteinheit Coffret dévidoir Toevoegbox
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.net
020219
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB V AMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel:+3612044182
Fax:+3612044186
ITALY
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Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
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AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
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Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
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Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Irica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
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Gothenburg
Tel:+4631509000
Fax:+4631509360
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ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
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CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
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ESAB S.A.
Contagem--MG
Tel: +55 31 333 43 33
Fax: +55 31 361 31 51
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
AUSTRALIA
ESAB Australia Pty Ltd
Ermington
Tel: +61 2 9647 1232
Fax: +61 2 9748 1685
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
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ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
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Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
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ESAB SeAH Corporation
Kyung --Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
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ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
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Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA--CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.net
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ESAB A6 SFF1C Compact 500 User manual

Category
Welding System
Type
User manual

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