GMD - Westermans International Ltd
Contents
1. A6 GMD Joint tracking equipment Simplified service manual 333 533 011 9704 LIST OF CONTENTS Page TECHNICAL DESCRIPTION 4 INSTALLATION e perd aus UE Ee Raph ra aor Ee 8 OPERATION codice etre o nae ten am 10 MAINTENANCE s ue tera tad cae Mace Ele ae 12 DIMENSION DRAWING 13 DIAGRAM sS e CE EIC ne on ede 16 SPARE PARTS LIST GMD 19 Rights reserved to alter specifications without notice 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 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 Insulate yourself from earth and the workpiece Ensure your working stance is safe FUMES AND GASES Can be dangerous to health Keep your head out of the fumes e Use ventilation extraction at the arc or both to keep fumes and gases from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin Protect your eyes and body Use the correct welding screen and filter lens and wear protective clothing Protect bystanders with suitable screens or curtains2. 267 101 301 2126 022 06 193 147 124 2129 101 06 2121 088 23 2126 011 03 323 941 001 323 941 002 368 544 005 2121 080 82 333 551 001 481 866 880 2121 080 83 2626 134 01 193 317 001 466 238 001 323 945 002 323 945 003 Denomination Rear panel compl Rear panel Fuseholder Quick blow fuse Fuse holder Fitting Nut Insulating washer Plug Screw Nut Sleeve socket Sleeve socket Sleeve socket Screw Spacer sleeve PC board Screw Cable Switch Switch Connector Connector 30 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 31 5417630 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 2 3 4 5 6 7 8 9 a416688s Orderingno 416 688 880 2121 080 29 156 106 880 415 836 880 415 739 001 417 258 880 416 671 001 415 328 001 2111 010 49 193 860 109 193 051 447 417 958 880 193 051 366 415 329 001 2122 045 45 146 586 001 415 332 002 418 090 001 6880 003 02 Denomination Sensor Screw Transducer unit Diffusor Insulation Sleeve Guide arm Yoke Pin Pressure pin Stop screw Ring Stop screw Guide arm attachment Stop screw Guide finger Seal Compression spring Allen key 32 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteil
3. 4000 rpm ratio 74 1 see 334 426 Motor cable order 417 310 xxx The cable is available in different lengths see spare parts list Controls and connections Control box 1 Indicating lamp red Lamp for joint tracking control When lit indi cates that the sensor finger is outside its working range vertically The automatic control devices are now blocked 5 2 Illuminated pushbutton orange Selection of high speed for manual operation 3 Joystick For manual control of servo slide motions Up Down and Left Right The joystick is always in command When the indicating lamp is out any manual motion downwards is blocked 4 Selector switch 5 positions Selection of joint location and joint tracking modes Manual pre setting e Vertical and horizontal joint tracking e Vertical and horizontal joint tracking with search location to right e Vertical and horizontal joint tracking with search location to left e Vertical joint tracking 5 Indicating lamp green Power On indication cga9diea 6 dga9d003 Joint tracking unit rear panel 1 Socket 4 way for connection of horizontal slide motor 2 Socket 4 way for connection of vertical slide motor 3 Socket 8 way for connection of guide finger 4 Socket 23 way for connection of control unit Power supply 42 V 9 Control circuit fuse 10 A an
4. 50 90 00 Fax 46 31 50 93 60 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 454 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 333 43 33 Fax 455 31 361 31 51 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 452 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 44 58 Asia Pacific AUSTRALIA ESAB Australia Pty Ltd Ermington Tel 61 2 9647 1232 Fax 61 2 9748 1685 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 01 88 Fax 62 21 461 29 29 MALAYSIA ESAB Malaysia Snd Bhd Selangor Tel 60 3 703 36 15 Fax 460 3 703 35 52 SINGAPORE ESAB Singapore Pte Ltd Singapore Tel 65 861 43 22 Fax 65 861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyung Nam Tel 82 551 2 89 81 11 Fax 82 551 289 88 63 THAILAND ESAB Thailand Ltd Samutprakarn Tel 66 2 393 60 62 Fax 66 2 748 71 11 UNITED ARAB EMIRATES ESAB Middle East Dubai Tel 971 4 338 88 29 Fax 971 4 338 87 29 Representative offices ALGERIA ESAB Algeria Alger Tel 213 2 67 24 93 Fax 213 2 68 32 90 BULGARIA INTESA Sofia Te
5. FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are inflammable materials nearby MALFUNCTION Call for expert assistance in the event of malfunction HEAD AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING THE EQUIPMENT PROTECT YOURSELF AND OTHERS mvarnen1 3 TECHNICAL DESCRIPTION The A6 GMD joint tracking equipment is used for positioning and joint tracking of automatic welding machines with all types of joints in which there is a guide edge for the sensor finger to follow The equipment has been designed to suit standard ESAB slides and can control either one or two servo motors simultaneously Technical data Control and operating voltage 42 AC 50 60 Hz Power requirement 460V 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 53 Max ambient temperature 45 Weights Sensor and cross sadle with mount 2 2 kg Joint tracking unit 4 5 kg Sensor finger 0 6 kg Remote control unit 2 kg Working range sensor radially 360 4 mm The figure below shows the working range and setting speed of the equipment For the A6 servo slide see Simplified service manual no 334 346 001 Welding speed Angular deviation BO Normal gearing Reversed gearwheels 40 20 T T T T E 0 d 19 H 200 26
6. cm min Welding speed dga9d008 Maximum angular deviation of the weld joint in relation to the preset welding speed cga9diea 4 The A6 GMD comprises et oec oY Es Sensor order no 416 688 880 Control cable 2 m order no 416 749 887 Cross saddle for sensor order no 416 739 880 Control unit order no 416 065 880 Joint tracking unit order no 416 066 880 dga9b005 For welding column and boom units the control box and the control cable points 4 and 5 above are replaced by product specific items Extra equipment for GMD Sensor finger order no 416 719 001 L 100 mm Sensor finger order no 416 719 002 1 150 mm Sensor finger for internal and external corners order no 418 091 880 Auxiliary control power transformer for separate power supply from mains 190 220 380 415 440 500 V 50 Hz 200 230 380 415 440 500 V 60 Hz to secondary 42V 660 VA see order no 148 636 002 Cable 3 x 2 5 mm for transformer order no 2626 134 04 Sensor cable with 90 contact order no 418 091 887 Rubber guard bellows order no 412 013 001 Bracket for control box 433 762 xxx The bracket is available in different applications cga9diea 5 ESAB standard servo slides for A6 GMD e A6 servo slide of ball bushing type with permanently excited 42 V DC motor see 334 333 motorized slide long travel with sliding support and VEC motor 42 V DC
7. Tel 32 2 745 11 00 Fax 432 2 726 80 05 THE CZECH REPUBLIC ESAB VAMBERK s r o Vamberk Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Copenhagen Valby Tel 45 36 30 O1 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 2980 Fax 49 212 298 204 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 36 1 20 44 182 Fax 36 1 20 44 186 ITALY ESAB Saldatura S p A Mesero Mi Tel 39 2 97 96 81 Fax 39 297 28 91 81 THE NETHERLANDS ESAB Nederland B V Utrecht Tel 31 30 248 59 22 Fax 31 30 248 52 60 NORWAY AS ESAB Larvik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp z 0 0 Warszaw Tel 48 22 813 99 63 Fax 48 22 813 98 81 PORTUGAL ESAB Lda Lisbon Tel 351 1 837 1527 Fax 351 1 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A Alcobendas Madrid Tel 34 91 661 55 80 Fax 34 91 661 51 83 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31
8. elding head is inclined The sensor must not be radially misaligned by more than 3 from this position in relation to the axes of the slide cross Any large deviation towards one side or the other puts the control performance at risk see page 13 and 14 dga9b004 10 The equipment includes a fixing device for securing the sensor with a type D20 or D35 contact block This allows course setting of the welding direction height and angle round the contact block Important The distance B between the steel clamp A and live parts should be at least 5 mm 11 Use the mini slide cross head for exact adjustment of the position of the tip of the wire in the welded joint Adjust too the distance between the tip of the wire and tip of the guide finger if necessary The mini slide can be adjusted till no play exists by means of the stop screws on the runner 12 Check as follows that the sensor is operating correctly Turn the selector switch to Using the joystick run the vertical slide downwards towards a flat base until the tip of the guide finger contacts the base Continue to lower the slide until the red indi cating lamp goes out hold of the tip of the guide finger and push it to one side or the other If the equipment is working correctly the horizontal slide motor should then start and move in the same direction as the sensor tip is being pushed If this does not gt happen change
9. h green 23 s416749 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de 5 d tach es 2 3 4 5 6 7 8 9 o 5416739 Orderingno 416 739 880 190 684 362 413 366 112 192 238 374 2126 011 07 193 570 120 2151002 01 193 570 109 193 500 102 433 851 001 192 238 366 413 366 115 193 570 150 413 366 320 161 337 051 417 096 880 417 097 001 417 098 880 417 099 880 417 097 002 2151 001 01 Denomination Slide cross for sensor Screw Clamp Screw Nut M6 Locking lever M6 Washer D22 6 4x4 Locking lever M6 Washer D14 7x1 5 Mini slide Screw M6x12 Clamp 035 Locking lever Clamp D20 Box Bracket Clamp Bracket Plate Clamp Washer 6 4x12 6 24 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es r aga9s002 25 5416739 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de 5 d tach es 5416065 Orderingno 416 065 880 415 200 001 415 200 020 415 200 027 191 953 101 415 200 005 415 200 047 415 200 058 416 067 001 192 722 004 415 302 001 332 556 001 2121 080 45 2126 011 05 416 064 001 193 307 104 2126 022 08 433 145 001 368 541 005 333 158 880 415 200 024 415 200 026 161 337 051 2126 011 06 Denomination Control box Pushbutton Switc
10. h mechanism Cap orange Cable Indicating lamp Bulb Splash shield water Plate Selector swich Manipulator Protective clamp Screw Nut Apparatus box Cable fitting Nut Control cable Pin plug Knob Cap green Cap red Box Nut 26 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 10 12 20 2367 19 1 17 5 6 25 27 s416065 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 5416066 Orderingno 416 066 880 417 630 880 332 908 880 2121 107 18 416 060 001 417 615 003 481 859 880 333 181 881 Denomination Joint tracking equipment Rear plate Box Screw Front panel Housing pin PC board Feed unit 28 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es x opc 5 ESAB AS GMD 29 s416066 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 2 3 4 5 6 7 8 9 s417630 Orderingno 417 630 880 417 649 001 193 701 001 567 900 107 193 701 002
11. int table below for correct settings Examples of some different types of joints and of the guide finger angle against the guiding edges Joint type Settings control box Double flanged butt joint sss A ZAN I weld ES V weld ZASS 1 2 V weld A SS A Guide bar 1 2 V weld SS amp cga9diea 10 Double U weld J weld Double J weld X weld Asymmetrical X weld K weld K weld Fillet weld Joint type INK UN Positioning prior to start of welding Settings control box amp 45 4 d 1 Position the welding equipment so in relation to the weld joint that the working range of the cross slide covers the entire height of the joint as well as the deviation in the lateral from the starting point to the end point 2 Setswitch 4 see figure on page 6 to the desired joint tracking position Operate the guide finger vertically downwards using the joystick until the indicating lamp 1 goes out 3 GMD now looks for its zero position and by that also the position of the welding nozzle in the joint Adjust the position as necessary by means of the cross saddle of the control device cga9diea MAINTENANCE e Check each day that the guide fingers are not worn or damaged e Clean the sensor regularly using compressed air Follow the instructions for the components in the system See Commissioning of the joint tracking equipment on page 8 for details of syste
12. l 359 2 980 17 15 Fax 359 2 980 08 42 CHINA Shanghai ESAB A P Shanghai Tel 86 21 6539 7124 Fax 86 21 6543 6622 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 IRAN Kavosh Azmoon Teheran Tel 98 21 884 39 14 Fax 98 21 884 13 46 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 211 75 02 RUSSIA CIS ESAB Representative Office Moscow Tel 7 095 93 79 820 Fax 7 095 93 79 580 ESAB Representative Office St Petersburg Tel 7 812 325 6688 Fax 7 812 325 6685 Agents For addresses and phone numbers to our agents please contact ESAB International AB Sweden EUROPE Cyprus Greece Malta Turkey AFRICA Angola Cameron Ethiopia Gabon Ghana Kenya Liberia Morocco Mocambique Nigeria Senegal South Africa Tanzania Togo Tunisia Zambia Zimbabwe ASIA Bahrain Hongkong Israel Japan Jordania Korea Kuwait Lebanon New Guinea Oman Pakistan The Philippines Quatar Saudi Arabia Sri Lanka Syria Taiwan Turkey Vietnam Yemen LATIN AMERICA Bolivia Chile Colombia Costa Rica Curacao Equador El Salvador Guatemala Honduras Jamaica Paraguay Peru Trinidad Uruguay Venezuela P vt ESAB Welding Equipment AB SE 695 81 LAXA SWEDEN Phone 46 584 81 000 Fax 446 584 123 08 www esab com 990922
13. m ad justments cga9diea 12 DIMENSION DRAWING A6 dga9b001 cga9diea 13 DIMENSION DRAWING A2 pm mem e 4 ER Hr _ DW Was I I Ov dga9b002 14 cga9diea DIMENSION DRAWING 3 9 100 255 San ere 6 A L L dga9b003 cga9diea 15 DIAGRAM START US ISV EN wil ics il dga9ep01 16 cga9diea dga9ep02 17 cga9diea cga9diea 18 SPARE PARTS LIST A6 GMD Edition 9704 Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover Kindly indicate type of unit serial number denominations and ordering numbers according to the spare parts list A6GMD 19 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 3417142 Orderingno 417 142 880 416 688 880 416 749 887 416 739 880 416 065 880 416 066 880 161 337 158 417 142 881 416 688 880 416 739 880 416 066 880 161 337 158 Component designation in the circuit diagram Joint tracking equipment D35 D20 incl control box Sen
14. on See page 6 for details of the controls N B In case the adaptation does not take place on installation the joint tracking function can be seriously impaired and mechanical damages may come about on the control and contact devices through collission with the workpiece Trimming of the sensor voltage 1 2 3 4 Dismount the front panel of the control unit In case more space is needed for measuring the regulator boards can be removed Connect a voltmeter to measuring point TP1 TPO Run the vertical slide downwards by way of the remote control unit until the tip of the sensor finger contacts a flat base and the warning lamp on the remote control unit goes out Set the selector switch on the remote control to vertical tracking 1 Move finger aside as far as possible Check the value on the voltmeter and adjust with potentiometer R20 to 1 8 0 6 V see figure below Don t touch potentiometer R32 dga9do19 cga9diea 8 Fitthe sensor so that there is the least possible angle between the longitudinal axis of the sensor and the weld joint in both the horizontal and vertical planes less then 35 See the drawing on page 13 and 14 9 When fitting the sensor ensure that the front part of the sensor finger secured by a uni versal joint is pointing downwards towards the weld joint or towards the edge to be sensed tracked This applies for all types of joints including fillet welding when the w
15. over the switch marked on the apparatus unit backplane 13 As supplied the tip of the sensor is straight but can be bent by the user to suit a particu lar application or be replaced by some other type or shape of sensor see Extra Equipment for GMD cga9d1iea 9 OPERATION The joint tracking equipment is adjustable for different kinds of joint tracking such as tracking by sensing the edge and tracking by sensing the groove The adjustment is made both on the control box and on the sensor Joint tracking by sensing the edge Set the selector switch on the control box to gt lt depending on whether the de sired sensing direction is left or right The two stop screws shall be screwed home see figure on page 7 This means that the sensor fingers are laterally spring loaded and thus permit edge sensing Joint tracking by sensing the edge is used for fillet joints and similar joints see also table below Joint tracking by sensing the groove Set the selector switch on the control box to depending on whether vertical and horizontal sensing is desired or vertical sensing only The two stop screws shall be screwed out at least two turns or to stop see figure on page 7 This will disengage the spring load of the sensor fingers and permit groove sensing If the stop screws are not screwed out there is a risk that the sensor fingers start climbing the joint walls of shal low V and U joints See also jo
16. sor Cable Cross sadle sensor Control box Joint tracking unit Box Joint tracking equipment D35 D20 excl control box Sensor Cross sadle sensor Joint tracking unit Box Denomination 20 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de 5 d tach es ER P 21 3417142 Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de 5 d tach es 5416749 Orderingno 416 749 880 191 812 103 416 749 881 191 812 1038 416 749 882 191 812 1038 416 749 883 191 812 1038 416 749 884 191 812 103 416 749 885 191 812 103 416 749 886 191 812 103 416 749 887 191 812 103 416 749 888 191 812 103 416 749 889 191 812 103 5385 012 11 5385 023 02 323 942 002 323 945 001 323 943 102 Denomination Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Sleeve plug Sleeve rubber Pin plug Plug Counterbalance 22 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es muonuu eh wh blue wh or w
17. ti surge 1 pc 7 Switch for selection of horizontal slide direction of travel 8 Socket 3 way TI 10 6 8 11 for joint memory unit MEMO 9 Switch SUN Power supply On Off 10 Spare socket 11 Socket 8 way for connection of Limit switch Sensor 1 Sensor with cable connection for joint tracking unit and fixing device in front for the fit ting of different sensor fingers 2 Sensor fingers cga9diea 2 stop screws for adjustment of the horizontal flexibility of the of the fingers The screws are intended for the setting of the different joint types dga9d014 INSTALLATION 1 2 3 Commissioning of the joint tracking equipment A WARNING N B When the sensor is to be exchanged the joint tracking equipment ordering no 416 066 880 must be adapted to the supplied sensor ordering no 416 688 880 For dimensions and settings see Dimensions on page 13 Connection see page 16 Check that the necessary power supplies of the correct voltage are available When using a power source of one of the types LAE 800 1000 1250 1600 connected for 42 V control voltage the necessary power can be obtained from the standard automatic welding machine see terminal PEG1 When suitable voltage is unavailable or when an LAH 500 630 42 V power source is used there must always be installed a 42 V intermediary transformer for the volt age supply to the A6 GMD see Accessories secti
18. verzeichnis Liste de p cees d tach es IN wa Le aman p fa L Sai RS e LIN EE Ee PUNCHMARK KORNSLAG 33 a416688s Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es Orderingno 417 310 880 2626 134 01 417 310 881 2626 134 01 417 310 882 2626 134 01 417 310 883 2626 134 01 417 310 884 2626 134 01 417 310 885 2626 134 01 417 310 886 2626 134 01 417 310 887 2626 134 01 417 310 888 2626 134 01 417 310 889 2626 134 01 192 784 002 192 784 101 323 942 001 323 945 001 323 943 102 Denomination Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Control cable Apparatus cable Sleeve plug Plug Pin plug Plug Counterbalance Additional system components 5417310 34 Component designation in the circuit diagram Reservdelsf rteckning Spare parts list Ersatzteilverzeichnis Liste de p cees d tach es 35 5417310 ESAB subsidiaries representative offices and agents 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
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