AC.pdf

Welding Automation

Since 1904, ESAB has been a

pioneer in the welding and

cutting business. By

continuously improving and

developing our products and

methods, we meet the

challenges of technological

advance in every sector we

operate in.

Our focus on quality issues has

always been strong. Quality is

an ongoing process that is at

the heart of all our production

processes and facilities

worldwide. With world

leadership comes worldwide

applications experience and

expertise. Multinational

manufacturing of welding

consumables and equipment

brings ESAB quality and

innovation closer to our

customers.

ESAB customers enjoy full and

personal access to an unrivalled

resource of technical and

applications knowledge, service

and support. With local

representation all over the

world, together with a network of

independent distributors, ESAB

brings practical expertise and

solutions to challenges involving

materials, welding, cutting and

overall productivity at local level.

World leader in welding and cutting

technology and systems.

Wherever in the world quality and productivity in welding and cutting counts, ESAB is there to set the standard.

ESAB- 100 years of providing

innovative welding and cutting solutions

Welding Automation

Quality Welds- Every TimeESAB offers the widest range of filler metals in the world.

Our goal is to provide the most productive filler metal for

your job. ESAB will meet the needs of any welding

process and application.

Total System ResponsibilityBecause we build the entire system, we can integrate the welding

process, arc path, and material handling. An integrated design

simplifies the equipment, improves reliability, and ensures

unsurpassed performance. Operator appeal is maximized through

simple, straightforward control panels. Because ESAB provides Total

System Responsibility, including the filler metals and technical

service, we ensure your project is successful.

The 21st Century has brought many new challenges to the metal fabrication industry. Metal fabricators must meet the

demand for increased quality while providing their customers with an overall lower cost. Productivity is challenged by the

shortage of skilled workers and the added health and safety concerns for these workers. Profitability is under continued

pressure from intense global competition. As a result, manufacturers are required to utilize new fabrication techniques to

build increasingly complex designs and structures.

ESAB is committed to providing the necessary solutions to keep you competitive. Whether your metal fabrication project requires simple components such as tractors or requires large turn-key systems and production lines, ESAB offers a full range of automation products to meet every need. At ESAB, we consistently offer the best welding solutions to meet the ever changing challenges of the metal fabrication industry.

TABLE OF CONTENTS

TractorsRailtrac ...................................................................................................................Miggytrac 1000 .......................................................................................................A2 Multitrac with PEH Process Controller ..............................................................A2 Multitrac with PEI Process Controller ................................................................A2 Multitrac Accessories ........................................................................................A2 Tripletrac ...........................................................................................................A6 Mastertrac .........................................................................................................A6 DK .....................................................................................................................A2/A6 Wear Parts ...................................................................................................

Controllers and Power SourcesPEH Process Controller .........................................................................................PEI Process Controller ...........................................................................................LAF DC Power Sources .........................................................................................TAF AC Power Sources ..........................................................................................

Weld HeadsA2S Mini Master .....................................................................................................A2 Component System Modularization ..................................................................A6S Arc Master ......................................................................................................A6 Component System Modularization ..................................................................A6S Tandem Welding Heads ..................................................................................A6S Compact Welding Heads ................................................................................A6 Strip Cladding Head ..........................................................................................

Accessory ComponentsA6 Synergic Cold Wire ...........................................................................................A2/A6 Beam Carriage ............................................................................................Motorized Slides .....................................................................................................Joint Tracking Systems ..........................................................................................OPC Flux Recovery Systems ................................................................................Flux Feed and Recovery Systems .........................................................................CRE Air Drying Equipment .....................................................................................JS 200 & JK 50 Flux Drying Equipment .................................................................Weldoc WMS4000 Software ..................................................................................

Handling EquipmentTA Turning Rolls .....................................................................................................TNA Turning Rolls ..................................................................................................TXA Turning Rolls ...................................................................................................AHMA Positioners ..................................................................................................SKA Positioners .....................................................................................................SHA Positioners .....................................................................................................VA Positioners ........................................................................................................CRA Positioners .....................................................................................................Head & Tailstock Postioners ...................................................................................

Page5-7

89

1011121314

15-17

18192021

22232425262728

293031

32-3334

35-36373839

4041424344454647

48-49

Mechanized TIGProwelder 160/320/450 ...........................................................................................Weld Heads-PRB, PRC, PRD, POC, PRH .............................................................A25 Component System .........................................................................................MEI 21 and 10 wire feeder ......................................................................................G-Tech Tungsten Grinder .......................................................................................Printer .....................................................................................................................OCF 2M Cooler ......................................................................................................

RoboticsAristo Process Package .........................................................................................

Applied AutomationMechTrac ...............................................................................................................Manipulators- CaB S,M,C versions ........................................................................External/Internal Seamers ......................................................................................Circotech ................................................................................................................Rototech 80 ............................................................................................................

Special Application ProductsWind Energy Industry .............................................................................................Beam Welding Systems ..........................................................................................Welding Gantries ....................................................................................................Shipyard Applications .............................................................................................Custom Welding Solutions ......................................................................................Friction Stir Welding ................................................................................................Narrow Gap ............................................................................................................Mechanized Cutting Systems .................................................................................

Filler MetalsMIG Welding ...........................................................................................................Cored Wire ............................................................................................................Submerged Arc Welding .........................................................................................Strip Cladding .........................................................................................................Marathon PacTM ......................................................................................................

TABLE OF CONTENTS

Page50-5152-57

5859606162

63-64

6566-7172-73

7475

76-7778-79

8081

82-8384-8586-8788-90

9192939495

TRACTORS

Railtrac 1000A unique, flexible, multi-purpose system for welding and cutting

5

Create suitable solutions for most applicationsConsists of aluminum and steel parts to with-stand harsh environmentsWelding possibilities include horizontal tohorizontal and vertical (up only)Practical accessories availableNew joint system allows for both stiff andflexible rail applicationsStraightforward and well designed programmingunit with up to 5 different programsStandard software offers programmable intervalwelding and backfill functionRemote control allows functionality withoutlifting welding visorButtons featured on remote control include:start and stop, shift program, weaving width,zero line displacement, and many moreAdjust the welding current and voltage duringwelding with only two potentiometers on theremote control (when using ESAB equipment)Remote control only available on FW1000 andFWR1000 models

Instruction Manual Railtrac 1000 (F, FR), order number .............. 777167001Instruction Manual Railtrac 1000 (FW, FWR), order number ....... 777168001Instruction Manual Railtrac 1000 (BV, BVR)), order number ....... 777169002Sales Literature Railtrac 1000 (F, FR), order number ............... XA00086720Sales Literature Railtrac 1000 (FW, FWR), order number ........ XA00086720Sales Literature Railtrac 1000 (BV, BVR), order number ......... XA00067820

6

Railtrac 1000System Configuration

Railtrac FWR1000 Flexi-Weaver Return

Equipped with weaving unitAdjustable start, stop and return facilitiesUnique design remote control unit with ad-vanced solutions for a number of applications

Railtrac F1000 Flexi

Flexible combi-railSuitable for both inside and outside welding and

cuttingCut along curved and straight surfacesSuitable for thermal cutting

Railtrac FR1000 Flexi-Return

Flexible combi-rail and facilities for movable parts

Start and stop for automatic return of lengthIdeal for use in fixed installations or repetitivewelding

Railtrac FW1000 Flexi-Weaver

Flexible combi-railEquipped with weaver- use for different patternsEquipped with a user friendly remote controlunit

TRACTORS

TRACTORS

7

Railtrac 1000System Configuration

Ordering Information

Railtrac F1000 Flexi ................................................................ 398 146 002Railtrac FW1000 Flexi Weaver ............................................... 398 146 012Railtrac FR1000 Flexi Return .................................................. 398 146 003Railtrac FWR1000 Flexi Weaver Return ................................. 398 146 013

TRACTORS

Miggytrac 1000The perfect complement to your MIG power source


Miggytrac 1000, 42 VAC ………............................. 457 357 880

Instruction Manual Miggytrac 1000, order number ........... 457572001Sales Literature Miggyrtrac 1000, order number ........... XA000865208

Small and compactAccomodates any standard welding torchFour-wheel drive system ensures even andstable movementDrives itself against work piecesAdditional functions include setting travelspeed (150 - 1200 mm/min; 6 - 47 ipm),magnet on/off for free welding and welding on/offEquipped with two manual slides for finecorrections of torch positionIncludes rotating slide which allows precisetorch angle manipulation

Options and Accessories

ESAB Control Cable, 5 m (16.4 ft) .......................... 457 360 880(12 pin male- 23 pin male Burndy style) For all MEK(also requires 457 462 880), ESABFeed, andAristoFeed feeders (also requires 458 757 881)

ESAB MEK Wire Feeder Adaptor Kit ...................... 457 462 880(Required for connection of Miggytrac to MEKfeeders)

ESAB AristoFeed Wire Feeder Adaptor Kit ........... 458 757 881(required for connection of Miggytrac toAristoFeed feeders)

Universal Control Cable, 5 m (16.4 ft) .................... 457 360 881(12 pin male Burndy style-open end)Requires user-supplied plug to connectcable to OEM feeders

Transformer Kit, 115-42 VAC ........................................ 359C304Universal kit used to adapt 115 VAC wirefeeders to Miggytrac

(mm)

A2 Multitrac (PEH)The universal welding tractor

Instruction Manual SAW, order number................................. 449165060Instruction Manual GMAW MTW 600, order number (MTW) 449165060Instruction Manual MTW 600, order number ........................ 449006001Sales Literature SAW, order number ................................. XA00105420Sales Literature GMAW, order number............................... XA00105520


A2 Multitrac GMAW ……...…………................................ 449 161 880A2 Multitrac GMAW MTW 600 ….................................... 449 161 881A2 Multitrac SAW …………............................................. 449 160 880

9

Compact and efficient design allows for easymovement between work piecesSelf-propelled, four-wheel drive for stable, accurate,and constant operationPEH Process Controller with digital display, allowspresetting and control of welding parameters (formore info on PEH Controller, see pg 18)Horizontal, vertical and rotary slides allow for quickadjustment of weld nozzle into various positionsReliable mechanical parts, even under harshenvironmentsFor use with LAF (DC) or TAF (AC) power sourcesMany specially developed accessories available

Options and AccessoriesAccessories ..............................................................................Feed rolls, contact tips ......................................................Power supplies ...................................................................Control cables .....................................................................

TRACTORS

page 11page 15-17page 20-21page 20-21

A2 Multitrac (PEI)The welding tractor designed for simplicity & versatility

10

Compact and efficient design allows for easymovement between work piecesSelf-propelled, four-wheel drive for stable,accurate, and constant operationPEI Process Controller allows simple setting oftravel speed, voltage, and wire feed speed (formore info on PEI controller, see page 19)Heavy duty feed unit ensures an even and stablewire feed, a prerequisite for top quality andhomogenous weldingHorizontal, vertical and rotary slides allow forquick adjustment of nozzle into various positionsReliable mechanical components, even underharsh working conditionsEasy to use control equipment with different startmethods: direct start or scratch startMany specially developed accessories availableCan be connected to most DC power supplies(contact ESAB for more information)


A2 Multitrac SAW …………………............................ 449 360 880A2 Multitrac GMAW ………………............................. 449 361 880

Instruction Manual A2 Multitrac, order number ............... 449365060Sales Literature A2 Multitrac, order number .................. XA00114220

TRACTORS


Accessories ........................................................................Feed rolls, contact tips ...............................................Power supplies ............................................................Control cables .............................................................


625

11

A2 Multitrac (PEH & PEI)

(PEH)(PEI)

(PEH)

Dimensions (mm)

261 (PEI)

TRACTORS

A2 TripletracFor internal circumferential welding

TRACTORS

12Instruction Manual A2 Tripletrac, order number ......................... 449435104Sales Literature A2 Tripletrac, order number .......................... XA00118420

Increase productivity and qualityIdeal for internal circumferential welding of largecylindrical objects that are rotating on a turning rollsystemHeavy duty feed unit secures an even and stablewire feed for a top quality and homogenous weldDelivered with either the digital A2-A6 ProcessController (PEH) or the analog A2 WeldingController (PEI)Unique steering system allows operator tosimultaneously adjust the wheel and torch positionfor an accurate and effortless seam trackingControl equipment is easy to use and requiresminimal trainingChoose between start methods, burn-back timesand other settings

Ordering InformationA2 Tripletrac with PEH .......................................... 449 430 880A2 Tripletrac with PEI ........................................... 449 430 881


Accessories ..................................................................Feed rolls, contact tips ...........................................Power supplies .......................................................Control cables .........................................................


A6 MastertracFor heavy duty arc welding


A6 Single Mastertrac, standard……...................................... 449 260 880 156:1 feed motor (wire feed speed range of 0.2-4.0 m/min; 8-157 ipm)A6 Single Mastertrac, high speed…...................................... 449 260 890 74:1 feed motor

(wire feed speed range of 0.8-16 m/min; 31-654 ipm)A6 Tandem Mastertrac, complete…...................................... 334 191 882

13

Self-propelled, four-wheel drive for stable,accurate, and constant operationAvailable in three different wire configurationdesigns: Single, Twin, or TandemAmple capacity for heavy production weldingand can take up to 6 mm (1/4 in) wire using1500 Amps (DC or AC)PEH Process Controller with digital displayallows for preset accuracy in all weldingparametersDesigned for use with LAF (DC) or TAF (AC)power sourcesMany specially developed accessories available

TRACTORS


Feed rolls, contact jaws ............................................................Power supplies ...........................................................................Control cables .............................................................................

Instruction Manual A6 Mastertrac (SAW), order number ......... 449265060Instruction Manual A6 (GMAW) Mastertrac, order number ...... 456503001Instruction Manual A6 Tandem Mastertrac, order number ...... 456503001Sales Literature A6 Mastertrac, order number ....................... XA00085120

page 15-17page 20-21page 20-21

A6-DKPortable welding machine

Works with a single wire on each headEach weld head is controlled by a PEHprocess controller and a LAF (DC) or TAF(AC) power sourceIdeal for simultaneous horizontal-verticalwelding on both sides of a web or troughpanelStraddles work pieces up to 800 mm (31 in)tall and symmetrical profile widths of 400 mm(16 in)Travels directly on a work piece guided by ajointTravel speed adjustable from 0.15-2.0 m/min(6-79 ipm)Store up to 10 l (2.6 gal) of flux in the hopperEach weld head is equipped with an OPCFlux recovery system

Instruction Manual A6 DK, order number ................... Contact ESABSales Literature A6 DK, order number .......................... XA0010012014


A6DK-SAW single wire........................................ 454 200 901Excl. wire reel, feed rollers, and contact jaws


Feed rolls, contact tips ...........................................Power supplies .......................................................Control cables .........................................................Wire reel plastic 30 kg (66 lb) ...............................Wire reel steel 30 kg (66 lb) ..................................

TRACTORS

page 15-17page 20-21page 20-21

153 872 880416 492 880

Wear Parts

15

TRACTORS

Sales Literature A2 Wear & Spare Parts, order number ....... XA00115820

Wear Parts... (Continued)

16 Sales Literature A2 Wear & Spare Parts, order number ....... XA00115820

TRACTORS

17

Wear Parts... (Continued)

TRACTORS

Sales Literature A2 Wear & Spare Parts, order number ....... XA00115820

Instruction Manual PEH Controller (4.0 >), order number ...... 443745001Instruction Manual PEH Controller (4.0 <), order number ..... 443745160Sales Literature PEH Controller, order number .................... XA00089320

A2-A6 Process Controller (PEH)

Designed for use with ESAB’s LAF (DC) andTAF (AC) power sourcesSuitable for MIG or SAW processesPreset all welding parameters by keying valueson front panel; can store up to 10 different datasets in memory for easy recall during weldingSubmenus let user decide on welding direction,wire type/dimension, and weld start/stopMicroprocessor automatically fine tunes arccharacteristics depending on wire type andparameters selectedMicroprocessor controlled system is userfriendly and requires minimal trainingChoose between 12 different languages andview heat input on display


A2-A6 PEH Process Controller ……………….…… 443 741 880

Accessories

Control cable, 15 m (49 ft) …….............................. 449 449 880Control cable, 25 m (82 ft) …..…………………..…. 449 449 881Control cable, 35 m (115 ft) ………………….......... 449 449 882Control cable, 50 m (164 ft) …………………….….. 449 449 883Control cable, 75 m (246 ft) ……………………..…. 449 449 884Control cable, 100 m (328 ft) …………………….… 449 449 885PHH1 remote control, 5 m (16.4 ft) cable ............. 449 040 880

18

CONTROLLERS AND POWER SOURCES

Accessories

Control cable, 15 m (49 ft) …….............................. 449 500 880Control cable, 25 m (82 ft) …..……………………... 449 500 881Control cable, 35 m (115 ft) ……………………...… 449 500 882Control cable, 50 m (164 ft) ………………………... 449 500 883Control cable, 75 m (246 ft) ………………………... 449 500 884Control cable, 100 m (328 ft) ………………………. 449 500 885

A2 PEI Welding Controller

Control system for A2 tractors and A2 weldingheadsAnalog type that can control most brands ofpower suppliesSuitable for MIG or SAW processPreset travel speed, voltage, and wire speed bysimply turning the three knobs – actual datashown on digital displays during weldingChange direction of welding using switch onfront panelChoice of scratch start or direct start methodsAdjustable burn-back time


A2 PEI Welding controller …………………………. 449 330 880

19Instruction Manual PEI Process Contoller, order number ........ 449331001Sales Literature, PEI Process Controller, order number ........ XA00114320


LAF TO PEI CONTROLLERControl 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) …………………….….

449 500 880449 500 881449 500 882449 500 883449 500 884449 500 885

Options & Accessories

LAF TO PEH CONTROLLERControl 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) …………………….….

LAF 635, 1000, 1250, & 1600DC Power Sources

Used in conjunction with ESAB PEH or PEIProcess ControllerSolid state, SCR-controlled, three phase, fan-cooled DC welding power sourcesDesigned for high productivity mechanizedsubmerged arc or MIG weldingExcellent welding characteristics throughout theentire current and voltage range, with particu-larly good starting and re-ignition propertiesExtremely efficient power usage saves onpower costsThermal overload protectionExtend current range by connecting two powersources in parallel


LAF 635 …………………………………………………LAF 1000 ………………………………………………..LAF 1250 ………………………………………………..LAF 1600 ………………………………………………..

20


Instruction Manual LAF 635 Power Source, order number .................. 457795101Instruction Manual LAF 1000 Power Source, order number ............... 456512001Instruction Manual LAF 1250/1600 Power Source, order number ...... 456511001Sales Literature LAF Power Source, order number ........................... XA00090920

457 350 880456 321 881456 323 880456 324 880

449 449 880449 449 881449 449 882449 449 883449 449 884449 449 885

TAF TO PEI CONTROLLERControl 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) …………………….….

TAF 800 & 1250AC Power Sources

Used in conjunction with ESAB PEH or PEIProcess ControllerSolid state, SCR-controlled, three phase, fan-cooled AC welding power sourcesSquare wave AC output, no arc blowCapacity for continuous weldingArc voltage or current feedbackOptimized open circuit voltageExtremely efficient power usage saves onpower costsPrepared for Scott connection of two powersources


TAF 800 ……………………………………………….. 456 325 880TAF 1250 ……………………………………………… 456 326 880

21Instruction Manual TAF Power Sources, order number ........ 456513201Sales Literature, TAF Power Sources, order number .......... XA00088720

449 500 880449 500 881449 500 882449 500 883449 500 884449 500 885

Options & Accessories

TAF TO PEH CONTROLLERControl 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) ................................

449 449 880449 449 881449 449 882449 449 883449 449 884449 449 885


A2S Mini MasterA multi-purpose automatic welding system


MIG System (A2)A2S GMAW MTW w/Manual Slides 90x90 mm ....................A2S GMAW MTW w/Motorized Slides 180x180 mm & PAK .A2S GMAW MTW w/Motorized Slides 180x180 mm & GMD-Includes the PEH and Wire EquipmentSAW Systems (A2)A2 SAW w/Manual Slides 90x90 mm ………………..............A2 SAW w/Motorized Slides 180x180 mm & PAK …….........A2 SAW w/Motorized Slides 180x180 mm & GMD ……........-Includes the PEH, Flux & Wire Equipment


Pilot lamp, light bulb ……………….....................................Pilot lamp, laser diode ………………..................................Thin wire straightener, single wire …………………....…...Flux recovery unit OPC ......................................................Flux Hopper, 6 l (1.6 gal) ....................................................Concentric flux funnel ………………………………….........Contact tube, bent ……………………………………….........Wire reel plastic 30 kg (66 lb) ………………………….........Wire reel steel 30 kg (66 lb) ................................................Conversion kit MIG/MAG ………………………………...........

Versatile welding system for single wire SAW, twinwire SAW or GMAWLow weight and compact design allows for greaterflexibilityModular design allows user to expand, integrate, ormodify system quickly and easilyUses A2-A6 process controller (PEH) or A2 PEIcontroller (see pages 18 and 19 for more information)Accurate, easy joint-tracking with manual or motorizedslide system (see page 31 for more information onjoint-tracking)System attaches to any beam travelling carriage orColumn & Boom system

22

WELDING HEADS

Instruction Manual A2S Mini Master, order number ..... 449175060Sales Literature A2S Mini Master, order number ....... XA00088820

449 181 880449 181 881449 181 882

449 170 880449 170 881449 170 882

153 143 886457 788 884332 565 880148 140 880413 315 881145 221 881413 511 001153 872 880416 492 880413 526 881

23

WELDING HEADS


Single wire SAW system A6A6S SAW w/Manual slides 210x210 mm-156:1.....................A6S SAW w/motorized slides 300x300 mm & PAK-156:1 .....A6S SAW w/motorized slides 300x300 mm & GMD-156:1.....A6S SAW w/Manual slides 210x210 mm-74:1 .......................A6S SAW w/motorized slides 300x300 mm & PAK-74:1 ........A6S SAW w/motorized slides 300x300 mm & GMD-74:1 .......*TWIN wire SAW available

Flexibility, reliability, and superior performance capabilityComprehensive component and module system makeprocess customization easyA6 VEC motor for reliable and consistent wire feedAccurate, easy joint-tracking with manual slides orjoystick-controlled motor-operated cross slides (seepage 31 for more information on joint-tracking)Capable of heavy duty MIG, single/twin wire SAW, aswell as strip cladding and Synergic Cold Wire (SCW)welding with optional accessoriesUses PEH process controller – fast, accurate pre-setting of all parameters before welding commencesFeedback system ensures high and consistent weldingquality - save time and material

A6S ARC MASTERFlexible, complete solution for automated arc welding

24

WELDING HEADS

Instruction Manual A6S Arc Master, order number ...... 449275060Sales Literature A6S Arc Master, order number ......... XA00088920

449 270 880449 270 881449 270 882449 270 890449 270 891449 270 892

25

WELDING HEADS

WELDING HEADS

26

A6S Tandem Welding HeadsFor optimum productivity and profitability

Suitable for heavy construction weldingCapable of welding DC/DC, DC/AC or AC/ACUses PEH (digital) process controllers- quicklyand accurately program welding parameters foreach torchFeedback system gives high and consistentwelding quality from start to finish, saving timeand moneyVersatile positioning through easy to use, com-plete slide assembly for welding torch position,distance-stick-out, and angle on both leading andtrailing torchesEnhance productivity by adding optional equip-ment such as Twin Wire and Synergic Cold-Wiresystems (See page 29)Available in a two basic versions with severalconfigurations to match specific safety, qualityand productivity requirements

A6S Tandem Master is optimized for welding across multiple perpendicular axis’ and is key in thewelding 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 is optimized for welding in multiple directions and is key in the automatedwelding 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 CaB M-model systems; Simply rotate the head 180 and weld in the reverse direction


A6DS Tandem Master (gear ratio 156:1) ...................A6DS Tandem Master (gear ratio 74:1) .....................A6S Tandem Master (gear ratio 156:1) .....................A6S Tandem Master (gear ration 74:1) .....................

809 939 880809 939 881809 940 880809 940 881


Twinkit LD (one kit per torch) .....................................Twinkit HD (one kit per torch) ....................................Bump protection .........................................................GMD, joint tracking .....................................................Pilot lamp, light bulb ...................................................Pilot lamp, laser diode ................................................Bracket, (straight) for wire .........................................Brake hub, for wire reel ..............................................Wire reel, plastic, 30 kg (66 lb) ...................................Wire reel, steel, 30 kg (66 lb) ......................................

809 934 880809 934 881451 404 880417 142 880153 143 886457 788 880334 318 880146 967 880153 872 880416 492 880

Sales Literature A6 Tandem Welding Heads, order number ......... XA00119120

WELDING HEADS

27

A6S Compact Welding HeadsInternal welding for limited access applications

For the welding of longitudinal and circumferentialbutt joints inside tubesTwo versions available:

A6S Compact 300 for internal welding of tubes down to 300 mm (12 in) inside diameter A6S Compact 500 for internal welding of tubes down to 500 mm (20 in) inside diameter

Equipped with reliable, VEC feed motor for superiorweld performanceSupervise and adjust the head position from theoutside via TV monitoring systemUse standard mini-cross slide assembly and PAKmanual tracking system or GMD automatic jointtracking system to easily follow the jointAdd either the FFRS Basic/Super or FFRS 1200/3000 Flux Feed & Recovery System to optimize thewelding process


Contact ESAB

A6S SAW Strip Cladding head


Strip Cladding Kit ……………………………………. 155 972 880For use with A6 SAW Tractor or A6S Arc Master


Reel holder …………………………………………..... 417 636 880(not to be used with motor-operated cross slide)Wire reel, steel ………………………………..…..….. 416 492 880Suction nozzle, flux …………………………..….….. 156 025 001

Used in combination with standard A6S ArcMaster weld headProvides an economical solution for surfacingwith high alloyed materials such as stainlesssteel or nickel-based alloysChoose a wider variety of parent materials andconsumablesStainless steel cladding is widely used inproduction of components where additionalstrength or corrosion resistance is requiredWelding head can be fitted with electrode stripsas wide as 30-100 mm (1.2-4.0 in) and as thickas 0.5 mm (0.02 in)Recommended for use with LAF 1250 or LAF1600 power source and PEH process controller(for more info on LAF, see page 20; for moreinfo on PEH, see page 18)

28

WELDING HEADS

Sales Literature A6S Strip Cladding Head, order number .... XA00101020

Synergic Cold Wire Kit Components

Motor VEC 156-1 .......................................................Straightener Left ……………………………..…..........Brake hub ..................................................................Bracket A6 .................................................................Screw MC6S M6x60 ..................................................Nut M6M ....................................................................Cartridge A6 ..............................................................Hand-wheel isolated A6 ...........................................


Flex Conduit SCW ...........................................................Contact Device, L=400 mm (16 in) (D35) ................Wire Reel, Steel ........................................................Twin Wire Kit .............................................................SCW Motor Kit .................................................................

29

A6 Synergic Cold Wire

Increase productivity by boosting depositionrate by up to 50% for any given current/wirefeed speed (utilizes excess heat from arc)Synergic Cold Wire welding offers lessdistortion, reduced flux consumption, and fewerweld beadsEasy to use, requires no additional control unitsor separate wire feed mechanismsAllows flexible process configuration- solid/cored wires, single, twin wire, tandem andmultiple wire combinationsSynergic Cold Wire has no arc and can beused for “hard to weld” alloys with cored wireSet wire in leading or trailing positiondepending on requirement of penetration vs.build-upFits all ESAB A6 systems


Synergic Cold Wire Kit, complete ……………...….. 449 022 880Includes VEC Motor (156:1), straightener (left), brake hub,cartridge, hand-wheel, and mounting hardware

145 063 886147 639 881146 967 880154 734 001192 238 382212 601 107156 907 001218 810 183

Sales Literature A6 Synergic Cold Wire, order number ......... XA00094920

ACCESSORY COMPONENTS

500C23417 959 882416 492 880334 291 889

500C31

Ordering information

Beam-Travelling carriage ........................................


Mounting bracket for Tandem head ………...…......Track in lengths of 3,000 mm (9.8 ft) ………..…......

Required number of floor columns: 2Track in lengths of 4,500 mm (14.8 ft) ....................

Required number of floor columns: 3Track in lengths of 6,000 mm (19.7 ft) …...…….......

Required number of floor columns: 3Track in lengths of 8,000 mm (26 ft) .......................

Required number of floor columns: 4

30

A6B Beam Travelling Carriage

Ideal solution for submerged-arc and MIG/MAGwelding applications requiring beam-mountedcarriageCan be fitted with any A2 or A6 welding headPlace carriage on either a standard l-beam IPE300 or specially machined l-beam (contact ESABfor details)Fast and easy pre-programming of travel motionand welding parameters using PEH control

Instruction Manual A6B Beam Travelling Carriage, order number ..... 458028001Sales Literature A6B Beam Travelling Carriage, order number ....... XA00091920


458 026 001145 282 880

145 282 881

145 282 882

145 282 883

457 897 880

Motorized slidesServo slides for automated linear motion

Heavy duty capacity with high precision slide foraccurate and rapid joint tracking and positioningCan be installed in vertical or horizontalpositions- setting lengths up to 1,030 mm (41 in)with a central point of attachmentOperates jointly with A2 or A6 componentsSlides available from 60 mm (2.4 in) to 1,030mm (41 in) working rangePermissible load of 1500 N (337 ft-lbs) in anymounting positionMaximum torque for vertical unit is 400Nm(3540 ft-lb-in); maximum torque for horizontalunit is 280 Nm (2480 ft-lb-in)

31Instruction Manual Motorized Slides, order number ..... 443394060Sales Literature Motorized Slides, order number ....... XA00032720


417 310 887417 310 888417 310 889

Connection CablesOne connection cable is required for each servo slide forconnection of slide to linear motion controller (eg. GMD or PAK)

Connection cable, 2 m (6.5 ft) ......................................Connection cable, 5 m (16.5 ft) ....................................Connection cable, 10 m (32.8 ft) ..................................


32

PAK and GMD Joint Positioning and Tracking SystemsThe key to quality in automated welding

Simple and easy to useAdapt for use with almost any type of weldingjointPAK system is for manual joint tracking; GMDsystem is for automatic joint trackingPAK and GMD work equally well with A2 or A6welding systemsMotorized servo slides guarantee a reliableand accurate joint trackingPAK system available with or without remotecontrol, and can be integrated into a Columnand Boom welding systemGMD automatic joint tracking system isdesigned for use in fillet and butt joints usingsensor fingersGMD compensates for irregularities in weldjoint, tracks simple geometric shapes, andavoids parallax problemsStandard GMD components include: sensorwith finger, cross saddle and support forsensor, GMD joint tracking unit, GMD remotecontrol unit with a 3.5 m (11.5 ft) cable, andcontrol cable 2 m (6.5 ft) for connecting thecontrol unit with the sensor


GMD system, complete ……………..............…..…. 417 142 880

PAK Control Unit, joy-stick on front panel ........... 417 587 880PAK Control Unit, separate remote control .......... 417 587 882

Includes GMD joint tracking unit, GMD remote control with3.5 m (11.5 ft) cable, 2 m (6.5 ft) control cable, sensor withfinger, and cross saddle and support for sensor

Instruction Manual Joint Tracking System (GMD), order number ....... 443403002Instruction Manual Joint Tracking System (PAK), order number ........ 443405002Sales Literature Joint Tracking System (GMD/PAK), order number .. XA00068420


Options and Accessories*

Sensor with finger …………….................................Cross saddle and support for the sensor .............GMD joint tracking unit ...........................................GMD remote control unit ........................................Control cable 2m (6.5 ft) .........................................Control cable with 90 contact 2m (6.5 ft) ...............Finger with ball ........................................................Protective rubber boot ............................................Finger for tube panel ...............................................Finger for beam welding .........................................Standard finger ........................................................Intermediate transformer ........................................Cable for transformer connection (order per m) ...* Only for GMD models

416 688 880416 739 880416 066 880416 065 880416 749 887417 346 887416 719 001412 013 001443 328 880443 187 880146 586 001148 636 002262 613 404

33


PAK and GMD Joint Positioning and Tracking Systems (Cont’d)The key to quality in automated welding

34

OPC Flux Recovery SystemsRobust, compact flux recovery units

Robust and compact designEasy to operate and practically maintenance-freeIntegrated system for maximum productivity-lower investment and service costsAdapts to any A2 or A6 welding system- tractoror stationaryUses only compressed air- safe andinexpensive to useCan be integrated into complete FFRS fluxfeeding and recovery systemThree filter types: Filter bag for A2 applications,cyclone filter with filter bag for most A6applications, and Tedak filter for heavy dutyapplicationsOPC system includes: Ejector, cyclone, filterwith attachment hardware, securing strap,suction hose, and four suction nozzles (for buttwelds, normal and large; fillet welds, left andright)


OPC Basic, with standard filter bag ………….......…...OPC Basic, with cyclone filter …………….........………OPC Basic, with Tedak filter ……………………….........OPC Super, with cyclone filter ……………..…….......…OPC Super, with Tedak filter ……………….……...........

148 140 880802 415 882802 415 883802 415 892802 415 893

Instruction Manual OPC Flux Recovery System, order number ...... 443407001Sales Literature OPC Flux Recovery System, order number ......... XA00105020

Works on ejector principle using compressedairCyclone separator, on top of flux hopper,efficiently separates dust from recovered fluxSlag is separated and flux is returned to hopper

OPC Basic Flux Recovery System OPC Super Flux Recovery System

Similar to Basic system but with stronger ejectorand cyclone – provides better suctionCan also be used with pre-heated flux



Air center ..................................................................................................Air pressure hose 1/2” (max 50 m, 164 ft) .............................................Suction hose D47/38 (max 12 m, 39 ft) ..................................................Bent inlet for flux hopper ........................................................................Straight inlet for flux hopper ...................................................................Flux hopper with bent inlet pipe 10 L (2.6 gal) ........................................ left hand side seen from frontFlux hopper with bent inlet pipe 6 L (1.6 gal) .......................................... left hand side seen from frontFlux hopper with bent inlet pipe 10 L (2.6 gal) ........................................ front sideFlux hopper with bent inlet pipe 6 L (1.6 gal) .......................................... front sideFlux hopper with bent inlet pipe 10 L (2.6 gal) ........................................ right hand side seen from frontFlux hopper with bent inlet pipe 6 L (1.6 gal) .......................................... right hand side seen from frontLow level indicator TPC-75 flux tank ....................................................

35


All FFS systems consist of TPC 75 flux pressure tank, 30 m (98 ft) plastic flux delivery hose, and flux hopper inlet.FFRS 1200 & 3000 systems consist of TPC-75 flux pressure tank, motor driven vacuum unit with dust filter, common mounting post forsystem, air pressure regulator with water trap, suction hose between primary separator and vacuum unit, air central with 10 m (33 ft) airhose ½” included, flux suction nozzle, and flux feeding hose 30 m (98 ft) included

FFRS Flux Feed and Recovery SystemsEfficient flux handling puts economy into your welding

Ideal for continuous and high capacityweldingAutomatic flux fill and recovery - improvedproductivity and less downtimeMinimum manual flux handling and reducedconsumptionFlux feeds from a 75 L (20 gal) capacity TPC-75 pressurized flux tank to the ESAB fluxhopper of your choice: 6 L (1.6 gal) or 10 L(2.6 gal)Flux feed inlet options: straight or bent

FFRS – Basic & SuperBased on ejector vacuum principle utilizingOPC Basic/Super systemsBasic type is for normal welding; Super isused with increased flux and heat conditionsClosed system ensures better workingenvironment with fresh air

FFS, straight inlet …................................................................................FFS, bent inlet ………...............................................................................FFRS 1200 ……………………………………..............................................FFRS 3000 ……………………………………..............................................

FFRS 1200 & FFRS 3000Ultimate flux feed and recovery system fordemanding applicationsDesigned for use when extra high recoveryforce is requiredBased on an electric suction unit to createpowerful vacuum of fluxElectrical vacuum unit has low noise level

Instruction Manual FFRS Basic/Super Flux Equipment, order number ...... Contact ESABInstruction Manual FFRS 1200 & 3000 Flux Equipment, order number ...... Contact ESABSales Literature FFRS Basic/Super Flux Equipment, order number .............. XA00104820Sales Literature FFRS 1200 & 3000 Flux Equipment, order number .............. XA00104920

806 697 887806 697 886801 500 901801 500 921


417 714 880190 343 106379 016 001186 961 881186 961 880156 230 883

413 404 883

156 230 884

413 404 884

156 230 885

413 404 885

452 048 880

FFRS 1200 and FFRS 3000

36


CRE 30 & CRE 60 Air Drying Units

37


Designed for use with any flux handling systemSystem is based on absorption principle -reduces the risk of hydrogen cracking in weldmetal by ensuring SAW flux remains dryBuilt in monitor- warns if the programmedhumidity limit is exceededReduces condensation- less corrosion andmalfunctionsSimple system monitoring- Manometer onpressurized dryer bottles with easy-to-read dewpoint indicator


CRE 30 air drying unit .......................................................................... 443 570 880CRE 60 air drying unit .......................................................................... 443 570 881

Accessories

Desiccant, type 512, order per kg .......................................................Oil filter .................................................................................................Dust filter ..............................................................................................

Instruction Manual CRE 30/60 Air Dryer, order number ...... 443423001Sales Literature CRE 30/60 Air Dryer, order number ......... XA00101920

443 570 017443 570 018443 570 019


JS200 Storage Silo ……………………………......................…JK50 Powder Dryer……………………………......................…

Flux Drying Equipment

JS200 Flux Storage silo

000 515 090 000 515 091

38

JK50 Powder Dryer


Keeps flux dry and cleanMakes it easy to handle fluxAdjustable temperature

Can dry up to 50 kg (110 lb) of flux at a maximumtemperature of 500 o C (932 o F) in 3 hoursAfter drying, temperature falls automatically to a pre-setdry storage temperature of 150 o C (302 o F) within 12hours

WeldocTM WMS 4000Data program for welding supervision and documentation

Enables welding industry to comply with rigorousquality requirement in the ISO 9000 standardsProvides necessary documentation for qualityrequirements – user-specified limit valuesfacilitates monitoring and process deviationUse with the following ESAB power sources:

Prowelder 160/320, Protig 450LUD/AristoMig 450LAF 635, 1000, 1250, 1600TAF 800, 1250

No manual settings required – automatic record-ing of date, time, and reference number of weldjointsProgram automatically receives and storeswelding parameter data from power sourceSPS 4000 documentation program providessetting welding data in power source


39Instruction Manual Weldoc WMS 4000, order number ..... 457413074Sales Literature Weldoc WMS 4000, order number ....... XA00088020



All Turning Rolls include RC-30 remote control with 12 m (39.4 ft) cablePOWER SECTION 5 TA ……………………..... 103563POWER SECTION 10 TA ............................... 103564POWER SECTION 25 TA ............................... 103565POWER SECTION 40 TA ............................... 103566POWER SECTION 70 TA ............................... 103567POWER SECTION 100 TA ............................. 103568POWER SECTION 150 TA ............................. 103569POWER SECTION 200 TA ............................. 103570POWER SECTION 300 TA ............................. 103571POWER SECTION 500 TA ............................. 103572

5 - 500 TASelf-aligning Turning Rolls

Ideal for difficult and demanding work piecesEven weight distribution for thin-walled workpieces and heavy objectsCompact and narrow design with durable rollersDual drive motors and gears- eliminate need forinterconnect driveshaftVector inverter control system for constant andprecise speed controlEquipped with RC-30 remote control with a 12m (39.4 ft) cablePlug & play connection to accessories availableincluding synchronization control, externalconnection, rail bogies, anti-creep/fit-up control,start/stop foot pedal, and PEH processcontroller

40 Sales Literature TA Turning Rolls, order number ....... XA00120320

HANDLING EQUIPMENT

IDLER SECTION 5 TA ............................... 103573IDLER SECTION 10 TA ............................. 103574IDLER SECTION 25 TA ............................. 103575IDLER SECTION 40 TA ............................. 103576IDLER SECTION 70 TA ............................. 103577IDLER SECTION 100 TA ........................... 103578IDLER SECTION 150 TA ........................... 103579IDLER SECTION 200 TA ........................... 103580IDLER SECTION 300 TA ........................... 103581IDLER SECTION 500 TA ........................... 103582

HANDLING EQUIPMENT

3 - 500 TNAConventional Turning Rolls

Basic solution for handling a variety of workpiecesEasy to use screws for adjusting diametersDual drive motors and gears- eliminate need forinterconnect driveshaftVector inverter control for a constant andprecise speed adjustmentCompact and narrow design with durable rollersEquipped with RC-30 remote control with 12 m(39.4 ft) cableMany accessories available includingsynchronization control, external connection,rail bogies, anti-creep/fit-up, and start/stop footpedal

41Sales Literature TNA Turning Rolls, order number ....... XA00120220


All Turning Rolls include RC-30 remote control with 12 m (39.4 ft) cablePOWER SECTION 3 TNA ................................. 103584POWER SECTION 5 TNA ................................. 103585POWER SECTION 10 TNA ............................... 103586POWER SECTION 25 TNA ............................... 103587POWER SECTION 40 TNA ............................... 103588POWER SECTION 60 TNA ............................... 103589POWER SECTION 100 TNA ............................. 103590POWER SECTION 150 TNA ............................. 103591POWER SECTION 200 TNA ............................. 103592POWER SECTION 300 TNA ............................. 103593POWER SECTION 500 TNA ............................. 103594

IDLER SECTION 3 TNA ............................... 103595IDLER SECTION 5 TNA ............................... 103596IDLER SECTION 10 TNA ............................. 103597IDLER SECTION 25 TNA ............................. 103598IDLER SECTION 40 TNA ............................. 103599IDLER SECTION 60 TNA ............................. 103600IDLER SECTION 100 TNA ........................... 103601IDLER SECTION 150 TNA ........................... 103602IDLER SECTION 200 TNA ........................... 103603IDLER SECTION 300 TNA ........................... 103604IDLER SECTION 500 TNA ........................... 103605


ESAB 1 TXA, Idler Unit..................................................... 102600ESAB 3 TXA, Idler Unit .................................................... 102601ESAB 5 TXA, Idler Unit .................................................... 102602ESAB 3 TXA, Power Unit .................................................. 102606ESAB 5 TXA, Power Unit .................................................. 102607

TXA Turning RollsScissor-type Turning Rolls

Ideal for applications requiring a constantcentre heightComplete with a low voltage (24V) remotecontrol unit for all functionsAvailable as a motorized or freely rotating idlingunitEasily adjust the diameter with manuallyoperated hydraulic hand-pumpsIdeal for handling long objectsPlug & play connection to accessories availableincluding synchronization control, externalconnection, rail bogies, start/stop foot pedal,and PEH process controller

42 Sales Literature TXA Turning Rolls, order number ....... XA00120420

HANDLING EQUIPMENT


All positioners include remote control and cable as indicated intechnical data table250 AHMA Positioner …………………........…….....................750 AHMA Positioner ……………………….............................1500 AHMA Positioner ……………………..............................3500 AHMA Positioner ……………………..............................7000 AHMA Positioner ……………………............................15000 AHMA Positioner ……………………............................25000 AHMA Positioner ………………………........................35000 AHMA Positioner …………………...............................

HANDLING EQUIPMENT

250-35000 AHMAPositioners for lifting, rotating and tilting demanding work pieces

3-axis positioning: height, angle, and rotationUnique design allows for a large operatingrangeAll positioners above 250 kg (551 lb) capacityhave AC drivesImproved hydraulics with integrated safetyvalves for total safety operationVector inverter control system for constant andprecise rotation speed and improved torque atlow speedsEquipped with RC-30 remote controlPlug & play connection to accessories availableincluding external connection, start/stop footpedal, speed control foot pedal, and PEHprocess controller

103653103654103655103656103657103658103659103660

43Sales Literature AHMA Positioner, order number ....... XA00119320

44

HANDLING EQUIPMENT

75-750 SKAFor small and light work pieces

Ideal for small and light work piecesComplete with a low voltage (24V) remotecontrol unit for all functionsIncludes manual height adjustment, manualtilting angle adjustment and motorized rotation

Sales Literature SKA Positioner, order number ....... XA00119520


ESAB 75SKA ................................................ 102729ESAB 150SKA .............................................. 102730ESAB 750SKA .............................................. 106134

HANDLING EQUIPMENT


ESAB 750SHA .............................................. 105373ESAB 1500SHA ............................................ 105374ESAB 3500SHA ............................................ 105375ESAB 5000SHA ............................................ 105376ESAB 7000SHA ............................................ 105377ESAB 10000SHA .......................................... 105378

750-10000 SHAPositioners for demanding and heavy work pieces

Handle large and demanding work pieces in allpositionsEquipped with adjustable hydraulics with built-insafety valves3-axis operation (height, tilting angle, androtation) for ideal ergonomic working conditionsLow voltage (24 V) remote control with allfunctionsRotation and tilting speed controlled by vectorinverters for improved accuracy and betterrotation torqueDrives equipped with an AC motorPlug & play connection to accessories availableincluding external connection, start/stop footpedal, speed control foot pedal, and PEHprocess controller

45Sales Literature SHA Positioner, order number ....... XA00119620

46

HANDLING EQUIPMENT


ESAB 750VA ................................................ 105326ESAB 1500VA .............................................. 105327ESAB 3500VA .............................................. 105328ESAB 7000VA .............................................. 105329ESAB 15000VA ............................................ 105330ESAB 25000VA ............................................ 105331ESAB 35000VA ............................................ 105332ESAB 50000VA ............................................ 105333

750-50000 VAPositioner for automated circumferential welding

Ideal for large and heavy work piecesComplete with a low voltage (24V) remotecontrol unit for all functionsMotorized rotation for economicalcircumferential weldingVector inverter control system for constant andprecise speed controlDrives equipped with an AC motorPlug & play connection to accessories availableincluding external connection, start/stop footpedal, speed control foot pedal, and PEHprocess controller

Sales Literature VA Positioner, order number ....... XA00119920

HANDLING EQUIPMENT


ESAB 25000CRA ......................................... 105430ESAB 35000CRA ......................................... 105431ESAB 50000CRA ......................................... 105432

25000-50000 CRAPositioners for highly demanding and large work pieces

Ideal for large and heavy work piecesComplete with a low voltage (24V) remotecontrol unit for all functionsAdjustable rotation and tilting for idealpositioningVector inverter control system for constant andprecise speedDrives equipped with an AC motorPlug & play connection to accessories availableincluding external connection, start/stop footpedal, speed control foot pedal, and PEHprocess controller

47Sales Literature CRA Positioner, order number ....... XA00119820

Ordering InformationMotorized Rotation, Fixed Height:750 HSA ............................................................................750 TSA ............................................................................1500 HSA ..........................................................................1500 TSA ..........................................................................3500 HSA ..........................................................................3500 TSA ..........................................................................7000 HSA ..........................................................................7000 TSA ..........................................................................1500 HSA ..........................................................................15000 TSA ........................................................................25000 HSA ........................................................................25000 TSA ........................................................................35000 HSA ........................................................................35000 TSA ........................................................................50000 HSA ........................................................................50000 TSA ........................................................................

Height Extension Blocks:750 HSA/HSLA Extension ...............................................1500 HSA/HSLA Extension .............................................3500 HSA/HSLA Extension .............................................7000 HSA/HSLA Extension .............................................15000 HSA/HSLA Extension ...........................................25000 HSA/HSLA Extension ...........................................35000 HSA/HSLA Extension ...........................................50000 HSA/HSLA Extension ...........................................

HANDLING EQUIPMENT

750-50000 Head & TailstockPositioners for long revolving workpieces

Ideal for circumferential welding and assemblyof difficult workpiecesComplete with a low voltage (24V) remotecontrol unit for all functionsUse headstock with or without tailstockHead & tailstock can be equipped with astepless height adjustment and tailstock withhydraulic motorized rail-bogie for variouslengthsPlug & play connection to accessories availableincluding external connection, rail bogies, start/stop foot pedal, and PEH process controllerHeadstock HSA features motorized rotation andfixed heightHeadstock HSLA features motorized rotationand stepless height adjustmentTailstock TSA/TSLA features freely rotatingtable plate, and fixed/adjustable height

48 Sales Literature Head and Tailstock, order number ....... XA00119320

105280105396105381105397105382105398105383105399105384105400105385105401105386105402105387105403

106507106507106508106509106510106511106512106513

Motorized Rotation, Adjustable Height:750 HSLA ............................................................................750 TSLA ............................................................................1500 HSLA ..........................................................................1500 TSLA ..........................................................................3500 HSLA ..........................................................................3500 TSLA ..........................................................................7000 HSLA ..........................................................................7000 TSLA ..........................................................................1500 HSLA ..........................................................................15000 TSLA ........................................................................25000 HSLA ........................................................................25000 TSLA ........................................................................35000 HSLA ........................................................................35000 TSLA ........................................................................50000 HSLA ........................................................................50000 TSLA ........................................................................

Motorized Railbogies:750 RBTSA .........................................................................1500 RBTSA .......................................................................3500 RBTSA .......................................................................7000 RBTSA .......................................................................15000 RBTSA .....................................................................25000 RBTSA .....................................................................35000 RBTSA .....................................................................50000 RBTSA .....................................................................

105388105404105389105405105390105406105391105407105392105408105393105409105394105410105395105411

105412105413105414105415105416105417105418105419

750-50000 Head & TailstockPositioners for long revolving workpieces

HANDLING EQUIPMENT

49

Prowelder 160, Prowelder 320, & Protig 450

Micro-processor controlled DC TIG power sources for high weld quality and productivityRobust design engineered to withstand wear and tear from daily use in industrial environmentsFieldbus communication/connection technology - fewer cables required and less sensitive todisturbancesProwelder 160, 320 can control two motors: travel motor and wire feed motorProtig 450 can control four motors: travel, wire feed, arc voltage control, and weaveProtig 450 and Prowelder 320 have a built in cooling unit for flexibility in adapting to customer needsPossibility to store and transfer welding programs to a PC-cardProgrammed through a pendant with large display and intuitive programming menusCan be used with documentation printer or WeldocTM WMS4000 Welding Monitoring DocumentationSystem – ensures accurate weld procedure specification and documentationProwelder 160 and 320 can be used with PRB, PRH, and POC welding heads, MEI 21/10 wire feeders,and A25 system with manual/floating slidesProtig 450 can be used with PRB, PRC, PRD, PRH, and POC welding heads, MEI 21/10 wire feeders,and A25 system with manual/floating/weaving AVC slides

50

MECHANIZED TIG


Prowelder 160, 230 V, 1 ph, 50/60 Hz ..............................................................................Prowelder 320, with water cooler 208/230/460/475 V, 3 ph, 60 Hz ...............................Protig 450, with water cooler 208/230/460/475 V, 3 ph, 60 Hz …...............................…


Undercarriage, large for two gas cylinders…….............................................................Trolley for Prowelder 160 ……………………....................................................................OCF 2M cooling unit (only Prowelder 160) ....................................................................WeldocTM WMS 4000 Software…………......................................….................................SPS 4000 Software ..........................................................................................................Optical connection kit, 15 m (49 ft) ...........................................................................…..Optical connection kit, 2 m (6.6 ft) ..................................................................................Weld Heads ......................................................................................................................MEI 21/10 wire feeder .............................................................................................................Printer ......................................................................................................................................

51

Instructional Manual Prowelder 160/250, order number .......................... 458343001Instructional Manual Prowelder 320, order number ................................. 457690201Instructional Manual Prowelder 450, order number ................................. 456634001Instructional Manual Prowelder Programming Manual, order number .. 457706174Instructional Manual Protig Programming Manual, order number ......... 456638174Sales Literature Prowelder 160/250, order number ............................... XA00096220Sales Literature Prowelder 320, order number ...................................... XA00096220Sales Literature Prowelder 450, order number ...................................... XA00096220

MECHANIZED TIG

458 300 880456 650 883456 650 881

457 221 880301 100 880457 216 882457 410 880457 410 881457 072 881457 072 882Pages 52-58

Page 59Page 61


All PRB weld heads include 7 m (23 ft) of connection cablePRB 17-49, water cooled ………………………………………….............PRB 17-49, air cooled …………………………………………......……….PRB 33-90, water cooled ………………………………………....………..PRB 33-90, air cooled ………………………………………......………….PRB 60-170, water cooled …………………………………..........……….PRB 60-170, air cooled ………………………………………............……


Angular Support Bracket ......................................................................Rebuilding kit, PRB/PRC 17-49 ……....……..........................................

For welding tubes with OD of 8-17 mm (0.3-0.7 in)Rebuilding kit, PRB/PRC 33-90 …….…………......................................

For welding tubes with OD of 20-33 mm (0.8-1.3 in)Rebuilding kit PRB/PRC 60-170 …..............................................….…..

For welding tubes with OD of 44-60 mm (1.7-2.4 in)

A21 PRBTube to Tube Weld Heads

Small, flexible, and lightweightHeads based on unique clamp-on principle toreduce set-up timeAvailable in air-cooled or water-cooled versionsAvailable in three sizes for tubes with outerdiameters of 17 mm (0.67 in) to 170 mm (6.7 in)Use with Prowelder and Protig power sourcesComplete with 7 m (23 ft) connection cable

443 750 880443 750 881443 760 880443 760 881443 770 880443 770 881

52Instruction Manual PRB Welding Head, order number ..... 443808001Sales Literature PRB Welding Head, order number ....... XA00098520

MECHANIZED TIG

443 875 880444 002 880

443 908 880

443 909 880

A21 PRCFlexible Tube to Tube Weld Heads

Water-cooledFeatures arc weaving movement and arc voltagecontrolIncrease productivity and quality of weld,particularly when welding thick-walled tubesUse in combination with Protig 450 power source

53Instruction Manual PRC Welding Head, order number ..... 443934001Sales Literature PRC Welding Head, order number ....... XA00098520

MECHANIZED TIG


PRC 17-49 with AVC ………………………….....……….... 443 751 880PRC 17-49 with AVC and weaving ……...…….....……… 443 752 880PRC 33-90 with AVC …………………………….....…….... 443 761 880PRC 33-90 with AVC and weaving ………….....………... 443 762 880PRC 60-170 with AVC ………………………….....……….. 443 771 880PRC 60-170 with AVC and weaving ………….....………. 443 772 880


Angular Support Bracket ........................................................ 443 875 880Rebuilding kit, PRB/PRC 17-49 ............................................... 442 002 880

For welding tubes with OD of 8-17 mm (0.3-0.7 in)Rebuilding kit, PRB/PRC 33-90 ............................................... 443 908 880

For welding tubes with OD of 20-33 mm (0.8-1.3 in)Rebuilding kit PRB/PRC 60-170 .............................................. 443 909 880

For welding tubes with OD of 44-60 mm (1.7-2.4 in)

444 151 880444 151 881444 151 882444 151 883

444 151 884

444 016 880441 623 880441 623 881


PRD 160 Weld HeadWeave unit complete .......................................................Wire feeder unit complete ...............................................AVC (Arc Voltage Control) complete ..............................For range of pipe racks, see sales literature for PRD 160PRD 100 Weld HeadStraight rack with suction feet, 2 m (6.6 ft) ...................Straight rack with suction feet, 4 m (13.1 ft) .................Vacuum pump ..................................................................For range of pipe racks, see sales literature for PRD 100

334 150 880334 150 881334 504 001


PRD 160 Weld HeadBasic unit, intended only for fusion welding with afloating head ........................................................................Basic unit with wire feeder unit complete .........................Basic unit with AVC (Arc Voltage Control) …………………Basic Unit with AVC plus wire feeder unit complete …….Basic Unit with AVC plus wire feeder unit complete andweave unit ….....................................................................…PRD 100 Weld HeadPRD 100 Unit ........................................................................Narrow Gap head, 50mm (1.97 in) ......................................Narrow Gap head, 80mm (3.15 in) ......................................

444 140 880444 137 880443 656 881

A21 PRD

Orbital Tube Weld HeadsPrecision TIG tube and pipe welding heads that are rugged andeasy to useWater-cooled, designed for up to 400 Amps

PRD 160 Weld HeadFor pipes with OD of 160 mm (6.3 in) and greaterUse with Prowelder 160/320 and Protig 450 power sourcesModular design allows wire feed, Arc Voltage Control, andweaving unit to be added to basic system

PRD 100 Weld HeadFor pipes with OD of 100 mm (3.9 in) and greaterCompact low-profile design- requires only 73 mm (2.9 in)clearance around pipeUse with Protig 450 power sourceStandard features include synchronized current pulsing withwire feed and carriage movement, arc weaving, and automaticArc Voltage ControlCapable of TIG Narrow Gap Orbital welding (with optionalhead) to achieve increased productivity and reduced heat inputon tubes with a wall thickness greater than 10 mm (0.39 in)

54

Instruction Manual PRD 100, order number ..... 444061001Instruction Manual PRD 160, order number ..... 444100001Sales Literature PRD 100, order number ....... XA00091720Sales Literature PRD 160, order number .... Contact ESAB

MECHANIZED TIG

55

MECHANIZED TIG


POC 12-60 welding head, complete with wire feed unit ..................................…


Counterbalancing block ………………………………..............................................3-point support, includes electrode holder ..…….................................................For fillet welding up to 36 mm (1.4 in) diameter3-point support, includes electrode holder ..........................................................For fillet welding from 36 mm (1.4 in) to 93 mm (3.6 in) diameterAdditional gas cup ………………………………………................…………………...Internal bore welding torch, 9.5-15 mm (0.37-0.59 in) …………................………Internal bore welding torch, 15-20 mm (0.59- 0.79 in) ………….......................…Internal bore welding torch, 20-30 mm ( 0.79-1.18 in) ………….................……...For Shafts and Centering cartridges, see POC 12-60 sales literature

Easy to handle, precision built, robust andversatile welding headCapable of pulsing at 200 Amps, 60% dutycycleWorking range of 12-60 mm (0.5-2.4 in) tubeouter diameterLightweight, compact water-cooled systemPrecise centering ensures a consistent andperfect weldMany accessories availableEasy to maintain and service – no special toolsneeded

56Instruction Manual POC 12-60 Welding Head, order number ..... 443959041Sales Literature POC 12-60 Welding Head, order number ....... XA00087220

MECHANIZED TIG

POC 12-60Tube-to-tube sheet weld heads

443 930 880

332 330 005333 897 880

333 897 883

441 000 880441 131 880441 132 880441 133 880

Protects the welding arc with shielding gas fromexternal environmentsWeld without filler materialRotating components and tungsten electrodeare enclosed in gas chamber formed by outercasingThin water-cooled design- for use whereclearances are limitedAvailable in three sizes for pipes with outerdiameter ranging from 3 mm (0.12 in) up to 76.2mm (3.0 in)All heads equipped with encoder motors forprecise positioning of each sector when weldingvarious parametersMay be used with Prowelder 160, 320 or Protig450 power sources


Welding head PRH 3-12 ......................................... 444 300 880Welding head PRH 3-38 ......................................... 444 301 880Welding head PRH 6-76 ......................................... 444 302 880

57Instruction Manual PRH Welding Head, order number ..... 444291104Sales Literature PRH Welding Head, order number ....... XA00115920

MECHANIZED TIG

A21 PRHEnclosed tube welding heads

Modular components can be easily combined tocreate customized solution for specific weldingtasksAvailable add-on components:

Rotary slide for adjusting the torchangleMotorized slide for Arc Voltage Control(AVC)Motorized slide for weavingFloating headNarrow Gap kit for BTE 500MVEC motor with pulse-controlller forrotation of the work piece or connectionto a turn table

Available with either a BTE 250M (max 250 A)or BTE 500M (max 500 A) TIG torchFor use with Prowelder 160/320 power sourcesfor basic welding process and Protig 450 powersource for advanced functionality

Accessory Components

1. Bracket 441 404 880 14. Holder BTE 500M 441 414 8812. Wire feed unit diam 0.6-0.8 mm (.023-.030 in) 441 300 882 15. Slide AVC 443 913 8803. Feed roller diam 1.0-1.2 mm (.040-.045 in) 369 557 003 16. Circular slide 145 945 8804. Feed roller diam 1.2-1.6 mm (.045-1/16 in) 369 557 007 17. Slide manual 413 518 8805. Outlet pipe diam 0.8-1.2 mm (.030-.045 in) 441 456 881 18. Slide weaving 443 913 8816. Outlet pipe diam 1.6 mm (1/16 in) 441 456 882 19. Slide floating 441 674 8817. Connection cable, feed unit 8 m (26 ft) 443 828 880 20. Single guide wheel unit, BTE 250M 441 833 8808. Wire hose, per meter (std 400 mm; 15.75 in) 192 799 112 Single guide wheel unit, BTE 500M 441 833 8819. Wire nozzle, BTE 250M 441 407 880 21. Double guide wheel unit, BTE 250M 442 358 88010. Wire nozzle, BTE 500M 441 407 881 Double guide wheel unit, BTE 500M 442 358 88111. TIG torch BTE 250M 441 362 880 22. Bracket 441 412 88012. TIG torch BTE 500M 441 418 880 23. Brake hub 146 967 88113. Holder BTE 250M 441 414 880 24. Bobbin protection 157 482 880

58

Instruction Manual BTE Torch, order number ...................... 443424001Instruction Manual A25 Welding Station, order number ..... 443922001Sales Literature A25 Welding Station, order number ....... XA00089520

MECHANIZED TIG

A25 Component SystemMechanized TIG Modular Component System


MEI 21Four-roll drive systemEasily connected to welding head through aflexible wire guideCan use 5 kg (11 lb) wire spoolsUse with wire diameters from 0.6-0.8 mm (0.023-0.030 in)Geared DC drive motor with microprocessorclosed-loop feedback ensures precise wire feedspeed

MEI 10Developed for mounting on PRB/PRC 17-170 tools


MEI 21 Wire Feed Unit ....................................................MEI 10 for PRB 17-49 and PRC 17-49 with AVC ............MEI 10 for PRB 33-90, PRC 60-170 with AVC and .........PRC 33-90 with AVC and weavingMEI 10 for PRB 60-170, PRC 60-170 with AVC and ......PRC 60-170 with AVC and weaving

59

Instruction Manual MEI 21 Cold Wire Feed Unit, order number ..... 443831001Instruction Manual MEI 10 Cold Wire Feed Unit, order number ..... 444215001Sales Literature MEI 21 Cold Wire Feed Unit, order number ....... XA00089020Sales Literature MEI 10 Cold Wire Feed Unit, order number ....... XA00098620

MECHANIZED TIG

MEI 21 and MEI 10Wire feed unit for Mechanized TIG Welding

443 830 880444 211 880444 212 880

444 213 880

Ordering information

G-Tech Tungsten Grinder, 110/115 V, 1 ph, 60 Hz ................... 700 009 882Complete with one diamond grinding disc andaccessory kit for .040 – 5/32" electrodes


Diamond grinding disc ………………….……………….............…Grinder fluid, 250 ml (.06 gal) ……………….………………….…Return bottle, 250 ml (.06 gal) ....................................................Electrode clamp 1.0 mm (0.040in) .............................................Electrode clamp 1.6 mm (1/16 in) ...............................................Electrode clamp 2.4 mm (3/32 in) ...............................................Electrode clamp 3.2 mm (1/8) .....................................................Electrode clamp 4.0 mm (5/32) ...................................................Electrode holder, stainless .........................................................Grinder fluid, 5.0 l (1.32 gal) …………………….………………....Waste Container …………………………………............................Accessory kit, complete .............................................................

Unique enclosed wet grinding systemStable, concentrated TIG welding arc-guarantees accuracy and repeatabilityAutomatic collection of grinding dust- no risk towelder or environmentNo oxidation of the tungsten electrode whenwet grindingLonger life of electrode point

700 009 002700 009 004700 009 005700 009 007700 009 008700 009 009700 009 010700 009 011700 009 014700 009 015700 009 017700 009 020

60Instruction Manual G-Tech Grinder, order number ..... 700009027Sales Literature G-Tech Grinder, order number ............. 898C129

MECHANIZED TIG

G-TechPrecision TIG Electrode Grinder


Parameter Documentation Printer, Complete ……............................................................…… 449 322 880Includes: one paper roll, and all items marked with * below


Interface card for upgrading old power source LTS, LTP …………….....................................Software for upgrading old LTS, English/French ……………….................................………..Software for upgrading LTP, English/French …………………….................................………...Paper roll, 40 pcs …………………………………………………………........................................* Cassette for printer ……………………………………………………..........................................* Plastic cover ……………………………………………………………….......................................* Control cable 1.5 m (59 in) ……………………………………….....................................……….* Adapter incl 2.0 m (79 in) power cable …………………………….......................................….* Double sided tape ……………………………………………………......................................……

Parameter documentation printer

Printer for documentation of welding parametersUse with Prowelder 160, 320 and Protig 450Prints programmed and measured values forspeed, current, voltage, wire and powerPrint-out indicates power source used, time, runnumber and total welding time

486 764 884459 370 885459 370 881449 327 880449 324 001449 325 001449 326 001449 329 001456 986 001

61Sales Literature Documentation Printer, order number ....... XA00114420

MECHANIZED TIG

OCF 2M Cooling Unit

Cooling unit designed for use withProwelder 160Easy to mount under power sourceMaximum working height: 7 m (23 ft)


Cooling unit OCF 2M ………………..………….. 457 216 882

62 Instruction Manual OCF 2M Coolant Circulator, order number ..... 457680001

MECHANIZED TIG

Aristo Robotic Welding ProcessPackage

Complete component system for mechanized MIG weldingSupports DeviceNet, CANopen, and Profi buscommunication systems- easy to interface to any robot ormechanized applicationAnalog Interface is available and ideal for retrofitting toolder robots

AristoMig 450 power supply

Rated 425 Amps @ 60% duty cycle, 360 Amps @ 100%duty cycleRobust inverter power source with unparalleled reliabilityand performanceUses CAN-bus communication technologySame power supply can be used for manual or robotic/mechanized weldingBuilt-in water cooler optional

AristoPendant U8

Store all welding parameters in an easily accessible andlogical control unitLarge display with easy-to-understand functionality210 pre-programmed parameter relationships for optimizedprocess performanceCreate, store, and recall up to 99 sets of custom weldingdataPulsed-arc MIG welding

Aristo SuperPulseTM

Exceptional heat control technology- ideal for root pass inall positions, and materialsVery tolerant of joint gap variationsExceptional pulse on pulse performance provides low heatinput and uniform penetration- ideal for thin materialsLarge variety of unique weld process combinations includ-ing tig appearance welds, efficient out of position welding,and MIG brazing

Laser Hybrid Welding Head

Laser power and arc power concentrated to the same weldpool gives tolerances of MIG/MAG with laser weldingpenetrationEspecially suitable for welding of primered plates (one-sided welding, stiffener welding), and welding of high-strength steels

ROBOTICS

Instruction Manual Aristo Process Package, order number ..... Contact ESABSales Literature Aristo Process Package, order number ............. XA00107220 63

Analog Interface

Connect welding equipment to externalequipment using analog or serial signalsAccess the following signals:

Arc Voltage referenceWire feed referenceFunctions for start, inching, gas control and cleaningWelding acknowledge outputError indicationFive schedulesWelding busy outputRelease wire

Feed 30/48 Wire Feeder

Encoder communicates with other equipment toensure accuracy in wire feedingFeed 30 Unit – Single motor drive with four 30 mm(1.18 in) drive rollsFeed 48 Unit –Dual motor drive with four 48 mm(1.9 in) drive rolls

Mech/MEK Wire Feeder Control Unit

Controls wire feeder motorCompact and easy to position close to wire feedmotor

Tandem Mig Welding Head

Tandem mig advantages include high speed welding,low heat input, and increased productivityIsolated wire contacts allow different parameters,wire type, and diameter for each wireTorch has variable wire spacing, angles, electricalstickout, and various gas shielding cupsAvailable for robotics or hard automationUses either dual AristoMig pulse system or LAF (DC)power supplies

ROBOTICS

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65

Mechtrac 1730/2100/2500/3000Components for mechanized gantry automation

Fast and flexible way to increase productivityEquipped with PEH process controller and A2welding equipment for mechanized SAW orMIG weldingWeld various profiles such as I-, T-, or L-beams, straight columns, or tapered columnsAvailable in four versions (width of gantry):1730mm (68 in), 2100 mm (83 in), 2500 mm(94 in), or 3000 mm (118 in)All versions have standard gantry leg height of1500 mm (59 in)Floor mounted rail delivered in standard lengthsof 3 m (118 in) - can be easily extendedDual-drive motors are standard on Mechtrac2100/2500/3000, Mechtrac 1700 available assingle or dual-driveGantry can support a maximum weight of 220kg (485 lb) - up to two A2 weld heads, completewith GMD joint tracking, and OPC flux recoverysystems


Mechtrac 1730, single drive ...................................Mechtrac 1730, dual drive ......................................Mechtrac 2100, dual drive ......................................Mechtrac 2500, dual drive ……………………......…Mechtrac 3000, dual drive ......................................

809 670 880809 670 881809 670 882809 670 883809 670 884

Instruction Manual Mechtrac 1730/2100/2500/3000, order number ....... 807230101Sales Literature Mechtrac 1730/2100/2500/3000, order number ......... XA00101220

APPLIED AUTOMATION


Traveling rail, 3m (9.8 ft) ......................................... 806 707 880Traveling rail, extension, 3 m (9.8 ft) ..................... 806 707 881

ESAB CaB SystemsFlexible, Modular Column & Booms

Modular design concept allows total customization using standard componentsLarge selection of available components to integrate for a custom solution:

Any A2 or A6 weld head systemPEH Process Controller with LAF/TAF power sourcesESAB turning rolls and positionersESAB flux feeding and recovery systemsGMD and Laser Joint Tracking SystemsMonitoring systems, cameras, WMS 4000 quality supervision software

Four basic station designs suitable for most standard applicationsThree different sizes: 300, 460 and 600 (number refers to boom profile height which determines workingrange and load capability)Different types of foundations available- stationary or rail-travelling carriageA variety of options to cover any automation demands

APPLIED AUTOMATION

66

Standard CaB Stations

Basic station 1Standard set-up with welding equipment on one orboth ends of the boomPositioning of welding equipment in 4-axisApplication: Vessels, pipes, profiles and otherlarge welding constructions. Perfect for narrowspaces

Basic station 2Basic station 1 with the added advantages of aside boom carriage with welding equipmentBoom is movable and simultaneous welding canbe achieved with two headsApplication: Vessels and pipes or conical girdersand box profiles

Basic station 3Welding station with horizontally fixed boom and isequipped with two side boom carriages supportingwelding equipment on same side of boomWeld simultaneously with two headsApplication: Straight and conical girders, boxprofiles, beams, stiffeners and vessels

Basic station 4Welding station with horizontally fixed boomfeaturing double track with boom carriages sup-porting welding equipment on both sides of theboomSimultaneous welding operation with two heads asstandardApplication: Containers, truck platform bodies, boxgirders, beams, stiffener section and jointing ofplates and section

APPLIED AUTOMATION

67

Sales Literature CaB 300S, order number ........ XA00118720Sales Literature CaB 300M, order number ....... XA00118820Sales Literature CaB 460S, order number ........ XA00118920Sales Literature CaB 460M, order number ....... XA00119020

Standard CaB Sizes

The manipulators are divided into three different sizes 300, 460 and 600. These sizes are the throatdimensions of the boom in millimeters. Each size has a corresponding column. The different sizes are notonly limited in where it can fit, but also how far the boom can extend and how much load that can be put on.

Performance CategoriesThe system is divided into three different categories for performance:

S: StandardStandard mechanical performance, no cable chainA few options, camera-system, tacho-regulated speed and flux controlOnly for Basic station 1

M: ModularStandard mechanical performance, including cable chain for Columns and BoomsMore than 20 options fully integrated, such as tandem, shift function, transport speed etcOnly for Basic station 1

C: CustomizedBased on the same mechanical performance as the S- and M- modelBased on the same electrical system as the M- modelIncludes everything that is not a S- or M- model such as:

Basic station 2, 3, and 4Odd sizes (ex. 4.35 m x 5.15 m)Option demands not offered in S- or M- model.

APPLIED AUTOMATION

Sales Literature CaB S, M, C version, order number ....... XA0009512068

APPLIED AUTOMATION

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APPLIED AUTOMATION

70

APPLIED AUTOMATION

71

ESAB Seamers for External WeldingLongitudinal seam welding machine

Best solution for welding high quality longitudinalwelds to plates, tanks or other cylindrical workpiecesSeamers are delivered ready to weldAvailable for 1-6 m (39-236 in) long welds and fordiameters 150-1000 mm (6-39 in)Easy alignment of plates with help from laser lightPneumatically operated stoppers for plate alignmentavailableWater cooled backing barCopper backing bar equipped with shielding gas forplasma and TIG processesManual and remote control operations with PLCcontroller

APPLIED AUTOMATION

72Sales Literature ED External Seamers, order number ....... XA00120020Sales Literature ID Internal Seamers, order number .......... XA00120120

ESAB Seamers for Internal Welding

Best solution for welding high quality longitudinalwelds to plates, tanks or other cylindrical workpiecesSeamers are delivered ready to weldAvailable for welding a max of 6 m (236 in) longwelds and diameters greater than 1500 mm (60 in)Easy alignment of plates with help from laser lightbeamPneumatically operated stoppers for plate alignmentavailableCopper backing bar equipped with shielding gas forPlasma and TIG processesConserve shielding gas with divided gas valvesManual and remote control operations with PLCcontroller

Sales Literature ED External Seamers, order number ....... XA00120020Sales Literature ID Internal Seamers, order number .......... XA00120120 73

Ordering Information- Internal Seamers

APPLIED AUTOMATION

Optional Accessories

Ordering Information- External Seamers

Optional Accessories

* Welding Equipment PackagesSAW1 LAF 635 power source, A2 wire feeder with PEH control, OPC flux recovery unitSAW2 LAF 1000 power source, A2 wire feeder with PEH control, OPC flux recovery unitMIG1 ESABMig 500 power source, ESABFeed 48-4, M14 wire feeder, MIG torchMIG2 AristoMig 400 power source, AristoFeed 48-4W, MA6 wire feeder, MIG torchMIG3 AristoMig 450 power source, AristoFeed 48-4W, MA6 wire feeder, MIG torchTIG1 AristoTIG 400 power source, BTE500M TIG torchTIG2 AristoTIG 400 power source, MEI 10 and MEI 21 wire feeder (cold wire), BTE500M TIG torchPlasma 1 PLW202 200A power source, CWC3-CWF1 wire feeder, PTM150 plasma torchPlasma 2 PLW402 400A power source, CWC3-CWF1 wire feeder, PT300 plasma torchPlasma 3 PLW402 400A power source, CWC3-CWF1 wire feeder, PT8 plasma torch

*

*

*

CircotechMechanized compact girth welding system

Self propelled three o’clock welding systemDesigned for on-site erection of large storagetanks, silos, blast furnaces and cylindricalobjectsAvailable in single-sided or double-sidedDesigned to travel along the edge of a tankshell, on a rail temporarily attached to shell, oron a stand-alone ring outside the shellEquipped with caged cabin for maximum safetyand easy to reach welding controlsStandard equipment includes single-wire SAW,or twin wire SAW on requestUtilizes ESAB’s flux supply and recoverysystemContributes to a consistent quality weldFully functional package consists of: Subarcwelding machine type A2 or A6 with motorisedslides, PAK manual tracking system, PEHprocess controller, a weather shielded safetycabin, LAF power source, 6 L (1.6 gal) fluxhopper and flux support, 50 m (164 ft) controlcable, and welding and return cables

APPLIED AUTOMATION

74 Sales Literature Circotech, order number ....... XA00083620


Contact ESAB

Rototech 80Programmable rotary welding equipment for automated MIG/MAG, TIG and Plasma welding

Programmable welding system for welding lightand medium weight cylindrical objectsWelding process and parameters are controlledby modern PLC control technologyIncludes the following main components:

Rigid frame with two support legsMovable turning device with vectorcontrolled frequency transformer andasynchronous motorSpindle with double-sided bearingsTurntable with guide holes for attachingfixturesMovable clamping device with pneu-matic cylinder and hand-operatedlocking devicePneumatically controlled gun holderwith movable armPLC control and operation boxCentre point for clamping

Weld components as large as 400 mm (16 in )in diameter, 3000 mm (118 in) in length, and upto 80 kg (176 lb) in weight

APPLIED AUTOMATION

75Sales Literature Rototech 80, order number ....... XA00079820


Contact ESAB

The Wind Energy IndustryWind is an untapped and virtually unlimited source of clean, renewable energy. Advances in electricalgeneration turbines are transforming the wind into abundant and competitive electrical energy. The growingshortage, as well as the pollution associated with fossel fuels, practically guarantees that wind energy willcontinue to grow at a rapid pace.

Wind energy creates a new market for many industries, including metal fabrication. The industry requires allsorts of products, from the blades, turbines and towers, to specialized cranes and handling equipment,trucks, excavation equipment, concrete, transmission lines, switch gear, and much more.

One area where ESAB has been particularly successful is in the windtower industry. Towers are usuallylarge, conical, welded steel structures, which must support the turbine and blades (Nacelle). It is a verydemanding application. The tower must support the immense weight of the nacelle, as well as resist thevibration, cyclical bending stresses, in all weather and temperatures. This is a welding challenge.

ESAB has worked with the fabricators of towers since the beginning. In doing so, ESAB has developedextensive specialized equipment, weld metals and procedures to reduce the cost of tower manufacturing.From the filler metals and small tractors, to bevel cutting machines through to highly automated assemblylines, ESAB is helping customers around the globe to succeed in efficient windtower production.

Wind tower production provides a great opportunity for metal fabricators. Please call ESAB for more infor-mation on specialized windtower equipment.

SPECIAL APPLICATIONS

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Complete Tower Assembly line.Reduces assembly time to a fraction of conventional assembly methods

Sales Literature WindTower Production Lines, order number ..... Contact ESAB

The Wind Energy Industry


Automated Assembly Line

Large Column and Boom Manipulators

Turning Rolls and Transport Equipment

Door Frame Welder

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Extensive variety of turning rolls customized forheavy windtower sectionsTransfer carriages on bogiesFit-up, transport and paint rolls

Unique, multiaxis robot, drastically reduces weldtime, while improving quality. Available for avariety of door designsBased on the Railtrac Flexible Automationsystem, control offers programmable beadshape, oscillation, and full control over ESABsemi-automatic welderOperator can easily modify program on the fly toallow for changing fitup of the joint

Uses A6 subarc weld heads and PEHmicroprocessor controllerHigh deposition rates can be achieved withoptions such as twin wire, synergic cold wire, fluxfeed and recovery, and large wire reelsOperator controls process from floor heightplatform, through seam tracking and videocamerasCan be equipped with tandem wire process forhigher production in thick sections

Unique Head and Tailstock sytem, capacity 80ton, up to 6.1 m (20 ft) diameter. Precisionclamping system ensures roundness of cans, forprecision fit-upSpecial fit-up jig allows operator effortlessalignment adjustmentTurning rolls and transport equipment,adapted for conical towersSystem reduces assembly time to a fraction ofconventional assembly

CaB Based Beam Welders

Aluminum Trailer Beam Welder, With NarrowPrecision Track

Submerged Arc Trailer Beam Welder

Walltrac Wall Mounted CaB Welding Station

Beam Welding


Sales Literature Beam Welding, order number ..... Contact ESAB

ESAB offers a variety of beam welding solutions from simple tractors to fully automated beam assemblylines for all styles of beams, from I-, T-, L-beams, wide flange beams, columns, tapered beams and non-symmetrical beams. Our extensive experience in beam welding ensure optimum straightness andproductivity.Some beam welder examples are shown, please call for further information on specific applications.

78

Weld a large variety of beams with various configurations ofstandard columns and boomsProcesses include: subarc, tandem subarc, MIG, cored wire,and aluminum weldingPEH integrated process controllerA2/A6 headsSeam tracking options can be modified for curved shapes,such as trailer beams

Pivot base allows welding on both sides of trackUnique joint tracking allows proper torch alignment throughthe transition curves on the beamMIG welding process with AristoMIG 450 and includesintegrated fume extraction system

Available similar to above but equipped A2/A6 subarc heads,PEH process control, and flux recovery systemAlso available for metalcore process

For production of various beams structures, such as I/H, boxbeams and non symmetrical designFloor space is minimized with single rail/wall supportLongitudinal and transverse welding proceduresUses A6 welding heads, PEH process control and GMD jointtracking

Beam Welding


79Sales Literature Beam Welding, order number ..... Contact ESAB

Pull Through Beam Welders:Welding head is stationary and beam is pulled through the station. Parts are automatically aligned andcompressed, eliminating tacking. Tight fit-up ensures high weld quality. Models available for vertical orhorizontal web.

IT 2000 Web Horizontal Pull ThroughBeam Welder

IT 100, 258 and 3200 Web Vertical PullThrough Beam Welder

Both sides of flange welded simultaneouslyBuilt-in straightening device to compensate forpullback of the flangesOptional induction or gas heating equipment toensure straight beams. Required for T beamsComplete material handling systems availablePLC controlled, uses A6 DC-AC tandem subarcheads on each side for high speedweldingSpecs: IT 100: web height max 1 m (3.3 ft)IT 258: Web height max 2.5 m (8.2 ft)IT 3200: Web height max 3.2 m (10.5 ft)

Both flanges welded simultaneouslyEasy to install, no special foundation requiredPlace two machines in line for continuous flowInfeed and outfeed conveyors availablePLC controlled, uses A6 DC-AC tandem subarcheads on each side for high speed weldingSpecs: Flange size 100 – 700 mm; beamheight 246 – 2200 mm

Welding Gantries

ESAB has a variety of gantry designs, most oftencustomized for customer applications. Call ESAB formore information.

GantracThis gantry is rigid, and has dual drive system toensure a uniform and stable welding speed. Operatorcontrols welding process from platform mounted onone bogie carriage. Well proven A6 subarc heads aremounted on rack and pinion slides with long workingrange for easy access to various size work pieces.Automatic joint tracking ensures consistent weldingquality. Heads can be rotated 90 degress for weldingin horizontal direction, as well as 180 degrees forwelding in the return direction. Flux feed and recoverysystem for continous welding, while reducing fluxconsumption and keeping the installation clean.

Combination Cutting and Welding GantryBased on Avenger 2 series Gantry Cutting Machine,this computer controlled machine automates thecutting of web and flanges from plate, facilitating themanufacture of straight, curved or cambered beams.Plasma Markers apply text information and layoutlines for post process positioning of ancillary compo-nents. Beams are assembled on special fixturebetween the rails. Oxyfuel heating torches provideweld preheat prior to both welds being processedusing A6 Tandem DC-AC Submerged arc heads;positioning is automated using Heavy Duty SeamTracking Servo Slides. Long stroke vertical slides onall processes allow access to deep beams, as well asretracting the heads clear of the weldment when not inuse.

Stable gantry station with a width of 7000 mm forwelding stainless steel railway wagon roofsThe joints are of the overlap type without prior tackwelding. A pneumatic clamping device ensures thatthe plates are tightened to each other during the MIGwelding procedure. An Aristo power source withpulsed welding sequences provides superior weldquality. An A2 welding head equipped with a durablewater cooled torch is used to withstand the verygrueling working conditions. Non-interrupted weldinglength of up to 30 m (98 ft) at a rapid welding speed ispossible. The reverse speed is 10 m/min (390 ipm)using efficient AC synchronic motors.


80 Sales Literature Welding Gantry, order number ..... Contact ESAB


81

ESAB provides total panel line solutions forshipbuilding, from plate cutting and marking toassembly and material handling. Call for moreinformation.

One Side Welder (OSW)One side welding improves panel assemblyefficiency by eliminating the need to rotate largepanels. ESAB OSW uses vacuum clamping tosecurely hold plates in position during welding,without tackwelding. System uses ESAB A6welding heads, and 3-wire subarc systems.Backing flux is automatically and accuratelydeposited on the water-cooled backup bar. Platesare fed through the OSW with infeed and outfeedtables with gripper conveyor system.

Stiffener Assembly and WeldingStiffener assembly gantry positions and weldsboth sides of stiffener. Programmable stitch orcontinous. Gantry can carry dual stations (4 weldheads) for increased productivity. PLC controlled,uses A2 MIG welding components. Variousdesigns and levels of automation are available.

Vertical up welderA unique system, specifically designed for doublehull construction. A four torch head is lowered intoan intersection and then welds all four jointssimultaneously. Extensive programmingcapabilities allow oscillation, multi pass, stitch, aswell as ability to sense and skip cutouts orhorizontal stiffeners. Can be fitted with ESABpulse or cored wire systems. An extremelyefficient system, eliminating a difficult task whileimproving health and safety of welders.

Shipyard Applications


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Custom Welding SolutionsRoll Buildup and Hard SurfacingRototech 2000 is an integrated unit for surfacing of cylindricalobjects, such as steel mill rolls. It uses a head and tailstock,with PLC controlled positioning equipment. Weld process canbe plasma, MIG, subarc or strip cladding. Program variablesinclude selectable bead placement style, carriage and rotationspeed, bead width and overlap, oscillation speed andamplitude. Process variables are preset on the PEH weldingcontrol.

Electroslag Welding MachineMachine for longitudinal welding of cylinders for the pulpindustry. The picture shows a machine with the welded cylinderin the vertical position. The assembly is equipped with aninside-cooling support column for applying a cooling shoe to theclosed joint of the upright cylinder. The machine permits thewelding of plates with a thickness of 40-450 mm (1.6-17.7 in)while using one to three electrode wires.

Pipemill Welding equipment, for Longitudinal and Spiralpipe millsEquipment includes GMAW high speed, high current tackingequipment, internal booms with up to 4 weld heads, and exter-nal heads up to 6 wires. Advanced controls easily control andmonitor the parameters of all wires. A wide range of ancillaryequipment is available, including laser or mechanical guidancesystems, flux delivery and recycling equipment, slag crushers,pipe handling lines and Weldoc™ monitoring software.This equipment is designed for retrofit of existing mills as wellas for new mills.

Lamp Pole WelderVarious systems available for tapered lamp pole welding. Photoshows single sheet formed pole, which is pulled through thewelding station. Heavy guide rollers ensure a tight fitup at theseam. Joint tracking keeps the arc centered on the joint.Available with ESAB subarc or MIG equipment. Infeed andoutfeed conveyors are also available.

Column and Boom station for welding dish ends in thechemical and petrochemical reactors marketThe weld object, which is clamped to a positioner table istilted during the weld operation. Integrated motions betweenthe positioner and the boom-travelling welding head allowfor constant welding speeds.Station consists of NC controlled CaB 600 manipulator, 10x6m (33x20 ft) column and boom; A6 submerged arc weldingheads, and 50 ton positioner.

Multi-head gantry stations for the energy and processmarketWelding heavy winch drums intended for the ship andoffshore industry. The circumferential weld procedure utlizestwin-wire flux cored wire. The shell of the drum is joined atvarious lengths using butt joints. Simultaneously weldedwith two welding heads.Dimension of object: Shell diameter max 3500 mm (137.8in). Length of drum max 9300 mm (366.1 in). Wall thicknessmax 80 mm (3.1 in). The station comprises of the following:stationary gantry with two motorized carriages (eachequipped with slide assemblies and special A6 weldingheads), TV monitoring system for remote control from floorlevel and turning rolls for support and weld rotation.

Column and Boom station for welding turbines in thehydropower energy marketCNC-controlled welding manipulator with six programmableaxes (teach in). Butt joining of the blades to the shaft of theturbine rotor. The complex 4 m (157.5 in) longitudinalpreparation is curved into three dimensions. The process isTwin-wire SAW. The working range of the manipulators is2x4.3x2 m (78.7x1693x78.7 in) [HxLxW]. The threeremaining axes are integrated in the customized weldinghead.

Boiler Manufacturing AutomationESAB offers a complete line of boiler equipment from tube-fin prefab machines, fin-bar and tube-to-tube machines, tocomplete membrane wall panel welding and finishing.Membrane welders can be moveable gantry or stationarypull-through systems. Multiple head A6 subarc welding isnormally used. Photo shows stationary membrane welder.

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Friction Stir Welding System

Friction Stir Welding (FSW) is based on the principal of obtaining a sufficiently high temperature andpressure to join two components together. This is done by using a rotating tool which under highpressure moves along the joint and thereby creates a weldFSW is ideal for joining straight profiles and flat plates from 1.2 to 30 mm (0.045-1.18 in). Butt, lapand corner joints can be welded. Round and circular welds can be welded with multiaxis machinesMetals that can be welded include aluminum, copper and magnesium. It is also possible to welddissimilar alloys and dissimilar materials such as copper to aluminum, magnesium to aluminumAdvantages of FSW include:

Much higher weld strength than conventional arc weldingVery low distortion and shrinkageNo joint preparation- only degreasing is requiredEnvironmentally friendly- no fumes, arc glare, spatter or noiseExtremely reliable process- expect year after year of defect free welds

Suitable applications include:Aluminum production of large extrusions, large panels, girders and trusses, such as used infast ferries, ships, offshore living quarters and railway wagonsAerospace, such as rocket fuel tanks, aircraft structures and componentsProduction of cooling blocks, coolers and housings for electrical motorsAluminum in automotive applications, such as frame components, seats and cooling compo-nentsLeisure vehicle aluminum frames and componentsImprovement of material in high stress areas, such as edges on diesel pistonsProduction of panels with stiffeners in 5000-series aluminumJoining of dissimilar alloys and metals, such as copper to aluminum


84 Sales Literature Friction Stir Welding, order number ....... XA00098320

ESAB is the world leader for commercial installations of Friction Stir Welding machines

LegioTM Friction Stir Welder Super StirTM Friction Stir Welder


The ESAB LEGIOTM concept combines the latesttechnology with proven quality. The modular systemmakes it possible to assemble welding stations tosuit the most varied Friction Stir Weldingapplications.

The LEGIOTM system consists of five basic designsin a series of seven sizes, covering a welding depthof 1.2 mm (.045 in) to 60 mm (2.4 in). These basictypes can be supplemented with different types ofequipment to suit the most varied production needsand give maximum flexibility to any production line.

The ESAB SuperStirTM program includes avariety of machines developed from astandarized ESABSuperStirTM base unit andwith working ranges of 0.5x1.5 m (19.7x59 in)up to 10x20 m (33x66 ft) within the sameconcept.

The program includes customized models ofvarious designs for specific customerrequirements in different production areas.

These different designs are used worldwide inR&D centers for joining of extrusions to panels,in production of pressure vessels as well assmall parts for the automotive and electronicindustries.

85Sales Literature LEGIO, order number .......... XA00117820Sales Literature SuperStir, order number ...... XA00098320

LegioTM Modular Friction Stir Welder Installation of a SuperStirTM at DanStir ApS, Copenhagen, Denmark

The versatile Legio family includes linear motionwith single or dual (over /under) heads, with orwithout tables. Dual axis(x – y) model is availablewith or without table. Tables include a holepattern for attaching fixtures.

Legio includes ESAB HMI control specificallydesigned for Friction Stir Welding. It is a closedloop welding control, including the ability tocontrol the Z axis either by pressure or position.PC network connections and data transferoptions are available


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Narrow Gap Welding

HNG-S and HNG-T

FANG

ABW

Highly mechanized multi-run system technology for heavy walled work piecesContinuous welding process requires little or no operator inputAchieve high quality welds with accuracy and repeatabilityESAB offers four different “state of the art” systems: HNG-S, HNG-T, FANG, and ABW

For joint depths up to 350 mm (13.78 in)Employs Programmable Logic Welding control forsimple handling of different joint configurationsFeatures: Automatic 2-axis joint tracking and shiftfunction for automatic fillIdeal for pressure vessel manufacturing

Fully automated longitudinal and circumferentialseam weldingFeatures: Automatic bead placement and uniform fillfunctionsIdeal for continuous mass production of products,such as heavy wall, offshore structural pipes

Fully automatic and adaptive welding for any kind ofbutt jointFeatures: Excellent adaptive function capable ofhandling joint gap or mismatch deviations along thejoint lineAvailable in single and tandem wire versions

Sales Literature Narrow Gap Systems- HNG, order number ....... XA00080520Sales Literature Narrow Gap Systems- ABW, order number ...... XA00048320Sales Literature Narrow Gap Systems- FANG, order number ..... XA00055820

Narrow Gap System- HNG Fully automatic Submerged Arc Welding

Automatic welding process based on tworuns-per-layer technologyEquipment available for both single wire(HNG-S) and tandem wire (HNG-T) applica-tionsOperate with joint gaps ranging from 18-24mm (0.71-0.95 in) for single and > 20 mm(>0.79 in) for tandemWelding defects such as lack of fusion,undercut, and slag entrapment are elimi-natedProduces a perfect seam shape andsurface finish (smooth blending with sidewalls and excellent self-releasing action)Improved weld metal and heat-affectedzone toughnessCan be integrated with ESAB’s CaB andturning roll unitsAchieve precise and accurate bead place-ment with two-axis joint tracking systemSystem includes all required hardware,software, and programming information forautomatic joint tracking and bead place-ment


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Contact ESAB

Sales Literature Narrow Gap Systems- HNG, order number ....... XA00080520Sales Literature Narrow Gap Systems- ABW, order number ...... XA00048320Sales Literature Narrow Gap Systems- FANG, order number ..... XA00055820

Mechanized Cutting Systems

ESAB Cutting Systems offers the widest range of mechanized cutting products available for plate cutting applications, whether it isstraight line or shape cutting. ESAB is the only cutting machine manufacturer to offer all 4 major cutting processess: laser, oxy-fuel,plasma and waterjet.

There is a machine for virtually every requirement, from custom fabrication shops to large production operations. Although machinesare standardized by model and type, each piece of equipment is generally customized to the individual customer’s specifications. Notwo plants are exactly alike, and very few applications are identical.

Among the many features to be found in ESAB cutting systems are heavy-duty structural designs, rack-and-pinion coordinate drives,advanced electronic controls and a wide array of processes such as: oxy/fuel-gas, plasma systems, water jet systems, laser systems,plate marking, routing and drilling.

From blueprint to shipment, every piece of equipment undergoes rigid quality control procedures. Detailed examination of componentparts, specification checks and operational testing result in equipment of the highest quality and expert craftsmanship. Because of this,product performance is unsurpassed.

Oxy-fuel Gas Cutting

Commonly used for cutting steel with thickness greater than25mm (1 in) and can cut very thick material up to 500 mm(20 in)Provides straight cut face and minimal clean-upFor use only on carbon steel - will not cut through alumi-num, stainless steel, brass, or copperIdeal for multi-torch applicationsOxy Beveling is available

Conventional Plasma

Used to cut variety of metals including carbon steel, stain-less steel, aluminum, brass, and copperCuts much faster than oxy-fuel or waterjet cutting, particu-larly on thin materialsMay leave small bevel angle on cut faceCreates a smaller heat affected zone for minimal warpingGenerally suited for plate thickness of 25 mm (1 in) or lessIdeal for multi-torch applicationsPlasma beveling is available

Precision Plasma

Highly precise form of plasma cuttingUses proprietary arc technology to constrict plasma arc -provides low dross and low bevel angle cutsCreates a very smooth cut faceIdeal for use on carbon steel, stainless steel, and aluminumup to 25 mm (1 in) thick


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Plasma Bevel Process

ESAB plasma bevel system increases productivity by apply-ing the benefits of high speed plasma cutting for plate edgepreparation. Fully programmable to cut parts with straightand bevel, up to 1.25” (30 mm). Bevel from -45o to + 45o,multipass for Y bevel, change angles on the fly. Above orunder water. Cut quality maximized though CNC process andmotion control with Vision PC. This tool is essential for highvolume plate cutting such as in the windtower industry

Waterjet cutting

Uses high velocity, high pressure stream of water - oftencombined with powdered abrasives such as garnet toincrease cutting abilityCut any metal as well as paper, cardboard, glass, graphite,epoxy, fiberglass, and many more materialsNo heat is involved in cutting process and produces no heataffected zone - no warping, cracking or need for secondarymachining operationsAllows for precise contours, intricate shapes, sharp corners,and low bevel anglesMay combine with conventional plasma on a gantryWaterjet beveling is available

Laser Cutting

Cut carbon steel up to 25 mm (1 in) thick and stainless steelup to 16 mm (5/8 in) thickExtremely accurate cut, very small kerf width and excellentedge qualityEliminate the need for a secondary machining processESAB Alpharex Gantry system provides cutting capability upto 5 m (16.5 ft) wide and unlimited lengthProvides high accuracy, speed, and innovative processautomationMay combine with conventional plasma on a single gantryLaser beveling is available

Columbus software

Programming software developed and maintained by ESAB,the manufacturer of the cutting system makes creating,posting and nesting parts much faster and easierComplete integration with ESAB controllersAlso upgrade your existing software used on other cuttingmachines you may already have in-houseAdvanced capabilities including

CAD translation and drawingAutomatic nestingPlate and data managerEstimation softwareInteractive CNC files


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Filler Metals

ESAB is one of the world’s leading manufacturers and innovators of welding consumables. Our range ofcovered electrodes, cored wires, solid wires, TIG rods, strips and Submerged arc welding flux, covers anyapplication for almost any type of material.

MIG Welding

ProcessWith MIG welding, also called Gas Shielded Metal Arc Welding (GMAW), an arc is maintained between acontinuous solid wire electrode and the work piece. The arc and weld pool are shielded by a stream of inertor active gas. The process is suitable for most materials and filler wires are available for a wide range ofmetals.

MIG welding is a versatile process, which can deposit weldmetal at a very high rate and in all positions. The process iswidely used on light to medium gauge steel fabrications andon aluminium alloy structures particularly where high-ratemanual operator production is required..

Process AdvantagesEasy to mechanize or adapt to a robotCost-effective method for process automation on thinmaterialsAvailable in wide array of diameters and packages forany requirementHigh deposition efficiency (up to 98%)

FILLER METALS

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Cored Wire

ProcessFlux Cored Arc Welding (FCAW) is quite similar to MIG welding as far as operation and equipment areconcerned. However, the wire is not solid but consists of a metal sheath surrounding a flux core. The wirebegins as a flat metal strip, which is formed first into a ‘U’ shape. Flux and alloying materials are depositedinto the ‘U’, which is then closed into a tube by a series of forming rolls.

As in MIG welding, the flux cored welding process depends on a gas shield to protect the weld zone fromatmospheric contamination. In addition to the gas shield, the flux cored wire produces a slag covering forfurther protection of the weld metal as it cools. This is subsequently removed.

Process AdvantagesHigh deposition ratesExcellent weld bead appearance with little or nospatterDeep arc penetration when welding – allows tighterjoint design, reducing quantity of filler metal neededto fill the jointWide selection of alloys availableHigh deposition efficiency (up to 98%)Metal Cored wires have high current capacity andproduce little or no slag – very high weld efficiencyand deposition rates are possibleMay also be used in a Submerged arc weldingprocess

FILLER METALS

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Submerged Arc Welding

ProcessIn SAW (Submerged Arc Welding) an arc is struck between the work piece and the end of a consumableelectrode, both of which are covered by a layer of granular flux (hence ‘submerged’ arc). The arc is thereforehidden. Some of the flux melts to provide a protective slag cover over the weld pool. The remainder may becollected for re-use. Submerged Arc Welding is principally carried out with fully automatic equipment. Toincrease productivity, cored wires, or arrangements with several solid wires can be introduced. Due to itshigh metal deposition rate it is particularly suited to long straight joints of good quality in the flat position. It iswidely used in the pressure vessel, chemical plant, heavy structural, repair, and shipbuilding industries.

Process AdvantagesVery high deposition rates and travel speedsExcellent and consistent weld qualityDeep arc penetration when welding – allows tighter joint design,increasing productivity and reducing quantity of filler metal neededto fill the jointOperating factor can approach 100%No fumes or arc radiation

FILLER METALS

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Strip Cladding

ProcessThe methods that are mainly used for cladding larger areas are strip cladding by submerged arc welding(SAW) or by electroslag welding (ESW). Both methods offer a high deposition rate, in terms of both kg/h andarea coverage (m2/h), combined with low penetration and high deposit quality. Stainless steel strip claddingis widely used in the production of components for the chemical, petrochemical and nuclear industries.SAW strip cladding has been widely used with strip electrodes since the mid-1960s. The strip, normallymeasuring 60 x 0.5 mm, is used as the electrode and an electric arc is formed between the strip and theworkpiece. Flux is used to form a molten slag to protect the weld pool from the atmosphere and helps toform a smooth weld bead surface.ESW strip cladding - is a development of submerged arc strip and has established itself as a reliable highdeposition rate process. ESW is an arcless method using ohmic heating to melt the strip/flux/parent mate-rial. The heating is a result of current flowing through the strip electrode and a comparatively shallow layer ofliquid electro-conductive slag. The penetration is lower for ESW than for SAW since the molten slag pool isused to melt the strip and some of the parent material rather than as an arc between the strip electrode andthe parent material. As a rule of thumb, electroslag strip surfacing reduces dilution by up to 50% comparedwith submerged arc strip surfacing for the same heat input with a significantly higher deposition rate.

Process AdvantagesReduces requirement of expensive highly-alloyed base material, such as stainless steel or nickel-base alloys in many applications – can use low cost base material with strip clad overlay to achieverequired material propertiesOffers the chance to choose a wide variety of parent materials and consumablesHigh deposition processes with low dilutionAllows for flexibility in the production of objects of various shapes and sizes

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FILLER METALS

Marathon PacTM

Packaging improves Productivity

Marathon Pac™ is a bulk pack for 200-475 kg of solid or flux-cored welding wire. The welding wire has beenwound into the drum using a special technique. The wire is straight and comes out of the gun withouttwisting or warping making this product ideal for welding robots and other mechanised welding stations.Stoppages for spool changes and maintenance requirements are reduced by almost 90% — the arc-timefactor is increased. Improved welding quality MARATHON PAC™ reduces repairs and rejects resulting fromwelding defects. The straight, untwisted wire offers major benefits when welding narrow joints, weaving inheavy material and welding thin plates where the wire must be precisely positioned to avoid welding defects.

Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 726 80 05

THE CZECH REPUBLIC ESAB VAMBERK s.r.o. PragueTel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK Aktieselskabet ESAB Copenhagen-Valby Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 204

GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81

THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: +31 30 248 59 22 Fax: +31 30 248 52 60

NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND ESAB Sp.z.o.o Warszaw Tel: +48 22 813 99 63 Fax: +48 22 813 98 81

PORTUGAL ESAB Lda Lisbon Tel: +351 1 837 1527 Fax: +351 1 859 1277

SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN ESAB Ibérica S.A. Alcobendas (Madrid) Tel: +34 91 623 11 00 Fax: +34 91 661 51 83

SWEDEN ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB International AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

North and South America ARGENTINA CONARCOBuenos AiresTel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL ESAB S.A. Contagem-MG Tel: +55 31 3369 4333 Fax: +55 31 3369 4440

CANADAESAB Group Canada Inc. Mississauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 44 58

Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: +86 21 6539 7124 Fax: +86 21 6543 6622

INDIA ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA P.T. Esabindo Pratama Jakarta Tel: +62 21 460 01 88 Fax: +62 21 461 29 29

MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 703 36 15 Fax: +60 3 703 35 52

SINGAPORE ESAB Singapore Pte Ltd Singapore Tel: +65 861 43 22 Fax: +65 861 31 95

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 861 74 42 Fax: +65 863 08 39

SOUTH KOREA ESAB SeAH Corporation Kyung-Nam Tel: +82 551 289 81 11 Fax: +82 551 289 88 63

UNITED ARAB EMIRATES ESAB Middle East Dubai Tel: +971 4 338 88 29 Fax: +971 4 338 87 29

Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88

EGYPT ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

ROMANIA ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74

RUSSIA-CIS ESAB Representative Office Moscow Tel: +7 095 937 98 20 Fax: +7 095 937 95 80

ESAB Representative Office St Petersburg Tel: +7 812 325 43 62 Fax: +7 812 325 66 85

ESAB subsidiaries and representative offices

2004/02 Printed in the USA

ESAB North America Automation

Canada6010 Tomken RoadMississauga, OntarioL5T 1X9Phone: 905-670-0220 Toll Free: 1-877-935-3226 Fax: 905-670-4879www.esabna.com

U.S.A411 S. Ebenezer RoadFlorence, South Carolina 29501-0545 Phone: 843-669-4411 Fax: 843-664-4258www.esabna.com

MexicoDiego Diaz de Berlanga no. 130San Nicolas de Los Garza N.L.CP 66480 Mexico Phone: (52) 81-8305-37-00 Fax: (52) 81-8350-59-20www.esabna.com

Distributed by:

ESAB Europe Automation

SE-695 81LaxaSwedenPhone: +46 584 810 00 Email: [email protected]

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