Catalogue Automation

a full line of automated welding products for every application and industry

automated welding solutions from esaB

Welding Automation Equipment

WELDING | CUTTING | FILLER METALS

ESAB WElding & cutting productS

gloBal solutions for locAl customErs - everywhere

ESABisthepreferredpartnerthroughouttheworldforprofessionalcustomersrequiringweldingandcuttingsolutions.Weapplythehigheststandardsofhonesty,ethicsandintegrityinallaspectsofourbusiness.Weconstantlyseek to improveourservice tocustomersaroundtheworldandwesetthehighestproductandprocessqualitystandardsinourindustry.

Throughteamwork,weinvolveallofouremployeesinstrivingtowardprovidingourcustomerswiththemostcost-effective solutions for their welding and cuttingapplications. Through technological leadership, themostreliableproductsanddeliveries,andcontinuousimprovementofourprocesses,wewillstrivetoexceedcustomerexpectations.

TheESABbrandissynonymouswithworldleadingexpertiseinthefollowingkeyareas:

ManualweldingandcuttingequipmentWeldingconsumablesWeldingautomationMechanizedcuttingsystems

Continuous development of methods, materialsandknow-howisbeingdirectedtomeetthechallengesposed by the diversity of our customers. ESAB isorganizedtodeliverefficient,high-productivitysolutionstomeetindustryrequirementsinamannerthatexceedstheir expectations. Our customers our found in thefollowingindustries:

AutomotiveGeneralfabrication&civilconstructionPipelinesPipemillsPowergenerationProcessindustryRepair&maintenanceShipbuilding&offshoreTransport&mobilemachinery

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ESAB Welding Automation

Welding automation meets some of thesechallenges with higher quality, capacity and, ofcourse, much higher productivity than manualwelding applications.At ESAB, we develop andmanufacture a wide range of mechanized andautomatedweldingproductstocreatethespecialsolutionyoumightneed.

Whetheryourmetalfabricationprojectrequiressimple components such as tractors or requireslargeturn-keysystemandproductionlines,weofferafullrangeofautomationproductstomeeteveryneedincludingthewidestrangeoffillermetalsintheworld.

esab welding & cutting products

You can also rely on ESAB for total systemresponsibility. Because we manufacture our ownequipment, we can integrate the welding process,arcpathandmaterialhandling.Anintegrateddesignsimplifies the equipment, improves reliability andensuresunsurpassedperformance. Usedasaguide,thiscataloguecanprovetobeausefultoolindeterminingtherightsolutionforyourapplication.Weencourageyou toconsultanESABRepresentativeformoredetail regardingprocesses,applicationsandcustomizedsolutions.

Call us today!1-877-935-3226

The21stcenturyhasbroughtmanynewchallengestothemetalfabricationindustry:metalfabricatorsmustmeetthedemandforincreasedqualitywhileprovidingtheircustomerswithanoveralllowercost;productivityischallengedbytheshortageofskilledworkers;profitabilityischallengedbythepressurefromintenseglobalcompetition.Asaresult,manufacturersarerequiredtoutilizenewfabricationtechniquestobuildincreasinglycomplexdesignsandstructures.

tractorsRailtrac 1000 ............................................................................................................................................... 4-6Miggytrac 1001 ............................................................................................................................................... 7Miggytrac 2000 ............................................................................................................................................... 8Miggytrac 3000 ............................................................................................................................................... 9A2 Multitrac with A2-A6 PEH Process Controller/A2 PEH Process Controller ........................................ 10-11A2 Tripletrac ................................................................................................................................................. 12A6 Mastertrac ............................................................................................................................................... 13A6 DK Portable Welding Machine ................................................................................................................ 14Frametrac ..................................................................................................................................................... 15A2/A6 Tractor Wear Parts ........................................................................................................................ 16-19

controllers and power sourcesA2-A6 PEH Process Controller..................................................................................................................... 20A2 PEI Process Controller ............................................................................................................................ 21 LAF DC Power Sources ............................................................................................................................... 22TAF AC Power Sources ................................................................................................................................ 23

weld HeadsA2S Mini Master ........................................................................................................................................... 24 A2 Component System Modularization ........................................................................................................ 25A6S Arc Master............................................................................................................................................. 26A6 Component System Modularization ........................................................................................................ 27 A6S Tandem Welding Heads ................................................................................................................... 28-29Tandem MIG Welding Head ......................................................................................................................... 29A6S Compact Welding Heads ...................................................................................................................... 30A6 Strip Cladding Head ................................................................................................................................ 31A6 “MHW” Manhole Welder .......................................................................................................................... 32

accessory componentsA6 Synergic Cold Wire ................................................................................................................................. 33Beam Travelling Carriage ............................................................................................................................. 34MBVA 330/550 Beam Welding Carriage ....................................................................................................... 34Motorized Slides ........................................................................................................................................... 35PAK & GMD Joint Positioning & Tracking Systems ...................................................................................... 36OPC Flux Recovery Systems ...................................................................................................................... 37OPC Flux Recovery Systems Wear Parts .................................................................................................... 38FFRS Flux Feed and Recovery Systems ..................................................................................................... 39CRE 30 & CRE 60 Air Drying Units .............................................................................................................. 40Flux Oven ..................................................................................................................................................... 40Flux Drying Equipment ................................................................................................................................. 41Water Circulators .......................................................................................................................................... 41Rotatable Earth (Rotating Ground) Couplings .............................................................................................. 42Earth Clamps for Rotating Workpieces ........................................................................................................ 42Camera Systems for Submerged Arc & Open Arc Welding .......................................................................... 43Weldoc WMS 4000 Data Program ............................................................................................................... 44

Handling equipment5-500 TA Self-Aligning Turning Rolls ............................................................................................................ 453-500 TNA Conventional Turning Rolls ........................................................................................................ 46

table of contents

table of contents

Handling equipment, cont’dTXA “Scissor-Type” Turning Rolls................................................................................................................. 47 250-35000 AHMA Positioners....................................................................................................................... 4875-150 SK Positioners .................................................................................................................................. 49750-10000 SHA Positioners ......................................................................................................................... 50750-50000 VA Positioners ............................................................................................................................ 5125000-50000 CRA Positioners ..................................................................................................................... 52750-50000 Head & Tailstock Positioners ................................................................................................. 53-54

Mechanized tigProwelder 160/250/320 Mechanized TIG Welding Machines ....................................................................... 55A21 PRB Tube-to-Tube Welding Head ......................................................................................................... 56A21 PRC Tube-to-Tube Welding Head......................................................................................................... 57A21 PRH Enclosed Tube Welding Head ...................................................................................................... 58A21 PRD Orbital Tube & Pipe TIG Welding Heads ...................................................................................... 59A22 POC 12-60 Tube-to-Tube Sheet TIG Welding Heads ........................................................................... 60A25 Mechanized TIG Modular Component System ..................................................................................... 61MEI 21/10 Wire Feed Units .......................................................................................................................... 62G-Tech Precision TIG Electrode Grinder ...................................................................................................... 63OCF 2M Cooler ............................................................................................................................................ 63Welding Parameter Documentation Printer .................................................................................................. 64

roboticsAristoMig Process Packages for Mechanized MIG Welding ........................................................................ 65Standard AristoMig Robot Package Configuration ....................................................................................... 66

applied automationMechtrac 1730/2100/2500/3000 ................................................................................................................... 67 Column & Boom Systems........................................................................................................................ 68-71Seamers for External/Internal Longitudinal Welding ............................................................................... 72-73Circotech Compact Girth Welding System ................................................................................................... 74Rototech 80 for Rotary Welding ................................................................................................................... 75

special application productsWindmill Tower Manufacturing ................................................................................................................. 76-78Beam Welding ......................................................................................................................................... 79-80 Welding Gantries .......................................................................................................................................... 81Shipyard Applications ................................................................................................................................... 82 Custom Welding Solutions ...................................................................................................................... 83-84Hybrid Laser Welding ................................................................................................................................... 85Narrow Gap Welding Systems ................................................................................................................ 85-86ESAB Retrofit ............................................................................................................................................... 87 Friction Stir Welding ................................................................................................................................ 88-89Mechanized Cutting Systems .................................................................................................................. 90-92

welding filler MetalsMIG Welding ................................................................................................................................................. 93 Cored Wire ................................................................................................................................................... 94Submerged Arc Welding ............................................................................................................................... 95Strip Cladding ............................................................................................................................................... 96Packaging ..................................................................................................................................................... 97

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Railtrac 1000 Multi-Purpose System for Welding & Cutting

• IdealforawidevarietyautomatedMIGapplications• Consistsofaluminumandsteelpartstowithstand harshenvironments• Weldingpossibilitiesincludehorizontaltohorizontal andvertical(uponly)• Practicalaccessoriesavailable• Newjointsystemallowsforbothstiffandflexiblerail applications• Straightforward,welldesignedprogrammingunitwith upto5differentprograms• Standardsoftwareoffersprogrammableinterval weldingandbackfillfunction• Remotecontrolallowsfunctionalitywithoutlifting weldingvisor• Buttonsfeaturedonremotecontrolinclude:start andstop,shiftprogram,weavingwidth,zeroline displacement,andmanymore• Adjusttheweldingcurrentandvoltageduringwelding withonlytwopotentiometersontheremotecontrol (whenusingESABequipment)• RemotecontrolonlyavailableonFW1000and FWR1000models

Railtrac 1000 F, FR, FW, FWR Sales Literature ..............XA00086720Railtrac 1000 BV, BVR Sales Literature .........................XA00067820 Railtrac 1000 F, FR Instruction Manual ............................777 167 001Railtrac 1000 FW, FWR Instruction Manual .....................777 168 001Railtrac 1000 BV, BVR Instruction Manual .....................777 169 002

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Technical Data Railtrac F1000Flexi

Railtrac FW1000(L)Flexi-Weaver

Railtrac FR1000Flexi-Return

Railtrac FWR1000Flexi-Weaver-Return

Power Supply, VAC/VDC 36-46-/40-60 36-46/40-60 36-46-/40-60 36-46/40-60Max. Power Consumption, W 30 80 30 80Weight, excluding rails, Kg (lbs.) 6 (13) 7 (15) 6 (13) 7 (15)Dimensions, LxWxH, mm (in.) 170x400x190 (6.7x15.8x7.5) 170x350x190 (6.7x13.8x7.5) 170x400x190 (6.7x15.8x7.5) 170x350x190 (6.7x13.8x7.5)Flexi Rail Dimensions, LxW, mm (in.) 60x5 (2.4x0.2) 60x5 (2.4x0.2) 60x5 (2.4x0.2) 60x5 (2.4x0.2)Stiffener Bar , LxW, mm (in.) 40x10 (1.6x0.4) 40x10 (1.6x0.4) 40x10 (1.6x0.4) 40x10 (1.6x0.4)Min. Bend Diameter, external, mm (in.) 3000 (118) 3000 (118) 3000 (118) 3000 (118)Slide for Height Adjustment, mm (in.) +/- 22 (+/- 0.87) +/- 22 (+/- 0.87) +/- 22 (+/- 0.87) +/- 22 (+/- 0.87)Mechanical Lateral Adjustment, mm (in.) - +/- 35 (+/- 1.4) - +/- 35 (+/- 1.4)Welding Speed, cm/min (ipm) 10-150 (3.9-59) 10-150 (3.9-59) 10-150 (3.9-59) 10-150 (3.9-59)Quick Transport, cm/min (ipm) 150 (59) 150 (59) 150 (59) 150 (59)Preheating Time, s 0.0-9.9 0.3 0.0-9.9 0.3Interval Welding, cm (in.) 1-99 (0.4-39) 1-99 (0.4-39) 1-99 (0.4-39) 1-99 (0.4-39)Crater-filling Time, s 0.0-9.9 0.0-9.9 0.0-9.9 0.0-9.9“Backfill”, mm (in) 0-99 (0-3.9) 0-99 (0-3.9) 0-99 (0-3.9) 0-99 (0-3.9)Weaving Speed, mm/s (ips) - 6-60 (0.2-2.4) - 6-60 (0.2-2.4)Weaving Width, mm (in.) - 1-30 (0.04-1.2) - 1-30 (0.04-1.2)Electrical 0-Line Displacement, mm (in.) - +/- 12.5 (+/- 0.5) - +/- 12.5 (+/- 0.5)Pause Time at Outer Edge, s - 0.0-9.9 - 0.0-9.9Weaving Pattern, No. - 3 - 3No. of Programs 5 5 5 5Temp. Machine and Magnets, oC 0-70 0-70 0-70 0-70Temp. Vacuum Attachment, oC 0-90 0-90 0-90 0-90Safety Class (DIN 40050) IP 23 IP 23 IP 23 IP 23

5

Railtrac 1000 System Configuration

railtrac fwr1000 flexi-weaver return• Equippedwithweavingunit• Adjustablestart,stopandreturnfacilities• Uniquedesignremotecontrolunitwithadvanced solutionsforanumberofapplications

railtrac f1000 flexi• Flexiblecombi-rail• Suitableforbothinsideandoutsideweldingandcutting• Cutalongcurvedandstraightsurfaces• Suitableforthermalcutting

railtrac fr1000 flexi-return• Flexiblecombi-railandfacilitiesformovableparts• Startandstopforautomaticreturnoflength• Idealforuseinfixedinstallationsorrepetitivewelding

railtrac fw1000 flexi-weaver• Flexiblecombi-rail• Equippedwithweavingunit• Equippedwithauserfriendlyremotecontrolunit

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Railtrac 1000, cont’d

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

Options & AccessoriesstandardWeaving Unit*Control UnitRemote Control*Universal Torch Holder with SlideAutomatic start and stop function**

componentsFlexible alu-rail, 2.5 m (8’) ............................................. 398 146 115Flexible alu-rail, 2.5 m (8’), 8 magnets ......................... 398 146 112Flexible alu-rail, 2.5 m (8’), 4 VAC. attachment ........... 398 146 113Stiffener Bar, 2.5 m (8’).................................................. 398 146 116Magnetic attachment, at least 8/2.5 m* (8’) (1) ............398 146 100Vacuum attachment, at least 4/2.5 m (8’).....................398 146 104Screw attachment for stiffened rail.............................. 398 146 114

accessoriesTorch holder PSF 400/500 .............................................398 145 101Adapter for stiffened rail attachments .....................................398 146 106Universal pivoted torch holder.....................................398 145 104Attachment for IMP cutting torch .................................398 145 260Torch angle attachment ................................................398 145 215Tilt unit for weaving unit* ..............................................398 145 200Turning unit for weaving unit* ......................................398 145 201“Floating” head .............................................................. 398 145 211IMP cutting torch ...........................................................398 145 250Transport and storage box ...........................................398 145 199Control cable, 5 m (16.4’) ..............................................457 360 880AristoFeed wire feeder adaptor kit ..............................458 757 881Universal control cable, 5 m (16.4’) .............................457 360 881Transformer kit, 115-42 VAC .............................................. 359C304

*FW1000&FWR1000only**FR1000&FWR1000only

7

Miggytrac 1001

Ordering InformationMiggytrac 1001...............................................................457 357 881

Options & AccessoriesWelding Screen ..............................................................457 463 880ESAB Control Cable, 5 m (16.4 ft) ................................457 360 880(12 pin male- 23 pin male Burndy style) ESABFeed, and AristoFeed feedersESAB AristoFeed Adaptor Kit ......................................459 681 880(required for connection of Miggytrac to AristoFeed feeders)Universal Control Cable, 5 m (16.4 ft) ..........................457 360 881(12 pin male Burndy style-open end). Requires user-supplied plug to connect cable to OEM feedersTransformer Kit, 115-42 VAC ............................................. 359C304Universal kit used to adapt 115 VAC wire feeders to Miggytrac

Miggyrtrac 1001 Sales Literature ....................................XA00126320 Miggytrac 1001 Instruction Manual..................................449 476 001

• Small,compact,motorizedtractor• QuicklyattachestoESABweldingtorch• Even,stablemovementguaranteed• Decidetraveldirectionwiththeremotecontrol• Start/stopfunctionfromtheremotecontrolpanel• Travelspeedsettingsof150-1200mm/min(6-47 ipm),wirefeedspeed,andvoltageallfunctionsof theremotecontrol• Significantlyincreasesweldingspeed,especially whenusingcoredwire

tractors

Technical DataControl voltage, VAC 36-46Power, W 20Welding Speed, cm/min (ipm) 15-120 (6-47)Remote control outlet Volt and Ampere (Wire Feed Speed)Connection Burndy, 12 pinsDimensions, LxWxH, mm (in.) 266x257x267 (10.5x10x10.5)Weight, Kg (lbs.) 7 (15.5)

(mm)

8

Miggytrac 2000

• Idealforlongweldseliminatingstressfulwelding positionsforthewelder• Magnethelpstoholdthetractorinthecorrectposition ontheworkpieceeveniftheworkpieceisbentor angled• Guidewheelsadjusttoallowtheunittodriveitself againsttheworkpiece• Programforintermittentwelding• Setlengthofweldanddistancebetweenweldsfrom 1-99cm(0.4-39in.)• High-speedtravelbetweenwelds-250cm/min(98 ipm)-toincreaseefficiency• Backfillfunctionforcraterfillingattheendoftheweld

Ordering InformationMiggtrac 2000.........................................................................457 358 880

Options & AccessoriesWelding Screen ......................................................................457 463 881ESAB Control Cable, 5 m (16.4 ft) ........................................457 360 880(12 pin male- 23 pin male Burndy style) ESABFeed, and AristoFeed feeders ESAB AristoFeed Adaptor Kit ..............................................459 681 880(required for connection of Miggytrac to AristoFeed feeders)Universal Control Cable, 5 m (16.4 ft) ..................................457 360 881(12 pin male Burndy style-open end). Requires user-supplied plug to connect cable to OEM feedersTransformer Kit, 115-42 VAC ..................................................... 359C304Universal kit used to adapt 115 VAC wire feeders to Miggytrac

Technical DataControl voltage, VAC 36-46Power, W 40Welding Speed, cm/min (ipm) 15-150 (6-47)Fast Travel Speed, cm/min (in/min) 250 (98.4))Programmable Interval Welding, cm (in.) 1-99 (0.4-37)Adjustment of Slide, mm (in.) +/- 17 (+/-0.67)Remote Control Outlet Volt and Ampere (Wire Feed Speed)Connection Burndy, 12 pinsCrater Fill Time, s 0-9.9 Backfill, cm (in.) 0-9.9 (0-4)Dimensions, LxWxH, mm (in.) 330x260x360 (13x10x14)Weight, Kg (lbs.) 9.5 (21)

Miggytrac 2000 Sales Literature......................................XA00104720 Miggytrac 2000 Instruction Manual..................................449 310 001

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tractors

Miggytrac 3000

• Small,compact,motorizedtractorwithintegrated wirefeedandwater-cooledweldingtorchdesignedfor horizontalmechanizedMIGweldingofplatesandbeams• Four-wheeldrivecarriage• Carriagecantraveldiagonallytowardstheflange orstiffenertobewelded• Programforintermittentwelding• Carriagemotionandwirefeedcontrolledseparately• Setweldlengthanddistancebetweenweldsfrom 1-99cm(0.4-39in.)• Distancebetweenbeadsrunattransportspeed of250cm/min(98ipm)foroptimalefficiency• Programwirefeedspeed,timeforgaspre-flow, gaspost-flowandburnback

Ordering InformationMiggytrac 3000...............................................................457 359 880With straight, water-cooled swan neck; delivered without contact tip

Options & AccessoriesContact Tip M8 Heavy-Duty, 0.9 mm (.035 in.) ............468 502 004Contact Tip M8 Heavy-Duty, C02 1.2, Mix/Ar 1.0..........468 502 007Contact Tip M8 Heavy-Duty C02 1.4, Mix/Ar 1.2 ..........468 502 008Gas Nozzle, water-cooled .............................................449 903 101Bent Swan Neck, 15o ..................................................... 449 903 115Bent Swan Neck, 30o .....................................................449 903 130ESAB Control Cable, 5 m (16.4 ft) ................................457 360 880(12 pin male- 23 pin male Burndy style) ESABFeed, and AristoFeed feedersESAB AristoFeed Wire Adaptor Kit ..............................459 681 880(required for connection of Miggytrac to AristoFeed feeders)Universal Control Cable, 5 m (16.4 ft) ..........................457 360 881(12 pin male Burndy style-open end). Requires user-supplied plug to connect cable to OEM feedersTransformer Kit, 115-42 VAC ............................................. 359C304Universal kit used to adapt 115 VAC wire feeders to Miggytrac

Technical DataWire Dimenisions, mm Unalloyed Steel 1.0-1.4

1.0-1.41.0-1.4

Stainless SteelCored Wire

Control Voltage, VAC 36-4680 Power, W

Welding Speed, cm/min (ipm) 15-150 (6-59)Transport Speed, cm/min (ipm) 250 (98)Lengths at Intermittent Welding, cm (in.) 1-99 (0.4-37)Crater-fill time, s 1-9.9Backfill, cm (in.) 1-9.9 (0.4-3.7)Wire Feed Speed, m/min (ipm) 2-25 (79-984)Gas Pre-Flow/Post-Flow, s 0-9.9

0-9.9Burnback, sFiller Wire Reel, mm (in.) 305 (12)Dimensions, LxWxH, mm (in.) 370x400-530x520 (14.5x16-21x20.5)Slide Adjustment, mm (in.) +/- 17 (+/-0.67)Remote Control, max value, Kohm 2.5

5Max Current Over the Start Relay, AConnection with straight 23-pin BurndyEnclosure Class IP 23Weight, excl. wire reel, Kg (lbs.) 17 (37.5)

Miggytrac 3000 Sales Literature......................................XA00123620 Miggytrac 3000 Instruction Manual..................................449 453 001

(mm)

10

A2 Multitrac (PEH)

A2 Multitrac GMAW Sales Literature ..............................XA00105520A2 Multitrac SAW Sales Literature ..................................XA00105420A2 Multitrac SAW/GMAW Instruction Manual .................456 502 001

Ordering Information A2 Multitrac GMAW (2WD) ....................................................449 161 880A2 Multitrac GMAW MTW 600 (4WD) ...................................449 161 881A2 Multitrac SAW ...................................................................449 160 880A2 Multitrac Twin SAW ..........................................................449 160 881

• ForusewithLAF(DC)orTAF(AC)powersources• Compactandefficientdesignallowsforeasy movementbetweenworkpieces• Self-propelled,four-wheeldriveforstable,accurate, andconstantoperation• A2-A6PEHprocesscontrollerwithdigitaldisplay, allowspresettingandcontrolofweldingparameters• Horizontal,verticalandrotaryslidesallowforquick adjustmentofweldnozzleintovariouspositions• Reliablemechanicalparts,evenunderharshenvironments• Manyspeciallydevelopedaccessoriesavailable

A2 Multitrac (PEI)

Canbeconnectedtomostanalog,DCpowersuppliesCompactandefficientdesignallowsforeasymovementbetweenworkpieces

• Self-propelled,four-wheeldriveforstable, accurate,andconstantoperation• A2PEIprocesscontrollerallowssimplesettingof travelspeed,voltage,andwirefeedspeed• Heavy-dutyfeedunitensuresanevenand stablewirefeed,aprerequisitefortopquality, homogenouswelding• Horizontal,verticalandrotaryslidesallowforquick adjustmentofnozzleintovariouspositions• Reliablemechanicalcomponents,evenunder harshworkingconditions• Easytousecontrolequipmentwithdifferentstart methods:directstartorscratchstart• Manyspeciallydevelopedaccessoriesavailable

••

Ordering Information A2 Multitrac SAW ...................................................................449 360 880A2 Multitrac GMAW ...............................................................449 361 880A2 Multitrac Twin SAW ..........................................................449 360 881

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A2 Multitrac GMAW Sales Literature ..............................XA00105520A2 Multitrac SAW Sales Literature ..................................XA00105420A2 Multitrac SAW/GMAW Instruction Manual .................456 502 001

Technical Data Single SAW Twin SAW GMAW GMAW MTW 600

Wire Dimensions, mm (in.) Steel 1.6-4.0 (1/16-5/32) 2x1.2-2.4 2x(.045x3/32) 0.8-1.6 (.030-1/16) 1.0-1.6 (.040-1/16)Stainless Steel 1.6-4.0 (1/16-5/32) 2x1.2-2.4 2x(.045x3/32) 0.8-1.6 (.030-1/16) 1.0-1.6 (.040-1/16)Cored Wire 1.6-4.0 (1/16-5/32) - 1.2-2.4 (.045-3/32) 1.0-2.4 (.040-3/32)Aluminum - - 1.2-1.6 (.045-1/16) 1.0-2.0 (.040-5/64)

Max. Wire Feed Speed, m/min (ipm) >9 (>354) >9 (>354) >16 (>630) >25 (>984)Electrode Weight, Kg (lbs.) 30 (66) 2x15 (2.2x33) 30 (66) 30 (66)Flux Volume, L (gal.) 6 (1.4) 6 (1.4) - -Weight, excl. wire and flux, Kg (lbs.) 47 (103) 47 (103) 43 (95) 43 (95)Permissible Load 100%, A 800 800 600 600Control Voltage, VAC 42 42 42 42Travel Speed, m/min (ipm) 0.1-1.7 (4-67) 0.1-1.7 (4-67) 0.1-1.7 (4-67) 0.1-1.7 (4-67)Linear Slides Setting Length, mm (in.) 90 (3.5) 90 (3.5) 90 (3.5) 90 (3.5)Rotary Slide Setting Angle 360o 360o 360o 360o

Options & Accessories (PEH & PEI)auxiliary guiding equipmentGuide wheel bogie .........................................................413 542 880Idling roller .....................................................................333 164 880Guide bar 3 m (10 ft.) .....................................................154 203 880V-guide wheel.................................................................333 098 881V-wheeltrack in steel .....................................................443 682 881Loop for connection of two tractors ............................334 680 881Pilot lamp, light bulb .....................................................153 143 886Pilot lamp, laser diode ..................................................457 788 880

wire reel*Wire reel, plastic, 30 Kg (66 lbs.) ..................................153 872 880Wire reel, steel, 30 Kg (66 lbs.) .....................................416 492 880

flux Handling equipmentFlux recovery unit OPC .........................................................148 140 880Bracket suction......................................................................332 947 880Flux hopper of silumin alloy .................................................413 315 881Concentric flux feeding funnel, D20 ....................................145 221 881Contact tube, bent ................................................................. 413 511 001

gas Handling equipment**Water circulator, WC-8C, 115/230 VAC...........................................33739Arc shield ...............................................................................334 689 880

Wear Parts ...................................................................... see pages 16-19

*SAWOnly**GMAWOnly

A2 Multitrac PEH & PEI, cont’d

RECOMMENDEDPOWERSOURCES:LAF635,1000andTAF800

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(mm)

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A2 Tripletrac for Internal Circumferential Welding

A2 Tripletrac Sales Literature ......................................... XA00118420 A2 Tripletrac Instruction Manual ......................................449 435 104

• Increaseproductivityandquality• Idealforinternalcircumferentialweldingoflarge cylindricalobjectsthatarerotatingonaturningrollsystem• Heavy-dutyfeedunitsecureseven,stablewirefeed fortopquality,homogenouswelds• DeliveredwitheitherthedigitalA2-A6PEHprocess controllerortheanalogA2PEIweldingcontroller• Uniquesteeringsystemallowsoperatorto simultaneouslyadjustthewheelandtorchpositionfor accurateandeffortlessseamtracking• Controlequipmentiseasytouseandrequiresminimaltraining• Choosebetweenstartmethods,burn-backtimesand othersettings

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

Options & Accessoriesauxiliary guiding equipmentPilot lamp, light bulb (PEH) ..................................................153 143 885Pilot lamp, laser diode (PEH)................................................457 788 884Utility light ..............................................................................449 443 880

flux Handling equipmentFlux recovery unit OPC .........................................................148 140 880Bracket suction......................................................................332 947 880Flux hopper of silumin alloy .................................................413 315 881Concentric flux feeding funnel, D20 ....................................145 221 881Contact tube, bent ................................................................. 413 511 001

wire reelWire reel, plastic, 30 Kg (66 lbs.) ..........................................153 872 880Wire reel, steel, 30 Kg (66 lbs.) .............................................416 492 880

Wear Parts ...................................................................... see pages 16-19

tractors

RECOMMENDEDPOWERSOURCES:LAF635,1000andTAF800

Technical Data Single Saw

Wire Dimensions, mm (in.) Steel 1.6-4.0 (1/16-5/32)Stainless Steel 1.6-4.0 (1/16-5/32)Cored Wire 1.6-4.0 (1/16-5/32)

Max. Wire Feed Speed, cm/min (ipm) >900 (>354)Electrode Weight, Kg (lbs.) 30 (66)Flux Volume, L (gal.) 6 (1.4)Weight excl. Wire and Flux, Kg (lbs.) 47 (103)Permissible Load 100%, A 800Control Voltage, VAC 42Travel Speed, cm/min (ipm) 10-170 (4-67)Linear Slides Setting Length, mm (in.) 90 (3.5)Rotary Slide Setting Angle 360o

(mm)

13

A6 Mastertrac

Ordering Information A6 Mastertrac, single wire, standard ...........................449 260 880156:1 feed motor (wire feed speed range of 0.2-4.0 m/min; 8-57 ipm)A6 Mastertrac, twin wire, standard ..............................449 260 881A6 Mastertrac, single wire, high speed .......................449 260 89074:1 feed motor (wire feed speed range of 0.8-16 m/min; 31-654 ipm)A6 Mastertrac, twin wire, high speed ..........................449 260 891A6 Mastertrac, tandem wire, complete ........................334 191 882

Options & AccessoriesContact equipment heavy Twin Arc, complete ...........334 291 889Wire reel, plastic, 30 Kg (66 lbs.) ..................................153 872 880Wire reel, steel, 30 Kg (66 lbs.) .....................................416 492 880Wire reel, steel, flexible width ......................................449 125 880Brake hub extra .............................................................146 967 880Rebuilding kit GMAW ....................................................334 299 890Strip cladding kit ...........................................................155 972 880Flux hopper holder for strip cladding ..........................148 107 003Wire reel, steel for strip cladding, 30-100 mm (1-4 in.) ........671 161 880Flux recovery nozzle, strip ...........................................156 025 001Flux funnel .....................................................................254 900 880Insert, extended .............................................................254 900 301

• Self-propelled,four-wheeldriveforstable, accurate,andconstantoperation• Availableinthreedifferentwireconfiguration designs:Single,Twin,orTandem• Amplecapacityforheavyproductionwelding;takes upto6mm(1/4in.)wireusing1500Amps(DCorAC)• A2-A6PEHprocesscontrollerwithdigital displayallowsforpresetaccuracyinallwelding parameters• Manyspeciallydevelopedaccessoriesavailable

A6 Mastertrac SAW Sales Literature...............................XA00109420A6 Mastertrac SAW Instruction Manual ..........................449 265 060A6 Tandem Mastertrac Instruction Manual .....................456 503 000

tractors

Angular slide ..........................................................................671 171 580Pilot lamp, light bulb .............................................................153 143 885Pilot lamp, laser diode ..........................................................457 788 884Flux recovery unit, OPC ........................................................148 140 880Bracket suction......................................................................332 947 880Idler rollers (2 per automat) ..................................................333 164 880Guide wheel, fillet ..................................................................671 125 780Magnetic guide rail, 3 m (9.8 ft.) ...........................................154 203 880Rebuilding kit carbon arc gouging ......................................153 592 880Use with carbon electrodes ø 5/16”, 3/8”, 1/2”VEC-motor, 312:1 for carbon arc gouging ..........................145 063 905Wear Parts ...................................................................... see pages 16-19

Technical Data Single SAW Twin SAW GMAW Tandem SAW

Wire Dimensions, mm (in.) 3.0-6.0 (1/8-1/4) 2x2.0-3.0 2x(3/32-1/8) 1.0-3.2 (3/64-1/8) 2x3.0-6.0 2x(1/8-1/4)Max. Wire Feed Speed, cm/min (ipm) 20-400 (8-157) 0.2-4.0 (8-157) 0.8-16.6 (31.5-653.5) 0.2-4.0 (8-157)Max. Wire Feed Speed High, cm/min (ipm) 40-800 (16-31.5) 0.4-8.0 (16-31.5) - - 0.4-8.0 (16-31.5)Flux Volume, L (gal.) 10 (2) 10 (2) - - 10 (2)Weight, excl. wire and flux, Kg (lbs.) 110 (242.5) 110 (242.5) 100 (220.5) 158 (348)Permissible Load 100%, A 1500 1500 600 2x1500Control Voltage, VAC 42 42 42 42Travel Speed, cm/min (ipm) 10-200 (8-79) 0.1-2.0 (8-79) 0.1-2.0 (8-79) 0.1-2.0 (8-79)Wire Reel, Kg (lbs.) 30 (66) 2x30 2x(66) 30 (66) 2x30 2x(66)

RECOMMENDEDPOWERSOURCES:LAF635,1000,1250,1600andTAF800,1250

14

A6-DK Portable Welding Machine

• Workswithasinglewireoneachhead• EachweldheadiscontrolledbytheA2-A6PEH processcontrollerandLAF(DC)orTAF(AC)power source• Idealforsimultaneoushorizontal-verticalweldingon bothsidesofawebortroughpanel• Straddlesworkpiecesupto800mm(31in.)talland symmetricalprofilewidthsof400mm(16in.)• Travelsdirectlyonaworkpieceguidedbyajoint• Travelspeedadjustablefrom0.15-2.0m/min(6-79ipm)• Storeupto10L(2.6gal)offluxinthehopper• EachweldheadisequippedwiththeOPCFlux recoverysystem

A6-DK Sales Literature.....................................................XA00100120 A6-DK Instruction Manual .............................................Contact ESAB

Ordering Information A6-DK SAW single wire .........................................................454 200 901Excl. wire reel, feed rollers, and contact jaws

Options and AccessoriesWire reel plastic 30 kg (66 lbs.) ............................................153 872 880 Wire reel steel 30 kg (66 lbs.) .............................................416 492 880Wear Parts ...................................................................... see pages 16-19

tractors

Technical DataPermissable load 100%,A 1500Travel Speed, cm/min (ipm) 15-200 (6-79)Wire Feed Speed, cm/min (ipm) 20-400 (8-157)Wire Reel (optional), Kg (lbs.) 2x30 (2-66)Wire Diameter SAW, mm (in.) 3.0-6.0 (1/8-1/4)Flux Capacity (each welding head), l (gal) 10 (2.6)Weight, excl. wire and flux, Kg (lbs.) 150 (331)Straddle OpeningVertical Space Limitation, mm (in.) 800 (31)Longitudinal symmetrical extension, mm (in.) 400 (16)

RECOMMENDEDPOWERSOURCES:LAF635,1000,1250,1600andTAF800,1250

(mm)

15

tractors

Frametrac™ for Welding Windtower Door Frames

• Compact,motor-poweredtractorthattravelson thedoorframetobewelded• Fourdrivingwheelsguaranteeeven,stable movementontheframe• StandardESABtorchcanbeattachedand adjustedtofittheframeandtypeofwelding• Controltraveldirectionandspeed,weavingspeed andwidthfromthecontrolboxandremotecontrol• TheAutomaticCurrentControl(ACC)holdsthe arclengthstabletosecurethebestpossiblearc• Usedirectlyonframeswithaconstantthicknessof 20-75mm(0.78-2.95in.)

Ordering InformationFrametrac with ACC ......................................................449 925 880

Options & AccessoriesSpring arms for frames 50-75 mm (1.97-2.95 in.)........449 904 025Connection cable ...........................................................457 360 880

ContactESABforrecommendedweldingequipment

Technical DataControl Voltage, VAC 36-46Power, W 80 Welding Speed, cm/min (ipm) 10-99 (4-39)Frame Width, mm (in.) 20-50 (0.78-1.97)Min. Radius on Frame, mm (in.) 150 (5.9)Min. Height on Frame, mm (in.) 40 (1.57)Max. Height Difference on Frame, mm (in.) 120 (4.72)Dimensions, LxWxH, mm (in.) 280x430x508 (11x17x20)Weight, excl. wire reel, Kg (lbs.) 30 (66)

Frametrac Sales Literature ..............................................XA00126620 Frametrac Instruction Manual ..........................................460 072 001

16

A2/A6 Tractor Wear Parts

Technical Reference KeyProcess Duty Type Contact Tube Contact Tips/Jaws

A2 Contact EquipmentSAW, single wire Light-Duty D20 M12SAW, twin wire Light-Duty D35* M6GMAW, 2WD Light-Duty D35 M10 or M6 with adaptorGMAW, 4WD Light-Duty MTW 600 M8A6 Contact EquipmentSAW, single wire Light-Duty D20 M12SAW, twin wire Light-Duty D35 M6SAW, single or twin wire Heavy-Duty D35 Contact JawsSAW, compact Heavy-Duty D35 Contact JawsGMAW, single wire only Light-Duty D35 M10 or M6 with adaptor* D35 twin wire adaptor P/N 333 772 001

Accessories: GMAW MTW 600Wire Diameter Wire Material Type Wear Insert (liner) Type

mm (in) Fe SS CW Al Part Number Steel Teflon Teflon Brass Ref. Item

1.0 (.040) * * * 457 625 005 A A1.0 (.040) * 457 625 005 B B1.2 (.045) * * * 457 625 006 A A1.2 (.045) * 457 625 007 B B1.4 (.052) * * * 457 625 008 A A1.6 (1/16) * * * 457 625 009 A A1.6 (1/16) * 457 625 009 B B1.6 (1/16) * * * 457 625 010 A A1.6 (1/16) * 457 625 010 B B2.0 (5/64) * * 457 625 011 D D2.0 (5/64) * 457 625 011 C C2.4 (3/32) * * 457 625 012 D D2.4 (3/32) * 457 625 012 C C

Wire Diameter

Reference Item Wear Insert (liner) Type mm (in.) Part Number

A Steel Spiral 1.0-1.6 (.040-1/16) 457 454 002B Teflon Insert 1.0-1.6 (.040-1/16) 457 619 001 (to be cut to length when mounting)C Teflon Insert 2.0-2.4 (5/64-3/32) 457 619 002 (to be cut to length when mounting)D Brass Tube 2.0-2.4 (5/64-3/32) 457 620 002

A2 Wear Parts Catalogue ................................................. XA00115820A2 GMAW (MIG) Wear Parts Brochure ...........................XA00126820A6 Wear Parts Catalogue .................................................XA00125820

tractors

17

Feed RollersWire Diameter

mm (in.) Part Number

SAW Feed roller, single wire0.8 (.030) 145 538 8811.0 (.040) 145 538 8821.2 (.045) 145 538 8831.6 (1/16) 218 510 2812.0 (5/64) 218 510 282

2.4-2.5 (3/32) 218 510 2833.0-3.2 (1/8) 218 510 298

4.0 (5/32) 218 510 2865.0 (3/16) 218 510 2876.0 (1/4) 218 510 288

Pressure Roller 153 148 880SAW Feed roller, single wire, knurled V-groove

0.8-1.6 (.030-1/16) 146 024 8802.0-4.0 (5/64-5/32) 146 024 8813.0-5.0 (1/8-3/16) 218 510 299Pressure Roller 153 148 880

GMAW Feed roller, single wire, 2WD drive, knurled U-groove 0.8-1.6 (.030-1/16) 146 024 8802.0-4.0 (5/64-5/32) 146 024 881Pressure Roller

0.8-1.6 (.030-1/16) 146 025 880*2.0-4.0 (5/64-5/32) 146 025 881*

*Shaft for pressure roller 212 901 101SAW Feed roller, twin wire

2x1.2 2x(.045) 218 522 4862x1.6 2x(1/16) 218 522 4882x2.0 2x(5/64) 218 522 484

2x2.4-2.5 2x(3/32) 218 522 4802x3.0-3.2 2x(1/8) 218 522 481

Pressure roller (spherical type with shaft) 218 524 580SAW Feed roller, twin wire, knurled-U-groove

2x2.0-3.2 2x(5/64-1/8) 148 772 880Pressure roller (spherical type with shaft) 218 524 580GMAW Feed roller, single wire, 4WD

0.6-0.8 (.023-.030) 369 557 0010.8-0.9*** (.030-.035) 369 557 001

0.8-1.0 (.030-.040) 369 557 0021.0-1.2 (.040-.045) 369 557 003

1.0-1.2** (.040-.045) 369 557 0061.2-1.6 (.045-1/16) 369 557 0071.4-1.6 (.052-1/16) 369 557 013

1.6** (1/16) 369 557 0082.0** (5/64) 369 557 009

2x1.2 2x(.045) 369 557 010Pressure roller (flat roller) 369 728 001

GMAW Feed roller, single wire, knurled, 4WD**1.0-1.2/1.4-1.6 (.040-.045/.052-1/16) 369 557 0041.4-1.6/2.0-2.4 (.052-1/16/5/64-3/32) 369 557 005Pressure roller (knurled roller) 466 262 001

**Aluminumonly***forCoredWire

A2/A6 Tractor Wear Parts, cont’d

tractors

Idling pressure roller

Driving feed roller with groove

Idling pressure roller

Driving feed roller with knurled groove

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

←

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

Driving feed with grooves for twin wire sysem

Contact TipsWire Diameter


SAW contact tip, M12 for single wire1.6 (1/16) 154 623 0082.0 (5/64) 154 623 007

2.4-2.5 (3/32) 154 623 0063.0 (1/8) 154 623 0053.2 (1/8) 154 623 0044.0 (5/32) 154 623 003

SAW contact tip, M6 for twin wire2x0.8 2x(.030) 153 501 0022x1.0 2x(.040) 153 501 0042x1.2 2x(.045) 153 501 0052x1.6 2x(1/16) 153 501 0072x2.0 2x(5/64) 153 501 009

2x2.4-2.5 2x(3/32) 153 501 010GMAW contact tip, M10 for single wire

0.8 (.030) 258 000 9141.0 (.040) 258 000 9131.2 (.045) 258 000 9081.6 (1/16) 258 000 9092.0 (5/64) 258 000 9102.4 (3/32) 258 000 9113.2 (1/8) 258 000 915

GMAW contact tip, M8 for single wire1.0 (.040) 457 625 0051.2 (.045) 457 625 006

1.2* (.045) 457 625 0071.4 (.052) 457 625 0081.6 (1/16) 457 625 0092.0 (5/64) 457 625 0112.4 (3/32) 457 625 012

ESAB contact tip, twin**2.0 (5/64) Q4505590011.6 (1/16) Q4505590022.5 (3/32) Q4505590031.2 (.045) Q450559004

*Aluminumonly**Fortrailerbeamwelding;forOEMtips,omit“Q”onpartnumber.


tractors

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

←

←M12

←M6 ←

Guide tubes 415 032 002Spiral insert 334 279 001

Nozzle holder 333 772 001

Contact nozzle x2

←M10 ←

Contact JawsWire Diametermm (in.) Part Number

SAW contact jaws for single wire, length 65/58 mm (2.5/2.3 in.)2.0 (5/64) 332 581 880

2.4-2.5 (3/32) 332 581 8813.0-3.2 (1/8) 265 900 880

4.0 (5/32) 265 900 8825.0 (3/16) 265 900 8836.0 (1/4) 265 900 884

SAW contact jaws for single wire, length 75 mm (3.0 in.)1.6-3.2 (1/16-1/8) 265 901 480

SAW contact jaws for single wire, length 120 mm (4.7 in.)3.0-3.2 (1/8) 000 237 320

4.0 (5/32) 000 237 321SAW contact jaws for twin wire, length 58 mm (2.3 in.)

2x1.6 2x(1/16) 265 902 8822x2.0 2x(5/64) 265 902 881

2x3.0-3.2 2x(1/8) 265 902 880SAW contact jaws for twin wire, length 73 mm (2.8 in.) w/ guide tube connection

2x1.6 2x(1/16) 808 650 8822x2.0 2x(5/64) 808 650 881

2x3.0-3.2 2x(1/8) 808 650 880

L=65 mm L=58 mm

L=120 mm

Long contact jaws 120 mm for improved access to deep joints

L=75 mm

L=58 mm twin

Guide tube for twin wire

←

←

M8

19


Flux NozzlesPart Number

D20 Contact TubeTube 332 948 001Clamp 333 094 880Flux hose, 0.5 m (16’) 443 383 002Flux hose free length/m 443 383 001Flux funnel complete 145 221 881Insulation sleeve 333 667 001D35 Contact TubeFlux nozzle, complete 153 299 880Tube bent 153 296 001Tube holder 153 290 002Flux hose 0.5 m (16’) 443 383 002Flux hose free length/m 443 383 001Flux funnel, complete 254 900 880Insert 254 900 301A2 flux gate w/ shut-off valve 0903787Flux gate nozzle (18 mm) 0708876

Contact TubesLength


D20 light-duty system100 (3.9) 413 510 003190 (7.5) 413 510 002260 (10.2) 413 510 001

260, bent 30o (10.2) 413 511 001500 (19.7) 413 510 004

Contact clamp 334 571 880Contact device D20 complete GMAW

90 (3.5) 030 465 389140 (5.5) 030 465 388

Gas nozzle 145 227 882Insulating sleeve 145 226 001Contact tube 145 534 882Plug 146 099 001

Extension 040 979 803 (158mm)040 979 804 (108mm)

Guide tube 415 032 001O-ring 22.2x3.0 (0.87x1/8) 190 680 405O-ring 15.3x2.4 (.60x3/32) 190 680 313O-ring 5.3x2.4 (.20x3/32) 190 680 303D-35 heavy-duty system

220 (8.7) 417 959 880275 (10.8) 417 959 881400 (15.7) 417 959 882500 (19.7) 417 959 883700 (27.5) 417 959 884

Clamp half 809 342 880

Contact device D35 complete twin wire220 (8.7) 333 852 880275 (10.8) 333 852 881

Nozzle holder 333 772 001Guide tube 415 032 001Spiral wire guide insert 334 279 001MTW 600 GMAW light-duty system

200 (7.8) 457 455 005250 (9.8) 457 455 006300 (11.8) 457 455 007400 (15.7) 457 455 008

Contact device MTW 600 complete singe wireGas nozzle 457 451 001Splatter protection 457 452 001Centering sleeve 457 453 001O-ring 457 458 001Nozzle adaptor 808 311 001

tractors

1

2

3

1. Tube2. Clamp3. Insert flux hose

D20 Contact Tube

D35 Contact Tube

1

2 3

1. Flux funnel2. Insulation sleeve3. Flux hose

1. Flux nozzle, complete2. Tube bent3. Tube holder4. Flux hose

1

2

3

4

1. Flux funnel2. Insert3. Flux hose

1

2

3

A2 Flux Gate w/ Shut-off Valve

1

2

1. Flux gate2. Nozzle

20

A2-A6 PEH Controller Sales Literature...........................XA00089320 A2-A6 PEH Controller (4.0 >) Instruction Manual ...........443 745 001A2-A6 PEH Controller (4.0 <)Instruction Manual ............443 745 160

A2-A6 PEH Process Controller

• DesignedforusewithLAF(DC)andTAF(AC) powersources• SuitableforMIGorSAWprocesses• Presetallweldingparametersbykeyingvalues onfrontpanel;canstoreupto10differentdatasetsin memoryforeasyrecallduringwelding• Sub-menusletuserdecideonweldingdirection,wire type/dimension,andweldstart/stop• Microprocessorautomaticallyfinetunesarc characteristicsdependingonwiretypeandparameters selected• Microprocessorcontrolledsystemisuserfriendlyand requiresminimaltraining• Choosebetween12differentlanguagesandviewheat inputondisplay

Ordering Information A2-A6 PEH Process Controller.............................................443 741 880Step Regulator Unit & Oscillation Control for PEH ........Contact ESAB

controllers and power sources

Options & AccessoriesControl 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

Technical DataConnection voltage from the power source, 50/60 Hz,VAC 42Connection Power, VA max. 900Motor connection adjusted for ESAB’s A2 and A6 motors Motor current 5A continuous max. 10ASpeed Control Internal EMK-adjustment, alt. with AC-tachoWelding Speed, m/min (ipm) 0.1-2 (4-80)Min. - Max. Man. Travel Speed, m/min (ipm) (depending on travel unit) 0.1-2 (4-80)Consumable Wire Feed Speed, m/min (ipm) 30-250 (12-984)Gas Valve/Auxiliary, VAC, A 42, 0.5Inputs For connection of sensors or limit switch (2 pcs. NC)Connection to power source through operating cable max 100 m (328’) Burndy contact, 12-polesMax. Ambient Temperature, oC (oF) 45 (113)Min. Ambient Temperature, oC (oF) -15 (5)Relative air humidity 98%Weight, Kg (lbs.) 5.5 (12)Dimensions LxWxH, mm (in.) 355x210x164 (14x8x6)Enclosure Class IP 23

21

A2 PEI Process Controller

• ControlsystemforA2tractorsandA2weldingheads• Analogtypethatcancontrolmostbrandsofpower supplies• SuitableforMIGorSAWprocesses• Presettravelspeed,voltage,andwirespeed bysimplyturningthethreeknobs–actualdata shownondigitaldisplaysduringwelding• Changeweldingdirectionusingswitchonfrontpanel• Choiceofscratchstartordirectstartmethods• Adjustableburn-backtime

Ordering InformationA2 PEI Process Controller ............................................449 330 880

Options & AccessoriesControl 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 Process Controller Sales Literature ................... XA00114320 A2 PEI Process Contoller Instruction Manual ................449 331 001


Technical DataConnection voltage from the power source, VAC, Hz 42, 50/60Connection Power, W max. 700Motor connection adjusted for ESAB’s A2 motors, VDC, A 42, 3.5Speed Control Internal EMK-adjustmentWelding Speed, cm/min (ipm) 10-200 (4-79)Max. Man. Travel Speed, m/min (ipm) 200 (79)Consumable Wire Feed Speed, cm/min (ipm) SAW 0.5-9 (20-355)

GMAW 0.9-16.2 (35-640)Burnback Time, s 0-2.0Pre-gas Flow Time, s 0.5Post-gas Flow Time, s 1.0Gas Valve/Auxiliary, VAC, A 42, 1Inputs For connection of sensors or limit switch (2 pcs. NC)Connection to power source through operating cable max 100 m (328’) Burndy contact, 23-polesWelding Voltage Control, VDC 0-10Flow Guard No contact/PNP OCLimit Switches No contact/PNP OCExternal Current Shunt, A/mV 1000/60

1500/60600/100750/100

Operating Temperature, oC (oF) -10-40 (14-104)Weight, Kg (lbs.) 6.2 (14)Dimensions LxWxH, mm (in.) 197x227x220 (7.8x9.0x8.7)Enclosure Class IP 23

ContactESABformoreinformationoncontrolcablesforOEMpowersources(Linde/L-Tec/Lincoln/Miller).

22

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

• UsedinconjunctionwithA2-A6PEHorA2PEI processcontroller• Solidstate,SCR-controlled,threephase,fan-cooled DCweldingpowersources• DesignedforhighproductivitymechanizedSAWor MIGwelding• Excellentweldingcharacteristicsthroughouttheentire currentandvoltagerange,withparticularlygood startingandre-ignitionproperties• Extremelyefficientpowerusagesavesonpowercosts• Thermaloverloadprotection• Extendcurrentrangebyconnectingtwopower sourcesinparallel

Ordering Information LAF 635...................................................................................457 350 880 LAF 1000.................................................................................456 321 881LAF 1250.................................................................................456 323 880LAF 1600.................................................................................456 324 880

Primarycablenotincluded

Options & Accessorieslaf to a2-a6 peH controllerControl cable, 15 m (49 ft.)....................................................449 449 880 Control cable, 25 m (82 ft.)....................................................449 449 881 Control 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.)................................................449 449 885

LAF Power Source Sales Literature................................XA00090920 LAF 635 Power Source Instruction Manual.....................457 795 101LAF 1000 Power Source Instruction Manual...................456 512 001LAF 1250/1600 Power Source Instruction Manual.......... 456 511 001

laf to a2 pei controllerControl cable, 15 m (49 ft.)............................................449 500 800 Control 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

Technical Data LAF 635 LAF 1000 LAF 1250 LAF 1600

Voltage, 3ph 60 Hz, VAC 440 400/440/550 400/440/550 400/440/550Current 100%, 60 Hz, A 52 64/64/52 99/99/80 136/136/108Fuse, slow 60 Hz, A 63 63 100/100/80 160/160/125Max. load at: 100% duty cycle, A/VAC 630/44 800/44 1250/44 1600/44

60% duty cycle, A/VAC 800/44 1000/44 - -Setting Range MIG, A/VAC 50/17-630/44 50/17-1000/45 60/17-1250/44 -

SAW, A/VAC 30/21-800/44 40/22-1000/45 40/22-1250/44 40/22-1600/46Open Circuit Voltage, VAC 54 52 51 54Open Circuit Power, W 150 145 220 220Efficiency 0.84 0.84 0.87 0.87Weight, Kg (lbs.) 260 (573) 330 (728) 490 (1080) 585 (1290)Dimensions, LxWxH, mm (in.) 670x490x930 (26x19x36) 646x552x1090 (25x22x43) 774x598x1428 (30x24x56) 774x598x1428 (30x24x56)Enclosure Class* IP 23 IP 23 IP 23 IP 23Application Class** S S S S*EquipmentmarkedIP23isdesignedforindoorandoutdooruse.**ThesymbolSindicatesthattheweldingpowersourcemaybeusedinareaswithanincreasedelectricalhazard,eg/areaswheretheelectricalhazardisincreasedduetodampand/ortheproximitytoearthedmetalobjects.


23

TAF 800 & 1250 AC Power Sources

• UsedinconjunctionwithA2-A6PEHorA2PEI processcontroller• Solidstate,SCR-controlled,onephase,fan- cooledACweldingpowersources• SquarewaveACoutput,noarcblow• Capacityforcontinuouswelding• Arcvoltageorcurrentfeedback• Optimizedopencircuitvoltage• Extremelyefficientpowerusagesavesonpower costs• PreparedforScottconnectionoftwopower sources

Ordering Information TAF 800 ...........................................................................456 325 880TAF 1250 .........................................................................456 326 880

Options & Accessoriestaf to a2-a6 peH controllerControl cable, 15 m (49 ft.)............................................449 449 880 Control cable, 25 m (82 ft.)............................................449 449 881Control cable, 35 m (115 ft.) ..........................................449 449 882 Control cable, 50 m (164 ft.)..........................................449 449 883Control cable, 75 m (246 ft.)..........................................449 449 884Control cable, 100 m (328 ft.)........................................449 449 885

TAF Power Sources Sales Literature ..............................XA00088720 TAF Power Sources Instruction Manual ..........................456 513 201


taf to a2 pei controllerControl cable, 15 m (49 ft.)....................................................449 500 880 Control 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

Arc gouging supplement ......................................................449 070 880

Technical Data TAF 800 TAF 1250

Voltage, 1ph 60 Hz, VAC 400/440/550 400/440/550Max. load at: 100% duty cycle, A/VAC 800/44 1250/44

60% duty cycle, A/VAC 1000/44 1500/44Setting Range, A/VAC 300/28-800/44 400/28-1250/44Open Circuit Voltage, VAC 71 72Open Circuit Power, W 230 230Efficiency 0.86 0.86Weight, Kg (lbs.) 495 (1091) 608 (1340)Dimensions, LxWxH, mm (in.) 774x598x1428 (30x24x56) 774x598x1428 (30X24X56)Enclosure Class* IP 23 IP 23Application Class** S S*EquipmentmarkedIP23isdesignedforindoorandoutdooruse.**ThesymbolSindicatesthattheweldingpowersourcemaybeusedinareaswithanincreasedelectricalhazard,eg/areaswheretheelectricalhazardisincreasedduetodampand/ortheproximitytoearthedmetalobjects.

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A2S Mini Master

Ordering Information a2s Mini Master gMaw Mtw (4wd) systems Includes the A2-A6 PEH Process Controller and Wire EquipmentA2S Mini Master w/ manual slides, 90x90 mm ....................449 181 880 A2S Mini Master w/ motorized slides 180x180 mm & PAK ...............449 181 881A2S Mini Master w/ motorized slides 180x180 mm & GMD .......... 449 181 882Includes the A2 PEI Process Controller and Wire EquipmentA2S Mini Master w/ manual slides, 90x90 mm ....................449 380 880A2S Mini Master w/ motorized slides 180x180 mm & PAK ...............449 380 881A2S Mini Master w/ motorized slides 180x180 mm & GMD .......... 449 380 882

a2s Mini Master saw systems Includes the A2-A6 PEH Process Controller and Wire EquipmentA2S Mini Master w/ manual slides 90x90 mm .....................449 170 880 A2S Mini Master w/ motorized slides 180x180 mm & PAK ........449 170 881A2S Mini Master w/ motorized slides 180x180 mm & GMD .......449 170 881Includes the A2 PEI Process Controller and Wire EquipmentA2S Mini Master w/ manual slides 90x90 mm .....................449 370 880 A2S Mini Master w/ motorized slides 180x180 mm, PAK ........449 370 881A2S Mini Master w/ motorized slides 180x180 mm, GMD .......449 370 881

To connect to Lincoln or Miller ........................................ contact ESAB

• VersatileweldingsystemforsinglewireSAW,twin wireSAWorGMAW• Light-weightandcompactdesignallowsforgreater flexibility• Modulardesignallowsusertoexpand,integrateor modifysystemquicklyandeasily• UsesA2-A6PEHorA2PEIprocesscontroller• Accurate,easyjoint-trackingwithmanualormotorized slidesystemandmanualPAKorautomaticGMDjoint tracking• Systemattachestoanybeamtravellingcarriageor Column&Boomsystem

welding Heads

Options & AccessoriesPilot lamp, light bulb for PEH .......................................153 143 886 Pilot lamp, laser diode for PEH ....................................457 788 880 Thin wire straightener, single wire...............................332 565 880

gas handling equipment, gMaw onlyCooling unit OCE 2H 220 VAC, 50/60 Hz .....................414 191 881Gas hose ........................................................................190 270 101Water-cooling hose .......................................................190 315 104Arc shield .......................................................................334 689 880 Flux recovery unit OPC .................................................148 140 880 Flux Hopper, 6 L (1.6 gal.) .............................................413 315 881 Concentric flux funnel ...................................................145 221 881Contact tube, bent ......................................................... 413 511 001Wire reel, plastic 30 Kg (66 lbs.) ...................................153 872 880Wire reel, steel, 30 Kg (66 lbs.) .....................................416 492 880Wire reel, steel Ø 220 mm (8.7 in.) ...............................671 164 080Conversion kit from SAW to GMAW A2 (2WD) ...........413 526 881Conversion kit from SAW to GMAW MTW (4WD) .......449 030 880

Wear Parts .............................................................. see pages 16-19

Technical Data Single Wire SAW Twin Wire SAW GMAW GMAW MTW 600

Wire size, mm (in.) Steel 1.6-4.0 (1/16-5/32) 2x1.2-2.5 (2x.045-3/32) 0.8-1.6 (.030-1/16) 1.0-1.6 (.040-1/16)Stainless Steel 1.6-4.0 (1/16-5/32) - 0.8-1.6 (.030-1/16) 1.0-1.6 (.040-1/16)Cored Wire 1.6-4.0 (1/16-5/2) - 1.2-2.4 (.045-3/32) 1.0-2.4 (.040-3/32)Aluminum - - 1.2-1.6 (.045-1/16) 1.0-2.0 (.040-5/64)

Max. wire feed speed, cm/min (ipm) 900 (354) 900 (354) 1600 (630) 2500 (984)Flux volume, L (gal.) 6 (1.4) 6 (1.4) - - - -Max. permissable load 100%, A 1000 1000 1000 1000Control voltage, VAC 42 42 42 42Linear slides / setting range, mm (in.) 90 (3.5) 90 (3.5) 90 (3.5) 90 (3.5)Angular slide setting range 360o 360o 360o 360o

A2S MiniMaster Sales Literature .....................................XA00088820 A2S MiniMaster Instruction Manual .................................449 175 060

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welding Heads

26

Ordering Information single wire saw system a6With standard wire feed unit (gear ratio 156:1)A6S Arc Master w/ manual slides 210x210 mm ..........449 270 880 A6S Arc Master w/ motorized slides 300x300 mm & PAK....449 270 881A6S Arc Master w/ motorized slides 300x300 mm & GMD ..449 270 882With high-speed wire feed unit (gear ratio 74:1)A6S Arc Master w/ manual slides 210x210 mm ..........449 270 890A6S Arc Master w/ motorized slides 300x300 mm & PAK ....449 270 891 A6S Arc Master w/motorized slides 300x300 mm & GMD ...449 270 892

twin-wire saw system a6With high-speed wire feed unit (gear ratio 74:1)A6S Arc Master w/ manual slides 210x210 mm ..........449 271 890A6S Arc Master w/ motorized slides 300x300 mm & PAK ....449 271 891A6S Arc Master w/ motorized slides 300x300 mm & GMD ..449 271 892

Options & AccessoriesWear Parts .............................................................. see pages 16-19

Flexibility,reliability,andsuperiorperformancecapabilityComprehensivecomponentandmodulesystemmakeprocesscustomizationeasyA6VECmotorforreliableandconsistentwirefeedAccurate,easymanualPAKorautomaticGMDjointtrackingwithmanualslidesorjoystick- controlledmotor-operatedcrossslidesCapableofheavy-dutyMIG,single/twinwireSAW,aswellasstripcladdingandSynergicColdWire(SCW)weldingwithoptionalaccessoriesUsesA2-A6PEHprocesscontroller–fast,accuratepre-settingofallparametersbeforeweldingstartsFeedbacksystemensureshighandconsistentweldingquality-savetimeandmaterialTheweldingheadscanbeequippedwiththestandardwirefeedunit(gearratio156:1)orwiththehigh-speedwirefeedunit(gearratio74:1)

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A6S Arc Master

A6S Arc Master Sales Literature .....................................XA00088920 A6S Arc Master Instruction Manual ................................449 275 060

Technical DataWelding current and wire dimensionsSubmerged arc welding DC or AC, A max. 1500A6 Feed Unit - High Speed, 74:1Wire feed speed, cm/min (ipm) 40-800 (16-315)Single wire, mm (in.) 1.6-4.0 (1/16-5/32)Twin wire, mm (in.) 2x1.2-2x2.5 (2x.045-2x3/32)Single cored wire, mm (in.) 1.6-4.0 (1/16-5/32)A6 Feed Unit - Low Speed, 156:1Wire feed speed, cm/min (ipm) 20-400 (8-157)Single wire, mm (in.) 3.0-6.0 (1/8-1/4)Twin wire, mm (in.) 2x2.0-2x3.0 (2x5/64-2x1/8)Single cored wire, mm (in.) 3.0-4.0 (1/8-5/32)Angular PositioningCircular slide, crank operated +/- 180°Straightener +/- 45°

welding Heads

27

welding Heads

28

A6S Tandem Welding Heads

SuitableforheavyconstructionweldingCapableofweldingDC/DC,DC/ACorAC/ACUsesA2-A6PEHprocesscontroller-quicklyandaccuratelyprogramweldingparametersforeachtorchFeedbacksystemgiveshighandconsistentweldingqualityfromstarttofinish,savingtimeandmoneyVersatilepositioningthrougheasytouse,completeslideassemblyforweldingtorch position,distancestick-out,andangleonbothleadingandtrailingtorchesEnhanceproductivitybyaddingoptional equipmentsuchastwinwireandSynergicColdWiresystemsAvailableinatwobasicversions,A6STandemMasterandA6DSTandemMaster,withseveralconfigurationstomatchspecificsafety,qualityandproductivityrequirementsWeldingheadscanbeequippedwiththestandardwirefeedunit(gearratio156:1)orwiththehigh-speedwirefeedunit(gearratio74:1)

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• A6S Tandem Masterisoptimizedforweldingacrossmultipleperpendicularaxis’andiskeyintheweldingofcylindrical objectswherebothlongitudinalandcircumferentialweldingisrequired • Adjustable±90°intervalturningbracketandcrossslide • Automaticjointtrackingkeepsintracknomatterwhichdirectionweldingoccurs • A6DS Tandem Masterisoptimizedforweldinginmultipledirectionsandiskeyintheautomatedweldingoflongweldjoints suchasbeamsandgirders • Adjustable±90°intervalturningbracketandfixedcrossslide • AutomaticjointtrackinginanydirectionwhenintegratedtoESABcolumnandboomM-modelsystems;simplyrotatethe head180°andweldinthereversedirection

Ordering Information A6S Tandem Master, standard (156:1) .........................809 940 880A6S Tandem Master, high-speed (74:1) .......................809 940 881A6DS Tandem Master, standard (156:1) ......................809 939 880 A6DS Tandem Master, high-speed (74:1) ....................809 939 881

Options & Accessories Twin kit LD (one kit per torch) ......................................809 934 880Twin kit HD (one kit per torch) ......................................809 934 881Bump protection ............................................................451 404 880GMD, joint tracking ........................................................417 142 880Pilot lamp, light bulb .....................................................153 143 886Pilot lamp, laser diode ..................................................457 788 880Bracket, (straight) for wire ............................................334 318 880Brake hub, for wire reel.................................................146 967 880Wire reel, plastic, 30 Kg (66 lbs.) ..................................153 872 880Wire reel, steel, 30 Kg (66 lbs.) .....................................416 492 880

ESAB Tandem Welding Heads Sales Literature ............ XA00119120

A6S Tandem

A6DS Tandem

welding Heads

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Technical Data (Basic Components) A6S Tandem Master A6DS Tandem Master

A6 feed unit for HD-type for wire 3.0-6.0 mm (1/8-1/4 in.) * *Horizontal motorized slide with double runners L = 355 mm (14 in.) * *Vertical motorized slide with double runners L = 595 mm (23.4 in.) * *A2 PEH Process Controller * *Flux Hopper, 10 l (2.3 G) incl. bracket * *Cable holder * *Welding head, 2 pcs. Each head has:A6 manual slide L = 90 mm (3.5 in.) P/N 154 465 880 * *A6 circular slide P/N 671 171 580 * *Insulators (4 pcs) P/N 278 300 180 * *Main bracket with mounting flange for cross slide assembly P/N 810 786 880 *Swivel bracket for rotating head 90° 334 549 880 809 873 880Total weight, excl. PEH, wire and flux, Kg (lbs.) 215 (474) 190 (419)

A6S Tandem Welding Heads, cont’d

A6S Tandem A6DS Tandem

welding Heads

Tandem MIG Welding Head

TandemMIGadvantagesincludehighspeedwelding,lowheatinput,andincreasedproductivityIsolatedwirecontactsallowdifferentparameters, wiretype,anddiameterforeachwireTorchhasvariablewirespacing,angles,electrical stickout,andvariousgasshieldingcupsAvailableforroboticsorhardautomationUseseitherdualAristoMigpulsesystemorLAF(DC)powersupplies

ContactESABformoreinformation.

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Straight min. 80 max. 170960

min.

385/m

ax. 9

80

min. 140/max. 495

1480

801

R920

min. 70 max. 130

min.

80/m

ax. 6

75

1200

730

780

max.

935

(mm) (mm)

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A6S Compact Welding Heads for Internal Tube Welding

• Forweldinglongitudinalandcircumferentialbuttjoints insidetubes• Twoversionsavailable: • A6SCompact300forinternalweldingoftubes downto300mm(12in.)insidediameter • A6SCompact500forinternalweldingoftubes downto500mm(20in.)insidediameter• Equippedwithreliable,VECfeedmotorforsuperior weldperformance• SuperviseandadjusttheheadpositionviaTV monitoringsystem• Usestandardmini-crossslideassemblyandPAK manualtrackingsystemorGMDautomaticjoint trackingsystemtoeasilyfollowthejoint• AddeithertheFFRSBasic/SuperorFFRS1200/3000 FluxFeed&RecoverySystemtooptimizethewelding process

Ordering Information A6S Compact 300 Welding Head, standard ................809 280 880A6S Compact 300 Welding Head, high-speed ............809 280 881A6S Compact 500 Welding Head* ................................416 967 880

*ContactESABforOrderingInformation,Options&AccessoriesandTechnicalDataforA6SCompact500WeldingHeads

Options & AccessoriesFlux Valve Control Kit ...................................................813 620 880Includes solenoid valve and 5 m (16.4 ft.) air hoseInductive Sensor............................................................ 811 178 880TV Monitoring Equipment ............................................ 811 176 880Laser Pointer.................................................................. 811 177 880

contact tips, wire sizeM12, 3.0 mm (7/64 in.)....................................................154 623 005M12, 3.5 mm (1/8 in.)......................................................154 623 004M12, 4.0 mm (5/32 in.)....................................................154 623 003

feed rollers, wire size3.0-3.2 mm (1/8 in.) ........................................................218 510 2984.0 mm (5/32 in.).............................................................218 510 286

Technical DataWire Dimensions, mm (in.) Steel 3.0-4.0 (1/8-5/32)

Stainless Steel 3.2 (1/8)Permissible Load 100%, A 800Control Voltage, VAC 42Travel Speed, cm/min (ipm) 10-170 (4-67)Linear Slides Setting Range, mm (in.) 50 (2)Angular Slide Setting Range, o 360Wire Feed Speed, standard, cm/min (ipm) 20-400 (8-157)Wire Feed Speed, high-speed, cm/min (ipm) 40-800 (15.7-315)

A6S Compact 500 Welding Head

A6S Compact 300 Welding Head

ESAB A6S Compact 300 Sales Literature ......................XA00124620

welding Heads

31

A6S SAW Strip Cladding Head

Ordering Information Strip Cladding Kit ..................................................................155 972 880For use with A6 SAW Tractor or A6S Arc MasterElectroslag Welding (ESW) Strip Cladding Head ...............772 306 880Electromagnetic Steering Unit .............................................772 285 880

Options & Accessories Reel holder .............................................................................417 636 880(not to be used with motor-operated cross slide)Wire reel, steel, 30 Kg (66 lbs.) .............................................416 492 880Suction nozzle, flux ...............................................................156 025 001

• UsedincombinationwithstandardA6SArcMaster weldinghead• Providesaneconomicalsolutionforsurfacingwith highalloyedmaterialssuchasstainlesssteelor nickel-basedalloys• Chooseawidervarietyofparentmaterialsand consumables• Stainlesssteelcladdingiswidelyusedin productionofcomponentswhereadditional strengthorcorrosionresistanceisrequired• Weldingheadcanbefittedwithelectrodestrips aswideas30-100mm(1.2-4.0in.)andasthickas 0.5mm(0.02in.)

ESW* - Electroslag Welding -isamethodofstripcladding,butdiffersfromSAWstripcladdinginthatthearciscreatedbetweentheelectrodeandtheworkpiece.Theweldingfluxthatisputintothejointmeltsandaslagpoolisproduced,whichthenincreasesindepth.Whenthetemperatureoftheslaganditsconductivecapacitytherebyincreases,thearcisextinguishedandtheweldingcurrentisconductedviathemoltenslagwherethenecessaryweldingenergyisproducedthroughresistance.Thismethodcanbeusedforjoiningthicknessesof25mm(1in.)andabove.

*ContactESABforOptions&AccessoriesandTechnicalDatafortheESWWeldingHead.

Technical DataCurrent capacity, A max. 1500Feed roller diameter, mm (in.) 50 (2.0)Strip width, mm (in.) 30-100 (1.2-4.0)Strip thickness, mm (in.) 0.5 (0.02)Strip feed speed: see A6 Mastertrac sales literature XA00109420 or A6S Arc Master

sales literature XA00088920

A6S SAW Strip Cladding Head Sales Literature ............XA00101020ESW Strip Cladding Head Information ........................Contact ESAB

RECOMMENDEDPOWERSOURCES:LAF1250,1600andA2-A6PEHProcessController

welding Heads

(mm)

32

A6-MHW “Manhole Welder”

EquipmentdesignedforweldingmanholesornozzlesoncyclindricalvesselsorflatplatesFixthemachinetotheworkpiecebymanualclampingwithspecialjawstoensuresafeconstraintofthemachinetomanholeswithdiametersbetween250-460mm(10-18in.)SafetyclampingbeamwithtensionbarinthecyclindricalbodytopreventtiltingRotationdevicefortheweldinghead,withagearwheeldrivebytheVEC44gear-motorwithacontinuousadjustablespeedof0.1-2.0rpmTorchmovedalongarigidrailbyalight-weightcarriageWeldingheadmadefromA6components

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Ordering InformationA6-MHW ..................................................................... Contact ESABIncludes jaws for diameters between 200-460 mm (8-18 in.)

Options & AccessoriesMini motorized slides, 90x90 mm............................ Contact ESABJoystick control panel PAG17 ................................. Contact ESABJaws for manholes +460 mm (+18 in.) .................... Contact ESAB

Technical DataWelding wire diameters, mm (in.) 2.0-4.0 (5/64-5/32)Manhole diameters, mm (in.) internal minimum 150 (6)

internal maximum 1100 (43)min. wall thickness 50 (2)

Min. depth necessary for correct clamping on the internal nozzle surface, mm (in.) 25 (1)Weight, Kg (lbs.) 360 (794)

A6-MHW VERSION B-comescompletewiththetiltingcontrolsystemfortheconnectionwiththeturningrolls.Thismakesitpossibletosynchronizetheweldingmovementofthetorchwiththeclockwiseorcounter-clockwiserotationoftheturningrollsinordertogetthejointalwaysinaflatpositionalongthewholecircumference.

FormoreinformationonthestandardA6-MHWortheBversion,pleasecontactESAB.

welding Heads

33

A6 Synergic Cold Wire

• Boostdepositionratesupto50%foranygiven current/wirefeedspeed(utilizesexcessheatfromarc)• SynergicColdWireweldingofferslessdistortion, reducedfluxconsumption,andfewerweldbeads• Easytouse,requiresnoadditionalcontrolunitsor separatewirefeedmechanisms• Allowsflexibleprocessconfiguration-solid/cored wire,single,twinwire,tandemandmultiplewire combinations• SynergicColdWirehasnoarcandcanbeusedfor “hardtoweld”alloyswithcoredwire• Setwireinleadingortrailingpositiondependingon requirementofpenetrationvs.build-up• FitsallESABA6systems

Ordering InformationSynergic Cold Wire Kit, complete ........................................449 022 880Includes VEC Motor (156:1), straightener (left), brake hub, bracket A6, screw MC6S M6x60, nut M6M, cartridge A6, hand-wheel, and mounting hardware

A6 Synergic Cold Wire Sales Literature .........................XA00094920

Options & AccessoriesFlex Conduit SCW ................................................................ 500C23Contact Device, L=400 mm (16 in.) (D35) ....................417 959 882Wire Reel, steel ..............................................................416 492 880Twin Wire Kit ..................................................................334 291 889SCW Motor Kit ...................................................................... 500C31Wear Parts .............................................................. see pages 16-19

accessory coMponents

34

Ordering InformationBeam-Travelling carriage ..............................................457 897 880

Options & AccessoriesMounting bracket for Tandem head .............................458 026 001Track in lengths of 3,000 mm (9.8 ft.)...........................145 282 880Required number of floor columns: 2

Beam Travelling Carriage

• Idealsolutionforsubmerged-arcandMIGwelding applicationsrequiringbeam-mountedcarriage• CanbefittedwithanyA2orA6weldinghead

Forlongitudinalweldingorweldingofcircular workpieces

• Placecarriageoneitherastandardl-beamIPE300or speciallymachinedl-beam(contactESABfordetails)• Fastandeasypre-programmingoftravelmotionand weldingparametersusingtheA2-A6PEHprocess controller

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MBVA 330/550 Beam Welding Carriage

Heavysidebeamcarriage,suitableformultiplesubmergedarcweldheadsandmostoptionsavailableoncolumnsandboomsCrossbeamsavailableupto1.2m,capacityupto1.4tonVECmotorwithgear,rackandpinion,forpowerful,consistentcarriagetravelDifferenttravelunitsforspeedstomatchprocess

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Technical DataTravel speed beam carriage, cm/min (ipm) 6-200 (2-79)Weight carriage, Kg (lbs.) 60 (132)

Ordering InformationMBVA 300 carriage ........................................................150 765 880MBVA 550 carriage ........................................................150 901 880

Options & AccessoriesCable length, 1.5 m (5 ft.) - 50 m (164 ft.) ................. contact ESAB

Travel unit, speed range 3-80 cm/min (1.2-32 ipm).....150 943 880Travel unit, speed range 11-125 cm/min (4-49 ipm) ....150 943 881Travel unit, speed range 14-250 cm/min (5.5-98 ipm) ......150 943 882Travel unit, speed range 37-1500 cm/min (14.5-590 ipm) ...... 150 943 883Travel unit, speed range 27-530 cm/min (11-208 ipm) .....150 943 884

Beam 330, 300 cm (118 in.), 240 Kg (529 lbs.) .............803 348 880Beam 330, 450 cm (177 in.), 480 Kg (1058 lbs.)...........803 348 881Beam 330, 600 cm (236 in.), 720 Kg (1587 lbs.)...........803 348 882Beam 330, 750 cm (295 in.), 960 Kg (2116 lbs.) ...........803 348 883Beam 330, 900 cm (354 in.), 1000 Kg (2204 lbs.).........803 348 884

Beam 330, 1050 cm (413 in.), 1200 Kg (2645.5 lbs.)....803 348 885Beam 330, 1200 cm (472 in.), 1420 Kg (3130.5 lbs.)....803 348 886Beam 550, 300 cm (118 in.) ...........................................321 527 880Beam 550, 450 cm (177 in.) ...........................................321 527 881Beam 550, 600 cm (236 in.) ...........................................321 527 882Beam 550, 800 cm (315 in.) ...........................................321 527 883Beam 550, 1200 cm (472 in.) .........................................321 527 884

Technical Data MBVA 330 MBVA 550

Rated load, N (kp) 10000 (1000) 20000 (2000)Rated moment, Nm (kpm) 3300 (330) 10000 (1000)Weight, Kg (lbs.) 95 (209) 275 (606)

A6B Beam Travelling Carriage Sales Literature ............XA00091920A6B Beam Travelling Carriage Instruction Manual ........458 028 001MBVA 330/550 Beam Welding Carriage Sales Literature .....XA00105120

Track in lengths of 4,500 mm (14.8 ft.).........................145 282 881 Required number of floor columns: 3Track in lengths of 6,000 mm (19.7 ft.).........................145 282 882 Required number of floor columns: 3Track in lengths of 8,000 mm (26 ft.)............................145 282 883 Required number of floor columns: 4

35

Servo Slide Motorized Slide for Linear Motion

• Heavydutycapacitywithhighprecisionslidefor accurateandrapidjointtrackingandpositioning• Canbeinstalledinverticalorhorizontalpositions- settinglengthsupto1030mm(41in.)withacentral pointofattachment• OperatesjointlywithA2orA6components• Slidesavailablefrom60mm(2.4in.)to1,030mm (41in.)workingrange• Permissibleloadof1500N(337lbf/ft.)inany mountingposition• Maximumtorqueforverticalunitis400Nm(3540 lbf/in.);maximumtorqueforhorizontalunitis280 Nm(2480lbf/in.)


Ordering InformationServo Slide, 60 mm (2 in.) .....................................................334 333 880Servo Slide, 120 mm (5 in.) ...................................................334 333 881Servo Slide, 180 mm (7 in.) ...................................................334 333 882Servo Slide, 240 mm (9 in.) ...................................................334 333 883Servo Slide, 300 mm (12 in.) .................................................334 333 884Servo Slide, 420 mm (17 in.) .................................................334 333 885Servo Slide, 540 mm (21 in.) .................................................334 333 886Servo Slide, 730 mm (29 in.) .................................................334 333 887Servo Slide, 1030 mm (41 in.) ...............................................334 333 888Servo Slide, 358 mm (14 in.), heavy duty ............................416 190 880Servo Slide, 598 mm (23.5 in.), heavy duty .........................416 190 884

Options & AccessoriesConnection cable, 2 m (6.5 ft.) ..............................................417 310 887Connection cable, 5 m (16.4 ft.)............................................417 310 888Connection cable, 10 m (32.8 ft.)..........................................417 310 889

Oneconnectioncableisrequiredforeachservoslideforconnectionofslidetolinearmotioncontroller(eg.GMDorPAK)

Technical Data, cont’dServo Slide 334 333 -880 -881 -882 -883 -884 -885 -886 -887 -888

Travel length, mm (in.) 305 (12) 365 (14) 425 (17) 485 (19) 545 (21.5) 665 (26) 785 (31) 1025 (40) 1385 (54.5)# of 60 mm indexings, n 3 4 5 6 7 9 11 14 21Clearance at limit, mm (in.) 0 (0) 0 (0) 0 (0) 0 (0) 0 (0) 0 (0) 0 (0) 24 (1) 55 (2)Weight, Kg (lbs.) 11.5 (25) 13.2 (29) 15.0 (33) 16.7 (37) 18.5 (41) 21.9 (48) 25.4 (56) 30.9 (68) 38.8 (85.5)

Technical DataControl Voltage, V DC 42Max. ambient temperature 80oC (176oF)Axial play, runner, mm 0.1Max. torque-free load, Kg (lbs.) 150 (330)

Servo Slide Sales Literature ............................................XA00032720Servo Slide Instruction Manual ........................................443 394 060

36

PAK and GMD Joint Positioning and Tracking Systems

SimpleandeasytouseAdaptforusewithalmostanytypeofweldingjointPAKsystemisformanualjointtracking;GMDsystemisforautomaticjointtrackingPAKandGMDworkequallywellwithA2orA6weldingsystemsMotorizedservoslidesguaranteeareliableandaccuratejointtrackingPAKsystemavailablewithorwithoutremotecontrol,andcanbeintegratedintoaColumnandBoomsubmergedarcweldingsystemGMDautomaticjointtrackingsystemisdesignedforuseinfilletandbuttjointsusingsensorfingersGMDcompensatesforirregularitiesinweldjoint,trackssimplegeometricshapes,andavoidsparallaxproblems

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Ordering InformationGMD system, complete .................................................417 142 880Includes GMD joint tracking unit, GMD remote control with 3.5 m (11.5 ft) cable, 2 m (6.5 ft) control cable, sensor with finger, and cross saddle and support for sensor

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

Options & Accessories*Sensor with finger .........................................................416 688 880Cross saddle and support for the sensor ...................416 739 880GMD joint tracking unit .................................................416 066 880GMD remote control unit ..............................................416 065 880Control cable 2m (6.5 ft) ................................................416 749 887Control cable with 90 contact 2m (6.5 ft) .....................416 346 887Finger with ball ..............................................................416 719 001Protective rubber boot ..................................................412 013 001Finger for tube panel .....................................................443 328 880Finger for beam welding ...............................................443 187 880Standard finger ..............................................................146 586 001Intermediate transformer ..............................................148 636 002Cable for transformer connection (order per m) ........262 613 404Submerged arc camera system w/ cooling ................. 811 387 880

*OnlyforGMDmodels

Technical DataPAK Control UnitControl and operating voltage, VAC 42Power requirement, VA 460Enclosure type IP 23Max. ambient temperature, oC (oF) +45 (+113)Weight, Kg (lbs.) 4.5 (10)Weight, remote control unit, Kg (lbs.) 2.0 (4.4)GMD Sensor with FingerSensitivity, mm (in.) +/- 0.1 (+/- 0.004)Weight, sensor, Kg (lbs.) 0.6 (1.3)Cross saddle and support for the sensorCross saddle, setting length, mm (in.) 80 (3.1)Weight, cross saddle, Kg (lbs.) 1.3 (3.5)GMD Joint Tracking UnitControl and operating voltage, VAC 42Power requirement, VA 460Enclosure type IP 53Max. ambient temperature, oC (oF) +45 (+113)Weight, Kg (lbs.) 2.2 (4.9)GMD Remote Control UnitPositioning speed High/LowWeight, Kg (lbs.) 2.0 (4.4)GMD AccessoriesFinger with ball, length, mm (in.) 100 (3.9)Intermediate transformer, for separate voltage supply

200/230/440/500V 60 Hz main to 42V secondary


GMD/PAK Joint Tracking System Sales Literature ........XA00068420GMD Joint Tracking System Instruction Manual ............443 403 002PAK Joint Tracking System Instruction Manual .............443 405 002

37

OPC Flux Recovery Systems

• Robustandcompactdesign• Easytooperateandpracticallymaintenance-free• Integratedsystemformaximumproductivity-lower investmentandservicecosts• AdaptstoanyA2orA6weldingsystem-tractoror stationary• Usesonlycompressedair-safeandinexpensive• CanbeintegratedintocompleteFFRSfluxfeeding andrecoverysystem• Threefiltertypes:filterbagforA2applications, cyclonefilterwithfilterbagformostA6 applications,andTedakfilterforheavy-duty applications• OPCsystemincludes:ejector,cyclone,filterwith attachmenthardware,securingstrap, suctionhose,andfoursuctionnozzles(forbutt welds,normalandlarge;filletwelds,leftandright)

Ordering Information OPC Basic, with standard filter bag.....................................148 140 880 OPC Basic, with cyclone filter ..............................................802 415 882OPC Basic, with Tedak filter .................................................802 415 883

OPC Super, with standard filter bag ....................................339 719 880OPC Super, with cyclone filter .............................................802 415 892OPC Super, with Tedak filter .................................................802 415 893

opc basic flux recovery systemWorksonejectorprincipleusingcompressedairCycloneseparator,ontopoffluxhopper,efficiently

separatesdustfromrecoveredflux• Slagisseparatedandfluxisreturnedtohopper

••

opc super flux recovery systemSimilartoBasicsystembutwithstrongerejectorandcyclone–providesbettersuctionCanalsobeusedwithpre-heatedflux

•

•


OPC Flux Recovery System Sales Literature ................XA00105020OPC Flux Recovery System Instruction Manual ............443 407 001

Options & AccessoriesWear Parts ..................................................................... see page 38

1. Air pressure hose, 3/8”2. Air pressure hose, 1/2”3. Air pressure tube, 63 mm4. Air central5. Plastic bag6. Filter bag7. Filter bag, cyclone, tedak

38

OPC Basic OPC Super1 Ejector 147 640 880 1 Ejector 339 720 0012 Spiral hose, D47, 0/38, 1 191 813 801 2 Spiral hose D47, 0/38, 1 191 813 8013 Tension band 192 855 002 3 Tension band 192 855 0024 Cone 148 143 001* 4 Cone 332 279 0015 Tension ring 148 144 001* 5 Tension ring 148 144 0016 O-ring, 189.3x5.7 215 201 353 6 O-ring, 189.3x5.7 215 201 3537 Ball valve 145 824 881 7 Ball valve 333 625 0018a Filter, paper 155 966 001 8a Filter, paper 155 966 0018b Filter, cotton 332 448 001* 8b Filter, cotton 332 448 001*9 Funnel 148 142 001 9 Funnel 332 280 00110 Rubber lining 145 565 001 10 Rubber lining 332 282 00111 O-ring 149.2x5.7 215 201 345 11 O-ring 149.2x5.7 215 201 34512 Cyclone 148 141 001 12 Cyclone 332 281 00113 Rubber lining 145 073 001 13 Rubber lining 332 283 00114 Tension spring 145 815 001 14 Tension spring 145 815 00216 Strainer 020 301 780 15 Clamp 340 612 001

16 Strainer 020 301 780Suction Nozzle1a Butt weld 1 145 501 0011b Butt weld 2 145 502 0011c Fillet weld left 145 504 0011d Fillet weld right 145 505 0012 Nozzle bracket 147 384 8813a Insulator D20 145 131 0043b Insulator D35 145 131 0024 Flux hose, D32.0/25.0, free

length / m, length 0.5 m443 383 001

5 Pipe bent 153 296 001

Cyclone Filter1a Cone basic 148 143 0011b Cone super 332 279 0012 Tension ring 148 144 0013 Bend 413 576 0014 Spiral hose D67, 2/63 193 125 0035 Cyclone 148 141 0016a Filter, paper 155 966 0016b Filter, cotton 332 448 001*7 Tension band 192 855 0028 Plastic bag 190 665 0049 U-screw 379 600 00110 Bracket 379 599 880

*OptionalItem


OPC Flux Recovery System Wear Parts

8a8b

7

HoseD16/9.5

2 1

3

56

1512

7 43

8a8b

HoseD22/12.5

4

9

10

12

111314

16

1a 1b

1d 1c

1a1b1c1d

2 3a3b

5

4

31a1b

2

4

6a6b

7

1a2

9, 105

8

39

Options & Accessories ffrs basic & superAir central .......................................................................417 714 880Flux hopper with bent inlet pipe 10 L (2.6 gal) ............156 230 883left hand side seen from front Flux hopper with bent inlet pipe 6 L (1.6 gal) ..............413 404 883left hand side seen from front Flux hopper with bent inlet pipe 10 L (2.6 gal) ............156 230 884front side Flux hopper with bent inlet pipe 6 L (1.6 gal) ..............413 404 884front sideFlux hopper with bent inlet pipe 10 L (2.6 gal) ............156 230 885 right hand side seen from frontFlux hopper with bent inlet pipe 6 L (1.6 gal) ..............413 404 885 right hand side seen from front

ffrs 1200 & 3000Bent inlet to flux hopper ...............................................186 961 881Straight inlet to flux hopper ..........................................186 961 880Extra hopper with inlet ..............................seeFFRSBasic&SuperAir pressure hose 1/2 in., max. 50 m (164 ft.)*** .........190 343 106Suction hose D47/38, max. 12 m (39 ft.)*** ..................379 016 001

***Lengthaccordingtocustomerrequirement

Ordering Information FFS, straight inlet ..........................................................806 697 887 FFS, bent inlet ................................................................806 697 886 FFRS Basic & Super systems consist of theTPC 75 air flux feed tank, 25 m (82 ft) plastic hose for flux, and flux hopper inlet.

FFRS 1200 ......................................................................801 500 901 FFRS 3000 ......................................................................801 500 921FFRS 1200 & 3000 consist of the TPC 75 air flux feed tank, primary separator, motor-driven vacuum unit (for 1200 system only), air pressure regulator with water tap, suction hose between the primary separator and vacuum unit (1200 = 2m (6.5 ft.), 3000 = 5m (16.4 ft.), air central with 10 m (32.8 ft.) air hose 1/2 in. included, flux suction nozzle, fixing bracket and filter bags (4) and flux feeding hose, 25 m (82 ft.) included.

FFRS Flux Feed and Recovery Systems

• Idealforcontinuousandhighcapacitywelding• Minimalmanualfluxhandling• Reducedfluxconsumptionforbetterweldingeconomy

FewerweldstopsforincreasedefficiencyEfficientfiltrationofusedair

• Fluxfeedsfroma75L(20gal.)capacityTPC-75 pressurizedfluxtanktotheESABfluxhopperof yourchoice:6L(1.6gal.)or10L(2.6gal.) • Fluxfeedinletoptions:straightorbent

ffrs – basic & super• BuiltonOPCBasic&Supermodules• “Basic”-fornormalweldingoperation

“Super”-forincreasedfluxandheatconditions• Basedonejectorvacuumprincipleffrs 1200 & ffrs 3000• Baseduponanelectricalsuctionunitcreatingavacuum• Forusewhenextrahighrecoveryforceisrequired

Fluxdustseparatedautomaticallyinapre-separator

••

•

•


Technical DataFlux feeding and recovery system FFRS 1200 FFRS 3000Weight, Kg. (lbs.)* 230 (507) 400 (882)Dimensions, LxWxH, mm (in.) 1053x450x2210 (41x18x87) 750x450x2210** (30x18x87)*** without flux ** suction unit dimensions belowSuction unit FFRS 1200 - P160 FFRS 3000 - E-PAK 150Power, W 1200 3000Mains supply, V/Hz 110-230/50-60 400/3~50Fuse, A 10 16Max. vacuum, kPA -21 -25Max. air flow capacity, m3/h 156 270Sound level, dB 74 63Filter area, m2 0.6 3Filtration efficiency, % 99.95 99.95Life-span of filter, work hours 5-6000 4000-6000Weight, Kg (lbs.) 19 (42) 194 (428)Dimensions, LxWxH, mm (in.) 480x400x1160 (19x16x46) 1200x690x2000 (47x27x79)Primary separator FFRS 1200 FFRS 3000Volume, L (gal.) 50 (13) 50 (13)Dimensions, LxW, mm (in.) 450x700 (18x28) 450x900 (18x35)

FFRS Basic/Super Sales Literature ................................XA00104820FFRS 1200/3000 Sales Literature ....................................XA00104920TCP 75 Sales Literature ...................................................XA00009320

40

CRE 30 & CRE 60 Air Drying Units

• Designedforusewithanyfluxhandlingsystem• Systemisbasedonabsorptionprinciple-reducesthe riskofhydrogencrackinginweldmetalbyensuring fluxremainsdry• Builtinmonitor-warnsiftheprogrammedhumidity limitisexceeded• Reducescondensation-lesscorrosionandmalfunctions• Simplesystemmonitoring-manometeronpressurized dryerbottleswitheasy-to-readdewpointindicator

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


Technical Data CRE 30 CRE 60

Supply Voltage, VAC 230 230Max. power rating, W 40 50Net air flow capacity at bar, m3/h (ft3/hr @ 87 psi) 30 Normal (1060) 60 Normal (2120)Regenerating flow at 6 bar (87 psi), % 14 14Max. dew point under nominal working conditions, oC (oF) -26 (-14) -26 (-14)Desiccant, Type 512

Sodium-Aluminum-Silicate, Kg (lbs.) 10 (22) 16 (35)Normal pore size, Ångstrom 4 4Particle size, mm (in.) 2.5-5.0 (0.01-0.20) 2.5-5.0 (0.01-0.20)Density, Kg/m3 (lbs./in.3) 720 (0.023) 720 (0.026)

Cycle time per container 5 5Max. permissable air flow for oil separation filter, m3/hr 60 Normal 60 NormalManifold thread size R12 R12Max. working pressure, bar (psi) 6 (87) 6 (87)Max. air pressure at testing, bar (psi) 10 (145) 10 (145)Max. inlet air temp under nominal conditions, oC (oF) 30 (86) 30 (86)

CRE 30/60 Air Drying Unit Sales Literature ....................XA00101920CRE 30/60 Air Drying Unit Instruction Manual ................443 423 001

• Keepsfluxataminimumof220oF(104.4oC) wheremoisturecannotbeabsorbed• Constructedofstainlesssteelinsideandout

4ft.(48in.)high,top-loadingwithroomforfluxbucketunderneathStandincludedModelsfor115V,1phoutletor220V,1phoutletFX300modelhascapacityof136Kg(300lbs.);FX600modelhascapacityof272Kg(600lbs.)

•

•••

Options & Accessories Desiccant, type 512, [packaged per 25 Kg (55 lbs.)] ..........443 570 017Oil filter ...................................................................................443 570 018Dust filter ................................................................................443 570 019

Flux Oven

Ordering InformationFlux Oven, 136 Kg (300 lbs.) ............................................. FX300SSFlux Oven, 272 Kg (600 lbs.) ............................................. FX600SS

41

Flux Drying Equipment


Technical Data JK-50 JS200

Capacity, Kg (lbs.) 50 (110) 200 (440)Storage temperature, oC (oF) <200 (<392) 50-300 (122-572)Drying temperature, oC (oF) <500 (<932) -Mains voltage, V/phase 400/3 230/1Output, W 3700 2000Dimensions, LxWxH, mm (in.) - 510x570x1750 (20x22x69)Inner diameter, mm (in.) 1720 (68) -Weight, Kg (lbs.) 190 (419) 115 (254)

wc-8cForMIGtorchesupto600A,TIGtorchesupto500AFitscylinderrackofmostpowersourcetrucksHigh-efficiency,fan-cooledradiatordissipates6480BTU/hrRust-proof5.7L(1.5gal.)reservoirCirculates1gal./min(3.8L/min)@50psi(345kPa)115/230V,50/60Hz.,1ph

•

••

••

•

wc-9Extraheavy-dutycirculatordesignedforMIGtorches,TIGtorchesandplasmacuttingtorchesHigh-efficiency,fan-cooledradiatordissipates8000BTU/hrRust-proof15L(4gal.)reservoirCirculates1gal./min(3.8L/min)@50psi(345kPa)115/230V,50/60Hz.,1ph

•

•

••

•

Js200 flux storage silo• Keepsfluxdryandclean• Makesiteasytohandleflux• Adjustabletemperature

JK-50 powder dryer• Candryupto50Kg(110lbs.)offluxat

amaximumtemperatureof932oF(500oC)in3hours

• Afterdrying,temperaturefallsautomaticallytoapre-setdrystoragetemperatureof302oF(150oC)within12hours

Water Circulators

Ordering InformationWC-8C ...............................................................................................33739WC-9 .................................................................................................33540Water Circulator Coolant, 3.75 L (1 gal.)......................................156F05

Ordering InformationJS200 Storage Silo ................................................................000 515 090JK-50 Powder Dryer ..............................................................000 515 091

42


ForagoodconnectiontotheworkpiecetoobtainoptimalweldingperformanceForrotatingworkpieces,anearthconnectionwitharotatableearthcouplingisthesafestchoiceToattachthecouplingtotheworkpiece,specialclampsareavailable,see“EarthClamps”below

•

•

•

Ordering InformationNKK 600 - max. 600A, 2.2 Kg (4.8 lbs.) ........................700 004 007NKK 800 - max. 800A, 2.7 Kg (5.9 lbs.) ........................700 004 001NKK 1200 - max. 1200A, 4.0 Kg (8.8 lbs.) ....................700 004 002NKK 2000 - max. 2000A, 7.3 Kg (16 lbs.) .....................700 004 003

Rotatable Earth (Rotating Ground) Couplings

Ordering InformationK2 - clamp head for NKK 800/1200 ..............................700 004 004GA 800 - handle connection for K2 ..............................700 004 005PZ3 - pole clamp for NKK 2000 ....................................700 004 006

Earth Clamps for Rotating Workpieces

K2orPZ3earthclampscanbemounteddirectlyontotherotatableearthcouplingtocreategoodcontactbetweentheworkpieceandthereturncableReturnclampscanalsobeusedtoegherwiththeGA800handleconnectiontoformacompleteearthclamptohandlehighcurrentweldingonnon-rotatingworkpieces

•

•

43

Camera Systems for Submerged and Open Arc Welding

Camera Systems Sales Literature...................................XA00124520

Togetherwithalaserorpilotlamp,controltheweldingprocessfromaconvenientlocationSystemconsistsofapurposefuldesignedcamerawithbuilt-incrosshairgeneratortoprovideacontinuousanddistinctjointscanningIncombinationwiththe15in.flatscreen,itbecomesaunitforexcellentcontrolandjointtrackingUponwelding,thecameraswitchesovertoviewingthepool,facilitatingthesupervisionoftheprocessOptionaloverviewcamerawillreproduceapictureoftheweldedjointtogetanimmediateinspectionoftheweldingquality

•

•

•

•

•

Ordering InformationIncludes camera, camera housing, monitor, crosshair generator, camera mounting bracket, work light, work light bracket, necessary cables

A2/A6 SAW camera system with cooling unit..................... 811 412 880A2/A6 SAW camera system without cooling unit ............... 811 412 881

SAW compact camera system with cooling unit ................ 811 413 900SAW compact camera system without cooling unit .......... 811 413 901

GMAW camera system with cooling unit ............................ 811 414 880GMAW camera system without cooling unit ....................... 811 414 881

Overview SAW camera system without cooling unit ......... 811 413 881SAW compact basic camera system with cooling unit ...... 811 413 880SAW compact basic camera system without cooling unit ...... 811 413 882

Technical DataSAW Camera

GMAW/SAW Compact Camera

Overview/SAW Compact Basic Camera

TV Standard PAL/NTSC PAL/NTSC PAL/NTSCModel No. VUP2.01P/VUP2.01N WeldCam/SAWC OV3.04Resolution 480TVL 480TVL 350TVLMin. illumination 0.25lx (at F1.6) - 3.0lxElectronic Iris Automatic 1/60 (1/50)~1/10000 sec. Automatic 1/50~1/10000 sec. 1/50~1/10000 sec.Horizontal field angle approx. 79o at focal 3.5 mm (WIDE)

~approx. 33o at focal 8 mm (TELE)- -

Vertical field angle approx. 63o at focal 3.5 mm (WIDE) ~approx. 25o at focal 8 mm (TELE)

- -

Focal length variofocal lens, 3.5 mm - 8 mm - -External terminals (A) power input +12V DC, (B) GND, (C)

video output, (D) GND- -

Output resistance - 75 ohm -Power supply range DC 12V DC +/- 0.5V DC + 6.0V~DC + 7.5VPower consumption 200mA (max.) 360mA (max.) 200mA (max.)Temperature range -10oC (14oF)~50oC (122oF), (PCB) -10oC (14oF)~50oC (122oF), (PCB) -Dimensions, mm (in.) 60x60x105 (2.4x2.4x4.1) 145x24x24 (5.7x0.9x0.9) 18x18x43+lens (0.7x0.7x1.7+lens)Weight, Kg (lbs.) approx. 0.46 (approx. 1) approx. 0.46 (approx. 1) approx. 0.025 (approx. 0.05)

Note:SAWcompactbasicandOverviewcamerahavethesamespecifications,butSAWcompactbasicisusedforcompactapplications.SAWcompactbasicisasimpleralternativetoSAWcompactcamera.


44

WeldocTM WMS 4000 Data Program

• Enablesweldingindustrytocomplywithrigorous qualityrequirementsintheISO9000standards• Providesnecessarydocumentationfor qualityrequirements–user-specifiedlimit valuesfacilitatesmonitoringandprocessdeviation• UsewiththefollowingESABpowersources:

• Prowelder160/320,Protig450• LUD/AristoMig450• LAF635,1000,1250,1600• TAF800,1250

• Nomanualsettingsrequired–automaticrecording ofdate,time,andreferencenumberofweldjoints• Programautomaticallyreceivesandstores weldingparameterdatafrompowersource• SPS4000documentationprogramprovides settingweldingdatainpowersource

Ordering InformationWeldoc WMS 4000, complete version ............................... 457 410 880For use with all power sources

Options & AccessoriesSPS 4000, documentation program .............................457 410 881Connection kit, AristoMig .............................................457 415 880Connection kit, LAF/TAF ...............................................457 755 880Opto-cable WMS 4000, 15 m (49 ft.) .............................457 072 881Opto-cable WMS 4000, 2 m (6.5 ft.) ..............................457 072 882

Technical DataWeldoc WMS 4000 Software for surveillance of Prowelder 320, Protig 450, LUD 450, AristoMig 450 and the LAF/TAF range

equipped with CAN- and Echelon-busOperating system 16-bit Minimum Windows 95 or Windows NT 4.0Computer IBM Compatible. For workshop environment, a computer with robust design and EMC equipment according to

Mil standard 461C&D is required. For connected printer, the same is required. (not supplied by ESAB)Processor Pentium 133 MHz or betterRam memory 16 MB or betterCapacity of the hard disc 1.5 GB minimum recommendedScreen 15-inch colour monitor or larger with resolution of 800x600 or better. The resolution is important for the number

of welding parameters that can be shown in real timeSerial data communication RS-232Signal transfer Optical through fiber cable to the serial port to avoid interference from peripheral equipment

Weldoc WMS 4000 Sales Literature ................................XA00088020Weldoc WMS 4000 Instruction Manual ............................457 413 074


5-500 TA Self-Aligning Turning Rolls

TA Turning Rolls Sales Literature ...................................XA00120320Accessories for Turning Rolls .........................................XA00120720

handling equipment

45

Ordering Information All turning rolls include RC-31H remote control with 12 m (39.4 ft) cable

power

5 TA .........................................................................................10356310 TA .......................................................................................10356425 TA .......................................................................................10356540 TA .......................................................................................10356670 TA .......................................................................................103567100 TA .....................................................................................103568150 TA .....................................................................................103569200 TA .....................................................................................103570300 TA .....................................................................................103571500 TA .....................................................................................103572

• Idealfordifficultanddemandingworkpieces• Evenweightdistributionforthin-walledwork piecesandheavyobjects• Compactandnarrowdesignwithdurablerollers• Dualdrivemotorsandgears-eliminateneedfor interconnectdriveshaft• Vectorinvertercontrolsystemforconstantand precisespeedcontrol• Equippedwithremotecontrolwitha12m(39.4ft.) cable• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,railbogies,anti- creep/fit-upcontrol,start/stopfootpedal,andA2- A6PEHprocesscontroller

Synchronizationcontrolincludedasstandardcomponent

•

idler

5 TA .................................................................................................10357310 TA ...............................................................................................10357425 TA ...............................................................................................10357540 TA ...............................................................................................10357670 TA ...............................................................................................103577100 TA .............................................................................................103578150 TA .............................................................................................103579200 TA .............................................................................................103580300 TA .............................................................................................103581500 TA .............................................................................................103582

Technical Data5 TA 10 TA 25 TA 40 TA 70 TA 100 TA 150 TA 200 TA 300 TA 500 TA

Max. load, metric ton (U.S. ton) 2.5 (2.8) 5.5 (5.0) 12.5 (13.8) 20 (22) 35 (38.6) 50 (55.1) 75 (82.7) 100 (110) 150 (165) 250 (276)Rolling capacity, metric ton (U.S.) 7.5 (8.3) 15 (16.5) 37.5 (41.3) 60 (66.1) 105 (116) 150 (165) 225 (248) 300 (331) 450 (496) 750 (827)Max. rotating force, kN (lbf) 5.5 (1236) 11 (2473) 20 (4496) 32 (7194) 60 (13490) 75 (16860) 110 (24730) 165 (37090) 210 (47210) 250 (56200)Rotation speed, cm/min (ipm) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49)Dia. range 75% load min-max, cm (in.) 50-450 (20-177) 50-450 (20-177) 50-450 (20-177) 100-520 (39-205) 100-780 (39-07) 100-780 (39-307) 100-780 (39-307) 100-780 (39-307) 100-780 (39-307) 100-780 (39-307)Dia. range 100% load min-max, cm (in.) 125-450 (49-177) 125-450 (49-177) 125-450 (49-177) 175-520 (69-205) 175-520 (69-205) 200-780 (79-307) 200-780 (79-307) 200-780 (79-307) 200-780 (79-307) 200-780 (79-307)Rollers pcs/axel 4 4 8 4 8 4 8 8 8 4Roller dia, cm (in.) 35 (14) 35 (14) 35 (14) 42.5 (17) 42.5 (17) 58 (23 58 (23) (23) 71 (30) 71 (30)Roller total width, cm (in.) 7.5 (3) 7.5 (3) 15 (6) 15 (6) 30 (12) 22 (9) 45 (18) 45 (18) 52 (20) 26 (10)Roller material PU PU PU PU PU PU PU PU PU SteelLength, cm (in.) Power 256 (101) 262.5 (103) 266.5 (105) 307 (121) 307 (121) 375 (148) 380 (150) 380 (150) 470 (185) 550 (217)

Idler 220 (87) 220 (87) 220 (87) 271 (107) 271 (107) 345 (136) 345 (136) 345 (136) 420 (165) 440 (173)Width, mm (in.) Power 72 (28) 72 (28) 77.5 (31) 105 (41) 123 (48) 140 (55) 190 (75) 200 (79) 220 (87) 220 (87)

Idler 40 (16) 49 (19) 49 (19) 83 (33) 83 (33) 90 (35) 130 (51) 140 (55) 140 (55) 140 (55)Weight, Kg (lbs.) Power 760 (1670) 925 (2040) 1185 (2610) 1770 (3900) 2430 (5357) 5000 (11030) 6200 (13670) 7000 (15430) 12000 (26460) 18000 (39680)

Idler 585 (1290) 585 (1290) 751 (1660) 1220 (2685) 1670 (3680) 4000 (8820) 4500 (9920) 5300 (11690) 9000 (19480) 15000 (33070)Primary input voltage, VAC, 60 Hz 230, 1ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 16 16 16 16 16 16 16 16 16

handling equipment

3-500 TNA Conventional Turning Rolls

TNA Turning Rolls Sales Literature ................................XA00120220Accessories for Turning Rolls .........................................XA0012072046

• Basicsolutionforhandlingavarietyofworkpieces• Easytousescrewsforadjustingdiameters• Dualdrivemotorsandgearseliminateneedfor interconnectdriveshaft• Vectorinvertercontrolforconstantandprecisespeed adjustment• Compactandnarrowdesignwithdurablerollers• Equippedwithremotecontrolwith12m(39.4ft.)cable• Manyaccessoriesavailableincludingexternal connection,railbogies,anti-creep/fit-up,start/stop footpedalandA2-A6PEHprocesscontroller

Synchronizationcontrolincludedasstandard component

•

Ordering Information All Turning Rolls include RC-31H remote control with 12 m (39.4 ft) cable

power

3 TNA ..............................................................................................1035845 TNA ..............................................................................................10358510 TNA ............................................................................................10358625 TNA ............................................................................................10358740 TNA ............................................................................................10358860 TNA ............................................................................................103589100 TNA ..........................................................................................103590150 TNA ..........................................................................................103591200 TNA ..........................................................................................103592300 TNA ..........................................................................................103593500 TNA ..........................................................................................103594

idler

3 TNA ......................................................................................1035955 TNA ......................................................................................10359610 TNA ....................................................................................10359725 TNA ....................................................................................10359840 TNA ....................................................................................10359960 TNA ....................................................................................103600100 TNA ..................................................................................103601150 TNA ..................................................................................103602200 TNA ..................................................................................103603300 TNA ..................................................................................103604500 TNA ..................................................................................103605

Technical Data3 TNA 5 TNA 10 TNA 25 TNA 40 TNA 60 TNA 100 TNA 150 TNA 200 TNA 300 TNA 500 TNA

Max. load, metric ton (U.S. ton) 1.5 (1.65) 2.5 (2.8) 5 (5.5) 12.5 (14) 20 (22) 30 (33) 50 (55) 75 (83) 100 (110) 150 (165) 250 (275)Rolling capacity, metric ton (U.S.) 5 (5.5) 7.5 (8.3) 15 (17) 37.5 (41) 60 (66) 90 (99) 150 (165) 225 (248) 300 (331) 450 (496) 750 (827)Max. rotating force, kN (lbf) 3 (670) 5.5 (1230) 11 (2470) 20 (4500) 32 (7190) 60 (13488) 75 (16860) 110 (24730) 165 (37090) 210 (47210) 250 (56200)Rotation speed, cm/min (ipm) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49) 6-125 (2.4-49)Dia. range min-max, cm (in.) 15-320 (6-126) 15-320 (6-126) 15-450 (6-177) 15-450 (6-177) 30-450 (12-177) 30-450 (12-177) 50-780 (20-307) 50-780 (20-307) 50-780 (20-307) 50-780 (20-307) 50-

780(20-307)

Rollers pcs/axel 2 2 4 6 4 6 4 6 8 8 2Roller dia, cm (in.) 35 (14) 35 (14) 35 (14) 35 (14) 42.5 (17) 42.5 (17) 58 (23) 58 (23) 58 (23) 71 (30) 71 (30)Roller total width, cm (in.) 7.5 (3) 7.5 (3) 15.5 (6) 23.5 (9) 31 (12) 47 (19) 47 (19) 72 (28) 97 (38) 113 (44) 26 (10)Roller material PU PU PU PU PU PU PU PU PU PU SteelLength, cm (in.) Power 231 (91) 231 (91) 304 (120) 304 (120) 446 (176) 461 (181) 510 (201) 520 (205) 520 (205) 850 (228) 720 (283)

Idler 195 (77) 195 (77) 268 (105) 268.5 (106) 306 (120) 306 (120) 470 (185) 480 (189) 480 (189) 450 (213) 680 (268)Width, cm (in.) Power 63 (25) 63 (25) 66 (26) 70 (28) 83 (33) 83 (33) 140 (55) 170 (67) 200 (79) 290 (114) 210 (83)

Idler 400 (16) 400 (16) 490 (19) 490 (19) 830 (33) 830 (33) 850 (35) 1100 (43) 1400 (55) 1600 (63) 1600 (63)Weight, Kg (lbs.) Power 455 (1005) 530 (1170) 660 (1455) 1035 (2280) 2200 (4850) 2410 (5313) 3500 (7720) 6500 (14330) 7000 (15432) 10000 (22050) 16500 (36380)

Idler 310 (685) 310 (685) 385 (850) 670 (1480) 1360 (3000) 1620 (3571) 2500 (5515) 5500 (12125) 6000 (13230) 8800 (19400) 15200 (33510)Primary input voltage, VAC, 60 Hz 230, 1ph 230, 1ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 16 16 16 16 25 25 25 25 25 25

TXA “Scissor-Type” Turning Rolls

TXA Turning Rolls Sales Literature .................................XA00120420Accessories for Turning Rolls .........................................XA00120720

handling equipment

47

Ordering Information All Turning Rolls include RC-31H remote control with 12 m (39.4 ft) cable

power

3 TXA ......................................................................................1026065 TXA ......................................................................................102607

idler

1 TXA ......................................................................................1026003 TXA ......................................................................................1026015 TXA ......................................................................................102602

• Idealforapplicationsrequiringaconstantcentre height• Completewithalowvoltageremotecontrolunitfor allfunctions• Availableasamotorizedorfreelyrotatingidlingunit• Easilyadjustthediameterwithmanuallyoperated hydraulichand-pumps• Idealforhandlinglongobjects• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,railbogies, start/stopfootpedal,andA2-A6PEHprocess controller

Synchronizationcontrolincludedasstandardcomponent

•

Technical Data 1 TXA 3 TXA 5 TXA

Max. load, metric ton (U.S. ton) 0.5 (0.55) 1.5 (1.65) 2.5 (2.7)Rolling capacity, metric ton (U.S.) - 3 (3.3) 5 (5.5)Rotation speed, mm/min (ipm) - 60-1200 (2.4-47) 60-1200 (2.4-47)Centre height /dia., mm (in.) - 105-780/800 (4.1-30.7/31.5) 105-780/800 (4.1-30.7/31.5)Total dia. range, mm (in.) 30-1750 (1.2-69) 100-2100 (4-82.6) 100-2100 (4-82.6)Roller pcs/axel 2 2 4Roller dia, mm (in.) 200 (7.9) 350 (13.8) 350 (13.8)Roller total width, mm (in.) 50 (2) 75 (3) 75 (3)Roller material PU PU PULength, mm (in.) Power - 1685 (66.3) 1685 (66.3)

Idler 850 (33.5) 1445 (56.9) 1445 (56.9)Width, mm (in.) Power - 670 (26.4) 770 (30.3)

Idler 400 (15.7) 570 (22.4) 670 (26.4)Height, mm (in.) Power - 610-880 (24-34.6) 610-880 (24-34.6)

Idler 500-700 (19.4-27.5) 610-880 (24-34.6) 610-880 (24-34.6)Weight, Kg (lbs.) Power - 490 (1080) 540 (1190)

Idler 150 (331) 350 (772) 400 (882)Primary input voltage, VAC, 60 Hz - 230, 1ph 230, 1phPrimary input current, A - 16 16

handling equipment

250-35000 AHMA Positioners

AHMA Positioners Sales Literature ................................ XA00119320Accessories for Positioners ............................................XA0012062048

Ordering Information All positioners include RC-31H remote control and cable length as indicated in technical data table

250 AHMA .......................................................................................103653 750 AHMA .......................................................................................1036541500 AHMA .....................................................................................103655 3500 AHMA .....................................................................................103656 7000 AHMA .....................................................................................10365715000 AHMA ...................................................................................10365825000 AHMA ...................................................................................10365935000 AHMA ...................................................................................103660

• 3-axispositioning:height,angle,androtation• Uniquedesignallowsforalargeoperatingrange• Allpositionersabove250Kg(551lbs.)capacityhave ACdrives• Improvedhydraulicswithintegratedsafetyvalvesfor totalsafetyoperation• Vectorinvertercontrolsystemforconstantandprecise rotationspeedandimprovedtorqueatlowspeeds• Equippedwithremotecontrol• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,start/stopfootpedal, speedcontrolfootpedal,andA2-A6PEHprocess controller

Technical Data 250 AHMA

750 AHMA

1500 AHMA

3500 AHMA

7000 AHMA

15000 AHMA

25000 AHMA

35000 AHMA

Max. load, kN (lbs.) 2.5 (562) 7.5 (1686) 15 (3370) 35 (7870) 70 (15730) 150 (33720) 250 (56200 (350 (78700)Rotation speed, rpm 0.2-4.5 0.05-2.0 0.02-1.3 0.05-1.6 0.03-1.0 0.01-0.75 0.005-0.4 0.0005-0.4Max. rotation torque, Nm (lbs.-f) 80 (59) 600 (443) 1000 (738) 2800 (2065) 9000 (6638) 18000 (13276) 40000 (29500) 55000 (40565)Tilting/angle degree man 135 hy 135 hy 135 hy 135 hy 135 hy 135 hy 120 hy 120Tilting time: 0o -max angle, s manual 25 25 30 55 60 80 160Max. tilting torque, Nm (lbs.-f) 300 (221) 1500 (1106) 3000 (2213) 7500 (5532) 14000 (10325) 70000 (51630) 175000 (129000) 280000 (206500)Max. welding current, A 350 700 700 700 1400 1400 2100 2100Table plate dia., cm (in.) 40 (16) 70 (26) 70 (26) 95 (37) 110 (43) 149 (59) 195 (77) 195 (77)T-slots on table plate 3 pcs size M10 3 pcs size M12 3 pcs size M12 4 pcs size M20 4 pcs size M20 4 pcs size M24 8 pcs size M24 6 pcs size M24Centre hole dia., cm (in.) 6 (2.4) - - - - - - -Remote control cable length, m (ft.) 3 (9.8) 6 (19.7) 6 (19.7) 6 (19.7) 8 (26.2) 12 (39.4) 12 (39.4) 12 (39.4)Length, cm (in.) 94 (37) 157.5 (62) 164 (65) 218 (86) 264 (104) 315 (124) 408 (161) 475 (187)Width, cm (in.) 53.8 (21) 69.6 (27) 81 (32) 103 (41) 149 (59) 182 (72) 238 (94) 345 (136)Height, cm (in.) 49-91 (19-36) 72.5-

145(29-57) 77.5-

154(31-61) 98-

167.5(36-66) 100-

185.5(39-73) 130-

232.5(51-92) 160-

286(63-113) 200-

350(79-138)

Weight, Kg (lbs.) 170 (373) 550 (1215) 730 (1610) 1800 (3970) 3150 (6950) 6500 (14350) 15000 (33070) 23000 (50700)Primary input voltage, VAC, 50 Hz 230, 1ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 16 16 25 25 32 35 50

75-150 SK Positioners for Small, Light Workpieces

SK Positioners Sales Literature ...................................... XA00119520Accessories for Positioners ............................................XA00120620

handling equipment

49

• Idealforsmall,lightanddifficultworkpiecesMotorizedrotationoftableplateAdjustablerotationspeedsandlargetitlingangleproduceexcellentweldingresultsDesignedandbuiltfortoughmanufacturing workshopconditions

• Completewithalowvoltageremotecontrolunitfor allfunctions(connectedtotheframeon75SK)• Includes3-axismanualheightadjustment, manualtiltingangleadjustmentandmotorized rotation

Easytomaintain;minimalspareparts

••

•

•


75 SK.......................................................................................102729150 SK.....................................................................................102730

Technical Data 75 SK 150 SK

Max. load, kN (lbs.) 0.75 (169) 1.5 (337)Rotation speed, rpm 0.4-7.0 0.2-4.5Max. rotation torque, Nm (lbf/ft.) 30 (265) 80 (708)Tilting/angle degree 360 360Tilting time: 0o -max angle, s manual manualMax. tilting torque, Nm (lbf/ft.) 150 (1327) 300 (2655)Max. welding current, A 350 350Table plate dia., mm (in.) 300 (12) 350 (14)T-slots on table plate - 3 pcs size M10Centre hole dia., mm (in.) - 60 (2.4)Remote control cable length, m (ft.) fixed 3 (0.8)Length, mm (in.) 750 (30) 860 (34)Width, mm (in.) 610 (24) 650 (26)Height, mm (in.) 500-800 (20-32) 500-800 (20-32)Weight, Kg (lbs.) 60 (132) 90 (198)Primary input voltage, VAC, 50 Hz 230, 1ph 230, 1phPrimary input current, A 16 16

handling equipment

750-10000 SHA Positioners for Heavy Workpieces

SHA Positioner Sales Literature ..................................... XA00119620Accessories for Positioners ............................................XA0012062050


750 SHA ..........................................................................................1053731500 SHA ........................................................................................1053743500 SHA ........................................................................................1053755000 SHA ........................................................................................1053767000 SHA ........................................................................................10537710000 SHA ......................................................................................105378

• Forhandlinglargeanddemandingworkpiecesinallpositions• Equippedwithadjustablehydraulicswithbuilt-insafetyvalves• 3-axisoperation(height,tiltingangle,androtation)for idealergonomicworkingconditions• Lowvoltageremotecontrolwithallfunctions• Rotationandtiltingspeedcontrolledbyvector invertersforimprovedaccuracyandbetterrotationtorque• DrivesequippedwithanACmotor• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,start/stopfootpedal, speedcontrolfootpedal,andA2-A6PEHprocess controller

Technical Data 750 SHA 1500 SHA 3500 SHA 5000 SHA 7000 SHA 10000 SHA

Max. load, kN (lbs.) 7.5 (1686) 15.0 (3371) 35.0 (7868) 50.0 (11236) 70.0 (15370) 100.0 (22472)Rotation speed, rpm 0.05-2.0 0.02-1.3 0.05-1.6 0.01-1.5 0.03-1.0 0.02-0.75Max. rotation torque, Nm (lbf/ft.) 600 (443) 1000 (738) 2800 (2065) 6000 (4426) 9000 (6638) 18000 (13276)Tilting speed, rpm 0.1-1.5 0.1-1.5 0.1-1.0 0.1-0.75 0.1-0.75 0.1-0.75Tilting torque, Nm (lbf/ft.) 1500 (1106) 3000 (2213) 6000 (4426) 10000 (7376) 15000 (11064) 20000 (14752)Adjustable tilting axle height, mm (in.) 700-1500 (27.5-59) 700-1500 (27.5-59) 1100-1900 (43-75) 1200-2000 (47-79) 1200-2000 (47-79) 1200-2000 (47-79)Offset distance, mm (in.) 400 (16) 400 (16) 400 (16) 500 (20) 500 (20) 500 (20)Max. welding current, A 700 700 700 1400 1400 1400Max. work piece dia., mm (in.) 2000 (79) 2500 (98) 3000 (118) 3200 (126) 3500 (138) 4000 (157.5)Table plate dia., mm (in.) 700 (28) 700 (28) 950 (35) 1100 (43) 100 (43) 1490 (59)T-slots on table plate 3 pcs M12 3 pcs M12 4 pcs M20 4 pcs M20 4 pcs M20 4 pcs M20Remote control cable length, m (ft.) 6 (20) 6 (20) 6 (20) 6 (20) 12 (39) 12 (39)Length, mm (in.) 2240 (88.2) 2650 (104) 3710 (146) 4400 (173) 4700 (185) 5490 (216)Width, mm (in.) 940 (37) 1160 (46) 1450 (57) 2040 (80) 2040 (80) 2140 (84)Height, mm (in.) 2110 (83) 2200 (87) 3060 (120.5) 3200 (126) 3200 (126) 4000 (157.5)Weight, Kg (lbs.) 1200 (2646) 1700 (3748) 4950 (10913) 9550 (21054) 10800 (23810) 13500 (29762)Primary input voltage, VAC, 50 Hz 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 20 25 25 25 32

handling equipment

750-50000 VA Positioners for Circumferential Welding

VA Positioner Sales Literature ........................................ XA00119920Accessories for Positioners ............................................XA00120620 51


750 VA .....................................................................................1053261500 VA ...................................................................................1053273500 VA ...................................................................................1053287000 VA ...................................................................................10532915000 VA .................................................................................10533025000 VA .................................................................................10533135000 VA .................................................................................10533250000 VA .................................................................................105333

• Idealforlargeandheavyworkpieces• Completewithalowvoltageremotecontrolunitfor allfunctions• Motorizedrotationforeconomicalcircumferential welding• Vectorinvertercontrolsystemforconstantand precisespeedcontrol• DrivesequippedwithanACmotor• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,start/stopfoot pedal,speedcontrolfootpedal,andA2-A6PEH processcontroller

Technical Data 750 VA 1500 VA 3500 VA 7000 VA 15000 VA 25000 VA 35000 VA 50000 VA

Max. load, kN (lbf.) 7.5 (1686) 15 (3371) 35 (7868) 70 (15736) 150 (33721) 250 (56202) 350 (78683) 500 (112404)Rotation speed, rpm 0.05-2.0 0.02-1.3 0.05-1.6 0.03-1.0 0.02-0.75 0.01-0.4 0.01-0.4 0.004-0.2Max. rotation torque, Nm (lbf/ft.) 600 (443) 1000 (738) 2800 (2065) 9000 (6638) 18000 (13276) 40000 (29500 55000 (40565) 75000 (663800)Tilting torque, Nm (lbf/ft.) 1500 (1106) 3000 (2213) 7500 (5532) 14000 (10326) 70000 (51632) 175000 (12908) 280000 (206528) 400000 (295040)Max. welding current, A 700 700 700 1400 1400 2100 2100 2100Table plate dia., mm (in.) 700 (27.5) 700 (27.5) 950 (37) 1100 (43) 1490 (58) 1950 (77) 1950 (77) 1950 (77)T-slots on table plate 3 pcs size M12 3 pcs size M12 4 pcs size M20 4 pcs size M20 4 pcs size M24 8 pcs size M24 6 pcs size M24 6 pcs size M24Remote control cable length, m (ft.) 6 (20) 6 (20) 6 (20) 12 (39) 12 (39) 12 (39) 12 (39) 12 (39)Length, mm (in.) 725 (29) 725 (29) 1050 (41) 1050 (41) 1400 (55) 1400 (55) 1400 (55) 1400 (55)Width, mm (in.) 580 (23) 580 (23) 1050 (41) 1050 (41) 1400 (55) 1400 (55) 1400 (55) 1400 (55)Height, mm (in.) 690 (27) 690 (27) 810 (32) 810 (32) 900 (35) 900 (35) 900 (35) 950 (37)Weight, Kg (lbs.) 350 (772) 390 (860) 1100 (2424) 1200 (2646) 2300 (5071) 3600 (7937) 4500 (9921) 6500 (14330)Primary input voltage, VAC, 50 Hz 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 16 25 25 32 35 50 50

handling equipment

25000-50000 CRA Positioners for Large, Heavy Workpieces

CRA Positioner Sales Literature ..................................... XA00119820Accessories for Positioners ............................................XA0012062052


25000 CRA ......................................................................................10543035000 CRA ......................................................................................10543150000 CRA ......................................................................................105432

• Idealforlargeandheavyworkpieces• Completewithalowvoltageremotecontrolunitforall functions• Adjustablerotationandtiltingforidealpositioning• Vectorinvertercontrolsystemforconstantandprecise speed• DrivesequippedwithanACmotor• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,start/stopfootpedal, speedcontrolfootpedal,andA2-A6PEHprocess controller

Technical Data 25000 CRA 35000 CRA 50000 CRA

Max. load, kN (lbs.) 250 (56202) 350 (78683) 500 (112404)Rotation speed, rpm 0.01-0.4 0.01-0.4 0.004-0.2Max. rotation torque, Nm (lbf/ft.) 40000 (29502) 55000 (40566) 75000 (55317)Tilting speed, rpm 0.1-1.5 0.1-1.5 0.1-1.0Tilting torque, Nm (lbf/ft.) 70000 (51632) 110000 (81136) 150000 (110640)Offset distance, mm (in.) 600 (24) 800 (31) 800 (31)Max. welding current, A 2100 2100 2100Max. work piece dia., mm (in.) 6000 (236) 7000 (276) 7000 (276)Table plate dia., mm (in.) 1490 (59) 1490 (59) 1950 (77)T-slots on table plate 8 pcs size M24 8 pcs size M24 8 pcs size M30Remote control cable length, m (ft.) 12 (39) 12 (39) 12 (39)Length, mm (in.) 9340 (368) 10600 (417) 10600 (417)Width, mm (in.) 3160 (124) 3660 (144) 4000 (158)Height, mm (in.) 5100 (201) 5400 (213) 5600 (221)Weight, Kg (lbs.) 22000 (48502) 34000 (74957) 43000 (94799)Primary input voltage, VAC, 50 Hz 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 32 32 32)

handling equipment

750-50000 Head & Tailstock Positioners for Revolving Workpieces

Head & Tailstock Positioner Sales Literature ................ XA00119320Accessories for Positioners ............................................XA00120620 53

Ordering Information All positioners include RC-31H remote control

motorized Rotation, Fixed heightHSA - Headstock, TSA - Tailstock

750 HSA ..................................................................................105280750 TSA ..................................................................................1053961500 HSA ................................................................................1053811500 TSA ................................................................................105397 3500 HSA ................................................................................105382 3500 TSA ................................................................................1053987000 HSA ................................................................................105383 7000 TSA ................................................................................1053991500 HSA ................................................................................10538415000 TSA ..............................................................................10540025000 HSA ..............................................................................10538525000 TSA ..............................................................................10540135000 HSA ..............................................................................10538635000 TSA ..............................................................................10540250000 HSA ..............................................................................10538750000 TSA ..............................................................................105403

headstock height extension Blocks

750 HSA/HSLA .......................................................................1065071500 HSA/HSLA .....................................................................1065073500 HSA/HSLA .....................................................................1065087000 HSA/HSLA .....................................................................10650915000 HSA/HSLA ...................................................................10651025000 HSA/HSLA ................................................................... 10651135000 HSA/HSLA ...................................................................10651250000 HSA/HSLA ...................................................................106513

• Idealforcircumferentialweldingandassemblyof difficultworkpieces• Completewithalowvoltageremotecontrolunitfor allfunctions• Useheadstockwithorwithouttailstock• Head&tailstockcanbeequippedwitha steplessheightadjustmentandtailstockwith hydraulicmotorizedrail-bogieforvariouslengths• Plug&playconnectiontoaccessoriesavailable includingexternalconnection,railbogies, start/stopfootpedal,andA2-A6PEHprocess controller• HeadstockHSAfeaturesmotorizedrotationand fixedheight• HeadstockHSLAfeaturesmotorizedrotationand steplessheightadjustment• TailstockTSA/TSLAfeaturesfreelyrotatingtable plate,andfixed/adjustableheight

motorized Rotation, adjustable heightHSLA - Headstock, TSLA - Tailstock

750 HSLA ........................................................................................105388750 TSLA ........................................................................................1054041500 HSLA ......................................................................................105389 1500 TSLA ......................................................................................1054053500 HSLA ......................................................................................1053903500 TSLA ......................................................................................1054067000 HSLA ......................................................................................1053917000 TSLA ......................................................................................1054071500 HSLA ......................................................................................10539215000 TSLA ....................................................................................10540825000 HSLA ....................................................................................10539325000 TSLA ....................................................................................10540935000 HSLA ....................................................................................10539435000 TSLA ....................................................................................10541050000 HSLA ....................................................................................10539550000 TSLA .................................................................................... 105411

motorized Railbogies

750 RBTSA .....................................................................................1054121500 RBTSA ...................................................................................1054133500 RBTSA ...................................................................................1054147000 RBTSA ...................................................................................10541515000 RBTSA .................................................................................10541625000 RBTSA .................................................................................10541735000 RBTSA .................................................................................10541850000 RBTSA .................................................................................105419

handling equipment

750-50000 Head & Tailstock Positioners, cont’d.

54

Technical DataFixed Height

750 HSA/TSA

1500 HSA/TSA

3500 HSA/TSA

7000 HSA/TSA

15000 HSA/TSA

25000 HSA/TSA

35000 HSA/TSA

50000 HSA/TSA

Max. load, kN (lbf.) 7.5 (1686) 15 (3371) 35 (7868) 70 (15736) 150 (33721) 250 (56202) 350 (78683) 500 (112404)Rotation speed, rpm 0.05-2.0 0.02-1.3 0.05-1.6 0.03-1.0 0.02-0.75 0.01-0.4 0.01-0.4 0.004-0.2Max. rotation torque, Nm (lbf/ft.) 600 (443) 1000 (738) 2800 (2065) 9000 (6638) 18000 (13276) 40000 (29500) 55000 (40565) 75000 (663800)Max. welding current, A 700 700 700 1400 1400 2100 2100 2100Max. allowable tilting moment, Nm (lbf/ft.) 1500 (1106) 3000 (2213) 7500 (5532) 14000 (10326) 70000 (51632 175000 (129080) 280000 (206528) 400000 (295040)Center height, mm (in.) 800 (31.5) 800 (31.5) 800 (31.5) 1000 (39) 1200 (47) 1200 (47) 1400 (55) 1400 (55)Table plate dia., mm (in.) 700 (27.5) 700 (27.5) 950 (37) 1100 (43) 1490 (58) 1950 (77) 1950 (77) 1950 (77)T-slots on table plate 3 pcs size M12 3 pcs size M12 4 pcs size M20 4 pcs size M20 4 pcs size M24 8 pcs size M24 8 pcs size M24 8 pcs size M30Length, mm (in.) 940 (37) 940 (37) 940 (37) 1360 (53.5) 1900 (75) 2200 (87) 2600 (102) 2800 (110)Width, mm (in.) 900 (35) 900 (35) 1060 (42) 1450 (57) 2040 (80) 2040 (80) 2400 (94.5) 2400 (94.5)Height, mm (in.) 1300 (51) 1300 (51) 1300 (51) 1600 (63) 1700 (67) 1700 (67) 1900 (75) 1900 (75)Weight, Kg (lbs.) HSA/TSA 570 (1257)/

470 (1036)810 (1786)/720 (1587)

950 (2094)/850 (1874)

2100 (4630)/1950 (4299)

4900 (10803)/4700 (10362)

6400 (14109.5)/6200 (13669)

9000 (19842)/8500 (18739)

2000 (26455)/11500 (25353)

Primary input voltage, VAC, 50 Hz 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 20 25 25 32 35 50 50

Adjustable Height750

HSLA/TSLA1500

HSLA/TSLA3500

HSLA/TSLA7000

HSLA/TSLA15000

HSLA/TSLA25000

HSLA/TSLA35000

HSLA/TSLA50000

HSLA/TSLAMax. load, kN (lbf.) 7.5 (1686) 15 (3371) 35 (7868) 70 (15736) 150 (33721) 250 (56202) 350 (78683) 500 (112404)Rotation speed, rpm 0.05-2.0 0.02-1.3 0.05-1.6 0.03-1.0 0.02-0.75 0.01-0.4 0.01-0.4 0.003-0.2Max. rotation torque, Nm (lbf/ft.) 600 (443) 1000 (738) 2800 (2065) 9000 (6638) 18000 (13276) 40000 (29500) 55000 (40565) 75000 (663800)Max. welding current, A 700 700 700 1400 1400 2100 2100 2100Max. allowable tilting moment, Nm (lbf/ft.) 1500 (1106) 3000 (2213) 7500 (5532) 14000 (10326) 70000 (51632) 175000 (129080) 280000 (206528) 400000 (295040)Adjustable height, mm (in.) 700-1500 (27.5-59) 700-1500 (27.5-59) 700-1500 (27.5-59) 1100-1900 (43-75) 1200-2000 (47-79) 1400-2200 (55-87) 1400-2200 (55-87) 1400-2200 (55-87)Table plate dia., mm (in.) 700 (27.5) 700 (27.5) 950 (37) 1100 (43) 1490 (58) 1950 (77) 1950 (77) 1950 (77)T-slots on table plate 3 pcs size M12 3 pcs size M12 4 pcs size M20 4 pcs size M20 4 pcs size M24 8 pcs size M24 8 pcs size M24 8 pcs size M30Length, mm (in.) 940 (37) 940 (37) 940 (37) 1360 (53.5) 1900 (75) 2200 (87) 2600 (102) 2800 (110)Width, mm (in.) 900 (35) 900 (35) 1060 (42) 1450 (57) 2040 (80) 2040 (80) 2400 (94.5) 2400 (94.5)Height, mm (in.) 2340 (92) 2340 (92) 2340 (92) 3060 (120.5) 3200 (126) 3800 (150) 4000 (157.5) 4200 (165)Weight, Kg (lbs.) HSLA/TSLA 900 (1984)/

800 (1764)900 (1984)/800 (1764)

1310 (2888)/1210 (2667.5)

2900 (6393)/2750 (6063)

7000 (15432)/6800 (14991)

9000 (19842)/8800 (19400)

15000 (33069)/14500 (31967)

18000 (39683)/17500 (38580)

Primary input voltage, VAC, 50 Hz 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3ph 460/575, 3phPrimary input current, A 16 20 25 25 32 35 50 50

Extension750

HSA/HSLA1500

HSA/HSLA3500

HSA/HSLA7000

HSA/HSLA15000

HSA/HSLA25000

HSA/HSLA35000

HSA/HSLA50000

HSA/HSLALength, mm (in.) 1070 (42) 1070 (42) 1070 (42) 1400 (55) 2050 (81) 2400 (94.5) 2800 (110) 3000 (118)Height, mm (in.) 204 (8) 204 (8) 204 (8) 256 (10) 288 (11) 288 (11) 288 (11) 450 (18)

Rail Bogies750

RBTSA1500

RBTSA3500

RBTSA7000

RBTSA15000 RBTSA

25000 RBTSA

35000 RBTSA

50000 RBTSA

Travel speed, mm/min (ipm) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9) 0.2-2.3 (0.08-0.9)

Length, mm (in.) 1710 (67) 1710 (67) 1710 (67) 2130 (84) 2450 (96.5) 2700 (106) 3300 (130) 3600 (142)Height, mm (in.) 204 (8) 204 (8) 204 (8) 256 (10) 288 (11) 288 (11) 288 (11) 450 (18)

mechanized tig

Prowelder 160/250/320 & Protig 450 Mechanized TIG Welding Machines

Sales Literature and Instruction Manuals ...................Contact ESAB 55

prowelder 160/250/320Prowelderseriesisdesignedfortube-to-tubejoiningusingPRBweldingheads,tube-to-tubesheetweldingwiththePOCweldingheadortheA25modularcomponentsystemformechanizedTIGweldingforvariousapplicationsProgrammableweldingpowersourcemakesitpossibletocustomizetheweldingprocessInternalmemoryforprogramstorageCompatiblewithWeldocWMS4000parametermonitoringsystemortheSPS4000forsettingparameterdocumentationwithoutmonitoring

protig 450Protigisdesignedfortube-to-tubejoiningusingtheA21weldinghead,tube-to-tubesheetweldingusingthePOCweldingheadandtheA25modularcomponentsystemformechanizedTIGweldingforvariousapplicationsSplitweldingprogramsintoalargenumberofindependentandfreestandingunitsInternalmemoryforprogramstorageCompatiblewithWeldocWMS4000parametermonitoringsystemortheSPS4000forsettingparameterdocumentationwithoutmonitoring

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Ordering Informationprowelder

Prowelder 160 ........................................................................458 300 800Prowelder 250 ........................................................................458 300 881Prowelder 320, 230/400/500V, 3ph ........................................456 650 883

protig

Protig 450, 208/230/460/475V, 3ph ........................................456 650 881

Options & AccessoriesWeldoc WMS 4000 .................................................................457 410 880SPS 4000 ................................................................................457 410 881Opto-cable WMS 4000, 15 m (49 ft.) .....................................457 072 881Opto-cable WMS 4000, 2 m (6.5 ft.) ......................................457 072 882Trolley, Prowelder 160/250 ....................................................301 100 880Trolley, Prowelder 320, Protig 450 .......................................457 221 880OCF 2M cooling unit ..............................................................457 216 882

Technical Data Prowelder 160 Prowelder 250 Prowelder 320 Protig 450

Primary input voltage, VAC 230, 1ph, 60 Hz 400, 3PH, 50/60 Hz 208/230/460/475, 3ph, 60Hz 208/230/460/475, 3ph, 60 HzPermitted load at: 100% duty cycle, A/V 80/13 140/16 270/20.8 360/24.4

60% duty cycle, A/V 110/15 180/17 320/22.7 -45% duty cycle, A/V - - - 450/2835% duty cycle, A/V 160/16 250/20 - -

Welding current range, A 5-160 5-250 5-320 5-450Open circuit voltage, V 50-60 50-60 50-60 50-60No load power, W 50 55 520 520Dimensions, LxWxH, mm (in.) 515x285x835 (20x11x33) 515x285x620 (20x11x24) 734x489x695 (29x19x27) 734x489x695 (29x19x27)Weight, Kg (lbs.) 37 (81.5) 38 (83) 110 (242.5) 156 (344) 113 (249) 159 (350.5)

mechanized tig

A21 PRB Tube-to-Tube TIG Welding Head

A21 PRB Sales Literature ................................................XA00098520A21 PRB Instruction Manual ............................................443 808 00156

Ordering InformationWater-cooled

A21 PRB, 17-49 mm (0.67-2 in.) ............................................443 750 880A21 PRB, 33-90 mm (1-3.5 in.) ..............................................443 760 880A21 PRB, 60-170 mm (2-6.5 in.) ............................................443 770 880

air-cooled

A21 PRB, 17-49 mm (0.67-2 in.) ............................................443 750 881A21 PRB, 33-90 mm (1-3.5 in.) ..............................................443 760 881A21 PRB, 60-170 mm (2-6.5 in.) ............................................443 770 881

Options & AccessoriesAngular Support Bracket ......................................................443 875 880 Rebuilding kit, PRB/PRC 17-49 ............................................444 002 880 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)

• Small,flexible,andlightweight• Uniquepinceractionreducesset-uptimes

AccuratelypositionsandsecuresaroundthetubewithinsecondsAvailableinthreesizefortubeswithouterdiametersof17to170mm(0.67-6.7in.)UsewithProwelderandProtigpowersourcesChoosefromair-cooledandwater-cooledversionsIncludes7m(23ft.)ofconnectioncable

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Technical Data A21 PRB 17-49 mm A21 PRB 33-90 mm A21 PRB 60-170 mm

Rate of rotation, rpm 0.1-2.4 0.1-1.6 0.04-0.95Tube dia., mm (in.) 17-49 (0.67-2) 33-90 (1-3.5) 60-170 (2-6.5)Tube dia. optional, mm (in.) 8-17 (0.3-0.67) 20-33 (0.8-1) 44-60 (1.5-2)Max. welding current@ 100% duty cycle

water-cooled 250 250 250air -cooled 100 100 100

Electrode dia., mm (in.) 1.6-2.4 (1/16-3/32) 1.6-2.4 (1/16-3/32) 1.6-2.4 (1/16-3./32)Min. spacing between parallel tubes, mm (in.) D/2+70* (D/2+2.76*) D/2+94* (D/2+3.7*) D/2+137 (D/2+5.4)Weight, Kg (lbs.) 2.8 (6) 3.2 (7) 4.4 (10)* Without fine adjustment wheel for wire. Electrode cap and spacer screw may need to be replaced with the shortest variant supplied with the tool.

A21 PRC Tube-to-Tube TIG Welding Head

A21 PRC Sales Literature ................................................XA00098520A21 PRC Instruction Manual ............................................443 934 001

mechanized tig

57

Choosebetweenarcvoltagecontrol(AVC)modelswithorwithoutweavingZig-zagweavingmovementwithAVCproducesbetterweldqualitywithincreasedproductivityparticularlywhenweldingthick-walledtubesAvailableinthreesizefortubeswithouterdiametersof17to170mm(0.67-6.7in.)UsewithProtig450powersourceIncludes7m(23ft.)ofconnectioncableWater-cooledonly

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Ordering InformationaVc Only

A21 PRC, 17-49 mm (0.67-2 in.) ....................................443 751 880A21 PRC, 33-90 mm (1-3.5 in.) ......................................443 761 880A21 PRC, 60-170 mm (2-6.5 in.) ....................................443 771 880

aVc w/ Weaving

A21 PRC, 17-49 mm (0.67-2 in.) ....................................443 752 880A21 PRC, 33-90 mm (1-3.5 in.) ......................................443 762 880A21 PRC, 60-170 mm (2-6.5 in.) ....................................443 772 880

Options & AccessoriesAngular Support Bracket ..............................................443 875 880Rebuilding kit, PRB/PRC 17-49 ....................................442 002 880For welding tubes with OD of 8-17 mm (0.3-0.7 in)Rebuilding kit, PRB/PRC 33-90 ....................................443 908 880For welding tubes with OD of 20-33 mm (0.8-1.3 in)Rebuilding kit PRB/PRC 60-170 ...................................443 909 880For welding tubes with OD of 44-60 mm (1.7-2.4 in)

Technical Data A21 PRC 17-49 mm A21 PRC 33-90 mm A21 PRC 60-170 mm

Rate of rotation, rpm 0.1-2.4 0.1-1.6 0.04-0.95Tube dia., mm (in.) 17-49 (0.67-2) 33-90 (1-3.5) 60-170 (2-6.5)Tube dia. optional, mm (in.) 8-17 (0.3-0.67) 20-33 (0.8-1) 44-60 (1.5-2)Max. welding current @ 100% duty cycle 250 250 250Electrode dia., mm (in.) 1.6-2.4 (1/16-3/32) 1.6-2.4 (1/16-3/32) 1.6-2.4 (1/16-3./32)Arc adjustment rate, mm/s (in./s) 2.5 (0.1) 2.5 (0.1) 2.5 (0.1)Oscillation: Adjustment range, mm/s (in./s) 20 (0.8) 20 (0.8) 20 (0.8)

Amplitude, mm (in.) +/-6 (+/-0.24) +/-6 (+/-0.24) +/-6 (+/-0.24)Weave speed, mm/s (in./s) 2-12 (5/64-0.5) 2-12 (5/64-0.5) 2-12 (5/64-0.5)

Min. spacing between parallel tubes, mm (in.) D/2+70* (D/2+2.76*) D/2+94* (D/2+3.7*) D/2+137 (D/2+5.4)Weight, Kg (lbs.) AVC 3 (7) 4 (8) 5 (11)

AVC w/ weave unit 5 (11) 5.5 (12) 7 (15)* Without fine adjustment wheel for wire. Electrode cap and spacer screw may need to be replaced with the shortest variant supplied with the tool.

mechanized tig

A21 PRH Enclosed Tube TIG Welding Head

A21 PRH Welding Head Sales Literature ........................ XA00115920A21 PRH Welding Head Instruction Manual ....................444 291 10458

Designedforweldingthin-walled,stainlesssteeltubestoprovidemaximumgasshieldingaroundthetubeRotatingpartandtungstenelectrodesareenclosedinagaschamberformedbytheoutercasing,whichalsoconstitutestheclampingarrangementforthetubetobeweldedWater-cooledandavailableinthreesizestoweldtubesbetween3-76.2mm(0.1-3in.)EquippedwithencodermotorsforprecisepositioningofeachsectorwhenweldingwithdifferentsetsofparametersIncludes8m(26ft.)connectioncableForusewithProwelderandProtigpowersources

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Ordering Information A21 PRH, 3-12 mm (0.1-0.5 in.) .....................................444 300 880A21 PRH, 3-38 mm (0.1-1.5 in.) .....................................444 301 880A21 PRH, 6-76 mm (0.2-3 in.) ........................................444 302 880

Options & AccessoriesCartridges and collets are available for all diameters within the working range of each tool ...................................... Contact ESAB

Technical Data A21 PRH 3-12 mm A21 PRH 3-38 mm A21 PRH 6-76 mm

Rotation, rpm 0.65-12.6 0.5-9.5 0.31-6.15Tube outer diameter, mm (in.) 3-12.7 (0.12-0.50) 3-38.1 (0.12-1.50) 6-76.2 (0.24-3)Max. welding current @ 100% duty cycle 15 A continuous 40 A pulsed 50 A continuous 100 A pulsed 60 A continuous 100 A pulsedElectrode diameter, mm (in.) 1 (0.040) 1.6-2.4 (1/16-3/32) 1.6-2.4 (1/16-3/32)Weight, incl. cables, Kg (lbs.) 5 (11) 6.5 (14) 7.5 (16.5)

mechanized tig

A21 PRD Orbital Tube and Pipe TIG Welding Heads

A21 PRD 100 Sales Literature .........................................XA00091720A21 PRD 160 Sales Literature ......................................Contact ESABA21 PRD 100 Instruction Manual .....................................444 061 001A21 PRD 160 Instruction Manual .....................................444 100 001 59

Ordering Informationa21 pRd 100

A21 PRD 100 welding head...................................................444 016 880Narrow gap head, 50 mm (2 in.) ...........................................441 623 880Narrow gap head, 80 mm (3 in.) ...........................................441 623 881

a21 pRd 160

A21 PRD 160 welding head, basic .......................................444 151 880For use only when fusion welding with a floating headA21 PRD 160 w/ wire feeder..................................................444 151 881A21 PRD 160 w/ AVC .............................................................444 151 882

a21 pRd 100Designedfortubeswithanouterdiameterof100mm(4in.)ormoreRequiresonly73mm(3in.)clearancearoundthetubeWater-cooledanddesignedforamperageofupto400AAllweldingparametersareincorporatedintotheprocedureprogram,controlledbyamicroprocessorsystemForusewiththeProtig450powersourceIncludes8m(26ft.)ofconnectioncable

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A21 PRD 100 welding head A21 PRD 160 welding head

A21 PRD 160 w/ AVC and wire feeder ..........................444 151 883A21 PRD 160 w/ AVC, wire feeder and weaving ..........444 151 884

Options & AccessoriesFor A21 PRD 160 onlyWire feed unit .................................................................444 137 880Arc voltage control (AVC) .............................................443 656 881Weave unit ......................................................................444 140 880Standard racks for A21 PRD 100 & 160 .................. Contact ESAB

Technical Data A21 PRD 100 A21 PRD 160

Max. welding current @ 100% duty cycle 315 A continuous DC 400 A pulsed DC 315 A continuous DC 400 A pulsed DCWorking range, external, mm (in.) 160-1025 (6.3-40.4) 100 to flat (3.94 to flat)Clearance height, mm (in.) 111-119 (4.4-4.7) 73 minimum (2.87)

+37 for handle (+1.5) -Min. distance to flange, mm (in.) 18 at 0o skew (0.71) 18 at vertical (0.71)Rotation speed, cm/min (ipm) 2-40 (0.8-15.7) 2-40 (0.8-15.7)Torch, water-cooled with gas lens Electrode size, mm (in.) 1.6-3.2 (1/16-1/8) 1.0-4.0 (0.040-5/32)

Angular adjustment -30o - +45o -30o - +45o

Filler wire Feed speed, cm/min (ipm) 15-150 (5.9-59) 10-250 (3.9-98)Diameter, mm (in.) 0.8-0.9 (0.030-0.035) 0.6-1.2 (0.023-0.045)Contact tip Adjustable in X, Y, Z direction Adjustable in X, Y, Z directionWire spool dia., mm (in.) 100 (4) 100 (4)

Weaving Speed, mm/s (in./s) 2-12 (0.08-0.47) 2-19 (0.08-0.75)Amplitude, mm (in.) +/-15 (+/-0.6) +/-15 (+/-0.6)Rest time at end position, s 0.1-10 0.1-10

AVC Speed, mm/s (in./s) 2.0 (0.08) 2.0 (0.08)Amplitude, mm (in.) - 25 (1.0)

Weight, Kg (lbs.) 8 (17.6) 8 (17.6)

a21 pRd 160Designedforpipeswithanouterdiameterof160mm(6in.)ormoreCarriagetravelsaroundthepipeonarackadaptedtomatchthediameterofthepipeBasicmodelforthin-walledpipesincludesonemotorfortravelOptionsforthick-walledpipesincludewirefeed,arcvoltagecontrol(AVC),andweavingmodulesForusewithProwelderpowersourcesForuseonlywithProtig450whenusingAVCandweavingIncludes8m(26ft.)ofconnectioncable

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mechanized tig

A22 POC 12-60 Tube-to-Tube Sheet TIG Welding Heads

A22 POC 12-60 Welding Head Sales Literature .............XA00087220A22 POC 12-60 Welding Head Instruction Manual .........443 959 04160

Ordering InformationA22 POC 12-60 welding head w/ wire feed ..................443 930 880

Options & AccessoriesCounter-balancing block ..............................................332 330 005 3-point support, includes electrode holder .................333 897 880 For fillet welding up to 36 mm (1.4 in) diameter 3-point support, includes electrode holder .................333 897 883 For fillet welding from 36 mm (1.4 in) to 93 mm (3.6 in) diameter Additional gas cup ........................................................441 000 880 Internal bore welding torch, 9.5-15 mm (0.37-0.59 in) ........441 131 880Internal bore welding torch, 15-20 mm (0.59- 0.79 in) ...441 132 880 Internal bore welding torch, 20-30 mm ( 0.79-1.18 in) ...441 133 880Spindles and centering cartridges.......................... Contact ESAB

Precision-built,robust,versatileweldingheadforalltypesoftube-to-tubesheetweldingWorkingrangeof12-60mm(0.5-2.4in.)outerdiameterHighcenteringaccuracyPatentedcenteringmandrelsareavailableforinnertubediametersfrom9.9mm(0.38in.)Water-cooledandcapableofpulsingat200A,60%dutycycleIncludes8m(26ft.)ofconnectioncableandwirefeedunitasstandard

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Technical DataWorking range diameter Electrode parallel with tube axis, mm (in.) 12-60 (0.5-2.4)

Electrode 30o from tube axis, mm (in.) 12-36 (0.5-1.4)Rotation, rpm 0.2-4.5Electrode diameter, mm (in.) 1.6-2.4 (1/16-3/32)Rating, A @ 60% duty cycle 180Welding cable length, m (ft.) 8 (26.2)Weight, welding head only, Kg (lbs.) 4.8 (10.6)Wire feed unit Filler wire diameter, mm (in.) 0.8-0.9 (0.030-0.035)

Filler wire speed, m/min (ipm) 0.15-1.5 (5.9-59)Wire spool diameter, mm (in.) 100 (4)Wire reel weight, Kg (lbs.) 0.5 (1.1)

mechanized tig

A25 Mechanized TIG Modular Component System

A25 Component System Sales Literature ......................XA00089520A25 Component System Instruction Manual ..................443 922 001BTE Torch Instruction Manual ..........................................443 342 001

A22 POC 12-60 Welding Head Sales Literature .............XA00087220A22 POC 12-60 Welding Head Instruction Manual .........443 959 041 61

• Modularcomponentscanbeeasilycombinedto createcustomizedsolutionsforspecificwelding requirements

TIGNarrowGapmethodcanbeusedtogetherwithA25systemforextremelysmalljointangleandsubsequentlowjointvolumeChoosebetweendifferentmodelswitharcvoltagecontrol(AVC),weavingslides,manualhorizontalandverticalslides,floatingslides,circularslides,wirefeederandBTE250MorBTE500MtorchForusewithProwelderandProtigpowersources

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Ordering Informationa25 Welding automat w/ Bte 250m torch models

A25 complete system ....................................................443 910 880Includes A25 welding automat, AVC, weaving slides, wire feed unit, VEC motor w/ turntable and BTE 250M torch mounted on standw/ AVC ............................................................................. 443 911 880w/ AVC, weaving slides ................................................. 443 911 882w/ AVC, manual horizontal slides ................................. 443 911 884w/ manual vertical and horizontal slides ..................... 443 911 886w/ slides for floating head ............................................443 912 880

a25 Welding automat w/ Bte 500m torch models

A25 complete system ....................................................443 910 881Includes A25 welding automat, AVC, weaving slides, wire feed unit, VEC motor w/ turntable and BTE 500M torch mounted on standw/ AVC ............................................................................. 443 911 881w/ AVC, weaving slides ................................................. 443 911 883w/ AVC, manual horizontal slides ................................. 443 911 885w/ manual vertical and horizontal slides ..................... 443 911 887w/ slides for floating head ............................................443 912 880

Technical DataAVC slide amplitude, mm (in.) 76 (3)AVC slide speed, mm/s (ipm) 2.8 (0.1)Weaving slide amplitude, mm (in.) 76 (3)Weaving slide speed, mm/s (ipm) 19 (0.75)Manual slide amplitude, mm (in.) 93 (3.6)Floating slide amplitude, mm (in.) 76 (3)Wire diameter, m/min (ipm) 0.6-1.6 (23.6-63)Wire feed speed, m/min (ipm) 0.1-2.6 (4-102)VEC motor with encoder speed, rpm 1000VEC motor with encoder ratio 672:1

Options & Accessories1. Bracket ...............................................................................441 404 8802. Wire feed unit, dia. 0.6-0.8 mm (0.023-0.030 in.) .............441 300 8823. Feed roller, dia. 1.0-1.2 mm (0.040-0.045 in.) ...................369 557 0034. Feed roller, dia. 1.2-1.6 mm (0.045-1/16 in.) .....................369 557 0075. Outlet pipe, dia. 0.8-1.2 mm (0.030-0.045 in.) ..................441 456 8816. Outlet pipe, dia. 1.6 mm (1/16 in.).....................................441 456 8827. Connection cable, feed unit 8 m (26 ft.) ...........................443 828 8808. Wire hose, per meter [std. 400 mm (15.75 in.)] ............... 192 799 1129. Wire nozzle, BTE 250M torch ............................................441 407 88010. Wire nozzle, BTE 500M torch ..........................................441 407 88111. BTE 250M TIG torch.........................................................441 362 88012. BTE 500M TIG torch ........................................................441 418 88013. BTE 250M torch holder ...................................................441 414 88014. BTE 500M torch holder ...................................................441 414 88115. AVC slide ..........................................................................443 913 88016. Circular slide ....................................................................145 945 88017. Manual slide .....................................................................413 518 88018. Weaving slide ...................................................................443 913 88119. Floating slide ...................................................................441 674 88120. Single guide wheel unit, BTE 250M torch .....................441 833 880Single guide wheel unit, BTE 500M torch ...........................441 833 88121. Double guide wheel unit, BTE 250M torch ....................442 358 880Double guide wheel unit, BTE 500M torch ..........................442 358 88122. Bracket .............................................................................441 412 88023. Brake hub .........................................................................146 967 88124. Bobbin protection ............................................................157 482 880Multi-contact plug for connection with Protig ....................441 600 880VEC motor with tacho, speed 1000 rpm, ratio 672:1 ............457 258 880Control unit to VEC ...............................................................457 222 880Turntable with return cable connection for VEC motor .....442 712 880Narrow gap kit for BTE 500M torch ......................................441 667 880Motor control unit PAL 3 .......................................................457 870 990

mechanized tig

MEI 21/10 Wire Feed Units

MEI 21 Wire Feed Unit Sales Literature ..........................XA00089020MEI 10 Wire Feed Unit Sales Literature ..........................XA00098620MEI 21 Wire Feed Unit Instruction Manual ......................443 831 001MEI 10 Wire Feed Unit Instruction Manual ......................444 215 00162

mei 21 Wire Feed unitFourwirerollersfororbitalTIGweldingEliminatestheneedforawirefeedunitandwirespoolmountedontheweldingheadUsewith5Kg(11lbs.)wirespoolsForwirediametersof0.6mm(0.023in.)to0.8mm(0.031in.)Includeswirehose

mei 10 Wire Feed unitDevelopedformountingPRB17-170tools(PRC17-49onlywithAVC)PRBtoolswithMEI10canbeusedwithProwelderpowersourcesPRCtoolswithMEI10canbeusedwithProtig450IdealforaluminumweldingwithshortwirefeeddistancefromthereeltothemoltenpoolAlsouseformildsteelandstainlesssteelForwirediametersof0.8mm(0.030in.)to1.0mm(0.040in.)foraluminum,0.8mm(0.030in.)forsteelMotorequippedwithpulsegeneratorforprecisewirefeedspeedadjustment

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Ordering InformationMEI 21 .....................................................................................443 830 880 MEI 10 - PRB 17-49/PRC 17-49 w/ AVC ................................ 444 211 880 MEI 10 - PRB 33-90/PRC 33-90 w/ AVC and weaving ..........444 212 880MEI 10 - PRB 60-170/PRC 60-170 w/ AVC and weaving ......444 213 880

Technical Data MEI 21 MEI 10

Wire diameter, mm (in.) 0.6-0.8 (0.023-0.031) 0.8 (0.031)Wire feed, m/min (ipm) 0.1-2.6 (0.004-0.1) 0.1-1.2 (0.004-0.05)Max. spool dimension/weight, Ø mm/Kg (in./lbs.) 200/5 (8/11) 60/0.26 (2.4/0.6)Hub width, mm (in.) 60 (2.4) -Hub hole diameter, m (ft.) 51.5 (169) -Wire guide length, m (ft.) 4.2 (14) 0.1 (0.3)Weight, Kg (lbs.) 4 (8.8) 0.5 (1.1)

MEI 10

MEI 21

mechanized tig

G-Tech Precision TIG Electrode Grinder

OCF 2M Cooling Unit

CoolingunitdesignedforusewithProwelder160EasytomountunderthepowersourceMaximumworkingheight-7m(23ft.)

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Ordering InformationOCF 2M cooling unit ......................................................457 216 882

G-Tech TIG Electrode Grinder Sales Literature ................... 898C129G-Tech TIG Electrode Grinder Instruction Manual .........700 009 027OCF 2M Cooling Unit Instruction Manual ........................457 680 001 63

Ordering InformationG-Tech Tungsten Grinder, 110/115 V, 1 ph, 60 Hz ...... 700 009 882Complete with one diamond grinding disc and accessory kit for .040 – 5/32” electrodes

Options & Accessories Side wall seal .................................................................700 009 001Diamond grinding disc ..................................................700 009 002Inspection cover ............................................................700 009 003Inspection window kit ...................................................700 009 038 Grinder fluid, 250 ml (.06 gal) .......................................700 009 004Grinder fluid, 5000 ml (1.3 gal) .....................................700 009 015Return bottle, 250 ml (.06 gal) ......................................700 009 005Electrode clamp 1.0 mm (0.040 in.) ..............................700 009 007Electrode clamp 1.6 mm (1/16 in.) ................................700 009 008

• Uniqueenclosedwetgrindingsystemfortungsten electrodes• Stable,concentratedTIGweldingarcguarantees accuracyandrepeatability• Automaticcollectionofgrindingdust-noriskto welderorenvironment• Nooxidationofthetungstenelectrodewhenwet grinding• Contributestolongerlifeofelectrodepoint

Disposalandrecyclingsysteminthegrinder•

Electrode clamp 2.4 mm (3/32 in.) ........................................700 009 009Electrode clamp 3.2 mm (1/8 in.) ..........................................700 009 010Electrode clamp 4.0 mm (5/32 in.) ........................................ 700 009 011T-piece ....................................................................................700 009 012Spacer piece ..........................................................................700 009 013Electrode holder ....................................................................700 009 039Accessory kit, complete .......................................................700 009 016 Waste Container ....................................................................700 009 017

Technical DataPrimary input, VAC 230Max. power consumption, W 250Max. water pressure, bar (psi) 3 (43.5)Cooling power, degree, L/min, kW 4Total water consumption, L (gal) 5 (1.32)

mechanized tig

Welding Parameter Documentation Printer

Parameter Documentation Printer Sales Literature ...... XA0011442064

Ordering InformationParameter Documentation Printer .......................................449 322 880 Includes: one paper roll, and all items marked with * below

Options & Accessories Interface card for upgrading old power source LTS, LTP ........486 764 884 Software for upgrading old LTS, English/French ...............459 370 885 Software for upgrading LTP, English/French ......................459 370 881Paper roll, 40 pcs ..................................................................449 327 880* Cassette for printer .............................................................449 324 001* Plastic cover ........................................................................449 325 001* Control cable 1.5 m (59 in.) ................................................449 326 001* Adapter incl 2.0 m (79 in.) power cable .............................449 329 001* Double sided tape ...............................................................456 986 001

• Printerfordocumentationofweldingparameters• UsewithProwelder160,320andProtig450• Printsprogrammedandmeasuredvaluesforspeed, current,voltage,wireandpower• Print-outindicatespowersourceused,time,run numberandtotalweldingtime

Technical DataPrinting principle Thermoprinter for 58 mm (2.3 in.) thermo paper with fixed printer headPrinting speed 8 lines/sResolution 384 points/linePaper load Automatic and manual feedControl voltage 9-32 V DC, protected against incorrect polarity and overload/”load dump”Power consumption @ 12 V DC “Sleep mode” Max. 10 mA

“Standby” Max. 100 mA“Printing” Max. 2 A

Temperature range Operation mode -25-+55oC (-13-131oF)Standby mode -40-+70oC (-40-157oF)

Number of sectors Max. 20; change of max. 3 parameters in each sector is possible to secure proper printing of 20 sectors

ROBOtics

AristoMig Robotic Packages Sales Literature ...............XA00125020AristoMig Retrofit Components Sales Literature ..........XA00125220AristoMig Components Sales Literature ........................XA00125320 65

AristoMig Process Packages for Mechanized MIG Welding

Powersourcewithbuilt-inweldingknowledgeforstorageofmanysynergiclinesforoptimalperformanceSpecialwirefeederversionslikeAristoRoboFeedwithcapsulatedfeederStandardwirefeederscanalsobeusedforroboticapplicationsUsewithstandardspoolsorbulkpackwire,max.475Kg(1047lbs.)drumswithautomaticswitchingtonewdrumforendlesswirefeed-excellentforhighproductivityBussplittersimplifiesquickchangeofcablesandapparatusandlinkstheESABinternalbuswiththerobot’scontrolsystemExternalbuscommunicationandcontrolcablecontrolsboththeweldingprocessandcoincideswiththerobotcontrolConventionalinterfaceneededifnotusingbuscontrolsystems

applied Welding solutions

When a component or complete welding system foranother robot & communication network solution isneeded, eg/ with CANopen, DeviceNet or ProfiBus,ESABhastheexperiencetomakecustomerorientedcomponentstosuitmostapplications.

For many mechanized applications, ESAB has astandardsolution.ESABalsoprovidescustomeradaptedsolutionstosuitspecificapplications.

mechanized mig processes

MIGweldingMIGpulseweldingMIGAristoSuperPulseTM

Shortarc/pulsePulse/pulsePulse/sprayarcMIGbrazing

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standard aristomig Welding components for devicenet communication

AristoMig 450230-575 vac459 349 890

AristoMig 450w230-575 vac459 349 888

AristoMig 500 460 vac

459 230 884

AristoMig U500w 460 vac

459 230 885

AccesoriesWater flow guard AristoMig Power source ........................ 456 855 880Trolly AristoMig 400/500 ................................................... 461 043 880

External Bus InterfaceAristoPendant U8 - DeviceNet.......................................... 461 050 880AristoPendant U8 - CANopen........................................... 461 050 883

SplitterBus splitter DeviceNet Harting 24..................................... 461 105 880

Control Cable, Power Source - robot1.7 m (6 ft.) ....................................................................... 456 527 8805 m (16.5 ft.) ..................................................................... 456 527 88110 m (33 ft.) ...................................................................... 456 527 89015 m (50 ft.) ...................................................................... 456 527 88225 m (80 ft.) ...................................................................... 456 527 88335 m (115 ft.) .................................................................... 456 527 884

Cable Package, Power Source - drive unit Air-Cooled Water-Cooled5 m (16.5 ft.) 740 538 890 .................................... 740 538 89510 m (33 ft.) 740 538 881 .................................... 740 538 88615 m (50 ft.) 740 538 882 .................................... 740 538 88725 m (82 ft.) 740 538 883 .................................... 740 538 88835 m (115 ft.) 740 538 884 .................................... 740 538 889

Drive Unit System - External (Assembly bracket incl.)AristoFeed Control................................................. 461 080 880

Drive Unit System - EnclosedAristo RoboFeed 3004w, 23p Burndy ............ 461 000 880Aristo RoboFeed 3004w, 12p Burndy .............461 000 881

Assembly BracketAssembly bracket universal .......................... 461 038 880

Aristo Feed Mech 4804w23p Burndy ..................... 461 070 88012p Burndy ..................... 461 070 881

Cable & Hose Kit, 2m (6.6 ft) 461 135 881

Accessories3 m (10’) Heavy Duty Conduit ( with quick-connect fittings) 899F844.5 m (15’) Heavy Duty Conduit ( with quick-connect fittings) 899F456 m (20’) Heavy Duty Conduit ( with quick-connect fittings) 899F85Heavy Duty Conduit ( per metre) 899F74Quick Connector Adaptor Kit ( connects conduit to feeder) 899F50Quick Conduit Adaptor Kit for Marathon Pac™ 899F71

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Standard AristoMig Robot Package Configuration

ROBOtics

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Assembly BracketAssembly bracket universal .......................... 461 038 880

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applied autOmatiOn

Mechtrac 1730/2100/2500/3000 for Mechanized Gantry Automation

Mechtrac 1730/2100/2500/3000 Sales Literature ............XA00101220Mechtrac 1730/2100/2500/3000 Instruction Manual ........807 230 101

Standard AristoMig Robot Package Configuration

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• Fastandflexiblewaytoincreaseproductivity• EquippedwithA2-A6PEHprocesscontrollerand A2weldingequipmentformechanizedSAWorMIG welding• WeldvariousprofilessuchasI-,T-,orL-beams, straightcolumns,ortaperedcolumns• Availableinfourversions(widthofgantry):1730mm (68in),2100mm(83in.),2500mm(94in.),or3000 mm(118in.)• Allversionshavestandardgantrylegheightof1500 mm(59in.)• Floormountedraildeliveredinstandardlengthsof3 m(118in.)-canbeeasilyextended• Dual-drivemotorsarestandard• Gantrycansupportamaximumweightof220Kg (485lbs.)-uptotwoA2weldingheads,complete withGMDjointtracking,andOPCfluxrecovery systems

Ordering InformationMechtrac 1730, dual drive .....................................................809 670 881Mechtrac 2100, dual drive .....................................................809 670 882Mechtrac 2500, dual drive .....................................................809 670 883Mechtrac 3000, dual drive .....................................................809 670 884

Options & AccessoriesTraveling rail, 3m (9.8 ft) .......................................................806 707 880Traveling rail, extension, 3 m (9.8 ft)....................................806 707 881Bracket ...................................................................................812 578 880

Technical DataTravel speed, m/min (ipm) 0.2-1.9 (8-75)Maximum load, Kg (lbs.) 220 (485)Standard rail length, m (ft.) 3 (9.8)Gantry dimensions, WxH, mm (in.) 1730-3000 (68-118)

applied autOmatiOn

Column & Boom Systems

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• Modulardesignconceptallowstotalcustomization usingstandardcomponents• Largeselectionofavailablecomponentsto integrateforacustomsolution:

• AnyA2orA6weldheadsystem• A2-A6PEHprocesscontrollerwithLAFor

TAFpowersources• ESABturningrollsandpositioners• ESABfluxfeedingandrecoverysystems• GMDandlaserjointtrackingsystems• Monitoringsystems,cameras,WMS4000

qualitysupervisionsoftware• Fourbasicstationdesignssuitableformost standardapplications• Threedifferentsizes:300,460and600[number referstoboomprofileheight(mm)which determinesworkingrangeandloadcapability]• Choosefromstationaryormobile,rail-travelling carriagesystems

Versatiletorespondtoanyautomatedweldingdemand

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standard caB sizesThemanipulatorsaredividedintothreedifferentsizes300,460and600.Thesesizesarethethroatdimensionsoftheboominmillimeters.Eachsizehasacorrespondingcolumn.Thedifferentsizesarenotonlylimitedinwhereitcanfit,butalsohowfartheboomcanextendandhowmuchloadthatcanbeputon.

performance categories Thesystemisdividedintothreedifferentcategoriesforperformance:

S: Standard• Standardmechanicalperformance,nocablechain• Afewoptions,camera-system,tacho-regulatedspeedandfluxcontrol• OnlyforBasicstation1

M: Modular • Standardmechanicalperformance,includingcablechainforcolumnandbooms• Morethan20optionsfullyintegrated,suchastandem,shiftfunction,transportspeedetc• OnlyforBasicstation1

C: Customized• BasedonthesamemechanicalperformanceastheS-andM-model• BasedonthesameelectricalsystemastheM-model• IncludeseverythingthatisnotaS-orM-modelsuchas:

• Basicstation2,3,and4• Oddsizes(ex.4.35mx5.15m)• OptiondemandsnotofferedinS-orM-model.

applied autOmatiOn

Column & Boom Systems - Basic Stations

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Basic station 1• Standardset-upwithweldingequipmentononeor bothendsoftheboom• Positioningofweldingequipmentin4-axis• Application:Vessels,pipes,profilesandotherlarge weldingconstructions.

Perfectfornarrowspaces•

Basic station 2• Basicstation1withtheaddedadvantagesofa sideboomcarriagewithweldingequipment• Boomismovableandsimultaneousweldingcan beachievedwithtwoheads• Application:vesselsandpipesorconicalgirders andboxprofiles

Basic station 3• Weldingstationwithhorizontallyfixedboomandis equippedwithtwosideboomcarriagessupporting weldingequipmentonsamesideofboom• Weldsimultaneouslywithtwoheads• Application:straightandconicalgirders,boxprofiles, beams,stiffenersandvessels

Basic station 4• Weldingstationwithhorizontallyfixedboom featuringdoubletrackwithboomcarriages supportingweldingequipmentonbothsidesofthe boom• Simultaneousweldingoperationwithtwoheadsas standard• Application:containers,truckplatformbodies,box girders,beams,stiffenersectionandjoiningof platesandsections

applied autOmatiOn

Technical Data 300S/300MColumn - Effective working range, m (ft.) 3 (10) 4 (13) 5 (16.5)Max. boom height A, w/ moveable carriage, mm (ft.) 4070 (13) 5070 (16.5) 6070 (20)Min. boom height A, w/ moveable carriage, mm (ft.) 950 (3) 950 (3) 950 (3)Max. boom height B, w/ concrete stand, mm (ft.) 3750 (147) 4750 (187) 5750 (226)Min. boom height B, w/ concrete stand, mm (ft.) 610 (24) 610 (24) 610 (24)Max. boom height C, w/ floor plate, mm (ft.) 3955 (156) 4955 (195) 5955 (234.5)Min. boom height C, w/ floor plate, mm (ft.) 815 (32) 815 (32) 815 (32)Total height D, w/ moveable carriage, mm (ft.) 5170 (17) 6170 (20) 7170 (23.5)Total height E, w/ concrete stand, mm (ft.) 5055 (16.5) 6055 (20) 7055 (23)Total height F, w/ foot plate, mm (ft.) 4850 (16) 5850 (19) 6850 (22.5)Lifting speed, m/min (ipm) 0.7 (27.5) 0.7 (27.5) 0.7 (27.5)

Boom - Effective working range, m (ft.) 3 (10) 4 (13) 5 (16.5)Max. extension G, mm (ft.) 3580 (11.75) 4580 (15) 5580 (18)Min. extension G, mm (ft.) 540 (2) 540 (2) 540 (2)Permissible loads total, Kg (lbs.) 300 (660) 220 (485) 150 (330)

one end, Kg (lbs.) 240 (530) 150 (330) 75 (165)Cross sectional diameter H, mm (in.) 325 (13) 325 (13) 325 (13)Welding speed, m/min (ipm) 0.1-2.0 (4-79) 0.1-2.0 (4-79) 0.1-2.0 (4-79)Transport speed, m/min (ipm) 2 (78) 2 (79) 2 (79)

Rail Carriage/Concrete Stand/Foot PlateRail carriage track width, inside to inside L, mm (in.) 1730 (68)Rail carriage dimensions,WxL, mm (in.) 2060x2330 (81x92)Rail carriage height I, mm (in.) 365 (14)Welding speed, m/min (ipm) 0.1-2.0 (4-79)Transport speed, m/min (ipm) 2 (79)Concrete stand dimensions, WxL, mm (in.) 2060x2100 (81x83)Concrete stand height J, mm (in.) 250 (10)Foot plate dimensions, WxL, mm (in.) 1100x1100 (43x43)Foot plate height K, mm (in.) 40 (1.6)

Column & Boom 300S Sales Literature .......................... XA00118720Column & Boom 300M Sales Literature ......................... XA0011882070

Technical Data 460S/460MColumn - Effective working range, m (ft.) 4 (13) 5 (16.5) 6 (20)Max. boom height A, w/ moveable carriage, mm (ft.) 4950 (16) 5950 (19.5) 6950 (23)Min. boom height A, w/ moveable carriage, mm (ft.) 950 (3) 950 (3) 950 (3)Max. boom height B, w/ concrete stand, mm (ft.) 4845 (16) 5845 (19) 6845 (22.5)Min. boom height B, w/ concrete stand, mm (ft.) 845 (3) 845 (3) 845 (3)Max. boom height C, w/ floor plate, mm (ft.) 4510 (15) 5510 (18) 6510 (21.5)Min. boom height C, w/ floor plate, mm (ft.) 510 (1.6) 510 (1.6) 510 (1.6)Total height D, w/ moveable carriage, mm (ft.) 6275 (20.5) 7275 (24) 8275 (27)Total height E, w/ concrete stand, mm (ft.) 6170 (21) 7170 (23.5) 8170 (27)Total height F, w/ foot plate, mm (ft.) 5835 (20) 6835 (22.5) 7835 (25.5)Lifting speed, m/min (ipm) 0.7 (27.5) 0.7 (27.5) 0.7 (27.5)

Boom - Effective working range, m (ft.) 4 (13) 5 (16.5) 6 (20)Max. extension G, mm (ft.) 4850 (16) 5850 (19) 6850 (22.5)Min. extension G, mm (ft.) 850 (3) 850 (3) 850 (3)Permissible loads total, Kg (lbs.) 1100 (2423) 1050 (2313) 1000 (2203)

one end, Kg (lbs.) 550 (1211) 450 (991) 350 (771)Cross sectional diameter H, mm (in.) 630 (25) 630 (25) 630 (25)Welding speed, m/min (ipm) 0.1-2.0 (4-79) 0.1-2.0 (4-79) 0.1-2.0 (4-79)Transport speed, m/min (ipm) 2 (78) 2 (79) 2 (79)

Rail Carriage/Concrete Stand/Foot PlateRail carriage track width, inside to inside L, mm (in.) 1730 (68)Rail carriage dimensions,WxL, mm (in.) 2100x2380 (83x94)Rail carriage height I, mm (in.) 485 (19)Welding speed, m/min (ipm) 0.1-2.0 (4-79)Transport speed, m/min (ipm) 2 (79)Concrete stand dimensions, WxL, mm (in.) 2100x2410 (83x95)Concrete stand height J, mm (in.) 380 (15)Foot plate dimensions, WxL, mm (in.) 1600x1600 (63x63)Foot plate height K, mm (in.) 40 (1.6)

Column & Boom 460S Sales Literature .......................... XA00118920Column & Boom 460M Sales Literature ......................... XA00119020

applied autOmatiOn

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applied autOmatiOn

Seamers for External Longitudinal Seam Welding

Seamers for Internal Longitudinal Seam Welding

ED External Seamers Sales Literature ...........................XA00120020ID Internal Seamers Sales Literature ..............................XA0012012072

• Bestsolutionforhighqualitylongitudinalweldsto plates,tanksorothercylindricalworkpieces• Seamersaredeliveredreadytoweld• Availablefor1.5-6m(59-236in.)longweldsand fordiameters180-1000mm(7-39in.)• Easyalignmentofplateswithhelpfromlaserlight• Pneumaticallyoperatedstoppersforplate alignmentavailable• Water-cooledbackingbar• Copperbackingbarequippedwithshieldinggas forplasmaandTIGprocesses• ManualandremotecontroloperationswithPLC controller

• Bestsolutionforhighqualitylongitudinalweldsto plates,tanksorothercylindricalworkpieces• Seamersaredeliveredreadytoweld• Availableforweldingamaxof6m(236in.)long weldsanddiametersgreaterthan1500mm(60in.)• Easyalignmentofplateswithhelpfromlaserlightbeam• Pneumaticallyoperatedstoppersforplate alignmentavailable• Copperbackingbarequippedwithshieldinggas forPlasmaandTIGprocesses• Conserveshieldinggaswithdividedgasvalves• ManualandremotecontroloperationswithPLC controller

Technical Data ED15H10 ED20H10 ED30H10 ED40H10 ED60H10

Nominal length, mm (in.) 1500 (59) 2000 (78) 3000 (118) 4000 (157) 6000 (236)Welding length, mm (in.) 1750 (69) 2250 (89) 3250 (128) 4250 (167) 6250 (246)Min. diameter, mm (in.) 180 (7) 180 (7) 250 (10) 350 (14) 600 (24)Max. diameter, mm (in.)1 1000 (39) 1000 (39) 1000 (39) 1000 (39) 1000 (39)Plate thickness, not tack-welded mm (in.) 1-8 (0.04-0.31) 1-8 (0.04-0.31) 1-8 (0.04-0.31) 1-8 (0.04-0.31) 1-8 (0.04-0.31)Max. plate thickness, tack-welded, mm (in.) 10 (0.40) 10 (0.40) 10 (0.40) 10 (0.40) 10 (0.40)

1extensionblockavailable

Technical Data ID40H10 ID60H10

Nominal length, mm (in.) 4000 (157) 6000 (236)Welding length, mm (in.) 4250 (167) 6250 (246)Min. diameter, mm (in.) 1500 (59) 1500 (59)Plate thickness, not tack-welded mm (in.) 1-8 (0.04-0.31) 1-8 (0.04-0.31)Max. plate thickness, tack-welded, mm (in.) 10 (0.40) 10 (0.40)

applied autOmatiOn

Seamers for Longitudinal Seam Welding, cont’d

Ordering Informationpackage* ed15h10 ed20h10 ed30h10 ed40h10 ed60h10 id40h10 id60h10SAW1 1069500 10695100 10695200 10695300 10695400 10696300 10696400SAW2 10630900 10631000 10631100 10631200 10631300 10637600 10637700MIG1 10695500 10695600 10695700 10695800 10695900 10696500 10696600MIG2 10631400 10631500 10631600 10631700 10631800 10637800 10637900MIG3 10631900 10632000 10632100 10632200 10632300 10638000 10638100TIG1 10632400 10632500 10632600 10632700 10632800 10638200 10638300TIG2 10632900 10633000 10633100 10633200 10633300 10638400 10638500

*SeetablebelowforPackagecontents

Options & Accessoriesexternal seamers ed15h10 ed20h10 ed30h10 ed40h10 ed60h10High extension block, 500 mm (20 in.) 10639200 10639300 10639400 10639500 10639600Plate stopper, required amount 2 2 2 2 2Stopper ring 10639800 10639900 10640000 10640100 10640200

internal seamers

AVC control for plasma equipment ................................. 10642300Camera monitoring systems ........................................... 10642200Pneumatic plate stopper (3 required) ............................. 10645900

*packagesSAW1 LAF 635 power source, A2 wire feeder w/ A2-A6 PEH Process Controller, OPC flux recovery unitSAW2 LAF 1000 power source, A2 wire feeder w/ A2-A6 PEH Process Controller, OPC flux recovery unit

MIG1 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 torchTIG 2 AristoTig 400 power source, MEI 10 and MEI 12 wire feeder (cold wire), BTE500M TIG torch

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Circotech Compact Girth Welding System

Circotech Sales Literature ...............................................XA0008362074

• Selfpropelledthreeo’clockweldingsystem• Designedforon-siteerectionoflargestorage tanks,silos,blastfurnacesandcylindricalobjects• Availableassingleordouble-sided• Designedtotravelalongtheedgeofatankshell onarailtemporarilyattachedtotheshell,orona stand-aloneringoutsidetheshell• Equippedwithcagedcabinformaximumsafety andeasytoreachweldingcontrols• Standardequipmentincludessingle-wireSAW,or twinwireSAWonrequest• UtilizesESAB’sfluxsupplyandrecoverysystem

Ordering InformationCircotech complete package ................................... Contact ESABSystem includes: A2 or A6 submerged arc welding machine with motorized slides, PAK manual tracking system, A2-A6 PEH Process Controller, weather shielded safety cabin, LAF power source, 6 L (1.6 gal.) flux hopper and flux support, 50 m (164 ft.) control cable, welding and return cables

Technical DataPlate height, mm (ft.) 1000-3000 (3.3-10)Plate thickness, mm (in.) 8-35 (0.3-1.4)Shell curvature, radius, mm/min (ipm) 4000 (157)

Rototech 80 for Rotary Welding

• Programmableweldingsystemforlightand mediumweightcylindricalobjects• Weldingprocessandparametersarecontrolledby modernPLCcontroltechnology• Weldcomponentsaslargeas400mm(16in.)in diameter,3000mm(118in.)inlength,andupto 80Kg(176lbs.)inweight

Ordering InformationRototech 80 ............................................................... Contact ESABSystem includes: rigid frame with 2 support legs, movable

turning device with vector controlled frequency transformer and asynchronous motor, spindle with double-sided bearings, turntable with guide holes for attaching fixtures, movable clamping device with pneumatic cylinder and hand-operated locking device, pneumatically controlled gun holder with movable arm, PLC control and operation box, centre point for clamping

applied autOmatiOn

Technical DataInput power, 3 phase As requestedRecommended fuses, A 16Max. welding current per gun, A 450Air supply, kPa (psi) 500 (72.5)Operational voltage, VDC 24Contact function (galvanically insulate) for current contactor/cold wire feed unit 2A resistive load, 80 VA inductive loadClamping force, Nm (lbf-ft) 150 at max. 0.3 MPa (110.6 max. 3.5 psi)Clamping length, pressure cylinder, mm (in.) 80 (3)Protection class, motor unit IP 23Protection class, electrical cabinet IP 55Rotation speed, rpm 0.12-7.0Weld length, o (# of rotations) 0.1-3600 (0-10)# of programs 1Max. torque during continuous operation, Nm (lbf-ft.) 60 (44.3)Max. diameter of work object, mm (in.) 400 (16)Weight, Kg (lbs.) 80 (176)Ambient temperature, oC (oF) 5-40 (41-104)Operational noise, dBA <50Total height, mm (in.) 1550 (61)Total length, excluding weld length, mm (in.) 1300 (51)Weld length, mm (in.) 500-3000 (19.6-118)

Rototech 80 Sales Literature ...........................................XA00079820 75

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special applications

Windmill Tower Manufacturing

Efficient Welding in Tower Manufacturing Brochure ....XA00126920

Windmill tower manufacturing using a Column & Boom system.

The secret behind the efficient production of wind towers is smooth component flow in the workshop. The benefit of a high deposition welding process is completely lost if the set-up or handling of components in any area of the process fails or takes an unacceptable amount of time. ESAB can assist with the welding and cutting process in wind tower production and deliver finely tuned solutions for each step in the production process. With a complete package from ESAB, you only need to work with one supplier for product, service and support. This results in a large project being organized efficiently, with a fixed cost and agreed time schedule. Smooth production flow is a part of the complete delivery.

Dedicated solutions for Dedicated Manufacturers

High productivity welding with a deposition rate of up to 40 Kg/hr with a tandem twin submerged-arc welding head is possible. The process is specially designed for production of wind towers where benefits for working in narrow weld preparations with reduced weld volumes can be achieved. This combination will result in dramatically reduced welding time and increased productivity. A dedicated wire and flux combination can eliminate major obstacles such as reduced impact strength in the weld, and poor slag release in narrow joints. Spoolarc 81 or OK Autrod 12.22 wire and OK 10.72 flux from ESAB gives good impact strength at -50oC (-58oF), to satisfy offshore wind tower applications.

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Windmill Tower Manufacturing - Production Line

Plate and joint preparation is done by mechanized oxy-fuel or plasma cutting

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The plate is roll-formed and tack welded•

Longitudinal seams are then externally welded with the submerged arc welding process using a Column & BoomThe Column & Boom uses an A6 submerged arc welding head and A2-A6 PEH process controllerHigh deposition rates can be achieved with options such as twin wire, synergic cold wire, flux feed and recovery and large wire reelsThe operator can control the process from the ground and monitor the weld through seam tracking and video camerasThe seams are welded internally using the Column & Boom

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Flanges are welded using the submerged arc process•

Shells are fitted together using hydraulic fit-up rolls or special rounding jigSections are tack welded

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Joining the tower sections is done with the Column & Boom using submerged arc weldingThe turning rolls or head & tailstock positioners rotate the sections while the welding head follows the seam from the top - external circumferential welding

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Windmill Tower Manufacturing - Production Line, cont’d


Internal joining of the sections is done using a the A2 Tripletrac welding tractor or a column and boom, depending on the production line configurationTurning rolls or a head & tailstock turn the section during internal weldingThis process is supervised by the operator inside the workpiece

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The ESAB Frametrac is used for automatic welding of the door frame, using the MIG welding processThe tractor is specially designed for travelling along the door frame

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Production of sub-components, such as the gear box housing, are welded using positioning equipment and manual welding equipment

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Beam Welding

column & Boom Beam Welders• Weld a large variety of beams with various configurations of

standard columns and booms• Processes include: subarc, tandem subarc, MIG, cored wire, and

aluminum welding• Integrated A2-A6 PEH process controller• A2/A6 welding heads• Seam tracking options can be modified for curved shapes, such

as trailer beams

aluminum trailer Beam WelderWith narrow precision track

• Pivot base allows welding on both sides of the track• Unique joint tracking allows proper torch alignment through the

transition curves on the beam• MIG welding process with AristoMIG 450 power source includes

integrated fume extraction system

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submerged-arc trailer Beam WelderAvailable in narrow track or carriage configurationCaB 300 for trailer beams; CaB 460 for larger beamsEquipped with A2 or A6 welding heads, A2-A6 PEH process controller, seam tracking, flux delivery and recovery systemsPivot base allows welding on both sides of the trackCan be equipped with mounting for up to 4 drums, 450 Kg (1000 lbs.) each, of welding wire for dual twin-arc welding headsAlso available for GMAW processes with metalcored of flux cored wire

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Wall-Mounted column & Boom Welding station• For production of various beam structures, such as I/H, box beams

and non-symmetrical design• Floor space is minimized with single rail/wall support• Longitudinal and transverse welding procedures• Uses A6 welding heads, A2-A6 PEH process controller and GMD

automatic joint tracking

ESAB offers a variety of beam welding solutions from simple tractors to fully automated beam assembly lines for all styles of beams, from I-, T-, L-beams, wide flange beams, columns, tapered beams and non-symmetrical beams. ESAB’s extensive experience in beam welding ensures optimum straightness and productivity. Some beam welder examples are shown, please call for further information on specific applications.

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Beam Welding - Pull Through Welders

For more detailed information about beam welding, please contact ESAB

On pull-through beam welders, the welding head is stationary and beam is pulled through the station. Parts are automatically aligned and compressed, eliminating tacking. Tight fit-up ensures high weld quality. Models available for vertical or horizontal web.

it 100, 258, 3200 Web Vertical pull-through Beam WelderBoth sides of flange welded simultaneouslyBuilt-in straightening device to compensate for pullback of the flangesOptional induction or gas heating equipment to ensure straight beams; required for T beamsComplete material handling systems availablePLC controlled, uses A6 DC-AC tandem subarc welding heads on each side for high speed weldingSpecs: 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.)

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it 2000 Web Horizontal pull-through Beam Welder• Both flanges welded simultaneously• Easy to install, no special foundation required• Place two machines in line for continuous flow• Infeed and outfeed conveyors available• PLC controlled, uses A6 DC-AC tandem subarc welding heads

on each side for high speed welding• Specs: Flange size 100 – 700 mm (4-27.5 in.); beam height 246 – 2200 mm (9.6-86.6 in.)

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Welding Gantries

For more detailed information and ordering information, please contact ESAB

GantracRigid legs supported by tacho-controller, DC-driven bogie carriages as well as a cross beam to ensure uniform, stable welding speedGantry beam is equipped with guides and a rack on both sides for the two motorized welding carriagesA6 welding heads are mounted on rack-and-pinion slides with comprehensive working strokes to obtain good access to the workpiecesIncorporates the A2-A6 PEH process controller equipped with GMD automatic joint tracking to control the vertical and horizontal axes Welding heads can be turned +/- 180 degrees for welding in both X directions as well as 90 degrees for welding in Y direction across the beamOptions include twin wire, synergic cold wire and tandem heads; turntables for up to 4-450 Kg drums of wire and flux feed and recovery systems

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stable Gantry station for stainless steel Railway Wagon Roofs

7000 mm (275.5 in.) widthOverlap joints without prior tack weldingPneumatic clamping device ensures plates are tightened to each other during weldingAristo power source with pulsed welding sequences A2 welding head equipped with durable water cooled torch is used to withstand harsh working conditionsNon-interrupted welding length of up to 30 m (98 ft.) Reverse speed is 10 m/min (390 ipm) using efficient AC synchronic motors

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Robotic production GantryDesigned for shipyard panel lineAlso suitable for other plate and stiffener assemblies such as large earth-moving equipmentDifferent programming methods available

Teach, welding macrosOffline programmingVision assisted programming

Vision System - entire assembly is scanned to determine absolute part position, then macros used for welding procedures30 minute programming for 8 hours of welding

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Shipyard Applications

For more detailed information and ordering information, please contact ESAB

ESAB provides total panel line solutions for shipbuilding, from plate cutting and marking to assembly and material handling.

one side Welder (osW)One side welding improves panel assembly efficiency by eliminating the need to rotate large panelsVacuum clamping securely holds plates in position during welding, without tack weldingSystem uses A6 welding heads and 3-wire subarc systemsBacking flux is automatically and accurately deposited on the water-cooled backup barPlates are fed through the OSW with infeed and outfeed tables with gripper conveyor system

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stiffener assembly and WeldingPositions and welds both sides of stiffener Programmable stitch or continuousGantry can carry dual stations (4 weld heads) for increased productivityPLC controlled, uses A2 MIG welding componentsVarious designs and levels of automation are available.

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Vertical up welderA unique system, specifically designed for double hull constructionA four torch head is lowered into an intersection and then welds all four joints simultaneouslyExtensive programming capabilities allow oscillation, multi-pass, stitch, as well as ability to sense and skip cutouts or horizontal stiffenersCan be fitted with ESAB pulse or cored wire systemsAn extremely efficient system, eliminating a difficult task while improving health and safety of welders.

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Custom Welding Solutions

Roll Buildup and Hard surfacingRototech 2000 is an integrated unit for surfacing of cylindrical objects, such as steel mill rollsUses head and tailstock, with PLC controlled positioning equipmentWeld process can be plasma, MIG, subarc or strip claddingProgram variables include selectable bead placement style, carriage and rotation speed, bead width and overlap, oscillation speed and amplitudeProcess variables are preset on the A2-A6 PEH process controller

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electroslag Welding MachineMachine for longitudinal welding of cylinders for the pulp industryPicture shows machine with the welded cylinder in the vertical positionThe assembly is equipped with an inside-cooling support column for applying a cooling shoe to the closed joint of the upright cylinderThe machine permits the welding of plates with a thickness of 40-450 mm (1.6-17.7 in.) while using one to three electrode wires

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pipemill Welding equipment For longitudinal and spiral pipe Mills

Equipment includes GMAW high speed, high current tacking equipment, internal booms with up to 4 weld heads, and external heads up to 6 wiresAdvanced controls easily control and monitor the parameters of all wiresA wide range of ancillary equipment is available, including laser or mechanical guidance systems, flux delivery and recycling equipment, slag crushers, pipe handling lines and Weldoc™ monitoring softwareThis equipment is designed for retrofit of existing mills as well as for new mills

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lamp pole WelderVarious systems available for tapered lamp pole weldingPhoto shows single sheet formed pole, which is pulled through the welding stationHeavy guide rollers ensure a tight fitup at the seamJoint tracking keeps the arc centered on the jointAvailable with ESAB subarc or MIG equipmentInfeed and outfeed conveyors are also available

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column and Boom station for welding dish ends in the chemical and petrochemical reactors market

The weld object, which is clamped to a positioner table is tilted during the weld operationIntegrated motions between the positioner and the boom-travelling welding head allow for constant welding speeds Station consists of NC controlled CaB 600 manipulator, 10x6 m (33x20 ft.) column and boom; A6 submerged arc welding heads, and 50 ton positioner

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Multi-head gantry stations for the energy and process market

Welding heavy winch drums intended for the ship and offshore industryThe circumferential weld procedure utlizes twin-wire flux cored wireThe shell of the drum is joined at various lengths using butt jointsSimultaneously welded with two welding headsDimension of object: Shell diameter max 3500 mm (137.8 in.), length of drum max 9300 mm (366.1 in.), wall thickness max 80 mm (3.1 in.)The station comprises the following: stationary gantry with two motorized carriages (each equipped with slide assemblies and special A6 welding heads), TV monitoring system for remote control from floor level and turning rolls for support and weld rotation

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column and Boom station for welding turbines in the hydropower energy market

CNC-controlled welding manipulator with six programmable axes (teach in)Butt joining of the blades to the shaft of the turbine rotorThe complex 4 m (157.5 in.) longitudinal preparation is curved into three dimensionsThe process is twin-wire SAWThe working range of the manipulators is 2x4.3x2 m (78.7x1693x78.7 in.) [HxLxW]The three remaining axes are integrated in the customized welding head

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Boiler Manufacturing automationESAB offers a complete line of boiler equipment from tube-fin prefab machines, fin-bar and tube-to-tube machines, to complete membrane wall panel welding and finishingMembrane welders can be moveable gantry or stationary pull-through systemsMultiple head A6 subarc welding is normally used

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Hybrid Laser Welding

ESAB offers state-of-the art Hybrid Laser Welding (HLAW) systems for high production of structural beam, pipe, vessel and panel applicationsComplimented by real-time, closed-loop process controls and automated quality assurance systemsTechnology is capable of achieving unprecedented performance in welding thick materials at very high speeds and in accomodating many types of fit variation commonly found in steel fabricationResults include improved welding performance, quality and reduced downstream costs due to distortionHLAW combines the best attributes of laser welding with those of conventional MIG welding

laser:Deep weld penetrationVery low heat inputSmall heat affected zones (HAZ)

MiG:Wide tolerance of joint gaps, surfaces and impuritiesGap filling and contouringControl of weld metallurgySlows cooling rate to prevent brittleness

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Contact ESAB for more information.

Fully automated longitudinal and circumferential seam weldingFeatures: automatic bead placement and uniform fill functionsIdeal for continuous mass production of products, such as heavy wall, offshore structural pipes

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FANG Narrow Gap Welding Sales Literature .................XA00055820

FANG Narrow Gap Welding System

Contact ESAB for more information

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HNG Narrow Gap Welding System

Contact ESAB for more information.

HNG Narrow Gap Welding System .................................XA00080520

Automatic welding process based on two runs-per-layer technologyEquipment available for both single wire (HNG-S) and tandem wire (HNG-T) applications Operate with joint gaps ranging from 18-24 mm (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 eliminatedProduces a perfect seam shape and surface finish (smooth blending with side walls and excellent self-releasing action)Improved weld metal and heat-affected zone toughness Can be integrated with ESAB’s column and boom systems and turning roll unitsAchieve precise and accurate bead placement with two-axis joint tracking systemSystem includes all required hardware, software, and programming information for automatic joint tracking and bead placement

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Technical DataWire dimension, mm (in.) 3-4 (1/8-5/32)Wire feed motor, A6-VEC 312:1Wire feed speed, m/min (ipm) 4 (157)Welding current, A Max. 1x800/2x800Beads per layer 2Electrode angular setting Max. +/- 3.5o

Flux hopper capacity, L (gal.) 9.5 (2.5)Air consumption, Nm3/min 0.35 af 6 Kp/cm3

Working range - slide assembly Horizontal, mm (in.) 300 (12)Vertical, mm (in.) 420 (16.5)

Weight, Kg (lbs.) HNG-S 140 (309)HNG-T 165 (364)

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ESAB Retrofit

ESAB’s service group can upgrade any brand of existing equipment to virtually new condition, with the latest process equipment and accessoriesWeld Process: add the versatile A2-A6 PEH process controller with DC, AC or tandem upgrade to improve weld quality, speed and operator convenienceMulti-axis Control: the A2-A6 PEH process controller includes a third axis drive used to control travel speed, allowing the operator to program weld sequences with volts, amps/wfs as well as travel speedThe controller will drive an ESAB VEC travel motor, suitable for boom or carriageA very economical system for column and boom manipulator retrofits because it eliminates the need for an extra drive for the boomAlternately, a separate analog interface board can enable the weld controller to interface with most typical drives used on turning rolls; postionersAccessories include seam trackers, flux recovery systems, wire handling equipment, strip cladding equipment - all can be added to existing equipmentESAB works with many OEMs for equipment - specify the ESAB process system and accessories and get the advantage of ESAB performance from your existing supplier of machinery

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ESAB Retrofit Sales Brochure ........................................XA00130220

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Friction Stir Welding (FSW)

Friction Stir Welding Informational Booklet ..................XA00123720

• FSW is ideal for joining straight profiles and flat plates from 1.2 to 30 mm (0.045-1.18 in.)

Butt, lap and corner joints can be weldedRound and circular welds can be welded with multiaxis machines

• Metals that can be welded include aluminum, copper and magnesium

Can also weld dissimilar alloys and dissimilar materials such as copper to aluminum, magnesium to aluminum

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

applications:Aluminum production of large extrusions, large panels, girders and trusses, such as used in fast 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 components

• Leisure vehicle aluminum frames and components• Improvement of material in high stress areas, such as edges on diesel pistons• Production of panels with stiffeners in 5000-series aluminum• Joining of dissimilar alloys and metals, such as copper to aluminum

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FsW processFriction Stir Welding (FSW) is based on the principal of obtaining a sufficiently high temperature and pressure to join two components together by using a rotating tool, which under high pressure, moves along the joint and thereby creates a weld.

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Friction Stir Welding Systems

Legio FSW System Sales Literature ............................... XA00117820SuperStir FSW System Sales Literature.........................XA00098320

legiotM Friction stir Welding systemThe modular system makes it possible to assemble welding stations to suit the most varied Friction Stir Welding applicationsThe LEGIOTM system consists of five basic designsin a series of seven sizes, covering a welding depth of 1.2 mm (.045 in.) to 60 mm (2.4 in.)These basic types can be supplemented with different types of equipment to suit the most varied production needs with maximum flexibility to any production lineThe versatile Legio family includes linear motion with single or dual (over/under) heads, with or without tablesDual axis(x – y) model is available with or without tableTables include a hole pattern for attaching fixturesLegio includes the ESAB HMI control specifically designed for Friction Stir Welding - a closed loop welding control, including the ability to control the Z axis either by pressure or position PC network connections and data transfer options are available

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superstirtM Friction stir Welding systemThe ESAB SuperStirTM program includes avariety of machines developed from astandarized ESAB SuperStirTM base unit and with working ranges of 0.5x1.5 m (19.7x59 in.) up to 10x20 m (33x66 ft.) within the sameconceptThe program includes customized models ofvarious designs for specific customer requirements in different production areasThese 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

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Mechanized Cutting Systems

Mechanized Cutting Systems Product Catalogue ....................F7594

oxy-fuel cuttingCommonly used for cutting steel with thickness greater than 25 mm (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 aluminum, stainless steel, brass, or copperIdeal for multi-torch applicationsOxy-beveling is available

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conventional plasmaFor cutting a variety of metals including carbon steel, stainless steel, aluminum, brass, and copperCuts much faster than oxy-fuel or waterjet cutting, particularly on thin materialsMay leave small bevel angle on cut faceCreates 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

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precision plasmaHighly 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 aluminum up to 25 mm (1 in.) thick

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m3 plasmaNew generation plasmaCombines conventional plasma, precision plasma and plasma marking in one torch

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ESAB offers the widest range of mechanized cutting products available for plate cutting applications, whether it is straight line or shape cutting. ESAB is the only cutting machine manufacturer to offer all 4 major cutting processes: laser, oxy-fuel, plasma and waterjet. There is a machine for virtually every requirement, from custom fabrication shops to large production operations. Although machines are standardized by model and type, each piece of equipment is generally customized to the individual customer’s specifications. No two 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, waterjet systems, laser systems, plate marking, routing and drilling. From blueprint to shipment, every piece of equipment undergoes rigid quality control procedures. Detailed examination of component parts, specification checks and operational testing result in equipment of the highest quality and expert craftsmanship. Because of this, product performance is unsurpassed.

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plasma Bevel processESAB’s plasma bevel system increases productivity by applying the benefits of high speed plasma cutting for plate edge preparationFully programmable to cut parts with straight and bevel, up to 30 mm (1.25 in.)Bevel from -45o to + 45o, multipass for Y bevel, change angles on the flyCut above or under waterCut quality maximized though CNC process and motion control with Vision PCThis tool is essential for high volume plate cutting such as windmill tower manufacturing

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Waterjet cuttingUses high velocity, high pressure stream of water and often combined with powdered abrasives, such as garnet, to increase cutting abilityCut any metal as well as paper, cardboard, glass, graphite, epoxy, fiberglass, and various other materialsNo heat involved in the cutting process - no heat affected zone, warping, cracking or need for secondary machining operationsAllows for precise contours, intricate shapes, sharp corners, and low bevel anglesMay combine with conventional plasma on a gantryWaterjet beveling is available

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

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columbus softwareSoftware developed and maintained by ESABComplete integration with ESAB controllersUpgrade your existing software Advanced capabilities include: CAD translation and drawing; automatic nesting; plate and data manager; estimation software; interactive CNC filesOn-line support and training

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Mechanized Cutting Systems, cont’d

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Mechanized Cutting Systems, cont’d

Standard Cutting System Selection GuideMax. Cutting Width Standard Torch Capacity Speed Range

Machine Model mm (in.) Oxy-Fuel Plasma mm/min (ipm) Photocell Tracing Numerical Control

Oxy-Fuel Gas & Plasma

Ultra-Line Straight Line 1 1 76.2 - 2794 (3 - 100) N/A N/AUltra-Graph 2794 (110) 1 1 101.6 - 3810 (4 - 150) N/A N/ASilhouette 500 609 (24) 2 1 50 - 3000 (2 - 118) HL-90 OptionalSilhouette 1000 1219 - 1828 (48-72) 4 1 50 - 3000 (2 - 118) HL-90 OptionalPiecemaker 2 1524 - 1828 (60-72) N/A 1 50 - 19050 (2 - 750) Optional StandardPiecemaker Plus 1524 - 2133 (60-84) 4 1 50 - 19050 (2 - 750) Optional StandardShadow 2 2438 - 3048 (96-120) 4 1 50 - 19050 (2 - 750) Optional StandardSabre SXE 2133 - 4724 (84-186)* 8 2 50 - 35560 (2 - 1400) Optional StandardAcer 1524 - 1828 (60-72) N/A 1 100 - 19050 (4 - 750) Optional StandardAcer 2 1828 - 2438 (72-96) N/A 2 50 - 35560 (2 - 1400) Optional StandardAvenger X 2438 - 5486 (96-216)* 12 4 50 - 35560 (2 - 1400) Optional StandardAvenger 2 4267 - 9321 (168-360+) 12 4 50 - 25400 (2 - 1000) Optional StandardAvenger 3 4267 - 9906 (168-384+) 12 4 50 - 25400 (2 - 1000) Optional StandardAvenger 3-Telerex 9000-14000 (348-540) 12 4 50 - 19050 (2 - 750) N/A StandardAvenger 4-Telerex 14000-26000 (540-1020) 6 4 50 - 19050 (2 - 750) N/A StandardWaterjet Cutting Systems Waterjet Plasma

Hydrocut PR 1219 - 1828 (48-72) 2 1 2.5 - 25400 (0.1 - 1000) Optional StandardHydrocut LR 2438 - 6096 (96-240)* 4 2 2.5 - 15240 (0.1 - 600) Optional StandardHydrocut HR 2438-3657 (96-144) 3 1 2.5 - 15240 (0.1 - 600) Optional Standard

Laser Cutting Systems Laser Plasma

Alpharex 3048-4877 (120-192) 1 - 50 - 25400 (2 - 1000) Optional Standard

Note: The specifications in the above chart are generalized * = Increments of 48 in. (609.6 mm) + = Increments of 39.6 in. (1005.8 mm)

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WelDinG FilleR Metals

MIG Welding

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

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Selected Product Listing*Product AWS Class Features &Typical Applications

Mild Steel

Spoolarc 65 ER70S-2 Copper-coated triple deoxidized carbon steel wireDesigned for welding over rust and mill scalePreferred wire for positional welding of small dia. pipe

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Spoolarc 29S ER70S-3 Copper-coated carbon steel wire for general purpose applications including heavy equipment, automotive applications and sheet metal

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Spoolarc 86 ER70S-6 Copper-coated carbon steel wire with higher tolerance to rust and mill scale than ER70S-3Often used for butt and fillet welding applicatoins including heavy equipment, structural, automotive and general carbon steel fabrication

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MIG-6 ER70S-6 General purpose copper-coated wireSimilar applications to Spoolarc 86

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OK Aristorod 12.50 ER70S-6 Non-copper-coated carbon steel wireASC (advanced surface characteristic) technology provides lower spatter levels, superior feedability and welding performance for robotic or automated welding

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Spoolarc 87HP ER70S-7 Copper-coated carbon steel wire with optimized manganese and silicon ratio to produce weld beads with excellent appearanceWidely used in robotic welding applications in the automotive industry

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•Spoolarc 83 ER80S-D2 Copper-coated low-alloy steel wire 1/2% Mo for higher weld deposit strength

Often used for high tensile tubing and pipe as well as earthmoving and construction equipment

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Stainless Steel

OK Autrod 308LSi, 309LSi, 316LSi Various Full range of stainless steel welding wires for any applicationAll OK Autrod stainless steel solid wires have a matte finish to improve feedability and provide a smooth stable arc

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Aluminum

OK Autrod 4043, 5356 ER4043, ER5356 Full range of aluminum alloys to meet any requirementAll ESAB wires are manufactured with a patented process to optimize feeding characteristics

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

process advantagesEasy to mechanize or adapt to a robotCost-effective method for process automation on thin materials Available in wide array of diameters and packages for any requirementHigh deposition efficiency (up to 98%)

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Cored Wire

processFlux Cored Arc Welding (FCAW) and Metal Cored Arc Welding (MCAW) are similar to MIG welding as far as operation and equipment are concernedDifference is that the wire is not solid, but consists of a metal sheath surrounding a flux coreWire begins as a flat metal strip, which is formed into a “U” shapeFlux and alloying materials are deposited into the “U”, which is then closed into a tube by a series of forming rolls

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Selected Product Listing*Product AWS Class Features & Typical Applications

Flux Cored Wires

Dual Sheild R-70 Ultra E70T-1/9 Flat and horizontal, low fuming wireSingle or multi-pass welding on carbon steelsUses CO2 gas only

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Dual Shield 7100 Ultra E71T-1/1M/9/9M All-position, low fuming wireSingle or multi-pass welding on carbon steelsUses CO2 or Ar/ CO2 gas mixtures

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Dual Shield II 70 Ultra E71T-1/1M/9/9M All-position, low fuming wireSingle or multi-pass welding on carbon steelsWide operating rangeUses CO2 or Ar/ CO2 gas mixtures

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Dual Shield II 70T12-H4 E71T-1MJ/12MJ-H4 All-position, low fuming wireProvides excellent low temperature toughness in as-welded and/or stress-relieved conditionDiffusable hydrogen levels < 4 mL/100 gWeld metal analysis similar to E7018-1 electrodeUses 75% Ar/25% CO2 gas only

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Mild Steel Metal Cored Wires

Coreweld 70 E70C-6M High deposition efficiency (up to 98%)Smaller diameters (up to 1/16 in.) can be used out of positionIdeal for robotic applicationsUses Ar/CO2 gas only

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Coreweld Ultra E70C-6M Similar to Coreweld 70, but with 40% lower fume and improved mechanical properties•Coreweld C-6 E70C-6M Similar to Coreweld Ultra but designed for high-speed robotic welding applications•Stainless Steel Cored Wires

Shield-Bright 308L, 309L, 316L Various Full line of stainless steel flux cored wires designed for flat and horizontal or all-position welding

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Arcaloy MC-308L, 309L, 316L Various Full line of stainless steel metal cored wires designed for high production automated and robotic applications

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FilleR Metals

process advantagesHigh deposition ratesExcellent weld bead appearance with little or no spatterDeep arc penetration when welding - allows tighter joint design, reducing quantity of filler metal needed to fill the jointWide selection of alloys availableHigh deposition efficiency (up to 98%)Metal cored wires have high current capacity and produce little or no slag - very high weld efficiency and deposition rates are possible

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FilleR Metals

Submerged Arc Welding

processArc is struck between the workpiece and the end of a consumable electrode, both of which are covered by a layer of granular flux, covering the arcSome of the flux melts to provide a protective slag cover over the weld pool; the remainder can be collected for re-usePrincipally carried out with fully automated equipmentFor increased productivity, cored wires or arrangements of multiple solid wires can be introducedBecause of its high metal deposition rate, it is particularly suited to long straight joints of good quality in the flat positionIt is widely used in the pressure vessel, chemical plant, heavy structural, repair and shipbuiling industries

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Common ESAB Wire/Flux Combinations*Wire Flux AWS Class Typical Applications

Spoolarc 29SOK Flux 429 F7A2-EM13K Carbon steels, multi-pass; good mechanical properties and weld performance for general fabrications•

OK Flux 10.71 F7A4-EM13KF6P4-EM13K

Carbon steels, multi-pass; for general fabricationExcellent as-welded or stress relieved mechanical properties, combined with good weld performance

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Spoolarc 81

OK Flux 231 F7A2-EM12K Carbon and low-alloy steels, single pass only; high tolerance to rust and mill scaleApplications include water heaters, rail cars and structural steel

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OK Flux 350 F7A2-EM12KCarbon steels, single pass only; high tolerance to rust and mill scaleSuitable for use with AC or DC power, single or multi-wireApplications include shipbuilding, thin wall pressure vessels and structural applications

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OK Flux 429 F7A2-EM12KF6P4-EM12K

Carbon and low alloy steels, multi-pass; moderate tolerance to rust and mill scaleApplications include bridge, ship, pressure vessel and general structural fabrication

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OK Flux 10.62 F7A6-EM12K

Carbon and low alloy steels, multi-pass; base plate must be free of rust and mill scaleFor use with AC or DC welding up to 1000 amps; exceptional impact toughness at low temperaturesIdeal for critical applications including pressure vessels, offshore construction and structures requiring good CTOD values

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OK Flux 10.71 F7A4-EM12KCarbon and low alloy steels, multi-pass; moderate tolerance to rust and mill scaleImproved mechanical properties compared to OK Flux 429Ideal for narrow gap applications, shipbuilding, pressure vessels and spiral/longitudinal welding of line pipe

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OK Flux 10.72 F7A8-EM12K

Carbon and low alloy steels, multi-passExcellent slag removal in narrow V-joints; excellent low temperature impact propertiesDesigned for high current-carrying capacity, DC or AC, with single or multi-wire systemsIdeal for windmill tower and pressure vessel construction

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Spoolarc 71OK Flux 10.71 F7A2-EM14K

F7P4-EM14KCarbon and low alloy steels, multi-passUsed for welding pressure vessels and other applications requiring good mechanical properties after stress relievingUse OK Flux 10.62 for improved impact toughness

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•OK Flux 10.62 F7A6-EM14KF7P6-EM14K

Spoolarc 75 OK Flux 429 or OK Flux 10.71 F8A4-ENi1K-Ni1 Weathering and carbon steels with up to 1% nickel, multi-pass

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OK Tubrod 14.00S OK Flux 10.71 F7A2-EC1 Carbon steels, multi-passMCAW wire provides higher travel speeds; up to 20% increase in deposition rate compared to solid wire

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OK Tubrod 15.00S OK Flux 10.71 F7A4-EC1Carbon steels, multi-passBasic metal cored wire provides higher travel speeds; up to 30% increase in deposition rate compared to solid wireExcellent mechanical properties and impact properties at -40oC (-40oF)

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OK Autrod 308L, 309L, 316L OK Flux 10.93 N/A Provides stainless steel deposit to match corresponding welding alloyBasic, non-alloying flux providing excellent weld properties and performance

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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 needed to fill the jointOperating factor can approach 100%No fumes or arc radiation

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Strip Cladding

Common ESAB Strip/Flux CombinationsConsumable %C %Si %Mn %Cr %Ni %Mo Other Ferrite

Typical all weld metal composition using OK Flux 10.05

An agglomerated flux for SAW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo austenitic satinless types of strip. Slag removal and overlapping with this flux is provides excellent results. Use with OK Band 308L, 309L, 316L. Basicity Index: 1.11. 308L overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7m/hOK Band 309L 0.020 0.4 1.9 23 13 - - -Weld composition 1st layer 0.027 0.7 1.1 19 11.3 - - FN 5OK Band 308L 0.022 0.3 1.7 19.6 10.1 - - -Weld composition 2nd layer 0.021 0.6 1.0 18.9 10.6 - - FN82. 316 overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7 m/hOK Band 309L 0.020 0.4 1.9 23 13 - - -Weld composition 1st layer 0.028 0.7 1.1 19 11 - - FN 5OK Band 316L 0.017 0.4 1.8 18.2 13.1 2.8 - -Weld composition 2nd layer 0.018 0.7 1.1 18 12.9 2.1 - FN 7Typical all weld metal composition using OK Flux 10.10

An agglomerated flux for ESW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo types, with or without Nb-stabilization. Weldability, bead appearance and slag removal with this flux provides excellent results. Use with OK Band 309L ESW, 309LMo ESW and 309LNb ESW. Basicity Index: 4.01. “308L” overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 1250A, 25V, 9m/hOK Band 309L ESW 0.015 0.2 1.8 21 11.4 - - -Weld composition 1st layer 0.023 0.45 1.2 18.5 10 - - FN 62. ”316” overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+m 1250A, 25V, 9m/hOK Band 309LMo ESW 0.015 0.2 1.8 20 13.7 2.7 - -Weld composition 1st layer 0.024 0.4 1.2 18 12 2.7 - FN 8

FilleR Metals

processSubmerged arc welding (SAW) or electroslag welding (ESW) typically used for cladding large areasBoth methods offer a high deposition rate, in terms of both kg/h and area coverage (m2/h), combined with low penetration and high deposit qualityStainless steel strip cladding is widely used in the production of components for the chemical, petrochemical and nuclear industries

process advantagesReduces requirement of expensive highly-alloyed base material, such as stainless steel or nickel-base alloysCan choose a wide variety of parent materials and consumablesHigh deposition processes with low dilution Allows for flexibility in the production of objects of various shapes and sizes

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

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

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FilleR Metals

Packaging Improves Productivity

ESAB offers many different package types to meet almost any requirementStandard packaging for ESAB solid and cored wires includes spools and coilsBulk packages for mechanized, robotic and high production welding include Marathon Pacs for mild steel, stainless steel and aluminum solid wiresMost cored wires are also available in Marathon PacsSubmerged arc wire is available in coils and bulk drumsSubmerged arc flux is available in standard plastic-lined bags and as a unique “BigBag” bulk package

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coilsStandard package for most solid and cored wires27.2-29.5 Kg (60-65 lbs.) of wire on a coil with 300 mm (12 in.) internal diameterCoil adaptor is required

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Jumbo coilsUnique bulk solution for SAW wires 90-100 Kg (100-220 lbs.) of wire on a large coil with 570 mm (22.5 in.) internal diameterOften used with column & boom systemsSpecial coil adapter is required

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payoff pacLarge diameter drum, most often used with SAW wiresPackage weights are typically 250-363 Kg (550-800 lbs.)Efficient solution for high productivity, stationary SAW welding stations

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Marathon pacBulk pack for 200-475 Kg (450-1050 lbs.) of solid or cored wireWire wound into the drum using special techniqueWire is straight and comes out of the gun without twisting or warping - ideal for robotic or mechanized welding stationsStopping for spool changes and maintenance are reduced by almost 95% for increased arc-on timeImproves weld quality with reduced repair and rejects resulting in less weld defectsOctogon drums are 100% recyclable

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BigBagUnique solution for bulk users of SAW welding flux500-1000 Kg (1100-2200 lbs.) per bagBag is made of layers of fabric, coated on the inside for moisture protectionDischarge spout in the bottom of the bag with an opening that can be easily opened and re-closed by a ropeFour strong straps for lifting by forklift or overhead crane

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esab global offices

North/south america asia/PacificARGENTIACONARCOBuenos AiresTel: +54 11 4 753 4039Fax: +54 11 4 753 6313

CHINAShanghai ESAB A/PShanghaiTel: +86 21 6539 7124Fax: +86 21 6543 6622

BRAZILESAB S.A.Contagem-MGTel: +55 31 3369 4333Fax: +55 31 3369 4440

INDIAESAB India Ltd.CalcuttaTel: +91 33 478 45 17Fax: +91 33 468 18 80

CANADAESAB Group Canada Inc.Mississauga, ONTel: 1 905 670 0220Fax: 1 905 670 4879

INDONESIAP.T. Esabindo PratamaJakartaTel: +62 21 460 01 88Fax: +62 21 461 29 29

MEXICOESAB Mexico S.A.MonterreyTel: +52 8 350 5959Fax: +52 8 350 7554

MALAYSIAESAB (Malaysia) Snd BhdSelangorTel: +60 3 703 36 15Fax: +60 3 703 35 52

UNITED STATES OF AMERICAESAB Welding & Cutting ProductsFlorence, SCTel: 1 843 669 4411Fax: 1 843 664 4458

SINGAPOREESAB Singapore Pte Ltd.SingaporeTel: +65 861 43 22Fax: +65 861 31 95

Representative offices

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

BULGARIAESAB Representative OfficeSofiaTel/Fax: +359 2 974 42 88

SOUTH KOREAESAB SeAH CorporationKyung-NamTel: +82 551 289 81 11Fax: +82 551 289 88 63

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UNITED ARAB EMIRATESESAB Middle EastDubaiTel: +971 4 338 88 29Fax: +971 4 338 87 29

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europeAUSTRIAESAB Ges.m.b.HVienna-LiesingTel: +43 1 888 25 11Fax: +43 1 888 25 11 85

NORwAYAS ESABLarvikTel: +47 33 12 10 00Fax: +47 33 11 52 03

BELGIUMS.A. ESAB N.V.BrusselsTel: +32 2 745 11 00Fax: +32 2 726 80 05

POLANDESAB Sp.z.o.o.WarszawTel: +48 22 813 99 63Fax: +48 22 813 98 81

CZECH REPUBLICESAB Vamberk s.r.o.PragueTel: +420 2 819 40 885Fax: +420 2 819 40 120

PORTUGALESAB LdaLisbonTel: +351 1 837 1527Fax: +351 1 859 1277

DENMARKAktieselskabet ESABCopenhagen-ValbyTel: +45 36 30 01 11Fax: +45 36 30 40 03

SLOVAKIAESAB Slovakia s.r.o.BratislavaTel: +421 7 44 88 24 26Fax: +421 7 44 88 87 41

FINLANDESAB OyHelsinkiTel: +358 9 547 761Fax: +358 9 547 77 71

SPAINESAB Iberica S.A.Alcobendas (Madrid)Tel: +34 91 623 11 00Fax: +34 91 661 51 83

FRANCEESAB France S.A.Cergy PontoiseTel: +33 1 30 75 55 00Fax: +33 1 30 75 55 24

SwEDENESAB Sverige ABGothenburgTel: +46 31 50 95 00Fax: +46 31 50 92 22

GERMANYESAB GmbhSolingenTel: +49 212 298 0Fax: +49 212 298 204

ESAB International ABGothenburgTel: +46 31 50 90 00Fax: +46 31 50 93 60

GREAT BRITAINESAB Group (UK) Ltd.Waltham CrossTel: +44 1992 76 85 15Fax: +44 1992 71 58 03

SwITZERLANDESAB AGDietikonTel: +41 1 741 25 25Fax: +41 1 740 30 55

HUNGARYESAB KftBudapestTel: +36 1 20 44 182Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.AMesero (Mi)Tel: +39 02 97 96 81Fax: +39 02 97 28 91 81

THE NETHERLANDSESAB Nederland B.V.UtrechtTel: +31 30 248 59 22Fax: +31 30 248 52 60

ESAB Welding & Cutting Products

In Canada In USA

Head Office:6010 Tomken RoadMississauga, Ontario L5T 1X9Phone: 877-935-3226, 905-670-0220Fax: 905-670-4879

25B de Lauzon Boucherville, Quèbec J4B 1E7Phone: 450-655-4318Fax: 450-449-6620

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Head Office:411 S. Ebenezer RoadFlorence, South Carolina 29501Phone: 843-669-4411Fax: 843-664-4258

801 Wilson AvenueHanover, Pennsylvania 17331-1058Phone: 717-637-8911Fax: 717-637-9859

In Mexico

ESAB MÉXICO, S.A. DE C.V.:Ave. Diego Diaz de Berlanga 130Apartado Postal 4259-FMonterrey, N.L., 54000MexicoPhone: 52-81-8305-3700Fax: 52-81-8350-5920Fax: (Sales) 52-81-8350-7554

Call

1-877-935-3226or visit

www.esabna.comFor the latest product information, special announcements, Material Safety Data Sheets (MSDS) and

company news

898C160 09/06 Printed in Canada

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