ESAB A6 Welding heads User manual

Brand: ESAB

Model: A6 Welding heads

Category: Welding System

Type: User manual

Valid for serial no. 232--xxx--xxxx0449 275 101 2009--03--02

A6 Welding heads

A6 SF / A6 SF (Twin)

112101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

Eksploatavimo instrukcijos

Instrukcja obs³ugi

Návod k pou¾ívání

-- 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.

Ci riserviamo il diritto di variare le specifiche senza preavviso.

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

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

Zastrzegamy sobie prawo do wprowadzenia zmian.

Výrobce si vyhrazuje právo na zmìnu údajû bez pøedcházejiciho upozomìni.

Įmonė pasilieka teisę keisti specifikacijas be įspėjimo.

SVENSKA 5..............................................

DANSK 22................................................

NORSK 39................................................

SUOMI 56................................................

ENGLISH 73..............................................

DEUTSCH 90.............................................

FRANÇAIS 107.............................................

NEDERLANDS 124.........................................

ESPAÑOL 141..............................................

ITALIANO 158..............................................

PORTUGUÊS 175..........................................

ÅËËÇÍÉÊÁ 192.............................................

POLSKI 210.................................................

ÈESKY 227.................................................

LIETUVIÙK 244..............................................

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, försäkrar under eget ansvar

att svetsautomat A6 SF från serienummer 740 är i överensstämmelse med standard

EN 60292 enligt villkoren i direktiv ( 89/392/EEG) med tillägg.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

OVERENSSTEMMELSEERKLÆRING

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden garanterer under eget ansvar,

at svejseautomat A6 SF fra serienummer 740 er i overensstemmelse med standard

EN 60292 ifølge betingelserne i direktiv (89/392/EEC) m ed tillægg.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

FORSIKRING OM OVERENSSTEMMELSE

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, forsikrer på eget ansvar at

sveiseautomat A6 SF med serienummer 740 er i samsvar med standard EN 60292 i

overensstemmelse med bestemm e lsene i direktiv (89/392/EØF) med tillegg.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

VAATIMUSTENMUKAISUUSVAKUUTUS

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, vakuuttaa omalla vastuullaan,

että hitsausautomaatti A6 SF sarjanumerosta 740 täyttää standardin EN 60292 vaa -

timukset direktiivin (89/392/EEC) ja sen lisäyksen mukaisesti.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, gives its unreserved guaran -

tee that automatic welding machine A6 SF from serial number 740 complies with

standard EN 60292, in accordance with the requirements of directive (89/392/EEA)

and addendum.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

KONFORMITÄTSERKLÄRUNG

ESAB AB, Welding Equipment, 695 81 Laxå Sweden, versichert hiermit auf eigene

Verantwortung, daß der Schweißautomat A6 SF ab Serien --Nr 740 mit der norm EN

60292 gemäß den Bedingungen der Richtlinien (89/392/EWG) mit der Ergänzung in

Übereinstimmung steht.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

CERTIFICAT DE CONFORMITÉ

ESAB AB, Welding Equipment, 695 81 Laxå Sweden, certifie sous sa propre respon-

sabilité que la appareil de soudage automatique A6 SF à partir du numér o de serié

740 répond aux normes de qualité EN 60292 conformément aux directives

(89/392/EEC) avec annexe.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

OVEREENKOMSTIGHEIDSVERKLARING

ESAB AB, Welding Equipment, 695 81 Laxå Sweden, verklaart op eigen verantwoor-

delijkheid dat lasautomaat A6 SF van serienum m er 740 overeenkomt met norm EN

60292 volgens richtlijn (89/392/EEG) van de Raad me t toevoeging.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

DECLARACIÓN DE CONFORMIDAD

ESAB AB, Welding Equipment, 695 81 Laxå, Sweden, declara, asumiendo toda res-

ponsabilidad, que la equipo par a soldadura automática A6 SF desde el númer o de

serie 740 está fabricada de conformidad con la normativa EN 60292 según los re-

quisitos de la directiva (89/392/EEC) con el suplemento.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

DICHIARAZIONE DI CONFORMITA

ESAB AB, Welding Equipment, 695 81 Laxå Sweden, dichiara sotto la propria re -

sponsabilità che la saldatrice autom atica A6 SF dal numero di serie 740 è conforme

alla norma EN 60292 ai sensi dei requisiti previsti dalla direttiva (89/392/CEE) e suc-

cessive integrazioni nella direttiva.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

DECLARAÇÃO DE CONFORMIDADE

ESAB AB, Welding Equipment, 695 81 Laxå Sweden, certifica, sob a sua própria

responsabilidade que, o equipam ento automático para soldadura A6 SF desde o nú-

mero de série 740 está em conformidade com a norma EN 60292, segundo os re -

quisitos constantes na directiva (89/392/EEC) e com o suplemento.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

ÂÅÂÁÉÙÓÇ ÓØÌÖÙÍÉÁÓ

Ç ESAB AB, Welding Equipment, 695 81 Laxå Sweden, âåâáéþíåé ìå äéêÞ ôç ò

åõèýíç oôé ç áõôüìáôò óõãêïëëçôÞò A6 SF áðü ôïí áñéèìü óåéñÜò 740 âñßóêåôáé

óå óõìöùíßá ìå ôï óôáíôáñô ÅÍ 60292 óýìöùíá ìå ôïõ üñïõò ôçò ïäçãßáò

(89/392/ÅÅC) ê áé ôçí ðñïóèÞêç .

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

ZAPEWNIENIE ZGODNO¦CI Z NORMA

ESAB AB, Welding Equipment, 695 81 Laxå, Szwecja, zapewnia z peln±

odpowiedzialno¶ci±, ¿e automat do spawania A6 SF od numeru seryjnego 740 zgodny jest

z norm± EN 60292 wed³ug warunków ustalonych w dyrektywie (89/392/EEG) z

dodatkiem uzupe³niaj±cym.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

PROHLÁ©ENÍ O SHODÌ

Spoleènost ESAB AB, Welding Equipment, 69581 Laxå, ©védsko, vydává nevyhrazenou

záruku, ¾e svaøovací automat A6 SF od výrobního èísla 740 splòuje normu EN 60292 v

souladu s po¾adavky smìrnice (89/392/EHS) a dodatkem.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

ATITIKTIES DEKLARACIJA

“ESAB AB, Welding Equipment“, 695 81 Laxå, Švedija, suteikia visišką garantiją,kad

automatinis suvirinimo aparatas A6 SF su serijiniu numeriu 740 atitinka standartą

EN 60292 pagal direktyvos (89/392/EEA) ir jos priedo reikalavimus.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

Paul Karlsson

Managing Director

ESAB AB, Welding Equipment

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Laxå 97--11--19

ENGLISH

-- 7 3 --

TOCe

1SAFETY 74...........................................................

2 INTRODUCTION 76...................................................

2.1 General 76..................................................................

2.2 Welding Method 76...........................................................

2.3 Definitions 76................................................................

2.4 Technical Data 76............................................................

2.5 Main Components A6 SF 77...................................................

2.6 Main Components A6 SF (Twin) 77.............................................

2.7 Description of Main Components 78............................................

3 INSTALLATION 79....................................................

3.1 General 79..................................................................

3.2 Mounting 79.................................................................

3.3 Adjusting the Brake Hub 80....................................................

3.4 Connections 81..............................................................

4 OPERATION 82.......................................................

4.1 General 82..................................................................

4.2 Loading the Welding Wire (A6 SF) 83...........................................

4.3 Changing the Feed Roller (A6 SF) 84...........................................

4.4 Contact Equipment for Submerged Arc Welding 85...............................

4.5 Refilling with Flux Powder (Submerged Arc Welding) 86...........................

4.6 Conversion of A6 SF (Submerged Arc Welding) to MIG/MAG welding 86............

4.7 Conversion of A6 SF (Submerged Arc Welding) to Twin--arc 86.....................

5 MAINTENANCE 87....................................................

5.1 General 87..................................................................

5.2 Daily 87.....................................................................

5.3 Regularly 87.................................................................

6 FAULT TRACING 88...................................................

6.1 General 88..................................................................

6.2 Possible faults 88............................................................

7 ACCESSORIES 89....................................................

8 ORDERING OF SPARE PARTS 89......................................

DIMENSION DRAWING 261................................................

SPARE PARTS LIST 263...................................................

-- 7 4 --

fhb4safe

1SAFETY

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 precautions. Safety precautions

must meet the requirements that apply to this type of welding equipment. The following recommen-

dations 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 operation 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:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from draughts

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, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

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 o r

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 in ju re 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 no ise can damage hearing

S Protect your ears. Use ear defenders or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION

S Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

READ AND UNDERSTAND THE INSTRUCTION MANUAL

BEFORE INSTALLING OR OPERATING.

-- 7 5 --

fhb4safe

-- 7 6 --

fhb4d1ea

2 INTRODUCTION

2.1 General

All the welding heads included in this instruction manual are designed for SAW

welding of butt and fillet joints.

They are intended for use in combination with A2--A6 Process Controller (PEH) and

ESAB’s welding power source LAF or TAF.

2.2 Welding Method

Submerged Arc Welding (SAW), Heavy du t y

S Submerged--arc heavy duty, with a ∅ 35 mm connector, which permits a load of

up to 1500 A.

This version can be equipped with feed rollers for single or twin wire welding

(twin--arc). A special knurled feed roller is available for flux--cored wire, which

guarantees even wire feed without the risk of deformation due to high feed pressure.

2.3 Definitions

SAW welding The weld bead is protected by a cover of flux during the weld -

ing.

SAW Heavy du ty This version permits a load up to 1500 A ( 100%) and welding

with a thick wire.

Twin--arc weldin g Welding with two wires in one welding head.

2.4 Technical Data

A6 SF/ A6 SF (Twin)

Rated load 100% 1500 A

Wire dimensions:

solid single wire

flux--cored wire

twin wire

3,0--6,0 mm

3,0--4,0 mm

2x2,0--3,0mm

Wire feed speed 0,2--4,0 m/min

Brake drum braking torque 1,5 Nm

Max weight, wire 2x30 kg

Flux hopper capacity (Not to be filled with preheated flux) 10 l

Weight (flux and wire excluded)

with hand--operated linear slides

with motor--driven linear slides

¶ 58 kg

¶ 75 kg

Sideways tilt, max. 25_

Setting length of the slide*

hand--operated

motor--driven

210 mm

300 mm

*) NB! Other lengths on request.

-- 7 7 --

fhb4d1ea

2.5 Main Components A6 SF

1. Wire feed unit

2. Slide kit, manual

3. Slide kit, motorised

4. Contact tube

5. Motor with gear (A6 VEC)

6. Carrier for wire drum

7. Flux hopper

8. Flux tube

9. Flux nozzle

2.6 Main Components A6 SF (Twin)

1. Wire feed unit

2. Slide kit, manual

3. Slide kit, motorised

4. Connector (Twin)

5. Motor with gear (A6 VEC)

6. Carrier for wire drum

7. Flux hopper

8. Flux tube

9. Flux nozzle

See on page 78 for a description of the m ain components.

-- 7 8 --

fhb4d1ea

2.7 Description of Main Components

2.7.1 Wire Feed Unit

The unit is used for guiding and feeding the welding wire down into the contact

tube/connector.

2.7.2 Manual and Motorised Slides

The horizontal and vertical position of the welding head is adjusted by way of linear

slides. The angular motion can be freely adjusted using the rotary slide.

Forthemotorisedslide(A6 Slide), see instruction manual 0443 394 xxx.

2.7.3 Contact Tube / Connector

Transfers welding current to the wire during welding.

2.7.4 Motor with Gear (A6 VEC)

The motor is used for feeding the welding wire.

For more information regarding the A6 VEC see instruction manual 0443 393 xxx.

2.7.5 Carrier for Wire Drum

The carrier is provided with a brake hub on which one the wire drum is to be fitted.

2.7.6 Flux Hopper / Flux Tube / Flux Nozzle

The flux is filled into the flux hopper and is then tr ansfer r e d to the workpiece through

the flux tube and the flux nozzle.

The amount of flux to be dropped down is controlled by way of the flux valve fitted to

the flux hopper.

See Refilling with flux on page 86.

-- 7 9 --

fhb4i1ea

3 INSTALLATION

3.1 General

The installatio n must be executed by a p rofession al.

WARNING

Rotating parts can cause injury, take great care.

3.2 Mounting

3.2.1 Welding Head

The welding head can be mounted on a beam--travelling carriage or on a welding

column and boom unit by way of four M12 screws.

N.B.

Make sure the bolts do not touch the bottom of the insulator, which has a thread

depth of 14 mm.

3.2.2 A6 Slide

For m ounting/ dismounting of A6 Slide, see instruction manual 443 394 xxx.

This safety sign is placed on the cover of the vertical slide.

-- 8 0 --

fhb4i1ea

3.2.3 Wire reel (Accessories)

Thewirereel(1) is mounted on the brake hub ( 2).

S 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 r ed 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 the wire feed stops.

S Adjusting the Braking Torque

S Turn the red handle to the locked position.

S 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.

-- 8 1 --

fhb4i1ea

3.4 Connections

3.4.1 General

S TheA2--A6ProcessController(PEH) is to be connected by a qualified person.

S For the connection of A6 GMH, see instruction manual 0460 671 xxx.

S For the connection of A6 PAV, see instruction manual 0460 670 xxx.

3.4.2 Welding Head A6 SF (Submerged Arc Welding, SAW)

1. Connect the control cable (7) between the welding power source (8) and the

A2--A6 Process Controller (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).

-- 8 2 --

fhb4o1ea

4 OPERATION

4.1 General

Caution:

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 74. Read through before you start using the equipment!

S Select wire type and flux powder or shielding gas so that the weld material is as

close as possible to the analysis of the base metal.

S Select wire size and welding data in accordance with the values recommended

by the welding materials supplier.

S Thorough preparation of the weld surfaces is necessary to achieve a good weld.

NOTE! The width of the weld joint gap must be uniform.

S To minimise the risk of heat crack formation, the width of the weld must be

greater than the penetration depth.

S 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.

S For control and adjustment of the automatic welding machine and welding power

supply, see the instruction m anual for the A2--A6 Process Controller (PEH).

-- 8 3 --

fhb4o1ea

4.2 Loading the Welding Wire (A6 SF)

1. Mount the wire drum according to the instructions on page 80.

2. Check that feed roller (1) and contact jaw or contact tip (3) are of the correct

dimension for the selected wire size.

3. For A6 SF (Twin):

S Feed the wire through the wire guide (8).

4. When welding with fine wire:

S Feed the wire through the fine wire feed unit (6).

Ensure that the straightener is correctly adjusted so that the wire emerges

straight out through the contact jaws or contact tip (3).

5. Pull the end of the wire through the straightener (2).

S For a wire diameter greater than 2 mm; straighten out 0.5 m of wire and feed

it by hand down through the straightener.

6. Locate the end of the wire in the feed roller (1) groove.

7. Set the wire tension on the feed roller with the knob (4).

S Note! Do not tension m ore than is required to achieve an even feed.

8. Feed the wire forward 30 mm by pressing on the control box

A2--A6 Process Controller ( PEH).

9. Straighten the wire by adjusting the knob (5).

S Always use a guide tube (7) to ensure even feed of fine wire (1.6 -- 2.5 mm).

-- 8 4 --

fhb4o1ea

4.3 Changing the Feed Roller (A6 SF)

Single wire

S Release the knobs (3) and (4).

S Release the hand wheel (2).

S Change the feed roller ( 1).

The rollers are marked with their respective wire

sizes.

Twin Wire (Twin--arc)

S Change the feed roller ( 1) with twin grooves in the same way as for single wire.

S NOTE! The pressure roller (5 ) must also be changed. A special curved pressure

roller for twin wire replaces the standard pressure roller for single wire.

S Assemble the pressure roller with a special stub shaft

(order no. 0146 253 001).

Flux--cored Wire for Knurled Rollers (Accessories)

S Change the feed roller ( 1) and pressure roller (5)asapairforthewiresizetobe

used.

NOTE! A special stub shaft is required for the pressure roller

(order no. 0212 901 101).

S Tighten the pressure screw (4) with moderate pressure to ensure that the

flux--cored wire does not deform.

-- 8 5 --

fhb4o1ea

4.4 Contact Equipment for Submerged Arc Welding

4.4.1 For Single Wire 3,0 -- 6,0 mm

Use automatic welding machine A6 SF (UP) where

the following units units are included:

S Wire feed unit (1),

S Connector D35 (2)

S Contact jaw (3 )

Ensure that good contact is achieved between the

contact jaws and the wire.

4.4.2 ForTwinWires2x2,0--3,0mm(D35)

Use automatic welding machine A6 SF (UP, Twin)

where the following are included:

S Wire feed unit (1),

S Connector Twin D35 (2)

S Contact jaw (3 )

Ensure that good contact is achieved between the

contact jaws and the wire.

S Guide tubes ( 4, 6).

Accessories:

S Fine--wire straightener (5)tobefittedontopof

the clamp of the wire feed unit (1).

N.B. When mounting the fine--wire straightener,

remove the existing p late (7).

Adjustment of the Wires for Twin--arc Welding:

S Position the wires in the joint so as to achieve optimal weld quality by r otating the

connector. T he two wires can be rotated so that they are positioned one after the

other along the line of the joint, or in any position up to 90° across the joint, i.e.

one wire on each side of the joint.

-- 8 6 --

fhb4o1ea

4.5 Refilling with Flux Powder (Submerged Arc Welding)

1. Close the flux valve (1) on the flux hopper.

2. Remove the cyclone on the flux recovery unit, if fitted.

3. Fill with flux powder.

NOTE! The flux powder must be dry. Where possible

avoid u sing agglomerating flux powder outdoors and

in damp environments.

4. Position the flux tube so that it does not become

kinked.

5. 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.

4.6 Conversion of A6 SF (Submerged Arc Welding) to MIG/MAG

welding

For the conversion kit see instruction manual 0456 756 xxx.

4.7 Conversion of A6 SF (Submerged Arc Welding) to Twin--arc

For the conversion kit see instruction manual 0456 757 xxx.

-- 8 7 --

fhb4m1ea

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 m achine during the warranty period.

NB! Before doing any kind of maintenance work, make sure the mains is

disconnected.

For the maintenance of the A2--A6 Process Controller (PEH), see the instruction

manual 0443 745 xxx.

5.2 Daily

S Keep the m oving parts of the welding head clean.

S Make sure contact nozzles, hoses and electric cables are properly connected.

S Make sure all bolted joints are tightened and that the conduit and the feed rollers

are not worn or damaged.

S Check the brake hub braking torque. It should not be so low, that the wire reel

continues to rotate when wire feed is stopped and it should not be so great that

the feed rollers slip. As a guide, the braking torque for a 30 kg wire reel should

be 1.5 Nm.

To adjust the braking torque see on page 80.

5.3 Regularly

S Check the wire feed motor brushes once every three months. Replace when

they are worn down to 6 mm.

S Examine the slides and lubricate if they bind.

S Inspect the wire guides, drive rollers and contact tip on the wire feed unit.

Replace any worn or damaged components, (see spare parts list on page 263).

S Inspect the gas nozzle and clear it regularly of welding spatter.

S Blow the wire conduit clean at regular intervals and clean the gas nozzle.

S For trouble--free wire feed the wear parts of the feed mechanism should be

cleaned and replaced at regular intervals.

NOTE that too hard pre--tensioning can lead to abnormal wear of the pressure

roller, feed roller and wire conduit.

-- 8 8 --

fhb4f1ea

6 FAULT TRACING

6.1 General

Equipment

S Instruction manual for A2--A6 Process Controller ( PEH).

Check

S that the power supply is connected for the correct mains supply

S that all three phases are supplying the correct voltage

(phase sequence is not important)

S that welding cables and connections are not damaged

S that the controls are correctly set

that the mains supply is disconnected before starting repairs

6.2 Possible faults

1. Symptom Current and voltage readings show large fluctuations

Cause 1.1 Contact jaws or nozzle are worn or wrong size.

Action Replace contact jaws or nozzle.

Cause 1.2 Feed roller pressure is inadequate.

Action Increase pressure on feed rollers.

Cause 1.3 The gas nozzle is choked up.

Action Clear of welding spatter.

2. Sympto m Wire feed is irregular

Cause 2.1 Pressure on feed rollers incorrectly set.

Action Adjust the pressur e .

Cause 2.2 Feed rollers wrong size.

Action Replace feed rollers.

Cause 2.3 Grooves in feed rollers are worn.

Action Replace feed rollers.

3. Symptom Welding cables overheating

Cause 3.1 Poor electrical connection.

Action Clean and tighten all electrical connections.

Cause 3.2 Cross --sectional area of welding cables too small.

Action Use cables with a larger cross--section or use parallel cables.

Page is loading ...

ESAB A6 Welding heads User manual

Brand: ESAB

Model: A6 Welding heads

Category: Welding System

Type: User manual

Download PDF

report

ESAB A6 Welding heads User manual

ESAB A6 Welding heads User manual

Related papers