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Welding Automation solutions from ESAB

A full line of welding automation equipment for every application, industry and environment.

Contents
Controllers and power sources Welding tractors Welding heads Columns and booms Carriers and gantries Accessory components Handling equipment Special applications 3 11 31 41 51 55 71 87

Controllers & Power Sources

Controllers & Power Sources

A2-A6 Process Controller PEK



For use with ESAB automatic DC power sources LAF 631/ 1001/1251/1601 and AC power sources TAF 801/1251. 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. Documentation of used welding parameters on PC or through LAN with WeldPoint. Five soft keys can be configured according to operator preferences.

For use with ESAB CAN-controlled power sources and motors

Ordering Information
A2-A6 process controller PEK 0460 504 880

Options & Accessories


Adjustable sun shield for better visibility for outdoor use

I/O-Module Set of connectors Cable restraining bracket

0462 080 001 0462 119 880 0460 861 880

Technical Data
Connection voltage from the power source Connection power Motor connection adjusted for ESABs A2 and A6 motors Speed control Welding speed, m/min (ipm) Max. manual travel speed, m/min (ipm) Consumable wire feed speed, m/min (ipm) Valve output Inputs Connection to power source Max ambient temperature, C (F) Min ambient temperature, C (F) Relative humidity (of air) Dimensions, LxWxH, mm (in.) Weight, kg (lbs) Enclosure class
4

42V AC, 50/60 Hz max 900 VA connection of 2 motors, motor current 6A cont., max 10A feedback from pulse encoder 0.1-2.0 (4-79) depending on travel carriage 2.0 (79) 0.3-25 (12-984) depending on wire feed unit 1 pc, 42 V AC, 0.5A for connection of sensors or limit switches Burndy contact 12-poles 45 (113) -15 (5) 98% 246x235x273 (7x9.25x11) 6.6 (14.5) IP23

Controllers & Power Sources

A2 Process Controller PEI


For use with ESAB power sources and motors
Control system for A2 tractors and A2 welding heads Analog 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

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 Connection power Motor connection adjusted for ESABs A2 motors Speed control Welding speed, m/min (ipm) Max. transport speed, m/min (ipm) Consumable wire feed speed, m/min (ipm) Burnback time, s Gas pre-flow time, s Gas post-flow time, s Connection to power source Welding voltage control, V DC Flow guard Limit switches External current shunt, A/mV Operating temperature, C (F) Weight, kg (lbs.) Dimensions LxWxH, mm (in.) Enclosure class
5

42V AC, 50/60 Hz max 700 VA 42V DC, 3.5 A P100%, 4.5A P60% Internal EMK-adjustment 0.1-2.0 (4-79) depending on travel carriage 2.0 (79) 0.5-16.2 (20-640) depending on wire feed unit 0-2.0 0.5 1.0 Burndy contact, 23 poles 0-10 NO Contact / PNP OC NO Contact / PNP OC 1000/60, 1500/60, 600/100, 750/100 -10 - +40 (14-104) 6.2 (14) 197x227x220 (7.8x9.0x8.7) IP23

Controllers & Power Sources

Power Sources LAF 631, 1001, 1251 and 1601



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 ESABs A2-A6 equipment range and he A2-A6 PEK or A2 PEI process controllers. t 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 power sources in parallel for the most demanding applications. Power source prepared for communication using most standard protocols like TCP/IP (LAN), CAN or even straight communication with a PLC. Optional communication modules ight be needed depending on the type of m protocol used. Ideal for SAW applications such as wind tower components, nuclear power vessels, boilers and ship building applications Ideal for GMAW applications such as welding the root pass in heavy pipe production.

DC power sources for submerged arc welding (SAW) or gas metal arc welding (GMAW)

Ordering Information
LAF 631 LAF 1001 LAF 1251 LAF 1601 0460 512 880 0460 513 880 0460 514 880 0460 515 880

Options & Accessories


A2-A6 process controller PEK 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 process controller 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 0460 910 881 0460 910 882 0460 910 883 0460 910 884 0449 500 880 0449 500 881 0449 500 882 0449 500 883 0449 500 884 0449 500 885 0457 787 880

Controllers & Power Sources

Power sources LAF 631, 1001, 1251 and 1601


Technical Data
Mains supply, 3 ph 50 Hz, V Mains supply, 3 ph 60 Hz, V Current 100%, 50/60 Hz, A Fuse, slow, 50/60 Hz, A Maximum load at: 100% duty cycle, A/V 80% duty cycle, A/V 60% duty cycle, A/V Setting range, A/V GMAW SAW Open circuit voltage, V Open circuit power, W Efficiency Power factor Enclosure class Dimensions, LxWxH, mm (in.) Weight, kg (lbs.) Application class LAF 631 400/415 440 52 63 630/44 800/44 50/17-630/44 30/21-800/44 54 150 0.84 0.90 IP23 670x490x930 (26x19x37) 260 (573) LAF 1001 400/415/500 400/440/550 64/64/52 63 800/44 1000/44 50/17-1000/45 40/22-1000/45 52 145 0.84 0.95 IP23 646x552x1090 (25x22x43) 330 (727.5) LAF 1251 400/415/500 400/440/550 99/99/80 100/100/80 1250/44 60/17-1250/44 40/22-1250/44 51 220 0.87 0.92 IP23 774x598x1428 (30.5x23.5x56) 490 (1080) LAF 1601 400/415/500 400/440/550 136/136/108 160/160/125 1600/44 40/22-1600/46 54 220 0.86 0.87 IP23 774x598x1428 (30.5x23.5x56) 585 (1290)

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 the proximity to earthed metal objects and/or dampness.

LAF 631 in combination with MechTrac and GMH

Controllers & Power Sources

Power sources TAF 801 and 1251



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. Arc voltage pre-set. Reliable square wave striking. Arc voltage or current feedback. Optimized open circuit voltage. Compensation of mains supply fluctuation. Voltage drop compensation for long welding cables. High power factor ensuring low power consumption. Designed for easy maintenance. Safety control voltage, 42V. Prepared for Scott connection of two power sources. Used in combination with ESABs A2-A6 equipment range and he A2-A6 PEK or A2 PEI process controllers. t Power source prepared for communication using most standard protocols like TCP/IP (LAN), Anybus, Profibus, CAN or even straight communication with a PLC.

Square wave AC power sources for submerged arc welding (SAW)

Ordering Information
TAF 801 TAF 1251 0460 516 880 0460 517 880

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.) 0460 910 881 0460 910 882 0460 910 883 0460 910 884

Technical Data
Mains supply, 1 ph 50 Hz, V Mains supply, 1 ph 60 Hz, V Maximum load at: 100%duty cycle, A/V 60% duty cycle, A/V Setting range, A/V Open circuit voltage, V Open circuit power, W Efficiency Power factor Dimensions, LxWxH, mm (in.) Weight, kg (lbs) Enclosure class Application class

TAF 801 400/415/500 400/440/550 800/44 1000/44 300/28-800/44 71 230 0.86 0.75 774x598x1428 (30.5x23.5x56) 495 (1091) IP23

TAF 1251 400/415/500 400/440/550 1250/44 1500/44 400/28-1250/44 72 230 0.86 0.76 774x598x1428 (30.5x23.5x56) 608 (1340) IP23

Beyond expectation
The all new Aristo 1000 AC/DC SAW
Available 2012

Welding Tractors

Welding Tractors

Railtrac 1000

Multi-purpose system for welding and cutting


Ideal for a wide variety of automated gas metal arc welding (GMAW) applications. Made from aluminum 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 ackfill function. b 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/FWR1000 models.
Railtrac F1000 Flexi
36-46/40-60 30 6 (13) 170x400x190 (6.7x15.8x7.5) 60x5 (2.4x0.2) 40x10 (1.6x0.4) 3000 (118) 22 (0.87) 10-150 (3.9-59) 150 (59) 0.0-9.9 1-99 (0.4-39) 0.0-9.9 0-99 (0-3.9) 5 0-70 0-90 IP23

Technical Data
Mains supply, V AC/DC Max power consumption, W Weight, excl rails, Kg (lbs) Dimensions, LxWxH, mm (in.) Flexi rail dimensions, LxW, mm (in.) Stiffener bar, LxW, mm (in.) Min bend diameter, external, mm (in.) Slide for height adjustment, mm (in.) Mechanical lateral adjustment, mm (in.) Welding speed, cm/min (ipm) Quick transport, cm/min (ipm) Preheating time, sec Interval welding, cm (in.) Crater-filling time, sec Backfill, mm (in.) Weaving speed, mm/s (ips) Weaving width, mm (in.) Electrical 0-line displacement, mm (in.) Pause time at outer edge, s Weaving pattern, No. Number of programs Temperature machine and magnets, C Temperature vacuum attachments, C Enclosure class

Railtrac FR1000 Flexi Return


36-46/40-60 30 6 (13) 170x400x190 (6.7x15.8x7.5) 60x5 (2.4x0.2) 40x10 (1.6x0.4) 3000 (118) 22 (0.87) 10-150 (3.9-59) 150 (59) 0.0-9.9 1-99 (0.4-39) 0.0-9.9 0-99 (0-3.9) 5 0-70 0-90 IP23

Railtrac FW1000 Flexi-Weaver


36-46/40-60 80 7 (15) 170x350x190 (6.7x13.8x7.5) 60x5 (2.4x0.2) 40x10 (1.6x0.4) 3000 (118) 22 (0.87) 35 (1.4) 10-150 (3.9-59) 150 (59) 0.0-9.9 1-99 (0.4-39) 0.0-9.9 0-99 (0-3.9) 6-60 (0.2-2.4) 1-30 (0.04-1.2) 12.5 (0.5) 0.0-9.9 3 5 0-70 0-90 IP23

Railtrac FWR1000 Flexi-Weaver-Return


36-46/40-60 80 7 (15) 170x350x190 6.7x13.8x7.5 60x5 (2.4x0.2) 40x10 (1.6x0.4) 3000 (118) 22 (0.87) 35 (1.4) 10-150 (3.9-59) 150 (59) 0.0-9.9 1-99 (0.4-39) 0.0-9.9 0-99 (0-3.9) 6-60 (0.2-2.4) 1-30 (0.04-1.2) 12.5 (0.5) 0.0-9.9 3 5 0-70 0-90 IP23

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Welding Tractors

Railtrac 1000
System configuration
Railtrac F1000 Flexi
A mechanized 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 Flexi Return


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


This version has a flexible combi-rail and a weaver for weaving in many different patterns. It is also equipped with a remotecontrolled unit with a user-friendly design.

Railtrac FWR1000 Flexi Weaver Return


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.

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Welding Tractors

Railtrac 1000
Ordering Information
Railtrac F1000 Flexi Railtrac FR1000 Flexi Return Railtrac FW1000 Flexi Weaver Railtrac FWR1000 Flexi Weaver Return 0398 146 002 0398 146 003 0398 146 012 0398 146 013

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 Universal pivoted torch holder Attachment for IMP cutting torch 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/FWR1000 only

** FR1000/FWR1000 only

0398 145 101 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

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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 ESABs semi-automatic 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

Options & Accessories


Floating head Orbital ring 15.2 cm (6 in.) Orbital ring 20.3 cm (8 in.) Orbital ring 25.4 cm (10 in.) Orbital ring 30.5 cm (12 in.) Orbital ring 35.5 cm (14 in.) Orbital ring 40.6 cm (16 in.) Orbital ring 45.7 cm (18 in.) Orbital ring 50.8 cm (20 in.) Orbital ring 55.8 cm (22 in.) Orbital ring 60.9 cm (24 in.) Orbital ring 66.4 cm (26 in.)
Larger ring sizes available on request

Ordering Information
Railtrac Orbital W 0398 146 032

0398 145 211 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

Technical Data
Control voltage, V AC Power, W Connection Welding speed, cm/min (ipm) Slide for height adjustment, mm (in.) Weaving speed, mm/sec. (ips.) Weaving width, mm (in.) Pause time at outer edge, s Electrical 0-line displacement, mm (in.) Number of programs Dimensions (LxWxH), mm (in.) Weight, kg (lbs) Enclosure class
15

36-46 90 Burndy, 12 pins 5-99 (2-39) 22 (0.9) 6-60 (0.2-2.4) 1-30 (0.04-1.2) 0.0-9.9 12.5 (0.5) 5 312x327x181 (12.3x12.9x7.1) 8 (17.6) IP 23

Welding Tractors

Railtrac BV/BVR 1000


Programmable equipment for hardfacing and repair of rail profiles


Lightweight makes it quick and easy to remove the aluminum travel beam from rail or crossing and simple to restore to its original position on the workpiece. 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. IP 23 enclosure class makes it suitable for use outdoors. Control voltage level of 42V AC is safe for use anywhere.

Ordering Information
Railtrac BV 1000* Railtrac BVR 1000*
* Complete, excluding welding equipment

0398 145 002 0398 145 003

Options & Accessories


Torch holder 0398 145 101

Technical Data
Connection voltage, V AC / V DC Max. output consumption, W Weight excl. rail, kg (lbs.) Weight of rail 2 m (6.5 ft.), kg (lbs.) Slide for adjusting height of torch, mm (in.) Mechanical lateral adjustment, mm (in.) Gun attachment universal, mm (in.) Max. effective weld length, mm (in.) Welding speed, cm/min (ipm) Fast transport speed, cm/min (ipm) Weaving speed, mm/s (ips) Weaving width (W), mm (in.) Zero-line shift, mm (in.) Programmable edge length (L), cm (in.) Number of programs Enclosure class 36-46 / 40-60 80 7 (15.4) 4 (8.8) 22 (0.9) 200 (7.9)

12-36 ( 0.5-1.4)
1500 (59) 10-150 (0.2-59) 150 (59) 7-50 (0.3-2.0) 1-80 (0.04-3.1) 25 / 12.5 (1.0 / 0.5) 6-99 (2.4-39) BV: 4, BVR: 6 IP23

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Welding Tractors

Tramtrac II

A cost-efficient and flexible solution for the repair of embedded city streetcar rails.
Tramtrac II is ESABs latest equipment for the repair of embedded grooved city streetcar rails. Using the flux cored arc welding (FCAW) process with self-shielded wires, instead of the conventional submerged arc welding (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 streetcars to pass within a controlled safety environment.

Ordering Information
Tramtrac II 0814 721 880

Options & Accessories


Connection cable 10 m (33 ft.) Origo MIG 410 Origo MIG 320 Magnetic return cable & clamp OK Tubrodur 14.71, 1.6 mm (1/16 in.) OK Tubrodur 15.65, 1.6 mm (1/16 in.) 0457 360 884 0349 302 408 0349 303 562 0000 500 415 1471 167 730 1565 167 730

Technical Data
Control voltage, V AC Power, W Welding speed, mm/min (ipm) Dimensions LxWxH, mm (in.) Weight without consumables, kg (lbs.) 36-46 90 30-100 (1.2-3.9) 600x300x150 (23.6x11.8x5.9) 12 (26.5)

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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

Options & Accessories


ESAB control cable, 5 m (16.4 ft)* ESAB AristoFeed adaptor kit** Universal control cable, 5 m (16.4 ft)*** Welding screen 0457 360 880 0459 681 880 0457 360 881 0457 463 881

* 12 pin male-23 pin male Burndy style Origo Feed and AristoFeed 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 Power, W Welding speed, mm/min (ipm) Fast travel speed, cm/min (ipm) Programmable interval welding, cm (in.) Linear slide stroke length (horizontal), mm (in.) Remote control outlet Connection Crater fill time, s Backfill, cm (in.) Dimensions, LxWxH, mm (in.) Weight, kg (lbs)
19

36-46 40 150-1500 (6-59) 250 (98.4) 1-99 (0.4-37) 17 (0.67) Volt and ampere(wire feed speed) Burndy, 12 pins 0-9.9 0-9.9 (0-4) 330x260x360 (13x10x14) 9.5 (21)

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 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

Options & Accessories


ESAB control cable, 5 m (16.4 ft)* ESAB AristoFeed adaptor kit** Universal control cable, 5 m (16.4 ft)*** Welding screen 0457 360 880 0459 681 880 0457 360 881 0457 463 880

* 12 pin male-23 pin male Burndy style Origo Feed and AristoFeed 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 Power, W Welding speed, mm/min (ipm) Remote control outlet Connection Dimensions, LxWxH, mm (in.) Weight, kg (lbs.)
18

36-46 20 150-1200 (6-47) Volt and ampere (wire feed speed) Burndy, 12 pins 266x257x267 (10.5x10x10.5) 7 (15.4)

Welding Tractors

A2 Multitrac with A2 Process Controller PEI


The universal welding tractor for better welding economy
Can be connected to most analog, 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. Units available for gas metal arc welding (GMAW) and submerged arc welding (SAW)

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 Laser lamp kit Lincoln Electric interface Miller interface 0413 542 880 0333 164 880 0154 203 880 0333 098 881 0443 682 881 0334 680 881 0821 440 880 34351L 34351M

Ordering Information
A2 Multitrac SAW, PEI A2 Multitrac SAW Twin, PEI A2 Multitrac GMAW, PEI 0449 360 880 0449 360 881 0449 361 880

Technical Data
Wire diameters, mm (in.) - Steel - Stainless steel - Cored wire - Aluminum Max wire feed speed, m/min (ipm) Wire reel weight, kg (lbs.) Flux hopper capacity, l (gal.) Permissible load 100%, A Control voltage, V AC Travel speed, m/min (ipm) Linear slides stroke length, mm (in.) Rotary slide setting angle Weight, excl wire and flux, kg (lbs.)
20

Single SAW 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 9 (354) 30 (66) 6 (1.4) 800 42 0.1-1.7 (4-67) 90 (3.5) 360 47 (103)

Twin SAW 2x1.2-2.5 (2x(0.45x3/32)) 2x1.2-2.5 (2x(0.45x3/32)) 9 (354) 2x15 (2.2x33) 6 (1.4) 800 42 0.1-1.7 (4-67) 90 (3.5) 360 47 (103)

GMAW 0.8-1.6 0.8-1.6 1.2-2.4 1.2-1.6 30 (66) 600 42 0.1-1.7 (4-67) 90 (3.5) 360 43 (95) (.030-1/16) (.030-1/16) (.045-3/32) (.045-1/16)

16 (630)

Welding Tractors

A2 Multitrac with A2-A6 Process Controller PEK


The universal welding tractor for submerged arc welding and gas metal arc welding
The A2 Multitrac with the A2-A6 process controller PEK is available for both submerged arc welding (SAW) and gas metal arc welding (GMAW). Choose single or twin wire for submerged arc welding (SAW) 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 setup for different workpieces. Designed for use with LAF (DC) or TAF (AC) welding power sources.

Ordering Information
A2 Multitrac A2TF, SAW, PEK A2 Multitrac A2TF, SAW Twin, PEK A2 Multitrac A2TG, GMAW, PEK A2 Multitrac A2TG, GMAW 4WD, MTW 600, PEK 0461 233 880 0461 233 881 0461 234 880 0451 234 881

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 Laser lamp kit 0413 542 880 0333 164 880 0154 203 880 0333 098 881 0443 682 881 0334 680 881 0821 440 880

Technical Data
Wire diameters, mm (in.) - Steel - Stainless steel - Cored wire - Aluminum Max wire feed speed, m/min (ipm) Wire reel weight, kg (lbs.) Flux hopper capacity, l (gal.) Permissible load 100%, A Control voltage, V AC Travel speed, m/min (ipm) Linear slides stroke length, mm (in.) Rotary slide setting angle Weight, excl wire and flux, kg (lbs.)
21

Single SAW 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 9 (354) 30 (66) 6 (1.4) 800 42 0.1-1.7 (4-67) 90 (3.5) 360 47 (103)

Twin SAW 2x1.2-2.5 (2x(0.45x3/32)) 2x1.2-2.5 (2x(0.45x3/32)) 9 (354) 2x15 (2.2x33) 6 (1.4) 800 42 0.1-1.7 (4-67) 90 (3.5) 360 47 (103)

Single GMAW 0.8-1.6 0.8-1.6 1.2-2.4 1.2-1.6 30 (66) 600 42 0.1-1.7 (4-67) 90 (3.5) 360 43 (95) (.030-1/16) (.030-1/16) (.045-3/32) (.045-1/16)

GMAW w/ MTW 600 1.0-1.6 1.0-1.6 1.0-2.4 1.0-2.0 30 (66) 600 42 0.1-1.7 (4-67) 90 (3.5) 360 43 (95) (.040-1/16) (.040-1/16) (.040-3/32) (.040-5/64)

16 (630)

25 (984)

Welding Tractors

A2 Tripletrac A2TF

For increased productivity and quality.

The superb welding tractor for internal circumferential welding

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 analog 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 A2 Tripletrac with PEI 0461 236 880 0449 430 881

Options & Accessories


Laser lamp kit Utility light, incl transf. and 50 m (164 ft.) cable Flux recovery unit OPC Bracket suction Flux hopper of silumin alloy, 6 l (1.4 gal) Concentric flux feeding funnel (included) Contact tube, bent Wire reel, plastic 30 kg (66 lbs.) Wire reel, steel, fixed width 30 kg (66 lbs.) Wire reel, steel, flexible width 30 kg (66 lbs.) Wire reel, steel, 220 mm (8.6 in.) 0821 440 880 0449 443 880 0148 140 880 0332 947 880 0413 315 881 0145 221 881 0413 511 001 0153 872 880 0416 492 880 0449 125 880 0671 164 080

Technical Data
Wire diameters, mm (in.) - Steel - Stainless steel - Cored wire Max wire feed speed, m/min (ipm) Wire reel weight, kg (lbs.), W Flux hopper capacity, l (gal.) Permissible load 100%, A Control voltage, V AC Travel speed, m/min (ipm) Linear slides stroke length, mm (in.) Rotary slide setting angle Max inclination for the tractor Weight, excl. wire and flux, kg (lbs.)
22

1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 9 (354) 30 (66) 6 (1.4) 800 42 0.1-1.7 (4-67) 90 (3.5) 360 5 47 (103)

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 in.) wire using 1500A direct or alternating current. Designed for use with LAF (DC) or TAF (AC) 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 twin-arc welder for fillet and butt welds without the use of an extra machine or power source. Tandem: the high deposition rate using a multielectrode 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.

A6 Mastertrac Tandem

Options & Accessories


Heavy-duty twin arc conversion kit Wire reel, plastic 30 kg (66 lbs.) Wire reel, steel 30 kg (66 lbs.) Wire reel, steel, flexible width 30 kg (66 lbs.) Heavy-duty brake hub SAW-GMAW conversion kit Strip cladding kit Flux hopper holder for strip cladding Wire reel, steel, strip cladding, 30-100 mm (1.2-4.0 in.) Flux recovery nozzle, strip cladding Flux funnel Flux insert Angular slide Laser lamp kit Flux recovery unit OPC Bracket suction Idler rollers (2 per automat) Guide wheel, assembly Magnet guide rail, 3 m (10 ft.) 0334 291 889 0153 872 880 0416 492 880 0449 125 880 0146 967 880 0334 299 910 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

Weld mild steel and aluminum 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 0461 235 880 0461 235 881 0461 235 890 0461 235 891 0461 232 882

Carbon arc gouging Rebuilding kit (use with carbon electrodes 8.9-12.7) 0153 592 880 VEC-motor, 312:1 0145 063 905
Twin SAW 1500 2x2.0-3.0 (2x3/32-1/8) 0.2-4.0 (8-157.5) 0.4-8.0 (16-315) 0.1-2.0 (4-79) 42 2x30 (2x66) 10 (2.6) 110 (242.5) Tandem SAW 2x1500 2x3.0-6.0 (2x1/8-1/4) 0.2-4.0 (8-157.5) 0.1-2.0 (4-79) 42 2x30 (2x66) 10 (2.6) 158 (348)

Technical Data
Permissible load 100%, A Wire diameter, mm (in.) Wire feed speed, m/min (ipm) Wire feed speed high, m/min (ipm) Travel speed, m/min (ipm) Control voltage, V AC Wire reel weight, kg (lbs.) Flux hopper capacity, l (gal.) Weight excl wire and flux, kg (lbs.)
23

Single SAW 1500 3.0-6.0 (1/8-1/4) 0.2-4.0 (8-157.5) 0.4-8.0 (16-315) 0.1-2.0 (4-79) 42 30 (66) 10 (2.6) 110 (242.5)

Single GMAW 600 1.0-3.2 (0.045-1/8) 0.8-16.6 (31.5-653.5) 0.1-2.0 (4-79) 42 30 (66) 100 (220.5)

Welding Tractors

A6-DK

The portable welding machine


Works with a single wire on each head. Each weld head is controlled by the A2-A6 process controller PEK and LAF (DC) or TAF (AC) power source. Ideal for simultaneous horizontal welding on both sides of a web or through panel. Straddles workpieces up to 800 mm (31 in.) tall and symmetrical profile widths of 400 mm (16 in.). 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* 0461 237 901
*Wire reel, feed rollers and contact jaws must 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 Travel speed, m/min (ipm) Wire feed speed, m/min (ipm) Wire reel weight, kg (lbs.) Wire diameter SAW, mm (in.) Flux hopper capacity (each weld head), l (gal.) Weight, excl wire and flux, kg (lbs.) Straddle opening: Vertical space limitation, mm (in.) Longitudinal. symmetrical extension, mm (in.)
24

1500 0.15-2.0 (6-79) 0.2-4.0 (8-157.5) 2x30 (2x66) 3.0-6.0 (1/8-1/4) 10 (2.6) 150 (331) 800 (31) 400 (16)

Welding Tractors

A2/A6 Tractor Wear Parts


Technical Reference Key
Process A2 Contact Equipment SAW, single wire SAW, twin wire GMAW, 2WD GMAW, 4WD A6 Contact Equipment SAW, single wire SAW, twin wire SAW, single or twin wire SAW, compact GMAW, single wire only Light-Duty Light-Duty Heavy-Duty Heavy-Duty Light-Duty D20 D35 D35 D35 D35 M12 M6 Contact Jaws Contact Jaws M10 or M6 with adaptor Light-Duty Light-Duty Light-Duty Light-Duty D20 D35* D35 MTW 600 M12 M6 M10 or M6 with adaptor M8 Duty Type Contact Tube Contact Tips/Jaws

* D35 twin wire adaptor P/N 0333 772 001

Accessories: GMAW MTW 600


Wire Diameter mm 1.0 1.0 1.2 1.4 1.6 1.6 1.6 1.6 2.0 2.0 2.4 2.4 (in) (.040) (.040) (.045) (.052) (1/16) (1/16) (1/16) (1/16) (5/64) (5/64) (3/32) (3/32) * * * * * * * * * * * * * * * * * * * * Fe * Wire Material Type SS * CW * * Al Part Number 0457 625 005 0457 625 005 0457 625 006 0457 625 008 0457 625 009 0457 625 009 0457 625 010 0457 625 010 0457 625 011 0457 625 011 0457 625 012 0457 625 012 C C D A B D A A A B Steel A B Wear Insert (liner) Type Teflon Teflon Brass Ref. Item A B A A A B A B D C D C

Wire Diameter Reference Item A B C D Wear Insert (liner) Type Steel Spiral Teflon Insert Teflon Insert Brass Tube mm 1.0-1.6 1.0-1.6 2.0-2.4 2.0-2.4 (in.) (.040-1/16) (.040-1/16) (5/64-3/32) (5/64-3/32) Part Number 0457 454 002 0457 619 001 (to be cut to length when mounting) 0457 619 002 (to be cut to length when mounting) 0457 620 002

25

Welding Tractors

A2/A6 Tractor Wear Parts


Feed Rollers
Wire Diameter mm (in.) Part Number 0145 538 882 0145 538 883 0218 510 281 0218 510 282 0218 510 283 0218 510 298 0218 510 286 0218 510 287 0218 510 288 0153 148 880 0146 024 880 0146 024 881 0218 510 299 0153 148 880 0146 024 880 0146 024 881 0146 025 880* 0146 025 881* 0212 901 101 0218 522 486 0218 522 488 0218 522 484 0218 522 480 0218 522 481 0218 524 580 0148 772 880 0218 524 580 0369 557 001 0369 557 001 0369 557 002 0369 557 003 0369 557 006 21156 0369 557 013 0369 557 008 0369 557 009 0369 557 010 0369 728 001 0369 557 004 0369 557 005 0466 262 001 SAW Feed roller, single wire 1.0 (.040) 1.2 (.045) 1.6 (1/16) 2.0 (5/64) 2.4-2.5 (3/32) 3.0-3.2 (1/8) 4.0 (5/32) 5.0 (3/16) 6.0 (1/4) Pressure Roller SAW Feed roller, single wire, knurled U-groove 0.8-1.6 (.030-1/16) 2.0-4.0 (5/64-5/32) 3.0-5.0 (1/8-3/16) V-groove Pressure Roller GMAW Feed roller, single wire, 2WD drive, knurled U-groove 0.8-1.6 (.030-1/16) 2.0-4.0 (5/64-5/32) Pressure Roller 0.8-1.6 (.030-1/16) 2.0-4.0 (5/64-5/32) *Shaft for pressure roller SAW Feed roller, twin wire 2x1.2 2x(.045) 2x1.6 2x(1/16) 2x2.0 2x(5/64) 2x2.4-2.5 2x(3/32) 2x3.0-3.2 2x(1/8) Pressure roller (spherical type with shaft) SAW Feed roller, twin wire, knurled-U-groove 2x2.0-3.2 2x(5/64-1/8) Pressure roller (spherical type with shaft) GMAW Feed roller, single wire, 4WD 0.6-0.8 (.023-.030) 0.8-0.9*** (.030-.035) 0.8-1.0 (.030-.040) 1.0-1.2 (.040-.045) 1.0-1.2** (.040-.045) 1.2-1.6 (.045-1/16) 1.4-1.6 (.052-1/16) 1.6** (1/16) 2.0** (5/64) 2x1.2 2x(.045) Pressure roller (flat roller) GMAW Feed roller, single wire, knurled, 4WD** 1.0-1.2/1.4-1.6 (.040-.045/.052-1/16) 1.4-1.6/2.0-2.4 (.052-1/16/5/64-3/32) Pressure roller (knurled roller) *Not for MTW 600 4WD **Aluminum only *** for Cored Wire

Idling pressure roller Driving feed roller with groove

Idling pressure roller Driving feed roller with knurled groove

Geared driving feed and pressure roller with knurled groove, eg/ soft Tubular wire

Spherical idling pressure roller for equally distributed pressure on the two wires

Driving feed with grooves for twin wire system

26

Welding Tractors

A2/A6 Tractor Wear Parts


Contact Tips
SAW contact tip, M12 for single wire 1.6 (1/16) 2.0 (5/64) 2.4-2.5 (3/32) 3.0 (1/8) 3.2 (1/8) 4.0 (5/32) SAW contact tip, M6 for twin wire 2x0.8 2x(.030) 2x1.0 2x(.040) 2x1.2 2x(.045) 2x1.6 2x(1/16) 2x2.0 2x(5/64) 2x2.4-2.5 2x(3/32) GMAW contact tip, M10 for single wire 0.8 (.030) 1.0 (.040) 1.2 (.045) 1.6 (1/16) 2.0 (5/64) 2.4 (3/32) 3.2 (1/8) GMAW contact tip, M8 for single wire 1.0 (.040) 1.2 (.045) 1.4 (.052) 1.6 (1/16) 2.0 (5/64) 2.4 (3/32) ESAB contact tip, twin** 2.0 (5/64) 1.6 (1/16) 2.5 (3/32) 1.2 (.045) * Aluminum only Wire Diameter mm (in.)

0154 623 008 0154 623 007 0154 623 006 0154 623 005 0154 623 004 0154 623 003 0153 501 002 0153 501 004 0153 501 005 0153 501 007 0153 501 009 0153 501 010 0258 000 914 0258 000 913 0258 000 908 0258 000 909 0258 000 910 0258 000 911 0258 000 915 0457 625 005 0457 625 006 0457 625 008 0457 625 009 0457 625 011 0457 625 012 Q450559001 Q450559002 Q450559003 Q450559004 M6

M10

M8

** For trailer beam welding; for OEM tips, omit Q on part number.

Contact Jaws
Wire Diameter mm (in.) Part Number SAW contact jaws for single wire, length 65/58 mm (2.5/2.3 in.) 2.0 (5/64) 0332 581 880 2.4-2.5 (3/32) 0332 581 881 3.0-3.2 (1/8) 0265 900 880 4.0 (5/32) 0265 900 882 5.0 (3/16) 0265 900 883 6.0 (1/4) 0265 900 884 SAW contact jaws for single wire, length 75 mm (3.0 in.) 1.6-3.2 (1/16-1/8) 0265 901 480 SAW contact jaws for single wire, length 120 mm (4.7 in.) 3.0-3.2 (1/8) 0000 237 320 4.0 (5/32) 0000 237 321 SAW contact jaws for twin wire, length 58 mm (2.3 in.) 2x1.6 2x(1/16) 0265 902 882 2x2.0 2x(5/64) 0265 902 881 2x3.0-3.2 2x(1/8) 0265 902 880 SAW contact jaws for twin wire, length 73 mm (2.8 in.) w/ guide tube connection 2x1.6 2x(1/16) 0808 650 882 2x2.0 2x(5/64) 0808 650 881 2x3.0-3.2 2x(1/8) 0808 650 880
27

L=65 mm

L=120 mm

L=58 mm twin

Part Number

M12

D20 - Slim design for improved access into narrow V-joints

Guide tubes 0415 032 002 Spiral insert 0334 279 001 Nozzle holder 0333 772 001

Contact nozzle x2

L=58 mm

Long contact jaws 120 mm (4.7 in.) for improved access to deep joints L=75 mm Guide tube for twin wire

Welding Tractors

A2/A6 Tractor Wear Parts


Contact Tubes
Length mm (in.) D20 light-duty system 100 190 260 260, bent 30 500 Contact clamp Contact device D20 complete GMAW 90 140 Gas nozzle Insulating sleeve Contact tube Plug Extension Guide tube O-ring 22.2x3.0 (0.87x1/8) O-ring 15.3x2.4 (.60x3/32) O-ring 5.3x2.4 (.20x3/32) D-35 heavy-duty system 220 275 400 500 700 Clamp half Contact device D35 complete twin wire 220 275 Nozzle holder Guide tube Spiral wire guide insert MTW 600 GMAW light-duty system 200 250 300 400 Gas nozzle Splatter protection Centering sleeve O-ring Nozzle adaptor (7.8) (9.8) (11.8) (15.7) 0457 455 005 0457 455 006 0457 455 007 0457 455 008 0457 451 001 0457 452 001 0457 453 001 0457 458 001 0808 311 001 A2 Flux Gate w/ Shut-off Valve (8.7) (10.8) 0333 852 880 0333 852 881 0333 772 001 0415 032 001 0334 279 001 1 3 2 1. Flux nozzle, complete 2. Tube bent 3. Tube holder 4. Flux hose 1 1. Flux funnel 2. Insert 3. Flux hose 4 D35 Contact Tube 3 (8.7) (10.8) (15.7) (19.7) (27.5) 0417 959 880 0417 959 881 0417 959 882 0417 959 883 0417 959 884 0809 342 880 1. Tube 2. Clamp 3. Insert flux hose (3.5) (5.5) 0030 465 389 0030 465 388 0145 227 882 0145 226 001 0145 534 882 0146 099 001 0040 979 803 (158mm) 0040 979 804 (108mm) 0415 032 001 0190 680 405 0190 680 313 0190 680 303 2 1 1 1. Flux funnel 2. Insulation sleeve 3. Flux hose D20 Contact Tube 2
o

Flux Nozzles
Part Number Part Number 0413 510 003 0413 510 002 0413 510 001 0413 511 001 0413 510 004 0334 571 880 D20 Contact Tube Tube Clamp Flux hose, 0.5 m (16) Flux hose free length/m Flux funnel complete Insulation sleeve D35 Contact Tube Flux nozzle, complete Tube bent Tube holder Flux hose 0.5 m (16) Flux hose free length/m Flux funnel, complete Insert A2 flux gate w/ shut-off valve Flux gate nozzle (18 mm) 3 3 0332 948 001 0333 094 880 0443 383 002 0443 383 001 0145 221 881 0333 667 001 0153 299 880 0153 296 001 0153 290 002 0443 383 002 0443 383 001 0254 900 880 0254 900 301 0903787 0708876

(3.9) (7.5) (10.2) (10.2) (19.7)

Contact device MTW 600 complete singe wire

1 1. Flux gate 2. Nozzle

2
28

Welding Heads

Welding Heads

A2S Mini Master


A multi-purpose automatic welding system


Versatile welding system for single wire submerged arc welding (SAW), twin wire SAW or gas metal arc welding (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
A2S Mini Master SAW Systems
Includes A2-A6 process controller PEK and wire equipment

Options & Accessories


0449 170 900 0449 170 901 0449 170 902 0449 370 880 0449 370 881 0449 370 882 Laser lamp kit (for PEK), 2 m (6.5 ft.) cable Laser lamp kit (for PEK), 7 m (23 ft.) cable Thin wire straightener, single wire Gas handling equipment, GMAW only: Cooling unit OCE 2H, 220V AC 50/60 Hz Gas hose Water-cooling hose Arc shield 0821 440 880 0821 440 883 0332 565 880 0414 191 881 0190 270 101 0190 315 104 0334 689 880

With manual slides 90x90 mm With motorized slides 180x180 mm and PAV With motorized slides 180x180 mm and GMH
Includes 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 A2S Mini Master GMAW MTW (4WD) Systems

Includes 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
Includes A2 process controller PEI and wire equipment

0449 181 900 0449 181 901 0449 181 902 0449 380 880 0449 380 881 0449 380 882

With manual slides 90x90 mm With motorized slides 180x180 mm and PAV With motorized slides 180x180 mm and GMH

Optional equipment SAW: Flux recovery unit OPC 0148 140 880 Flux container, silumin alloy 0413 315 881 Concentric flux funnel 0145 221 881 Contact tube, bent 0413 511 001 Wire reel, plastic, 30 kg (66 lbs.) 0153 872 880 Wire reel, steel, 30 kg (66 lbs.) 0416 492 880 Wire reel, steel, flexible width 0449 125 880 Wire reel, steel, 220 mm (8.7 in.) 0671 164 080 For PEK: Conversion kit, SAW to GMAW MTW (4WD)
Twin wire SAW 2x1.2-2.5 (2x.045-3/32) 9 (354) 6 (1.4) 800 42 90 (3.5) 360 GMAW 0.8-1.6 (.030-1/16) 0.8-1.6 (.030-1/16) 1.2-2.4 (.045-3/32) 1.2-1.6 (.045-1/16) 16 (630) 600 42 90 (3.5) 360

0461 248 880

Technical Data
Wire diameter, mm (in.) Steel Stainless Steel Cored wire Aluminum Max. wire feed speed, m/min (ipm) Flux hopper capacity, l (gal.) Max. permissible load 100%, A Control voltage, V AC Linear slide stroke length, mm (in.) Rotary slide setting range
32

Single wire SAW 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 1.6-4.0 (1/16-5/32) 9 (354) 6 (1.4) 800 42 90 (3.5) 360

GMAW MTW 600w 1.0-1.6 (.040-1/16) 1.0-1.6 (.040-1/16) 1.0-2.4 (.040-3/32) 1.0-2.0 (.040-5/64) 25 (984) 600 42 90 (3.5) 360

Welding Heads

A2 Component System Modularization - PEK


Wire feed unit Cable kit Slides Control unit Holder Carrier Control unit

0449 100 883 SAW Single 0449 150 900 T 1.6 m 0449 153 900 Manual 0449 152 880 Tractor 0449 154 880 PEK 0460 504 880

PAV * SAW Twin 0449 150 901 S 5.0 m 0449 153 905 Motorized 0449 151 880 PAV/GMH Cables 0461 215 880 Head 0449 155 880

GMH *

GMAW 2 WD 0449 150 902

*Part numbers for PAV and GMH, see Accessory Components.

GMAW 4 WD 0449 150 903

A2 Component System Modularization - PEI


Wire feed Cable kit Slides Control unit Holder Carrier Control unit

T 1.6 m 0449 153 980 SAW Single 0449 150 880 Manual 0449 152 880

0449 100 882 Tractor 0449 154 880 PEI 0449 330 880

S 5.0 m 0449 153 985

Motorized 0449 151 880

PAV * PAV/GMH Cables 0461 215 880 Head 0449 155 880

SAW Twin 0449 150 881

GMH *

GMAW 2 WD 0449 150 882

*Part numbers for PAV and GMH, see Accessory Components.

33

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, motoroperated cross slides. Capable of heavy-duty gas metal arc welding (GMAW), single/twin wire submerged arc welding (SAW), as well as strip cladding and Synergic Cold Wire (SCW) welding with optional accessories. Uses A2-A6 process controller PEK for fast, accurate presetting 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
High-speed wire feed unit (gear ratio 74:1)

0449 270 900 0449 270 901 0449 270 902 0449 270 910 0449 270 911 0449 270 912

With manual slides 210x210 mm With motorized slides 300x300 mm and PAV With motorized slides 300x300 mm and GMH Twin-wire SAW systems
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


Ratio 156:1 0.2-4.0 (8-157) 3.0-6.0 (0.118-0.236) 2x2.0-2x3.0 (2x0.079-2x0.118) 3.0-4.0 (0.118-0.157) 90 (3.5) 180 45 1500 Ratio 74:1 0.4-8.0 (16-315) 1.6-4.0 (0.063-0.157) 2x1.6-2x2.5 (2x0.063-2x0.098) 1.6-4.0 (0.063-0.157) 90 (3.5) 180 45 1500

Technical Data
Max. wire feed speed, m/min (ipm) Wire diameter, single, mm (in.) Wire diameter, twin, mm (in.) Tubular wire single, mm (in.) Linear slide stroke length, mm (in.) Rotary slide setting range: Circular slide, crank operated Straightener Max. permissible load, 100%, A
34

Welding Heads

A6 Component System Modularization


Wire feed unit Cable kit Slides Control unit for motorized slides Holder Carrier Control unit

SAW Single 0449 250 880

T 1.6 m 0449 253 900

Manual T 0449 252 880 GMH *

Holder 0449 254 880

0449 490 881 PEK 0460 504 880

SAW Twin 0449 250 881

PAV *

Bobbin holder 0449 255 880 S 5.0 m 0449 253 902 Motorized 0449 251 884

Single High-speed 0449 250 890

PAV/GMH cables 0461 215 880

Twin High-speed 0449 250 891

Manual S 0449 252 881

Bobbin holder 0449 255 881

* Part numbers for PAV and GMH, see Accessory Components.

35

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 assembly 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 Synergic 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
A6S Tandem Master, standard (156:1) A6S Tandem Master, high-speed (74:1) A6DS Tandem Master, standard (156:1) A6DS Tandem Master, high-speed (74:1) 0818 971 880 0818 971 881 0818 970 880 0818 970 881

Options & Accessories


Twin kit (one per torch) GMH, joint tracking with remote GMH, joint tracking with control panel GMH, slide motor cables, 5.0 m (16 ft.) Laser lamp kit, cable, 7 m (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.)
A6S Tandem Master 2 pcs 1 pc 1 pc 2 pcs 1 pc 1 pc 1 pc (0810 786 880) 1 pc (0334 549 880) 2 pcs 1 pc (0154 465 880) 1 pc (0671 171 580) 4 pcs (0278 300 180) 215 (474)

0809 934 882 0460 884 880 0460 884 881 0461 215 880 0821 440 883 0334 318 880 0146 967 880 0153 872 880 0416 492 880 0449 125 880

Technical Data (Basic Components)


A6 feed unit HD type for wire 3-6 mm (1/8-1/4 in.) Horizontal motorized slide with double runners L=355 mm (14 in.) Vertical motorized slide with double runners L=595 mm (23.4 in.) A2-A6 process controller PEK Flux hopper, 10 l (2.3 gal.) including bracket Cable holder Main bracket with mounting flange for cross slide assembly Swivel bracket for rotating head 90 Welding head Each welding head has: A6 manual slide L=90 mm A6 circular slide Insulators Total weight (excl PEK, wire and flux) approx. kg (lbs)

A6DS Tandem Master 2 pcs 1 pc 1 pc 2 pcs 1 pc 1 pc 1 pc (0809 873 880) 2 pcs 1 pc (0154 465 880) 1 pc (0671 171 580) 4 pcs (0278 300 180) 190 (419)

36

Welding Heads

A6S and A6DS Tandem Welding Heads


A6S 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. Adjustable +90 interval turning bracket and cross slide. Automatic joint tracking keeps in track no matter which direction welding occurs.

A6DS Tandem Master


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 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.

A6S Tandem Master

A6DS Tandem Master

37

Welding Heads

A6S Compact Welding Heads for Internal Welding


For excellent welding results
For welding longitudinal and circumferential butt joints inside tubes. Two versions available: 1. A6S Compact 300 for internal welding of tubes down to 300 mm (12 in.) inside diameter. 2. A6S Compact 500 for internal welding of tubes down to 500 mm (20 in.) 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 using a 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 500 mm 550 mm

Ordering Information
A6S Compact 300, standard A6S Compact 300, high-speed A6S Compact 500, standard A6S Compact 500, high-speed 0809 280 880 0809 280 881 0416 967 880 0416 967 882

Options & Accessories - Compact 300


Flux valve control kit* Laser pointer
* including solenoid valve and 5 m (16.4 ft.) air hose

0813 620 880 0811 177 880

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.) Feed rollers, wire size 3.0-3.2 mm (1/8 in.) 4.0 mm (5/32 in.)
Compact 300 3.0-4.0 (1/8-5/32) 3.2 (1/8) 800 42 0.1-1.7 (4-67) 50 (2) 360 0.2-4.0 (8-157) 0.4-8.0 (15.7-315)

0154 623 005 0154 623 004 0154 623 003 0218 510 298 0218 510 286

For technical data and more information for Compact 500, please contact your local ESAB representative.

Technical Data
Wire diameters, mm (in.) - Steel - Stainless steel Permissible load 100%, A Control voltage, V AC Travel speed, m/min (ipm) Linear slides stroke range, mm (in.) Rotary slide setting range Wire feed speed, standard, m/min (ipm) Wire feed speed, high.speed, m/min (ipm)
38

Welding Heads

A6S SAW Strip Cladding Head


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 components 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 in.) and as thick as 0.5 mm (0.02 in.).

Ordering Information
Strip cladding kit*
* for use with A6T SAW Tractor or A6S Arc Master HD

0155 972 880

Options & Accessories


Reel holder (do not use with motor-operated cross slide) 0417 636 880 Wire reel, steel 0416 492 880 Suction nozzle, flux 0156 025 001

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 Ordering Information and Technical Data for the ESW Welding Head.

Technical Data
Max. welding current at 100% duty cycle, A Feed roller diameter, mm (in.) Strip width, mm (in.) Strip thickness, mm (in.)
39

A6S SAW Strip Cladding Head 1500 50 (2.0) 30-100 (1.2-4.0) 0.5 (0.02)

Column & Booms

Column & Booms

Column and Boom (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 welding 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; these numbers refer 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 has a working range of 3 to 5 m (10 to 16.5 ft.) both vertically and horizontally. The CaB 460S has a working range of 5 to 7 m (16.5 to 23 ft.) both vertically and horizontally.
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.

42

Column & Booms

Column and Boom (CaB) Systems


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 A customized range of welding column and booms for different requirements and applications.

Loading capacities and working strokes for utmost accessibility to the welding joints. Based on the modular CaB range, solutions to meet the most demanding request can be achieved. Welding methods as gas tungsten arc welding (GTAW), gas metal arc welding (GMAW) and submerged arc welding (SAW) cladding as well as Narrow Gap can be chosen on customized stations.

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 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. 43

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.

Column & Booms

CaB Systems

Technical data CaB 300S and CaB 300M Technical Data - Column
Effective working range, m (ft.) Max. boom height A, mm (ft.) using movable carriage, min mm (ft.) Max. boom height B, mm (ft.) using concrete stand, min mm (ft.) Max. boom height C, mm (ft.) using stationary foot plate, min mm (ft.) Total height D using movable carriage, mm (ft.) Total height E using concrete stand, mm (ft.) Total height F using stationary foot plate, mm (ft.) Lifting speed, m/min (ipm) Max total load on column platform, kg (lbs) 3 (10) 4070 (13) 930 (3) 3955 (15.6) 815 (2.7) 3750 (14.7) 610 (2.4) 5170 (17) 5055 (16.5) 4850 (16) 0.7 (27.5) 600 (1320) CaB 300S / 300M 4 (13) 5070 (16.5) 930 (3) 4955 (19.5) 815 (2.7) 4750 (18.7) 610 (2.4) 6170 (20) 6055 (20) 5850 (19) 0.7 (27.5) 600 (1320) 5 (16.5) 6070 (20) 930 (3) 5955 (23.5) 815 (2.7) 5750 (22.6) 610 (2.4) 7170 (23.5) 7055 (23) 6850 (22.5) 0.7 (27.5) 600 (1320)

Technical Data - Boom


Extension G, max mm (ft.) min mm (ft.) Permissible loads: total, max kg (lbs.) one end, max kg (lbs.) Cross-sectional diameter H, mm (ft.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) 3580 (11.8) 540 (1.8) 300 (660) 240 (530) 325 (13) 0.1-2.0 (4-79) 2.0 (79) 4580 (15) 540 (1.8) 220 (485) 150 (330) 325 (13) 0.1-2.0 (4-79) 2.0 (79) 5580 (18) 540 (1.8) 150 (330) 75 (165) 325 (13) 0.1-2.0 (4-79) 2.0 (79)

Technical Data - Rail Carriage


Track width L, inside to inside, mm (in.) Width x length, mm (in.) Height I, mm (in.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) Total weight, kg (lbs.) 1730 (68.11) 2060x2330 (81.1x91.7) 365 (14.4) 0.1-2.0 (4-79) 2.0 (79) 1670 (3681)

Technical Data - Concrete Stand


Width x length, mm (in.) Height J, mm (in.) Total weight, kg (lbs.) 2060x2100 (81.1x82.7) 250 (9.84) 1550 (3417)

Technical Data - Foot Plate


Width x length, mm (in.) Height K, mm (in.) Total weight, kg (lbs.)
44

1100x1100 (43.3x43.3) 40 (1.6) 350 (772)

Column & Booms

CaB Systems

Technical data CaB 460S and CaB 460M Technical Data - Column
Effective working range, m (ft.) Max. boom height A, mm (ft.) using movable carriage, min mm (ft.) Max. boom height B, mm (ft.) using concrete stand, min mm (ft.) Max. boom height C, mm (ft.) using stationary foot plate, min mm (ft.) Total height D using movable carriage, mm (ft.) Total height E using concrete stand, mm (ft.) Total height F using stationary foot plate, mm (ft.) Lifting speed, m/min (ipm) Max total load on column platform, kg (lbs) CaB 460M only 4 (13) 4950 (16) 950 (3.12) 4845 (16) 845 (2.8) 4510 (15) 510 (1.6) 6275 (20.5) 6170 (21) 5835 (20) 2.0 (79) 1500 (3300) CaB 460S CaB 460M 5 (16.5) 5950 (19.5) 950 (3.12) 5845 (19) 845 (2.8) 5510 (18) 510 (1.6) 7275 (24) 7170 (23.5) 6835 (22.5) 2.0 (79) 1500 (3300) CaB 460S CaB 460M 6 (20) 6950 (23) 950 (3.12) 6845 (22.5) 845 (2.8) 6510 (21.5) 510 (1.6) 8275 (27) 8170 (27) 7835 (25.5) 2.0 (79) 1500 (3300) CaB 460S CaB 460M 7 (23) 7950 (26.08) 950 (3.12) 7845 (25.7) 845 (2.8) 7510 (24.6) 510 (1.6) 9275 (30.4) 9170 (30) 8835 (29) 2.0 (79) 1500 (3300)

Technical Data - Boom


Extension G, max mm (ft.) min mm (ft.) Permissible loads: total, max kg (lbs.) one end, max kg (lbs.) Cross-sectional diameter H, mm (in.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) 4715 (15.5) 715 (2.4) 1100 (2423) 550 (1211) 630 (25) 0.1-2.0 (4-79) 2.0 (79) 5715 (18.8) 715 (2.4) 1050 (2313) 450 (1211) 630 (25) 0.1-2.0 (4-79) 2.0 (79) 6715 (22) 715 (2.4) 1000 (2203) 350 (1211) 630 (25) 0.1-2.0 (4-79) 2.0 (79) 7715 (25.3) 715 (2.4) 950 (2094) 150 (331) 630 (25) 0.1-2.0 (4-79) 2.0 (79)

Technical Data - Rail Carriage


Track width L, inside to inside, mm (in.) Width x length, mm (in.) Height I, mm (in.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) Total weight, kg (lbs.) 1730 (68.11) 2100x2380 (82.7x93.7) 485 (19.1) 0.1-2.0 (4-79) 2.0 (79) 2860 (6305)

Technical Data - Concrete Stand


Width x length, mm (in.) Height J, mm (in.) Total weight, kg (lbs.) 2100x2410 (82.7x94.9) 380 (15) 2900 (6393)

Technical Data - Foot Plate


Width x length, mm (in.) Height K, mm (in.) Total weight, kg (lbs.)
45

1600x1600 (63x63) 40 (1.57) 505 (1113)

Column & Booms

CaB Systems

Technical data CaB 600M Technical Data - Column


Effective working range, m (ft.) Max. boom height A, mm (ft.) using movable carriage, min mm (ft.) Max. boom height B, mm (ft.) using concrete stand, min mm (ft.) Max. boom height C, mm (ft.) using stationary foot plate, min mm (ft.) Total height D using movable carriage, mm (ft.) Lifting speed, m/min (ipm) Max total load on column platform, kg (lbs) 6 (20) 7025 (276.6) 1075 (42.3) 6950 (22.8) 1000 (3.3) 8585 (28.2) 8510 (27.9) 2.0 (79) 7 (23) 8025 (316) 1075 (42.3) 7950 (26.1) (1000 (3.3) 9585 (31.4) 9510 (31.2) 2.0 (79)

CaB 600M
8 (26) 9025 (355.3) 1075 (42.3) 8950 (29.4) 1000 (3.3) 10585 (34.7) 10510 (34.5) 2.0 (79) 9 (29.5) 10025 (395) 1075 (42.3) 9950 (32.6) 1000 (3.3) 11585 (38) 11510 (37.8) 2.0 (79) 10 (33) 11025 (434) 1075 (42.3) 10950 (35.9) 1000 (3.3) 12585 (41.3) 12510 (41) 2.0 (79)

Technical Data - Boom


Extension E, max mm (ft.) min mm (ft.) Permissible loads: total, max kg (lbs.) one end, max kg (lbs.) Cross-sectional diameter H, mm (ft.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) Total weight incl cables, kg (lbs.) 1050 (2315) 1165 (2568) 1280 (2822) 7000 (23) 1000 (3.3) 1940 (4277) 550 (1213) 1000 (3.3) 0.1-2.0 (4-79) 8000 (26) 1000 (3.3) 1830 (4034) 400 (882) 1000 (3.3) 0.1-2.0 (4-79) 9000 (29.5) 1000 (3.3) 1700 (3748) 250 (551) 1000 (3.3) 0.1-2.0 (4-79)

Technical Data - Rail Carriage 4Wd


Track width L, inside to inside, mm (in.) Width x length, mm (in.) Height I, mm (in.) Welding speed, m/min (ipm) Transport speed, m/min (ipm) Total weight, kg (lbs.) 2500 (98.4) 3100x2600 (122x102) 490 (19.3) 0.1-2.0 (4-79) 2.0 (79) 4800 (10582)

Technical Data - Concrete Stand


Width x length, mm (in.) Height J, mm (in.) Total weight, kg (lbs.) 3100x2680 (122x105.5) 415 (16.3) 4250 (9370)

46

Column & Booms

CaB 22 VLS

For small and medium sized objects


The CaB 22 VLS is specifically designed for light-duty applications. Smooth 360-degree 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 using low voltage on the generous 10 m (33 ft.) cable. A standard safety feature including anti-fall device and limit switches for all motions.

Ordering Information
For ordering information, please contact your nearest ESAB representative.

Technical Data
Mains supply, V Frequency, Hz Vertical speed, mm/min (ipm) Boom speed, mm/min (ipm) Rotation
47

400 50/60, 3-phase 600 (23.6) 0-2050 (0-80.7) Manual

Column & Booms

CaB 44, 55, 66 and 77


Column and Boom systems
Designed and robustly build 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 55 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 420 kg (924 lbs.).

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
CaB 44 5425 (213.5) 5700 (224.5) 4000 (157.8) 1000 (39.3) 4000 (157.8) 2000 (78.7) 1250/1500 (49/59) 165/1650 (6.5/65) 1500 (3307) 750 (1653.5) IP 55 380/400/415 440/460/480 24 Manual

Options & Accessories


Camera system Spools at rear end of the boom Motorized rotation Tandem platform 0.5 m (1.6 ft.) boom section 0.5 m (1.6 ft.) column section 0370 250 616 0370 250 617 0370 250 618 0370 250 619 0370 250 620 0370 250 621

Technical Data
Overall height, mm (in.) Boom length, mm (in.) Effective vertical under boom: max. mm (in.) min. mm (in.) Effective boom range horizontal, mm (in.) Rail, mm (in.) Vertical speed, mm/min (ipm) Boom speed, mm/min (ipm) Total permissible load, kg (lbs.) Permissible load per end, kg (lbs.) Electrical panel Mains supply, V, 3ph 50 Hz Mains supply, V, 3ph 60 Hz Control voltage, V AC Slewing
48

CaB 55 6425 (253) 6700 (263.8) 5000 (197) 1000 (39.3) 5000 (197) 2000 (78.7) 1250/1500 (49/59) 165/1650 (6.5/65) 1000 (2205) 500 (1102) IP 55 380/400/415 440/460/480 24 Manual

CaB 66 7425 (292) 7700 (303) 6000 (236.2) 1000 (39.3) 6000 (236.2) 2000 (78.7) 1250/1500 (49/59) 165/1650 (6.5/65) 600 (1323) 300 (661) IP 55 380/400/415 440/460/480 24 Manual

CaB 77 8425 (331.7) 8700 (342.5) 7000 (275.5) 1000 (39.3) 7000 (275.5) 2000 (78.7) 1250/1500 (49/59) 165/1650 (6.5/65) 400 (882) 200 (441) IP 55 380/400/415 440/460/480 24 Manual

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 thicknesses are to be welded. Loaded with 1000 kg (2204 lbs.) flux BigBag and 1000 kg (2204 lbs.) wire EcoCoils, welding is continuously performed and costly down times are minimized.

Ordering Information
For ordering information, please contact your 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 (optional). Remote-controlled height adjustment of joint tracking sensor (optional). Reduced factory floor footprint. Increased workshop safety. Enables flexible production. Big Pack handling concepts (optional). Camera supervision system (optional).

Applications Technical Data


Effective working range, m (ft.) Max extension, m (ft.)* Max load at boom end, kg (lbs.) Welding process Welding heads Control system Operator seat
*Measured from column centre. 49

Power generation, especially wind tower manufacturing lines. Pipeline, pipemill contactors. General fabrication (small workshops with limited space).

Telbo 6500 6.5 (21.33) 8.0 (26.25) 300 (661.4) SAW / GMAW A6 PLC / GMH No

Telbo 9500 9.5 (31.17) 12.5 (41) 500 (1102) SAW A6 SAW, Single/Tandem and Tandem/Twin PLC / GMH Yes

Carriers & Gantries

Carriers & Gantries

Mechtrac 1730/2100/2500/3000
For mechanized gantry automation
Fast and flexible way to increase productivity Equipped with A2-A6 process controller PEK 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 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 0809 670 881 0809 670 882 0809 670 883 0809 670 884

Options & Accessories


Travelling rail, 3 m (9.8 ft.) Travelling rail, extension, 3 m (9.8 ft.) 0806 707 880 0806 707 881

Torch angle 30o

Torch angle 90o

Torch angle 30o Min. 360 mm

Max. 1320 mm

Min. 360 mm

Technical Data
Max. load, kg (lbs.) Standard rail length, m (ft.) Working range, mm (in.): A max. B max. C max. Travel speed, m/min (ipm) Dimensions, WxH, mm (in.)

Mechtrac 1730 220 (485) 3 (10) 630 (24.8) 1010 (39.7) 1390 (54.7) 0.2-1.9 (8-75) 1730x1500 (59x68)

Mechtrac 2100 220 (485) 3 (10) 1000 (39.4) 1380 (54.3) 1760 (69.2) 0.2-1.9 (8-75) 2100x1500 (83x59)

Mechtrac 2500 220 (485) 3 (10) 1400 (55) 1780 (70) 2160 (85) 0.2-1.9 (8-75) 2500x1500 (98.5x59)

Mechtrac 3000 220 (485) 3 (10) 1900 (74.8) 2280 (89.7) 2660 (104.7) 0.2-1.9 (8-75) 3000x1500 (118x59)

52

Carriers & 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 (SAW) is the ideal method for the applications intended for this station. The flux handling equipment can be operated conveniently, without time-wasting 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. A large number of positioning axes permit flexible welding production.

Ordering Information
For ordering information, please contact your nearest ESAB representative.

Walltrac

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.

Ordering Information
For ordering information, please contact your nearest ESAB representative.
53

Accessory Components

Accessory Components

Beam Travelling Carriage


For use 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 fit 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 specially machined I-beam (contact ESAB for details). Fast and easy pre-programming of travel motion and wel- ding parameters using the A2-A6 process controller PEK.

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 carriage travel. Different travel units for speeds to match process.

Ordering Information
MBVA 330 carriage MBVA 550 carriage 0150 765 880 0150 901 880

Options & Accessories


Cable, length 1.5-50 m (5-164 ft.) contact ESAB
0150 943 880 0150 943 881 0150 943 882 0150 943 883 0150 943 884 0803 348 880 0803 348 881 0803 348 882 0803 348 883 0803 348 884 0803 348 885 0803 348 886 0321 527 880 0321 527 881 0321 527 882 0321 527 883 0321 527 884 Travel unit, 3-80 cm/min (1.2-32 ipm) Travel unit, 11-125 cm/min (4-49 ipm) Travel unit, 14-250 cm/min (5.5-98 ipm) Travel unit, 37-1500 cm/min (14.5-590 ipm) Travel unit, 27-530 cm/min (11-208 ipm) 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.) 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.)

Ordering Information
Beam travelling carriage 0457 897 881

Options & Accessories


Mounting bracket for tandem head Track in lengths of 3000 mm (9.8 ft.)
Required number of floor columns: 2

0458 026 001 0145 282 880 0145 282 881 0145 282 882 0145 282 883

Track in lengths of 4500 mm (14.8 ft.)


Required number of floor columns: 3

Track in lengths of 6000 mm (19.7 ft.)


Required number of floor columns: 3

Track in lengths of 8000 mm (26 ft.)


Required number of floor columns: 4

Technical Data
Travel speed beam carriage, cm/min (ipm) Weight carriage, kg (lbs.)
56

Technical Data
Rated load, N (kp) 6-200 (2-79) 60 (132) Rated moment, Nm (kpm) Weight, kg (lbs.)

MBVA 330 10000 (1000) 3300 (330) 95 (209)

MBVA 550 20000 (2000) 10000 (1000) 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.).

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 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

Options & Accessories


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 Max ambient temperature Axial play, runner, mm (in.) Max. torque-free load, kg (lbs.) 42 80C (176F) 0.1 (0.004) 150 (330)

Technical Data
Total length, mm (in.) Number of 60 mm indexings Weight, kg (lbs.)
57

Slide 60 mm (2 in.) 305 (12) 3 11.5 (25)

Slide 120 mm (5 in.) 365 (14) 4 13.2 (29)

Slide 180 mm (7 in.) 425 (17) 5 15 (33)

Slide 240 mm (9 in.) 485 (19) 6 16.7 (37)

Slide 300 mm (12 in.) 545 (21.5) 7 18.5 (41)

Slide 420 mm (17 in.) 665 (26) 9 21.9 (48)

Slide 540 mm (21 in.) 785 (31) 11 25.4 (56)

Slide 730 mm (29 in.) 1025 (40) 14 30.9 (68)

Slide 1030 mm (41 in.) 1385 (54.5) 21 38.8 (85.5)

Accessory Components

PAV

Manual joint positioning system


Simple and easy to use. Adapt for use with almost any type of welding joint. For manual joint tracking. Works equally well with ESAB A2 or A6 welding systems. Motorized servo slides guarantee reliable, accurate joint tracking. Available in three versions: 1. with control panel on the front 2. with remote control 3. without control panel suitable for integration into customized solutions

Ordering Information
PAV without control panel PAV with control panel PAV with remote control 0460 502 880 0460 502 881 0460 697 880

Options & Accessories


Cable restraining bracket 0460 861 880 Motor cable, 5 m (16.4 ft.) 0460 745 881 Motor cable, 10 m (32.8 ft.) 0460 745 882 Motor cable, 19 m (62.3 ft.) 0460 745 884 Servo slides see page 53 for ordering information

Technical Data
Mains supply, V AC, 50-60 Hz Primary input current, A Duty cycle 100%, A Fuse, A Armature voltage, V DC Field voltage, V DC Current limit, A Dimensions, LxWxH mm (in.) Weight, kg (lbs.) Enclosure class 42 15 6 10 40 60 15 246x235x273 (9.7x9.3x10.7) 13 (6) IP 23

58

Accessory Components

GMH

Automatic joint positioning and tracking system


Simple and easy to use. Adapt for use with almost any type of welding joint. For automatic joint tracking. Works equally well with ESAB A2 or A6 welding systems Motorized servo slides guarantee reliable, accurate joint tracking. Available in three versions: 1. with control panel on the front 2. with remote control 3. without control panel suitable for integration into customized solutions

Designed for use in fillet and butt joints using sensor fingers. Compensates for irregularities in weld joint, tracks simple geometric shapes and avoids parallax problems.

Technical Data
Mains supply, V AC, 50-60 Hz Primary input current, A Duty cycle 100%, A Fuse, A Armature voltage, V DC Field voltage, V DC Current limit, A Remote control dimensions, LxWxH, mm (in.) Remote control weight, kg (lbs.) Sensor sensitivity, mm (in.) Sensor weight, kg (lbs.) Mini-cross saddle and support for the saddle, setting length, mm (in.) 42 15 6 10 40 60 15 205x135x118 (8x5x4.6) 2.7 (6) 0.1 (0.004) 0.6 (1.3) 80 (3)

Ordering Information
GMH without control panel GMH with control panel GMH with remote control GMH system* GMH system** 0460 503 880 0460 503 881 0460 698 880 0460 884 880 0460 884 881

* Comes with with remote control, sensor, sensor cable and mini cross saddle **Complete with control panel,sensor, sensor cable and mini cross saddle

Options & Accessories


Cable restraining bracket 0460 861 880 Motor cable, 5 m (16.4 ft.) 0460 745 881 Motor cable, 10 m (32.8 ft.) 0460 745 882 Motor cable, 19 m (62.3 ft.) 0460 745 884 Servo slides see page 53 for ordering information Sensor cable, 5 m (16.4 ft.) 0416 749 888 Sensor cable, 9 m (29.5 ft.) 0416 749 889 Sensor cable, 19 m (62.3 ft.) 0416 749 880 Sensor with finger 0416 688 880 Mini cross saddle + sensor support 0416 739 880 Remote control 0460 570 880 Protective rubber boot for sensor 0412 013 001 Standard finger 0146 586 001 Finger with ball 0416 719 001 Finger for heat exchange plates 0443 328 880 Finger for beam welding 0443 187 880 Intermediate transformer 0148 636 002

Mini-cross saddle and support for 1.6 (3.5) the saddle, weight, kg (lbs.) Intermediate transformer, input rating, V, 50 Hz Intermediate transformer, input rating, V, 60 Hz Intermediate transformer, output voltage, V/VA Intermediate transformer, dimensions, LxWxH, mm (in.) 190, 230, 400, 415, 440, 500 200, 230, 400, 415, 440, 500 42/660 308x223x133 (12x8.7x5.2)

Intermediate transformer, weight, 15.6 (34.4) kg (lbs.) Dimensions, LxWxH mm (in.) Weight, kg (lbs.) Enclosure class 246x235x273 (9.7x9.3x10.7) 13 (6) IP 23

59

Accessory Components

AVPS Laser Seam Tracking System



Laser vision sensing improves the productivity and quality of circumferential, longitudinal welding processes as typically found in wind tower manufacturing. Longitudinal weld seam tracking on roll-formed tubes. Inside circumferential weld seam tracking. Outside circumferential weld seam tracking. Servo-Robots intelligent seam tracking technology, combi- ned with ESABs GMH joint tracking system and pendant control, maintains precise wire position both in the joint and ith respect to the vertical direction ensuring a consisw tent wire stickout. Parameters are easily set with the ESAB remote control 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.

Improves the productivity and quality of circumferential, longitudinal welding processes

Ordering Information
For ordering information, please contact your nearest ESAB representative.

Technical Data
Laser class Stand-off-distance, mm (in.) Field of view depth, mm (in.) Field of view width, mm (in.) Average depth resolution, mm (in.) Average lateral resolution, mm (in.) Dimensions LxWxH, mm (in.) Weight, kg (lbs.)

Mini-I/D laser-camera IIIb 80 (3.15) 100 (3.94) 30 - 60 (1.18 - 2.36) 0.05 (0.002) 0.05 (0.002) 30x56x90 (1.18x2.2x3.5) 0.5 (1.1)

Technical Data
Mains supply, V DC HMI port E-STOP input Camera cooling control output Laser enable key-lock Operating temperature Dimensions LxWxH, mm (in.) Weight, kg (lbs.)
60

Mini-Box Control Unit with ESAB GMH Interface 24 Ethernet 10/100 Mbits External alarm input for laser safety Used with SRI camera air cooling system Key-lock switch for laser safety 5 - 40oC (41 - 104oF) 300x300x150 (11.8x11.8x6) 3.5 (7.7)

Accessory Components

OPC Basic & Super



Robust and compact design. Easy operation and maintenance.

Sturdy compact flux recovery systems

Integrated system for maximum productivity - lower investment and service costs. Adapts to any A2 or A6 welding system - mobile 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 dust from recovered flux. Slag is separated and flux is returned to hopper.

OPC Super Flux Recovery System


Similar to basic system but with stronger ejector and cyclone - provides better suction. Can also be used with preheated flux.

Ordering Information
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
* excludes hose, nozzles and filter.

Options & Accessories


0148 140 880 0802 415 882 0802 415 883 0339 719 880 0802 415 892 0802 415 893 Air pressure hose 9.5 mm (3/8 in.) Air pressure hose 12.7 mm (1/2 in.) Air pressure tube 63 mm, 63.5 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

Technical Data
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 Max working pressure, MPa Max suction height: at working pressure 0.4 MPa, m* at working pressure 0.5 MPa, m* at working pressure 0.6 MPa, m* Sound level at work, dB Max working temperature, C Short term temperature, C**

OPC Basic 175 225 250 0.6 0.8 0.8 0.8 70 130 170

OPC Super 420 500 580 0.6 1.0 1.2 1.4 72 150 190

* Suction height with normal flux bead and a welding speed of 100 cm/ min (39.3 ipm) ** Tested with preheated flux to temp. max 220C (428F) and weld object temp. max 350C. (662F)
61

Accessory Components

OPC Flux Recovery System Wear Parts


8a 8b Hose D22/12.5 7 Hose D16/9.5 2 1 9 0147 640 880 0379 016 001 0192 855 002 0148 143 001* 0148 144 001* 0215 201 353 0145 824 881 0155 966 001 0332 448 001* 0148 142 001 0145 565 001 0215 201 345 0148 141 001 0145 073 001 0145 815 001 0020 301 780 10 3 4 2 1 OPC Super 1 Ejector 2 Hose Id 4000 D47/38 3 Tension band 4 Cone 5 Tension ring 6 O-ring, 189.3x5.7 7 Ball valve 8a Filter, paper 8b Filter, cotton 9 Funnel 10 Rubber lining 11 O-ring 149.2x5.7 12 Cyclone 13 Rubber lining 14 Tension spring 15 Clamp 16 Strainer 1a 1b 1c 1d 4 7 4 3 5 6 15

8a 8b

OPC Basic 1 Ejector 2 Hose Id 4000 D47/38 3 Tension band 4 Cone 5 Tension ring 6 O-ring, 189.3x5.7 7 Ball valve 8a Filter, paper 8b Filter, cotton 9 Funnel 10 Rubber lining 11 O-ring 149.2x5.7 12 Cyclone 13 Rubber lining 14 Tension spring 16 Strainer 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, length 0.5 m Pipe bent

12

11 13 14 16

0339 720 001 0379 016 001 0192 855 002 0332 279 001 0148 144 001 0215 201 353 0333 625 001 0155 966 001 0332 448 001* 0332 280 001 0332 282 001 0215 201 345 0332 281 001 0332 283 001 0145 815 002 0340 612 001 0020 301 780

0145 501 001 0145 502 001 0145 504 001 0145 505 001 0147 384 881 0145 131 004 0145 131 002 0443 383 001 0153 296 001

1a

1b

1d

1c

3a 3b 6a 6b

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, cotton 7 Tension band 8 Plastic bag 9 U-screw 10 Bracket * Optional Item

0148 143 001 0332 279 001 0148 144 001 0413 576 001 0193 125 003 0148 141 001 0155 966 001 0332 448 001* 0192 855 002 0190 665 004 0379 600 001 0379 599 880

1a 1b 2 9, 10 5 1a 2

62

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 cost efficiency. 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. For increased flux and heat conditions. Based on ejector vacuum principle.
FFRS 3000

FFRS 1200 & 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.

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

Options & Accessories


Air central Flux hopper 10 l (2.6 gal.) Flux hopper 6 l (1.6 gal.) Holder for hopper Level indicator for TPC Pneumatic flux valve Flux valve control unit 0417 714 880 0147 649 881 0413 315 881 0148 487 880 0452 048 880 0802 540 880 0813 620 880

FFRS Super systems include 25 m (82 ft.) 1/2 air pressure hose, 25 m (82 ft.) flux feed hose from TPC to hopper [20 m (65.6 ft.) for heated systems] 2 m (6.5 ft.) flux suction hose, 6 m (19.7 ft.) dust hose from hopper to filter [10 m (32.8 ft.) for systems with Tedak], bent inlet for flux hopper and flux recovery nozzles.

FFRS 1200 FFRS 1200 with heaters FFRS 3000 FFRS 3000 with heaters

0809 914 885 0809 914 886 0809 914 887 0809 914 888

FFRS 1200/3000 systems include 25 m (82 ft.) 1/2 air pressure hose, 25 m (82 ft.) flux feed hose from TPC to hopper [20 m (65.6 ft.) for heated systems)] 16 m (52.5 ft.) flux suction hose, suction hose between the primary separator and the vacuum unit [1200 = 2 m (6.5 ft.), 3000 = 5 m (16.4 ft.)], bent inlet for flux hopper and flux recovery nozzles.

Technical Data
Weight without flux, kg (lbs.) Dimensions, LxWxH, mm (in.) Primary separator: Volume, l (gal.) Dimensions, LxW, mm (in.) Suction unit Type Power, W Mains supply, V/Hz Fuse, A Max. vacuum, kPA Max. air flow capacity, m3/h Sound level, dB Filter area, m2 Life-span of filter, work hours Weight, kg (lbs.) Dimensions, LxWlH, mm (in.)
63

FFRS 1200 230 (507) 1053x450x2210 (41x18x87) 50 (13) 450x700 (18x28) P160 1200 110-230 / 50-60 10 -21 156 74 0.6 99.95 19 (42) 480x400x1160 (19x16x46)

FFRS 3000 400 (882) 750x450x2210 (30x18x87) 50 (13) 450x900 (18x35) E-PAK 150 3000 400 / 3-50 16 -25 270 63 3 99.95 194 (428) 1200x690x2000 (47x27x79)

Accessory Components

CRE 30 & CRE 60 Air Drying Units


For use with 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 0443 570 880 0443 570 881

Options & Accessories


Desiccant, type 512* Oil filter Dust filter
* packaged per 25 kg (55 lbs.)

0443 570 017 0443 570 018 0443 570 019

Technical Data
Mains supply, V AC, Hz Max. power rating, W Net air flow capacity at 6 bar, m3/h (ft3/hr at 87 psi) Regenerating flow at 6 bar (87 psi), % Max. dew point under nominal working conditions, C (F) Desiccant Type 512: Sodium-Aluminum-Silicate, kg (lbs.) Normal pore size, ngstrm Particle size, mm (in.) Density, kg/m3 (lbs/in.3) Cycle time per container Max. permissible air flow for oil separation filter, cmh (cfh) Manifold thread size Max. working pressure, bar (psi) Max. air pressure at testing, bar (psi) Max. inlet air temperature under nominal conditions, C (F)

CRE 30 230, 50/60 40 30 Normal (1060) 14 -26 (-14) 10 (22) 4 2.5-5.0 (0.01-0.20) 720 (0.023) 5 60 (197) Normal R12 6 (87) 10 (145) 30 (86)

CRE 60 230, 50/60 50 60 Normal (2120) 14 -26 (-14) 16 (35) 4 2.5-5.0 (0.01-0.20) 720 (0.026) 5 60 (197) Normal R12 6 (87) 10 (145) 30 (86)

64

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

65

Accessory Components

Camera Systems

For submerged arc welding (SAW) and open arc welding


Together with a laser or pilot lamp, control the welding process from a convenient location. The system consists of a camera with built-in crosshair generator to provide continuous and distinct joint scanning. In combination with the 15 inch flat screen monitor, it becomes a unit for excellent control and joint supervision. Upon welding, the GMAW camera switches over to view the weld pool, facilitating the supervision of the process. An optional overview camera produces a picture of the welded joint for immediate weld quality inspection.

Ordering Information
All systems include camera, camera housing, monitor, crosshair generator, camera mounting bracket, work light, work light bracket, necessary cables:

A2/A6 SAW camera with cooling unit A2/A6 SAW camera without cooling unit SAW compact camera with cooling unit SAW compact camera without cooling unit SAW compact Basic/Overview camera GMAW camera with cooling unit GMAW camera without cooling unit

0811 412 880 0811 412 881 0811 413 900 0811 413 901 0811 413 880 0811 414 880 0811 414 881

Ordering Information - Components


SAW camera GMAW camera GMAW camera (prepared for cooling) SAW compact camera SAW compact camera (prepared for cooling) SAW compact Basic/Overview Monitor including crosshair generator
Housing is included in cameras and monitor.

0810 092 880 0811 380 880 0811 380 881 0811 381 880 0811 381 881 0810 517 880 0811 383 880

Technical Data
Panel type Operating temperature range

Monitor LCD 15 with protective glass -5 - +35C

Technical Data
TV standard Temperature range: Operating Cooled version (water cooling is required) Dimensions, mm (in.) Weight, kg (lbs.)
66

SAW Camera PAL/NTSC -5 - +50C 60x60x105 (2.4x2.4x4.1) approx 0.46 (1)

GMAW Camera/ SAW Compact camera PAL/NTSC -10 - +50C (14-122F) approx. 300C 145x24x24 (5.7x0.9x0.9) approx 0.46 (1)

SAW Compact camera Basic/Overview PAL/NTSC 25x25x126 (1x1x5) + lens approx. 0.16 (0.35)

Accessory Components

OCE-2H Cooling unit


Compact and efficient
Can be used for gas metal arc welding (GMAW) as well as gas tungsten arc welding (GTAW). For manual and automatic welding. Flow guard optional. Designed for use with water-cooled welding equipment, manual or automatic. The water tank and pump are made of corrosion-resistant material. A flow guard is available as optional equipment 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 0414 191 881 0414 231 880

Technical Data - Pump With Motor


Max power consumption, W Mains supply, V, Hz Mains water pressure at: 50 Hz 300 kPa, bar 60 Hz 410 kPa, bar 250 230, 50/60, 1-phase 3 4.1

Technical Data - Cooler


Cooling power: 40 overtemp and 2.0 l/min, kW 60 overtemp and 2.0 l/min, kW Water pressure at 2.0 l/min, kPa Total water consumption, l (gal.) Dimensions, LxWxH, mm (in.)
67

1.1 1.7 kW 220 8 (2.11) 236x316x398 (9.3x12.4x15.7)

Accessory Components

FX-Series Flux Ovens


For the heated storage of welding flux
FX Series Flux Ovens are dual input voltage machines (230/440V) designed for the heated storage of welding flux. Ovens feature adjustable hold temperature thermostats ranging from 50 - 300C (122 572F). Available in a variety of storage capacities from 68 to 272 kg (150 to 600 lbs.).

Ordering Information
FX300 flux oven, 70 kg (300 lbs) capacity FX460 flux oven, 95 kg (460 lbs) capacity FX300 FX460

FX150 & FX600 also available. Contact ESAB to speak with an Automation Specialist.

Technical Data
Mains supply, V Capacity, kg (lbs) Max. temperature, oC (oF) Dimensions, LxWxH, mm (in.) Weight, kg (lbs.)

FX300 220/440 140 (300) 50 - 300 (122 - 572) 740 x 650 x 1150 (30 x 26 x 45) 95 (210)

FX460 220/440 210 (460) 50 - 300 (122 - 572) 740 x 650 x 1350 (30 x 26 x 53) 103 (227)

FX-Series High Heat Flux Ovens


For the heated storage of welding flux The HT Series Flux ovens are unique, automatic, 3 stage
heating machines with a bottom loading hopper. The heating cells are divided into three zones: 1. The first cell automatically transfers 1/3 of the rated load capacity of flux from the bottom loading hopper to the first preheat cell. 2. After the flux is preheated to a set temperature and time, it is automatically transferred to the second high-temperature baking cell. 3. After the flux is baked to a set temperature and time, the flux is automatically transferred to a third or bottom storage cell where the flux is easily removed via a manual lever.

Ordering Information
FX440 HT flux oven, 200 kg (440 lbs) capacity FX660 HT flux oven, 300 kg (660 lbs) capacity FX440HT FX660HT

The process of three heating cells ensures that flux moisture content is less than 0.05%.
FX440 HT 220/440 200 (440) 500 (932) 5 (11) 3 (37) 0.05 740 x 650 x 1150 (30 x 26 x 45) 95 (210) FX660 HT 220/440 300 (660) 500 (932) 5 (11) 3 (37) 0.05 740 x 650 x 1350 (30 x 26 x 53) 103 (227)

Technical Data
Mains supply, V Capacity, kg (lbs) Max. temperature, oC (oF) Suction speed, kg/min (lbs/min) Temperature rising speed, oC/min (oF/min) Moisture after drying, % Dimensions, LxWxH, mm (in.) Weight, kg (lbs.)
68

Handling Equipment

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. Oversized bearings. 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
Drive unit Roller bed CD-5 Roller bed CD-10 Roller bed CD-15 Roller bed CD-30 Roller bed CD-60 Roller bed CD-100 Roller bed CD-120 Idler unit Roller bed CI-5 Roller bed CI-10 Roller bed CI-15 Roller bed CI-30 Roller bed CI-60 Roller bed CI-100 Roller bed CI-120 0370 250 000 0370 250 002 0370 250 004 0370 250 006 0370 250 008 0370 250 010 0370 250 012

Options & Accessories


Foot pedal Synchronize kit Interface kit 0370 250 301 0370 250 302 0370 251 514

0370 250 001 0370 250 003 0370 250 005 0370 250 007 0270 250 009 0370 250 011 0370 250 013

Technical Data
Max loading capacity, ton/section Turning capacity, ton Turning speed, min-max, mm/min (ipm) Workpiece diameter, mm (in.) min 90, max 30 Mains supply, V Fuse, A Control voltage, V AC Weight, kg (lbs.) Dimensions LxHxW, mm (in.) Drive unit Idler unit Drive unit Idler unit 50Hz, 3ph 60Hz, 3ph Drive unit Idler unit Drive unit

CD/CI-5 2.5 2.5 7 62-618 (2.4-24.3) 165-6430 (6.5-253)


380/400/415 440/460/480

CD/CI-10 5 5 15 102-1020 (4-40) 165-6430 (6.5-253)


380/400/415 440/460/480

CD/CI-15 7.5 7.5 25 114-1137 (4.5-45) 222-7580 (8.7-298)


380/400/415 440/460/480

CD/CI-30 15 15 45 130-1300 (5-51) 466-8366 (18.3-329)


380/400/415 440/460/480

CD/CI-60 30 30 100 130-1300 (5-51) 466-8366 (18.3-329)


380/400/415 440/460/480

CD/CI-100 50 50 150 130-1300 (5-51) 466-8366 (18.3-329)


380/400/415 440/460/480

CD/CI-120 60 60 250 130-1300 (5-51) 466-8366 (18.3-329)


380/400/415 440/460/480

16 24 401 (884) 221 (487)


2090x540x534 (82x21x21) 2090x540x386 (82x21x15)

16 24 506 (1115) 270 (595)


2090x540x564 (82x21x22) 2090x540x450 (82x21x17.7)

16 24 665 (1466) 348 (767)


2465x620x562 (97x24.5x22) 2465x620x500 (97x24.5x19.6)

16 24 1222 (2694) 668 (1473)


2790x765x765 (110x30x35) 2790x765x700 (110x30x35)

16 24 2002 (4413) 1237 (2727)


2790x765x933 (110x30x37) 2790x765x888 (110x30x35)

32 24 2688 (5926) 1555 (3428)


3400x765x1177 (134x30x46) 2790x765x1080 (110x30x42.5)

50 24 3323 (7326) 2019 (4451)


3400x765x1284 (134x30x50.5) 2900x765x1110 (110x30x43.7)

Cable length, control box, m (in.)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

72

Handling Equipment

CD-30/60/100/120-DB and CI-30/60/100/120-DB


Conventional roller beds with rail bogie
Robust design with durable rollers. Gritblasted steelwork with polyurethane finished coating to endure the abrasive environment of offshore and marine industries. Oversized bearings. 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 variants. Ideal for: - Wind tower fabrication - Offshore and shipyards - Pressure vessels - Pipelines

Ordering Information
Drive unit CD-30-DB with Motorized Rail Bogie, 60 Hz CD-60-DB with Motorized Rail Bogie, 60 Hz CD-100-DB with Motorized Rail Bogie, 60 Hz CD-120-DB with Motorized Rail Bogie, 60 Hz Idler unit CI-30-IB with Idler Rail Bogie CI-60-IB with Idler Rail Bogie CI-100-IB with Idler Rail Bogie CI-120-IB with Idler Rail Bogie 0370 250 022 0370 250 024 0370 250 026 0370 250 028

Options & Accessories


Foot pedal Synchronize kit 0370 250 301 0370 250 302

0370 250 015 0370 250 017 0370 250 019 0370 250 021

Technical Data
Max loading capacity, ton/section Turning capacity, ton Turning speed, min-max, mm/min (ipm) Travel speed rail bogie, mm/min (ipm) Workpiece diameter, mm (in.) min 90, max 30 Mains supply, V Fuse, A Control voltage, V AC Weight, kg (lbs.) Dimensions LxHxW, mm (in.) Drive unit Idler unit Drive unit Idler unit 50Hz, 3ph 60Hz, 3ph Drive unit Idler unit Drive unit

CD-30-DB / CI-30-IB 15 15 45 130-1300 (5-51) 292-2920 (11.5-115) 466-8366 (18.3-329.4) 380/400/415 440/460/480 16 24 1739 (3834) 1082 (2385.5)
2790x955x1382 (110x37.5x54.5) 2790x955x1082 (110x37.5x42.5)

CD-60-DB / CI-60-IB 30 30 100 130-1300 (5-51) 292-2920 (11.5-115) 466-8366 (18.3-329.4) 380/400/415 440/460/480 16 24 2550 (5622) 1560 (3439)
2790x955x1592 (110x37.5x63) 2790x955x1450 (110x37.5x57)

CD-100-DB / CI-100-IB 50 50 150 130-1300 (5-51) 292-2920 (11.5-115) 466-8366 (18.3-329.4) 380/400/415 440/460/480 32 24 3275 (7220) 1901 (4191)
3400x970x1782 (134x38x70) 2790x955x1482 (110x37.5x58)

CD-120-DB / CI-120-IB 60 60 250 130-1300 (5-51) 292-2920 (11.5-115) 466-8366 (18.3-329.4) 380/400/415 440/460/480 50 24 3938 (8682) 2391 (5271)
3400x1040x1992 (134x41x78.5) 2900x955x1692 (114x37.5x67)

Cable length, control box, m (in.)

10 (394)

10 (394)

10 (394)

10 (394)

73

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 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
Max loading capacity, ton Workpiece diameter, mm (in.) Tire type, steel, mm (in.) Control voltage, V AC Mains supply, 50Hz-3ph, V Enclosure class (electrical) Power pack rating, kW Pump, cc Tank capacity, l (gal.) Stroke length cylinder A, mm (in.) Stroke length cylinder B, mm (in.) Stroke length cylinder C, mm (in.) Net weight, kg (lbs.) Cable length control pendant, m (in.)
74

FIR 35 35 2200-5000 (86.6-197) 300 (11.8) 24 480 IP43 3 3.2 60 (15.9) 125x160x2 (4.9x6.3x0.08) 100x210x4 (3.9x8.3x0.16) 150x300 (5.9x11.8) 4850 (10692) 10 (394)

FIR 75 75 900-6000 (35.4-236) 300 (11.8) 24 480 IP43 5.5 5.5 90 (23.8) 150x85x160x2 (5.9x3.3x6.3x0.08) 150x85x350x4 (5.9x3.3x13.8x0.16) 150x85x300 (5.9x3.3x11.8) 8400 (18519) 10 (394)

FIR 100 100 900-6000 (35.4-236) 300 (11.8) 24 480 IP43 5.5 5.5 90 (23.8) 180x160x2 (7.1x6.3x0.08) 180x400x4 (7.1x15.8x0.16) 180x300 (7.1x11.8) 9000 (19842) 10 (394)

Handling Equipment

FIT 30, 60 and 100


Conventional idler roller beds with built-in hydraulic height adjustment


Designed and robustly built to withstand rugged work environments. This unit can be used individually for aligning several workpieces or used as part of a growing line, ideal for wind tower production. Two independently adjusted rollers to align the workpieces 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
Max. loading capacity, ton Max. lifting capacity, ton Workpiece diameter, mm (in.) Fuse, A Control voltage, V AC Mains supply, 50/60Hz-3ph, V Enclosure class (motor) Enclosure class (electrical) Power pack rating, kW Weight, kg (lbs.) Dimensions with travel car, LxWxH, mm (in.) Dimensions without travel car, LxWxH, mm (in.) Cable length control box, m (in.)
75

FIT 30 15 15 1500-6500 (59x256) 16 24 400 IP55 IP43 1.1 1800 (3968) 3730x900x1590 (147x35.4x62.6) 3730x540x945 (147x21.3x37.2) 6 (236)

FIT 60 30 30 1500-6500 (59x256) 16 24 400 IP55 IP43 2.2 1900 (4189) 3730x1130x1590 (147x44.5x62.6) 3730x770x945 (147x30.3x37.2) 6 (236)

FIT 100 50 50 1524-5486 (60x216) 16 24 400 IP55 IP43 4 2295 (5060) 3730x1330x1590 (147x52.4x62.6) 3730x1070x945 147x42.1x37.2) 6 (236)

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 endure the abrasive environment of offshore and marine industries. Oversized bearings. 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 Ideal for: - Wind tower fabrication - Offshore and shipyards - Pressure vessels - Thin-wall vessels / Pipes

Ordering information
Drive unit Roller bed SD-5 Roller bed SD-10 Roller bed SD-20 Roller bed SD-40 Roller bed SD-60 Roller bed SD-80 Roller bed SD-100 Roller bed SD-120 Idler unit Roller bed SI-5 Roller bed SI-10 Roller bed SI-20 Roller bed SI-40 Roller bed SI-60 Roller bed SI-80 Roller bed SI-100 Roller bed SI-120 0370 250 050 0370 250 052 0370 250 054 0370 250 056 0370 250 058 0370 250 060 0370 250 062 0370 250 095

Options & Accessories


Foot pedal 0370 250 301

0370 250 051 0370 250 053 0370 250 055 0370 250 057 0270 250 059 0370 250 061 0370 250 063 0370 250 096

Technical Data
Max loading capacity, ton/section Turning capacity, ton Turning speed, mm/min (ipm) Workpiece diameter, mm (in.) Mains supply, V Fuse, A Control voltage, V AC Weight, kg (lbs.) Dimensions LxHxW, mm (in.)
Drive unit Idler unit Drive unit Idler unit 50Hz, 3ph 60Hz, 3ph Drive unit Idler unit Drive unit

SD/SI-5
2.5 2.5 7.5 130-1300 (5-51) 200-6500 (8-256) 380/400/415 440/460/480 16 24 880 (1940) 580 (1279)
3100x930x480 (122x37x19) 3100x930x420 (122x37x17)

SD/SI-10
5 5 15 130-1300 (5-51) 200-6500 (8-256) 380/400/415 440/460/480 16 24 950 (2094) 660 (1455)
3080x930x500 (121x37x20) 3080x930x440 (121x37x17.3)

SD/SI-20
10 10 30 130-1300 (5-51) 200-6500 (8-256) 380/400/415 440/460/480 16 24 1138 (2509) 758 (1671)
3600x930x550 (142x37x21.7) 3600x930x480 (142x37x18.9)

SD/SI-40
20 20 60 124-1240 (4.9-49) 500-6500 (20-256) 380/400/415 440/460/480 16 24 2720 (5997) 1960 (4321)
3780x1400x632 (149x55x24.9) 3300x1400x632 (130x55x24.9)

SD/SI-60
30 30 100 125.5-1255 (4.94-49.4) 500-6500 (20-256) 380/400/415 440/460/480 32 24 3295 (7264) 2255 (4971)
3780x1400x632 (149x55x24.9) 3300x1400x632 (130x55x24.9)

SD/SI-80
40 40 120 140-1400 (5.5-55) 500-6500 (20-256) 380/400/415 440/460/480 32 24 3420 (7540) 2385 (5258)
4250x1386x990 (167x55x39) 3240x1386x890 (128x55x35)

SD/SI-100
50 50 150 140-1400 (5.5-55) 500-6500 (20-256) 380/400/415 440/460/480 32 24 4250x1386x1090 (167x55x43) 3240x1386x990 (128x55x39)

SD/SI-120
60 60 180 100-1000 (4-40) 500-6500 (20-256) 380/400/415 440/460/480 32 24 4100x1400x830 (161x55x33) 3600x1400x790 (142x55x31)

Cable length, control box, m (in.)


76

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

Handling Equipment

SD 5-100 DB and SI 5-100 IB


Self-aligning roller beds with rail bogie
Robust design with durable rollers. Gritblasted steelwork with polyurethane finished coating to endure the abrasive environment of offshore and marine industries. Oversized bearings. 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
Drive unit Roller bed SD-5-DB Roller bed SD-10-DB Roller bed SD-20-DB Roller bed SD-40-DB Roller bed SD-60-DB Roller bed SD-80-DB Roller bed SD-100-DB Roller bed SD-120-DB Idler unit Roller bed SI-5-IB Roller bed SI-10-IB Roller bed SI-20-IB Roller bed SI-40-IB Roller bed SI-60-IB Roller bed SI-80-IB Roller bed SI-100-IB Roller bed SI-120-IB
SD-40-DB SI-40-IB
20 20 60 130-1300 (5-51) 300-3000 (11.8-118) 300-6500 (11.8-256) 380/400/415 440/460/480 16 24
3780x1600x1855 (149x63x73) 3300x1600x1475 (87.5x50x51.5)

0370 250 064 0370 250 066 0370 250 068 0370 250 070 0370 250 072 0370 250 074 0370 250 076 0370 250 097 0370 250 065 0370 250 067 0370 250 069 0370 250 071 0270 250 073 0370 250 075 0370 250 077 0370 250 098
SD-80-DB SI-80-IB
40 40 120 130-1300 (5-51) 300-3000 (11.8-118) 500-6500 (20-256) 380/400/415 440/460/480 32 24
4305 (9490) 3140 (6923) 4250x1538x1710 (167x61x67) 3240x1538x1560 (128x61x61.4)

Options & Accessories


Foot pedal 0370 250 301
SD-5-DB SI-5-IB
2.5 2.5 7.5 130-1300 (5-51) 300-3000 (11.8-118) 300-6500 (11.8-256)
50Hz, 3ph 60Hz, 3ph

Technical data
Max loading capacity, Drive unit Idler unit ton/section Turning capacity, ton Turning speed, mm/min (ipm) Travel speed, mm/min (ipm) Workpiece diameter, mm (in.) Mains supply, V Fuse, A Control voltage, V AC Weight, kg (lbs.) Dimensions LxHxW, mm (in.)
Drive unit Idler unit Drive unit

SD-10-DB SI-10-IB
5 5 10 130-1300 (5-51) 300-3000 (11.8-118) 300-6500 (11.8-256) 380/400/415 440/460/480 16 24
1400 (3086) 920 (2028) 3080x1200x1210 (121x47x47.6) 3080x1200x1050 (121x47x41.3)

SD-20-DB SI-20-IB
10 10 20 130-1300 (5-51) 300-3000 (11.8-118) 300-6500 (11.8-256) 380/400/415 440/460/480 16 24
1620 (3571) 1090 (2403) 3600x1200x1210 (142x47x47.6) 3600x1200x1050 (142x47x41.3)

SD-60-DB SI-60-IB
30 30 100 130-1300 (5-51) 300-3000 (11.8-118) 500-6500 (20-256) 380/400/415 440/460/480 32 24
4000 (8818) 2700 (5952) 3780x1600x1855 (149x63x73) 3300x1600x1475 (87.5x50x51.5)

SD-100-DB SI-100-IB
50 50 150 130-1300 (5-51) 300-3000 (11.8-118) 500-6500 (20-256) 380/400/415 440/460/480 32 24
4250x1538x1850 (167x61x73) 3240x1538x1700 (128x61x67)

SD-120-DB SI-120-IB
60 60 150 130-1300 (5-51) 300-3000 (11.8-118) 500-6500 (20-256) 380/400/415 440/460/480 32 24
4100x1600x2055 (161x63x81) 3600x1600x1675 (142x50x66)

380/400/415 440/460/480 16 24
1180 (2601) 880 (1940) 3100x1200x1210 (122x47x47.6) 3100x1200x1050 (122x47x41.3)

Cable length, control box, m (in.)


77

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

10 (394)

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 520.7 x 177.8 mm (20.5 x 7 in.). Ideal for: - Wind tower fabrication - Vessels - Pipemills

Ordering Information
FUB 30 FUB 60 0370 250 931 0370 250 932

Technical Data
Max. loading capacity, ton Min. workpiece diameter, mm (in.) at 90 included angle Max. workpiece diameter, mm (in.) at 30 included angle Roller speed, mm/min (ipm) Control voltage, V DC Mains supply, 50 Hz, 3-phase, V 60 Hz, 3-phase, V Travel car bogie Travel car speed, mm/min (ipm) Travel car drive, AC kW Power pack rating, kW Enclosure class (motor) Enclosure class (electrical) Pump, cc Tank capacity, l (gal.) Weight, kg (lbs.)
78

FUB 30 30 610 (24) 6435 (253.3) 130-1295 (5-51) 24 380/400/415 400/460/480 yes 238-2380 (9.4-94) 1.1 1.5 IP55 IP43 2.1 16 (4.23) 5250 (11575)

FUB 60 60 610 (24) 6435 (253.3) 130-1295 (5-51) 24 380/400/415 yes 240-2400 (9.5-95) 2.2 1.5 IP55 IP43 2.1 16 (4.23) 7360 (16226)

Handling Equipment

RT3 - RT35

Two-axis positioner for rotating and tilting workpieces


Continuous (stepless), adjustable speed. Low voltage (24V) 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
Positioner RT3 Positioner RT5 Positioner RT10 Positioner RT15 Positioner RT20 Positioner RT35 0370 250 851 0370 250 852 0370 250 853 0370 250 854 0370 250 855 0370 250 856

Options & Accessories


Foot pedal 0370 250 298

Technical Data
Max. loading capacity, ton Rotation motor, kW Rotation cont AC inverter, kW Rotation speed, rpm Tilting range table plate, Tilting speed, sec. Tilting motor c/w brake Mains supply, 50 Hz, 3-ph, V 60 Hz, 3-ph, V Fuse, A Control voltage, V AC Table plate diameter, mm (in.) Max. welding current, A Enclosure class Weight, kg (lbs.) Dimensions LxWxH, mm (in.) Cable length, control box, m (in.)
79

RT3 3 1.5 1.5 0.1-1.0


0-135

RT5 5 2.2 2.2 0.08-0.82


0-135

RT10 10 4 4 0.048-0.48
0-135

RT15 15 5.5 5.5 0.1-1.0


0-135

RT20 20 9.2 11 0.048-0.48


0-135

RT35 35 11 11 0.029-0.29
0-90

80 1.5 380/400/415 440/460/480 16 24 1200 (47) 800 IP55 1570 (3461)


1625x1070x1057 (64x42x41)

113 2.2 380/400/415 440/460/480 18 24 1500 (59) 1000 IP55 2720 (5996.5)
1720x1590x1227 (68x62.5x48)

177 4 380/400/415 440/460/480 25 24 1800 (71) 1000 IP55 4530 (9987)


2453x2070x1586 (96.5x81.5x62.4)

120 7.5 380/400/415 440/460/480 40 24 1800 (71) 1000 IP55 7100 (15653)
2800x2190x1840 (110x86x72.5)

177 9.2 380/400/415 440/460/480 60 24 2200 (87) 1000 IP55 10000 (22046)
3050x2400x1850 (120x94.5x73)

105 7.5 380/400/415 440/460/480 60 24 2800 (110) 1000 IP55 17000 (37479)
1940x2950x2600 (76x116x102)

6 (236)

6 (236)

6 (236)

10 (394)

10 (394)

10 (394)

Handling Equipment

TAP 1T-STD / TAP 3T-STD and TAP 1T-HD / TAP 3T-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 with fewer components for easier maintenance and fewer spare parts. Compared with TAP-STD, the TAP-HD have higher rotation torque, smaller backlash on table top and are more stable on front back swaying. Ideal for: - Pipe shops - Vessels - Cladding of dish ends - Fuel tanks

Ordering Information
Positioner TAP 1T-STD Positioner TAP 3T-STD Positioner TAP 1T-HD Positioner TAP 3T-HD 0370 250 750 0370 250 751 0370 250 753 0370 250 754

Options & Accessories


Foot pedal 0370 250 298

Technical Data
Max. loading capacity, ton Max. rotational torque, Nm Tilting torque, Nm Rotation speed, rpm Tilting range table plate, degree Tilting range arm, degree Mains supply 50/60 Hz, 3ph, V Fuse, A Control voltage, V AC Table plate diameter, mm (in.) Max. welding current, A Weight, kg (lbs.) Dimensions, LxWxH, mm (in.) Cable length, control box, m (in.)
80

TAP 1T-STD 1 750 4070 0.1-1.5 0-135 0-45 400 16 24 900 (35.4) 800 782 (1724) 1875x1023x751 (73.8x40.3x29.6) 6 (236)

TAP 1T-HD 1 2730 4070 0.1-1.5 0-135 0-45 400 16 24 900 (35.4) 800 782 (1724) 1620x1124x773 (63.8x44.3x30.4) 6 (236)

TAP 3T-STD 3 1250 9980 0.06-0.6 0-135 0-45 400 16 24 1000 (39) 800 1500 (3307) 2040x1268x1019 (80.3x49.9x40.1) 6 (236)

TAP 3T-HD 3 4860 9980 0.06-0.6 0-135 0-45 400 16 24 1000 (39) 800 1500 (3307) 2282x1280x1045 (89.8x50.4x41.1) 6 (236)

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
Max loading capacity, ton Vessel size, mm (in.) Roller type Roller size, mm (in.) Weight, kg (lbs.) Dimensions, LxWxH, mm (in.)

MTS1 1 100-610 (3.94-24.02) PU Black 150 (5.9) 198 (436.5) 635x1020x500 (25x40.2x19.7)

MTS3 3 150-914 (5.9-36) PU Black 200 (7.87) 335 (738.5) 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 in.). A manually operated hydraulic system sets the rollers for the desired diameter.

Ordering Information
Pipe rotator HTS-3T 0370 251 044

Technical Data
Max loading capacity, ton Workpiece size, mm (in.) Roller size, mm (in.) Weight, kg (lbs.) Dimensions, LxWxH, mm (in.)
81

MTS3 3 100-1000 200 (7.87) 345 (761) 1500x1100x710 (59x43.3x28)

Handling Equipment

LLR-500P / LLR-500I and LLR-3000P / LLR-3000I


Conventional roller beds for small workpieces
Ideal handling equipment for lightweight workpieces. Continuous (stepless) adjustable speed. Supplied with a low-voltage foot pedal with Start/Stop function. Mechanically and electrically designed for easier maintenance and fewer spare parts. Ideal for: - Manufacturing of cylindrical objects - Pipe shops

LLR 500P and LLR 500I

Ordering Information
LLR-500P, drive unit LLR-500I, idler unit LLR-3000P, drive unit LLR-3000I, idler unit 0370 250 190 0370 250 191 0370 250 196 0370 250 197

LLR 3000P and LLR 3000I

Technical Data
Max loading capacity, kg (lbs.) Turning capacity, kg (lbs.) Turning speed, mm/min (ipm) Workpiece diameter, mm (in.) min (150), max (60) Mains supply, 50Hz 1ph, V Motor, W Control voltage, V AC Weight, kg (lbs.) Dimensions LxHxW, mm (in.) Drive unit Idler unit Drive unit Idler unit Cable length, control box, m (in.)
82

LLR-500 Drive unit Idler unit Drive unit 250 (551) 250 (551) 750 (1653) 0-4420 (174) 50-1000 (1.97-39.4) 220 100 24 60 (132) 45 (99)
1120x322x300 (44.1x12.7x11.8) 960x322x200 (37.8x12.7x7.9)

LLR-3000P 1500 (3307) 1500 (3307) 4500 (9921) 0-4000 (157.5) 286-1006 (11.3-39.6) 220 100 24 109 (240) 71 (157)
1260x413x405 (49.6x16.3x15.9) 950x413x340 (37.4x16.3x13.4)

3 (118)

3 (118)

Handling Equipment

LLP-200, LLP-500, LLP-750 and LLP-1000


Two axes positioner
Ideal handling equipment for lightweight workpieces. Continuous (stepless) adjustable speed. Supplied with a low-voltage foot pedal with Start/Stop function. The LLP positioners have 2 axes. The LLP-200 has manual tilting adjustment while the LLP500, LLP-750 and LLP-1000 have motorized tilting. The 2-axes operation provide an ideal ergonomic position. Mechanically and electrically designed for easier maintenance and fewer spare parts. Ideal for: - Pipe shops - Repair

Ordering information
Positioner LLP-200 Positioner LLP-500 Positioner LLP-750 Positioner LLP-1000 0370 250 202 0370 250 203 0370 250 204 0370 250 205

Technical data
Max loading capacity, turning, kg (lbs.) Max loading capacity, tilting, kg (lbs.) Rotation speed, rpm Tilt range, degree Mains supply (50Hz/1-phase), V Mains supply (50Hz/3-phase), V Control voltage, V AC Rotation drive motor, W Earthing, A Table plate diameter, mm (in.) Dimensions, LxWxH, mm (in.) Cable length foot pedal, m (in.)
83

LLP-200 200 (441) 200 (441) 0.6-6 0 - 90 220 24 0.065


300

LLP-500 500 (1102) 500 (1102) 0.2-2 -45 - 90 220 24 150


300

LLP-750 750 (1653) 750 (1653) 0.09-0.9 -45 - 90 380 24 550


600

LLP-1000 1000 (2205) 1000 (2205) 0.09-0.9 -45 - 90 380 24 750


600

400 (15.7) 400x550x540 (15.7x21.7x21.3) 3 (118)

620 (24.4) 620x680x817 (24.4x26.8x32.2) 3 (118)

900 (35.4) 900x1100x1230 (35.4x43.3x48.4) 3 (118)

900 900x1140x1390 (35.4x44.9x54.7) 3 (118)

Handling Equipment

LLP-50H and LLP-150H


Two axes positioner with center hole
Ideal for rotating and tilting lightweight workpieces. Continuous (stepless) adjustable speed. Supplied with a low-voltage foot pedal with Start/Stop function. The LLP-H positioners have 2 axes, motorized rotation and manual tilting. The center hole is 120 mm (4.7 in.). The 2-axes operation provides an ideal ergonomic position. Mechanically and electrically designed for easier maintenance and fewer spare parts. Ideal for: - Pipe shops - Repair

Ordering Information
Positioner LLP-50H Positioner LLP-150H 0370 250 200 0370 250 201

Technical Data
Max loading capacity, turning, kg (lbs.) Max loading capacity, tilting, kg (lbs.) Rotation speed, rpm Tilt range, degree Mains supply (50Hz/1-phase), V Control voltage, V AC Rotation drive motor, W Earthing, A Table plate diameter, mm (in.) Table hole diameter, mm (in.) Dimensions, LxWxH, mm (in.) Cable length foot pedal, m (in.)

LLP-50H 50 (110) 50 (110) 0 - 4.5 90 220 24 60


200

LLP-150H 150 (330) 150 (330) 0 - 4.5 90 220 24 65


200

450 (17.7) 120 (4.7) 530x486x500 (20.9x19.1x19.7) 3 (118)

450 (17.7) 120 (4.7) 600x486x560 (23.6x19.1x22) 3 (118)

84

Handling Equipment

LLT-250 and LLT-750


Turntables
Ideal for rotating lightweight workpieces. Assures easy access for welding and assembly. Continous (stepless) adjustable speed. Supplied with a low-voltage foot pedal with Start/Stop function. For improved productivity and quality.

Ordering Information
Turntable LLT-250 Turntable LLT-750 0370 250 210 0370 250 211

Technical Data
Max loading capacity, kg (lbs.) Rotation speed, rpm Mains supply (50Hz/1-phase), V Control voltage, V AC Rotation drive Table plate diameter, mm (in.) Dimensions, LxWxH, mm (in.) Cable length foot pedal, m (in.)

LLT-250 250 (551) 0 - 4.5 220 24 DC 100W 500 (19.7) 600x500x310 (23.6x19.7x12.2) 3 (118)

LLT-750 750 (1653) 0.08 - 0.8 220 24 AC 0.75 kW 620 (24.4) 716x810x537 (28.2x31.9x21.1) 3 (118)

Chuck LLC

3-Claw chuck for ESAB low load positioning equipment


Used as a support in combination with ESAB low load positioning equipment for lightweight workpieces. Designed for easy maintenance and assembly.

Ordering Information
Chuck LLC, 3-claw chuck 0370 250 209

Technical Data
External diameter, mm (in.) External height, mm (in.) Clamping range (alt 1), mm (in.) Clamping range (alt 2), mm (in.) Weight, kg (lbs.)
85

Chuck-125 83 (3.3) 200 (7.9) 10 - 230 (0.39-9) 10 - 250 (0.39-9.8) 7.5 (16.5)

Special Applications

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 pressure to join two components together by using a rotating tool, which under high pressure, moves along the joint, thereby creating a weld. FSW is ideal for joining straight profiles and flat plates from 1.2 to 130 mm (0.045 - 1.18 in.) with full penetration. Butt, lap and corner joints can be welded.

Key benefits Suitable applications


Shipbuilding / Offshore platforms Aerospace industry Railway wagons, streetcars, underground train carriages Automotive industry Production of electric motors Defense industry Cooling elements Basically all aluminum, copper and magnesium alloys can be Friction Stir welded with high quality and speed. Minimal distortion and shrinkage No joint preparation - degreasing only No grinding, polishing or straightening No repair welding Reduced weight (40% less than GMAW) High joint-gap tolerance Consistent weld quality Increased tensile strength Outstanding fatigue properties No fumes, sparks or spatter Low noise level Simple operation (HMI) Improved repeatability

SuperStir Friction Stir Welding System


The ESAB SuperStir range is designed for high-volume production of large aluminum 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 defense and aerospace.
88

Special Applications

Legio Friction Stir Welding


A modular Friction Stir Welding system
The modular system makes it possible to assemble welding stations to suit the most varied Friction Stir welding applications. In a series of seven sizes there are five basic designs - S, ST, U, UT and double headed ST. The S-and ST-models are designed for linear welding (x and z), U-and UT-models for 2-D (x-y and z) and double headed versions are for welding hollow profiles. 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 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. All machines are designed with a rigid framework for high performance during load conditions. The welding head travels on heavy-duty linear bearings and is driven by a rack and pinion drive system. All LEGIOTM machines have an ESAB HMI (Human Machine Interface) control system, specially developed for Friction Stir Welding. Control the welding process (the vertical Z-axis) either by force or position control; a hydraulic cylinder with a closed loop system controls the Z-axis.

Ordering Information
For ordering information, please contact your nearest ESAB representative.

Technical Data
Welding depth, mm (in.) Al 6000 mm (236 in.) Al 5000 mm (197 in.) Al 2000 mm (79 in.) Al 7000 mm (275.5 in.) Cu (oxygen free) Max. welding speed, m/min (ipm) Vertical down force, kN

FSW 1 3 (0.12) 2 (0.08) 1.5 (0.06) 1.5 (0.06) 0.8 (0.03) 2 (79) 6

FSW 2 5 (0.20) 3.5 (0.14) 2.5 (0.10) 2.5 (0.10) 1.5 (0.06) 2 (79) 12.5

FSW 3 10 (0.40) 7 (0.28) 5 (0.20) 5 (0.20) 3 (0.12) 2 (79) 25

FSW 4 18 (0.71) 10 (0.40) 9 (0.35) 9 (0.35) 7 (0.28) 2 (79) 60

FSW 5 35 (1.38) 20 (0.80) 18 (0.71) 18 (0.71) 12 (0.47) 2 (79) 100

FSW 6 60 (2.36) 40 (1.57) 25 (0.98) 25 (0.98) 25 (0.98) 2 (79) 150

FSW 7 100 (3.94) 75 (2.95) 70 (2.75) 70 (2.75) 40 (1.57) 2 (79) 200

89

Special Applications

Rosio Friction Stir Welding Robot


Friction Stir Robot for welding challenging joints
The ESAB Friction Stir Welding robot system enables flexible joining of complex structures, ideally aluminum. The ability to perform welds in an arbitrary direction of a 3-dimensional workspace increases the possibilities of usage for new challenging FSW applications. The cell consists of an ABB IRB 7600 robot, modified for the purpose of FSW. The welding equipment is integrated in the mechanical structure of the robot without limiting the robots standard working envelope. The robots reachable workspace spans over 2.5 meters (8.2 ft.), in which a down force of up to 13 kN may be applied during welding. Running on the state-of-the-art control system IRC5, an embedded force control solution allows in-contact motions with high accuracy. An extension to the standard motion programming language is included - this extension includes instructions for welding linear in arbitrary directions, circular and square shaped paths, as well as functionalities to support custom made path programming and spindle operations. To provide valuable feedback to the operator, a manmachine-interface is included extending the IRC5s own interface on the Flex Pendant, based on WinCE.

Ordering Information
For ordering information, please contact your nearest ESAB representative.

Technical Data
Welding depth, mm (in.) Al 6000 mm (236 in.) Al 5000 mm (197 in.) Al 2000 mm (79 in.) Al 7000 mm (275.5 in.) Welding speed, m/min (ipm) Spindle rotation, max rpm Vertical down force, kN Spindle torque (stall), Nm Robot reach, mm (in) Robot base dimension, LxW mm (in.) Robot weight, kg (lbs.) Cabinet dimension, LxWxH mm (in.) Cabinet weight, kg (lbs.) Mains supply, V, 50 Hz
90

1-7 (0.04-0.28) 1-6 (0.04-0.24) 1-5 (0.04 - 0.20) 1-5 (0.04 - 0.20) >1 (>39.4) 3000 13 44 2550 (100) 1206.5 x 1200 (47.5 x 47) 2500 (5511.5) 2160 x 725 x 710 (85 x 28.5 x 28) 250 (551) 400

Special Applications

Hybrio - Hybrid Laser Welding


Lighting the way
ESABs 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 gas metal arc welding (GMAW) in combination with a laser, the Hybrio process overcomes the limitations of laser-only welding with its ability to produce quality 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 welds metallurgical properties and create beads and fillets, while the slower cooling rate reduces hardness. These features are especially beneficial when joining high performance carbon and stainless steels. ESABs 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.
GMAW Laser-Only Hybrid Laser Welding

Graphic illustrating differences between GMAW, Laser and Hybrid Laser Welding weld profiles.

The Hybrio Advantage:


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 simple, PC-machine controller. Lower downstream assembly, welding and finishing costs, through reduced part distortion. Higher overall plant throughput and revenue generation. Feasibility of new, lighter, stiffer and simpler product design and construction methods. Full backing and support of ESABs process experts and service professionals, with extended warranty and service agreements.

Ordering Information
For more information, please contact your nearest ESAB representative.

91

Special Applications

Hybrio - Hybrid Laser Welding


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 envelopes up to 4 m x 20 m (13 ft x 67 ft) 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 a large variety of product geometries and weld joint configurations.

Hybrio Beam
The Hybrio Beam hybrid laser beam welding system is based upon ESABs 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 pressed 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 on 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


ESABs 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.

92

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.). Meets the demands for a fully automatic welding process with accurate controlling of all parameters for reduced welding times and perfect weld metal when welding hightensile material. Designed around the flat, welding nozzle. The reciprocating movement of the nozzle is accomplished by means of a pneumatic three position cylinder and is transferred from cylinder to nozzle through a shaft transmission system. The welding head is equipped with separate joint tracking system for vertical and horizontal joint tracking, respectively. Automatic shift overlap. Possible to weld up to 50 mm (1.97 in.) joint width. Air-cooled torch High productivity. Optional WeldLog - computer program for welding supervision and documentation.

Technical Data
Weld joint type Wire dimension, mm (in.) Wire feed motor Max. wire feed speed, m/min (ipm.) Max welding current DC, A Max welding current AC, A Beads in each layer Deposition rate, kg/h (lbs./h) Tilting angle of weld nozzle Max. joint depth, mm (in.) Joint width, mm (in.) Wire angle between wires Distance between wires, mm (in.) Accuracy of joint tracking, mm (in.) Max heat resistance, workpiece, C (F) Min weld diameter, mm (in.) Flux hopper unit Flux hopper capacity, l (gal.) Min clearance internal weld - Longitudinal, mm (in.) - Circumferential, mm (in.) Butt 3-4 (0.12-0.16) A6 VEC 156:1, 4000 rpm 4 (157) 800 800 2-4 approx. 7/16 (15.4/35.3) (Single/Tandem) 3.5 350 (13.8) 18-50 (0.71-1.97) 15 15 (0.59) (valid for 30 mm (1.18) stick-out) 0.15

Ordering Information
For more information, please contact your nearest ESAB representative.

300 (572) 500/1200 (19.7/47.2) Single/Tandem OPC Super approx. 10 (2.64) 1500 (59.06) 1500 (59.06) 140/165 (309/364) (Single/Tandem)

Double-sided joint tracking

Weight, kg (lbs.)

93

Special Applications

AGW1 and AGW2


Single-side & Double-side tank welder


Self-propelled, 3 oclock welding equipment primarily developed for on-site erection of large storage tanks, silos, blast furnaces and similar cylindrical objects. Available as single-side and double-side versions. Designed to travel along the top edge of the tank shell. With the double-side version, the operator 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 maximum safety and comfort. The cage can be covered by curtains for protection against weather. The cabin on the double-side version is equipped with step ladders and a joining bridge at the top for operators to climb aboard. The bridge has guard rails for operator safety.

Ordering Information
AGW1, tank welder, single-side AGW2, tank welder, double-side 0370 250 700 0370 250 701

Options & Accessories


AGW1 transportable stand AGW2 transportable stand Cable set, 95 mm2, 100 m (75+25) Cabin light 0370 250 703 0370 250 704 0370 250 705 0370 250 706

Technical Data
Max. load, kg (lbs) Shell height, m (in.) Height increment, mm (in.) Max. shell thickness, mm (in.) Min. side clearance, mm (in.) Travel speed, mm/min (ipm) Flux hoist (max), kg (lbs.) Dimensions, LxWxH, mm (in.) Weight, kg (lbs.)
94

AGW1 300 (661) 1.8-3.5 (71-138) 100 (4) 50 (2) 1450 (57) 244-2440 (10-96) 70 (154) 1440x5836x2102 (5x19x7) 1300 (2866)

AGW2 300 (661) 1.8-3.5 (71-138) 100 (4) 50 (2) 1450 (57) 278-2780 (11-110) 70 (154) 2210x5836x2120 (7.25x19x7) 1460 (3219)

Special Applications

Beam Welding - Pull Through Welders


For welding 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 nonsymmetrical 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:

Examples of beams than can be welded:

Total range of beam sizes that can be welded:


Machine type
Beam welder IT-258

Web 200-2500 mm (7.8-98.4 in.) 200-1500 mm (7.8-59 in.)

Flange 100-800 mm (4-31.5 in.) 100-800 mm (4-31.5 in.)

IT-258 IT-158

95

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 submerged arc welding (SAW) applications which are particularly suitable for pipe welding.

Precise, high-speed longitudinal welding


Our concept for longitudinal SAW is suitable for pipes in a normal diameter range of 508-1626 mm (20-64 in.), 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 and 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.
Internal welding

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.

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.

External welding

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.

Ordering Information
For more information, please contact your nearest ESAB representative.

96

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.

Submerged arc welding of flanges and supports.

Rolling, forming and tack welding of the shell.

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.

External longitudinal submerged arc welding using a column and boom.

Automatic welding of the door frame.

Internal longitudinal submerged arc welding using a column and boom.

Production of sub-components using an ESAB positioner and manual welding equipment.

97

Special Applications

ESAB Retrofit

System upgrades for a modern solution


ESABs service group can upgrade any brand of existing equipment to virtually new condition, with the latest process equipment 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 determine 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 to any carrier. ESAB Retrofit is an ideal alternative to investment in new equipment. In addition to increased availability, a conversion of this kind frequently leads to a substantial rise in productivity and quality, not to mention improvements to the working environment. ESAB works with many OEMs for equipment - specify the ESAB process system and accessories and get the advantage of ESAB performance from your existing machinery.

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, flash butt welding machines, etc. 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.

98

Filler Metals

Filler Metals

Gas Metal Arc Welding (GMAW)


Process
Gas Metal Arc Welding (GMAW), also known as MIG welding. Arc is maintained between a continuous solid wire electrode and the workpiece. Arc and weld pool are shielded by a stream of inert or active gas. The process is suitable for most materials and filler wires are available for a wide range of metals. Versatile process, which can deposit weld metal at a very high rate in all positions. Widely used on light to medium gauge steel fabrications and on aluminum alloy structures, particularly where high-rate manual operator production is required.

Advantages
Easy to mechanize or adapt to a robot. Cost-effective method for process automation on thin materials. Available in a wide array of diameters and packages for any requirement. High deposition efficiency, up to 98%.

Selected Product*
Mild Steel Spoolarc 65 AWS Class ER70S-2 Features & Typical Applications

Spoolarc 29S Spoolarc 86

ER70S-3 ER70S-6

Copper-coated, triple deoxidized carbon steel wire Designed for welding over rust and mill scale Preferred wire for positional welding of small diameter pipe Copper-coated carbon steel wire for general purpose applications including heavy equip Copper-coated carbon steel wire with higher tolerance to rust and mill scale than Often used for butt and fillet welding applications including heavy equipment, structural,
ER70S-3 ment, automotive applications and sheet metal

OK Aristorod 12.50

ER70S-6

Non-copper-coated carbon steel wire ASC (advanced surface characteristic) technology provides lower spatter levels, superior Copper-coated carbon steel wire with optimized manganese and silicon ratio to produce Widely used in robotic welding applications in the automotive industry Copper-coated low-alloy steel wire 0.5% Mo for higher welding deposit strength Often used for high tensile tubing and pipe as well as earth moving and construction
equipment weld beads with excellent appearance feedability and welding performance for robotic or automated welding

automotive and general carbon steel fabrication

Spoolarc 87HP

ER70S-7

Spoolarc 83

ER80S-D2

Stainless Steel OK Autrod 308LSi OK Autrod 309LSi OK Autrod 316LSi Aluminum OK Autrod 4043, 5356 ER4043, ER5356 ER308Si/308LSi ER309Si/309LSi ER316Si/316LSi

Full range of stainless steel welding wires for any application All OK Autrod stainless steel solid wires have a matte finish to improve feedability and
provide a smooth, stable arc

Full range of aluminum alloys to meet any requirement All ESAB wires are manufactured with a patented process to optimize feeding characteristics

*Small representation of full product line. Please contact ESAB for more information.
102

Filler Metals

Flux Cored Arc Welding (FCAW)


Process
Flux Cored Arc Welding (FCAW) and Metal Cored Arc Welding (MCAW) are similar to GMAW as far as operation and equipment are concerned. The main difference between FCAW/MCAW and GMAW is that the wire is not solid, but consists of a metal sheath surrounding a flux core. Wire begins as a flat metal strip which is formed into a U shape. Flux and alloying materials are deposited into the U which is then closed into a tube by a series of forming rolls.

Advantages
High deposition rates and efficiency, up to 98%. Excellent weld bead appearance with little or no spatter. Deep arc penetration when welding - allows tighter joint design, reducing quantity of filler metal needed to fill the joint.

Wide selection of alloys available. Metal cored wires have high current capacity and produce little to no slag - very high weld efficiency and deposition rates are possible.

Selected Product*
Flux Cored Wires Dual Shield R-70 Ultra AWS Class E70T-1/9 Features & Typical Applications

Dual Shield 7100 Ultra

E71T-1/1M/9/9M

Dual Shield II 712X

E71T-MJH8/12MJH8

Flat and horizontal positions, low fuming wire Single or multi-pass welding on carbon steels Uses CO gas only All-position, low fuming wire Single or multi-pass welding on carbon steels Uses CO or Ar/CO gas mixtures All-position, low fuming wire with wide operating range Provides excellent low temperature toughness in as-welded and/or stress-relieved condi2 2 2

Uses 75% Ar/25% CO


Mild Steel Metal Cored Wires Coreweld 77-HS E70C-6MH4

tions at -40oC (-40oF)

gas only

Coreweld C-6

E70C-6MH4

High deposition efficiency, up to 98% Smaller diameters, up to 1/16 in., can be used out of position Ideal for robotic applications Uses Ar/CO gas only Developed for handheld, automatic, and robotic welding Ideal for flat or horizontal fillet welds Performs well with Ar/CO shielding gas mixes from 75%-92% Ar
2 2

Stainless Steel Cored Wires Shield-Bright 308L Shield-Bright 309L Shield-Bright 316L E308LT1-1/T1-4 E309LT1-1/T1-4 E316LT1-1/T1-4

Full line of stainless steel flux cored wires designed for flat and horizontal or all-position
welding

*Small representation of full product line. Please contact ESAB for more information.
103

Filler Metals

Submerged Arc Welding (SAW)


Process
Arc is struck between the workpiece and the end of a consumable electrode, both of which are covered by a layer of granular flux covering the arc. Some of the flux melts to provide a protective slag cover over the weld pool; the remainder can be collected for re-use. Principally carried out with fully automated equipment. For increased productivity, cored wires or arrangements of multiple solid wires can be introduced. Because of its high metal deposition rate, it is particularly suited to long straight joints of good quality in the flat position. It is widely used in the pressure vessel, chemical plant, heavy structural, repair and shipbuilding industries and wind mill tower fabrication.

Advantages
Very high deposition rates and travel speeds. Excellent and consistent weld quality. Deep arc penetration when welding - allows tighter joint design, increasing productivity and reducing amount of filler metal needed to fill the joint. Operating factor can approach 100%. No fumes or arc radiation.

Selected Product*
Wire Spoolarc 29S Flux OK Flux 429 OK Flux 10.71 Spoolarc 81 OK Flux 231 OK Flux 350 OK Flux 429 OK Flux 10.62 AWS Class F7A2-EM13K F7A4-EM13K F7A2-EM12K F7A2-EM12K F7A2-EM12K F6P4-EM12K F7A6-EM12K

Carbon steels, multi-pass; good mechanical properties and weld performance for general fabri Carbon steels, multi-pass; for general fabrication Excellent as-welded or stress relieved mechanical properties combined with good weld perfor Carbon and low-alloy steels, single pass only; high tolerance to rust and mill scale Applications include water heaters, rail cars and structural steel Carbon steels, single pass only; high tolerance to rust and mill scale Suitable for use with AC or DC power, single or multi-wire Applications include shipbuilding, thin wall pressure vessels and structural applications Carbon and low alloy steels, multi-pass; moderate tolerance to rust and mill scale Applications include bridge, ship, pressure vessel and general structural fabrication Carbon and low alloy steels, multi-pass; base plate must be free of rust and mill scale For use with AC or DC power up to 1000 A; exceptional impact toughness at low temperatures Ideal for critical applications including pressure vessels, offshore construction and structures Carbon and low alloy steels; multi-pass; moderate tolerance to rust and mill scale Improved mechanical properties compared to OK Flux 429 Ideal for narrow gap applications, shipbuilding, pressure vessels and spiral/longitudinal welding of line pipe Carbon and low alloy steels, multi-pass Excellent slag removal in narrow V-joints; excellent low temperature impact properties Designed for high current-carrying capacity, DC or AC, with single or multi-wire systems Ideal for windmill tower and pressure vessel construction Carbon and low alloy steels, multi-pass Used for welding pressure vessels and other applications requiring good mechanical properties Use OK Flux 10.62 for improved impact toughness Weathering and carbon steels with up to 1% nickel, multi-pass Ideal for bridge and structural welding Carbon steels, multi-pass Basic metal cored wire provides higher travel speeds; up to 30% increase in deposition rate compared to solid wire Excellent mechanical properties and impact properties at -46 C (-50 F) Provides stainless steel deposit to match corresponding welding alloy Basic non-alloying flux providing excellent welding properties and performance
o o

Features & Typical Applications


cations

mance

requiring good CTOD values

OK Flux 10.71 OK Flux 10.72

F7A5-EM12K F7A8-EM12K F6P8-EM12K F7A2-EM14K F7P4-EM14K F7A6-EM14K F7P6-EM14K F8A4-ENi1K-Ni1 F7A5-EC1-H8 N/A

Spoolarc 71

OK Flux 10.71 OK Flux 10.62

after stress relieving

Spoolarc 75 Alloy Shield 70S OK Autrod 308L/309L/316L

OK Flux 429 or OK Flux 10.71 OK Flux 10.71 OK Flux 10.93

104

Filler Metals

Strip Cladding
Process
Submerged Arc Welding (SAW) or Electroslag Welding (ESW) typically used for cladding large areas. Both methods offer a high deposition rate in terms of both kg/h and area coverage (m2/h), combined with low penetration and high deposit quality. Stainless steel strip cladding is widely used in the production of components for the chemical, petrochemical and nuclear industries.

SAW Strip Cladding


An electric arc is formed between the strip electrode and the workpiece. Flux is used to form a molten slag to protect the weld pool from the atmosphere and helps form a smooth weld bead surface.

ESW Strip Cladding


A development of SAW strip; established as a reliable high deposition rate process. An arc-less method using ohmic heating to melt the strip/ flux/parent material. Current flows through the strip electrode and a comparatively shallow layer of liquid electro-conductive slag. Penetration is lower for ESW than for SAW since the molten slag pool is used to melt the strip and some of the parent material rather than as an arc between the strip electrode and the parent material. ESW strip surfacing reduces dilution by up to 50% compared with SAW strip surfacing for the same heat input with a significantly higher deposition rate.

Advantages Reduces the need for expensive highly-alloyed base mate


rial, such as stainless steel or nickel-base alloys. Choose from a wide variety of parent materials and consumables. High deposition processes with low dilution. Allows for flexibility in the production of pieces in varying shapes and sizes.

Common ESAB Strip/Flux Combinations


Consumable %C %Si %Mn %Cr %Ni %Mo Other Ferrite Typical all weld metal composition using OK Flux 10.05
An agglomerated flux for SAW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo austenitic stainless types of strip. Slag removal and overlapping with this flux provides excellent results. Use with OK Band 308L, 309L, 316L. Basicity Index: 1.1

1. 308L overlay combination on 2.25 Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7 m/h OK Band 309L Weld composition 1st layer OK Band 308L Weld composition 2nd layer OK Band 309L Weld composition 1st layer OK Band 316L Weld composition 2nd layer 0.020 0.027 0.022 0.021 0.020 0.028 0.017 0.018 0.4 0.7 0.3 0.6 0.4 0.7 0.4 0.7 1.9 1.1 1.7 1.0 1.9 1.1 1.8 1.1 23 19 19.6 18.9 23 19 18.2 18 13 11.3 10.1 10.6 13 11 13.1 12.9 2.8 2.1 FN 5 FN 8 FN 5 FN 7

2. 316 overlay combination on 2.25 Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7 m/h

Typical all weld metal composition using OK Flux 10.10

An agglomerated flux for ESW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo types, with or without Nb-stabilization. Weldability, bead appearance and slag removal with this flux provides excellent results. Use with OK Band 309L ESW, 309LMo ESW and 309LNb ESW. Basicity Index: 4.0

1. 308L overlay combination on 2.25 Cr 1Mo steel, typical parameters: DC+, 1250A, 25V, 9 m/h OK Band 309L ESW Weld composition 1st layer OK Band 309LMo ESW Weld composition 1st layer
105

0.015 0.023 0.015 0.024

0.2 0.45 0.2 0.4

1.8 1.2 1.8 1.2

21 18.5 20 18

11.4 10 13.7 12

2.7 2.7

FN 6 FN 8

2. 316 overlay combination on 2.25 Cr 1Mo steel, typical parameters: CD+, 1250A, 25V, 9 m/h

Filler Metals

Packaged for Productivity



ESAB offers many different package types to meet almost any requirement. Standard packaging for ESAB solid and cored wires includes spools and coils. Bulk packages for mechanized, robotic and high production welding include Marathon Pac for mild steel, stainless steel and aluminum solid wires. Most cored wires are also available in a Marathon Pac. Submerged arc wire is available in coils and bulk drums. Submerged arc flux is available in standard plastic-lined bags and as a unique Big Bag bulk package.

Packaging Types Coils Standard package for most solid and Payoff Pac Large diameter drum, most often used
with SAW wires Package weights are typically 454 kg (1000 lbs.) Efficient solution for high productivity, stationary SAW welding stations

cored wires 27.2-29.5 kg (60-65 lbs.) of wire on a coil with a 300 mm (12 in.) internal diameter Coil adapter is required

Marathon Pac Bulk pack for 200-475 kg (450-1050 Reels Unique bulk solution for SAW wires 136 kg (300 lbs.) of wire on an adaptor
less wooden reel Often used with column and boom systems

lbs.) of solid or cored wire, up to 1.6 mm (1/16 in.) Wire wound into the drum using special technique Wire is straight and comes out of the gun without twisting or warping - ideal for robotic or mechanized welding stations Stopping for spool changes and maintenance are reduced by almost 95% for increased arc-on time Improves weld quality with reduced repair and rejects resulting in less weld defects Octagon drums are 100% recyclable

Eco-Coil Ideal for high-production fabrication inclu


106

ding wind towers and pipe mills holding 1000 kg (2200 lbs.) of wire in an economical and ecologically-friendly package The package is shipped around a cardboard core, shrink wrapped and strapped to the pallet for shipping Once received, the Eco-Coil is then removed from the pallet and placed on a one-way spider or stem for use The one-way spider is intended for reuse with future Eco-Coils by the fabricator

Big Bag Unique solution for bulk users of SAW

welding flux 500-1000 kg (1100-2200 lbs.) per bag Bag is made of layers of fabric, coated on the inside for moisture protection Discharge spout in the bottom of the bag with an opening that can be easily opened and reclosed by a rope Four strong straps for lifting by forklift or overhead crane

Unrivaled service and support.


Every ESAB product is backed by our commitment to superior customer service and support. Our skilled customer service department is prepared to quickly answer any questions, address problems, and help with maintenance and upgrading of your machines. With ESAB, you can be sure that you purchased a machine that will meet your needs today and in the future. Product and process training is also available. Ask your ESAB sales representative or distributor for a complete ESAB solution.

ESAB Welding & Cutting Products / esabna.com / 1.800.ESAB.123


USA: P.O. Box 100545, 411 South Ebenezer Road, Florence, SC 29501-0545 Canada: 6010 Tomken Road, Mississauga, Ontario L5T 1X9 Mexico: Ave. Diego Daz de Berlanga, No. 130, Col. Nogalar San Nicols de los Garza N.L. CP 66480 Monterrey, Mexico
The ESAB group is certified according to ISO 14001 & OHSAS 18001

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08/11