ESAB Automation catalogue

ESAB Automation catalogue
SECOND EDITION
Mechanized & Orbital TIG
Automation Catalogue
1
Contents
Controllers and power sources 5
Welding tractors 13
Welding heads
29
Columns and booms
39
Carriers and gantries
49
Accessory components 53
Handling equipment 65
Special applications 79
Wear parts93
3
4
Mechanized & Orbital TIG
Controllers &
Power Sources
5
Controllers and Power Sources
A2-A6 Process Controller PEK
For use with ESAB CAN-controlled power sources and motors
•
For use with ESAB automatic power sources LAF 631/ 1001/1251/1601, TAF 801/1251 and Aristo® 1000 AC/DC SAW.
• CAN-bus system for data transfer.
• Prepared for submerged arc welding (SAW), gas metal arc
welding (GMAW) and arc gouging.
• User-friendly clear text menus.
• Selectable welding process.
• Memory for 255 parameter sets.
• Constant current or constant wire speed.
• Encoder controlled motors for top performance motion control.
• USB port for data back-up and transfer.
• Used welding parameters can be stored directly on a USB
memory drive.
Ordering information
• Five Soft Keys can be configured according to operator
A2-A6 process controller PEK
0460 504 880
Sales LiteratureXA00143720
preferences.
Options & Accessories
I/O-Module0462 080 001
Set of connectors
0462 119 880
Cable restraining bracket
0460 861 880
Control cable, 15 m (49 ft.)
0460 910 881
Control cable, 25 m (82 ft.)
0460 910 882
Control cable, 35 m (115 ft.)
0460 910 883
Control cable, 50 m (164 ft.)
0460 910 884
Adjustable sun shield for
better visibility for outdoor use
Technical data
Connection voltage from the power source
42V AC, 50/60 Hz
Connection power
max 900 VA
Motor connection adjusted for ESAB’s A2 and A6 motors
connection of 2 motors, motor current 6A cont., max 10A
Speed control
feedback from pulse encoder
Welding speed, m/min (ipm)
0.1-2.0 (4-79) depending on travel carriage
Max. manual travel speed, m/min (ipm)
2.0 (79)
Consumable wire feed speed, m/min (ipm)
0.3-25 (12-984) depending on wire feed unit
Valve output
1 pc, 42 V AC, 0.5A
Inputs
for connection of sensors or limit switches
Connection to power source
Burndy contact 12-poles
Max ambient temperature, °C (°F)
45 (113)
Min ambient temperature, °C (°F)
-15 (59)
Relative humidity (of air)
98%
Dimensions, LxWxH, mm (in.)
246x235x273 (7x9.25x11)
Weight, kg (lbs)
6.6 (14.5)
Enclosure class
IP23
Standards
EN60974-1, EN60974-10
6
Controllers and Power Sources
A2 Process Controller PEI
For use with ESAB power sources and motors
• Control system for A2 tractors and A2 welding heads
• Analogue type that can control most brands of power supplies.
• Suitable for submerged arc welding (SAW) or gas metal arc welding (GMAW)
•
Travel speed, voltage and wire feed speed can be adjusted by simply turning the knobs - actual data is shown on digital displays during welding.
• Change welding direction using switch on front panel.
• Choice of scratch start or direct start methods.
• Adjustable burn-back time.
Ordering information
A2 process controller PEI
0449 330 880
Sales LiteratureXA00114320
Options & Accessories
Control cable, 15 m (49 ft)
Control cable, 25 m (82 ft.)
Control cable, 35 m (115 ft.)
Control cable, 50 m (164 ft.)
Control cable, 75 m (246 ft.)
Control cable, 100 m (328 ft.)
0449 500 880
0449 500 881
0449 500 882
0449 500 883
0449 500 884
0449 500 885
Technical data
Connection voltage from the power source
42V AC, 50/60 Hz
Connection power
max 700 VA
Motor connection adjusted for ESAB’s A2 motors
42V DC, 3.5 A P100%, 4.5A P60%
Speed control
Internal EMK-adjustment
Welding speed, m/min (ipm)
0.1-2.0 (4-79) depending on travel carriage
Max. transport speed, m/min (ipm)
2.0 (79)
Consumable wire feed speed, m/min (ipm)
0.5-16.2 (20-640) depending on wire feed unit
Burnback time, s
0-2.0
Gas pre-flow time, s
0.5
Gas post-flow time, s
1.0
Connection to power source
Burndy contact, 23 poles
Welding voltage control, V DC
0-10
Flow guard
NO Contact / PNP OC
Limit switches
NO Contact / PNP OC
External current shunt, A/mV
1000/60, 1500/60, 600/100, 750/100
Operating temperature, °C (°F)
-10 - +40 (14-104)
Weight, kg (lbs.)
6.2 (14)
Dimensions LxWxH, mm (in.)
197x227x220 (7.8x9.0x8.7)
Enclosure class
IP23
Standards
EN50199, EN60974-1
7
Controllers and Power Sources
Power sources LAF 631, 1001, 1251 and 1601
DC power sources for submerged-arc welding (SAW) or gas metal arc welding (GMAW)
• Three-phase, fan-cooled DC welding power sources designed for high productivity automated submerged-arc welding (SAW) or high productivity gas metal arc welding (GMAW).
• Used in combination with ESAB’s A2-A6 equipment range and the A2-A6 Process Controllers (PEK or PEI).
• Good arc stability at both high and low arc voltages.
• Adjust and monitor the welding parameters on the power
source from the front panel of the process controller (PEK or PEI).
• Welding current range can be extended by connecting two po
wer sources in parallel for the most demanding applications.
• Ideal for SAW applications such as wind tower components, nuclear power vessels, boilers and in the ship building industry.
•
Ideal for GMAW applications such as welding the root pass in heavy pipe production.
8
Ordering information
LAF 6310460 512 880
LAF 1001
0460 513 880
LAF 1251
0460 514 880
LAF 1601
0460 515 880
LAF 1001 M
0460 513 881
LAF 1251 M
0460 514 881
LAF 1601 M
0460 515 881
Sales LiteratureXA00143820
Options & Accessories
PEK
Control cable, 15 m
Control cable, 25 m
Control cable, 35 m
Control cable, 50 m
LAF 631 in combination with
MechTrac and GMH
(49 ft.)
(82 ft.)
(115 ft.)
(164 ft.)
0460 910 881
0460 910 882
0460 910 883
0460 910 884
PEI
Control cable, 15 m (49 ft.)
Control cable, 25 m (82 ft.)
Control cable, 35 m (115 ft.)
Control cable, 50 m (164 ft.)
Control cable, 75 m (246 ft.)
Control cable, 100 m (328 ft.)
Wheel set LAF 631
0449 500 880
0449 500 881
0449 500 882
0449 500 883
0449 500 884
0449 500 885
0457 787 880
Controllers and Power Sources
Power sources LAF 631, 1001, 1251 and 1601
Cont.
Technical data
LAF 631
LAF 1001
LAF 1251
LAF 1601
Mains supply, 3 ph 50 Hz, V
400/415
400/415/500
400/415/500
400/415/500
Mains supply, 3 ph 60 Hz, V
440
400/440/550
400/440/550
400/440/550
Current 100%, 50 Hz, A
52
64/64/52
99/99/80
136/136/108
Current 100%, 60 Hz, A
52
64/64/52
99/99/80
136/136/108
Fuse, slow, 50 Hz, A
63
63
100/100/80
160/160/125
Fuse slow, 60 Hz, A
63
63
100/100/80
160/160/125
Maximum load at:
100% duty cycle, A/V
80% duty cycle, A/V
60% duty cycle, A/V
630/44
800/44
800/44
1000/44
1250/44
-
1600/44
-
Setting range, A/V
GMAW
SAW
50/17-630/44
30/21-800/44
50/17-1000/45
40/22-1000/45
60/17-1250/44
40/22-1250/44
40/22-1600/46
Open circuit voltage, V
54
52
51
54
Open circuit power, W
150
145
220
220
Efficiency
0.84
0.84
0.87
0.86
Power factor
0.90
0.95
0.92
0.87
Enclosure class
IP23
IP23
IP23
IP23
Dimensions, LxWxH, mm (in.)
670x490x930
(26x19x37)
646x552x1090
(25x22x43)
774x598x1428
(30.5x23.5x56)
774x598x1428
(30.5x23.5x56)
Weight, kg (lbs.)
260 (573)
330 (727.5)
490 (1080)
585 (1290)
Application class
S
S
S
S
Technical data
LAF 1001 M
LAF 1251 M
LAF 1601 M
Mains supply, 3 ph 50 Hz, V
230/400/415/500
230/400/415/500
230/400/415/500
Mains supply, 3 ph 60 Hz, V
230/400/440/550
230/400/440/550
230/400/440/550
Current 100%, 50 Hz, A
111/64/64/52
171/99/99/80
235/136/136/108
Current 60%, 50 Hz, A
138/80/80/65
-
-
Current 100%, 60 Hz, A
111/64/64/52
171/99/99/80
235/136/136/108
Current 60%, 60 Hz, A
138/80/80/65
-
-
Fuse, slow, 50 Hz, A
125/63/63/63
160/125/125/80
200/160/160/125
Fuse, slow, 60 Hz, A
125/63/63/63
160/100/100/80
200/160/160/125
For all other technical information, see LAF 1001, LAF 1251 and LAF 1601, above.
These welding power sources comply with the requirements of EN 60974-1 and IEC 974-1.
S
This symbol indicates that the welding power source may be used in areas with an increased electrical hazard, e.g. areas
where the electrical hazard is increased due to damp and/or the proximity to earthed metal objects.
9
Controllers and Power Sources
Power sources TAF 801 and 1251
Square wave AC power sources for submerged arc welding (SAW)
• Square wave AC power sources that convert the secondary
voltage from a sinus wave via a thyristor controlled rectifier bridge to a square wave arc voltage with excellent strike
characteristics and good welding properties.
• Capacity for continuous welding
• Pre-setting of arc voltage.
• Reliable square wave striking.
• Arc voltage or current feed back.
• Optimized open circuit voltage.
• Compensation of mains supply fluctuation.
• Voltage drop compensation for long welding cables.
• High power factor ensuring low power consumption.
• Designed and built for convenient servicing.
• Safety control voltage 42V.
• Prepared for Scott connection of two power sources.
• Used in combination with ESAB’s A2-A6 equipment range and the A2-A6 Process Controllers (PEK or PEI).
Ordering information
TAF 8010460 516 880
TAF 1251
0460 517 880
Sales LiteratureXA00143920
Options & Accessories
Control cable, 15 m
Control cable, 25 m
Control cable, 35 m
Control cable, 50 m
(49 ft.)
(82 ft.)
(115 ft.)
(164 ft.)
Technical data
TAF 801
TAF 1251
Mains supply, 1 ph 50 Hz, V
400/415/500
400/415/500
Mains supply, 1 ph 60 Hz, V
400/440/550
400/440/550
Maximum load at:
100%duty cycle, A/V
60% duty cycle, A/V
800/44
1000/44
1250/44
1500/44
Setting range, A/V
300/28-800/44
400/28-1250/44
0460 910 881
0460 910 882
0460 910 883
0460 910 884
Open circuit voltage, V
71
72
Open circuit power, W
230
230
Efficiency
0.86
0.86
Power factor
0.75
0.76
Dimensions, LxWxH, mm (in.)
774x598x1428 (30.5x23.5x56)
774x598x1428 (30.5x23.5x56)
Weight, kg (lbs)
495 (1091)
608 (1340)
Enclosure class
IP23
IP23
Application class
S
S
10
Controllers and Power Sources
Power source Aristo® 1000 AC/DC SAW
AC/DC inverter power source for efficient submerged arc welding
• Based on unique and patent pending technologies to deliver the best welding performance with the lowest power consumption.
• Designed for use with the digital PEK controller and the robust A2/A6 feeder units.
• A global inverter - connect to a three phase mains supply from 380 to 575 V, 50 or 60 Hz.
• Change between DC and AC ”on the fly”. Minimize downtime and weld defects by the push of a button with the patent
pending ”on the fly” function.
• CableBoost™ patent-pending technology ensures the performance
of the power source is unaffected even when long welding cables
are used. What you set is what you get.
• Increase productivity up to 65% compared to DC+ welding by using
the higher deposition rate of unbalanced AC with the same heat
input.
• Bead Profile Modelling™ provides adjustable AC settings for
precise control of penetration profile and depth, dilution, arc stability
and weld appearance to achieve the best productivity and quality for
each weld.
Technical data
Mains supply, 3 ph, V, Hz
380-575, 50/60
Mains voltage (DC load), V
380/400/415/440/460/500/550/575
Mains current (DC load), A
86/82/79/74/71/66/59/57
Rated output at 100%, A / V
1000 / 44
AC Balance, %
25-75
AC Offset, A / V
±300 / ±10
AC Frequency, Hz
10-100
Output range, A
200-1000
EMC Filter
included
Parallel connection
Cable requirements, mm
2
Ordering information
Aristo® 1000 AC/DC SAW
0462 100 880
Interconnection cable, 4 m
(for parallel/tandem operation)
0463 282 880
Installation manual
(for parallel/tandem operation)
0740 801 030
Sales literatureXA00171020
available
Options & Accessories
2x95 / 2x120
Control cable, 15 m (49 ft.)
Control cable, 25 m (82 ft.)
Control cable, 35 m (115 ft.)
Control cable, 50 m (164 ft.)
A2-A6 Process controller PEK
Welding cable length (total)
up to 100 m
Remote On/Off input
available
Digital welding regulator
3rd generation
Open circuit voltage, V DC
130
Idle power, W
200
Efficiency at max output
0.88
Power factor
0.93
Dimensions, LxWxH, mm (in.)
865x610x1320 (34x24x52)
Weight, kg (lbs)
330 (727.5)
Enclosure class
IP23
Certification
CE-certified
Third party approvals
CSA, CCC, Ghost-R
0460 910 881
0460 910 882
0460 910 883
0460 910 884
0460 504 880
11
12
Controllers and Power Sources
Welding
Tractors
13
Welding Tractors
Railtrac™ 1000
Multi-purpose system for welding and cutting
•
Ideal for a wide variety automated gas metal arc welding (GMAW) applications.
•
Made from aluminium and steel parts to withstand harsh
environments.
•
Ideal for horizontal to horizontal and vertical (up only)
welding.
• Can be customized with a wide range of accessories.
• New joint system allows for both stiff and flexible rail
applications.
•
Straightforward, well designed programming unit with up to
5 different programs.
•
Standard software offers programmable interval welding and backfill function.
•
Operator can control machine motions with hand held remote without lifting welding visor.
•
Remote Control features: start and stop, shift program, weaving width, zero line displacement and many more.
•
Adjust the welding current and voltage during welding with the two potentiometers on the remote control (when using ESAB
equipment).
•
Remote control only available on FW1000 and FWR1000
models.
Technical data
Railtrac F1000
Flexi
Railtrac FR1000
Flexi Return
Railtrac FW1000
Flexi-Weaver
Railtrac FW1000L
Flexi-Weaver
Railtrac FWR1000
Flexi-Weaver-Return
Mains supply, V AC/DC
36-46/40-60
36-46/40-60
36-46/40-60
36-46/40-60
36-46/40-60
Max power consumption, W
30
30
80
80
80
Weight, excl rails, Kg (lbs)
6 (13)
6 (13)
7 (15)
7 (15)
7 (15)
Dimensions, LxWxH, mm (in.)
170x400x190
(6.7x15.8x7.5)
170x400x190
(6.7x15.8x7.5)
170x350x190
(6.7x13.8x7.5)
170x350x190
(6.7x13.8x7.5)
170x350x190
6.7x13.8x7.5
Flexi rail dimensions, LxW, mm (in.)
60x5 (2.4x0.2)
60x5 (2.4x0.2)
60x5 (2.4x0.2)
60x5 (2.4x0.2)
60x5 (2.4x0.2)
Stiffener bar, LxW, mm (in.)
40x10 (1.6x0.4)
40x10 (1.6x0.4)
40x10 (1.6x0.4)
40x10 (1.6x0.4)
40x10 (1.6x0.4)
Min bend diameter, external, mm (in.)
3000 (118)
3000 (118)
3000 (118)
3000 (118)
3000 (118)
Slide for height adjustment, mm (in.)
±22 (±0.87)
±22 (±0.87)
±22 (±0.87)
-
±22 (±0.87)
Mechanical lateral adjustment, mm (in.)
-
-
±35 (±1.4)
±35 (±1.4)
±35 (±1.4)
Welding speed, cm/min (ipm)
10-150 (3.9-59)
10-150 (3.9-59)
10-150 (3.9-59)
5-99 (1.95-39)
10-150 (3.9-59)
Quick transport, cm/min (ipm)
150 (59)
150 (59)
150 (59)
99 (39)
150 (59)
Prehating time, sec
0.0-9.9
0.0-9.9
0.0-9.9
0.0-9.9
0.0-9.9
Interval welding, cm (in.)
1-99 (0.4-39)
1-99 (0.4-39)
1-99 (0.4-39)
1-99 (0.4-39)
1-99 (0.4-39)
Crater-filling time, sec
0.0-9.9
0.0-9.9
0.0-9.9
0.0-9.9
0.0-9.9
”Backfill”, mm (in.)
0-99 (0-3.9)
0-99 (0-3.9)
0-99 (0-3.9)
0-99 (0-3.9)
0-99 (0-3.9)
Weaving speed, mm/s (ips)
-
-
6-60 (0.2-2.4)
6-60 (0.2-2.4)
6-60 (0.2-2.4)
Weaving width, mm (in.)
-
-
1-30 (0.04-1.2)
1-30 (0.04-1.2)
1-30 (0.04-1.2)
Electrical 0-line displacement, mm (in.)
-
-
±12.5 (±0.5)
±12.5 (±0.5)
±12.5 (±0.5)
Pause time at outer edge, sec
-
-
0.0-9.9
0.0-9.9
0.0-9.9
Weaving pattern, No.
-
-
3
3
3
Number of programs
5
5
5
5
5
Temperature machine and magnets, °C
0-70
0-70
0-70
0-70
0-70
Temperature vacuum attachments, °C
0-90
0-90
0-90
0-90
0-90
Enclosure class
IP23
IP23
IP23
IP23
IP23
14
Welding Tractors
Railtrac™ 1000
System configuration
Railtrac™ F1000 Flexi
Railtrac™ FR1000 Flexi Return
A mechanised system with a flexible combi-rail, suitable for both
inside and outside welding and cutting along sharp curves as well
as straight surfaces. This model is also suitable for thermal cutting.
Railtrac FR1000 has the combi-rail and facilities for movable start
and stop for automatic return for any length. This system is ideal for
use in fixed installations or where a weld is repeated over and over
again.
Railtrac™ FW1000 Flexi Weaver
Railtrac™ FWR1000 Flexi Weaver Return
This version has a flexible combi-rail and a weaver for weaving in
many different patterns. It is also equipped with a remote-controlled
unit with a user-friendly design.
Like the Flexi Weaver, this system has a weaving unit, but it also
has adjustable start, stop and return facilities. Equipped with a
remote control unit with a unique design, this is a very advanced
solution for a number of applications.
15
Welding Tractors
Railtrac™ 1000
Cont.
Ordering information
Railtrac™ F1000 Flexi
Railtrac™ FR1000 Flexi Return
Railtrac™ FW1000 Flexi Weaver
Railtrac™ FW1000L Flexi Weaver (low speed)
Railtrac™ FWR1000 Flexi Weaver Return
Sales Literature
0398 146 002
0398 146 003
0398 146 012
0398 146 014
0398 146 013
XA00135520
Options & Accessories
Standard
Weaving unit *)
Control unit
Remote control *)
Universal Torch holder with slide
Automatic start and stop function **)
Components
Flexible alu-rail, 2.5 m (8 ft.)
0398 146 115
Flexible alu-rail, 2.5 m (8 ft.), 8 magnets
0398 146 112
Flexible alu-rail, 2.5 m (8 ft.), vacuum attachments 0398 146 113
Stiffener Bar, 2.5 m (8 ft.)
0398 146 116
Magnetic attachment 90°, at least 8/2.5 m (8/8 ft.)0398 146 100
Vacuum attachment 90°, at least 4/2.5 m (4/8 ft.)0398 146 104
Vacuum attachment 200°, at least 4/2.5 m (4/8 ft.)0398 146 105
Screw attachment for stiffened rail
0398 146 114
Accessories
Torch holder
Adapter for stiffened rail attachments
Universal pivoted torch holder
Attachment for IMP cutting toch
Torch angle attachment
Tilt unit for weaving unit *)
Turning unit for weaving unit *)
”Floating” head
IMP cutting torch
Transport and storage box
Control cable, 5 m (16.4 ft.)
AristoFeed wire feeder adaptor kit
Universal control cable, 5 m (16.4 ft.)
Transformer kit
*) FW1000, FW1000L, FWR1000 only
**) FR1000 and FWR1000 only
16
0398 145 101
0398 146 106
0398 145 104
0398 145 260
0398 145 215
0398 145 200
0398 145 201
0398 145 211
0398 145 250
0398 145 199
0457 360 880
0458 757 881
0457 360 881
0457 467 880
Welding Tractors
Railtrac™ Orbital W
The machine to automate your tube welding
The Railtrac™ Orbital W is a superb alternative if you wish to
automate your tube welding. It is ideal for use with ESAB’s semiautomatic power sources and feed units.
The Railtrac Orbital W is a small compact motor powered tractor.
A standard ESAB welding torch can be attached quickly. Two motors guarantee an even, stable movement on the rail.
The control box allows you to control the following parameters and
store 5 different welding programs:
• Start and stop
• Shift program
• Travel or welding direction
• Travel or welding speed
• Weaving width
• Zero line displacement
• Welding current (wire feed speed)
• Welding voltage
• Backfill function
Ordering information
Technical data
Railtrac™ Orbital W
0398 146 032
Control voltage, V AC
36-46
Power, W
90
Connection
Burndy, 12 pins
Options & Accessories
Welding speed, cm/min (ipm)
5-99 (2-39)
Slide for height adjustment, mm (in.)
±22 (±0.9)
Floating head
0398 145 211
Weaving speed, mm/sec. (ips.)
6-60 (0.2-2.4)
Weaving width, mm (in.)
1-30 (0.04-1.2)
Pause time at outer edge, sec
0.0-9.9
Electrical 0-line displacement, mm (in.)
±12.5 (±0.5)
Number of programs
5
Dimensions (LxWxH), mm (in.)
312x327x181 (12.3x12.9x7.1)
Weight, kg (lbs)
8 (17.6)
Enclosure class
IP 23
Orbital ring 6”
Orbital ring 8”
Orbital ring 10”
Orbital ring 12”
Orbital ring 14”
Orbital ring 16”
Orbital ring 18”
Orbital ring 20”
Orbital ring 22”
Orbital ring 24”
Orbital ring 26”
Sales Literature
0449 900 706
0449 900 708
0449 900 710
0449 900 712
0449 900 714
0449 900 716
0449 900 718
0449 900 720
0449 900 722
0449 900 724
0449 900 726
XA00133720
Larger ring sizes available on request
17
Welding Tractors
Railtrac™ BV/BVR 1000
Programmable equipment for hardfacing and repair of rail profiles
•
Light weight makes it quick and easy to remove the aluminium travel beam from rail or crossing and simple to restore to its
original position on the work piece.
• It can be used with a number of different power sources and
wire feeder combinations.
•
Precise adjustments of the weaving pattern, travel speed and zero line can all be achieved during welding.
• Welding parameters are adjustable from the remote control.
• CE and EMC approved.
• IP 23 enclosure class makes it suitable for use out-doors.
Control voltage level of 42V AC is safe for use anywhere.
Ordering information
Railtrac™ BV 1000, complete excl weld equipment
Railtrac™ BVR 1000, complete excl weld equipment
Torch holder
Sales Literature
0398 145 002
0398 145 003
0398 145 101
XA00067820
Technical data
Control voltage, V AC / V DC
36-46 / 40-60
Max. output consumption, W
80
Weight excl. rail, kg (lbs.)
7 (15.4)
Weight of rail 2 m, kg (lbs.)
4 (8.8)
Slide for adjusting height of torch, mm (in.)
±22 (±0.9)
Mechanical lateral adjustment, mm (in.)
200 (7.9)
Gun attachment universal, mm (in.)
Ø 12-36 (Ø 0.5-1.4)
Max. effective weld length, mm (in.)
1500 (59)
Welding speed, cm/min (ipm)
10-150 (0.2-59)
Fast transport speed, cm/min (ipm)
150 (59)
Weaving speed, mm/s (ips)
7-50 (0.3-2.0)
Weaving width (W), mm (in.)
1-80 (0.04-3.1)
Zero-line shift, mm (in.)
25 / ±12.5 (1.0 / ±0.5)
Programmable edge length (L), cm (in.)
6-99 (2.4-39)
Number of programs
BV: 4, BVR: 6
Enclosure class
IP23
18
Welding Tractors
Tramtrac™ II
A cost-efficient and flexible solution for the repair of embedded city tramway rails.
Tramtrac™ II is ESAB’s latest equipment for the repair of embedded grooved city tramway rails. Using the FCAW process with selfshielded wires, instead of the conventional SAW process, provides
a number of advantages in terms of ease of use and cost-efficiency.
•
The FCAW process makes Tramtrac™ II a small and ultra light-
weight solution.
• Easy to store and move around from site to site.
• The tractor can be hand-carried and is easily installed and
removed on and off the rail, allowing trams to pass within a
controlled safety situation.
Ordering information
Tramtrac™ II
0814 721 880
Connection cable 10 m (33 ft.)
0457 360 884
Origo™ MIG 410
0349 303 563
Origo™ MIG 510
0349 303 565
Magnetic earth return cable & clamp
0000 500 415
OK Tubrodur 14.71, 1.6 mm (1/16 in.)
1471 167 730
OK Tubrodur 15.65, 1.6 mm (1/16 in.)
1565 167 730
Sales LiteratureXA00133420
Technical data
Control voltage, V AC
36-46
Power, W
90
Welding speed, cm/min (ipm)
30-120 (11.8-47.2)
Dimensions LxWxH, mm (in.)
600x300x150
(23.6x11.8x5.9)
Weight without consumables, kg (lbs.)
12 (26.5)
19
Welding Tractors
Miggytrac™ 1001
The perfect complement to your GMAW power source
• Small, compact, motorized tractor.
• Easy to attach to ESAB welding torch.
• The tractor is held in the correct position on the workpiece with
a magnet, even if the workpiece is bent or angled.
• Remote controlled travel.
• Start/stop function from the remote control panel.
• Travel speed settings of 150-1200 mm/min (6-47 ipm), wire feed speed and voltage all functions of the remote control.
• Significantly increased welding speed, especially when using cored wire.
Ordering information
Miggytrac™ 1001
0457 357 881
Welding screen
0457 463 880
Sales LiteratureXA00126320
Options & Accessories
ESAB Control cable, 5 m (16.4 ft)
0457 360 880
ESAB AristoFeed adaptor kit
0459 681 880
Universal control cable, 5 m (16.4 ft)
0457 360 881
(12 pin male-23 pin male Burndy style)
Origo™ Feed and Aristo™Feed feeders
(required for connection of Miggytrac to
Aristo™ Feed feeders)
(12 pin male Burndy style-open end).
Requires user-supplied plug to connect
cable to OEM feeders)
Technical data
Control voltage, V AC
36-46
Power, W
20
Welding speed, mm/min (ipm)
150-1200 (6-47)
Remote control outlet
Volt and ampere
(wire feed speed)
Connection
Burndy, 12 pins
Dimensions, LxWxH, mm (in.)
266x257x267
(10.5x10x10.5)
Weight, kg (lbs.)
7 (15.4)
20
Welding Tractors
Miggytrac™ 2000
The perfect complement to your GMAW power source
•
Ideal for long welds eliminating stressful welding positions for the welder.
•
The tractor is held in the correct position on the workpiece with a magnet, even if the workpiece is bent or angled.
•
Guide wheels adjust to allow the unit to drive itself against the workpiece.
• Program for intermittent welding.
• Set length of weld and distance between welds from 1-99 cm (0.4-39 in.)
•
High-speed travel between welds - 250 cm/min (98 ipm)
- for increased efficiency.
• Backfill function for crater filling at the end of the weld.
• Adjust the welding current and voltage during welding with the two potentiometers on the control panel (when using ESAB equipment).
Ordering information
Miggytrac™ 2000
0457 358 880
Welding screen
0457 463 881
Sales LiteratureXA00104720
Options & Accessories
ESAB Control cable, 5 m (16.4 ft)
0457 360 880
ESAB AristoFeed adaptor kit
0459 681 880
Universal control cable, 5 m (16.4 ft)
0457 360 881
(12 pin male-23 pin male Burndy style)
Origo™ Feed and Aristo™ Feed feeders
(required for connection of Miggytrac to
Aristo™ Feed feeders)
(12 pin male Burndy style-open end).
Requires user-supplied plug to connect
cable to OEM feeders)
Technical data
Control voltage, V AC
36-46
Power, W
40
Welding speed, mm/min (ipm)
150-1500 (6-59)
Fast travel speed, cm/min (ipm)
250 (98.4)
Programmable Interval Welding, cm (in.)
1-99 (0.4-37)
Linear slide stroke length
(horizontal), mm (in.)
±17 (±0.67)
Remote control outlet
Volt and ampere
(wire feed speed)
Connection
Burndy, 12 pins
Crater fill time, s
0-9.9
Backfill, cm (in.)
0-9.9 (0-4)
Dimensions, LxWxH, mm (in.)
330x260x360
(13x10x14)
Weight, kg (lbs)
9.5 (21)
21
Welding Tractors
Miggytrac™ 3000
The complete small welding automat for Gas Metal Arc Welding
•
Small, compact, motorized tractor with integrated wire feed and water-cooled welding torch designed for horizontal
mechanized MIG welding of plates and beams
• Four-wheel drive carriage
• Carriage can travel diagonally towards the flange or stiffener to be welded.
• Program for intermittent welding.
• Carriage motion and wire feed controlled separately.
• Set weld length and distance between welds from 1-99 cm (0.4-39 in.)
•
Distance between beads run at transport speed of 250 cm/min (98 ipm) for optimal efficiency.
• Program wire feed speed, time for gas pre-flow, gas post-flow and burnback.
Ordering information
Miggytrac™ 3000
0457 359 880
With straight, water-cooled swan neck
Delivered without contact tip
Sales LiteratureXA00123620
Technical data
Wire dimensions, mm (inch)
- Unalloyed steel
- Stainless steel
- Cored wire
1.0-1.4 (0.040 - 0.055)
1.0-1.4 (0.040 - 0.055)
1.0-1.4 (0.040 - 0.055)
Control voltage, V AC
36-46
Power, W
80
Welding speed, mm/min (ipm)
150-1500 (6-59)
Transport speed, cm/min (ipm)
250 (98.4)
Lengths at Intermittent welding, cm (in.)
1-99 (0.4-39)
Crater fill time, sec.
0-9.9
Backfill, cm (in.)
0-9.9 (0-4)
Wire feed speed, m/min (ipm)
2-25 (79-984)
Gas pre-flow/post-flow, sec
0-9.9
Burnback, sec.
0-9.9
Filler wire reel, in.
12
Dimensions, LxWxH, mm (in.)
370x400-530x520
(14.5x16-21x20.5)
Linear slide stroke length (horizontal), mm (in.)
±17 (±0.67)
Remote control, max value, Kohm
2.5
Max current over the start relay, A
5
Connection
straight 23-pin Burndy
Enclosure class
IP 23
Weight, excl wire reel, kg (lbs.)
17 (37.5)
22
Options & Accessories
Contact Tip M8 x 37 CuCrZr
- CO2 1.0
- CO2 1.2, Mix/Ar 1.0
- CO2 1.4, Mix/Ar 1.2
0468 502 005
0468 502 007
0468 502 008
Gas nozzle, water-cooled
Bent swan neck, 15°
Bent swan neck, 30°
Wire feed roller for aluminium
Pressure roller for aluminium
0449 903 101
0449 903 115
0449 903 130
0449 903 031
0449 903 032
For Connection cables and Adaptor Kit, please see separate
leaflet for Miggytrac 3000.
Welding Tractors
A2 Multitrac with A2 process controller PEI
The universal welding tractor for better welding economy
• Can be connected to most analogue, DC power supplies.
• Compact and efficient design allows for easy movement between workpieces.
•
Self-propelled, four-wheel drive for stable, accurate and
constant operation.
•
A2 Process Controller PEI allows simple setting of travel speed, voltage and wire feed speed.
•
Heavy-duty feed unit ensures an even and stable wire feed,
for top quality, homogenous welding.
•
Horizontal, vertical and rotary slides allow for quick adjustment of the nozzle into various positions.
•
Reliable mechanical components, even under harsh working conditions.
•
Easy to use control equipment with different start methods; direct start or scratch start.
• Wide range of accessories available.
Ordering information
Options & Accessories
A2 Multitrac SAW, PEI0449 360 880
A2 Multitrac SAW Twin, PEI0449 360 881
A2 Multitrac GMAW, PEI0449 361 880
Sales LiteratureXA00114220
Guide wheel bogie
Idlling roller
Guide bar 3 m (10 ft.)
V-guide wheel
V-wheeltrack in steel
Loop for connection of two tractors
Pilot lamp, laser diode
Technical data
Wire diameters, mm (in.)
- Steel
- Stainless steel
- Cored wire
- Aluminium
0413 542 880
0333 164 880
0154 203 880
0333 098 881
0443 682 881
0334 680 881
0821 440 880
Single SAW
Twin SAW
GMAW
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
-
2x1.2-2.5 (2x(0.45x3/32))
2x1.2-2.5 (2x(0.45x3/32))
-
0.8-1.6
0.8-1.6
1.2-2.4
1.2-1.6
(.030-1/16)
(.040-1/16)
(.045-3/32)
(.045-1/16)
Max wire feed speed, m/min (ipm)
9 (354)
9 (354)
16 (630)
Wire reel weight, kg (lbs.)
30 (66)
2x15 (2.2x33)
30 (66)
Flux hopper capacity, l (gal.)
6 (1.4)
6 (1.4)
-
Weight, excl wire and flux, kg (lbs.)
47 (103)
47 (103)
43 (95)
Permissible load 100%, A
800
800
600
Control voltage, V AC
42
42
42
Travel speed, m/min (ipm)
0.1-1.7 (4-67)
0.1-1.7 (4-67)
0.1-1.7 (4-67)
Linear slides stroke length, mm (in.)
90 (3.5)
90 (3.5)
90 (3.5)
Rotary slide setting angle
360°
360°
360°
23
Welding Tractors
A2 Multitrac with A2/A6 process controller PEK
The universal welding tractor for Submerged-arc Welding (SAW) and Gas Metal Arc Welding (GMAW)
• The A2 Multitrac with the A2/A6 process controller PEK is
available for both the SAW and the GMAW method.
•
If the SAW-version is chosen, the A2 Multitrac is capable of working equally well with either single or twin wire.
• The feed unit secures an even, stable wire-feed speed.
• Four-wheel drive ensures accurate travel speed.
• Digital control panel allows exact pre-set and control of welding parameters.
•
The Multitrac is fully mobile and can easily be moved from one welding station to another. It can also be quickly set-up for
different workpieces.
• Designed for use with LAF or TAF welding power sources.
Ordering information
A2 Multitrac A2TF (SAW), PEK
A2 Multitrac A2TF (SAW Twin), PEK
A2 Multitrac A2TG (GMAW), PEK
A2 Multitrac A2TG (4WD, GMAW MTW 600), PEK
Sales Literature SAW
Sales Literature GMAW
0461 233 880
0461 233 881
0461 234 880
0451 234 881
XA00143220
XA00143320
Options & Accessories
Guide wheel bogie
Idlling roller
Guide bar 3 m (10 ft.)
V-guide wheel
V-wheeltrack in steel
Loop for connection of two tractors
Pilot lamp, laser diode
0413 542 880
0333 164 880
0154 203 880
0333 098 881
0443 682 881
0334 680 881
0821 440 880
Single SAW
Twin SAW
Single GMAW
GMAW with
MTW 600
Wire diameters, mm (in.)
- Steel
- Stainless steel
- Cored wire
- Aluminium
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
-
2x1.2-2.5 (2x(0.45x3/32))
2x1.2-2.5 (2x(0.45x3/32))
-
0.8-1.6
0.8-1.6
1.2-2.4
1.2-1.6
1.0-1.6
1.0-1.6
1.0-2.4
1.0-2.0
Max wire feed speed, m/min (ipm)
9 (354)
9 (354)
16 (630)
25 (984)
Wire reel weight, kg (lbs.)
30 (66)
2x15 (2.2x33)
30 (66)
30 (66)
Flux hopper capacity, l (gal.)
6 (1.4)
6 (1.4)
-
-
Weight, excl wire and flux, kg (lbs.)
47 (103)
47 (103)
43 (95)
43 (95)
Permissible load 100%, A
800
800
600
600
Control voltage, V AC
42
42
42
42
Travel speed, m/min (ipm)
0.1-1.7 (4-67)
0.1-1.7 (4-67)
0.1-1.7 (4-67)
0.1-1.7 (4-67)
Linear slides stroke length, mm (in.)
90 (3.5)
90 (3.5)
90 (3.5)
90 (3.5)
Rotary slide setting angle
360°
360°
360°
360°
Technical data
24
(.030-1/16)
(.040-1/16)
(.045-3/32)
(.045-1/16)
(.039-1/16)
(.039-1/16)
(.039-3/32)
(.039-5/64)
Welding Tractors
A2 Tripletrac A2TF
The superb welding tractor for internal circumferential welding
• For increased productivity and quality.
• Ideal for internal circumferential welding of large cylindrical
objects that are rotating on a turning roll system.
•
Heavy-duty feed unit secures even and stable wire feed for top quality, homogenous welds.
•
Delivered with either the digital A2-A6 PEK or the analogue A2 PEI process controller.
•
Unique steering system allows operator to simultaneously
adjust the wheel and torch position for accurate and effortless seam tracking.
• Control equipment is easy to use and requires minimal training.
• Choose between start methods, burn-back times and other
settings.
Ordering information
A2 Tripletrac with PEK 0461 236 880
A2 Tripletrac with PEI
0449 430 881
Sales LiteratureXA00143520
Options & Accessories
Pilot lamp, laser diode
0821 440 880
Utility light, incl transf. and 50 m (164 ft.) cable 0449 443 880
Flux recovery unit OPC
0148 140 880
Bracket suction
0332 947 880
Flux hopper of silumin alloy
0413 315 881
Concentric flux feeding funnel
(included in the A2 Tripletrac)
0145 221 881
Contact tube, bent
0413 511 001
Wire reel, plastic 30 kg (66 lbs.)
0153 872 880
Wire reel, steel, fixed width
0416 492 880
Wire reel, steel, flexible width
0449 125 880
Wire reel, steel, Ø 220 mm (8.6)
0671 164 080
Technical data
Wire diameters, mm (in.)
- Steel
- Stainless steel
- Cored wire
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
Max wire feed speed, m/min (ipm)
9 (354)
Wire reel weight, kg (lbs.), W
30 (66)
Flux hopper capacity, l (gal.)
6 (1.4)
Weight, excl. wire and flux, kg (lbs.)
47 (103)
Permissible load 100%, A
800
Control voltage, V AC
42
Travel speed, m/min (ipm)
0.1-1.7 (4-67)
Linear slides stroke length, mm (in.)
90 (3.5)
Rotary slide setting angle
360°
Max inclination for the tractor
5°
25
Welding Tractors
A6 Mastertrac A6TF (SAW)
For efficient Submerged-arc Welding
• Self-propelled, four-wheel drive automatic welding machine.
• Easy to move with quick set-up for different workpieces.
• Suitable for heavy production welding with capacity for up to
6 mm (0.24 inch) wire using 1500A direct or alternating current.
• Designed for use with LAF or TAF welding power sources.
• Three different designs:
Single: available with standard or high speed motor
Twin-Arc: with a simple add-on for the extra wire, you can convert
an A6 Single Mastertrac into a highly productive automatic Twinarc welder for fillet and butt welds without the use of an extra
machine or power source.
Tandem: the high deposition rate using a multi-electrode system
increases productivity substantially. By selecting different combinations of direct and alternating currents, the A6 Tandem Mastertrac can handle any type of welding work resulting in increased
profitability.
Options & Accessories
•
Weld mild steel and aluminium solid or cored wire by modifying an A6 Single Mastertrac with an easy conversion kit for Gas metal arc welding (GMAW).
•
Pre-set and control of welding parameters with the A2-A6
Process Controller PEK - a digital control system with display menus; 255 different weld sets can be stored.
Ordering information
A6 Mastertrac A6TF (SAW)
A6 Mastertrac A6TF (SAW Twin)
A6 Mastertrac A6TF (SAW, high speed)
A6 Mastertrac A6TF (SAW, Twin, high-speed)
A6 Mastertrac Tandem A6TF (SAW, AC/DC 1500)
Sales Literature
A6 Mastertrac Tandem
0461 235 880
0461 235 881
0461 235 890
0461 235 891
0461 232 882
XA00143420
Contact equipment heavy Twin Arc, compl.
Wire reel, plastic 30 kg (66 lbs.)
Wire reel, steel 30 kg (66 lbs.)
Wire reel, steel, flexible width
Brake hub extra
Rebuilding kit GMAW
Strip cladding kit
Flux hopper holder for strip cladding
Wire reel, steel for strip cladding
30-100 mm (1.2-4.0 in.)
Flux recovery nozzle, strip cladding
Flux funnel
Insert, extended
Angular slide
Pilot lamp, laser diode
Flux recovery unit OPC
Bracket suction
Idler rollers (2 per automat)
Guide wheel, fillet
Magnet guide rail, 3 m (10 ft.)
Carbon arc gouging
Rebuilding kit
(use with carbon electrodes Ø 8.9-12.7)
VEC-motor, 312:1
0334 291 889
0153 872 880
0416 492 880
0449 125 880
0146 967 880
0334 299 890
0155 972 880
0148 107 003
0671 161 880
0156 025 001
0254 900 880
0254 900 301
0671 171 580
0821 440 880
0148 140 880
0332 947 880
0333 164 880
0671 125 780
0154 203 880
0153 592 880
0145 063 905
Technical data
Single SAW
Single GMAW
Twin SAW
Tandem SAW
Permissible load 100%, A
1500
600
1500
2x1500
Wire diameter, mm (in.)
3.0-6.0 (1/8-1/4)
1.0-3.2 (0.045-1/8)
2x2.0-3.0 (2x3/32-1/8)
2x3.0-6.0 (2x1/8-1/4)
Wire feed speed, m/min (ipm)
0.2-4.0 (8-157.5)
0.8-16.6 (31.5-653.5)
0.2-4.0 (8-157.5)
0.2-4.0 (8-157.5)
Wire feed speed high, m/min (ipm)
0.4-8.0 (16-315)
-
0.4-8.0 (16-315)
-
Travel speed, m/min (ipm)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
Control voltage, V AC
42
42
42
42
Wire reel weight, kg (lbs.)
30 (66)
30 (66)
2x30 (2x66)
2x30 (2x66)
Flux hopper capacity, l (gal.)
10 (2.6)
-
10 (2.6)
10 (2.6)
Weight excl wire and flux, kg (lbs.)
110 (242.5)
100 (220.5)
110 (242.5)
158 (348)
26
Welding Tractors
A6-DK
The portal welding machine
• Works with a single wire on each head.
• Each weld head is controlled by the A2-A6 PEK process
controller and LAF (DC) or TAF (AC) power source.
•
Ideal for simultaneous horizontal-vertical welding on both sides of a web or through panel.
•
Straddles workpieces up to 800 mm (31 inch) tall and
symmetrical profile widths of 400 mm (16 inch).
• Travels directly on a workpiece guided by a joint.
• Travel speed adjustable from 0.15-2.0 m/min (6-79 ipm).
• Store up to 10 l (2.6 gal.) of flux in the hopper.
• Each weld head is equipped with OPC flux recovery system.
Ordering information
A6-DK SAW, single wire
excl. wire reel, feed rollers and contact jaws *) 0461 237 901
Sales Literature
XA00143620
*) when contact equipment is excluded, feed rollers and contact jaws have
to be ordered separately.
Options & Accessories
Wire reel, plastic, 30 kg (66 Ibs.)
Wire reel, steel, 30 kg (66 Ibs.)
0153 872 880
0416 492 880
Technical data
Permissible load 100%, A
1500
Travel speed, m/min (ipm)
0.15-2.0 (6-79)
Wire feed speed, m/min (ipm)
0.2-4.0 (8-157.5)
Wire reel weight, kg (lbs.)
2x30 (2x66)
Wire diameter SAW, mm (in.)
3.0-6.0 (1/8-1/4)
Flux hopper capacity (each weld head), l (gal.)
10 (2.6)
Weight, excl wire and flux, kg (lbs.)
150 (331)
Straddle opening:
Vertical space limitation, mm (in.)
Longitudinal. symmetrical extension,
mm (in.)
800 (31)
400 (16)
27
28
Mechanized & Orbital TIG
Welding
Heads
29
Welding heads
A2S Mini Master
A multi-purpose automatic welding system
•
Versatile welding system for single wire SAW, twin wire
SAW or GMAW.
• Light-weight, compact design allows for greater flexibility.
• Modular design allows user to expand, integrate or modify the system quickly and easily.
• Uses A2-A6 PEK or A2 PEI process controller.
• Accurate, easy joint-tracking with manual or motorized slide system and manual PAV or automatic GMH joint tracking.
• The system attaches to any beam travelling carriage or
Column & Boom system.
Ordering information
Options & Accessories
A2S Mini Master SAW Systems
Pilot lamp, laser diode (for PEK), 2 m cable
Pilot lamp, laser diode (for PEK), 5 m cable
Pilot lamp, laser diode (for PEK), 7 m cable
Thin wire straightener, single wire
0821 440 880
0821 440 882
0821 440 883
0332 565 880
Gas handling equipment, GMAW only:
Cooling unit OCE 2H, 220V AC 50/60 Hz
Gas hose
Water-cooling hose
Arc shield
0414 191 881
0190 270 101
0190 315 104
0334 689 880
Optional equipment SAW:
Flux recovery unit OPC
Flux container, silumin alloy
Concentric flux funnel
Contact tube, bent
Wire reel, plastic, 30 kg (66 lbs.)
Wire reel, steel, 30 kg (66 lbs.)
Wire reel, steel, flexible width
Wire reel, steel, Ø 220 mm (8.7 inch)
0148 140 880
0413 315 881
0145 221 881
0413 511 001
0153 872 880
0416 492 880
0449 125 880
0671 164 080
Incl A2-A6 Process controller PEK and wire equipment
With manual slides 90x90 mm
With motorized slides 180x180 mm and PAV
With motorized slides 180x180 mm and GMH
0449 170 900
0449 170 901
0449 170 902
Incl A2 Process controller PEI and wire equipment
With manual slides 90x90 mm
With motorized slides 180x180 mm and PAV
With motorized slides 180x180 mm and GMH
0449 370 880
0449 370 881
0449 370 882
A2S Mini Master GMAW MTW (4WD) Systems
Incl A2-A6 Process controller PEK and wire equipment
With manual slides 90x90 mm
With motorized slides 180x180 mm and PAV
With motorized slides 180x180 mm and GMH
0449 181 900
0449 181 901
0449 181 902
Incl A2 Process controller PEI and wire equipment
With manual slides 90x90 mm
With motorized slides 180x180 mm and PAV
With motorized slides 180x180 mm and GMH
0449 380 880
0449 380 881
0449 380 882
For PEK:
Conversion kit, SAW to GMAW A2 (2WD) 0461 247 880
Conversion kit, SAW to GMAW MTW (4WD) 0461 248 880
For PEI:
Conversion kit, SAW to GMAW
0413 526 881
Technical data
Single wire
SAW
Twin wire
SAW
GMAW
Wire diameter, mm (in.) Steel
Stainless Steel
Cored wire
Aluminium
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
-
2x1.2-2.5 (2x.045-3/32)
-
0.8-1.6
0.8-1.6
1.2-2.4
1.2-1.6
Max. wire feed speed, m/min (ipm)
9 (354)
9 (354)
16 (630)
25 (984)
Flux hopper capacity, l (gal.)
6 (1.4)
6 (1.4)
-
-
Max. permissible load 100%, A
800
800
600
600
Control voltage, V AC
42
42
42
42
Linear slide stroke length, mm (in.)
90 (3.5)
90 (3.5)
90 (3.5)
90 (3.5)
Rotary slide setting range
360°
360°
360°
360°
30
GMAW MTW 600w
(.030-1/16)
(.030-1/16)
(.045-3/32)
(.045-1/16)
1.0-1.6
1.0-1.6
1.0-2.4
1.0-2.0
(.040-1/16)
(.040-1/16)
(.040-3/32)
(.040-5/64)
Welding Heads
A2 Component system Modularization - PEK
Wire feed unit
Cable kit
Control unit
Slides
Holder
Carrier
Control unit
0449 100 883
SAW single
0449 150 900
T 1.6 m
0449 153 900
Manual
0449 152 880
PEK
0460 504 880
Tractor
0449 154 880
PAV *)
SAW Twin
0449 150 901
S 5.0 m
0449 153 905
Motorised
0449 151 880
PAV/GMH
Cables
0461 215 880
Head
0449 155 880
GMH *)
GMAW 2 WD
0449 150 902
*) article numbers for PAV and GMH, see chapter Accessory components.
GMAW 4 WD
0449 150 903
A2 Component system Modularization - PEI
Wire feed
Cable kit
Control unit
Slides
Holder
T 1.6 m
0449 153 980
S 5.0 m
0449 153 985
SAW Twin
0449 150 881
Control unit
0449 100 882
Manual
0449 152 880
SAW single
0449 150 880
Carrier
Tractor
0449 154 880
PEI
0449 330 880
PAV *)
Motorised
0449 151 880
PAV/GMH
Cables
0461 215 880
Head
0449 155 880
GMH *)
GMAW 2 WD
0449 150 882
*) article numbers for PAV and GMH, see chapter Accessory components.
31
Welding heads
A6S Arc Master
Flexibility as standard
• Flexibility, reliability and superior performance capability
• Comprehensive component and module system make process customization easy.
• A6 VEC motor for reliable and consistent wire feed.
• Accurate, easy manual PAV or automatic GMH joint tracking with manual slides or joystick-controlled motor-operated cross slides.
• Capable of heavy-duty gas metal arc welding (GMAW),
single/twin wire submerged arc welding (SAW), as well as
strip cladding and Integrated Cold Electrode (ICE) welding with
optional accessories.
•
Uses A2-A6 PEK process controller for fast, accurate pre-setting of all parameters before welding starts.
•
Feedback system ensures high and consistent welding quality - saves time and material.
•
The welding heads can be equipped with a standard wire feed unit (gear ratio 156:1) or with a high-speed wire feed unit
(gear ratio 74:1).
Ordering information
Single wire SAW systems
standard wire feed unit (gear ratio 156:1)
With manual slides 210x210 mm
With motorized slides 300x300 mm and PAV
With motorized slides 300x300 mm and GMH
0449 270 900
0449 270 901
0449 270 902
high-speed wire feed unit (gear ratio 74:1)
With manual slides 210x210 mm
With motorized slides 300x300 mm and PAV
With motorized slides 300x300 mm and GMH
0449 270 910
0449 270 911
0449 270 912
Twin-wire SAW system
high-speed wire feed unit (gear ratio 74:1)
With manual slides 210x210 mm
With motorized slides 300x300 mm and PAV
With motorized slides 300x300 mm and GMH
0449 271 910
0449 271 911
0449 271 912
Technical data
Ratio 156:1
Ratio 74:1
Max. wire feed speed, m/min (ipm)
0.2-4.0 (8-157)
0.4-8.0 (16-315)
Wire diameter, single, mm (in.)
3.0-6.0 (0.118-0.236)
1.6-4.0 (0.063-0.157)
Wire diameter, twin, mm (in.)
2x2.0-2x3.0 (2x0.079-2x0.118)
2x1.6-2x2.5 (2x0.063-2x0.098)
Tubular wire single, mm (in.)
3.0-4.0 (0.118-0.157)
1.6-4.0 (0.063-0.157)
Linear slide stroke length, mm (in.)
90 (3.5)
90 (3.5)
Rotary slide setting range
Circular slide, crank operated
Straightener
± 180°
± 45°
± 180°
± 45°
Max. permissible load, 100%, A
1500
1500
32
Welding Heads
A6 Component system Modularization
Wire feed unit
Single
0449 250 880
Cable kit
T 1.6 m
0449 253 900
Slides
Control unit for
motorised slides
Manual T
0449 252 880
Holder
Holder
0449 254 880
GMH *)
Twin
0449 250 881
Carrier
Control unit
0449 490 881
PEK
0460 504 880
PAV *)
Bobbin holder
0449 255 880
Single High-speed
0449 250 890
Twin High-speed
0449 250 891
S 5.0 m
0449 253 902
Motorised
0449 251 884
Manual S
0449 252 881
PAV/GMH cables
0461 215 880
Bobbin holder
0449 255 881
*)article numbers for PAV and GMH,
see chapter Accessory components.
33
Welding heads
A6S and A6DS Tandem welding heads
For optimum productivity
• Suitable for heavy construction welding.
• Capable of welding DC/DC, DC/AC or AC/AC.
• Uses A2-A6 Process Controller PEK for quick and accurate programming of welding parameters for each torch.
•
Feedback system gives high and consistent welding quality from start to finish, saving time and money.
•
Versatile positioning through easy to use, complete slide as
sembly for welding torch position, distance stick-out and angle on both leading and trailing torches.
•
Enhance productivity by adding optional equipment such as Twin Wire and Integrated Cold Wire systems.
•
Available in two basic versions, A6S Tandem Master and A6DS Tandem Master with several configurations to match specific
safety, quality and productivity requirements.
•
Welding heads can be equipped with a standard wire feed unit (gear ration 156:1) or with a high-speed wire feed unit
(gear ratio 74:1).
Ordering information
Options & Accessories
A6S Tandem Master, standard (156:1)
0818 971 880
A6S Tandem Master, high-speed (74:1)
0818 971 881
A6DS Tandem Master, standard (156:1)
0818 970 880
A6DS Master, high-speed (74:1)
0818 970 881
Sales LiteratureXA00119120
Twinkit (one per torch)
GMH, joint tracking with remote, complete
GMH, joint tracking with control panel, compl
GMH, slide motor cables, 5.0 m (16 ft.)
Laser lamp, 5 m cable (16 ft.)
Laser lamp, 7 m cable (23 ft.)
Bracket (straight) for wire
Brake hub, for wire reel
Wire reel, plastic, 30 kg (66 Ibs.)
Wire reel, steel, fixed width, 30 kg (66 Ibs.)
Wire reel, steel, flexible width, 30 kg (66 Ibs.)
0809 934 882
0460 884 880
0460 884 881
0461 215 880
0821 440 882
0821 440 883
0334 318 880
0146 967 880
0153 872 880
0416 492 880
0449 125 880
Technical data (Basic components)
A6S Tandem Master
A6DS Tandem Master
A6 feed unit HD type for wire 3-6 mm (1/8-1/4 in.)
2 pcs
2 pcs
Horizontal motorized slide with double runners L=355 mm (14 in.)
1 pc
1 pc
Vertical motorized slide with double runners L=595 mm (23.4 in.)
1 pc
1 pc
PEK, process controller
2 pcs
2 pcs
Flux hopper, 10 l (2.3 gal.) incl bracket
1 pc
1 pc
Cable holder
1 pc
1 pc
Main bracket with mounting flange for cross slide assembly
1 pc (0810 786 880)
-
Swivel bracket for rotating head 90°
1 pc (0334 549 880)
1 pc (0809 873 880)
Welding head
2 pcs
2 pcs
Each welding head has:
A6 manual slide L=90 mm
A6 circular slide
Insulators
1 pc (0154 465 880)
1 pc (0671 171 580)
4 pcs (0278 300 180)
1 pc (0154 465 880)
1 pc (0671 171 580)
4 pcs (0278 300 180)
Total weight (excl PEK, wire and flux) approx. kg (lbs)
215 (474)
190 (419)
34
Welding Heads
A6S and A6DS Tandem welding heads
cont.
A6S Tandem Master
A6DS Tandem Master
Optimized for welding across multiple perpendicular axes and is key in the welding of cylindrical objects where both longitudinal and circumferential welding is required.
Optimized for welding in multiple directions and is key in the automated welding of long weld joints such as beams and
girders.
•
• Adjustable +90° interval turning bracket and cross slide.
• Automatic joint tracking keeps in track no matter which direction welding occurs.
•
• Adjustable ±90° interval turning bracket and fixed cross slide.
• Automatic joint tracking in any direction when integrated to ESAB column and boom M-model systems; simply rotate the head 180° and weld in the reverse direction.
35
Welding heads
A6S Compact welding heads for internal welding
For excellent welding results
•
For welding longitudinal and circumferential butt joints inside tubes.
• Three versions available:
A6S Compact 300 for internal welding of tubes down to 300 mm (12 inch) inside diameter.
A6S Compact 500 for internal welding of tubes down to 500 mm (20 inch) inside diameter.
A6S Compact 700 for internal welding of tubes down to 700 mm (27.5 inch) inside diameter.
A6S Compact 300
Longitudinal welding
Min ID circ. welding
300 mm
500 mm
•
Equipped with reliable, VEC feed motor for superior weld
performance.
•
Supervise and adjust the head position via TV monitoring
system - Optional.
•
Use standard mini-cross slide assembly and PAV manual
tracking system or GMH automatic joint tracking system to easily follow the joint - Optional.
•
Add either the FFRS Basic/Super or FFRS 1200/3000 Flux Feed
& Recovery System to optimize the welding process.
A6S Compact 500
Longitudinal welding
Min ID circ. welding
Ordering information
A6S Compact 300 Welding head, standard
A6S Compact 300 Welding head, high-speed
A6S Compact 500 Welding head, standard
A6S Compact 500 Welding head, high-speed
A6S Compact 700 Welding head, standard
A6S Compact 700 Welding head, high-speed
Sales Literature
0809 280 880
0809 280 881
0416 967 880
0416 967 882
0811 054 880
0811 054 881
XA00124620
Technical data
Compact 300
Wire diameters, mm (in.)
- Steel
- Stainless steel
3.0-4.0 (1/8-5/32)
3.2
(1/8)
Permissible load 100%, A
800
Control voltage, V AC
42
Options & Accessories - Compact 300
Travel speed, m/min (ipm)
0.1-1.7 (4-67)
Linear slides stroke range, mm (in.)
50 (2)
Rotary slide setting range
360°
Wire feed speed, standard, m/min (ipm)
0.2-4.0 (8-157)
Flux valve control kit, including
solenoid valve and 5 m (16.4 ft.) air hose 0813 620 880
TV monitoring equipment
0811 176 880
Laser pointer
0811 177 880
Wire feed speed, high.speed, m/min (ipm)
0.4-8.0 (15.7-315)
For technical data for Compact 500 and 700, please contact
your local ESAB representative.
36
500 mm
550 mm
A6S Compact 700
Longitudinal welding 700 mm
Min ID circ. welding 750 mm
Contact tips, wire size
M12, 3.0 mm (7/64 in.)
M12, 3.2 mm (1/8 in.)
M12, 4.0 mm (5/32 in.)
0154 623 005
0154 623 004
0154 623 003
Feed rollers, wire size
3.0-3.2 mm (1/8 in.)
4.0 mm (5/32 in.)
0218 510 298
0218 510 286
Welding Heads
A6S SAW strip cladding kit
For surfacing with high alloyed materials
•
Used in combination with standard A6S Arc Master welding head.
•
Provides an economical solution for surfacing with high alloyed materials such as stainless steel or nickel-based alloys.
• Choose a wider variety of parent materials and consumables.
• Stainless steel cladding is widely used in production of compo-
nents where additional strength or corrosion resistance is
required.
• Welding head can be fitted with electrode strips as wide as
30-100 mm (1.2-4.0 inch) and as thick as 0.5 mm (0.02 inch).
Ordering information
Strip cladding kit
(for use with A6T SAW Tractor or
A6S Arc Master HD)
Sales Literature
0155 972 880
XA00101020
Options & Accessories
Reel holder (not to be used with
motor-operated cross slide)
Wire reel, steel
Suction nozzle, flux
0417 636 880
0416 492 880
0156 025 001
Technical data
Max. welding current at 100%
duty cycle, A
1500
Feed roller diameter, mm (in.)
50 (2.0)
Strip width, mm (in.)
30-100 (1.2-4.0)
Strip thickness, mm (in.)
0.5 (0.02)
Strip feed speed
see sales literature for A6
Mastertrac, (XA00109420) or
A6S Arc Master (XA00088920)
ESW - Electroslag welding
ESW is a method of strip cladding, but differs from SAW strip
cladding in that the arc is created between the electrode and the
workpiece.
The welding flux that is put into the joint melts and a slag pool is
produced, which then increases in depth.
When the temperature of the slag and its conductive capacity thereby increases, the arc is extinguished and the welding current is
conducted via the molten slag where the necessary welding energy
is produced through resistance.
This method can be used for joining thicknesses of 25 mm (1 in.)
and above.
Contact ESAB for Options & Accessories and Technical Data for
the ESW Welding Head.
37
38
Mechanized & Orbital TIG
Column
& Booms
39
Column & Booms
CaB Systems
Cost efficient and flexible weld mechanization
• Modular design concept allows total customization using
standard components.
• Large selection of available components to integrate for a custom solution:
• Any A2 or A6 weld head
• A2-A6 Process Controller PEK with ESAB DC or AC power
sources
• ESAB turning rolls and positioners
• ESAB flux feeding and recovery systems
• Monitoring systems and cameras
• Four basic station configurations, suitable for most
standard applications.
• Three different sizes; 300, 460 and 600 (number refers to boom profile height (mm) which determines working range and load capability).
• Choose from stationary or mobile, rail-travelling carriage
systems.
• Versatile to respond to any automated welding demand.
Standard CaB sizes
The three different sizes 300, 460 and 600 are the beam height dimensions of the boom in millimeters. Each boom size has a
corresponding column. The different sizes are not only limited in where it can fit, but also how far the boom can extend and how
much load that can be put on.
CaB 300S / 460S
Standard format - exceptional economy
•
Conventional column and boom with a movable boom and the welding head mounted at the end of the boom.
• Standard mechanical performance, with cable support.
• Options like camera system, pulse encoder-regulated speed and flux control.
•
The CaB 300S have a working range of 3 to 5 m (10 to 16.5 ft.) both vertically and horizontally.
•
The CaB 460S have a working range of 5 to 7 m (16.5 to 23 ft.) both vertically and horizontally.
40
Basic Station 1 - Standard format
Conventional Column and boom, with a movable boom and welding head
at boom end. Welding equipment can be positioned along four axes.
Column & Booms
CaB Systems
Cont.
CaB 300M / 460M / 600M
Modular format - extended functionality
•
A modular range of column and booms, available in three load sizes.
• Standard mechanical performance, including cable chains for the boom motions.
• The welding head is mounted at the front end of the boom.
• More than 20 options fully integrated, such as tandem welding, shift function, transport speed etc.
• Due to modularity and the fixed configuration possibilities the lead times for delivery can be kept at a minimum.
Basic Station 1 - Modular and
Custom format
Conventional Column and boom, with a movable boom and welding head at boom
end. Welding equipment can be positioned along four axes. Cable chains are included.
CaB 300C / 460C / 600C
Custom format - special capabilities
•
• Loading capacities and working strokes for utmost accessibility A customized range of welding column and booms for different customer requirements and applications.
to the welding joints.
• Based on the modular CaB range, solutions to meet the most demanding request can be achieved.
• Welding methods as TIG, MIG and SAW cladding as well as Nar
row Gap can be chosen on customized stations.
Basic Station 3 - Custom format
Side-boom manipulator with horizontally fixed boom, supporting one or two welding
heads. This welding station, which offers flexible movement, is the basic unit for welding girders and profiles and for joining plates and sections.
Basic Station 2 - Custom format
Conventional Column and boom, with a movable boom and welding head at boom end
combined with a boom-carriage-mounted welding head (not CaB 300).
Basic Station 4 - Custom format
Side-boom manipulator with double-track boom. Welding heads mounted on either
side of the boom. The boom carriages can be individually controlled by the joint tracking systems, on separate tracks. Ideal for transversal double-fillet welding of stiffeners.
41
Column & Booms
CaB Systems
Technical data CaB 300S and CaB 300M
Technical data - Column
CaB 300S / 300M
Effective working range, m (ft.)
3 (10)
4 (13)
5 (16.5)
Max. boom height A, mm (ft.)
using movable carriage, min mm (ft.)
4070 (13)
930 (3)
5070 (16.5)
930 (3)
6070 (20)
930 (3)
Max. boom height B, mm (ft.)
using concrete stand, min mm (ft.)
3955 (15.6)
815 (2.67)
4955 (19.5)
815 (2.67)
5955 (23.5)
815 (2.67)
Max. boom height C, mm (ft.)
using stationary foot plate, min mm (ft.)
3750 (14.7)
610 (2.4)
4750 (18.7)
610 (2.4)
5750 (22.6)
610 (2.4)
Total height D
using movable carriage, mm (ft.)
5170 (17)
6170 (20)
7170 (23.5)
Total height E
using concrete stand, mm (ft.)
5055 (16.5)
6055 (20)
7055 (23)
Total height F
using stationary foot plate, mm (ft.)
4850 (16)
5850 (19)
6850 (22.5)
Lifting speed, m/min (ipm)
0.7 (27.5)
0.7 (27.5)
0.7 (27.5)
Max total load on column platform, kg (lbs)
600 (1320)
600 (1320)
600 (1320)
Technical data - Boom
Extension G, max mm (ft.)
min mm (ft.)
3580 (11.75)
540 (1.77)
4580 (15)
540 (1.77)
5580 (18)
540 (1.77)
Permissible loads:
total, max kg (lbs.)
one end, max kg (lbs.)
300 (660)
240 (530)
220 (485)
150 (331)
150 (330)
75 (165)
Cross-sectional diameter H, mm (ft.)
325 (13)
325 (13)
325 (13)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
Transport speed, m/min (ipm)
2.0 (79)
2.0 (79)
2.0 (79)
Technical data - Rail carriage
Track width L,
inside to inside, mm (in.)
1730 (68.11)
Width x length, mm (in.)
2060x2330 (81.1x91.7)
Height I, mm (in.)
365 (14.37)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
Transport speed, m/min (ipm)
2.0 (79)
Total weight, kg (lbs.)
1670 (3681)
Technical data - Concrete stand
Width x length, mm (in.)
2060x2100 (81.1x82.7)
Height J, mm (in.)
250 (9.84)
Total weight, kg (lbs.)
1550 (3417)
Technical data - Foot plate
Width x length, mm (in.)
1100x1100 (43.3x43.3)
Height K, mm (in.)
40 (1.57)
Total weight, kg (lbs.)
350 (772)
42
Column & Booms
CaB Systems
Technical data CaB 460S and CaB 460M
Technical data - Column
CaB 460M
only
CaB 460S
CaB 460M
CaB 460S
CaB 460M
CaB 460S
CaB 460M
Effective working range, m (ft.)
4 (13)
5 (16.5)
6 (20)
7 (23)
Max. boom height A, mm (ft.)
using movable carriage, min mm (ft.)
4950 (16)
950 (3.12)
5950 (19.5)
950 (3.12)
6950 (23)
950 (3.12)
7950 (26.08)
950 (3.12)
Max. boom height B, mm (ft.)
using concrete stand, min mm (ft.)
4845 (16)
845 (2.77)
5845 (19)
845 (2.77)
6845 (22.5)
845 (2.77)
7845 (25,74)
845 (2.77)
Max. boom height C, mm (ft.)
using stationary foot plate, min mm (ft.)
4510 (15)
510 (1.6)
5510 (18)
510 (1.6)
6510 (21.5)
510 (1.6)
7510 (24.64)
510 (1.6)
Total height D
using movable carriage, mm (ft.)
6275 (20.5)
7275 (24)
8275 (27)
9275 (30.43)
Total height E
using concrete stand, mm (ft.)
6170 (21)
7170 (23.5)
8170 (27)
9170 (30)
Total height F
using stationary foot plate, mm (ft.)
5835 (20)
6835 (22.5)
7835 (25.5)
8835 (29)
Lifting speed, m/min (ipm)
2.0 (79)
2.0 (79)
2.0 (79)
2.0 (79)
Max total load on column platform, kg (lbs)
1500 (3300)
1500 (3300)
1500 (3300)
1500 (3300)
Extension G, max mm (ft.)
min mm (ft.)
4715 (15.5)
715 (2.35)
5715 (18.8)
715 (2.35)
6715 (22)
715 (2.35)
7715 (25.3)
715 (2.35)
Permissible loads:
total, max kg (lbs.)
one end, max kg (lbs.)
1100 (2423)
550 (1213)
1050 (2313)
450 (992)
1000 (2203)
350 (772)
950 (2094)
150 (331)
Technical data - Boom
Cross-sectional diameter H, mm (ft.)
630 (25)
630 (25)
630 (25)
630 (25)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
Transport speed, m/min (ipm)
2.0 (79)
2.0 (79)
2.0 (79)
2.0 (79)
Technical data - Rail carriage
Track width L,
inside to inside, mm (in.)
1730 (68.11)
Width x length, mm (in.)
2100x2380 (82.7x93.7)
Height I, mm (in.)
485 (19.1)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
Transport speed, m/min (ipm)
2.0 (79)
Total weight, kg (lbs.)
2860 (6305)
Technical data - Concrete stand
Width x length, mm (in.)
2100x2410 (82.7x94.9)
Height J, mm (in.)
380 (14.96)
Total weight, kg (lbs.)
2900 (6393)
Technical data - Foot plate
Width x length, mm (in.)
1600x1600 (63x63)
Height K, mm (in.)
40 (1.57)
Total weight, kg (lbs.)
505 (1113)
43
Column & Booms
CaB Systems
Technical data CaB 600M
Technical data - Column
CaB 600M
Effective working range, m (ft.)
6 (20)
7 (23)
8 (26)
9 (29.5)
10 (33)
Max. boom height A, mm (ft.)
using movable carriage, min mm (ft.)
7025 (276.6)
1075 (42.3)
8025 (316)
1075 (42.3)
9025 (355.3)
1075 (42.3)
10025 (395)
1075 (42.3)
11025 (434)
1075 (42.3)
Max. boom height B, mm (ft.)
using concrete stand, min mm (ft.)
6950 (22.8)
1000 (3.3)
7950 (26.1)
1000 (3.3)
8950 (29.4)
1000 (3.3)
9950 (32.6)
1000 (3.3)
10950 (35.9)
1000 (3.3)
Max. total height C, mm (ft.)
using movable carriage
8585 (28.2)
9585 (31.4)
10585 (34.7)
11585 (38)
12585 (41.3)
Max. total height D, mm (ft.)
using concrete stand
8510 (27.9)
9510 (31.2)
10510 (34.5)
11510 (37.8)
12510 (41)
Lifting speed, m/min (ipm)
2.0 (79)
2.0 (79)
2.0 (79)
2.0 (79)
2.0 (79)
Technical data - Boom
Extension E, max mm (ft.)
min mm (ft.)
7000 (23)
1000 (3.3)
8000 (26)
1000 (3.3)
9000 (29.5)
1000 (3.3)
Permissible loads:
total, max kg (lbs.)
one end, max kg (lbs.)
1940 (4277)
550 (1213)
1830 (4034)
400 (882)
1700 (3748)
250 (551)
Cross-sectional diameter H, mm (ft.)
1000 (3.3)
1000 (3.3)
1000 (3.3)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
0.1-2.0 (4-79)
1050 (2315)
1165 (2568)
1280 (2822)
Transport speed, m/min (ipm)
Total weight incl cables, kg (lbs.)
Technical data - Rail carriage 4WD
Track width L,
inside to inside, mm (in.)
2500 (98.4)
Width x length, mm (in.)
3100x2600 (122x102)
Height I, mm (in.)
490 (19.3)
Welding speed, m/min (ipm)
0.1-2.0 (4-79)
Transport speed, m/min (ipm)
2.0 (79)
Total weight, kg (lbs.)
4800 (10582)
Technical data - Concrete stand
Width x length, mm (in.)
3100x2680 (122x105.5)
Height J, mm (in.)
415 (16.3)
Total weight, kg (lbs.)
4250 (9370)
44
Column & Booms
CaB 22 VLS
For light-duty applications
•
•
•
•
•
•
•
The CaB 22 VLS is specificially designed for light duty applica
tions.
Smooth 360° lockable rotation.
Linear guidings on column and boom for smooth movement
which makes it ideal for gas metal arc welding (GMAW), gas
tungsten arc welding (GTAW) and submerged arc welding
(SAW) processes.
Cable chain on column and boom.
Movable carriage or fixed stand.
Pendant control station uses low voltage, features generous 10 m (33 ft.) cable.
Standard safety features include anti-fall device and limit
switches for all motions.
Ordering information
Technical data
Mains supply, 50 Hz, 3-phase, V
60 Hz, 3-phase, V
380/400/415
440/460/480
Capacity, at 200 mm (7.8 in.) away
from end of boom, kg (lbs.)
120 (265)
Vertical speed at 50 Hz, mm/min (ipm)
600 (23.6)
Boom speed, mm/min (ipm)
275-2750 (10.8-108)
Max. under boom height, mm (in.)
2000 (78.7)
Min. under boom height, mm (in.)
700 (27.6)
Effective boom travel, mm (in.)
2000 (78.7)
Weight, kg (lbs.)
1270 (2800)
For ordering information, please contact your nearest ESAB
representative.
45
Column & Booms
CaB 44, 55, 66 and 77
•
Designed and robustly built to withstand rugged work
environments.
• Smooth 360° lockable rotation.
• All vertical and horizontal guidings are precisely machined for smooth movement.
•
Solid state inverter for variable speed of horizontal travel and travel carriage.
• Worm gearbox for vertical travel via AC motor, complete with
•
brake for added safety.
High tensile roller chain used for vertical travel with the
addition of a counter balance system with the column that
provides smooth, effortless travel.
•
IP 54 pendant control station using low voltage on the generous 10 m (33 ft.) cable.
• Anti-fall device and limit switches for all motions.
• Pay load of 300 kg (661 lbs.) at 600 mm (24 in.) from boom end.
Ordering information
CaB 44, motorized carriage
CaB 55. motorized carriage
CaB 66, motorized carriage
CaB 77, motorized carriage
CaB 44, fixed stand
CaB 55, fixed stand
CaB 66, fixed stand
CaB 77, fixed stand
0370 250 601
0370 250 602
0370 250 603
0370 250 604
0370 250 606
0370 250 607
0370 250 608
0370 250 609
Technical data
44
Overall height (motorised carriage), mm (in.)
5445 (214.3)
Overall height (fixed stand), mm (in.)
Options & Accessories
Spools at rear end of the boom
Motorized rotation
0.5 m boom section
0.5 m column section
66
77
6445 (253.7)
7445 (293.1)
8445 (332.4)
5420 (213.3)
6420 (252.7)
7420 (292.1)
8420 (331.5)
Max. boom height, mm (in.)
5700 (224.4)
6700 (263,.8)
7700 (303.1)
8700 (342.5)
Vertical under boom (min), mm (in.)
1000 (39.4)
1000 (39.4)
1000 (39.4)
1000 (39.4)
Vertical under boom (max), mm (in.)
4000 (157.5)
5000 (197)
6000 (236.2)
7000 (275.5)
Boom range horizontal, mm (in.)
4000 (157.5)
5000 (197)
6000 (236.2)
7000 (275.5)
Rail G-G, mm (in.)
2000 (78.7)
2000 (78.7)
2500 (98.4)
3000 (118.1)
Vertical speed, mm/min (ipm) at 50 Hz
1250 (49.2)
1250 (49.2)
1250 (49.2)
1250 (49.2)
Boom speed, mm/min (ipm) at 5-50 Hz
165/1650 (6.5/65)
165/1650 (6.5/65)
165/1650 (6.5/65)
165/1650 (6.5/65)
Travel speed, mm/min (ipm) at 5-50 Hz
333/3335 (13/131.3)
333/3335 (13/131.3)
333/3335 (13/131.3)
333/3335 (13/131.3)
Vertical drive AC, kW c/w brake
3
3
3
3
Boom drive AC, kW c/w force cooling
0.55
0.55
0.55
0.55
Travel car drive AC, kW c/w brake
0.75
0.75
0.75
0.75
IP classification
IP54
IP54
IP54
IP54
Power supply, V 50Hz/3ph
Power supply, V 60Hz/3ph
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
Control voltage, V AC
24
24
24
24
Slewing
Manual
Manual
Manual
Manual
46
55
0370 250 617
0370 250 618
0370 250 621
0370 250 622
Column & Booms
Telbo™ 6500 and Telbo™ 9500
Telescopic boom
• Save valuable workshop space with the unique 3-section telescope-like retraction of the boom, securing operator safety.
•
Outstanding reach-out with heavy loading capacity to ensure superior productivity and weld quality.
• Ideal for internal/external circumferential welding of windtower applications.
•
Flexible production, no matter if mixed sizes and plate thicknes-
ses are to be welded - productive results are obvious.
• Loaded with 1000 kg (2204 lbs.) Flux BigBag and 1000 kg Wire EcoCoils, welding is continuously performed and costly dwell times are minimized.
Ordering information
For ordering information, please contact nearest ESAB representative.
Features
• PLC control system for synchronized boom motion
• Automatic ”Wind Back” of wire during boom retraction
• Telescopic wire guides
• Remote controlled flux nozzle (option)
• Remote controlled height adjustm. of joint tracking sensor (option)
• Saving in factory-floor foot print
• Increased workshop safety
• Enables flexible production
• ”Big Pack” handling concepts (option)
• Camera supervision system (option)
Applications
• Power generation, especially wind tower manufacturing lines.
• Pipeline, pipe mill contactors.
• General fabrication (small workshops with limited space).
Technical data
Telbo™ 6500
Telbo™ 9500
Effective work range, m (ft.)
6.5 (21.33)
9.5 (31.17)
Max extension, m (ft.) *)
8.0 (26.25)
12.5 (41)
Max load at boom end, kg (lbs.)
300 (661.4)
500 (1102)
Welding process
SAW / GMAW
SAW
Welding heads
A6
A6 SAW, Single/Tandem and Tandem/Twin
Control system
PLC / GMH
PLC / GMH
Operator seat
No
Yes
*) Measured from column centre.
47
48
Mechanized & Orbital TIG
Carriers
& Gantries
49
Carriers and Gantries
Mechtrac 1730/2100/2500/3000
For mechanized gantry automation
• Fast and flexible way to increase productivity.
• Equipped with A2-A6 PEK process controller and A2 welding equipment for mechanized submerged arc welding (SAW) or gas metal arc welding (GMAW).
Weld various profiles such as I-, T- or L-beams, straight columns or tapered columns.
•
•
Available in four versions (width of gantry): 1730 mm (68 in.), 2100 mm (83 in.), 2500 mm (94 in.) or 3000 mm (118 in.).
• All versions have standard gantry leg height of 1500 mm (59 in.).
• Floor mounted rail delivered in standard lengths of 3 m
(118 in.) - can be easily extended.
• Dual-drive motors are standard.
• Gantry can support a maximum weight of 220 kg (485 lbs.) - up Mechtrac equipped with A2 welding heads, process controller PEK and power sources LAF 631
to two A2 welding heads, complete with GMH joint tracking and OPC flux recovery systems.
Ordering information
Mechtrac 1730, dual drive
Mechtrac 2100, dual drive
Mechtrac 2500, dual drive
Mechtrac 3000, dual drive
Sales Literature
0809 670 881
0809 670 882
0809 670 883
0809 670 884
XA00101220
Options & Accessories
Travelling rail, 3 m (9.8 ft.)
Travelling rail, extension, 3 m (9.8 ft.)
50
0806 707 880
0806 707 881
Technical data
Travel speed, m/min (ipm)
0.2-1.9 (8-75)
Maximum load, kg (lbs.)
220 (485)
Standard rail length, m (ft.)
3 (9.8)
Gantry width, mm (in.)
1730-3000 (68-118)
Carriers and Gantries
Gantrac
Highly stabilized manipulation of welding torches with optimized welding results
•
Rigid legs supported by encoder-controlled DC-driven bogie
carriages as well as a cross beam to ensure uniform, stable welding speed.
• The gantry beam is equipped with guides and a rack on one or both sides for motorized welding carriages.
•
The well-proven A6 welding heads are mounted on heavy duty slides with comprehensive working strokes to obtain good
access to the workpieces.
• Incorporates the A2-A6 Process Controller PEK, equipped with GMH automatic joint tracking to control the vertical and
horizontal axes.
• Submerged arc welding is the ideal method for the
applications intended for this station.
• The flux handling equipment can be operated conveniently, without time-waisting interruptions. At the same time as flux
consumption is reduced, the workplace is kept clean and free from flux spillage.
•
The welding heads can be turned ±180 degrees for welding in both X-directions as well as 90 degrees for welding in Y-direction across the beam.
Ordering information
• A large number of positioning axes permit flexible welding
For ordering information, please contact your nearest ESAB
representative.
production.
Walltrac
Minimal floor working area thanks to the single rail/wall support
• For production of various beam structures, such as I/H and box beams of tapered and non-symmetrical design, stiffener sections and the joining of plates and sections.
• Longitudinal and transverse welding procedures.
• Uses A6 welding heads and A2-A6 Process Controller PEK.
• Automatic joint tracking GMH controls the vertical and horizontal axes, i.e. the slides and the carriages, to safeguard the superior weld quality.
• A large number of positioning axes permit flexible welding
production.
51
52
Mechanized & Orbital TIG
Accessory
Components
53
Accessory Components
Beam Travelling Carriage
To be used with ESAB A2 and A6 welding heads
•
Ideal solution for submerged arc welding (SAW) or gas metal arc welding (GMAW) applications requiring beam mounted carriage.
• Can be fitted with any A2 or A6 welding head.
• For longitudinal welding or welding of circumferential workpieces.
• Place the carriage on either a standard I-beam IPE 300 or MBVA 330 and 550
Beam welding carriage
•
Heavy side beam carriage, suitable for multiple submerged arc welding heads and most options available on column
and booms.
• Cross beams available up to 1.2 m (4 ft.), capacity up to 1.4 ton.
• VEC motor with gear, rack and pinion, for powerful, consistent specially machined I-beam (contact ESAB for details).
carriage travel.
Fast and easy pre-programming of travel motion and welding parameters using the A2-A6 process controller PEK.
• Different travel units for speeds to match process.
•
Ordering information
Beam travelling carriage
Sales Literature
0457 897 881
XA00091920
Options & Accessories
Mounting bracket for Tandem head
Track in lengths of 3000 mm (9.8 ft.)
0458 026 001
0145 282 880
Required number of floor columns: 2
Track in lengths of 4500 mm (14.8 ft.)
0145 282 881
Required number of floor columns: 3
Track in lengths of 6000 mm (19.7 ft.)
0145 282 882
Ordering information
0145 282 883
MBVA 330 carriage
MBVA 550 carriage
Sales Literature
Required number of floor columns: 3
Track in lengths of 8000 mm (26 ft.)
Required number of floor columns: 4
0150 765 880
0150 901 880
XA00105120
Options & Accessories
Cable, length 1.5-50 m (5-164 ft.)
Technical data
Travel speed beam carriage, cm/min (ipm)
6-200 (2-79)
Weight carriage, kg (lbs.)
60 (132)
54
contact ESAB
Travel unit, speed range 3-80 cm/min (1.2-32 ipm)
Travel unit, speed range 11-125 cm/min (4-49 ipm)
Travel unit, speed range 14-250 cm/min (5.5-98 ipm)
Travel unit, speed range 37-1500 cm/min (14.5-590 ipm)
Travel unit, speed range 27-530 cm/min (11-208 ipm)
0150 943 880
0150 943 881
0150 943 882
0150 943 883
0150 943 884
Beam 330, 300 cm (118 in.), 240 kg (529 lbs.)
Beam 330, 450 cm (177 in.), 480 kg (1058 lbs.)
Beam 330, 600 cm (236 in.), 720 kg (1587 lbs.)
Beam 330, 750 cm (295 in.), 960 kg (2116 lbs.)
Beam 330, 900 cm (354 in.), 1000 kg (2204 lbs.)
Beam 330, 1050 cm (413 in.), 1200 kg (2645.5 lbs.)
Beam 330, 1200 cm (472 in.), 1420 kg (3130.5 lbs.)
0803 348 880
0803 348 881
0803 348 882
0803 348 883
0803 348 884
0803 348 885
0803 348 886
Beam 550, 300 cm (118 in.)
Beam 550, 450 cm (177 in.)
Beam 550, 600 cm (236 in.)
Beam 550, 800 cm (315 in.)
Beam 550, 1200 cm (472 in.)
0321 527 880
0321 527 881
0321 527 882
0321 527 883
0321 527 884
Technical data
MBVA 330
MBVA 550
Rated load, N (kp)
10000 (1000)
20000 (2000)
Rated moment, Nm (kpm)
3300 (330)
10000 (1000)
Weight, kg (lbs.)
95 (209)
275 (606)
Accessory Components
Servo Slide
Motorized slide for linear motion
•
Heavy duty capacity with high precision slide for accurate and rapid joint tracking and positioning.
•
Can be installed in vertical or horizontal positions - setting lengths up to 1030 mm (41 in.) with a central point of attachment.
• Operates jointly with A2 or A6 components.
• Slides available from 60 mm (2.4 in.) to 1030 mm (41 in.)
working range.
• Permissible load of 1500 N (337 lbf/ft.) in any mounting position.
• Maximum torque for vertical unit is 400 Nm (3540 lbf/in.);
maximum torque for horizontal unit is 280 Nm (2480 lbf/in.).
•
Designed to be used together with joint positioning and tracking
systems PAV and GMH.
Options & Accessories
Ordering information
Servo slide, 60 mm (2 in.)
Servo slide, 120 mm (5 in.)
Servo slide, 180 mm (7 in.)
Servo slide, 240 mm (9 in.)
Servo slide, 300 mm (12 in.)
Servo slide, 420 mm (17 in.)
Servo slide, 540 mm (21 in.)
Servo slide, 730 mm (29 in.)
Servo slide, 1030 mm (41 in.)
Servo slide, 358 mm (14 in.), heavy duty
Servo slide, 598 mm (23.5 in.), heavy duty
Sales Literature
0334 333 880
0334 333 881
0334 333 882
0334 333 883
0334 333 884
0334 333 885
0334 333 886
0334 333 887
0334 333 888
0416 190 880
0416 190 884
XA00032720
Slide
60 mm
(2 in.)
Slide
120 mm
(5 in.)
Total length, mm (in.)
305 (12)
365 (14)
Number of 60 mm (2.4 in.) indexings
3
Weight, kg (lbs.)
11.5 (25)
Technical data
Slide
180 mm
(7 in.)
Connecting cable, 2 m (6.5 ft.)
Connecting cable, 5 m (16.4 ft.)
Connecting cable, 10 m (32.8 ft.)
0460 745 880
0460 745 881
0460 745 882
Technical data
Control voltage, V DC
42
Max ambient temperature
80°C (176°F)
Axial play, runner, mm (in.)
0.1 (0.004)
Max. torque-free load, kg (lbs.)
150 (330)
Slide
240 mm
(9 in.)
Slide
300 mm
(12 in.)
Slide
420 mm
(17 in.)
Slide
540 mm
(21 in.)
Slide
730 mm
(29 in.)
Slide
1030 mm
(41 in.)
425 (17)
485 (19)
545 (21.5)
665 (26)
785 (31)
1025 (40)
1385
(54.5)
4
5
6
7
9
11
14
21
13.2 (29)
15 (33)
16.7 (37)
18.5 (41)
21.9 (48)
25.4 (56)
30.9 (68)
38.8
(85.5)
55
Accessory Components
PAV and GMH
Joint Positioning and Tracking systems
• Simple and easy to use.
• Adapt for use with almost any type of welding joint.
• The PAV system is for manual joint tracking and the GMH system is for automatic joint tracking.
•
The PAV and GMH work equally well with ESAB A2 or A6 welding systems.
•
Motorized servo slides guarantee a reliable and accurate joint tracking.
•
Both the PAV and GMH systems are available in three versions; with control panel on the front, with remote control or without
control panel suitable for integration into customized solutions.
The GMH automatic joint tracking system is designed for use in fillet and butt joints using sensor fingers.
GMH with and without remote control
•
•
GMH compensates for irregularities in weld joint, tracks simple geometric shapes and avoids parallax problems.
Adjustable sun shield for
better visibility for outdoor use
PAV with and without remote control
Ordering information
Options & Accessories
PAV without control panel
PAV with control panel
PAV with remote control
GMH without control panel
GMH with control panel
GMH with remote control
GMH system compl with remote control,
sensor, sensor cable and mini cross saddle
GMH system compl with control panel,
sensor, sensor cable and mini cross saddle
Sales Literature PAV
Sales Literature GMH
0460 502 880
0460 502 881
0460 697 880
0460 503 880
0460 503 881
0460 698 880
0460 884 880
0460 884 881
XA00139420
XA00139320
Technical data
Control voltage, V AC, Hz
42, 50-60
Fuse, A
10
Max. welding current at 100%
duty cycle, A
6
Armature voltage, V DC
40
Field voltage, V DC
60
Current limit, A
15
Dimensions, mm (inch)
246x235x273 (9.7x9.3x10.7)
Weight, kg (lbs.)
6 (13)
Enclosure class
IP23
56
Cable restraining bracket
Motor cable, 5 m (16.4 ft.)
Motor cable, 10 m (32.8 ft.)
Motor cable, 19 m (62.3 ft.)
Servo slides
(see former page)
For GMH only:
Sensor cable, 5 m (16.4 ft.)
Sensor cable, 9 m (29.5 ft.)
Sensor cable, 19 m (62.3 ft.)
Sensor with finger
Mini cross saddle + sensor support
Remote control
Protective rubber boot for sensor
Standard finger
Finger with ball
Finger for heat exchange plates
Finger for beam welding
Intermediate transformer
0460 861 880
0460 745 881
0460 745 882
0460 745 884
0334 333 xxx
0416 749 888
0416 749 889
0416 749 880
0416 688 880
0416 739 880
0460 570 880
0412 013 001
0146 586 001
0416 719 001
0443 328 880
0443 187 880
0148 636 002
Accessory Components
AVPS Laser Seam Tracking System
For Circumferential and Longitudinal Welding
●● Laser vision sensing improves the productivity and quality of
circumferential and longitudinal welding processes as typically
found in windtower manufacturing.
●● Longitudinal weld seam tracking on roll-formed tubes.
●● Inside circumferential weld seam tracking.
●● Outside circumferential weld seam tracking.
●● Servo-Robot’s intelligent seam tracking technology, combined
with ESAB’s GMH joint tracking system and pendant control,
maintains precise wire position both in the joint and with respect
to the vertical direction ensuring a consistent wire stickout.
●● Parameters are easily set with the ESAB remote conrol pendant eliminating the need for special operator training.
●● The operator selects the correct joint template (butt, groove,
etc.) using the remote control pendant.
●● The welding head is mounted on a motorized double servo
slide where the head can be moved up-down and left-right.
●● The Servo-Robot Mini-Box Control unit is at the center of the
tracking acting as both a vision control unit and as a process
control unit which communicates with the GMH system to perform the tracking tasks.
Ordering information
For ordering information, please contact your nearest ESAB
representative.
Technical data
Mini-I/D Laser Camera
Technical data
Mini-Box Control unit with
ESAB GMH Interface
Laser class
IIIb
Mains supply, V DC
24
Standoff distance, mm (in.)
80 (3)
HMI port
Ethernet 10/100 Mbits
100 (4)
E-STOP input
External arlam input for laser safety
Field of view width, mm (in.)
30-60 (1.2-2.4)
Camera cooling control output
Average depth resolution, mm (in.)
0.05 (0.0002)
Used with SRI camera air cooling
system
Average lateral resolution, mm (in.)
0.05 (0.0002)
Laser enable key-lock
Key-lock switch for laser safety
Dimension, LxWxH, mm (in.)
30x56x90 (1.2x2.2x3.5)
Operating temperature, °C (°F)
5-40° (41-104°)
Weight, kg (lbs.)
0.5 (1)
Dimension, LxWxH, mm (in.)
300x300x150 (12x12x6)
Weight, kg (lbs.)
3.5 (7.7)
Field of view depth, mm (in.)
57
Accessory Components
OPC Basic & Super
Sturdy compact flux recovery systems
• Robust and compact design.
• Easy to operate and practically maintenance-free.
• Integated system for maximum productivity - lower investment and service costs.
• Adapts to any A2 or A6 welding system - tractor or stationary.
• Uses only compressed air - safe and inexpensive.
• Can be integrated into complete FFRS flux feeding and
recovery system.
• Three filter types; filter bag for A2 applications, cyclone filter with filter bag for most A6 applications and Tedak filter for
heavy-duty applications.
• OPC system includes; ejector, cyclone, filter with attachment hardware, securing strap, suction hose and four suction nozzles (for butt welds, normal and large; fillet welds, left and right).
OPC Basic Flux Recovery System
• Works on ejector principle using compressed air
• Cyclone separator, on top of flux hopper, efficiently separates OPC Super Flux Recovery System
•
dust from recovered flux.
Similar to Basic System but with stronger ejector and cyclone - provides better suction.
• Slag is separated and flux is returned to hopper.
• Can also be used with pre-heated flux.
Ordering information
Options & Accessories
OPC Basic, with standard filter bag
OPC Basic, with cyclone filter
OPC Basic, with Tedak filter
OPC Super *)
OPC Super complete, with cyclone filter
OPC Super complete, with Tedak filter
Sales Literature
Sales Literature Wear parts OPC
*) excl. hose, nozzles and filter
0148 140 880
0802 415 882
0802 415 883
0339 719 880
0802 415 892
0802 415 893
XA00105020
XA00126420
Technical data
OPC
Basic
OPC
Super
Airflow capacity
at working pressure 0.4 MPa, l/min
at working pressure 0.5 MPa, l/min
at working pressure 0.6 MPa, l/min
175
225
250
420
500
580
Max working pressure, MPa
0.6
0.6
Max suction height
at working pressure 0.4 MPa, m *)
at working pressure 0.5 MPa, m *)
at working pressure 0.6 MPa, m *)
0.8
0.8
0.8
1.0
1.2
1.4
Sound level at work, dB
70
72
Max working temperature, °C
130
150
Short term temperature, °C **)
170
190
*) Suction height with normal flux bead and a welding speed of 100 cm/min
**) Tested with preheated flux to temp. max 220°C and weld object temp. max 350°C.
58
Air pressure hose 3/8 in.
Air pressure hose 1/2 in.
Air pressure tube Ø 63 mm, 2.5 in.
Air central
Plastic bag
Filter bag, paper
Filter bag, cotton
Cyclone filter
Tedak filter
0190 343 104
0190 343 106
0193 125 003
0417 714 880
0190 665 004
0155 966 001
0332 448 001
0379 538 880
0453 708 881
Accessory Components
FFRS Flux Feed and Recovery Systems
Efficient flux handling for cost-effective welding
• Ideal for continuous and high capacity welding
• Minimum manual flux handling.
• Reduced flux consumption for better welding economy.
• Fewer weld stops for increased efficiency.
• Efficient filtration of used air.
• Flux feeds from a 75 l (20 gal.) capacity TPC-75 pressurized flux tank to the ESAB flux hopper of your choice; 6 l or 10 l (1.6 gal. or 2.6 gal.)
• Flux feed inlet options; straight or bent.
FFRS Super
• Built on OPC Super modules
• Super - for increased flux and heat conditions.
• Based on ejector vacuum principle.
FFRS 2000 & 3000
• Based upon an electrical suction unit creating vacuum.
• For use when extra high recovery force is required and for compact welding heads.
• Flux dust separated automatically in a pre-separator.
Options & Accessories
Air central
0417 714 880
Flux hopper 10 l (2.6 gal.)
0147 649 881
Flux hopper 6 l (1.6 gal.)
0413 315 881
Holder for hopper
0148 487 880
Level indicator for TPC
0452 048 880
Pneumatic flux valve
0802 540 880
Flux valve control unit
0813 620 880
Sales Literature FFRS SuperXA00104820
Sales Literature FFRS 2000 & 3000XA00104920
FFRS 3000
Ordering information
FFRS Super with cyclone filter
FFRS Super with heaters in TPC
FFRS Super with Tedak dust filter FFRS Super with heaters and Tedak filter
0809 914 881
0809 914 882
0809 914 883
0809 914 884
FFRS Super systems include 25 m 1/2” air pressure hose, 25 m flux feed hose
from TPC to hopper (20 m for heated systems) 2 m flux suction hose, 6 m dust
hose from hopper to filter (10 m for systems with Tedak), bent inlet for flux hopper
and flux recovery nozzles.
FFRS 2000
FFRS 2000 with heaters
FFRS 3000
FFRS 3000 with heaters
0809 914 893
0809 914 894
0809 914 887
0809 914 888
FFRS 1200/3000 systems include 25 m 1/2” air pressure hose, 25 m flux feed
hose from TPC to hopper (20 m for heated systems) 16 m flux suction hose,
suction hose between the primary separator and the vacuum unit (1200 = 2 m,
3000 = 5 m), bent inlet for flux hopper and flux recovery nozzles.
Technical data
FFRS 2000
FFRS 3000
Weight without flux, kg (lbs.)
320 (705)
400 (882)
Dimensions, LxWxH, mm (in.)
1100x800x2210 (43.3x31.5x87)
750x450x2210 (30x18x87)
Primary separator
Volume, l (gal.)
Dimensions, LxW, mm (in.)
50 (13)
450x700 (18x28)
50 (13)
450x900 (18x35)
Suction unit
Power, W
Mains supply, V/Hz
Fuse, A
Max. vacuum, kPA
Max. air flow capacity, m3/h
Sound level, dB
Filter area, m2
Filtration efficiency, %
Life-span of filter, work hours
Weight, kg (lbs.)
Dimensions, LxWlH, mm (in.)
2000
400 / 3-50
16
-30
240
71
3
99.95
5-6000
74 (163)
950x640x1200 (37x25x47)
3000
400 / 3-50
16
-25
270
63
3
99.95
4000-6000
194 (428)
1200x690x2000 (47x27x79)
59
Accessory Components
CRE 30 & CRE 60 Air Drying Units
For use with ESAB flux handling systems
• Designed for use with any flux handling system.
• The system is based on the absorption principle - reduces the risk of hydrogen cracking in weld metal by ensuring flux remains dry.
•
Built-in monitor - warns if the programmed humidity limit is
exceeded.
• Reduces condensation - less corrosion and malfunctions.
• Simple system monitoring - manometer on pressurized dryer bottles with easy-to read dew point indicator.
Ordering information
CRE 30 air drying unit
CRE 60 air drying unit
Sales Literature
0443 570 880
0443 570 881
XA00101920
Options & Accessories
Desiccant, type 512
(package per 25 kg (55 lbs.)
Oil filter
Dust filter
0443 570 017
0443 570 018
0443 570 019
Technical data
CRE 30
CRE 60
Mains supply, V AC, Hz
230, 50/60
230, 50/60
Max. power rating, W
40
50
Net air flow capacity at 6 bar, m3/h (ft3/hr at 87 psi)
30 Normal (1060)
60 Normal (2120)
Regenerating flow at 6 bar (87 psi), %
14
14
Max. dew point under nominal working conditions, °C (°F)
-26 (-14)
-26 (-14)
Desiccant Type 512
Sodium-Aluminium-Silicate, kg (lbs.)
Normal pore size, Ångström
Particle size, mm (in.)
Density, kg/m3 (lbs/in.3)
10 (22)
4
2.5-5.0 (0.01-0.20)
720 (0.023)
16 (35)
4
2.5-5.0 (0.01-0.20)
720 (0.026)
5
5
Max. permissible air flow for oil separation filter, m /hr
60 Normal
60 Normal
Manifold thread size
R12
R12
Max. working pressure, bar (psi)
6 (87)
6 (87)
Max. air pressure at testing, bar (psi)
10 (145)
10 (145)
Max. inlet air temperature under nominal conditions, °C (°F)
30 (86)
30 (86)
Cycle time per container
3
60
Accessory Components
Rotating Ground Couplings
•
For a good connection to the workpiece to obtain optimal
welding performance.
• For rotating workpieces, a ground connection with a rotatable coupling is the safest choice.
•
To attach the coupling to the workpiece, special clamps are available, see ”Ground Clamps” below.
Ordering information
NKK 600, max. 600A, 2.2 kg (4.8 lbs.)
NKK 800, max. 800A, 2.7 kg (5.9 lbs.)
NKK 1200, max 1200A, 4.0 kg (8.8 lbs.)
NKK 2000, max 2000A, 7.3 kg (16 lbs.)
0700 004 007
0700 004 001
0700 004 002
0700 004 003
Rotating ground coupling NKK
Ground Clamps for Rotating Workpieces
•
K2 or PZ3 ground clamps can be mounted directly onto the rotatable ground coupling to create good contact between the workpiece and the return cable.
•
Return clamps can also be used together with the GA 800 handle connection to form a complete ground clamp to handle high current welding on non-rotating workpieces.
Ordering information
K2 Clamp head for NKK 800/1200
GA 800 Handle connection for K2
PZ3 Pole clamp for NKK 2000
0700 004 004
0700 004 005
0700 004 006
Pole clamp PZ3
K2 clamp head
Handle connection GA 800
61
Accessory Components
Camera System
For Submerged Arc Welding (SAW)
• Air-cooled camera (water cooling available on request).
• Designed for overview of submerged arc welding.
• 15” monitor with control box, work light (LED) and crosshair
generator forms a complete system powered from one point.
Scope (complete set)
●●
●●
●●
●●
●●
●●
●●
Camera (colour)
Monitor with protection box and crosshair generator
Camera cable, 30 m
Flexible arm
Mounting bracket for welding torch
Work light, LED
Air pressure regulator (for air cooling)
Ordering information
Camera system, complete set
Power supply unit, 12 V DC
0829 300 880
0809 928 880
Monitor with protection box
and crosshair generator
Camera with work light
(LED)
Technical data
Camera
Model
SAW Camera, v2 (PAL)
Image device
1/3 Sony CCD, colour
Number of pixels PAL
795 (H) x 596 (V)
Synchronizing system
Internal
Video output
Composite Video, 1Vp-p, 75 Ohm
Resolution (horizontal)
700 TV lines
Minimum illumination
0.01 Lux
Gamma characteristic
0.45
S/N ratio
> 48 dB
White balance
Automatic
Electronic iris
1/50 ~ 1/100,000 sec.
Built-in lens
4.0-9.0 mm
Vari-focal lens
F1.6
Power supply
+12 V DC
62
Camera installed onto
bracket for welding torch
Accessory Components
OCE-2H Cooling unit
Compact and efficient
•
Can be used for gas metal arc welding (GMAW) as well as for tungsten arc welding (GTAW).
• Both for manual and automatic welding.
• Flow guard as option.
• Designed for use together with water-cooled welding
equipment, manual or automatic.
•
The water tank and pump are manufactured of corrosion
resistant material. A flow guard is available as optional equip- ment for control of the water flow down to about 1 l/min (0.26 gal.)
Ordering information
Cooling unit OCE-2H
Flow guard for OCE-2H
Sales Literature
0414 191 881
0414 231 880
XA00043120
Technical data Pump with motor
Max power consumption, W
250
Mains supply, V, Hz
230, 50/60, 1-phase
Mains water pressure at
50 Hz
60 Hz
300 kPa (3 bar)
410 kPa (4.1 bar)
Technical data Cooler
Cooling power
40° overtemp and 2.0 l/min, kW
60° overtemp and 2.0 l/min, kW
1.1
1.7
Water pressure at 2.0 l/min, kPa
220
Coolant volume, l (gal.)
8 (2.11)
Dimensions, LxWxH, mm (in.)
236x316x398
(9.3x12.4x15.7)
63
64
Handling
Equipment
65
Handling Equipment
CD 5-120 and CI 5-120
Conventional Roller Beds
• Robust design with durable rollers.
• Gritblasted steelwork with polyurethane finished coating to endure
the abrasive environment of offshore and marine industries.
•
Specially formulated high-load polyurethane tire design for high wear resistance.
•
Cast steel gearbox with double worm gear arrangement for
smooth operation and minimum backlash.
• Solid state inverter for precise speed control.
• Motorized and idler rail bogie versions.
Ideal for:
- Wind tower fabrication
- Offshore and shipyards
- Pressure vessels
- Pipelines
Ordering information
Options & Accessories
Foot pedal
Synchronise kit
Pendant with digital display
PEK connection kit with 25 m cable
(Note: I/O board and PEK not included)
0370 250 301
0370 250 302
0370 250 431
0370 251 514
For rail bogie details, please see page 68.
Technical data
Max loading capacity,
ton/section
Drive unit
Idler unit
Turning capacity, ton
Drive unit
Drive unit
Roller bed CD-5
Roller bed CD-15
Roller bed CD-30
Roller bed CD-60
Roller bed CD-90
Roller bed CD-120
0370 250 000
0370 250 004
0370 250 006
0370 250 008
0370 250 107
0370 250 012
Idler unit
Roller bed CI-5
Roller bed CI-15
Roller bed CI-30
Roller bed CI-60
Roller bed CI-90
Roller bed CI-120
0370 250 001
0370 250 005
0370 250 007
0270 250 009
0370 250 109
0370 250 013
CD/CI-5
CD/CI-15
CD/CI-30
CD/CI-60
CD/CI-90
CD/CI-120
2.5
2.5
7.5
7.5
15
15
30
30
45
45
60
60
7.5
22.5
45
90
135
180
Turning speed, min-max,
mm/min (ipm)
100-1000
(3.94-39.37)
102-1020
(4-40)
125-1250
(4.92-49.2)
130-1300
(5-51)
130-1300
(5-51)
130-1300
(5-51)
Workpiece diameter, min-max,
mm (in.)
200-4300
(7.9-169)
200-5000
(7.9-197)
500-6000
(19.7-236)
500-6000
(19.7-236)
500-6000
(19.7-236)
500-6000
(19.7-236)
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
24
24
24
24
24
24
Mains supply, V
50Hz, 3ph
60Hz, 3ph
Control voltage, V AC
Weight, kg (lbs.)
Drive unit
Idler unit
480 (1058)
265 (584)
655 (1444)
360 (794)
1370 (3020)
820 (1808)
2000 (4409)
1342 (2959)
3200 (6107)
2100 (4630)
3355 (7397)
1841 (4059)
Dimensions LxHxW, mm (in.)
Drive unit
2908x540x671
(115x21x26)
2465x540x568
(97x21x22)
3416x620x791
(134x24.5x31)
2465x620x576
(97x24.5x23)
3916x765x892
(154x30x35)
2790x765x690
(110x30x27)
4026x765x940
(159x30x37)
2850x765x898
(112x30x35)
4323x865x1176
(170x34x46)
2850x865x1090
(112x34x43)
4232x947x1378
(167x37.2x54)
2850x865x1300
(112x34x51)
10 (394)
10 (394)
10 (394)
10 (394)
10 (394)
10 (394)
Idler unit
Cable, control box, m (in.)
66
Handling Equipment
SD 5-120 and SI 5-120
Self-aligning Roller Beds
• Robust design with durable rollers.
• Gritblasted steelwork with polyurethane finished coating to en
dure the abrasive environment of offshore and marine industries.
•
Specially formulated high-load polyurethane tire design for high wear resistance.
•
Cast steel gearbox with double worm gear arrangement for smooth operation and minimum backlash.
• Solid state inverter for precise speed control.
• Motorized and idler rail bogie versions.
• Electrical clutch
Ordering information
Ideal for:
- Wind tower fabrication
- Offshore and shipyards
- Pressure vessels
- Thinwall vessels / Pipes
Options & Accessories
Foot pedal
Synchronize kit
Pendant with digital display
PEK connection kit with 25 m cable
(Note: I/O board and PEK not included)
0370 250 301
0370 250 302
0370 250 431
0370 251 514
For rail bogie details, please see page 68.
Technical data
Max loading capacity,
ton/section
Drive unit
Idler unit
Turning capacity, ton
Drive unit
Drive unit
Roller bed SD-5
Roller bed SD-15
Roller bed SD-30
Roller bed SD-60
Roller bed SD-90
Roller bed SD-120
0370 250 050
0370 250 134
0370 250 136
0370 250 058
0370 250 138
0370 250 095
Idler unit
Roller bed SI-5
Roller bed SI-15
Roller bed SI-30
Roller bed SI-60
Roller bed SI-90
Roller bed SI-120
0370 250 051
0370 250 135
0370 250 137
0270 250 059
0370 250 139
0370 250 096
SD/SI-5
SD/SI-15
SD/SI-30
SD/SI-60
SD/SI-90
SD/SI-120
2.5
2.5
7.5
7.5
15
15
30
30
45
45
60
60
7.5
22.5
45
90
135
180
Turning speed,
mm/min (ipm)
127.3-1273
(5-50)
130-1300
(5-51)
120-1200
(4.7-47)
120-1200
(4.7-47)
100-1000
(4-40)
100-1000
(4-40)
Workpiece diameter - 2 tyre,
mm (in.)
200-788.8
(7.87-31.06)
200-788.8
(7.87-31.06)
300-1136
(11.8-44.72)
300-1136
(11.8-44.72)
200-1070
(7.87-42.13)
300-1156
(11.8-45.51)
Workpiece diameter - 4 tyre,
mm (in.)
789-6600
(31.06-259.84)
789-6600
(31.06-259.84)
1137-7200
(44.76-283.46)
1137-7600
(44.76-299.21)
1071-8300
(42.17-326.77)
1157-8100
(45.55-318.9)
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
IP54
IP54
IP54
IP54
IP54
IP54
24
24
24
24
24
24
3816x930x753
(150.24x37x29.6)
3100x930x686
(122x37x27)
3814x930x788
(150.16x37x31)
3100x930x756
(122x37x29.8)
4232x1295x818
(166.6x51x32.2)
3400x1295x814
(133.9x51x32
4537x1295x965
(178.6x51x38)
3600x1295x890
(141.7x51x35)
4800x1406x987
(189x55.4x38.9)
3900x1406x938
(153.5x55.4x37)
4866x1502x1082
(191.6x59x42.6)
3968x1502x975
(156.2x59x38.4)
880 (1940)
620 (1367)
1170 (2579)
820 (1808)
2245 (4949)
1465 (3230)
3000 (6614)
2000 (4409)
3260 (7187)
2466 (5437)
4397 (9694)
3410 (7518)
10 (394)
10 (394)
10 (394)
10 (394)
10 (394)
10 (394)
Mains supply, V
50Hz, 3ph
60Hz, 3ph
IP Classification
Control voltage, V AC
Dimensions LxHxW, mm (in.)
Drive unit
Idler unit
Weight, kg (lbs.)
Cable, control box, m (in,)
Drive unit
Idler unit
67
Handling Equipment
Rail Bogie DB/IB 5-120
Motorized and Idler Rail bogie Variants
• Space saving for transport.
• Modularization means easy stocking.
• Standard size rail 1730/2000 mm (68-79 in.)
• Bolted on with standard conventional and self-aligning roller beds.
Driven Bogie
Ordering information
Motorized Bogie
Rail bogie DB 5-30
Rail bogie DB 60
Rail bogie DB 90
Rail bogie DB 120
0370 250 250
0370 250 252
0370 250 254
0370 250 256
Idler Bogie
Rail bogie IB 5-30
Rail bogie IB 60
Rail bogie IB 90
Rail bogie IB 120
0370 250 251
0370 250 253
0370 250 255
0370 250 257
Idler Bogie
Technical data
DB/IB 5-30
DB/IB 60
DB/IB 90
DB/IB 120
Max loading capacity, drive/idler, ton
15
30
45
60
Turning capacity, drive unit, ton
45
90
135
180
Wheel, mm (in.)
1725/1995 (68/78.5)
1725/1995 (68/78.5)
1725/1995 (68/78.5)
1725/1995 (68/78.5)
Mains supply, 50 Hz 3-phase, V
60 Hz 3,phase, V
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
IP Classification
IP 54
IP 54
IP 54
IP 54
Isolator rating, A
50
50
50
50
Control voltage, V AC
24
24
24
24
Travel car speed, mm/min (ipm)
310-3100 (12-122)
315-3150 (12.4-124)
300-3000 (11.8-118)
300-3000 (11.8-118)
Motor, kW
2 x 0.75
2 x 1.1
2 x 1.1
2 x 1.5
Weight, kg (lbs.)
Drive unit
Idler unit
460 (1014)
360 (794)
660 (1455)
948 (430)
720 (1587)
526 (1159)
860 (1896)
640 (1411)
2242x320x1390
(88x12.5x55)
2242x320x1220
(88x12.5x48)
2253x328x1500
(89x13x59)
2253x343x1290
(89x13.5x51)
2252x320x1670
(87x12.5xx66)
2252x320x1490
(87x12.5x59)
2252x383x1920
(87x15x75.5)
2252x383x1700
(87x15x67)
Dimensions LxHxW, mm (in.)
Drive unit
Idler unit
68
Handling Equipment
FUB 30 and FUB 60
Fit-up beds
• Designed and robustly built to withstand rugged work environments.
• Fastest system to assemble 1 + 1 sections.
• One FUB set consists of one power and one idler roller bed 30T, four indepently adjustable rollers to align the two sections with each other.
• The roller bed and rollers are all mounted on one main frame.
• Tires of type Polyurethane 20.5 x 7 inch.
Ideal for:
- Wind tower fabrication
- Vessels
- Pipemills
Ordering information
FUB 30
FUB 60
0370 250 931
0370 250 932
Technical data
FUB 30
FUB 60
Max. loading capacity, ton
30
60
Min. workpiece diameter, mm (in.)
at 90° included angle
610 (24)
610 (24)
Max. workpiece diameter, mm (in.)
at 30° included angle
6435 (253.3)
6435 (253.3)
Roller speed, mm/min (ipm)
130-1295 (5-51)
130-1295 (5-51)
Control voltage, V DC
24
24
Mains supply,
50 Hz, 3-phase, V
60 Hz, 3-phase, V
380/400/415
400/460/480
380/400/415
Travel car bogie
yes
yes
Travel car speed, mm/min (ipm)
238-2380 (9.4-94)
240-2400 (9.5-95)
Travel car drive, AC kW
1.1
2.2
Power pack rating, kW
1.5
1.5
IP classification (motor)
IP55
IP55
IP classification (electrical)
IP43
IP43
Pump, cc
2.1
2.1
Tank capacity, l
16 (4.23)
16 (4.23)
Weight, kg (lbs.)
5250 (11575)
7360 (16226)
69
Handling Equipment
FIR 35, 75 and 100
Heavy duty Roller Beds for growing line production
• Designed and robustly built to withstand rugged work environments.
• This unit is part of a growing line, ideal for wind tower production.
• FIR has four independently adjustable rollers to align the workpieces (cans) with each other and two cross rollers to lift up the section for conveying out the workpiece.
Ideal for:
- Wind tower fabrication
- Vessels
- Pipemills
Ordering information
Roller bed FIR 35
Roller bed FIR 75
Roller bed FIR 100
0370 250 934
0370 250 935
0370 250 936
Technical data
FIR 35
FIR 75
FIR 100
Max loading capacity, ton
35
75
100
Workpiece diameter, mm (in.)
2200-5000 (86.6-197)
1500-6500 (59-256)
2000-6000 (79-236)
Tire type, steel, Ø mm (in.)
300 (11.8)
300 (11.8)
300 (11.8)
Control voltage, V AC
24
24
24
Mains supply, 50Hz-3ph, V
60Hz-3ph, V
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
Power supply voltage
8
13
13
Fuses
12
19
19
IP classification (electrical)
IP55
IP55
IP55
Power pack rating, kW
3
5.5
5.5
Pump, cc
3.2
5.5
5.5
Tank capacity, l (gal.)
60 (15.9)
90 (23.8)
90 (23.8)
Stroke length cylinder A, mm (in.)
Ø125x160x2 (4.9x6.3x0.08)
Ø150x85x160x2 (5.9x3.3x6.3x0.08)
Ø180x160x2 (7.1x6.3x0.08)
Stroke length cylinder B, mm (in.)
Ø100x210x4 (3.9x8.3x0.16)
Ø150x85x350x4 (5.9x3.3x13.8x0.16)
Ø180x400x4 (7.1x15.8x0.16)
Stroke length cylinder C, mm (in.)
Ø150x300 (5.9x11.8)
Ø150x85x300 (5.9x3.3x11.8)
Ø180x300 (7.1x11.8)
Net weight, kg (lbs.)
4850 (10692)
8400 (18519)
9000 (19842)
Dimension LxWlH, mm (in.)
2327x1600x1151
(91.6x63x45.3)
2680x1600x1329
(105.5x63x52.3)
2790x1480x1180
(109.8x58.3x46.5)
Cable lenght control pendant, m (in.)
10 (394)
10 (394)
10 (394)
70
Handling Equipment
FIT 30, 60 and 100
Fit-up Truck
• Designed and robustly built to withstand rugged work environments.
• This unit can be used in one for aligning several cans or used as part of a growing line, ideal for wind tower production.
•
Two independently adjusted rollers to align the workpieces (cans) with each other.
• Delivered with or without rail bogie.
Ideal for:
- Wind tower fabrication
- Vessels
- Pipemills
Ordering information
Roller bed FIT 30
Roller bed FIT 30IB
Roller bed FIT 60
Roller bed FIT 60IB
Roller bed FIT 100
Roller bed FIT 100IB
0370 250 937
0370 250 938
0370 250 939
0370 250 940
0370 250 941
0370 250 942
Technical data
FIT 30
FIT 60
FIT 100
Max. loading capacity, ton
15
30
50
Max. lifting capacity, ton
15
30
50
Workpiece diameter, mm
600-5000
1500-6500
2000-8000
Power supply, 50 Hz 3-phase, V
380/400/415
380/400/415
380/400/415
Power supply, 60 Hz 3-phase, V
440/460/480
440/460/480
440/460/480
Fuse, A
9
10
12
Control voltage, V AC
24
24
24
Mains supply, 50/60Hz-3ph, V
400
400
400
IP classification (motor)
IP54
IP54
IP54
Power pack rating, kW
1.1
2.2
4
Weight with rail bogie, kg
1915
2885
6075
Dimension with rail bogie, LxWxH, mm
3439x915x888
4220x730x935
5090x1400x1105
Dimension without travel car,
LxWxH, mm (in.)
3439x935x1115
4220x1017x1160
5090x1580x2210
Cable length control box, m (in.)
10 (394)
10 (394)
10 (394)
71
Handling Equipment
RT3 - RT35
Two-axis Positioner for rotating and tilting workpieces
• Continuously (stepless) adjustable speed.
• Low voltage (24) remote control unit for all functions.
• 2-axis: tilting and rotation.
• Inverter-controlled rotation speed.
• All drives are equipped with AC motors which require less
maintenance, no carbon-brush to change.
•
Mechanically and electrically designed for easier maintenance with few spare parts.
Ideal for:
- Pipe shops
- Vessels
- Cladding of dish ends
- Fuel tanks
Ordering information
Options & Accessories
Positioner RT3
Positioner RT5
Positioner RT10
Positioner RT15
Positioner RT20
Positioner RT35
Technical data
0370 250 851
0370 250 852
0370 250 853
0370 250 854
0370 250 855
0370 250 856
RT3
Foot pedal
Pendant with digital display
RT5
RT10
RT15
0370 250 298
0370 250 431
RT20
RT35
Max. loading capacity, ton
3
5
10
15
20
35
Rotation motor, kW
1.5
2.2
4
5.5
9.2
11
Rotation cont AC inverter, kW
1.5
2.2
4
5.5
11
11
Rotation speed, rpm
0.1-1.0
0.08-0.82
0.048-0.48
0.1-1.0
0.048-0.48
0.029-0.29
Tilting range table plate, °
0-135
0-135
0-135
0-135
0-135
0-90
Tilting speed, sec.
80
113
177
120
177
105
Tilting motor c/w brake
1.5
2.2
4
7.5
9.2
7.5
Power supply,
50 Hz, 3-ph, V
60 Hz, 3-ph, V
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
Power supply rating, Amp.
9
11
18
20
38
40
Fuse, A
13
16
27
30
57
60
Control voltage, V AC
24
24
24
24
24
24
Table plate diameter,
mm (in.)
1200 (47)
1500 (59)
1800 (71)
1800 (71)
2200 (87)
2800 (110)
Max. welding current, A
800
1000
1000
1000
1000
1000
IP54
IP classification
IP54
IP54
IP54
IP54
IP54
Weight, kg (lbs.)
1570 (3461)
2720 (5996.5)
4530 (9987)
7100 (15653)
10000 (22046)
17000 (37479)
Dimensions LxWxH,
mm (in.)
1625x1070x1057
(64x42x41)
1720x1590x1227
(68x62.5x48)
2453x2070x1586
(96.5x81.5x62.4)
2800x2190x1840
(110x86x72.5)
3050x2400x1850
(120x94.5x73)
1940x2950x2600
(76x116x102)
Cable length, control box, m (in.)
6 (236)
6 (236)
6 (236)
10 (394)
10 (394)
10 (394)
72
Handling Equipment
TAP 1-HD / TAP 3-HD / TAP 6-HD
Three-axis Positioner for small objects
• Height, angle and speed are continuously (stepless)adjustable.
• Low voltage (24V) remote control unit for all functions.
• 3-axis: height, tilting angle and rotation.
• Inverter-controlled rotation speed.
• All drives are equipped with AC motors which require less
maintenance, no carbon-brush to change.
•
The hydraulics for height and tilt adjustment are equipped with built-in safety valves preventing hose failure.
•
Mechanically and electrically designed to be more compact
and wih fewer components for easier maintenance and fewer spare parts.
Ideal for:
- Pipe shops
- Vessels
- Cladding of dish ends
- Fuel tanks
Options & Accessories
Ordering information
Positioner TAP 1-HD
Positioner TAP 3-HD
Positioner TAP 6-HD
0370 250 753
0370 250 754
0370 250 755
Foot pedal
0370 250 298
Pendant with LCD display for TAP series 0370 250 752
Technical data
TAP 1-HD
TAP 3-HD
TAP 6-HD
Max. loading capacity, ton
1
3
6
Max. turning capacity, ton @ mm (in.)
1 @ 11 (270)
3 @ 165 (6.5)
6 @ 150 (6)
Max tilting capacity, ton @ mm (in.)
1 @ 11 (270)
3 @ 165 (6.5)
6 @ 150 (6)
Rotation speed, rpm
0.115-1.15
0.061-0.61
0.089-0.89
Tilting range table plate, degree
0-135
0-135
0-135
Tilting range arm, degree
0-45
0-45
0-45
Mains supply 50 Hz, 3ph, V
Mains supply 60 Hz, 3 ph, V
380/400/415
440/460/480
380/400/415
440/460/480
380/400/415
440/460/480
Fuse, A
9
9
18
Control voltage, V AC
24
24
24
Motor, kW
0.75
1.5
3
IP classification
IP54
IP54
IP54
Table plate diameter, mm (in.)
900 (35)
1000 (39)
1200 (47)
Max. welding current, A
800
800
800
Max tilting height, mm (in.)
1354 (53)
1738 (68)
1976 (78)
Weight, kg (lbs.)
1150 (2535)
1935 (4266)
4340 (9568)
Dimensions, LxWxH, mm (in.)
1294x1620x790
(51x64x31)
1280x2280x1058
(50x90x42)
1690x2500x1130
(66.5x98x44)
Cable length, control box, m (in.)
6 (20)
6 (20)
6 (20)
73
Handling Equipment
SHP-6-MHA and SHP-10 MHA
Sky Hook Positioner
• A basic solution for handling large and demanding workpieces in
all positions.
• Optimized motor and gear drive sizes.
• The positioner have 3 axis: height adjustment, tilting angle and
rotation.
• All drives are equipped with AC motors which require less main
tenance, no carbon-brush to change.
• Adjustable height available
• Ideal for highly demanding tasks with heavy workpieces.
Ordering information
Sky Hook Positioner SHP-6-MHA
Sky Hook Positioner SHP-10-MHA
Technical data
0370 250 960
0370 250 961
SHP-6-MHA
SHP-10-MHA
Max loading capacity, rotation, tons
6 tons at 150 mm
10 tons at 140 mm
Max loading capacity, tilting, tons
6 tons at 300 mm
10 tons at 200 mm
Rotation speed, rpm
0.1-1
0.1-1
Rotation motor, kW
2.2
4.0
AC inverter, kW
3
7.5
Height adjust speed, mm/min (ipm)
82-820 (3.2-32.3)
70-700 (2.8-27.6)
Height adjust motor, kW
2.2
7.5
Tilting speed, rpm
0.03-0.3
0.075-0.75
Tilting motor, kW
3
4.0
Power supply, 50Hz/3-phase, V
60Hz/3-phase, V
380/400/415
440/460/480
380/400/415
440/460/480
Fuse, A
12
20
Control voltage, V AC
24
24
IP Classification
IP 54
IP 54
Table plate diameter, mm (in.)
1400 (55)
1400 (55)
Welding current, A
800
800
Weight, kg (lbs.)
5800
12195
Dimensions, LxHxW, mm (in.)
1360x3564x3978 (53.5x140.3x156.6)
2170x4413x5147 (85.4x173.7x202.6)
Cable length control box, m (in.)
10 (394)
10 (394)
74
Handling Equipment
PR7/10 and IR7
Pipe Spool Rotator & Idler
• Equipped with dual motorized drives.
• Even and certain rotation since both axes of power section
are motorized.
• Solid state inverter for precise speed control.
• Idler Rail Bogie option.
Ideal for:
- Pipe spool and flange welding applications
- Welding of pipes
- Prefabrication/welding of pipe systems
- Welding of curved pipes, angle tees
Ordering information
Pipe Spool Rotator PR7/10
Idler IR7
0370 251 056
0370 251 060
Options & Accessories
Pendant with digital display
Technical data
0370 250 431
PR7/10
IR7
Max loading capacity, ton
3.5
3.5
Turning capacity, kg (lbs).
10 (22)
-
Roller speed, mm/min (ipm)
75-750 (2.95-29.5)
-
Workpiece diameter, min-max
mm (in.)
100-970 (3.94-38.2)
165-970 (6.5-38.2)
Power supply,
50 Hz, 3-ph, V
60 Hz, 3-ph, V
380/400/415
440/460/480
-
Polyurethane Tire,
Ø mm (in.)
Width mm (in.)
254 (10)
80 (3.15)
254 (10)
80 (3.15)
Fuses, A
16
-
Control voltage, V AC
24
-
Motor, kW
1.1
-
IP classification (Motor)
IP 55
-
IP classification (Electrical)
IP 43
-
AC inverter, kW
1.1
-
Weight, kg (lbs.)
1210 (2668)
772 (1702)
Dimensions, LxWxH, mm (in.)
1500x3150x500 (59x124x19.7)
1200x850x715 (47.2x33.5x715)
Cable, control box, m (in.)
10 (394)
75
Handling Equipment
MTS1 and MTS3
Pipe rotator
•
MTS1 and MTS3 are used for supporting workpieces with
different diameter and length.
• Positioning of the workpiece with headstock and positioner.
Ordering information
Pipe rotator MTS1
Pipe rotator MTS3
0370 251 057
0370 251 058
Technical data
MTS1
MTS3
Max loading capacity, ton
1
3
Vessel size, Ø mm (in.)
100-610 (3.94-24.02)
150-914 (5.9-36)
Roller type
PU Black
PU Black
Roller size, mm (in.)
150 (5.9)
200 (7.87)
Weight, kg (lbs.)
198 (436.5)
335 (738.5)
Dimensions, LxWxH, mm (in.)
635x1020x500 (25x40.2x19.7)
800x1310x550 (31.5x51.6x21.7)
HPS-3T
Pipe rotator
•
The HPS pipe rotator is used for supporting tubes with diameter from 100 to 1000 mm (3.9 to 39 inch).
•
A manually operated hydraulic system will set the rollers for the diameter requested.
Ordering information
Pipe rotator HTS-3T
0370 251 044
Technical data
MTS3
Max loading capacity, ton
3
Workpiece size, Ø mm (in.)
100-1000
Roller size, mm (in.)
200 (7.87)
Weight, kg (lbs.)
345 (761)
Dimensions, LxWxH, mm (in.)
1500x1100x710 (59x43.3x28)
76
Handling Equipment
Tank welder AGW1 and AGW2
Single-side and double-side
•
A series of self-propelled 3 o’clock welding equipment, primarily developed for on-site erection of large storage tanks, silos, blast furnaces and similar cylindrical objects.
• Available as a single-side version and a double-side version.
• Designed to travel on the top edge of the tank shell.
• As there are different ways of building tanks, one machine in the series is designed to travel on a rail which is temporarily fixed to the shell or on a stand-alone ring outside the shell.
•
The operator of each machine (if a double-side version) rides in a cabin, where he supervises and controls the welding process with the control panel within easy reach.
•
The cabin, whose floor level under the carriage is variable to suit the height of the plate, is built as a cage to give the operator(s) maximum safety and comfort.
• For weather protection the cage can be covered by curtains.
• The cabin of a double-side machine is equipped with step
ladders and a joining bridge at the top to facilitate for the
operators to climb onboard. The bridge also has guard rails for the safety of the operators.
Ordering information
Tank welder single-side, AGW1
Tank welder double-side, AGW2
0370 250 700
0370 250 702
Options & Accessories
Transportable stand AGW1
Transportable stand AGW2
Set of cables, 95 mm2 (75 & 25 m)
Cabine light
0370 250 703
0370 250 704
0370 250 705
0370 250 706
Technical data
AGW1
AGW2
Carry load, kg (lbs.)
300 (661)
300 (661)
Shell height, mm (in.)
1800-3500 (70.8-137.8)
1800-3500 (70.8-137.8)
Height increment, mm (in.)
100 (3.9)
100 (3.9)
Max. shell thickness, mm (in.)
50 (1.96)
50 (1.96)
Min. side clearance, mm (in.)
1450 (57)
1450 (57)
Travel speed, mm (in.)
244-2440 (9.6-96.06)
278-2780 (10.9-109.4)
AC motor travel, kW
1x0.55
2x0.55
AC inverter travel, kW
1x1.1
1x1.1
IP classification (motor)
IP55
IP55
IP classification (electrical)
IP43
IP43
Max. flux hoist, kg (lbs.)
70 (154.3)
70 (154.3)
Electrical panel
yes
yes
Dimensions, LxWxH, mm (in.)
1440x5836x2102 (56.7x229.8x82.8)
2210x5836x2120 (87x229.8x83.5)
Weight, kg (lbs.)
1300 (2866)
1460 (3219)
77
78
Handling Equipment
Special
Applications
79
Special Applications
Friction Stir Welding
Quality in depth
• The Friction Stir Welding (FSW) method is based on the
principle of obtaining a sufficiently high temperature and pressu-
re to join two components together by using a rotating tool, which under high pressure, moves along the joint and thereby creates a weld.
• FSW is ideal for joining straight profiles and flat plates from
1.2 to 130 mm (0.045 - 1.18 inch) with full penetration.
• Butt, lap and corner joints can be welded.
Suitable application areas
The FSW process is capable of welding a large variety
of products in diverse industries:
• Aerospace - fuel tanks
• Transportation - rail cars
• Marine - deck panels
• Automotive - suspension, bumper, seat parts
• Nuclear power - copper canisters
• Heat transfer - heat sinks & exchangers
80
Key benefits
• Minimal distortion and shrinkage
• No joint preparation - degreasing only
• No grinding, polishing or straightening
• No repair welding
• Reduced weight (40% less than GMAW)
• Consistent weld quality
• Increased tensile strength
• Outstanding fatique properties
• No fumes, sparks or spatter
• Low noise level
• Improved repeatability
SuperStir™ Friction Stir Welding System
The ESAB SuperStir™ range is purpose-built for high-volume
production of large aluminium panels, girders and trusses. The
large custom-designed units offer a safe, clean and simple welding
process that can be fully automated, dramatically reducing production costs.
ESAB SuperStir™ FSW technology is applied across the entire
industrial spectrum, from shipping, offshore, construction and transportation to defence and aerospace.
Special Applications
Friction Stir Welding
Cont.
SuperStir™ FSW Gantry
• A flexible gantry for friction stir welding based upon a modular,
five-axis motion system platform that can be scaled to cover a
range of applications.
•
The SuperStir FSW Gantry system for automated friction stir
welding is a modular, 5-axis motion platform in a gantry configuration
•
The gantry system is based on ESAB’s well proven control
system and is designed to fit a broad range of welding applications with a modular architecture that allows it to be tailored
to the specific needs of your application.
•
The gantry operates on rails making it particularly well suited to
•
Fully Automated Process. At the heart of ESAB’s SuperStir
weld long components.
technology is the control system developed for the FSW process.
•
For fast support, operation of the gantry can be remotely
monitored in real time from any PC computer using a standard
Ethernet connection.
• High quality welds - increased tensile strength and outstanding
fatigue properties compared to conventional welding.
• Minimum of post treatment - low distortion and shrinkage
thanks to low heat input
Options
• FSW heads for different welding thicknesses
• Retractable PIN Tool (RTP) & Bobbin tool head
• Welding FSW tools
• Joint tracking system
• Weld video monitoring system
• Millng head
• Vacuum system
• Protection bellows for Y and Z range motion components
• Central lubrication system
• Fixture systems
Other combinations of working ranges and welding thicknesses available on request.
Technical data
Basic System
Working range, m
X axis
Y axis
Z axis
up to 150
up tp 10
up to 3
Rotation axis
A axis
B axis
± 6° (around Y axis)
± 90° (around X axis)
Transport speed, m/min
up to 10
Welding speed, m/min
up to 3
Welding tool rotation, rpm
100-3000
Power supply, V
400 ± 10%
Power consumption, kW
approx. 50
Welding aluminium thickness
(welding tool dependent)
Series 6000, mm
Series 5000 mm
Series 2000 & 7000 mm
Head 4
Head 5
1-18
1-10
1-8
1-35
1-20
1-18
Downforce Z axis, kN
60
100
81
Special Applications
Friction Stir Welding
Cont.
LEGIO™ Friction Stir Welding System
•
The modular system makes it possible to assemble welding stations to suit the most varied Friction Stir welding applications.
•
The LEGIO™ system consists of 5 basic designs in a series of seven sizes, covering a welding depth of 1.2 to 65 mm
(0.045 to 2.4 in.)
•
These basic types can be supplemented with different types of equipment to suit the most varied production needs with
maximum flexibility to any production line.
•
The larger S- and the U-models are designed to be easily
integrated with larger fixtures, rotary units and exchangeable clamping systems.
•
For the production of smaller workpieces, the UT- and the
ST-model are the most suitable. They have tables prepared
with a hole pattern, where fixtures can be attached.
82
Rosio™ Friction Stir Welding Robot
• Designed for complex joints.
• The latest IRC5 control system, featuring embedded force
control, ensures high accuracy in-contact motion.
•
The upgraded motion software permits linear welding in arbitrary patterns, as well as circular and square paths.
•
Additional functionalities to support customized path program-
ming and spindle operation, permit advanced welding, even with limited programming skills.
•
A user-friendly HMI extends the IRC5 interface, providing full operator feedback via a Flex Pendant.
Technical data
Rosio™
Aluminium series 6000, mm (in.)
series 5000, mm (in.)
series 2000, mm (in.)
series 7000, mm (in.)
1-7
1-6
1-5
1-5
Welding speed, mm/min (ipm)
>1000 (39.4)
Max.spindle rotation, rpm
3000
Max down force, kN
13
Robot reach, mm (inch)
2550 (100.4)
Robot base dimension, mm (in.)
1206.5 x 1200 (47.4 x 47.2)
Robot weight, kg (lbs.)
2500 (5511.55)
Cabinet dimension, mm (in.)
2160x725x710
(85.04x28.54x27.95)
Cabinet weight, kg (lbs.)
250 (551.16)
Mains, V/HZ
400/50
(0.04-0.28)
(0.04-0.24)
(0.04-0.20)
(0.04-0.20)
Special Applications
ICE™
Revolutionary SAW technology for enhanced productivity
•
ESAB’s patent pending ICE™ technology exploits the excess
heat from the Twin SAW process to increase productivity by up
to 100% without increasing heat input.
•
Up to 50% higher deposition rate. Submerged arc welding
is already the most productive welding process. But as with
any other welding process, the need to limit heat input inhibits
productivity. Instead of adding more energy, ICE™ utilises the
excess heat available to melt more wire. This boosts productivity by up to 50%, depending on the application.
•
High Deposition Root™ - the ICE™ technology enables the
use of tandem welding in root passes, for improved penetration and high productivity and eliminating the need for back
gouging. High Deposition Root can increase productivity up to
100% in root welding, depending on the application.
•
be utilised to increase welding speed. This can significantly
Comparison of deposition rate for ICE™ and
other methods.
improve productivity in applications where welding speed is the
Deposition rate
Higher welding speed - the increased deposition rate can also
key to maximising productivity.
•
Reduced energy consumption - welding is an energy inten-
ICE™
sive manufacturing operation. The ICE™ process enables an
increase in deposition rate by up to 50%, without adding more
energy. This combines environmental benefits with significantly
Twin DC+
reduced energy consumption.
•
Single DC+
Innovative Flat Cap Cotrol™ - adjusting the ratio of ”cold
wire” used for cap runs makes it possible to produce a flatter
Single power-source and welding-head solutions
cap to the weld. This increases fatigue resistance and reduces
the need for post weld treatment. Just one more boost to your
productivity.
• Reduced flux consumption - The significant productivity
Deposition rate
DC + AC ICE™
improvement provided by ICE™ enables many applications to
be completed with fewer runs. In this way, flux consumption
can be reduced by up to 20% when welding with a 50% higher
DC + Twin AC+
deposition rate.
Suitable application areas
• On- and offshore windtower manufacturing
• Offshore fabrication
• Pipe welding
• General heavy fabrication
• Shipbuilding
DC + AC
Two power-source and welding-head solutions (tandem
welding)
These results are based on the testing results carried out under controlled conditions by ESAB using ESAB consumables and experienced
welding engineers and may vary accordingly.
83
Special Applications
Hybrio™ - Hybrid Laser Welding
Lighting the way
•
ESAB’s Hybrio™ hybrid laser welding technology combines the deep weld penetration and low heat input associated with laser welding with the excellent weld properties and superior gap tolerance of gas metal arc welding (GMAW).
•
A radically new welding alternative, it produces extremely narrow and deep welds at very high travel speeds. In a single pass, the Hybrio™ process can often achieve what might require multiple weld passes using a conventional fusion welding process.
•
Heat input to the part is reduced, as is the associated weld shrinkage and distortion that can make post-welding geometry unpredictable - and costly to repair.
• Using GMAW in combination with a laser, the Hybrio™
process solves laser-only welding’s limitations, concerning its ability to produce acceptable welds in joints with less than perfect fit-up between parts. This enables a widened, more robust process envelope by a factor of three compared
to a conventional laser-only process.
• GMAW also allows users to add filler metal to adjust the weld’s metallurgical properties and create beads and fillets, while the slower cooling rate reduces hardness. These features are espe-
cially beneficial when joining high performance carbon and
stainless steels.
GMAW (MIG/MAG)
•
ESAB’s exclusive adaptive closed-loop control system detects joint fit-up conditions and changes the process parameters in real-time to achieve a constant weld profile. This broadens the process window by a further 5 times over non-adaptive control.
Autogenous Laser
(laser only)
Hybrid Laser
Welding
Graphic illustrating differences between GMAW, Laser and Hybrid Laser Welding
weld profiles
The Hybrio™ Value Proposition:
• Operating costs reduced by 50-80%.
• Productivity improved by 300-1000%.
• Heat input and distortion reduced by 80-90%.
• Reduced weld repair rates.
• Reduced labour content through fully automated operation.
• Reduced operator skill requirement due to easy,
PC-based machine controller.
• Lower downstream assembly, welding and finishing costs, through reduced part distortion.
Ordering information
For more information, please contact your nearest ESAB
representative.
Sales Literature
84
XA00153320
• Higher overall plant throughput and revenue generation.
• Feasibility of new, lighter, stiffer and simpler product design and construction methods.
•
Full backing and support of ESAB’s process experts and service professionals, with extended warranty and service agreements.
Special Applications
Hybrio™ - Hybrid Laser Welding
Cont.
Hybrio™ Flex
The Hybrio™ Flex flexible hybrid laser welding cell is based upon a modular, six-axis motion
system platform that can be scaled to cover a large range of working envelopees up to 4m
x 20 m and longer. Additionally, this system can be configured to cover a range of Z-axis
depths from 1 m to 3 m (3 to 10 ft.). This gives the user the flexibility to use the Hybrio™
Flex system for large variety of product geometries and weld joint configurations.
Hybrio™ Beam
The Hybrio™ Beam hybrid laser beam welding system is based upon ESAB’s robust
submerged-arc beam welding systems that can be found in plants around the world. These
systems come in horizontal and vertical configurations and are designed to center and feed
web and flange parts through a fixed welding station. Components are aligned and pres�sed together ensuring excellent joint conditions at the point of welding. Equipped with the
Hybrio™ process, these systems can out-produce traditional beam welding equipment by a
factor of three to ten times depending upon the web thickness.
Hybrio™ Seam
Hybrio™ Seam hybrid laser seam welding systems cover a range of raw sheet and plate
thicknesses and sizes from small sheet and coil joining systems to large panel line plate
welding machines. These systems are designed to press and clamp sheet or plate joints into
position as the Hybrio™ process moves along the joint, performing the weld. These systems
can achieve single-side, full-penetration butt welds up to 12.5 mm (1/2 in.) in thickness in a
single pass and thicker with subsequent passes.
Hybrio™ Tube
Hybrio™ Tube hybrid laser tube and pipe systems are longitudinal seam welding systems
designed to press the material together at the weld joint to achieve the fit up needed for
HLAW welding. The part is then drawn through the machine to perform the weld. These systems can produce straight or tapered tubes and pipes up to 1 m (3 ft.) in diameter and with
wall thicknesses up to 12.5 mm (1/2 in.).
Hybrio™ Orbit
The Hybrio™ Orbit hybrid laser pipe girth welding system is specially designed for welding
full pipe girths as well as for rapidly producing high-quality root passes for subsequent processing with traditional high-deposition processes. These are fully orbital welding systems,
capable of 360 degree continuous welds around cylindrical products with very low clearances. The Hybrio™ Orbit system was specifically developed for the oil and gas industry, but
has applications in many other industry segments.
Hybrio™ Process Package for Integrators
ESAB’s Hybrio™ hybrid laser arc welding process technology leads the industry in ease of
use and process robustness. ESAB has developed a fifth-generation welding system that is
capable of sensing its environment, the joint location and fit-up and then adapting the process
in real-time to maintain high weld quality over a wide range of fit-up conditions. ESAB has built
this technology into a complete process package that is available not only as part of our turnkey hybrid welding systems but also to
machine tool OEM and system integrators. ESAB provides the hybrid welding expertise along with the support of our Laser Process
Centers in North America and Europe, to minimize the technical risk to our OEM and integration partners worldwide.
85
Special Applications
Chain Making Equipment
For cost-efficient production and superior quality
Carousel - Anchor chain making equipment
Carousel is the most common chain making system thanks to its
flexibility and large capacity. ESAB delivers complete installations;
semi-automatic or fully automated for one to five operators, depending on the grade of automation.
Four or five chains (depending on type of chain) are simultaneously
undergoing working and the chains are transported from station to
station by the carousel. After completion the chains are transported
out of the plant in four or five endless lengths.
Overhead Crane - For heavy anchor chain
production
When welding chains in large dimensions (>130 mm) there is no
advantage in terms of production rate to have more than two chains
in production simultaneously.
The equipment consists of two overhead cranes, operating independently of each other on one parallel pairs of rails. On each
crane a carriage is placed for sideways movement between the
production stations.
Two chains are simultaneously undergoing production and the
chains are transported from station to station along the “working
line” – formed by the link forming machine, the flash welding
machine, the flash trimming machine and the stud press.
The chains are conveyed out of the plant after completion in two
endless lengths, which are collected outside the plant
Chain making installations can be custom-built to suit individual
specifications.
ESAB also supplies single machine units, resistance heaters, bending machines, flash butt welding machines, trimming machines,
stud presses, chain transport equipment and manipulator systems.
Main components
●●
●●
●●
●●
●●
●●
●●
Automatic resistance heater incl magazine for bars
Roller track
Automatic link forming machine
Automatic flash butt welding machine
Automatic upset trimming machine
Automatic stud press
Chain transport equipment
Chain types that can be produced
automatically or semi-automatically
●●
●●
●●
●●
●●
86
Anchor chain (with or without studs)
Intermediate and end links
Offshore chain including oil-rig and supply ship chain
Buoy mooring chain
Similar types or stud- and studless chain
Special Applications
Chain Making Equipment
Cont.
ZAC 42 MR - Automatic production of
mining chain
Operational control is automatic. Pre-setting the number of links
to be produced contributes to higher productivity and consistent
quality.
Robotic handling in combination with the PLC system ensure
correct positioning of the link throughout the production process for
fully automatic operation.
The PLC system also controls position and force on the hydraulic
cylinders. This is a big advantage when changing the link dimension, instead of adjusting mechanical stops, a major part of the
positions are part of the program.
Low energy consumption due to welding takes place immediately
after the heating/forming operation. Rings, single links or short
chain lengths can be continuously produced.
Systems for automatic welding of mining chains with forged links
and for welding of master links are available.
Advantages achieved by the process include superior welding quality and unsurpassed production rate.
Typical chain types
●● Chains for coal shearers
●● Conveyor chains for stage loaders and feeders
Main components
●●
●●
●●
●●
●●
●●
●●
●●
High capacity resistance heater with magazine
Link forming machine
Flash butt welding unit
Flash trimming machine
Chain transport equipment
Rotary platform with chain boxes for chain collection
Main operation table
Hydraulic power unit
Ordering information
For more information,
please contact your nearest
ESAB representative.
Sales Literature
XA00163720
87
Special Applications
HNG Multi
Narrow Gap Welding System
•
Designed for both Single (AC or DC) and tandem (DC/AC or AC/AC) wire welding in parallel or almost parallel joints, ranging in width from 18 mm (0.71 in.) and in depth down to 350 mm (13.8 in.).
•
Continuous double-sided joint tracking gives a high reliability at shift overlap.
• Continuous measuring of joint width
• Short-circuit protected, welding head - workpiece.
• Automatic positioning.
• Possible to weld up to 50 mm (1.97 in.) joint width
• Air-cooled torch
• Reliable and uniform high weld quality
• High productivity.
• Minimum of supplementary work.
Technical data
Weld joint type
Butt
Wire dimension, mm (in.)
3-4 (0.12-0.16)
Wire feed motor
A6 VEC 156:1, 4000 rpm
Max. wire feed speed, m/min (ipm.)
4 (157)
Max welding current DC, A
800
Max welding current AC, A
800
Beads in each layer
2-4
Deposition rate, kg/h (lbs./h)
approx. 7/16 (15.4/35.3)
(Single/Tandem)
Tilting angle of weld nozzle
± 3.5°
Max. joint depth, mm (in.)
350 (13.8)
Joint width, mm (in.)
18-50 (0.71-1.97)
Wire angle between wires
15°
Distance between wires, mm (in.)
15 (0.59)
(valid for 30 mm (1.18) stick-out)
Accuracy of joint tracking, mm (in.)
± 0.15
Max heat resistance, workpiece,
°C (°F)
300 (572)
Min weld diameter, mm (in.)
500/1200 (19.7/47.2)
Single/Tandem
Flux hopper unit
OPC Super
Flux hopper capacity, l (gal.)
approx. 10 (2.64)
Min clearance internal weld
- Longitudinal, Ø mm (in.)
- Circumferential, Ø mm (in.)
1500 (59.06)
1500 (59.06)
Weight, kg (lbs.)
88
140/165 (309/364)
(Single/Tandem)
Ordering information
For more information, please contact your nearest ESAB
representative.
Sales Literature
XA00141620
Double-sided joint tracking
Special Applications
Beam Welding - Pull Through Welders
For welding of beams and profiles
• ESAB offers a complete and effective way of welding beams and •
profiles. Whether you weld I-, T- or L-beams, wide flange beams, columns, tapered beams or non-symmetrical beams, ESAB has the expertise and welding equipment to match your efficiency, quality, precision, versatility, productivity, and overall welding economy requirements.
Two types of machines: IT-machines where the beams are welded with the web unit in the vertical position, and I-machines, where the beams are produced in horizontal position.
• High production capacity and perfect weld quality.
• The welding operation takes place when the flange and the web are pressed together under pressure in order completely to eliminate the gap between the surfaces.
Straightening principle:
Total range of beam sizes that can be welded:
Machine type
Web
Flange
IT-258
200-2500 mm
100-800 mm
IT-158
200-1500 mm
100-800 mm
Examples of beams
than can be welded:
Beam welder IT-258
89
Special Applications
Welding solutions for Pipemills
Our experience and knowledge - your benefit!
Flexible, reliable welding equipment
A wide range of products developed in-house for various multi-wire
SAW applications which are particularly suitable for pipe welding.
Precise, high-speed longitudinal welding
Our concept for longitudinal submerged-arc welding is suitable for
pipes in a normal diameter range of 20-64”, a normal wall thickness
of 6-40 mm (0.24-1.57 in.) and a length of up to 18 m (708.66 in.).
Internal and external welding
For internal welding we have designed pre-stressed booms as well
as welding heads for up to four wires.
The external welding station is based on a column and boom
solution with a very stable cross-slide to adapt to different pipe
diameters.
Return current systems (grounding)
High current circuits have to be closed back to the power source by
efficient systems at constantly moving pipes. Flexible steel brushes
in two rows in front and behind the welding process are pressed
with defined force from outside to the pipe to catch the current with
a minimum of voltage loss and to surely avoid any arc blow effect,
which would disturb the weld process.
Internal welding
Problem-free flux and wire feed systems
Smooth feeding of wire in different diameters and equally straightforward supply of new and re-used flux.
The correct combination of compressed air, flux feeding, easy
replenishment of new flux via the Big/Bag system, a vacuum unit,
a reliable magnetic separator and continuous recovery helps to
create welding stations with less downtime, high-quality welds and
a cleaner working environment.
Spiral pipe welding
Internal and external welding is performed at one and the same
station. Internal welding starts first and, after half a turn, external
welding then begins - internally with two or in some cases three
wires and externally with one or three wires in the welding process,
depending on the diameter and wall thickness of the pipe.
External welding
Ordering information
For more information, please contact your nearest ESAB
representative.
Sales Literature
XA00136520
90
Special Applications
Windmill Tower Manufacturing
Dedicated solutions for dedicated manufacturers
• The key to efficient production of wind towers is smooth component flow in the workshop. The benefit of a high deposition welding process is completely lost if the set-up or handling
of components in any area of the process fails or takes an
unacceptable amount of time.
• ESAB can assist with the welding and cutting process in wind tower production and deliver finely tuned solutions for each step in the production process.
• With a complete package from ESAB, you only need to work with one supplier for product, service and support. This results in a large project being organized efficiently, with a fixed cost and agreed time schedule. Smooth production flow is part of the complete delivery.
Oxy-fuel or plasma cutting of
plate and seam preparation
Rolling, forming and tack welding of the shell
External longitudinal submerged-arc welding using a
column and boom
Internal longitudinal submerged-arc welding using a
column and boom
Submerged-arc welding of
flanges and supports
Joining of shell sections using
roller beds with hydraulic fit-up
system. Internal and external
submerged-arc welding performed by a column and boom
station.
Automatic welding of the door
frame.
Production of sub-components
using an ESAB positioner and
manual welding equipment
91
Special Applications
ESAB Retrofit
Modernization and upgrading
•
ESAB’s service group can upgrade any brand of existing equip-
ment to virtually new condition, with the latest process equip-
ment and accessories.
• Accessories include seam trackers, flux recovery systems, wire handling equipment, strip cladding equipment - all can be added to existing equipment.
• Material quality, thickness and required properties will decide the •
most suitable welding process. Over a time these conditions will change which might lead to a change of process. ESAB can
offer a variety of different welding heads for different processes to be fitted on any carrier.
ESAB Retrofit is an ideal alternative to investment in new
equipment. Not least when it comes to the added values that frequently accompany this kind of upgrade.
•
In addition to increased availability, a conversion of this kind frequently also leads to a substantial rise in productivity
and quality, not to mention improvements to the working
environment.
•
ESAB works with many OEM’s for equipment - specify the ESAB process system and accessories and get the advantage of ESAB performance from your existing supplier of machinery.
92
Why Retrofit?
• It is difficult to find parts for your old equipment
• The productivity is too low with your present equipment
• The quality of the process is unacceptable
• The process is not ideal for the present production
Time to Retrofit?
What kind of carrier can be retrofitted?
• ESAB can retrofit manipulators, gantries, seamers, shipyard
•
•
panel lines etc. We even retrofit flash butt welding machines to
a new life.
Integration of welding equipment to new carriers or production lines produced by integrators of automation equipment for
example pipemills, panel lines etc.
We do small retrofits by just replacing the existing equipment
and we do large integrated solutions.
Handling Equipment
Wear
Parts
93
Wear Parts
A2 Wear Parts
Secure your welding quality and productivity with ESAB original parts
Wear Part Kits
Contents
Wire Diameter, mm (in.)
Part Number
2.5 (3/32)
3.0 (0.12)
3.2 (1/8)
4.0 (5/32)
0810123880
0810123881
0810123882
0810123883
1.0 (.035)
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
0810125880
0810125881
0810125882
0810125883
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
0810124880
0810124881
0810124882
Wear part kit A2 SAW
15 pcs contact nozzles
2 pcs feed rollers
2 pcs pressure rollers
1 pc contact tube
Wear part kit A2 GMAW
10 pcs contact nozzles
1 pc feed roller
1 pc pressure roller
1 pc contact tube
1 pc gas nozzle
2 pcs insulating sleeve
1 pc plug
1 pc tip adaptor
1 set of O-rings
Wear part kit A2 SAW Twin
20 pcs contact nozzles
1 pc feed roller
1 pc pressure roller
1 pc nozzle holder
Feed Roller Single Wire
Wire Dimension
mm (in.)
Part Number
0.8 (.030)
1.0 (.035)
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
2.4-2.5 (3/32)
3.0-3.2 (.012-1/8)
4.0 (5/32)
Pressure roller
0145538881
0145538882
0145538883
0218510281
0218510282
0218510283
0218510298
0218510286
0153148880
SAW Single
GMAW
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Feed Roller Twin Wire
Wire Dimension
mm (in.)
Part Number
SAW Twin
2 x 1.2 (.045)
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.4-2.5 (3/32)
Pressure roller
0218522486
0218522488
0218522484
0218522480
0218524580
•
•
•
•
•
94
Wear Parts
Feed Roller Grooved and Knurled
Wire Dimension
Cored Wire, mm (in.)
Part Number
SAW Single
GMAW
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
0146024880
0146024881
•
•
•
•
Pressure Roller Grooved and Knurled
Wire Dimension
Cored Wire, mm (in.)
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
Shaft for pressure
roller
1
Part Number
SAW Single
GMAW
01460258801
01460258811
0212901101
•
•
•
•
•
•
Use with shaft for pressure roller 0212901101.
Contact Tube D20 Single Wire
Length, mm (in.)
Part Number
SAW Single
100 (4)
190 (7.5)
260 (10.2)
500 (19.7)
260 (10.2) bent
0413510003
0413510002
0413510001
0413510004
0413511001
•
•
•
•
•
D20 Contact clamp
0334571880
Contact Nozzles
Wire Dimension
mm (in.)
Part Number
SAW Single
M12
1.6 (1/16)
2.0 (5/64)
2.5 (3/32)
3.0 (0.12)
3.2 (1/8)
4.0 (5/32)
0154623008
0154623007
0154623006
0154623005
0154623004
0154623003
•
•
•
•
•
•
M6
0.8 (.030)
1.0 (.035)
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
2.4-2.5 (3/32)
Tip adaptor M10
to M6
M10
0.8 (.030)
1.0 (.035)
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
2.4 (3/32)
3.0 (.012)
3.2 (1/8)
4.0 (5/32)
1
GMAW
01535010021
01535010041
01535010051
01535010071
0153501009
0153501010
0147333001
•
•
•
•
0258000914
0258000913
0258000908
0258000909
0258000910
0258000911
0258000918
0258000915
0258000919
•
•
•
•
•
•
•
•
•
•
SAW Twin
•
•
•
•
Use in conjunction with tip adaptor M10 to M6 for GMAW applications.
95
Secure your welding quality and productivity with E
original parts
Wear Parts
A2 Wear Parts
A2 S
Cont.
MTW 600
MIG/MAG torch
600 amp 100%
MIG/MAG torch
600
amp GMAW
100%
Contact Device D20
Complete
Description
A2 MIG Wear Parts
1. A2 torch
2. Gas nozzle
3. Insulating sleeve
4. Contact tube
5. Plug
6. Extension
7. Guide tube
8. O-ring, 22.2x3
9. O-ring, 15.3x2.4
10. O-ring, 5.3x2.4
0030465389
A2S
MIG
0145227882
0145226001
0145534882
0146099001
00409798-03/-041
0415032001
1.
0190680405
0190680313
0190680303
Part Number
GMAW
• welding quality and productivity with E
Secure Torch
your
MTW 600 MIG Torch
•
1
•
1.1
original parts
4
1. A2
0030 465 389
5 MTW 600 200 mm
• torch
2
0457 625 005
0457 625 006
0457 625 007
0457 625 008
0457 625 009
0457 625 011
0457 625 012
5.
1.6 mm
2.0 mm
2.4 mm
1.4 mm
1.6 mm
Wire dim.
Fe, Ss, Cw
1.0 mm
1.2 mm
M8.
7.
6.
2.4 mm
Contact nozzle M8
1.2 mm
8.
Wire dim.
Al
1.0 mm
4.
3.
2.
8.3 Plastic PTFE 1.0-1.6 mm L=400 m
0258 000 914
0258 000 913
0258 000 908
0258 000 909
0258 000 910
0258 000 911
0258 000 915
2.
0,8 mm
1.0 mm
1.6 mm
2.0 mm
2.4 mm
Wire dim.
Fe, Ss, Cw
0.8 mm
1.0 mm
1.2 mm
1.6 mm
2.0 mm
2.4 mm
3.2 mm
Wire dim.
Al
1.4 mm
1.6 mm
nozzle M10
7.
0147 333 001
Wirelength
dim.
*cut to suitable
M8
M8. Fe, Ss, Cw
1.0 mm
1.2 mm
5.
8.
9.
10.
6.
L=208 mm
L=258 mm
L=308 mm
8.
L=408 mm
Contact
nozzle M8
Plastic PTFE 2.0-2.4 mm L=400 m
1.6 mm
2.0 mm
2.4 mm
1.1
1.2
1.3
1.4
2.
3.
1. 4.
5.
6.
7.1
7.2
7.3
7.4
3
8.2 Brass 2.0-2.4 mm
7
2 Brass 2.0-2.4 mm
Brass 2.0-2.4 mm
6.
7.
6 2.0-2.4 mm
Brass
Tip adapter
M10 / M6
96
4.
Cut to suitable length
3.
1
A2 torch
Gas nozzle
Insulating sleeve
Contact tube
Plug
Extension L=158
Extension L=108
Guide tube
O-ring 22.2x3
O-ring 15.3x2.4
O-ring 5.3x2.4
2.4 (3/32)
1.
2.
3.
4.
5.
6.1
6.2
7.
8.
9.
10.
2.0 (5/64)
Torch
1.4 (.052)
1.6 (1/16)
G torch
p 100%
1.2 (.045)
0030 465 389
0145 227 882
0145 226 001
0145 534 882
0146 099 001
0040 979 803
0040 979 804
0415 032 001
0190 680 405
0190 680 313
0190 680 303
M10 / M6
0147 333 001
Wire dim.
Wire dim.
0457619001
Fe, Ss, Cw 0457619002
Al
Contact
nozzle
M10
M10.
0.8 mm
0153 501 002
mm (in.)
Fe, SS, CW
Al
Wire
dim.
Wire
dim. 0457625005
1.0
mm
0.8
mm
0153 501 004
0457625005
M10.
Fe,
Cw
Al
1.2Ss,
mm
1.0
mm
0153 501 005
0457625006
0457625007
0.8 mm
0258
000
1.2
mm
0153
501914
006
0457625008
M6.
1.0
0,8 mm
0258
1.6mm
mm
0153000
501913
007
0457625009
0457625009
1.2 mm
1.0
0258
1.6mm
mm
0153000
501908
008
1.6
0258
2.0mm
mm - 1.6
2.0mm
mm 0457625001
0153000
501909
009
0457625012
2.0
2.0
0258
2.4mm
mm
2.4mm
mm 0457625012
0153000
501910
010
2.4 mm
2.4 mm
0258 000 911
Tip adapter
3.2 mm
0258 000 915
M10 / M6
0147 333 001
IG Wear Parts
1.0 (.040)
0457620003
0457620004
8.3 Plastic PTFE 1.0-1.6 mm L=400 mm* 0457 619 001
Plastic PTFE 2.0-2.4 mm L=400 mm* 0457 619 002
*cut to suitable length
1.6 mm
0457620001
2.0
mm
0457620002
2.4
mm
0153 501 002
0153 501 004
0153 501 005
0153 501 006
0153 501 007
0153 501 008
0153 501 009
0153 501 010
2.0 mm
2.4 mm
0457454005
7.
Tip adapter
Contact nozzle
M6
8.3. Guide inserts, Plastic PTFE
1.0-1.6 (.040-1/16), L = 400 (16) 1
2.0-2.4 (5/64-3/32), L = 400 (16) 1
Contact Nozzle M8,
0153 501 002
0153 501 004
5. 501 005
0153
8. 501 006
0153
9. 501 007
0153
0153
10. 501 008
0153 501 009
0153 501 010
0.8 mm
1.0 mm
1.2 mm
(8.2)
(10.1)
(12.1)
(16.1)
1.6 mm
6.
0457454001
0.8
mm
0457454002
1.0
mm
0457454003
1.2
mm
0457454004
Wire dim.
Al
8.2. Guide inserts, Brass
2.0-2.4 (5/64-3/32), L = 208
2.0-2.4 (5/64-3/32), L = 258
2.0-2.4 (5/64-3/32), L = 308
2.0-2.4 (5/64-3/32), L = 408
your welding quality and productivity with ESAB
l parts
(8.3)
(10.2)
2.
(12.2)
(14)
M6.
(16)
0457455007
Wire
dim.
0457455008
Al
1.2 MTW 600 250 mm
Guide inserts
1.3 MTW 600 300 mm
1.4 MTW
400 mm
mm
8.1 Steel 1.0-1.6
mm 600
L=210
2. Gas
Steel 1.0-1.6
mmnozzle
L=260 mm
3. Splatter
protection
Steel 1.0-1.6
mm L=310
mm
4. Centring
sleeve
Steel1.1.0-1.6
mm L=360
mm
5. O-ring
Steel 1.0-1.6
mm L=410 mm
6. Nozzle adapter
8.2 Brass 2.0-2.4 mm L=208 mm
7.1 Contact tube 200 mm
Brass 2.0-2.4 mm L=258 mm
7.2 Contact tube 250 mm
Brass 2.0-2.4 mm L=308 mm
7.3 Contact tube 300 mm
Brass 2.0-2.4 mm L=408 mm
7.4 Contact tube 400 mm
8.3 Plastic PTFE 1.0-1.6 mm L=400 m
Guide
inserts
Plastic
PTFE 2.0-2.4 mm L=400 m
*cut
to
suitable
8.1 Steel 1.0-1.6length
mm L=210 mm
5 Steel 1.0-1.6 mm L=260 mm
Steel 1.0-1.6 mm L=310 mm
4
Steel 1.0-1.6 mm L=360 mm
Steel
8 1.0-1.6
2.mm L=410
3. mm 4
Wire dim.
Fe, Ss, Cw
0.8 mm
1.0 mm
1.2 mm
M10.
8.1. Guide inserts, Steel
1.0-1.6 (.040-1/16), L = 210
1.0-1.6 (.040-1/16), L = 260
1.0-1.6 (.040-1/16), L = 310
1.0-1.6 (.040-1/16), L = 360
1.0-1.6 (.040-1/16), L = 410
Wire dim.
Fe, Ss, Cw
0.8 mm
1.0 mm
1.2 3.
mm 4.
nozzle M6
7.4. Contact tube, 400 mm (16 in.)
nozzle M6
0457 620 001
0457 620 002
0457 620 003
0457 620 004
7.3. Contact tube, 300 mm) (12 in.)
L=208 mm
L=258 mm
L=308 mm
L=408 mm
7.2. Contact tube, 250 mmContact
(10 in.)
8.2 Brass 2.0-2.4 mm
Brass 2.0-2.4 mm
Brass 2.0-2.4 mm
Brass 2.0-2.4 mm
7.1. Contact tube, 200 mm (8 in.)
0457 454 001
0457 454 002
0457 454 003
0457 454 004
0457 454 005
6. Nozzle adaptor
L=210 mm
L=260 mm
L=310 mm
L=360 mm
L=410 mm
5. O-ring
8.1 Steel 1.0-1.6 mm
Steel 1.0-1.6 mm
Steel 1.0-1.6 mm
Steel 1.0-1.6 mm
Steel 1.0-1.6 mm
4. Centering sleeve
Guide inserts
3. Splatter protection
0457 460 880
0457 460 881
0457 460 882
0457 460 883
0457 451 001
0457 452 001
0457 453 001
0457 458 001
0808 311 001
0457 455 005
0457 455 006
0457 455 007
0457 455 008
2. Gas nozzle
0457460880
MTW 600 200 mm
MTW 600 250 mm
MTW 600 300 mm
MTW 600 400 mm
Gas nozzle
Splatter protection
Centring sleeve
O-ring
Nozzle adapter
Contact tube 200 mm
Contact tube 250 mm
Contact tube 300 mm
Contact tube 400 mm
1.
2.
1.4 MTW-600, 400 mm (16 in.)
MTW 600 MIG Torch
1.3 MTW-600, 300 mm (12 in.)
8
1. A2 torch 0457460881
0030 465 389
2. Gas nozzle
0145 227 882
0457460882
3. Insulating 0457460883
sleeve
0145 226 001
4. 3. Contact
0145 534 882
4. tube
5.
0457451001
5. Plug
0146
8. 099 001
6.1 Extension0457452001
L=158
0040 979 803
9.
6.
7.
6.2 Extension0457453001
L=108
0040 979 804
0457458001 10.
7. Guide tube
0415 032 001
0808311001
8. O-ring 22.2x3
0190 680 405
9. O-ring 15.3x2.4
0190 680 313
0457455005
10. O-ring 5.3x2.4
0190
680 303
0457455006
MTW 600
MIG/MAG torch
600 amp 100%
1.2 MTW-600, 250 mm (10 in.)
1.2 MTW
6 600 250 mm
1.3 MTW 600 300 mm
1.4 MTW 600 400 mm
2. Gas nozzle
MTW
600
9
10 Splatter protection
3.
1.
4. Centring
sleeve
MIG/MAG
torch
5. O-ring
600 amp
100%
6. Nozzle adapter
7.1 Contact tube 200 mm
7.2 Contact tube 250 mm
7.3 Contact
tube 300 mm
MTW 600
MIG Torch
7.4
Contact
tube
400
mm
1.1 MTW 600
200
mm
2.0 mm
2.4 mm
A2S MIG Torch
1.1 MTW-600, 200 mm (8 in.)
3
0145 227 882
0145 226 001
0145 534 882
0146 099 001
0040 979 803
0040 979 804
0415 032 001
0190 680 405
0190 680 313
0190 680 303
1.6 mm
2. Gas
• nozzle
•
3. Insulating
sleeve
•
4. Contact
tube
7
•
5. Plug
A2 S
•
6.1 Extension
L=158
•
MIG/MAG
torch
6.2
Extension
L=108
1
158 mm (6.2 in.) and 108 mm (4.3 in.) lengths.
Guide tube
600 amp7.100%
8. O-ring 22.2x3
MTW-600 GMAW Torch, 600A 9. O-ring 15.3x2.4
10. O-ring 5.3x2.4
Description
Part Number
6. 2.4 mm7.
Wire dim.
Al
1.0 mm
1.2 mm
3.
1.6 mm
2.0 mm
2.4 8.
mm
Wear Parts
A2 S powerful drive rollers for MIG/MAG system
A2S Feed roller V-groove single wire
Idling pressure roller
Wire dim.
MTW-600 GMAW
Feed Roller, Single Wire
0.8 mm
1.0 mm
1.2 mm
1.6 mm
2.0 mm
2.4-2.5 mm
Driving feed roller with groove
MTW-600 GMAW
Feed Roller, Single Wire, Groove, Knurled
Pressure roller
Wire Dimension
mm (in.)
Part Number
0.8-1.6 mm
0146
025 880*
Cored
2.0-4.0 mm
0146
025Wire
881*
*Shaft for pressure roller
0212
901 101
1.0-1.2 (.040-.045)
0369557004
1.4-1.6 (.052-1/16)
0369557005
Pressure roller (knurled roller)
0466262001
•
•
•
A2 4-WD Wire feeder for MIG/MAG system
MTW-600 Wire Feeder
Description
Feed roller single solid wire
1. Nipple wire conduitWire dim.
2. Intermediate nozzle0.6-0.8 mm
0.8-0.9 mm
3.1 Outlet nozzle, Fe 0.8-1.0 mm
3.2 Outlet nozzle, Al 1.0-1.2 mm
1.2-1.6 mm
1.4-1.6 mm
1.6 mm
2.0 mm
2 x 1.2 mm
Pressure roller
Flat roller
Fe, Ss
0369 557 001
0369 557 002
0369 557 003
0369 557 007
0369 557 013
0369 557 010
0369 728 001
Geared drive, feed and
pressure roller with knurled
groove for e.g. soft Tubular
wire
GMAW
Part Number
0455049001
Al
0455072001
0369 557 011
0469837880
1.
2009-02-25 / ESAB reserves the right to alter specifications without prior notice
0145 538 881
Part Number
0145 538 882
Fe, 0145
SS 538 883Al
GMAW
0218 510 281 0.6-0.8 (.023-.030)
0369557001
•
0218 510 282
0.8-0.9 (.030-.035)
0369557011
•
0218 510 283
0.8-1.0 (.030-.040)
0369557002
•
1.0-1.2 (.040-.045) Pressure roller 0369557003
0369557006
•
0153 148 880
1.2-1.6 (.045-1/16)
0369557007
•
1.4-1.6 (.052-1/16)
0369557013
•
1.6 (1/16)
0369557008
•
Feed roller, single- wire with
2-roller drive •
2.0 (5/64)
0369557009
Knurled U-groove
2x1.2 (2 x .045)
0369557010
•
Pressure roller (flat roller)
0369728001 0369728001
•
Wire dim.
0.8-1.6 mm
0146 024 880
2.0-4.0 mm
0146 024 881
Wire Dimension
mm (in.)
2.
2.
0369
557 006
0469837881
0369 557 008
0369 557 009
Feed
Feedroller
rollerxx22
3.
3.
0369 728 001
Pressure
Pressure
roller
x2
roller x 2
Groove knurled feed roller single wire
Wire dim.
1.0-1.2 mm
1.4-1.6 mm
Cw
0369 557 004
0369 557 005
Pressure roller
Knurled roller
0466 262 001
A2- 4WD Wire feeder
1.
2.
3.1
3.2
Nipple wire conduit
Intermediate nozzle
Outlet nozzle, Fe
Outlet nozzle, Al
0455 049 001
0455 072 001
0469 837 880
0469 837 881
ESAB AB
Welding Equipment
SE-695 81 LAXÅ SWEDEN
Phone: +46 584 81000
Fax:
+46 584 81243
www.esab.com
97
Wear Parts
A6 Wear Parts
Secure your welding quality and productivity with ESAB original parts
Feed Roller SAW Single Wire
Wire Dimension, mm (in.)
Part Number
1.6 (1/16)
2.0 (5/64)
2.4-2.5 (3/32)
3.0-3.2 (.012-1/8)
4.0 (5/32)
5.0 (3/16)
6.0 (1/4)
Pressure roller
0218510281
0218510282
0218510283
0218510298
0218510286
0218510287
0218510288
0153148880
Idling pressure roller
Driving feed roller
with groove
Feed Roller SAW Single Wire, Knurled V-Groove
Wire Dimension, mm (in.)
Part Number
3.0-5.0 (.012-3/16)
Pressure roller
0218510299
0153148880
Idling pressure roller
Driving feed roller
with knurled groove
Feed Roller SAW Single Wire with 2-Roller Drive, Knurled U-Groove
Wire Dimension, mm (in.)
Part Number
Feed Roller
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
0146024880
0146024881
Pressure Roller
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
Shaft for pressure roller
01460288801
01460258811
0212901101
←
Geared driving feed and pressure roller with knurled groove,
eg/ soft, tubular wire
Use with shaft for pressure roller #0212901101.
1
Feed Roller SAW Twin Wire
Wire Dimension, mm (in.)
2 x 1.2 (.045)
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.4-2.5 (3/32)
2x 3.0-3.2 (.012-1/8)
Part Number
0218522486
0218522488
0218522484
0218522480
0218522481
Spherical idling pressure roller
for equally distributed pressure
on the two wires
←
Driving feed with grooves
for twin wire system
Feed Roller SAW Twin Wire, Knurled U-Groove
1
Wire Dimension, mm (in.)
Part Number
2 x 2.0-3.2 (5/64-1/8)
Pressure roller1
0148772880
0218524580
Spherical type with shaft
98
Wear Parts
D35 Heavy-Duty System
Length, mm (in.)
Part Number
D35 Straight Contact Tube
Washer D22x10.5x2
0215100023
Spring Washer D20/10.2x1.1 0219504307
220 (8.7)
275 (10.8)
400 (15.7)
500 (19.7)
700 (27.5)
Clamp half
0417959880
0417959881
0417959882
0417959883
0417959884
0809342880
Ring 0417979001
Screw M8x16
Contact Jaws for Heavy-Duty System
Wire Dimension, mm (in.)
Part Number
Single Wire, Length 65/58 mm (2.5/2.3 in.)
2.0 (5/64)
2.4-2.5 (3/32)
3.0 (0.12)
3.2 (1/8)
4.0 (5/32)
5.0 (3/16)
6.0 (1/4)
0332581880
0332581881
0265900880
0265900881
0265900882
0265900883
0265900884
Single Wire, Length 120 mm (4.7 in.)
3.0 (0.12)
4.0 (5/32)
65 mm (2.5 in.)
0332581880/-881
Long contact jaws 120 mm (4.7 in.)
for improved access to deep joints
120 mm (4.7 in.)
0000237320/-321
0000237320
0000237321
Single Wire, Length 75 mm (3 in.)
1.6-3.0 (1/16-.012)
58 mm (2.3 in.)
0265900880/-884
0265901480
Durable contact jaws for all wire
dimensions between 1.6-3.0 mm
(1/16-.012 in.)
75 mm (3 in.)
Twin Wire, Length 73 mm (2.9 in.)
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.4-2.5 (3/32)
2 x 2.5-3.0 (3/32-.012)
0265902882
0265902881
0265902884
0265902880
Twin Wire, Length 73 mm (2.9 in.) with Guide Tube Connection
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.5-3.0 (3/32-.012)
0808650882
0808650881
0808650880
Twin Wire, Length 120 mm (4.7 in.) with Guide Tube Connection
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.4-2.5 (3/32)
2 x 2.5-3.0 (3/32-.012)
0816019882
0816019881
0816019883
0816019880
99
Wear Parts
A6 Wear Parts
Cont.
SAW Contact Nozzles for Light-Duty System
Wire Dimension, mm (in.)
Part Number
SAW Contact Nozzle M6 for Twin Wire
→
→
M6
2 x 1.2 (.045)
2 x 1.6 (1/16)
2 x 2.0 (5/64)
2 x 2.4-2.5 (3/32)
0153501005
0153501007
0153501009
0153501010
Guide tube, L=358, D6/4
0415032001
Guide tube, L=750, D6/4
0415032002
Spiral insert, L=366,D3.5/1.5 0334279001
Nozzle holder
0333772001
Contact nozzle x2
SAW Contact Jaws for ICE™
Description
Part Number
Contact jaw, 2.5 mm (3/32)
Contact jaw, 2.4-2.5 mm (3/32)
Wire guide
Ceramic sleeve
0819882880
0816019983
0824038001
0819883001
ICE Wear Kit
3 pcs contact jaw, 2.5 mm
3 pcs ceramic sleeve
1 pc feed roller, 2.5 mm
0824376880
L=73.5 mm (3 in.)
0819882880
L=120 mm (4.7 in.)
0816019983
Insulated Contact Nozzle with Nozzle Cap for Narrow V-Joints
Description
Part Number
Nozzle holder
Nozzle with cap:
2.0 (5/64)
2.5 (3/32)
3.0 (0.12)
3.2 (1/8)
4.0 (5/32)
Nozzle cap
0000237415
100
0000237329
0000237328
0000237330
0000237332
0000237327
0000237331
M16
Nozzle
holder
Contact
nozzle
Nozzle
cap
D35
contact
tube
Wear Parts
Guide Tubes
Length, mm (in.)
Part Number
Single/Twin Wire, max 3.2 mm (1/8 in.)
358 (14), D6/4
750 (29.5), D6/4
Clamp
04150320011
04150320022
0218514001
Single wire
Twin wire
Twin Wire: eg/ 2 x 358 mm (14 in.) for 275 mm (10.8 in.) contact tube. 2Guide tube 750 mm (29.5 in.) to be cut to suit the length of the contact tube.
1
Flux Nozzle
Description
Part Number
Description
Part Number
D20 Contact Tube
1. Tube
2. Clamp
5. Flux hose 0.5 m (1.6 ft.)
5.1. Flux hose free length/m (ft.)
5
0332948001
0333094880
0443383002
0443383001
2. Flux funnel complete
2.1 Insulated sleeve
5. Flux hose 0.5 m (1.6 ft.)
5.1. Flux hose free length/m (ft.)
2
1
0145221881
0333667001
0443383002
0443383001
5
2.1
2
D35 Contact Tube
3. Flux nozzle complete
3.1. Tube bent
3.2. Tube holder
5. Flux hose 0.5 m (1.6 ft.)
5.1. Flux hose free length/m (ft.)
0153299880
0153296001
0153290002
0443383002
0443383001
5
3
3.2
3.1
4. Flux funnel complete
4.1. Insert, 36 mm (1.4 in.)
4.2. Insert, 24 mm (0.9 in.)
5. Flux hose 0.5 m (1.6 ft.)
5.1. Flux hose free length/m (ft.)
0254900880
0254900301
0254900302
0443383002
0443383001
5
4
4.1/4.2
Contact Jaws for A6 SAW Cladding Head Assembly
Description
Part Number
Strip
Contact jaws
12 pcs required for complete
assembly
0148325001
Contact
jaw
101
Wear Parts
OPC Flux Recovery System Wear Parts
Secure your welding quality and productivity with ESAB original parts.
8a
8b
8a
Hose
D22/12.5
8b
3
4
7
7
Hose
D16/9.5
5
6
3
4
2
2
1
OPC Basic
1
Ejector
2
Spiral hose D47.0/38.1
3
Tension band
4
Cone1
5
Tension ring1
6
O-ring, 189.3x5.7
7
Ball valve
8a
Filter, paper
8b
Filter, cotton1
9
Funnel
10
Rubber lining
11
O-ring 149.2x5.7
12
Cyclone
13
Rubber lining
14
Tension spring
16
Strainer
9
0147640880
0191813801
0192855002
0148143001
0148144001
0215201353
0145824881
0155966001
0332448001
0148142001
0145565001
0215201345
0148141001
0145073001
0145815001
0020301780
15
1
OPC Super
1
Ejector
2
Spiral hose D47.0/38.1
3
Tension band
4
Cone
5
Tension ring
6
O-ring, 189.3x5.7
7
Ball valve
8a
Filter, paper
8b
Filter, cotton1
9
Funnel
10
Rubber lining
11
O-ring 149.2x5.7
12
Cyclone
13
Rubber lining
14
Tension spring
15
Clamp
16
Strainer
10
12
11
13
14
16
0339720001
0191813801
0192855002
0332279001
0148144001
0215201353
0333625001
0155966001
0332448001
0332280001
0332282001
0215201345
0332281001
0332283001
0145815002
0340612001
0020301780
Suction Nozzle
1a
1b
1c
1d
2
3a
3b
4
5
Butt weld 1
Butt weld 2
Fillet weld left
Fillet weld right
Nozzle bracket
Insulator D20
Insulator D35
Flux hose, D32.0/25.0,
free length, m
0.5 m (1.6 ft.)
Pipe bent
Cyclone Filter
1a
Cone basic
1b
Cone super
2
Tension ring
3
Bend
4
Spiral hose D67.2/63
5
Cyclone
6a
Filter, paper
6b
Filter, cotton1
7
Tension band
8
Plastic bag
9
U-screw
10
Bracket
1
Optional item.
102
0145501001
0145502001
0145504001
0145505001
0147384881
0145131004
0145131002
0443383001
0443383002
0153296001
1a
1b
1a
1b
1c
1d
4
2
1d
5
3a
3b
1c
6a
6b
0148143001
0332279001
0148144001
0413576001
0193125003
0148141001
0155966001
0332448001
0192855002
0190665004
0379600001
0379599880
3
7
1a
1b
1a
2
2
9, 10
5
4
8
103
XA00155920
2014/07
World leader in welding and cutting
technology and systems
ESAB operates at the forefront of welding and
Environmental, Health & Safety Management
cutting technology. Over one hundred years
Systems across all our global manufacturing
of continuous improvement in products and
facilities.
processes enables us to meet the challenges
At ESAB, quality is an ongoing process that
of technological advance in every sector in
is at the heart of all our production processes
which ESAB operates.
and
Quality and
environment standards
facilities
manufacturing,
an
international
worldwide.
local
Multinational
representation
network
of
and
independent
distributors brings the benefits of ESAB quality
Quality, the environment and safety are
and unrivalled expertise in materials and
three key areas of focus. ESAB is one of few
processes within reach of all our customers,
international companies to have obtained the
wherever they are located.
ISO 14001 and OHSAS 18001 standards in
* Includes manufacturing facilities of ESAB North America.
A wholly owned subsidiary of Anderson Group Inc.
ESAB AB
SE-695 81 LAXÅ, Sweden
Phone: +46 584-81000
esab.com
esab.com/automation
ESAB reserves the right to alter specifications without prior notice
ESAB Sales and Support offices worldwide
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