ESAB A6 Slide User manual

Valid for serial no. 452--xxx--xxxx0443 394 060 2006--07--13
A6 Slide
101103105102021104022100020040060
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Instruction manual
Betriebsanweisung

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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.
SVENSKA 4..............................................
DANSK 24................................................
NORSK 44................................................
SUOMI 64................................................
ENGLISH 84..............................................
DEUTSCH 104.............................................

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ENGLISH
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TOCe
1SAFETY 85...........................................................
2 TECHNICAL DESCRIPTION 87.........................................
2.1 General 87..................................................................
2.2 The A6 slide consists of: 87....................................................
2.3 TECHNICAL DATA 88........................................................
2.4 The carrying capacity of the slide 88............................................
2.5 The linear bearing of the runner 89.............................................
2.6 The distance between the fixation of the slide profile and the line of application of the load
91
2.7 Deformation of the slide profile under load 92....................................
2.8 Slide transfer 95.............................................................
3 INSTALLATION 96....................................................
3.1 General 96..................................................................
3.2 Connections of the runner 96..................................................
3.3 Connections of the slide profile 96..............................................
3.4 Fitting of vertical cross saddle 96...............................................
3.5 Recommended way of lifting servo slides 97.....................................
4 OPERATION 98.......................................................
4.1 General 98..................................................................
4.2 Changing the speed range 98..................................................
5 MAINTENANCE 100....................................................
5.1 General 100..................................................................
5.2 Daily: 100....................................................................
5.3 Every month: 100.............................................................
5.4 Every year 100................................................................
5.5 As necessary 100.............................................................
5.6 In case of a long standstill 100..................................................
5.7 Replacing the linear bearings 101................................................
6 ORDERING OF SPARE PARTS 103......................................
DIMENSION DRAWING 124................................................
SPARE PARTS LIST 125...................................................

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1SAFETY
Users of ESAB servo slides have the ultimate responsibility for ensuring that anyone
who works on or near the servo slide observes all the relevant safety regulations.
The following recommendations should be observed in addition to the standard re-
gulations that apply to the work place.
1. General
All manoeuvres must be performed according to the given instructions by
personnel well familiar with the functions of the servo slide.
An incorrect manoeuvre, caused by a wrong move or an incorrect release of a
functional sequence, can lead to an abnormal situation that can injure the
operator and cause damage to the equipment.
Personnel working with the servo slide must be well familiar with:
Sthe handling of the slide
Sthe location of emergency stops
Sthe function of the slide
Sall relevant safety regulations
2. Live electrical components are usually semi--protected.
SAny work on electrical units shall be carried out by a qualified electrician.
3. Danger of the load falling down
SMake sure the base will resist all types of forces coming up during operation.
SCheck that the slide is fastened to the base with at least 4 M10 or M12 Allen
screws.
SNever overload the slide (see on page 88 the carrying capacity of the slide)
SCheck the condition of the belt regularly (at least every 200 hours).
SReplace the belt at least every 5 years, or as necessary.
N.B.
When replacing the belt or the belt pulley the load must be secured. Read
the pages 98 -- 99.
In case of a belt rupture the load will fall down.
WARNING!
4. Danger of getting clamped
SWhen the runner goes towards its end position
SWhen the belt protection is dismounted
5. Maintenance
SLubrication and maintenance of the slide must not be carried out when the
slide is in operation.
GB

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GB
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
MANUFACTURER’S 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.
DANGER OF GETTING CLAMPED
SMoving parts can cause damage. Therefore, be very careful!
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse 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
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 ear defenders or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
READ AND UNDERSTAND THE OPERATING MANUAL BEFORE
INSTALLING OR OPERATING.
WARNING

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2 TECHNICAL DESCRIPTION
2.1 General
The A6 slide is designed to carry and transfer welding heads of different types of
welding plants. The slide can be mounted across the weld joint -- single or in a cross
saddle -- for adjustment or joint tracking. It can also be mounted along the weld joint
to bring about a welding movement.
The A6 slide is controlled over:
SControl box A6 GMD for joint tracking. (See instruction manual 443 403 xxx)
SControl box A6 PAK for positioning. (See instruction manual 443 405 xxx)
SControl box PEH for travel motion. (See instruction manual 443 745 xxx)
The A6 slide is a motorized linear slide. All movable parts are lodged in ball
bearings. The slide is available in different setting lengths from 60 to 1030 mm (see
dimension drawing on page 124) and in two different speed ranges.
2.2 The A6 slide consists of:
1. Slide profile, stiff U--profile.
2. Runner, lodged in open ball bushings, run-
ning over the axes which are supported by
the slide profile in their full length.
The driving system contains:
3. DC motor with worm gear.
4. Tooth belt transmission with built--in friction
clutch.
5. Ball screw with nu.
GB

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2.3 TECHNICAL DATA
Setting length
(mm) 60 120 180 240 300 420 540 730 1030
Total length (mm) 305 365 425 485 545 665 785 1025 1385
Weight (kg) 11,5 13,2 15,0 16,7 18,5 21,9 25,4 30,9 38,8
A6 Slide
Max control voltage 42 V DC
Max speed at 42 V DC 70 cm/min (175 cm/min with reversed
gear wheels in transmission)
Continuous A--weighted noise pressure 42 dB
Play of runner in the longitudinal direc-
tion of the slide 0,1 mm
Other play 0
Max ambient air temperature 80°C
Max load dimensions at full setting
length
Setting length 60 to 540: b=62
Setting length 60 to 730: b=86
Setting length 60 to 1030: b=117
2.4 The carrying capacity of the slide
To simplify the schematical representation it is assumed that the load on the slide is
a weight and that the different mounting positions are confined to:
SVertical position
SStanding horizontal position
SLying horizontal position.
With the following co--ordinate directions the force of gravity works in the y, x and z
directions.
GB

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2.5 The linear bearing of the runner
Max permissible momemt--free load on the runner of the slide is 150 kg irrespective
of the mounting position of the slide.
Max permissible moment--generating load on the runner of the slide depends on the
mounting position. The centre of gravity of the load can be displaced from the centre
of the runner within an area, the further limit of which depends on the size of the load
according to the three diagrams below, where the slide is seen from above.
Max. load at vertical mounting Max load at standing horizontal mounting
Max load at lying horizontal mounting
GB

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Examplel 1:
SAn A6 SFD1 automatic welding machine is
mounted on a standing cross saddle.
SNote that the wire drum and the drum holder are
mounted on th slide profile of the vertical slide.
Example 1a:
SThe load on the vertical slide is about 43 kg.
SThe centre of gravity (TP1) is displaced 0,35 m
from the runner of the vertical slide in the z
direction.
SThe displacement of the centre of gravity in the x
direction can be neglected.
SThe load is far below the permissible load of 110
kg in this position.
*1) Permissible position of the centre of gravity at a
load of 40 kg.
*2) Permissible position of the centre of gravity at a
load of 100 kg.
Example 2:
SA load of 50 kg is fitted on a lying
horizontal slide.
SThe centre of gravity is displaced 0,4
m in the x direction.
SThe centre of gravity can also be dis-
placed 0,17 m in the y direction with-
out the max load being exceeded.
*1) Permissible position of the centre of
gravity at a load of 50 kg.
GB

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2.6 The distance between the fixation of the slide profile and the
line of application of the load
Max permissible forces on the mounting screws of the slide profile limits the distance
(l) between the mounting screws and the application line of the load.
At standing horizontal mounting it is assumed that the tightening moment is 48 Nm
for an M10 screw and 84 Nm for an M12 screw (friction joint).
Max permissible distance; las a function of the load Fis shown in the following
diagram where ais the distance between the screw pairs.
Example 3
SThehorizontalslideinexample1istobefittedonacarrierwith2pairsof
screws with a=60 mm.
SLis mmax 0,4 m.
SAccording to the diagram the actual weight of 100 kg (F=1000 N) requires that
the mounting screws are of the M12 dimension and are tightened at 84 Nm.
*1) Standing horizontal mounting (SHM)
*2) Lying horizontal and vertical mounting (LHM and VM)
*3) Mounting screw
*4) 4 M12 screws torque moment 84 Nm
*5) 4 M10 screws torque moment 48 Nm
GB

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2.7 Deformation of the slide profile under load
When loaded, the slide profile is deformed (bent, twisted) so that the position of the
centre of gravity of the load is changed.
The deflection (d) depends on:
SThe size of the load
SThe mounting position of the slide
SThe distances a, L and x (y, z) are defined in the following fig.
Vertical mounting Standing horizontal mounting
Lying horizontal mounting
The deflection d (x, y, z) at the centre of gravity of the load per 10 kg is shown in the
following four diagrams, see on page 92 and 94. Lying horizontal mounting gives
the deflection dzas dz=d
zx+dzy.The deflection in other points of the load is
proportional or approximately propertional to the distance of these points to the
runner.
Note that the deflection varies with the position of the runner.
Vertical mounting. Bending of slide profile. Standing horizontal mounting. Twisting of slide profile.
GB

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Example 4:
SAn automatic welding machine is fitted on a vertical
cross saddle.
SThe load on the vertical slide is 43 kg.
SThe position of the centre of gravity is at the dis-
tance z=0,35 m from the runner.
SThe load on the horizontal slide is 100 kg and its
centre of gravity is at the distance z=0,17 m from
the runner.
Lmax of the vertical slide is 0,1 m and of the horizontal
slide 0,4 m. The deflection of the contact device due to
the deformation of the slide profiles of the slides can be
estimated as follows:
1. Deflection due to deformation of the vertical slide:
SInsert L=0,1 m and z=0,35 into the left diagram, see on page 94 (the distan-
ce to the centre of gravity TP1). In case a=60, use the solid curve lines.
SThen you will get a point that lies between curve 1 and curve 3 (closer to
curve 3).
SAccording to the table a=60 the deflection will be between 0,05 and 0,1 mm.
It is estimated at 0,08 mm. This is the deflection in the centre of gravity TP1
per 10 kg load.
SThe deflection at 43 kg is: 0,08 x 43/10 = 0,34 mm
SThe deflection of the contact device is then (due to proportinality): 0,34 x
0,33/0,35 = 0,32 mm.
S0,33 is the distance to the contact device
S0,35 the distance to TP1.
2. Deflection due to deformation of the horizontal slide:
SInsert in L=0,4 m and z=0,17 m into the diagram on the right, see on page
94 (the distance to the centre of gravity TP2).
SThen you will get a point indicating a deflection between 0,05 and 0,1 mm. It
is estimated at 0,07 mm. This is the deflection of the centre of gravity TP2
per 10 kg load.
SThe defection at 100 kg is: 0,07 x 100/10 = 0,7 mm
SThe deflection of the contact device is then (due to proportionality): 0,07 x
0,33/0,17 = 1,36 mm.
S0,33 is the distance to the contact device
S0,17 is the distance to TP2.
SThe total deflection of the contact device is then at Lmax 1,36 + 0,32 = ca 1,7
mm.
GB

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Lying horizontal mounting. Change of the centre
of gravity in the Y--direction. The slide profile
bends.
Lying horizontal mounting, Change
of the centre of gravity in the X--
direction. The slide profile twists.
Example 5:
A lying horizontal slide with Lmax= 0.4 m is loaded with 50 kg. The distance between
the mounting screws is 60 mm. The displacement of the centre of gravity in the in
the y direction = 0.17 m and in the x direction 0.4 m.
1. Deflection (dzy) at lying horizsontal mounting with displacement of the centre of
gravity in the y direction.
SInsert L=0.4 m and y=0.17 into the diagram on the left, on page 94.
SThen you will get a point lying on curve 3.
SAccording to the table a=60 the deflection will be 0.1 mm. This is the deflec-
tion per 10 kg load.
SDeflection (dzy) at 50 kg is: 0,1 x 50/10 = 0,5 mm
2. Deflection (dzx) at lying horizontal monunting with displacement of the centre of
gravity in the x direction.
SInsert L=0,4 m and x= 0,4 m into the diagram on the right on page 94.
SThen you will get a point indicating a deflection between 0,25 and 0,5 mm. It
is estimated at 0,35 mm. This is the deflection per 10 kg load.
SThe deflection (dzx) at 50 kg is: 0,35 x 50/10 = 1,75 mm
SThe total deflection (dz) at the centre of gravity of the load is: dzy+dzx =0,5+
1,75 = 2,25 mm.
SThe deflection at other points of the load is approximately proportional to the
distance of the runner in the y and x direction.
GB

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2.8 Slide transfer
Current consumption of electric motor and limit to self--braking
The current consumption is linearly depending on the load. In the table the current
consumption is indicated for different gear ratios at idle running, full load and sliding .
The table shows max load at self--braking of the motor worm gear.
Gear ratio for max
speed (cm/min) Total gear ratio, motor armature --
s
l
i
d
e
r
u
n
n
e
r
(
r
p
m
)
Current consump-
tion Max load at self-- retarding (N)
slide runner (r.p.m.) Idle
run-
ning
Load
1500
N
Slid-
ing
*1)
70 15,4 1,25 1,80 2,60 >1500
175 620 1,25 2,75 3,50 1000
*1) Adjustable, see on page 99.
GB

*1. Load
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3 INSTALLATION
3.1 General
The installation must be executed by a professional.
WARNING!
Incorrect installation of the servo slide or incorrect fitting of the load on the slide can
cause damage to the machine and injure people.
3.2 Connections of the runner
For the attachement of the load there are four M12 holes on the runner at a spacing
of 60 mm for M12 screws or M10 Allen screws with washer.
3.3 Connections of the slide profile
For the attachement on a carrier there are holes ø 13 at a spacing of 60 mm for M12
Allen screws or M10 Allen screws with washer.
Connect the slide to a suitable drive unit. For this purpose two cables are required
which are not included in the supply ot the slide: cable for control box PEH
(order no. 456 493) and for control box A6 GMD and A6 PAK (order no. 417 310).
3.4 Fitting of vertical cross saddle
The vertical cross saddle can be mounted in several
ways. For heavy loads the vertical slide is to be fitted
next to the load to lessen the pressure on the back
slide runner.
Recommended fitting for heavy loads: no torque on
the back slide runner.
The different mounting positions of the slide are:
vertical position, standing horizontal and lying
horizontal position.
Vertical mounting Standing horizontal mounting Lying horizontal mounting
GB

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3.5 Recommended way of lifting servo slides
The dead weight of most slides is so low that manual lifting can take place. For
slides with an adjustable length over 540 mm and for assembled cross saddles an
approved lifting device should be used.
NOTE. The runner must not be used for lifting.
Lifting points can be fitted in the holes on the slide profile. In exceptional cases a soft
lifting loop round the slide profile can be used. The loop must be properly secured so
as to prevent slipping.
GB

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4 OPERATION
4.1 General
Caution:
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 85. Read through before you start using the equipment!
WARNING
Rotating parts can cause injury, take great care.
4.2 Changing the speed range
Falling load can cause damage.
When replacing the belt or the belt pulley the load must be secured.
WARNING!
Replacing the belt pulley
Before starting the work, secure the load by running the slide/load to the bottom
position in order to prevent the load falling.
Max speed Wheel on motor
shaft Wheel on ball screw Motor 334 322--001 Cover plate
70 cm/min 19 teeth 30 teeth, for slip
coupling shaft journal, length 25 mm 334 321--001 T=1mm
175 cm/min 30 teeth, for slip
coupling 19 teeth shaft journal, length 25 mm 334 321--001
110 cm/min 30 teeth, for slip
coupling 30 teeth shaft journal, length 25 mm 334 321--001
When replacing the pulley, turn the cover plate between the motor and the motor
bracket so that the mounting holes get covered.
NB. When mounting or dismounting the belt pulley with the slip coupling the
lubricated cup springs must not get into contact with the friction surface of the pulley,
friction ring or friction stop.
GB

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Adjusting the friction moment
STighten the centre screw 3/4 turn after the position where the cup springs start
working.
SThe friction moment can be decreased as necessary (for instance to lessen the
friction current) by tightening the centre screw less than 3/4 turn.
SNB. The friction moment must not be set higher as this can cause damage to the
slide in the event of blocking.
Adjusting the tension of the belt
The belt must be replaced at least every 5 years,
or as necessary.
SMake sure the load is secured when
performing a piece of work.
SDismount the belt protection.
SLoosen the motor. In case the pulley with the slip coupling is fitted on the motor
shaft the belt drive must first be dismounted (in order that the mounting screws
of the motor become accessible), and then remounted again.
SMove the motor sideways until the belt is so tense that a force of 3,5 N applied
on the belt right between the pulleys gives a deflection of 2,5 mm.
STighten the mounting screws of the motor.
SWhen the pulley with the slip coupling is on the motor shaft, turn the pulley (slip
coupling loosened) until the notch in the edge comes just opposite the screw
fitted between the belt sides. Tighten the screw.
SDismount the belt pulleys to make it possible to tighten the other screws.
SFit the belt drive and adjust the slip coupling.
SPut back the belt protection.
GB

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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.
5.2 Daily:
SBlow the slide clean from flux and dust.
5.3 Every month:
SCheck the tooth belt and replace as necessary.
Note that the belt must be replaced at least every 5 years.
SNOTE. This is a safety requirement at vertical mounting position as the load of
the slide will fall down in case of a belt rupture.
When replacing the belt or the belt pulley the load must be secured. Read the
pages 98 -- 99.
5.4 Every year
SMake sure the slip coupling is adjusted to the right slipping torque. See the
pages 98 -- 99.
5.5 As necessary
SLubricate the telescope bellows with molybdendisulfide.
SLubrication of the slip coupling.
SLubricate the cup springs and the smallest inside diameter of the pulley using
molybdendisulfide.
NB. The lubricant must not get into contact with the friction surfaces of the pulley,
the friction ring or the friction stud.
SReplace wear parts of the slip coupling.
SReplace the friction ring and/or the cup spring.
SLubricate according to above recommendations.
SAdjust the friction moment (see also Operation on page 99).
STighten the centre screw of the slip coupling 3/4 turn after the position where the
cup springs start working.
5.6 In case of a long standstill
SLubricate the unprotected surfaces of the steel shafts to avoid corrosion.
SNB. Molybdendisulfide must not be used.
SAnti--corrosives in spray packing is recommended to make it possible to reach
even hidden surfaces.
GB