ESAB Frametrac User manual

Valid for serial no. 0607--xxx--xxxx0460 072 001 2006--05--08

Frametrac

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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

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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 5..............................................

DANSK 29................................................

NORSK 53................................................

SUOMI 77................................................

ENGLISH 101..............................................

DEUTSCH 125.............................................

FRANÇAIS 149.............................................

NEDERLANDS 173.........................................

ESPAÑOL 197..............................................

ITALIANO 221..............................................

PORTUGUÊS 245..........................................

ÅËËÇÍÉÊÁ 269.............................................

POLSKI 293.................................................

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FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sverige, försäkrar under eget ansvar att svetsauto-

mat Frametrac från serienummer 0607 är i överensstämmelse med standard EN 12100--2 och EN

60204--1 enligt villkoren i direktiv (73/27/EG) och standard EN 61000--2--2 samt EN 61000--6--3 enligt

villkoren i direktiv (89/336/EEG).

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OVERENSSTEMMELSEERKLÆRING

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sverige, erklærer på eget ansvar, at svejseautomat

Frametrac fra serienummer 0607 er i overensstemmelse med standarden EN 12100--2 og

EN 60204--1 ifølge betingelserne i direktiv (73/27/EØF) og standard EN 61000--2--2 samt

EN 61000--6--3 ifølge betingelserne i direktiv (89/336/EØF).

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FORSIKRING OM SAMSVAR

Esab Welding Equipment AB, SE--695 81 Laxå, Sverige, forsikrer på eget ansvar at sveiseautomat

Frametrac fra serienummer 0607 er i overensstemmelse med standard EN 12100--2 og EN 60204--1

i følge vilkårene i direktiv (73/27/EF) og standard EN 61000--2--2 samt EN 61000--6--3 i følge vilkårene

i direktiv (89/336/EF).

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VAATIMUSTENMUKAISUUSVAKUUTUS

ESAB AB, Welding Equipment, SE--695 81 Laxå, Ruotsi, vakuuttaa omalla vastuullaan, että

hitsausautomaatti Frametrac alkaen sarjanumerosta 0607 täyttää standardin EN 12100--2 ja

EN 60204--1 vaatimukset direktiivin (73/27/ETY) ehtojen mukaisesti sekä standardin EN 61000--2--2

sekä EN 61000--6--3 vaatimukset direktiivin (89/336/ETY).

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DECLARATION OF CONFORMITY

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that

automatic welding machine Frametrac from serial number 0607 complies with standard

EN 12100--2 and EN 60204--1, in accordance with the requirements of directive (73/27/EEC) and with

standard EN 61000--2--2 and also EN 61000--6--3, in accordance with the requirements of directive

(89/336/EEC).

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ZULASSUNGSNACHWEIS

ESAB AB, Welding Equipment, SE--695 81 Laxå Schweden, bestätigt hiermit in Eigenverantwortung,

daß der Schweißautomat Frametrac ab Seriennummer 0607 dem Standard EN 12100--2 und

EN 60204--1 gemäß den Bedingungen der Direktive (73/27/EEG) und dem Standard EN 61000--2--2

und EN 61000--6--3 gemäß den Bedingungen der Direktive (89/336/EEG).

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CERTIFICAT DE CONFORMITÉ

ESAB AB, Welding Equipment, SE--695 81 Laxå, Suède, certifie que la appareil de soudage

automatique Frametrac à partir du numéro de série 0607 est conforme à la norme EN 12100--2 et

EN 60204--1 selon les conditions de la directive (73/27/CEE) et à la norme EN 61000--2--2 et EN

61000--6--3 selon les conditions de la directive (89/336/CEE).

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VERKLARING VAN OVEREENSTEMMING

ESAB AB, Welding Equipment, SE--695 81 Laxå Zweden, verklaart geheel onder eigen verantwoor-

delijkheid dat lasautomaat Frametrac van het serienummer 0607 in overeenstemming is met norm

EN 12100--2 en EN 60204--1 conform de bepalingen in richtlijn (73/27/EEG) en met norm

EN 61000--2--2 en EN 61000--6--3 conform de bespalingen in richtlijn (89/336/EEG).

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DECLARACIÓN DE CONFORMIDAD

ESAB AB, Welding Equipment, SE--695 81 Laxå, Suecia, garantiza bajo propia responsabilidad que

la equipo para soldadura automática Frametrac a partir del número de serie 0607 concuerda con la

norma EN 12100--2 y EN 60204--1 conforme a la directiva (73/27/CEE) y con la norma

EN 61000--2--2 y EN 61000--6--3 según los requisitos de la directiva (89/336/CEE).

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DICHIARAZIONE DI CONFORMITA

ESAB AB, Welding Equipment, SE--695 81 Laxå Svezia, dichiara sotto la propria responsabilità che la

saldatrice automatica Frametrac con numero di serie a partire da 0607 è conforme alla norma

EN 12100--2 e EN 60204--1 come previsto dalla direttiva (73/27/CEE) ed alla norma EN 61000--2--2 e

EN 61000--6--3 come previsto dalla direttiva (89/336/CEE).

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DECLARAÇÃO DE CONFORMIDADE

ESAB AB, Welding Equipment, SE--695 81 Laxå Suécia, garante sob responsabilidade própria que, o

equipamento automático para soldadura Frametrac a partir do número de série 0607 está em con-

formidade com a norma EN 12100--2 e EN 60204--1 segundo os requisitos da directiva (73/27/CEE) e

com a norma EN 61000--2--2 e EN 61000--6--3 segundo os requisitos da directiva (89/336/CEE).

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ÄÇËÙÓÇ ÓÕÌÌÏÑÖÙÓÇÓ

ÇåôáéñåßáESAB AB, Welding Equipment, SE--695 81 Laxå, Óïõçäßá, äçëþíåé üôé ôá ìç÷áíÞìáôá

áõôüìáôò óõãêïëëçôÞò Frametrac áðü ôïí áñéèìü óåéñÜò 0607 êáé Ýðåéôá, óõììïñöþíïíôáé ìå

ôï ðñüôõðï EN 12100--2 êáé EN 60204--1 óýìöùíá ìå ôéò áðáéôÞóåéò ôçò ïäçãßáò (73/27/EEG)

êáé ôï ðñüôõðï EN 61000--2--2 êáé EN 61000--6--3 óýìöùíá ìå ôéò áðáéôÞóåéò ôçò ïäçãßáò

(89/336/EEG).

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CERTYFIKAT ZGODNO¦CI

Firma ESAB AB, Welding Equipment, SE-695 81 Laxå, Szwecja, gwarantuje pod rygorem odpowiedzialno¶ci,

¿e automat spawalniczy Frametrac od numeru seryjnego 0607 spe³nia wymagania normy EN 12100-2 i

EN 60204-1 wed³ug dyrektywy (73/27/EG) oraz normy EN 61000-2-2 i EN 61000-6-3 wed³ug

dyrektywy (89/336/EEG).

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Kent Eimbrodt

Global Director

ESAB AB, Welding Equipment

SE--695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

L

axå 2006--04--19

ENGLISH

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TOCe

1SAFETY 102...........................................................

2 TECHNICAL DESCRIPTION 104.........................................

2.1 General 104..................................................................

2.2 ACC Function 105.............................................................

2.3 Machine 106..................................................................

2.4 Components 107..............................................................

2.5 Technical data 107............................................................

3 INSTALLATION 108....................................................

3.1 General 108..................................................................

3.2 Connecting Frametrac to the Feed Unit 108.......................................

3.3 Other connections 109.........................................................

3.4 Connection 113...............................................................

3.5 Mounting 114.................................................................

4 OPERATION 118.......................................................

4.1 General 118..................................................................

4.2 Front Panel -- Carriage 118.....................................................

4.3 Front Panel - Weaving Unit 119.................................................

4.4 Remote Control Box 120.......................................................

4.5 Slide 122.....................................................................

4.6 Control Unit 122...............................................................

5 MAINTENANCE 123....................................................

5.1 General 123..................................................................

5.2 Daily 123.....................................................................

6 ACCESSORIES 124....................................................

7 ORDERING OF SPARE PARTS 124......................................

DIMENSION DRAWING 317................................................

DIAGRAM 319............................................................

SPARE PARTS LIST 321...................................................

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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.

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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!

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2 TECHNICAL DESCRIPTION

2.1 General

Frametrac is a welding carriage designed for efficient mechanisation of frame

welding in tubes for wind power stations. It consists of a carriage provided with a

weaving unit, a control unit with remote control and a slide arrangement for the

welding torch, which is floating both vertically and horizontally.

The vertical movement is obtained by way of an electrical slide ( ACC) controlled by

the welding current, so that the torch maintains constant height/current.

h

As to frames of consistent thickness the carriage runs directly on the frame. For

frames of varying thickness a separate path is needed for the carriage to run on.

The carriage runs on the frame The carriage runs on a separate path

on top of the frame

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2.2 ACC Function

ACC (Automatic Current Control) is a control unit designed to keep the current

constant during m echanised MIG/MAG welding. This is done by controlling the

height of the welding torch up/down during the welding process to make it possible to

follow a varying foundation, provided that the wire feed speed is constant.

The system consists of a motorised slide, a shunt box and a control unit, and is

designed as a free--standing unit, independent of the type of power source used.

The connection of the power source is done by way of a 12--pin Burndy plug. There

is also a 23--pin plug on the control unit for the transmission of power to the

Frametrac control unit, so that control cables of the standard type can be used.

Before start, set the desired wire stick-- out and height of the welding torch by running

the slide manually up/down. Start welding and fine--adjust the height of the welding

torch and the wire feed speed to the desired current (usually displayed on the feed

unit). When this is done, press the SET button (is found both on the slide and the

control unit). T he welding current is set on the control unit (can be read from the

separate shunt box). A blue LED on the front panel goes on. To make it possible for

the control unit to set a value, the current must be between 150 and 300 A.

The height of the welding torch can also be gradually fine-- adjusted by pressing the

up/down buttons on the slide. The change takes place as soon as the button has

been pressed. Increased height results in lower current, and decreased height in

higher current.

The wire feed speed is to be set before the SET button is pressed. If you want to

fine--adjust afterwards, keep the SET button pressed while the adjustment is going

on. This will stop the ACC regulation, which works against any change of the welding

current.

The control unit preserves the set welding current for 10 minutes after the welding

process is finished. A blue LED is on. After 10 minutes the value will be r e set and the

blue light goes out. If you would like to reset the value earlier, keep the SET button

pressed for 10 seconds and the blue LED goes out.

IMPORTANT! When using an Aristo welding power source, the Synergy function is

to be switched off.

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2.3 Machine

1. Switch for height adjustment

2. Weaving unit

3. Remote control unit ( x2)

4. Top wheel (x2)

5. Bracket for cable bundle counterbalance

6. Guide rollers, carriage

7. Slide wheel for floating horizontal slide

8. Hand wheel for torch angle adjustment

9. Coarse adjustment of the height

10. ACC slide (height adjustment)

11. Horizontal coarse adjustment of the welding torch

12. Locking bracket for height adjustment of the slide wheel

13. Frame

14. Driving wheel (x4)

15. Knob for discharging the spring pressure

16. Spring bracket

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2.4 Components

U1 Control unit Frametrac

U2 Remote control

W1 Frametrac

U3 PLC unit ACC

R1 Shunt box

S1 ACC slide

2.5 Technical data

Frametrac

Connection voltage 36--46VAC

Power 80W

Weight 30kg

Frame thickness 20--50mm

Min. frame radi us R 150mm

Min. frame height 40mm

Max. height difference, frame 120mm

Max. varying thickness, frame 3mm

Displacement, vertical slide +/--40mm

Displacement, horizontal slide +/--20mm

Max. slide load 3kg

Welding speed 10--99cm/min

Weaving speed 10--60mm/s

Weaving width 0--29mm

0--Line displacement +/--12.5mm

Max. working temperature 70ºC

GB

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3 INSTALLATION

3.1 General

The installation must be execu ted by a profession al.

3.2 Connecting Frametrac to the Feed Unit

Frametrac can be connected to most of ESAB’s feed units.

For connection to older feed units, please contact your nearest ESAB retailer.

Frametrac can also be powered by other welding power sources via a separate

transformer, see page 112.

For connection of the wire feed unit to F rametrac, use control cable acc. to

Accessories, on page 124.

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3.3 Other connections

Frametrac ! ESABFeed

Frametrac is to be connected directly to the remote control socket.

No intervention in the feed unit is necessary.

ESABFeed 30--2 with con t rol pan el M11.

Frametrac cannot be connected to this feed unit.

ESABFeed 30--4 och 48--4 with M12 con t rol pan el.

ESABFeed 30--4 och 48--4 with M13 and M14 control panels.

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Frametrac ! AristoFeed with co n trol pan el fitted

S Dismount the door and fit the sticker ( 1).

S Mount the switch with the cabling ( 2 ).

S Open the socket for remote control connection (3).

S Fit the cabling (4).

S Fit the remote control socket on the front panel ( 5).

S Connect the cabling with the printed circuit boards (6).

S Fit the printed circuit board at the bottom and then fit the door ( 7).

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Frametrac ! AristoFeed with U8

S Dismount the door ( 1).

S Open the socket for remote control connection (2).

S Fit the cabling (3).

S Fit the remote control socket on the front panel ( 4).

S Mount the switch with the cabling on the printed circuit board (5).

S Connect the cabling with the printed circuit boards (6).

S Fit the printed circuit board at the bottom and then fit the door ( 7).

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Frametrac ! oth er feed unit makes

When connecting F rametrac to other feed units, use the transformer and the control

cable you find under Accessories on page 124.

F – G = Start / Stop function

A – B = Voltage feed

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3.4 Connection

1. Welding power source

2. ACC Shunt box

3. Wire feed unit (42VAC)

4. ACC Control unit

5. Frametrac Control unit

6. Frametrac

7. ACC Slide

8. Remote control unit

9. Control cable, 0457 360--880

10. Control cable, 0457 360--880

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3.5 Mounting

1. Discharge the guide rollers by

turning the knob clockwise.

2. Carefully lift the carriage (without

welding torch) over the lowest

part of the frame.

3. Turn the knob back again

(counter--clockwise) until the

spring bracket has a play of 15

mm.

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4. Adjust the rocker arms A in/out, until the

distance of the spring guides

B = 40 mm.

5. Connect F rametrac to the control unit,

and the ACC slide to the PLC box.

Connect power to the 12--pin Burndy plug

on the PLC box.

6. Run the height adjustment slide up to

some 20 mm from the top.

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7. Adjust the slide wheel A in/out

by loosening the bracket B, so

that the horizontal slide comes

into mid position. The weaving

unit has a floating in/out

movement following the

thickness of the frame. The

wheel A is to be in close contact

with the edge of the frame.

8. Adjust the slide wheel vertically to

some 20 mm over the edge of the

joint. Connection on bracket B.

9. Press the button to set the 0--line.

(See the section Front Panel, Weaving Unit.)

GB

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ESAB Frametrac User manual

ESAB Frametrac User manual

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