ESAB A6S Arc Master Instruction Manual
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ESAB A6S Arc Master Instruction Manual

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A6S Arc Master
A6S G Master
A6S Compact 500
A6 SFE1/ A6 SFE2/ A6 SGE1/
A6 SFE1C
Instruction manual
0456 562 201 2009-11-09
Valid for serial no. 935-xxx-xxxx

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  • Page 1 A6S Arc Master A6S G Master A6S Compact 500 A6 SFE1/ A6 SFE2/ A6 SGE1/ A6 SFE1C Instruction manual 0456 562 201 2009-11-09 Valid for serial no. 935-xxx-xxxx...
  • Page 2 ENGLISH ..........Rights reserved to alter specifications without notice.

  • Page 4: Table Of Contents

    ENGLISH 1 SAFETY ............2 INTRODUCTION .

  • Page 5: Safety

    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.
  • Page 6 WARNING, RISK OF CRUSHING! Do not use safety gloves when replacing wire, feed rollers and wire bobbins. - 6 - SafeArcS GB...
  • Page 7 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.

  • Page 8: Introduction

    All the automatic welding machines included in this instruction manual are designed for SAW and MIG/MAG welding of butt and fillet joints. ESAB's welding heads are of the A6 S type and are intended for use in combination with PEK and ESAB's welding power sources LAF and TAF.

  • Page 9: Welding Method

    Welding method Submerged arc welding (SAW) For SAW welding the A6 SF welding head is always used. It is available in the following designs: Submerged-arc Light duty Submerged-arc light duty, with a 20 mm connector, which permits a load of up to 800 A (100%) or 1000 A (60%).

  • Page 10: Equipment

    Equipment Included in a complete welding head are a feed motor (A6 VEC) to feed in the wire and contact equipment which supplies current to the wire and provides a good con- tact. Contact equipment is available in several different versions. A6 SF is used for submerged-arc welding.

  • Page 11: Installation

    Example of the A6 SFE1C 3%# 78 4 & Connection instructions for SAW and MIG/MAG welding appear from the system dia- gram on page 12. INSTALLATION General Installation shall only be performed by qualified personnel. WARNING Rotating parts can cause injury, take great care. Mounting The automatic welding machines can easily be fitted with 4 screws M10x40 on a rail- borne carriage or on a column and boom unit.
  • Page 12 2. Connect the A6 welding heads as follows: SUBMERGED ARC WELDING (SAW) Connect the control cable (7) between the welding power source (8) and the PEK (2). Connect the return cable (11) between the welding power source (8) and the work piece (9).

  • Page 13: Operation

    OPERATION General General safety regulations for the handling of the equipment can be found on page 5. Read through before you start using the equipment! Starting work Loading the welding wire Remove the wire drum (1) from the brake hub (2) and take off the side plate (3).
  • Page 14 Check that the feed roller (1) and contact jaw or contact tip (3) are of the correct dimension for the selected wire size. Pull the end of the wire through the straightener (2). For a wire diameter greater than 2 mm; straighten out 0.5 m of wire and feed it by hand down through the straightener.
  • Page 15 Contact equipment for submerged-arc welding For single wire 3.0 - 4.0 mm. Light duty (D20) Use the straightener (3), connector (1) D20 with contact tip (2) (M12 thread). Tighten the contact tip (2) with a key in order to ensure that a good contact is achieved.
  • Page 16 For twin wires 2 x 2.0 - 3.0 Heavy Twin (D35) (Accessories) Use the straightener (3), connector (1) D35 with contact jaws (2). Fit the first contact jaw with the M5 bolts supplied, in the fixed connector (a). Fit the other contact jaw in the free half of the two-piece connector (b) under the bolt (8) and tighten down hard to ensure that a good contact is achieved between the contact jaws and the wire.

  • Page 17: Conversion Of A6 Sfe1 (Submerged Arc Welding) To Mig/Mag Welding

    Contact equipment for MIG/MAG welding. For single wire 1.6 - 2.5 mm (D35) Use the straightener (3), connector (1) D35 with contact tip (2) (M10 thread). Tighten the contact tip (2) with a key to ensure that a good contact is achieved. Fit the clamp (7) with guide tube (6) in the M12 hole on the standard straightener (3).

  • Page 18: Maintenance

    MAINTENANCE General NB! Before doing any kind of maintenance work, make sure the mains is discon- nected. For the maintenance of the PEK, see the instruction manual, 0460 948 xxx, 0460 949 xxx, 0459 839 036. Daily Clean flux and dirt off moving parts of the welding machine. Check that the contact tip and all electric cables are connected.

  • Page 19: Fault Tracing

    FAULT TRACING 0460 948 xxx, 0460 949 xxx, 0459 839 036 %# 78 1 0443 393 xxx " POSSIBLE FAULTS Current and voltage readings show large fluctuations Contact jaws or nozzle are worn or wrong size. " , !* ! Replace contact jaws or nozzle.

  • Page 20: Accessories

    ! *; +++ !! 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 25.

  • Page 21: Wear Components

    WEAR COMPONENTS Feed rollers - #%&. 0218 510 281 0218 522 480 0218 510 282 0218 522 481 3-3,2 0218 510 283 0218 522 484 0218 510 286 0218 522 486 0218 510 287 0218 522 487 0218 510 288 0218 522 488 0146 024 880 0,8-1,6...
  • Page 22 Pressure rollers 0146 025 880 0,8-1,6 0146 025 881 2,0-4,0 0146 025 882 5,0-7,0 0218 524 580 0146 253 001 Stub shaft 0144 953 001 Sperical ball bearing 0190 452 178 Washer Stub shaft for pressure roller 0212 901 101 Contact jaws # - #%&.
  • Page 23 Contact tip # - # $. 0154 623 003 0154 623 004 0154 623 005 0154 623 006 0154 623 007 0154 623 008 # - #%&. 0153 501 002 0153 501 004 0153 501 005 0153 501 007 0153 501 009 0153 501 010 2,4-2,5 - #%&.
  • Page 24 - 24 -...

  • Page 25: Spare Parts List

    SPARE PARTS LIST Edition 2009-11-09 2 + , !*(;;,!>!! %# 528, %# %7 !*(;;,!>!+ %# 528, !*(;;,!>!* %# 528, !*(;;,!>!( %# 528, !*(;;,!>!; %# 528, !*(;;,!>!> %# 528, %# %7 !*(;;,!> %# 528, 8:1 %# ? 0= !*(;;,!> + %# 528, 8:1 %# ? 0= !*(#(#+>!! %# 5? 8...
  • Page 26 Item Ordering no. Denomination Notes 0457720900 Welding head with PEK and A6 PAV A6 SFE2 0334549880 Swivel Bracket 0334333884 Motorised Slide A6 Slide (L=300), see separate manual 0334557880 Mounting bracket 0278300180 Insulator 200 V 0154465880 Slide manually operated L = 90 0671171580 Angular slide 0145063906...
  • Page 27 Item Ordering no. Denomination Notes >+ !**>*>$$$! >* !*#!>!$$>, - 27 - *(;;,!
  • Page 28 Item Ordering no. Denomination Notes 0457720904 Welding head A6 SFE2 0334549880 Swivel bracket 0334557880 Mounting bracket 0278300180 Insulator 0154465880 Slide manually operated L = 90 0671171580 Angular slide 0145063906 Motor with gear A6 VEC (156:1), see separate manual 0145063896 Motor with gear A6 VEC (156:1), see separate manual 0147639880 Wire straightener (right mounted)
  • Page 29 Item Ordering no. Denomination Notes 0460504880 Control box PEK, see separate manual 0461239883 Cable (arc voltage) 0457713001 >+ !**>*>$$$! >* !*#!>!$$>, - 29 - *(;;,!
  • Page 30 Item Ordering no. Denomination Notes 0457720907 Welding head with PEK A6 SFE2 0334549880 Swivel bracket 0334557880 Mounting bracket 0278300180 Insulator 0154465880 Slide manually operated L = 90 0671171580 Circular slide 0145063906 Motor with gear A6 VEC (156:1), see separate manual 0145063896 Motor with gear A6 VEC (156:1), see separate manual...
  • Page 31 Item Ordering no. Denomination Notes 0457713001 Junction box complete >+ !**>*>$$$! Encoder cable >* !*#!>!$$>, - 31 - *(;;,!
  • Page 32 Item Ordering no. Denomination Notes 0457720911 Welding head with PEK, A6 GMH A6 SFE2 0334549880 Swivel bracket 0334333884 Motorised Slide A6 Slide (L=300), see separate manual 0334557880 Mounting bracket 0278300180 Insulator 200 V 0154465880 Slide manually operated L = 90 0671171580 Angular slide 0145063906...
  • Page 33 Item Ordering no. Denomination Notes 0461239883 Cable (arc voltage) 0460884880 Joint tracking equipment A6 GMH, see separate manual 0457713001 >+ !**>*>$$$! >* !*#!>!$$>, - 33 - *(;;,!
  • Page 34 Item Ordering no. Denomination Notes 0456563900 Welding head A6 SGE1 0145063909 Motor with gear A6 VEC (74:1), see separate manual 0460907892 Cable L= 3 m 0218810183 Handwheel 0147639880 Wire straightener (right mounted) 0030465385 Connector 0148493001 Cable holder 0461238880 Solenoid valve with cable 0147336880 Hose connection 0461239883...
  • Page 35 - 35 - *(#(#+...
  • Page 36 Item Ordering no. Denomination Notes 0456563902 Welding head A6 SGE1 0145063909 Motor with gear A6 VEC (74:1), see separate manual 0460907892 Cable L= 3 m 0218810183 Handwheel 0147639880 Wire straightener (right mounted) 0030465385 Connector 0148493001 Cable holder 0461238880 Solenoid valve with cable 0147336880 Hose connection 0146967880...
  • Page 37 - 37 - *(#(#+...
  • Page 38 Item Ordering no. Denomination Notes 0456563904 Welding head A6 SGE1 0278300180 Insulator 2000 V 0145063909 Motor with gear A6 VEC (74:1), see separate manual 0460907892 Cable L= 3 m 0218810183 Handwheel 0147639880 Wire straightener (right mounted) 0030465385 Connector 0148493001 Cable holder 0461238880 Solenoid valve with cable 0147336880...
  • Page 39 Item Ordering no. Denomination Notes 0671171580 Angular slide 0334333884 Motorised slides A6 Slide (L=300), see separate manual 0146967880 Brake hub 0334318880 Reel holder, straight 0461239883 Cable (arc voltage) 3.0 m 0457713001 Junction box complete >+ !**>*>$$$! Encoder cable >* !*#!>!$$>, - 39 - *(#(#+...
  • Page 40 Item Ordering no. Denomination Notes 0456563907 Welding head A6 SGE1 0278300180 Insulator 2000 V 0145063909 Motor with gear A6 VEC (74:1), see separate manual 0460907892 Cable L= 3 m 0218810183 Handwheel 0147639880 Wire straightener (right mounted) 0030465385 Connector 0148493001 Cable holder 0461238880 Solenoid valve with cable 0147336880...
  • Page 41 - 41 - *(#(#+...
  • Page 42 Item Ordering no. Denomination Notes 0456564900 Welding head with PEK A6 SGE1 0460504880 Control box PEK, see separate manual 0456563901 Welding head 0456564901 Welding head with PEK A6 SGE1 0460504880 Control box PEK, see separate manual 0456563902 Welding head 0456564902 Welding head with PEK A6 SGE1 0460504880...
  • Page 43 Item Ordering no. Denomination Notes 0456564904 Welding head with PEK and A6 PAV A6 SGE1 0460504880 Control box PEK, see separate manual 0456563905 Welding head 0461241880 Motor cable 2.0 m 0460697880 Control system for motorised slides A6 PAV, see separate manual ! >!+ + !( >&...
  • Page 44 Item Ordering no. Denomination Notes 0456564906 Welding head with PEK and A6 GMH A6 SGE1 0460504880 Control box PEK, see separate manual 0456563907 Welding head 0461241880 Motor cable 2.0 m 0460884880 Joint-tracking equipment A6 GMH, see separate manual ! >!+ + !( >&...
  • Page 45 Item Ordering no. Denomination Notes 0416967880 Welding head A6 Compact 500 (A6-SFE1C) 0278300180 Insulator 2000 V. 0334333880 Motorised slide A6 Slide (l=60), see separate manual 0153856884 Flux hopper with flux valve 0254900880 Flux funnel 0145063896 Motor with gear A6 VEC (4000rpm, 156:1), see separate manual 0449253882 Cable unit L =5...
  • Page 46 Item Orderingno. Denomination Remarks 0154465880 Slide, manually operated L=90 0154464001 Slide frame 0154463880 Carriage with slide rails 0190509485 Stop screw M10x10 0154458001 End piece 0211102957 Roll pin D5x20 0154461001 Lead screw 0190531201 Ball bearing SKF 3201 0154456001 Lock nut 0154457001 Ball bearing cap 0334537001 Handle crank...
  • Page 47 Item Orderingno. Denomination Remarks 0671171580 Angular slide 0232601901 Housing (casing) 0232303101 Worm wheel 0040644080 Worm screw 0215401206 Locking washer 0215401306 0218522301 Eccentric bushing 0215100204 Washer D36/13x6 0212101628 Screw M12x30 0212911101 Screw 0212204346 Stop screw M5x12 - 47 - #; ; (...
  • Page 48 Item Ordering no. Denomination Notes 0147639880 Wire straightener(right mounted) 0156449001 Clamp 0215503601 Insulating sleeve 0156530001 Clamp half 0212900001 Spacer screw 0215201209 Sealing, O-ring D11.3x2.4 0218400801 Pressure roller arm 0218810181 Handwheel, insulated 0218810182 Handwheel, insulated 0332408001 Stub shaft 0153148880 Pressure roller 0415498001 Pressure roller, upper 0212902601...
  • Page 49 Item Ordering no. Denomination Notes 0147639889 Wire straightener(right mounted) A6 S COMPACT 500 (A6 SFE1C) 0156449001 Clamp 0215503601 Insulating sleeve 0212900001 Spacer screw 0215201209 OSealing, O-ring 11,3x2,4 0218400801 Pressure roller arm 0218810181 Insulated hand wheel 0218810182 Insulated hand wheel 0332408001 Stub shaft 0153148880 Pressure roller...
  • Page 50 Item Orderingno. Denomination Remarks 0334290880 Contact equipment single wire 0417959880 Contact jaw tube L=220 0153299880 Flux nozzle complete - 50 - ++*,>!
  • Page 51 5$66 " + #%& !* ;>(>$$ <B,;( ! (+,>>$$! - 51 - ++*,>!
  • Page 52 Item Ordering no. Denomination Notes 0417959880 Contact jaw tube L = 220mm 0443344880 Contact tube L = 220 mm 0443372001 Fitting bolt 0219504307 Cup spring d20/10.2, T=1.1 0417979001 Ring $ !75&566! " + 9 7& !**++;,!! !, >(!*+!; ,!& ! ,1 B !* ;>;>!! !**++**$$ <...
  • Page 53 Item Ordering no. Denomination Notes 0153299880 Flux nozzle complete 0153290002 Holder for flux pipe 0153296001 Flux pipe, bent 0153425001 Wheel - 53 - (+,>>...
  • Page 54 Item Orderingno. Denomination Notes Solenoid valve with cable $ ! %666$ 9 * $ : ; ! (;,(>!! Cable !,#,# ,$!, !1;( Cable !,#,# ++,> ,6!1;( Solenoid valve ! >+!(*!!, Bushing ! >*,#>!!, - 54 - *# ,+$...
  • Page 55 Item Orderingno. Denomination Remarks 0147649881 Flux hopper (complete) 10 l 0154007001 Hopper for flux 0148837001 Window 0153347880 Flux valve 0020301780 Flux strainer 0443383002 Flux hose L=500 - 55 - *;#*>...
  • Page 56 Item Ordering no. Denomination Notes 0153856884 Flux hopper without flux valve 0810153001 Holder 0153856780 Flux hopper, joint details 0153347880 Flux valve 0153856780 Flux hopper, joint details 0153853001 Flux hopper 0153854001 Pipe 0153855001 Filter - 56 - (+$(#...
  • Page 57 Item Ordering no. Denomination Notes 0153347880 Flux valve 0153348001 Outlet 0153349001 Shaft 0211102938 Roll pin d 3x20 - 57 - (++*;...
  • Page 58 Item Ordering no. Denomination Notes 0030465385 Connector 0145226001 Insulating sleeve 0190 680313 O-ring OR 15.3x2.4 0190680303 O-ring OR 5.3x2.4 0190680405 O-ring OR 22.2x3 0334278880 Insert tube 0334279001 Spiral 0146094001 Extension 0145534882 Contact tube 0145227882 Gas nozzle 0144998882 Water hose L = 180 - 58 - !!+!*#(...
  • Page 59 - 59 -...
  • Page 60 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna-Liesing Sofia Shanghai Fax: +47 33 11 52 03 Tel: +43 1 888 25 11...

This manual is also suitable for:

A6s g masterA6s compact 500

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