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.
SPARE PARTS LIST207...................................................
TOCe
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1DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that automatic welding machine A6 SFE1 / A6 SFE2 / A6 SGE1/ A6 SFE1C from
serial number 740 complies with standard EN 60292, in accordance with the requirements of directive (89/392/EEA) and addendum.
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDENTel: + 46 584 81000Fax: + 46 584 12336
2SAFETY
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 recommendations 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.
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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 MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3INTRODUCTION
3.1General
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 A2--A6 Process Controller and ESAB’s welding power sources LAF and T A F.
The welding head can be positioned horizontally and vertically with the linear slides.
The angular position is adjusted with the angular slide.
3.2Definitions
SAW weldingThe weld bead is protected by a cover of flux during the
welding.
SAW Heavy dutyPermits welding with high current load and thick wire.
SAW Light dutyPermits welding with low current load and thin wire.
MIG/MAG weldingThe weld bead is protected by shielding gas during wel-
ding.
Tandem weldingWelding with two welding heads.
Twinarc weldingWelding with two wires in the same welding head.
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3.3Technical data
A6 SFE1A6 SFE1A6 SFE2A6 SGE1A6 SFE1C
UPUPUPMIG/MAGUP
LD D20HD D35HD D35
Rated load100%
60 %
Wire dimensions:
solid single wire1.6--4.0 mm3.0--6.0 mm3.0--6.0 mm0.8--2.5 mm-- 4 . 0 m m
flux--cored wire1.6--4.0 mm3.0--4.0 mm--1.2--3.2 mm-twin wire2x1.2--2.0 mm2x2.0--3.0mm2x2.0--3.0mm----
Weight (flux and wire excluded)50 kg50 kg100 kg15 kg50 kg
Sideways tilt, max.25_25_25_25_25_
Setting length of slide *
manual
motor--driven (with ball bearings)
Continuous A--weighted noise pressure
800 A
1000 A
AC/DC
10 l10 l10 l--1l
210 mm
300 mm
68 dB68 dB68 dB83 dB68 dB
1500 A
--
AC/DC
210 mm
300 mm
1500 A
--
AC/DC
210 mm
300 mm
600 A
--
AC/DC
210 mm
300 mm
1500 A
--
AC/DC
60 mm
*) NB! Other lengths on request.
3.4Welding method
Submerged arc welding (SAW)
For SAW welding the A6 SF welding head is always used. It is available in the
following designs:
SSubmerged--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%).
SSubmerged--arc Heavy duty
Submerged--arc heavy duty, with a ∅ 35 mm connector, which permits a load of
up to 1500 A.
Both versions 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 r isk of deformation due to high feed pressure.
For work in confined spaces, (smaller than 50 cm), a special welding head of type
A6 SFE1C is available, which can be installed on the Mastertrac as required.
Tandem welding (submerged--arc)
For tandem welding, a welding head of type A6 SFE2 is always used, which must be
connected to 2 welding power sources and 2 control boxes of type A2 --A6 Process
Controller.
The tandem welding head includes 2 single welding heads (A6 SF), each with its
own contact tip. Each contact tip has a m aximum rated load of 1500 A.
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MIG/MAG welding
For MIG/MAG welding the A6 SG welding head is always used, permitting a max.
load of 600 A. The welding head is water--cooled, with the cooling water supplied by
hoses from connections intended for the purpose.
3.5Equipment
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 contact.
Contact equipment is available in several different versions.
SA6 SF is used for submerged--arc welding.
SA6 SG is used for MIG/MAG welding.
Example -- A6 SFE1 and A6 SFE2
1Straightener.
2Contact equipment which consists of a
contact tip, connector and flux tube.
3Angular slide
4Slide (motor--driven or manually operated)
5Motor and gearbox (A6 VEC)
6Wire drum
7Flux hopper (may be fitted with a cyclone)
Example -- A6 SGE1
1Straightener.
2Contact equipment which consists of a
connector, gas nozzle and water hoses.
3Angular slide.
4Slide (motor--driven or manually operated)
5Motor and gearbox (A6 VEC).
6Wire drum.
7Fine--wire straightener (Accessories).
8Wire guide.
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Example of the A6 SFE1C
1Straightener.
2Contact equipment, which consists of a contact tip, connector and flux tube.
3Slide (motor--driven).
4Motor and gearbox (A6 VEC).
5Flux hopper (1 l).
Connection instructions for SAW and MIG/MAG welding appear from the system diagram on page 69.
4INSTALLATION
4.1General
Installation shall only be performed by qualified personnel.
WARNING
Rotating parts can cause injury, take great care.
4.2Mounting
The automatic welding machines can easily be fitted with 4 screws M 10x40 on a
rail--borne carriage or on a column and boom unit.
4.3Connections
1.The connection of the A2--A6 Process Controller (PEH) to the welding machine
shall be done according to the connection instructions in the A2--A6 Process
Controller (PEH) service manual.
For further information, see instruction manual for the A2--A6 Process Controller
(PEH).
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2.Connect the A6 welding heads as follows:
SUBMERGED ARC WELDING (SAW)
SConnect the control cable (7) between the welding power source (8) and the
A2--A6 Process Controller (PEH) (2).
SConnect the return cable (11) between the welding power source (8) and the
work piece (9).
SConnect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
SConnect the measuring cable (12) between the welding power source (8)
and the work piece (9).
GAS METAL ARC WELDING (MIG/MAG)
SConnect the control cable (7) between the welding power source (8) and the
A2--A6 Process Controller (PEH) (2).
SConnect the return cable (11) between the welding power source (8) and the
work piece (9).
SConnect the welding cable (10) between the welding power source (8) and
the automatic welding machine (1).
SConnect the gas hose (5) between the reduction valve (6) and the gas valve
on the automatic welding machine (13).
SConnect the hoses for cooling water (3) between the cooling unit (4) and the
automatic welding machine (1).
SConnect the measuring cable (12) between the welding power source (8)
and the work piece (9).
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5OPERATION
5.1General
General safety regulations for the handling of the equipment can be found on
page 64. Read through before you start using the equipment!
SSelect wire type and flux or shielding gas so that the weld material is as close as
possible to the analysis of the base metal. Select wire size and welding data in
accordance with the values recommended by the welding materials supplier.
SThorough preparation of the weld surfaces is necessary to achieve a good weld.
NOTE! The width of the weld joint gap must be uniform.
STo minimise the risk of heat crack formation, the width of the weld must be
greater than the penetration depth.
SAlways carry out a test weld with the same joint type and sheet thickness as the
production work piece.
SFor control and adjustment of the automatic welding machine and welding power
supply, see the instruction manual for the A2--A6 Process Controller (PEH).
SFor replacement of wear parts, see table on page 204.
5.2Starting work
Loading the welding wire
SRemove the wire drum (1) from the brake hub (2)
and take off the side plate (3).
SLocate the wire reel on the wire drum (1).
SCut off the binding wires from around the
wire reel.
SFit the side plate (3).
SFit the wire drum (1) on the brake hub (2).
Check that the carrier (4) is in the correct position.
NOTE! The maximum angle for the wire bobbin is 25°.
At extreme angles, wear will occur on the brake hub locking
mechanism and the wire bobbin will slide off the brake hub.
WARNING
To prevent the r eel sliding off the hub:
S
Lock the reel in place by turning the red knob as shown
on the warning label attached next to the hub.
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SCheck that the feed roller (1) and contact jaw or contact tip
(3) are of the correct dimension for the selected wire size.
SPull 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.
SLocate the end of the wire in the feed roller (1) groove.
SSet the wire tension on the feed roller with the knob (7).
Note! Do not tension more than is required to achieve an
even feed.
SThe pressure screw (8) must not be dismantled. (Applies to
Submerged--arc Heavy duty).
SFeed the wire forward 30 mm by pressingon the
control box A2--A6 Process Controller.
SDirect the wire by adjusting the knob (6).
For fine wire, the special fine wire straightener (4) is used
for both single and twin wire.
Ensure that the straightener is correctly adjusted so that the
wire emerges straight out through the contact jaws or
contact tip.
SAW
MIG/MAG
Always use a guide tube (5) to ensure even feeding of fine
wire (1.6 -- 2.5 mm).
For MIG/MAG welding with wire sizes < 1.6 mm, use a
guide spiral, which is inserted in the guide tube (5).
Changing the feed roller
SSingle wire
SRelease the knobs (3) and (4).
SRelease the hand wheel (2).
SChange the feed roller (1). The rollers are marked with
their respective wire sizes.
STwin wire (Twin--arc)
SChange the feed roller (1) with twin grooves in the same way as for single
wire.
SNOTE! The pressure roller (5) must also be changed. A special spherical
pressure roller for twin wire replaces the standard pressure roller for single
wire.
SAssemble the pressure roller with special stub shaft
(order no. 146 253--001).
SFlux--cored wire (for knurled rollers)
SChange the feed roller (1) and pressure roller (5) in pairs for the wire size to
be used. NOTE! A special stub shaft is r equired for the pressure roller
(order no. 0212 901 101).
STighten the pressure screw (4) with moderate pressure to ensure that the
flux--cored wire does not deform.
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Contact equipment for submerged--arc welding
SFor single wire 3.0 -- 4.0 mm. Light duty (D20)
Use the straightener (3), connector (1) D20 with contact tip (2)
(M12 thread).
STighten the contact tip (2) with a key in order to ensure
that a good contact is achieved.
SFor single wire 1.6 -- 2.5 mm Submerged--arc.
Light duty (D20)
Use the straightener (3), connector (1) D20 with contact
tip (2) (M12 thread) and separate fine wire straightener (4)
with guide tube (6).
SFit the clamp (7) with guide tube (6) in the M12 hole on
the straightener (3). The guide tube (6) should bottom
on the contact tip (2).
SIf necessary, cut the guide tube (6) to length so that the
feed roller ( 5) runs freely.
SFit the fine wire straightener (4) on the upper side of the
clamp for the straightener (3).
SFor single wire 3.0 -- 6.0 mm. Heavy duty (D35)
Use the straightener (3), connector (1) D35 with contact
jaws (2).
SFit one of the contact jaws with the M5 bolts provided, in
the fixed contact tip (a).
SFit 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.
SFor flux--cored wire 1.6 mm -- 4.0 mm (D20 and D35) (Accessories)
If contact jaws (D35) are used, the contact jaws must not be tightened too hard
in order that the flux--cored wire is not deformed. Ensure that good contact is
achieved with the wire.
SAdjustment of the wire for tandem welding
SThe distance between the first and second wire must not be so great that the
slag gets time to solidify between the wires.
SEnsure that good flux coverage is achieved between the first and second
Use the straightener (3), connector (1) D35 with twin
adapter (9) and 2 contact tips (2) (M6 threads) and separate
fine wire straightener (4) with two guide tubes (6). For twin
wire < 1.6 mm, insert a guide spiral into each guide tube.
SFit the twin adapter (9) for M6 contact tips (2) with the
M5 bolts in the fixed half of the two--piece connector
(1).
SFit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube should
bottom on the twin adapter (9) for the contact tip (2).
STighten the contact tip (2) with a key to ensure that a
good contact is achieved.
SIf necessary, cut the guide tube (6) to length so that the
feed roller ( 5) runs freely.
SAdjustment of the wires for Twin--arc welding:
SPosition the wires in the joint so as to achieve optimal weld quality by
rotating the connector. The 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 e ach side of the joint.
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Contact equipment for MIG/MAG welding.
SFor single wire 1.6 -- 2.5 mm (D35)
Use the straightener (3), connector (1) D35 with contact
tip (2) (M10 thread).
STighten the contact tip (2) with a key to ensure that a
good contact is achieved.
SFit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube (6) should
bottom on the contact tip (2).
SIf necessary, cut the guide tube (6) to length so that the
feed roller ( 5) runs freely.
SFor single wire < 1.6 mm (D35)
Use the straightener (3), connector (1) D35 with contact tip (2)
(M12 thread), fine wire straightener (4) with guide tube (6)
and guide spiral, which is inserted in the guide tube (6).
SFit the clamp (7) with guide tube (6) in the M12 hole on
the standard straightener (3). The guide tube (6) should
bottom on the contact tip (2).
SIf necessary, cut the guide tube (6) to length so that the
feed roller ( 5) runs freely.
SFit the fine wire straightener (4) on the upper side of the
clamp for the straightener (3).
SConnect the cooling water and gas (MIG/MAG welding).
Filling o f flux ( Sub merged arc welding)
SClose the flux valve on the flux hopper.
SRemove the cyclone on the flux recovery unit, if fitted.
SFill with flux . NOTE! The flux must be dry. If possible, avoid using agglomerating
flux outdoors and in a damp environment.
SPosition the flux tube so that the flux hose does not become kinked.
SAdjust the height of the flux nozzle above the weld so that the correct amount of
flux is delivered.
The flux coverage should be high enough to prevent the arc from burning
through.
5.3Conversion of A6 SFE1 (Submerged arc welding) to MIG/MAG
welding
Assemble the conversion kit according to the instructions provided.
5.4Conversion of A6 SFE1 / A6 SFE2 (Submerged arc welding) to
Twin--arc
Assemble the conversion kit according to the instructions provided.
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6MAINTENANCE
6.1General
NB! Before doing any kind of maintenance work, make sure the mains is discon-
nected.
For the maintenance of the A2--A6 Process Controller (PEH), see the instruction
manual.
6.2Daily
SClean flux and dirt off moving parts of the welding machine.
SCheck that the contact tip and all electric cables are connected.
SCheck that all bolted joints are tight and that guides and drive rollers are not
worn or damaged.
SCheck 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.
Adjusting the braking torque:
SSet the locking button (2) to the
locked position.
SInsert a screwdriver into the hub
springs.
STurning the springs (1) clockwise
reduces the braking torque.
STurning the springs anticlockwise increases the torque.
NOTE! Turn the springs by the same amount.
6.3Regularly
SCheck the carbon brushes of the wire feed motor every three months. Replace
when they are worn down to 6 mm.
SCheck the slides and lubricate if they bind.
SCheck the wire guides, drive rollers and contact tip of the wire feed unit.
Replace any worn or damaged components, (see spare parts list on page 207).
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7FAULT TRACING
Equipment SInstruction manual for control box A2--A6 Process Controller.
SOperating manual for motor with gear A6 VEC,
order no. 0443 393.
CheckSthat the power source is connected for the correct mains supply
Sthat all three phases are live ( phase sequence is not important)
Sthat welding cables and connections are not damaged
Sthat the controls are correctly set
Sthat the mains supply is disconnected before starting repairs
POSSIBLE FAULTS
1. SymptomCurrent and voltage readings show large fluctuations
Cause 1.1Contact jaws or nozzle are worn or wrong size.
ActionReplace contact jaws or nozzle.
Cause 1.2Feed roller pressure is too low.
ActionIncrease pressure on feed rollers.
2. SymptomWire feed is irregular
Cause 2.1Feed roller pressure not correct.
ActionChange the feed roller pressure.
Cause 2.2Feed rollers wrong size.
ActionReplace feed rollers.
Cause 2.3Grooves in feed rollers are worn.
ActionReplace feed rollers.
3. SymptomWelding cables overheating
Cause 3.1Poor electrical connection.
ActionClean and tighten all electrical connections.
Cause 3.2Cross--section of welding cables too small.
ActionUse cables with a larger cross--section or use parallel cables.
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 designation and spare part number as shown in the spare parts list on page 207.
This will simplify dispatch and ensure you get the right part.