Valid for serial no. 452--xxx--xxxx0443 403 001 2006--03--24
A6 GMD
112101103105107109111102021110025108024042106023061104022041100020040060001
Fogföljningsutrustning
Fugestyringsudstyr
Fugefølgingsutstyr
Railonseurantalaite
Joint tracking equipment
Nahtverfolgungsausrüstung
Equipement pour suivi de joint
Lasnaadvolguitrusting
Equipo de seguimiento de costuras
Dispositivo di guida lungo il lembo
Equipamento de acompanhamento de juntas
Åîïðëéóìüò ðáñáêïëïýèçóçò ñáöÞò
óõãêüëëçóò
System ¶ledzeni a spoiny
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Instrukcja obs³ugi
-- 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.
SVENSKA 4..............................................
DANSK 20................................................
NORSK 36................................................
SUOMI 52................................................
ENGLISH 68..............................................
DEUTSCH 84.............................................
FRANÇAIS 100.............................................
NEDERLANDS 116.........................................
ESPAÑOL 132..............................................
ITALIANO 148..............................................
PORTUGUÊS 164..........................................
ÅËËÇÍÉÊÁ 180.............................................
POLSKI 196.................................................
-- 3 --
ENGLISH
-- 6 8 --
TOCe
1SAFETY 69...........................................................
2 INTRODUCTION 71...................................................
2.1 General 71..................................................................
2.2 Technical data 71............................................................
2.3 MAIN COMPONENTS 72.....................................................
3 INSTALLATION 76....................................................
3.1 General 76..................................................................
3.2 Installation and connection 76..................................................
3.3 Adjustment of joint tracking equipment 76.......................................
3.4 Adjusting the sensor voltage 77................................................
4 OPERATION 79.......................................................
4.1 General 79..................................................................
4.2 Joint tracking 79.............................................................
4.3 Positioning before weld start 82................................................
5 MAINTENANCE 83....................................................
5.1 General 83..................................................................
5.2 Wear components 83.........................................................
6 ORDERING OF SPARE PARTS 83......................................
DIMENSION DRAWING 212................................................
SPARE PARTS LIST 217...................................................
-- 6 9 --
SafE
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.
GB
-- 7 0 --
SafE
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 take fumes and gases away 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 s uitable 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 earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB
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2 INTRODUCTION
2.1 General
A6 GMD joint tracking equipment is designed to allow positioning and joint tracking
with automatic welding equipment on all types of joints that have a guide edge which
the tracking finger can follow. The equipment is designed for ESAB standard servo
slides and can control one or two servo motors simultaneously.
2.2 Technical data
Joint tracking equipment A6 GMD
Control and operating voltage 42V AC 50--60 Hz
Power requirement 460 V A
Motor regulator type Switched four--quadrant
Stator voltage, joystick control 40 V DC
Field voltage, separately excited motor 48 V DC
Enclosure type IP 23
Max. ambient temperature +45_ C
Weights:
Sensor and cross--slide with mounting 2,2 kg
Joint tracking unit 4.5 kg
T racking finger 0.6 kg
Remote control unit 2,0 kg
Working range sensor, radially 360_ 4mm
For working range and welding speed see the graph below and the
instruction m anual 0334 346 xxx for the A6 Servo slide.
Standard ratio
Alternate ratio
Angular deviation, degrees
Welding speed cm/min
Graph showing maximum angular deviation of weld joint in relation to set welding
speed.
GB
-- 7 2 --
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2.3 MAIN COMPONENTS
1. Sensor
2. Control cable (2 m)
3. Cross slide for sensor
4. Control unit
5. Joint tracking unit
6. Tracking finger
If used with a column and boom the above control unit and control cable are re-
placed by components specific to the application.
GB
-- 7 3 --
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2.3.1 Sensor
1. Sensor with connection for cable from joint tracking unit and with mounting for
various tracking fingers at front.
2. Tr acking fingers
3. Stop screws, 2 for adjustment of finger movement in horizontal axis. Screws
allow adjustment for various types of joint.
2.3.2 Control unit
1. Indicator lamp, red
Lamp for joint tracking system.
Lights up when tracking finger is
outside working area (vertically).
Automatic operation cuts out.
2. Pushbutton with lamp, orange
High speed selector for manual
operation.
3. Control lever
Manual operation of servo slides
up/down and left/right.
Control lever always has priority.
When warning lamp is extinguished
manual movement downwards is
prevented.
4. 5 position switch
Choice of joint tracking and
joint searching options:
S Manual preset
S Vertical and horizontal joint tracking
S Vertical and horizontal joint tracking with joint searching to right
S Vertical and horizontal joint tracking with joint searching to left
S Vertical joint tracking
5. Indicator lamp, green
Indicates the power is on.
GB
-- 7 4 --
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2.3.3 Joint tracking unit -- rear section
1. Socket, 4 pin.
for connection of horizontal slide motor
2. Socket, 4 pin.
for connection of vertical slide motor
3. Socket, 8 pin.
for connection of tracking finger
4. Socket, 23 pin.
for connection of control unit
5. Connection 42 V
6. Control fuses, 10 A slow (1)
7. Switch
for changing direction of travel of horizontal slide
8. Socket, 3 pin.
for joint memorising equipment (MEMO)
9. Switch
Supply voltage on/off
10. Spare socket
11. Socket, 8 pin.
for connection of limit switch
Component location:
GB
-- 7 5 --
fga9d1ea
Accessories for A6 GMD
S Finger with ball, order no. 416 719 --001 (L=100 mm)
S F inger with ball, order no. 416 719-- 002 (L=150 mm)
S Finger for inside and outside corners, order no. 418 091--880
S Transformer for separate power supply, from mains
190, 220, 380, 415, 440, 500V 50 Hz
200, 230, 380, 415, 440, 500V 60 Hz to secondary 42V, 660 VA
order no. 148 636--002
S Cable 3 x 2,5 mm
2
, for connecting transformer, order no. 2626 134--04
S Sensor cable with 90_--connector (2 m), order no. 417 346-- 887
S Rubber protective bellows, order no. 412 013--001
S Console for control unit order no. 433 762--xxx. Various versions available.
ESAB standard servo slides for A6 GMD
S A6 servo slide, ball bushing type with permanent magnet motor 42 V DC, see
instruction manual 0334 333 xxx.
S A6 motorised slide, long runners with sliding bearings, with A6 VEC motor
S 42V -- 4000 rpm, ratio 74:1, see instruction manual 0334 426 xxx.
S M o tor cable, order no. 417 310--xxx. Cable available in various lengths, see
relevant sales brochure for servo slide. (Contact your ESAB sales office).
GB
-- 7 6 --
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3 INSTALLATION
3.1 General
The installation must be executed by a p rofession al.
3.2 Installation and connection
1. Dimensions, see the dimension drawings on pages 212-- 215.
2. Connection, see on page 72.
3. Check that a power supply of the correct voltage and current rating is available
for the installation.
S If any of the LAE 800 -- 1000 -- 1250 -- 1600 power sources is used, and it is
wired for a control voltage of 42 V, the necessary supply may be taken from
the standard machine, see PEG socket.
S If a suitable supply is not available or if the LAH 500--630 42 V power supply
is used, a separate power supply must be installed using the 42 V
transformer for the A6 GMD, see ”Accessories for A6 GMD” on page 75.
4. Fit the guide finger parallel to the motor--driven cross saddle.
5. Control device, see the drawing on page 73.
3.3 Adjustment of joint tracking equipment
NOTE! If the sensor is replaced, the joint tracking unit, order no. 416 066--880
must be calibrated for the sensor supplied, order no. 416 688--880.
NOTE! If this calibration is not carried out on installation the joint tracking
performance may be severely impaired and may result in mechanical damage
to the tracking device and connector due to collision with the work piece.
GB
-- 7 7 --
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3.4 Adjusting the sensor voltage
1. Remove the front panel from the joint tracking unit.
2. If there is insufficient space to carry out measurements the regulator card can be
removed from the top of the joint tracking box.
3. Connect a voltmeter to m eter terminal TP1--TP0, (marked on circuit board).
4. The selector switch on the remote control should be set for vertical
movement .
5. Using the remote control, move the vertical slide downwards with the sensor
attached until the tip of the finger touches a flat horizontal surface, so that the
warning lamp on the remote control goes out.
6. Move the tip of the finger to one side as far as it will go.
7. Read the voltmeter and adjust using potentiometer
R20 to 1.8 +/-- 0.6 V. See diagram. Potentiometer
R32 must not be moved.
8. Fit the sensor to give the smallest possible angle
between the longitudinal axis of the sensor and the
welding joint, less than 35˚ in both horizontal and
vertical axes, see the dimension drawings on pages
212--215.
9. The sensor should be fitted so that the front tracking finger
mounted on the universal joint points down towards the weld joint or towards the
edge to be followed. This applies to all joint types even when fillet welding with
the welding head at an angle.
The sensor must not be rotated from this position more than ±3˚ in relation to the
axes of the cross slide.
Any significant deviation to one side or the other may impair the tracking
function, see the dimension drawings on pages 212--215.
GB
-- 7 8 --
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10. The equipment includes a mounting device with dual insulation for mounting the
sensor next to a welding machine connector of the type D20 or D35. This allows
coarse adjustment of the sensor in the welding direction, height and angle
around the connector using the two locking levers.
IMPORTANT! The distance B between the steel clip A and
current--carrying components must be at least 5 mm to avoid electric contact.
11. The mini cross--slide is used for precise adjustment of the electrode tip in the
joint. It also allows adjustment of the distance between the electrode tip and the
tip of the tracking finger. Play can be eliminated from the cross slide by adjusting
the stop screws on the runners.
12. Make sure the sensor is functioning correctly.
Proceed as follows:
S Set the selector switch to .
S Use the control lever to lower the vertical slide towards a flat surface until the
tip of the tracking finger just touches it. Stop when the red warning lamp
goes out.
S Grip the tip of the tracking finger and move it to one side or the other.
If the system is working correctly the horizontal slide m otor should start and follow in
the same direction as the tracking finger is moved.
If this does not happen -- reset the selector switch on the control unit marked .
13. The tips of the tracking fingers are straight when supplied, but can be modified
by the customer to suit a certain type of joint, or be replaced with a different
version or shape, see ”Sensor” on page 73 and ” Accessories for A6 GMD”on
page 75.
GB
-- 7 9 --
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4 OPERATION
4.1 General
General safety regulations for the handling of the equipment can be found on
page 69. Read through before you start using the equipment!
4.2 Joint tracking
The joint tracking equipment can be set for various methods of joint tracking. It can
be set for joint tracking with edge guidance, or for joint tracking with slot guidance.
Adjustment is carried out on the control unit and the sensor.
4.2.1 Joint tracking with edge guidance
Select either or on the control unit depending on whether you want left or
right edge guidance. On the sensor the two stop screws should be screwed in as far
as they will go. See the diagram below. The search fingers are now spring--loaded to
the side to allow edge guidance. Joint tracking with edge guidance is used when
welding fillet welds and similar joints. For more information, see on page 80.
Stop screws fully tightened
4.2.2 Joint tracking with slot guidance
Select either or depending on whether you want control over height and
transverse position, or just height. The stop screws on the sensor must be
unscrewed:ehp. at least two turns or as far as they will go, see the diagram below.
This releases the transverse spring--pressure on the search fingers and permits slot
guidance. If the stop screws are not unscrewed there is a risk that the search fingers
will ”climb” out of the joint in shallow V or U joints. For more information refer to the
joint table on page 80 for choice of setting.
Stop screws unscrewed 2 turns
GB
-- 8 0 --
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Examples of various types of joint and the tracking finger setting against the guiding
edge.
Joint type Setting,
control unit
Double flange butt joint
I--weld (A=guide)
V--weld
1/2 V--weld
1/2 V--weld
U--weld
Double U--weld
J--weld
Double J--weld
GB
-- 8 1 --
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X--weld
Asymmetrical X--weld
K--weld
K--weld
Fillet weld
GB
-- 8 2 --
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4.3 Positioning before weld start
1. Position the equipment relative to the weld so that the working area of the cross
slide covers the full height and width of the joint from start to finish.
2. Set the selector switch (4) to the desired joint tracking setting and lower the
tracking finger using the control lever (3),until the indicator lamp (1) goes out.
3. GMD will now search for the zero setting and position the contact tip in the joint.
Adjust the position as necessary using the cross slide.
GB
-- 8 3 --
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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.
S Check the tracking fingers daily for wear or damage.
S Clean the sensor regularly using compressed air.
S Follow the instructions for individual components.
S Adjustment of the system is descr ibed in ”Adju stment of joint tracking
equipment” on page 76.
5.2 Wear components
Tracking fingers
Order no. 146 586--001
6 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 217.
This will simplify dispatch and ensure you get the right part.
GB
ESAB AB
SE--695 81 L AXÅ
SWEDEN
Phone +46 584 81 000
www.esab.co m
041227
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 2 745 11 28
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: +49 212 298 218
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 2485 377
Fax: +31 30 2485 260
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
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 2191 4333
Fax: +55 31 2191 4440
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 57 48
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 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 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Shah Alam Selangor
Tel: +60 3 5511 3615
Fax: +60 3 5512 3552
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
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:+70959379820
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel:+78123254362
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.co m
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