ESAB A6S Compact 300 Instruction Manual
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ESAB A6S Compact 300 Instruction Manual

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A6S Compact 300
Instruction manual
0449 458 001 10-03-11
Valid for serial no. 440-xxx-xxxx

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Summary of Contents for ESAB A6S Compact 300

  • Page 1 A6S Compact 300 Instruction manual 0449 458 001 10-03-11 Valid for serial no. 440-xxx-xxxx...
  • Page 2 ENGLISH ..........Rights reserved to alter specifications without notice.
  • Page 3 " ! " $# % &' ( %& ) *" ! # $ ' & - # & $# " ' & " $ ( 1 2 ( 1 2 3 # )* #' ! + ' - 14 , !! ##, &' ( ' ( 5$ *# "...

  • 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

    INTRODUCTION 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.

  • Page 9: Main Components

    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.

  • Page 10: Installation

    INSTALLATION General The installation must be executed by a professional. WARNING Rotating parts can cause injury, take great care. 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.

  • Page 11: Adjusting The Brake Hub

    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.

  • Page 12: Connections

    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.

  • Page 13: Operation

    OPERATION 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.

  • Page 14: Loading The Welding Wire

    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.

  • Page 15: Changing The Feed Roller

    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. Filling with flux The flux container should be filled by connecting it to a pressurised flux tank (type TPC 75).

  • Page 16: Maintenance

    MAINTENANCE 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.

  • Page 17: Fault Tracing

    FAULT TRACING 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...

  • Page 18: Ordering Of Spare Parts

    0813620880 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.

  • Page 19: Dimension Drawing

    DIMENSION DRAWING *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. - 19 -...

  • Page 20: Wear Components

    WEAR COMPONENTS Feed rollers . / 0 1 . 0 & + Contact tip $& + & & + - 20 -...

  • Page 21: Spare Parts List

    SPARE PARTS LIST Edition 10-03-11 & !" !" - 21 -...
  • Page 22 Item Ordering no. Denomination Notes 0809280880 Welding head A6S Compact 300 0278300180 Insulator 2000 V 0334171001 Plate 0334170001 Clamping ring 0334172001 Gear bracket 0810252001 Bracket 0145063896 Motor with gear A6 VEC (156:1), see separate manual 0147639881 Straightener (left mounted) 0808974880...
  • Page 23 Item Ordering no. Denomination Notes 0809280881 Welding head A6S Compact 300 0278300180 Insulator 2000 V 0334171001 Plate 0334170001 Clamping ring 0334172001 Gear bracket 0810252001 Bracket 0145063897 Motor with gear A6 VEC (74:1), see separate manual 0147639881 Straightener (left mounted) 0808974880...
  • Page 24 Item Orderingno. Denomination Remarks 0147 639 881 Straightener (left mounted) 0156 449 001 Clamp 0215 503 601 Insulating sleeve 0156 530 001 Clamp half 0212 900 001 Spacer screw 0215 201 209 O-ring D11.3x2.4 0218 400 801 Pressure roller arm 0218 810 181 Handwheel 0218 810 182 Handwheel 0332 408 001 Stub shaft...
  • Page 25 - 25 -...
  • Page 26 Item Ordering no. Denomination Notes 0809273880 Slide stroke 50 mm 0809268001 Motor bracket 0809267001 Motor bracket 0809266001 Motor holder 0809275880 Motor with gear 2342-24cr 24v 8100 0809272001 Spacing tube 0808980001 Cross member 0808979001 Runner 0809274001 Ball bushing 0809271001 Ball screw drive nut 0809265001 Base plate 0808985001...
  • Page 27 - 27 -...
  • Page 28 Item Ordering no. Denomination Notes 0809333880 Flux hopper complete 0809332001 Flux hopper 0809338001 Net filter 0809337001 Filter holder 0809336880 Slide flange with pipe 0413937001 Cylinder 0367675001 Nippel - 28 -...
  • Page 29 Item Ordering no. Denomination Notes 0809289880 Wire guider 90 degrees 0191418089 Spacer sleeve 0809328001 Bushing 0809283001 0809330001 Roller bearing with groove 0809329001 Roller bearing 0809282001 0809288001 Spacing tube 0809325001 Bracket 0810282001 Wire lead attachment 0809331001 Guard plate 0810255002 Bracket - 29 -...
  • Page 30 Item Ordering no. Denomination Notes 0811176880 TV monitoring equipment Option 10 0810255001 Bracket 0811175001 Mounting plate 0811413880 Camera equipment with pressure guard 0811411880 Submerged arc welding Camera SAW C2 0453248880 Cooling air unit - 30 -...
  • Page 31 Item Ordering no. Denomination Notes 0811411880 Submerged arc welding Camera, complete SAW C2 0811383880 Screen-unit cpl. p1 0810517881 Submerged arc welding Camera (with cooling) 0811179003 Camera/ screen cable l=30m 0802713880 Halogen lighting 0810093880 Flexible arm - 31 -...
  • Page 32 Item Ordering no. Denomination Notes 0453248880 Cooling air unit 0451306001 Pressure switch 0.5/10 bar 0416898001 Pressure gauge 1/8” 0417163001 Regulator c 1104-r00 0417797009 Hose nipple d7-1/4” 0417851002 Bushing r1/2”r1/4” 0190343102 Hose d 12,7/6,3 0417851004 Bushing 1/2”-1/8” 0394791061 Double nipple r1/2-r1/4” 0416897003 Angular pipe 1/4”...
  • Page 33 Item Ordering no. Denomination Notes 0811177880 Laser lamp complete Option 20 0810255001 Bracket 0811175001 Mounting plate 0810093881 Flexible arm and attachment 0811174001 Laser lamp point llp-100 - 33 -...
  • Page 34 Item Ordering no. Denomination Notes 0811178880 Inductive joint tracking Option 30 0810255001 Bracket 0811175001 Mounting plate 0810093881 Flexible arm and attachment 0811052880 Inductive joint tracking 1 axis 12:1 0810876880 El. inductive joint tracking 12:2 0810860880 Inductive gauge - 34 -...
  • Page 35 Item Ordering no. Denomination Notes 0813620880 Pneumatic flux valve Option 40 0417859004 Magnetic valve 5/2-way 0417797008 Hose nipple D7-1/8” 0417792004 Nylon washer 1/8” 0190315104 Hose D12.5/6.4 0192238341 Allen screw steel 8.8 M5x50 0215100011 Washer BRB Steel 10/5.3x1 0417873001 Throttle valve with silencer - 35 -...
  • Page 36 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...

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