ESAB A6 OPC User manual

Brand: ESAB

Model: A6 OPC

Category: Welding System

Type: User manual

ESAB A6 OPC is a flux recovery unit designed for use with stationary and self-traveling automatic welding machines, providing an efficient and compact solution for recovering and returning welding flux to the welding area. Its key capabilities include:

Flux Recovery: The A6 OPC effectively recovers welding flux from the weld area, preventing flux waste and ensuring optimal flux utilization.
Improved Welding Quality: By recovering and reusing welding flux, the A6 OPC helps maintain consistent flux coverage and improves the quality of the weld.
Reduced Downtime: The continuous recovery and return of flux eliminates the need for frequent flux replenishment, reducing downtime and increasing productivity.

Flux Recovery: The A6 OPC effectively recovers welding flux from the weld area, preventing flux waste and ensuring optimal flux utilization.
Improved Welding Quality: By recovering and reusing welding flux, the A6 OPC helps maintain consistent flux coverage and improves the quality of the weld.
Reduced Downtime: The continuous recovery and return of flux eliminates the need for frequent flux replenishment, reducing downtime and increasing productivity.

Valid from Serial NO 452 XXX--XXXX0443 407 001 981210

A6 OPC

101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

-- 2 --

Rätt till ändring av specifikationer utan avisering förbehålles.

Ret til ændring af specifikationer uden varsel forbeholdes.

Rett til å endre spesifikasjoner uten varsel forbeholdes.

Oikeudet muutoksiin pidätetään.

Rights reserved to alter specifications without notice.

Änderungen vorbehalten.

Sous réserve de modifications sans avis préalable.

Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.

Reservado el derecho de cambiar las especificaciones sin previo aviso.

Specifiche senza preavviso.

Reservamo--nos o direito de alterar as especificações sem aviso prévio.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

SVENSKA 3..............................................

DANSK 10................................................

NORSK 17................................................

SUOMI 23................................................

ENGLISH 30..............................................

DEUTSCH 37.............................................

FRANÇAIS 44.............................................

NEDERLANDS 51.........................................

ESPAÑOL 58..............................................

ITALIANO 65..............................................

PORTUGUÊS 72..........................................

ÅËËÇÍÉÊÁ 79.............................................

ENGLISH

TOCe

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1SAFETY 31...........................................................

2 INTRODUCTION 33...................................................

2.1 General 33..................................................................

2.2 A6 OPC consists of: 33.......................................................

2.3 Technical data 33............................................................

3 INSTALLATION 34....................................................

3.1 General 34..................................................................

3.2 Connections 34..............................................................

4 OPERATION 35.......................................................

4.1 General 35..................................................................

4.2 Starting work 35..............................................................

5 MAINTENANCE 36....................................................

5.1 General 36..................................................................

5.2 Daily 36.....................................................................

5.3 As necessary 36.............................................................

6 ACCESSORIES 36....................................................

7 ORDERING OF SPARE PARTS 36......................................

DIMENSION DRAWING 86................................................

SPARE PARTS LIST 89...................................................

-- 3 1 --dgb4d1ea

1SAFETY

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 regulations 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 situation 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

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 mechanisms are operated.

3. The work place must:

S be clear of mechanical components, tools, or other obstructions that could prevent the oper-

ator 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 during its operation.

-- 3 2 --

dgb4d1ea

WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ 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 other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

-- 3 3 --dgb4d1ea

2 INTRODUCTION

2.1 General

Flux recovery unit A6 OPC is used with stationary and self--travelling automatic

welding machines when a light and small unit for recovering and returning the flux to

the welding place is wanted.

2.2 A6 OPC consists of:

1. Ejector, air-- operated. The side of the

ejector to be connected to the cyclone is

fitted with a flange. The other side has

connections for suction and

compressed--air hoses 3/8”.

2. Suction hose, connects the ejector

with the suction nozzle.

3. Suction nozzle, available in four

different executions.

S Butt welding, normal joints.

S Butt welding, big joints.

S Fillet welding, left.

S Fillet welding, right.

4. Nozzle holder, to keep the nozzle in place

over the weld joint.

5. Cyclone, to separate the flux from the air and

bring it back to the flux container. It is fitted on top

of the flux container.

6. Tensioning strap

7. Filter bag

2.3 Technical data

A6 OPC

Max permissible air pressure 6 kp/cm2

Continuous A--weighted noise pressure at idle running 78 dB

Max. continuous A--weighted noise pressure while welding 74 dB

Max air consumption at different pressures (max working pressure) bar 4 5 6

liter/min 175 225 250

See the dimension drawing on page 86.

The rubber parts are tried out for welding with pre--heated flux, max 220_ and

welding object max 350_C.

Note that a flux container of metal must be used.

Suction capacity, see on page 34.

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dgb4d1ea

Flux type FLUX 10.40 Flux type FLUX 10.80

*1 Air pressure (bar)

*2 Welding speed (m/min)

*3 Flux area (mm)

*4 H=Lifting height in m

At 0.8 m suction height the welding speed is not affected by the type of flux.

Air pressure, bar Suction height, m Welding speed m/min

6 0.8 1.16

5 0.8 1.00

4 0.8 0.75

3 INSTALLATION

3.1 General

The installation shall be executed by a professional.

3.2 Connections

S See dimension drawing on page 86.

S Fit the sealing ring in the groove on the flux container.

S Press the cyclone (5) on to the container till stop.

S Mount the ejector (1) on the cyclone (5)

and fix it with a hose clamp.

S Fasten the compressed --air connection carefully

to the nipple of the ejector valve (1).

S Fit the suction hose (2) between the ejector (1)

and the suction nozzle (3).

S Choose the right type of nozzle (3) for the work

piece and the welding position.

S Fit the holder (4) on the contact device.

Note. It is important to make sure that the suction

nozzle ( 3) is electrically insulated from live parts through the insulation of the

holder (4) and that it cannot get into contact with other live parts around the contact

device.

-- 3 5 --dgb4d1ea

4OPERATION

4.1 General

General safety regulations for the handling of the equipment appear from

page 31. Read through before you start using the equipment!

4.2 Starting work

S Make sure that the equipment is properly fitted and that all hoses are attached.

S Check that the flux valve is closed.

S Fill up the flux container with flux.

S Open the flux valve. (T he flux runs down to the joint at the contact tip.)

S Start welding and activate the flux recovery unit by opening the compressed--air

valve.

Unused flux is sucked up through the suction nozzle, the suction hose and the

ejector into the cyclone, where the flux is separated from the air. The flux runs

through the strainer down into the flux container. T he dusty air is cleaned in the

filter bag, where the dust will remain.

WARNING!

The flux recovery unit m ust not be started without a filter bag or with a damaged

filter bag. The whirling dust can be injurious to your eyes and lungs.

To obtain high suction capacity the filter bag must be replaced when it causes too

great pressure drop. The filter bag then becomes inflated and hard.

N.B.: A choked--up filter affects the strength of the filter bag and in the worst case it

can press the cyclone off the flux container causing air leakage or bursting of the

filter bag. Shake the filter bag now and then.

Replace the filter bag when the pressure drop cannot be remedied by shaking the

bag, or after about 8 working hours.

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dgb4d1ea

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.

5.2 Daily

S Check that the rubber lining of the cyclone is undamaged.

Replace the lining as necessary.

S Check packings and hoses for leakage.

5.3 As necessary

S Replace the filter bag when the suction capacity is insufficient or after about 5--8

working hours. Shake the filter bag as necessary.

6 ACCESSORIES

Flux container 10 litres,

(increased temperature, flux temp. max 220_, see on page 86) 147 649--881............

Flux container 7 litres,

(increased temperature, flux temp. max 220_, see on page 87) 413 315 xxx............

Flux container, plastic, 7 litres (A2), see on page 87 332 994 xxx.....................

Flux hose 443 383--001...........................................................

Flux tube 443 373--001...........................................................

Suction hose (1) 190 789--801.............................

Cover (2) 148 143--001....................................

O--ring (3) 2152 013--53....................................

Profile strap (4) 148 144--001..............................

7 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 89.

This will simplify dispatch and ensure you get the right part.

Måttskiss Målskitse Målskisse Mittapiirustus Dimension drawin g Mass-

bild Cotes d’encombrement Maatschets Croquis acotado Dimensioni

Esboço com dimensões Ó÷åäéÜãñáììá ìåãåèþí

Ó×ÅÄÉÁÑÁÌÌÁ ÌÅÃÅÈÙÍ

-- 8 6 --dgb4m11a

A6 OPC

1. Hose L= 1000 mm

2. Nozzle L= 210

Flux container 10 l (147 649--881)

-- 8 7 --dgb4m11a

Flux container 7 l (332 994 xxx)

Flux container 7 l (413 315 xxx)

-- 8 8 --sida

Reservdelsförteckning Reservedelsfortegnelse Reservedelsliste

Varaosaluettelo Spare parts list Ersatzteilliste Liste de pièces détachées

Reserveonderdelenlijst Lista de repuestos Elenco ricambi Lista de peças

sobressalentes Ðßíáêáò áíôáëëáêôéêþí ìåñþí

ÐÉíáÊ ÁÓ áíôáëë áêôéêÙí ìå ñÙí

-- 8 9 --OPC

A6 OPC

Edition 981202

(W) = This is a wear component

-- 9 0 --OPC

Item

Qty Orderingno. Denomination Notes

148 140--880 Flux recove ry unit

1 1 148 141--001 Cyclone

2 1 145 073--001 Rubber lining (cyclone) (W)

3 2 145 815--001 Locking ring (W)

4 1 148 142--001 Funnel

5 1 145 565--001 Rubber lining (W)

8 1 192 855--002 Securing strap (W)

11 2 155 966--001 Filter bag (W)

13 1 2529 004--11 Hose clamp

14 1 147 640--880 Ejector (W)

15 1 145 824--881 Valve

16 2 2529 004--09 Hose clamp (W)

17 1 191 813--801 Hose

18 1 145 740--880 Suction nozzle

19 1 147 384--881 Nozzle holder

28 1 2152 013--45 O--ring (W)

-- 9 1 --OPC

Item

Qty Orderingno. Denomination Notes

145 740--880 Suction nozzle kit

1 1 145 501--001 Suction nozzle (W)

2 1 145 502--001 Suction nozzle (W)

3 1 145 504--001 Suction nozzle (W)

4 1 145 505--001 Suction nozzle (W)

Item Qty Orderingno. Denomination Notes

147 384--881 Nozzle holder

4 1 147 387--001 Stop ring

9 4 147 391--001 Nut

10 2 147 392--001 Strip

11 1 145 131--002 Insulating sleeve

12 1 145 131--003 Insulating sleeve

13 2 154 739--001 Attachmen t

14 1 154 738--001 Boom

15 1 154 737--001 Boom

16 1 145 141--004 Insulating sleeve

-- 9 2 --OPC

Item

no.

Qty Ordering no. Denomination Notes

0147 649 881 Flux hopper compl 10 l (Optional equipment)

01 1 0154 007 001 Hopper for flux

02 1 0148 837 001 Window

03 1 0147 645 001 Fitting

04 4 Washer D8/4.3x0.8

05 4 0191 898 108 Rivet

06 1 0153 347 880 Flux valve

07 1 2152 012 32 O-- ring

08 2 0148 799 001 Washer

09 2 Screw M3x16

13 1 0020 301 780 Flux strainer

14 1 0443 383 002 Flux hose L=500

-- 9 3 --OPC

Item

no.

Qty Orderingno. Denomination Notes

0153 299 880 Flux nozzle Optional equipment

1 1 153 290--002 Pipe holder

2 1 153 296--001 Pipe bend

3 1 153 425--001 Wheel

ESAB Welding Equipment AB

SE--695 81 L AXÅ

SWEDEN

Phone +46 584 81 000

Fax + 46 584 123 08

www.esab.com

001004

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

ESAB Saldatura S.p.A.

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

NORWAY

AS ESAB

Larvik

Tel:+4733121000

Fax:+4733115203

POLAND

ESAB Sp.z.o.o

Warszaw

Tel: +48 22 813 99 63

Fax: +48 22 813 98 81

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 1 837 1527

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r .o.

Bratislava

Tel:+421744882426

Fax:+421744888741

SPAIN

ESAB Ibérica 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

ESAB International AB

Gothenburg

Tel:+4631509000

Fax:+4631509360

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

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

MALAYSIA

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

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 861 74 42

Fax: +65 863 08 39

SOUTH KOREA

ESAB SeAH Corporation

Kyung -- Nam

Tel: +82 551 289 81 11

Fax: +82 551 289 88 63

THAILAND

ESAB (Thailand) Ltd

Samutprakarn

Tel: +66 2 393 60 62

Fax: +66 2 748 71 11

UNITED ARAB EMIRATES

ESAB Middle East

Dubai

Tel: +971 4 338 88 29

Fax: +971 4 338 87 29

Representative offices

BULGARIA

ESAB Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

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.com

ESAB A6 OPC User manual

Brand: ESAB

Model: A6 OPC

Category: Welding System

Type: User manual

Flux Recovery: The A6 OPC effectively recovers welding flux from the weld area, preventing flux waste and ensuring optimal flux utilization.
Improved Welding Quality: By recovering and reusing welding flux, the A6 OPC helps maintain consistent flux coverage and improves the quality of the weld.
Reduced Downtime: The continuous recovery and return of flux eliminates the need for frequent flux replenishment, reducing downtime and increasing productivity.

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ESAB A6 OPC User manual

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