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Welding Automation Submerged Arc, TIG, MIG/MAG COMPLETE SOLUTIONS IN WELDING AND CUTTING FROM ESAB IA00900011 World leader in welding and cutting technology and systems. Since 1904, ESAB has been a pioneer in the welding and cutting business. By continuously improving and developing our products and methods, we meet the challenges of technological advance in every sector we operate in. Our focus on quality issues has always been strong. Quality is an ongoing process that is at the heart of all our production processes and facilities worldwide. With world leadership comes worldwide applications experience and expertise. Multinational manufacturing of welding consumables and equipment brings ESAB quality and innovation closer to our customers. ESAB customers enjoy full and personal access to an unrivalled resource of technical and applications knowledge, service and support. With local representation all over the world, together with a network of independent distributors, ESAB brings practical expertise and solutions to challenges involving materials, welding, cutting and overall productivity at local level. Wherever in the world quality and productivity in welding and cutting counts, ESAB is there to set the standard. Welding Automation The 21st Century has brought many new challenges to the metal fabrication industry. Metal fabricators must meet the demand for increased quality while providing their customers with an overall lower cost. Productivity is challenged by the shortage of skilled workers and the added health and safety concerns for these workers. Profitability is under continued pressure from intense global competition. As a result, manufacturers are required to utilize new fabrication techniques to build increasingly complex designs and structures. ESAB is committed to providing the necessary solutions to keep you competitive. Whether your metal fabrication project requires simple components such as tractors or requires large turn-key systems and production lines, ESAB offers a full range of automation products to meet every need. At ESAB, we consistently offer the best welding solutions to meet the ever changing challenges of the metal fabrication industry. Quality Welds- Every Time ESAB offers the widest range of filler metals in the world. Our goal is to provide the most productive filler metal for your job. ESAB will meet the needs of any welding process and application. Total System Responsibility Because we build the entire system, we can integrate the welding process, arc path, and material handling. An integrated design simplifies the equipment, improves reliability, and ensures unsurpassed performance. Operator appeal is maximized through simple, straightforward control panels. Because ESAB provides Total System Responsibility, including the filler metals and technical service, we ensure your project is successful. TABLE OF CONTENTS Tractors Railtrac 1000 ............................................................................................................. Miggytrac 1001-2000 ................................................................................................ Miggytrac 3000 ......................................................................................................... A2 Multitrac with PEH Process Controller ................................................................. A2 Multitrac – Accessories and Options ................................................................... A2 Tripletrac .............................................................................................................. A6 Mastertrac ............................................................................................................ A6 DK ........................................................................................................................ Frametrack ................................................................................................................ A2/A6 Wear parts ...................................................................................................... Pages 4-6 7 8 9 10 11 12 13 14 15-18 Controllers and Power Sources PEH Process Controller ............................................................................................. LAF DC Power Sources............................................................................................. TAF AC Power Sources ............................................................................................. 19 20 21 Weld Heads A2S Mini Master ........................................................................................................ A2 Component System Modularization .................................................................... A6S Arc Master ......................................................................................................... A6 Component System Modularization .................................................................... A6S Tandem .............................................................................................................. A6S Compact ............................................................................................................ A6S SAW Strip Cladding Head ................................................................................. A6S ESW Strip Cladding Head ................................................................................. MHW Automatic Head for Manhole Welding ............................................................ 22 23 24 25 26-27 28 29 29 30 Accessory Components A6 Synergic Cold Wire .............................................................................................. A6B Beam Carriage ................................................................................................... Motorized Slides........................................................................................................ PAK and GMD - Joint Tracking Systems................................................................... OPC – Flux Recovery Systems ................................................................................. FFRS – Flux Feed Recovery Systems ....................................................................... CRE – Air Drying Equipment ..................................................................................... Camera Systems ....................................................................................................... Weldoc WMS4000 Software ..................................................................................... 31 32 33 34-35 36-37 38-39 40 41 42 Handling Equipment TA Turning Rolls ......................................................................................................... TNA Turning Rolls ...................................................................................................... TXA Turning Rolls ...................................................................................................... AHMA Positioners ..................................................................................................... SKA Positioners......................................................................................................... SHA Positioners ........................................................................................................ FA Positioners ........................................................................................................... CRA Positioners ........................................................................................................ 2Head anf Tailstock ..................................................................................................... 43 44 45 46 47 48 49 50 51-52 TABLE OF CONTENTS Mechanized TIG Aristo MechTig - Aristo Mech Control ....................................................................... A21 – Weld Heads PRB, PRC, PRD, POC, PRH ....................................................... A25 – Components System....................................................................................... MEI 21/10 – Wire Feeder ........................................................................................... G-Tech Tungsten Grinder .......................................................................................... Pages 53-54 55-60 61 62 63 Robotics Aristo Robot Package ............................................................................................... 64-65 Applied Automation Mechtrac ................................................................................................................... Manipulators - CaB S, M, C versions ........................................................................ External / Internal Seamers ....................................................................................... Circotech ................................................................................................................... Rototech 80 ............................................................................................................... 66 67-71 72-73 74 75 Special Application Products Wind Energy Industry ................................................................................................ Beam Welding Systems ............................................................................................ Welding Gantries ....................................................................................................... Shipyard Applications ............................................................................................... Custom Welding Solutions ........................................................................................ Friction Stir Welding .................................................................................................. Narrow Gap ............................................................................................................... 76-77 78-79 80 81 82-83 84-85 86-87 Mechanized Cutting Systems Cutting Processes ..................................................................................................... Esab Precision Plasma .............................................................................................. Numeric Controls – Offline Programming.................................................................. Ultrarex UXC/UXL-P – E-Vent ................................................................................... Combirex CXL-P – Eagle ........................................................................................... Suprarex SXE-P Series.............................................................................................. Numorex NXB – Telerex TXB – Alpharex AXD ........................................................... 88-89 90 91 92 93 94 95 3 TRACTORS Railtrac 1000 A unique, flexible, multi-purpose system for welding and cutting • Create suitable solutions for most applications • Consists of aluminum and steel parts to withstand harsh environments • Welding possibilities include horizontal to horizontal and vertical (up only) • Practical accessories available • New joint system allows for both stiff and flexible rail applications • Straightforward and well designed programming unit with up to 5 different programs • Standard software offers programmable interval welding and backfill function • Remote control allows functionality without lifting welding visor • Buttons featured on remote control include: start and stop, shift program, weaving width, zero line displacement, and many more • Adjust the welding current and voltage during welding with only two potentiometers on the remote control (when using ESAB equipment) • Remote control only available on FW1000 and FWR1000 models Technical Data Power supply (VAC/VDC) Power consumption (Max) (W) Weight excl. rail, Kg Measurements, LxWxH, mm Rail measurements-flexi rail, mm Stiffener bar, mm Min bend diameter externally, mm Slide for height adjustment, mm Mechanical lateral adjustment, mm Welding speed, cm/min Quick transport, cm/min Preheating time (s) Interval welding, cm Crater-filling time (s) “Backfill”, mm Weaving speed, mm/s Weaving width, mm Electrical 0-line displacement, mm Pause time at outer edge, (s) Weaving pattern (No.) Number of programs Temp. machine and magnets (°C) Temp. vacuum attachment (°C) Safety class (DIN 40050) 4 Railtrac F1000 Flexi 36-46/40-60 30 6 170x400x190 60x5 40x10 3000 ± 22 10-150 150 0.0-9.9 1-99 0.0-9.9 0-99 - 5 0-70 0-90 IP 23 Railtrac FW1000(L) Flexi Weaver 36-46/40-60 80 7 170x350x190 60x5 40x10 3000 ± 22 ± 35 10-150 150 0.3 1-99 0.0-9.9 0-99 6-60 1-30 ± 12.5 0.0-9.9 3 5 0-70 0-90 IP 23 Railtrac FR1000 Flexi Return 36-46/40-60 30 6 170x400x190 60x5 40x10 3000 ± 22 10-150 150 0.0-9.9 1-99 0.0-9.9 0-99 5 0-70 0-90 IP 23 Railtrac FWR1000 Flexi Weaver Return 36-46/40-60 80 7 170x350x190 60x5 40x10 3000 ± 22 ± 35 10-150 150 0.3 1-99 0.0-9.9 0-99 6-60 1-30 ± 12.5 0.0-9.9 3 5 0-70 0-90 IP 23 Instruction Manual Railtrac 1000 (F, FR), order number ....................................0777167001 Instruction Manual Railtrac 1000 (FW, FWR), order number .............................0777168001 Instruction Manual Railtrac 1000 (BV, BVR)), order number ..............................0777169001 Sales Literature Railtrac 1000 (F, FR), order number ........................................ XA00086720 Sales Literature Railtrac 1000 (FW, FWR), order number ................................. XA00086720 Sales Literature Railtrac 1000 (BV, BVR), order number ................................... XA00086720 TRACTORS Railtrac 1000 System Configuration Railtrac F1000 Flexi Railtrac FR1000 Flexi-Return • • • • • Flexible combi-rail Suitable for both inside and outside welding and cutting Cut along curved and straight surfaces Suitable for thermal cutting • • Flexible combi-rail and facilities for movable parts Start and stop for automatic return of length Ideal for use in fixed installations or repetitive welding Railtrac FW1000 Flexi-Weaver Railtrac FWR1000 Flexi-Weaver Return • • • • • • Flexible combi-rail Equipped with weaver- use for different patterns Equipped with a user friendly remote control unit Equipped with weaving unit Adjustable start, stop and return facilities Unique design remote control unit with advanced solutions for a number of applications 5 TRACTORS Railtrac 1000 System Configuration Ordering Information Railtrac F1000 Flexi .............................................. 0398 146 002 Railtrac FW1000 Flexi-Weaver............................. 0398 146 012 Railtrac FR1000 Flexi-Return .............................. 0398 146 003 Railtrac FWR1000 Flexi-Weaver Return ............. 0398 146 013 Options and Accessories Basic Equipment (Standard) Weaving unit Control unit Remote control Universal torch holder with slide Automatic start and stop function Rails and attachments (Components) Flexible alu-rail, 2.5 m Flexible alu-rail, 2.5 m, 8 magnets Flexible alu-rail, 2.5 m, 4 vac. Attachm. Stiffener bar, 2.5 m Magnetic attachment, at least 8/2.5 m *(1) Vacuum attachment, at least 4/2.5 m Screw attachment for stiffened rail Accessories Torch holder PSF 400/500 Adapter for a majority of existing attachments to the stiffened rail Universal pivoted torch holder Attachment for IMP cutting torch Torch and attachment Tilt unit for weaving unit Turning unit for weaving unit “Floating” head IMP cutting torch Transport and storage box *(1) 2 pcs in each bag 6 Railtrac F1000 Flexi Railtrac FW1000 (L) Flexi Weaver * * * * * * * * * * * * Railtrac FR1000 Flexi Return Railtrac FWR1000 Flexi Weaver Return Ordering Information * * * * * * * * * * * * * * * * * * * * * * * * * * * * 0398 146 115 0398 146 112 0398 146 113 0398 146 116 0398 146 100 0398 146 104 0398 146 114 * * * * 0398 145 101 * * * * 0398 146 106 * * * * * * * * * * * * * * * * * * * * * * 0398 145 104 0398 145 260 0398 145 215 0398 145 200 0398 145 201 0398 145 211 0398 145 250 0398 145 199 * * * * * * * * TRACTORS Miggytrac 1001-2000 The perfect complement to your MIG power source • Small and compact • Accomodates any standard welding torch • Four-wheel drive system ensures even and stable movement • Drives itself against work pieces • Additional functions include setting travel speed, magnet on/off for free welding and welding on/off • Equipped with two manual slides for fine corrections of torch position • Includes rotating slide which allows precise torch angle manipulation • Continuous and interval welding (Miggytrac 2000 only Miggytrac 1001 Miggytrac 2000 Ordering Information Miggytrac 1001, 42 VAC ………............................. 0457 357 881 Miggytrac 2000, 42 VAC ………............................. 0457 358 880 Welding screen .......................................................0457 463 880 Options and Accessories (mm) Miggytrac 1001 Control Cable ESAB, 5mt ....................................... 0457 360 880 (12 pin male- 23 pin male Burndy style). For all MEK (also requires 457 462 880), ESABFeed, and ARISTOFeed feeders (also requires 458 757 881) ESAB MEK Wire Feeder Adaptor kit .......................0457 462 880 (Required for connection of Miggytrac to MEK feeders) ESAB ARISTOFeed ...................................................0459 491 911 (Required for connection of Miggytrac to ARISTOFeed) Universal Control Cable, 5mt ..................................0457 360 881 (12 pin male Burndy style-open end). Requires user-supplied plug to connect cable to OEM feeders Transformer kit, 220-42 VAC ....................................0457 467 880 Universal kit used to adapt 115 VAC wire feeders to Miggytrac Technical Data Control voltage Power Welding speed, mm/min Dimensions (LxWxH), mm Weight, kg Adjustment of slide, mm Connection Remote control outlet Welded interval, mm Non-welded interval, mm Backfill, sec Crater-fill time , sec Fast positioning speed, mm/min (mm) Miggytrac 2000 1001 2000 36-46 V AC 20 W 150-1200 266x257x267 7 ± 20 Burndy, 12 pins Volt and Ampere (wire feed speed) no no no no no 36-46 V AC 40 W 150-1500 330x260x360 9,5 ± 17 Burndy, 12 pins Volt and Ampere (wire feed speed) 10-990 10-990 0,3 0-9,9 2500 Instruction Manual Miggytrac 1001,order number .............................................0457572001 Instruction Manual Miggytrac 2000,order number .............................................0449310001 Sales literature Miggytrac 1001, order number ................................................. XA00086520 Sales literature Miggytrac 2000, order number ................................................. XA00104720 7 TRACTORS Miggytrac 3000 The most versatile and compact solution for fillet semiautomatic welding • Small, lightweight and complete with on-board wire feeder and water cooling • Four-wheel drive system ensures even and stable movement • Control panel for carriage movement, wire-feeder, continuous or interval welding • Programmable functions for Crater-fill / Backfill • For wire spools up to 20 kg • Adjustable pre and post gas Ordering Information Miggytrac 3000, 42 VAC ..........................................0457 359 880 Options and Accessories Contact tip, 1 mm CO2 .......................................... 0468 502 005 Contact tip, 1,2 mm CO2 ....................................... 0468 502 007 Contact tip, 1,4 mm CO2 ....................................... 0468 502 008 Cooled gas nozzle ................................................... 0449 903 101 15 m cable for Origo™Mig - Aristo™Mig .............. 0469 836 887 Steel wheels (4 pieces) ............................................0457 357 081 Technical Data Control voltage Power Welding speed, mm/min Dimensions (LxWxH), mm Weight, kg Adjustment of slide, mm Connection Remote control outlet Welded interval, mm Non-welded interval, mm Backfill, mm Crater-fill time, sec Wire feed speed, m/min Gas pre-flow / post-flow, sec Fast positioning speed, mm/min 8 (mm) 3000 36-46 V AC 80 W 150-1500 370x400-530x520 17 ± 17 Burndy, 23 pins Volt e Ampere (wire feed speed) 10-990 10-990 0-99 0-99 2-25 0-99 2500 Instruction Manual Miggytrac 3000,order number .............................................0449453001 Sales literature Miggytrac 3000, order number ................................................. XA00123620