Automated welding

solutions from ESAB

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

Welding Automation
Equipment
WELDING | CUTTING | FILLER METALS

ESAB Welding & cutting products

global solutions for local customers - everywhere

ESAB is the preferred partner throughout the world
for professional customers requiring welding and cutting
solutions. We apply the highest standards of honesty,
ethics and integrity in all aspects of our business. We
constantly seek to improve our service to customers
around the world and we set the highest product and
process quality standards in our industry.

Through teamwork, we involve all of our employees

in striving toward providing our customers with the most
cost-effective solutions for their welding and cutting
applications. Through technological leadership, the
most reliable products and deliveries, and continuous
improvement of our processes, we will strive to exceed
customer expectations.
The ESAB brand is synonymous with world leading
expertise in the following key areas:

Manual welding and cutting equipment

Welding consumables
Welding automation
Mechanized cutting systems

Continuous development of methods, materials

and know-how is being directed to meet the challenges
posed by the diversity of our customers. ESAB is
organized to deliver efficient, high-productivity solutions
to meet industry requirements in a manner that exceeds
their expectations. Our customers our found in the
following industries:

Automotive
General fabrication & civil construction
Pipelines
Pipemills
Power generation
Process industry
Repair & maintenance
Shipbuilding & offshore
Transport & mobile machinery

esab welding & cutting products

ESAB 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; profitability is challenged by the pressure from intense global
competition. As a result, manufacturers are required to utilize new fabrication techniques to build increasingly
complex designs and structures.
Welding automation meets some of these
challenges with higher quality, capacity and, of
course, much higher productivity than manual
welding applications. At ESAB, we develop and
manufacture a wide range of mechanized and
automated welding products to create the special
solution you might need.
Whether your metal fabrication project requires
simple components such as tractors or requires
large turn-key system and production lines, we offer
a full range of automation products to meet every
need including the widest range of filler metals in
the world.

You can also rely on ESAB for total system

responsibility. Because we manufacture our own
equipment, we can integrate the welding process,
arc path and material handling. An integrated design
simplifies the equipment, improves reliability and
ensures unsurpassed performance.

Used as a guide, this catalogue can prove to be
a useful tool in determining the right solution for your
application. We encourage you to consult an ESAB
Representative for more detail regarding processes,
applications and customized solutions.

Call us today!
1-877-935-3226

table of contents

Tractors

Railtrac 1000................................................................................................................................................ 4-6

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

Controllers and Power Sources

A2-A6 PEH Process Controller..................................................................................................................... 20

A2 PEI Process Controller............................................................................................................................. 21
LAF DC Power Sources................................................................................................................................ 22
TAF AC Power Sources................................................................................................................................. 23

Weld Heads

A2S Mini Master............................................................................................................................................ 24

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

Accessory Components

A6 Synergic Cold Wire.................................................................................................................................. 33

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

Handling Equipment

5-500 TA Self-Aligning Turning Rolls............................................................................................................. 45

3-500 TNA Conventional Turning Rolls......................................................................................................... 46

table of contents

Handling Equipment, contd

TXA Scissor-Type Turning Rolls................................................................................................................. 47

250-35000 AHMA Positioners....................................................................................................................... 48
75-150 SK Positioners................................................................................................................................... 49
750-10000 SHA Positioners.......................................................................................................................... 50
750-50000 VA Positioners............................................................................................................................. 51
25000-50000 CRA Positioners...................................................................................................................... 52
750-50000 Head & Tailstock Positioners.................................................................................................. 53-54

Mechanized TIG

Prowelder 160/250/320 Mechanized TIG Welding Machines........................................................................ 55

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

Robotics

AristoMig Process Packages for Mechanized MIG Welding......................................................................... 65

Standard AristoMig Robot Package Configuration........................................................................................ 66

Applied Automation

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

Special Application Products

Windmill Tower Manufacturing.................................................................................................................. 76-78

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

Welding Filler Metals

MIG Welding.................................................................................................................................................. 93
Cored Wire.................................................................................................................................................... 94
Submerged Arc Welding................................................................................................................................ 95
Strip Cladding................................................................................................................................................ 96
Packaging...................................................................................................................................................... 97

tractors

Railtrac 1000 Multi-Purpose System for Welding & Cutting

Ideal for a wide variety automated MIG 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,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

Railtrac F1000
Flexi

Railtrac FW1000(L)
Flexi-Weaver

Railtrac FR1000
Flexi-Return

Railtrac FWR1000
Flexi-Weaver-Return

Power Supply, VAC/VDC

Max. Power Consumption, W
Weight, excluding rails, Kg (lbs.)
Dimensions, LxWxH, mm (in.)
Flexi Rail Dimensions, LxW, mm (in.)
Stiffener Bar , LxW, mm (in.)
Min. Bend Diameter, external, mm (in.)
Slide for Height Adjustment, mm (in.)
Mechanical Lateral Adjustment, mm (in.)
Welding Speed, cm/min (ipm)
Quick Transport, cm/min (ipm)
Preheating Time, s
Interval Welding, cm (in.)
Crater-filling Time, s
Backfill, mm (in)
Weaving Speed, mm/s (ips)
Weaving Width, mm (in.)
Electrical 0-Line Displacement, mm (in.)
Pause Time at Outer Edge, s
Weaving Pattern, No.
No. of Programs
Temp. Machine and Magnets, oC
Temp. Vacuum Attachment, oC
Safety Class (DIN 40050)

36-46-/40-60
30
6 (13)
170x400x190 (6.7x15.8x7.5)
60x5 (2.4x0.2)
40x10 (1.6x0.4)
3000 (118)
+/- 22 (+/- 0.87)
10-150 (3.9-59)
150 (59)
0.0-9.9
1-99 (0.4-39)
0.0-9.9
0-99 (0-3.9)
5
0-70
0-90
IP 23

36-46/40-60
80
7 (15)
170x350x190 (6.7x13.8x7.5)
60x5 (2.4x0.2)
40x10 (1.6x0.4)
3000 (118)
+/- 22 (+/- 0.87)
+/- 35 (+/- 1.4)
10-150 (3.9-59)
150 (59)
0.3
1-99 (0.4-39)
0.0-9.9
0-99 (0-3.9)
6-60 (0.2-2.4)
1-30 (0.04-1.2)
+/- 12.5 (+/- 0.5)
0.0-9.9
3
5
0-70
0-90
IP 23

36-46-/40-60
30
6 (13)
170x400x190 (6.7x15.8x7.5)
60x5 (2.4x0.2)
40x10 (1.6x0.4)
3000 (118)
+/- 22 (+/- 0.87)
10-150 (3.9-59)
150 (59)
0.0-9.9
1-99 (0.4-39)
0.0-9.9
0-99 (0-3.9)
5
0-70
0-90
IP 23

36-46/40-60
80
7 (15)
170x350x190 (6.7x13.8x7.5)
60x5 (2.4x0.2)
40x10 (1.6x0.4)
3000 (118)
+/- 22 (+/- 0.87)
+/- 35 (+/- 1.4)
10-150 (3.9-59)
150 (59)
0.3
1-99 (0.4-39)
0.0-9.9
0-99 (0-3.9)
6-60 (0.2-2.4)
1-30 (0.04-1.2)
+/- 12.5 (+/- 0.5)
0.0-9.9
3
5
0-70
0-90
IP 23

Railtrac 1000 F, FR, FW, FWR Sales Literature...............XA00086720

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

tractors

Railtrac 1000 System Configuration

Railtrac F1000 Flexi

Railtrac FR1000 Flexi-Return

Railtrac FW1000 Flexi-Weaver

Railtrac FWR1000 Flexi-Weaver 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
Equipped with weaving unit
Equipped with a user friendly remote control unit

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

Equipped with weaving unit

Adjustable start, stop and return facilities
Unique design remote control unit with advanced
solutions for a number of applications

tractors

Railtrac 1000, contd

Ordering Information

Options & Accessories

Railtrac F1000 Flexi................................................................ 398 146 002

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

Standard
Weaving Unit*
Control Unit
Remote Control*
Universal Torch Holder with Slide
Automatic start and stop function**
Components
Flexible alu-rail, 2.5 m (8).............................................. 398 146 115
Flexible alu-rail, 2.5 m (8), 8 magnets.......................... 398 146 112
Flexible alu-rail, 2.5 m (8), 4 VAC. attachment............ 398 146 113
Stiffener Bar, 2.5 m (8).................................................. 398 146 116
Magnetic attachment, at least 8/2.5 m* (8) (1).............398 146 100
Vacuum attachment, at least 4/2.5 m (8).....................398 146 104
Screw attachment for stiffened rail.............................. 398 146 114
Accessories
Torch holder PSF 400/500..............................................398 145 101
Adapter for stiffened rail attachments......................................398 146 106
Universal pivoted torch holder.....................................398 145 104
Attachment for IMP cutting torch..................................398 145 260
Torch angle attachment.................................................398 145 215
Tilt unit for weaving unit*...............................................398 145 200
Turning unit for weaving unit*.......................................398 145 201
Floating head............................................................... 398 145 211
IMP cutting torch............................................................398 145 250
Transport and storage box............................................398 145 199
Control cable, 5 m (16.4)...............................................457 360 880
AristoFeed wire feeder adaptor kit...............................458 757 881
Universal control cable, 5 m (16.4)..............................457 360 881
Transformer kit, 115-42 VAC............................................... 359C304
* FW1000 & FWR1000 only ** FR1000 & FWR1000 only

Tractors

Miggytrac 1001

Small, compact, motorized tractor

Quickly attaches to ESAB welding torch
Even, stable movement guaranteed
Decide travel direction with the remote control
Start/stop function from the remote control panel
Travel speed settings of 150-1200 mm/min (6-47
ipm), wire feed speed, and voltage all functions of
the remote control
Significantly increases welding speed, especially
when using cored wire

Ordering Information
Miggytrac 1001...............................................................457 357 881

Options & Accessories

Welding Screen...............................................................457 463 880
ESAB Control Cable, 5 m (16.4 ft).................................457 360 880
(12 pin male- 23 pin male Burndy style) ESABFeed, and AristoFeed
feeders

Technical Data
Control voltage, VAC
Power, W
Welding Speed, cm/min (ipm)
Remote control outlet
Connection
Dimensions, LxWxH, mm (in.)
Weight, Kg (lbs.)

36-46
20
15-120 (6-47)
Volt and Ampere (Wire Feed Speed)
Burndy, 12 pins
266x257x267 (10.5x10x10.5)
7 (15.5)

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 feeders

Transformer Kit, 115-42 VAC.............................................. 359C304

Universal kit used to adapt 115 VAC wire feeders to Miggytrac

(mm)

Miggyrtrac 1001 Sales Literature.....................................XA00126320

Miggytrac 1001 Instruction Manual..................................449 476 001

tractors

Miggytrac 2000

Ideal for long welds eliminating stressful welding

positions for the welder
Magnet helps to hold the tractor in the correct position
on the workpiece even if the workpiece is bent or
angled
Guide wheels adjust to allow the unit to drive itself
against the workpiece
Program for intermittent welding
Set length of weld and distance between welds from
1-99 cm (0.4-39 in.)
High-speed travel between welds - 250 cm/min (98
ipm) - to increase efficiency
Backfill function for crater filling at the end of the weld

Ordering Information
Miggtrac 2000......................................................................... 457 358 880

Options & Accessories

Welding Screen....................................................................... 457 463 881
ESAB 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 feeders

Technical Data
Control voltage, VAC
Power, W
Welding Speed, cm/min (ipm)
Fast Travel Speed, cm/min (in/min)
Programmable Interval Welding, cm (in.)
Adjustment of Slide, mm (in.)
Remote Control Outlet
Connection
Crater Fill Time, s
Backfill, cm (in.)
Dimensions, LxWxH, mm (in.)
Weight, Kg (lbs.)

36-46
40
15-150 (6-47)
250 (98.4))
1-99 (0.4-37)
+/- 17 (+/-0.67)
Volt and Ampere (Wire Feed Speed)
Burndy, 12 pins
0-9.9
0-9.9 (0-4)
330x260x360 (13x10x14)
9.5 (21)

Transformer Kit, 115-42 VAC...................................................... 359C304

Universal kit used to adapt 115 VAC wire feeders to Miggytrac

(mm)

Miggytrac 2000 Sales Literature......................................XA00104720

Miggytrac 2000 Instruction Manual..................................449 310 001

tractors

Miggytrac 3000

Small, compact, motorized tractor with integrated

wire feed and water-cooled welding torch designed for
horizontal mechanized MIG welding of plates and beams
Four-wheel drive carriage
Carriage can travel diagonally towards the flange
or stiffener to be welded
Program for intermittent welding
Carriage motion and wire feed controlled separately
Set weld length and distance between welds from
1-99 cm (0.4-39 in.)
Distance between beads run at transport speed
of 250 cm/min (98 ipm) for optimal efficiency
Program wire feed speed, time for gas pre-flow,
gas post-flow and burnback

Ordering Information

Technical Data

Miggytrac 3000...............................................................457 359 880

Wire Dimenisions, mm

With straight, water-cooled swan neck; delivered without contact tip

Options & Accessories

Contact Tip M8 Heavy-Duty, 0.9 mm (.035 in.).............468 502 004
Contact Tip M8 Heavy-Duty, C02 1.2, Mix/Ar 1.0..........468 502 007
Contact Tip M8 Heavy-Duty C02 1.4, Mix/Ar 1.2...........468 502 008
Gas Nozzle, water-cooled..............................................449 903 101
Bent Swan Neck, 15o...................................................... 449 903 115
Bent Swan Neck, 30o......................................................449 903 130
ESAB Control Cable, 5 m (16.4 ft).................................457 360 880
(12 pin male- 23 pin male Burndy style) ESABFeed, and AristoFeed
feeders

ESAB 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 feeders

Transformer Kit, 115-42 VAC.............................................. 359C304

Universal kit used to adapt 115 VAC wire feeders to Miggytrac

Unalloyed Steel
Stainless Steel
Cored Wire

Control Voltage, VAC

Power, W
Welding Speed, cm/min (ipm)
Transport Speed, cm/min (ipm)
Lengths at Intermittent Welding, cm (in.)
Crater-fill time, s
Backfill, cm (in.)
Wire Feed Speed, m/min (ipm)
Gas Pre-Flow/Post-Flow, s
Burnback, s
Filler Wire Reel, mm (in.)
Dimensions, LxWxH, mm (in.)
Slide Adjustment, mm (in.)
Remote Control, max value, Kohm
Max Current Over the Start Relay, A
Connection
Enclosure Class
Weight, excl. wire reel, Kg (lbs.)

1.0-1.4
1.0-1.4
1.0-1.4
36-46
80
15-150 (6-59)
250 (98)
1-99 (0.4-37)
1-9.9
1-9.9 (0.4-3.7)
2-25 (79-984)
0-9.9
0-9.9
305 (12)
370x400-530x520 (14.5x16-21x20.5)
+/- 17 (+/-0.67)
2.5
5
with straight 23-pin Burndy
IP 23
17 (37.5)

(mm)

Miggytrac 3000 Sales Literature......................................XA00123620

Miggytrac 3000 Instruction Manual..................................449 453 001

tractors

A2 Multitrac (PEH)

For use with LAF (DC) or TAF (AC) power sources

Compact and efficient design allows for easy

movement between workpieces
Self-propelled, four-wheel drive for stable, accurate,
and constant operation
A2-A6 PEH process controller with digital display,
allows presetting and control of welding parameters
Horizontal, vertical and rotary slides allow for quick
adjustment of weld nozzle into various positions
Reliable mechanical parts, even under harsh environments
Many specially developed accessories available

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

A2 Multitrac (PEI)

Can be connected to most analog, DC power supplies

Compact and efficient design allows for easy
movement between workpieces
Self-propelled, four-wheel drive for stable,

accurate, and constant operation
A2 PEI process controller allows simple setting of
travel speed, voltage, and wire feed speed
Heavy-duty feed unit ensures an even and

stable wire feed, a prerequisite for top quality,

homogenous welding
Horizontal, vertical and rotary slides allow for quick
adjustment of nozzle into various positions
Reliable mechanical components, even under

harsh working conditions
Easy to use control equipment with different start
methods: direct start or scratch start
Many specially developed accessories available

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

10

A2 Multitrac GMAW Sales Literature...............................XA00105520

A2 Multitrac SAW Sales Literature...................................XA00105420
A2 Multitrac SAW/GMAW Instruction Manual..................456 502 001

tractors

A2 Multitrac PEH & PEI, contd

Options & Accessories (PEH & PEI)
Auxiliary Guiding Equipment
Guide wheel bogie..........................................................413 542 880
Idling roller......................................................................333 164 880
Guide bar 3 m (10 ft.)......................................................154 203 880
V-guide wheel.................................................................333 098 881
V-wheeltrack in steel......................................................443 682 881
Loop for connection of two tractors.............................334 680 881
Pilot lamp, light bulb......................................................153 143 886
Pilot lamp, laser diode...................................................457 788 880
Wire Reel*
Wire reel, plastic, 30 Kg (66 lbs.)...................................153 872 880
Wire reel, steel, 30 Kg (66 lbs.)......................................416 492 880

Flux Handling Equipment

Flux recovery unit OPC.......................................................... 148 140 880
Bracket suction...................................................................... 332 947 880
Flux hopper of silumin alloy.................................................. 413 315 881
Concentric flux feeding funnel, D20..................................... 145 221 881
Contact tube, bent.................................................................. 413 511 001
Gas Handling Equipment**
Water circulator, WC-8C, 115/230 VAC........................................... 33739
Arc shield................................................................................ 334 689 880
Wear Parts....................................................................... see pages 16-19
* SAW Only ** GMAW Only

RECOMMENDED POWER SOURCES: LAF 635, 1000 and TAF 800

Technical Data
Wire Dimensions, mm (in.)

Max. Wire Feed Speed, m/min (ipm)

Electrode Weight, Kg (lbs.)
Flux Volume, L (gal.)
Weight, excl. wire and flux, Kg (lbs.)
Permissible Load 100%, A
Control Voltage, VAC
Travel Speed, m/min (ipm)
Linear Slides Setting Length, mm (in.)
Rotary Slide Setting Angle

Single SAW
Steel
Stainless Steel
Cored Wire
Aluminum

1.6-4.0
1.6-4.0
1.6-4.0

(1/16-5/32)
(1/16-5/32)
(1/16-5/32)

>9 (>354)
30 (66)
6 (1.4)
47 (103)
800
42
0.1-1.7 (4-67)
90 (3.5)
360o

Twin SAW
2x1.2-2.4
2x1.2-2.4

2x(.045x3/32)
2x(.045x3/32)

>9 (>354)
2x15 (2.2x33)
6 (1.4)
47 (103)
800
42
0.1-1.7 (4-67)
90 (3.5)
360o

GMAW
0.8-1.6
0.8-1.6
1.2-2.4
1.2-1.6
>16
30

(.030-1/16)
(.030-1/16)
(.045-3/32)
(.045-1/16)
(>630)
(66)

43 (95)
600
42
0.1-1.7 (4-67)
90 (3.5)
360o

GMAW MTW 600

1.0-1.6
1.0-1.6
1.0-2.4
1.0-2.0
>25
30

(.040-1/16)
(.040-1/16)
(.040-3/32)
(.040-5/64)
(>984)
(66)

43 (95)
600
42
0.1-1.7 (4-67)
90 (3.5)
360o

(mm)

11

tractors

A2 Tripletrac for Internal Circumferential Welding

Increase productivity and quality

Ideal for internal circumferential welding of large
cylindrical objects that are rotating on a turning roll system
Heavy-duty feed unit secures even, stable wire feed
for top quality, homogenous welds
Delivered with either the digital A2-A6 PEH process
controller or the analog A2 PEI welding controller
Unique steering system allows operator to

simultaneously adjust the wheel and torch position for
accurate and effortless seam tracking
Control equipment is easy to use and requires minimal training
Choose between start methods, burn-back times and
other settings

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

Options & Accessories

Auxiliary Guiding Equipment
Pilot lamp, light bulb (PEH)................................................... 153 143 885
Pilot lamp, laser diode (PEH)................................................ 457 788 884
Utility light............................................................................... 449 443 880
Flux Handling Equipment
Flux recovery unit OPC.......................................................... 148 140 880
Bracket suction...................................................................... 332 947 880
Flux hopper of silumin alloy.................................................. 413 315 881
Concentric flux feeding funnel, D20..................................... 145 221 881
Contact tube, bent.................................................................. 413 511 001
Wire Reel
Wire reel, plastic, 30 Kg (66 lbs.)........................................... 153 872 880
Wire reel, steel, 30 Kg (66 lbs.).............................................. 416 492 880
Wear Parts....................................................................... see pages 16-19
RECOMMENDED POWER SOURCES: LAF 635, 1000 and TAF 800

Technical Data
Wire Dimensions, mm (in.)
Max. Wire Feed Speed, cm/min (ipm)
Electrode Weight, Kg (lbs.)
Flux Volume, L (gal.)
Weight excl. Wire and Flux, Kg (lbs.)
Permissible Load 100%, A
Control Voltage, VAC
Travel Speed, cm/min (ipm)
Linear Slides Setting Length, mm (in.)
Rotary Slide Setting Angle

12

Single Saw
Steel
Stainless Steel
Cored Wire

1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
1.6-4.0 (1/16-5/32)
>900 (>354)
30 (66)
6 (1.4)
47 (103)
800
42
10-170 (4-67)
90 (3.5)
360o

(mm)

A2 Tripletrac Sales Literature . ........................................ XA00118420

A2 Tripletrac Instruction Manual.......................................449 435 104

tractors

A6 Mastertrac

Self-propelled, four-wheel drive for stable,

accurate, and constant operation
Available in three different wire configuration
designs: Single, Twin, or Tandem
Ample capacity for heavy production welding; takes
up to 6 mm (1/4 in.) wire using 1500 Amps (DC or AC)
A2-A6 PEH process controller with digital
display allows for preset accuracy in all welding
parameters
Many specially developed accessories available

Ordering Information
A6 Mastertrac, single wire, standard............................449 260 880
156:1 feed motor (wire feed speed range of 0.2-4.0 m/min; 8-57 ipm)

A6 Mastertrac, twin wire, standard...............................449 260 881

A6 Mastertrac, single wire, high speed........................449 260 890
74:1 feed motor (wire feed speed range of 0.8-16 m/min; 31-654 ipm)

A6 Mastertrac, twin wire, high speed...........................449 260 891

A6 Mastertrac, tandem wire, complete.........................334 191 882

Options & Accessories

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

Angular slide........................................................................... 671 171 580

Pilot lamp, light bulb.............................................................. 153 143 885
Pilot lamp, laser diode........................................................... 457 788 884
Flux recovery unit, OPC......................................................... 148 140 880
Bracket suction...................................................................... 332 947 880
Idler rollers (2 per automat)................................................... 333 164 880
Guide wheel, fillet................................................................... 671 125 780
Magnetic guide rail, 3 m (9.8 ft.)............................................ 154 203 880
Rebuilding kit carbon arc gouging....................................... 153 592 880
Use with carbon electrodes 5/16, 3/8, 1/2

VEC-motor, 312:1 for carbon arc gouging........................... 145 063 905

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

RECOMMENDED POWER SOURCES: LAF 635, 1000, 1250, 1600 and TAF 800, 1250

Technical Data

Single SAW

Wire Dimensions, mm (in.)

Max. Wire Feed Speed, cm/min (ipm)
Max. Wire Feed Speed High, cm/min (ipm)
Flux Volume, L (gal.)
Weight, excl. wire and flux, Kg (lbs.)
Permissible Load 100%, A
Control Voltage, VAC
Travel Speed, cm/min (ipm)
Wire Reel, Kg (lbs.)

3.0-6.0 (1/8-1/4)
20-400 (8-157)
40-800 (16-31.5)
10 (2)
110 (242.5)
1500
42
10-200 (8-79)
30 (66)

A6 Mastertrac SAW Sales Literature...............................XA00109420

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

Twin SAW
2x2.0-3.0 2x(3/32-1/8)
0.2-4.0 (8-157)
0.4-8.0 (16-31.5)
10 (2)
110 (242.5)
1500
42
0.1-2.0 (8-79)
2x30 2x(66)

GMAW
1.0-3.2 (3/64-1/8)
0.8-16.6 (31.5-653.5)
- - 100 (220.5)
600
42
0.1-2.0 (8-79)
30 (66)

Tandem SAW
2x3.0-6.0 2x(1/8-1/4)
0.2-4.0 (8-157)
0.4-8.0 (16-31.5)
10 (2)
158 (348)
2x1500
42
0.1-2.0 (8-79)
2x30 2x(66)

13

tractors

A6-DK Portable Welding Machine

Works with a single wire on each head

Each weld head is controlled by the A2-A6 PEH

process controller and LAF (DC) or TAF (AC) power
source
Ideal for simultaneous horizontal-vertical welding on
both sides of a web or trough panel
Straddles work pieces up to 800 mm (31 in.) tall and
symmetrical profile widths of 400 mm (16 in.)
Travels directly on a workpiece guided by a joint
Travel speed adjustable from 0.15-2.0 m/min (6-79 ipm)
Store up to 10 L (2.6 gal) of flux in the hopper
Each weld head is equipped with the OPC Flux

recovery system

Ordering Information
A6-DK SAW single wire.......................................................... 454 200 901

Technical Data

Excl. wire reel, feed rollers, and contact jaws

Permissable load 100%,A

Travel Speed, cm/min (ipm)
Wire Feed Speed, cm/min (ipm)
Wire Reel (optional), Kg (lbs.)
Wire Diameter SAW, mm (in.)
Flux Capacity (each welding head), l (gal)
Weight, excl. wire and flux, Kg (lbs.)
Straddle Opening
Vertical Space Limitation, mm (in.)
Longitudinal symmetrical extension, mm (in.)

Options and Accessories

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

1500
15-200 (6-79)
20-400 (8-157)
2x30 (2-66)
3.0-6.0 (1/8-1/4)
10 (2.6)
150 (331)
800
400

(31)
(16)

RECOMMENDED POWER SOURCES: LAF 635, 1000, 1250, 1600 and TAF 800, 1250

(mm)

14

A6-DK Sales Literature.....................................................XA00100120

A6-DK Instruction Manual..............................................Contact ESAB

tractors

Frametrac for Welding Windtower Door Frames

Compact, motor-powered tractor that travels on

the door frame to be welded
Four driving wheels guarantee even, stable
movement on the frame
Standard ESAB torch can be attached and
adjusted to fit the frame and type of welding
Control travel direction and speed, weaving speed
and width from the control box and remote control
The Automatic Current Control (ACC) holds the
arc length stable to secure the best possible arc
Use directly on frames with a constant thickness of
20-75 mm (0.78-2.95 in.)

Ordering Information
Frametrac with ACC.......................................................449 925 880

Options & Accessories

Spring arms for frames 50-75 mm (1.97-2.95 in.)........449 904 025
Connection cable............................................................457 360 880
Contact ESAB for recommended welding equipment

Technical Data
Control Voltage, VAC
Power, W
Welding Speed, cm/min (ipm)
Frame Width, mm (in.)
Min. Radius on Frame, mm (in.)
Min. Height on Frame, mm (in.)
Max. Height Difference on Frame, mm (in.)
Dimensions, LxWxH, mm (in.)
Weight, excl. wire reel, Kg (lbs.)

36-46
80
10-99 (4-39)
20-50 (0.78-1.97)
150 (5.9)
40 (1.57)
120 (4.72)
280x430x508 (11x17x20)
30 (66)

Frametrac Sales Literature...............................................XA00126620

Frametrac Instruction Manual...........................................460 072 001

15

tractors

A2/A6 Tractor Wear Parts

Technical Reference Key
Process

Duty Type

Contact Tube

Contact Tips/Jaws

SAW, single wire

Light-Duty

D20

M12

SAW, twin wire

Light-Duty

D35*

M6

GMAW, 2WD

Light-Duty

D35

M10 or M6 with adaptor

GMAW, 4WD

Light-Duty

MTW 600

M8

SAW, single wire

Light-Duty

D20

M12

SAW, twin wire

Light-Duty

D35

M6

SAW, single or twin wire

Heavy-Duty

D35

Contact Jaws

SAW, compact

Heavy-Duty

D35

Contact Jaws

GMAW, single wire only

Light-Duty

D35

M10 or M6 with adaptor

A2 Contact Equipment

A6 Contact Equipment

* D35 twin wire adaptor P/N 333 772 001

Accessories: GMAW MTW 600

Wire Diameter
mm

Wire Material Type

Al

Wear Insert (liner) Type

(in)

Fe

SS

CW

1.0

(.040)

1.0

(.040)

1.2

(.045)

1.2

(.045)

1.4

(.052)

457 625 008

1.6

(1/16)

457 625 009

1.6

(1/16)

1.6

(1/16)

1.6

(1/16)

2.0

(5/64)

2.0

(5/64)

2.4

(3/32)

2.4

(3/32)

457 625 005

Teflon

Teflon

457 625 007

457 625 009

457 625 010

A
B

B
D

457 625 011

457 625 012

*

D
C

457 625 012

Ref. Item
A

457 625 011

*

Brass

457 625 010

*

Steel

457 625 005

457 625 006
*

Part Number

D
C

Wire Diameter
Reference Item

16

Wear Insert (liner) Type

mm

(in.)

Part Number

Steel Spiral

1.0-1.6

(.040-1/16)

457 454 002

Teflon Insert

1.0-1.6

(.040-1/16)

457 619 001 (to be cut to length when mounting)

Teflon Insert

2.0-2.4

(5/64-3/32)

457 619 002 (to be cut to length when mounting)

Brass Tube

2.0-2.4

(5/64-3/32)

457 620 002

A2 Wear Parts Catalogue.................................................. XA00115820

A2 GMAW (MIG) Wear Parts Brochure............................XA00126820
A6 Wear Parts Catalogue..................................................XA00125820

tractors

A2/A6 Tractor Wear Parts, contd

Feed Rollers
Wire Diameter
mm (in.)

Part Number

SAW Feed roller, single wire

0.8 (.030)
1.0 (.040)
1.2 (.045)
1.6 (1/16)
2.0 (5/64)
2.4-2.5 (3/32)
3.0-3.2 (1/8)
4.0 (5/32)
5.0 (3/16)
6.0 (1/4)
Pressure Roller
SAW Feed roller, single wire, knurled V-groove
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
3.0-5.0 (1/8-3/16)
Pressure Roller
GMAW Feed roller, single wire, 2WD drive, knurled U-groove
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
Pressure Roller
0.8-1.6 (.030-1/16)
2.0-4.0 (5/64-5/32)
*Shaft for pressure roller
SAW Feed roller, twin wire
2x1.2 2x(.045)
2x1.6 2x(1/16)
2x2.0 2x(5/64)
2x2.4-2.5 2x(3/32)
2x3.0-3.2 2x(1/8)
Pressure roller (spherical type with shaft)
SAW Feed roller, twin wire, knurled-U-groove
2x2.0-3.2 2x(5/64-1/8)
Pressure roller (spherical type with shaft)
GMAW Feed roller, single wire, 4WD
0.6-0.8 (.023-.030)
0.8-0.9*** (.030-.035)
0.8-1.0 (.030-.040)
1.0-1.2 (.040-.045)
1.0-1.2** (.040-.045)
1.2-1.6 (.045-1/16)
1.4-1.6 (.052-1/16)
1.6** (1/16)
2.0** (5/64)
2x1.2 2x(.045)
Pressure roller (flat roller)
GMAW Feed roller, single wire, knurled, 4WD**
1.0-1.2/1.4-1.6 (.040-.045/.052-1/16)
1.4-1.6/2.0-2.4 (.052-1/16/5/64-3/32)
Pressure roller (knurled roller)

145 538 881

145 538 882
145 538 883
218 510 281
218 510 282
218 510 283
218 510 298
218 510 286
218 510 287
218 510 288
153 148 880

Idling pressure roller

Driving feed roller
with groove

Idling pressure roller

146 024 880

146 024 881
218 510 299
153 148 880
146 024 880
146 024 881
146 025 880*
146 025 881*
212 901 101
218 522 486
218 522 488
218 522 484
218 522 480
218 522 481
218 524 580
148 772 880
218 524 580

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

369 557 001

369 557 001
369 557 002
369 557 003
369 557 006
369 557 007
369 557 013
369 557 008
369 557 009
369 557 010
369 728 001
369 557 004
369 557 005
466 262 001

**Aluminum only *** for Cored Wire

17

tractors

A2/A6 Tractor Wear Parts, contd

Contact Tips

153 501 002

153 501 004
153 501 005
153 501 007
153 501 009
153 501 010

M6

Guide tubes 415 032 002

Spiral insert 334 279 001

Nozzle holder 333 772 001
Contact nozzle x2

258 000 914

258 000 913
258 000 908
258 000 909
258 000 910
258 000 911
258 000 915

M10

457 625 005

457 625 006
457 625 007
457 625 008
457 625 009
457 625 011
457 625 012

M8

154 623 008

154 623 007
154 623 006
154 623 005
154 623 004
154 623 003

D20 - Slim design for improved access

into narrow V-joints

M12

SAW contact tip, M12 for single wire

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

Part Number

Wire Diameter
mm (in.)

Q450559001
Q450559002
Q450559003
Q450559004

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

Contact Jaws
Wire Diameter
mm (in.)

Part Number

SAW contact jaws for single wire, length 65/58 mm (2.5/2.3 in.)
2.0 (5/64)
332 581 880
2.4-2.5 (3/32)
332 581 881
3.0-3.2 (1/8)
265 900 880
4.0 (5/32)
265 900 882
5.0 (3/16)
265 900 883
6.0 (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)
000 237 321
SAW contact jaws for twin wire, length 58 mm (2.3 in.)
2x1.6 2x(1/16)
265 902 882
2x2.0 2x(5/64)
265 902 881
2x3.0-3.2 2x(1/8)
265 902 880
SAW contact jaws for twin wire, length 73 mm (2.8 in.) w/ guide tube connection
2x1.6 2x(1/16)
808 650 882
2x2.0 2x(5/64)
808 650 881
2x3.0-3.2 2x(1/8)
808 650 880

L=65 mm

L=58 mm

Long contact jaws

120 mm for improved
access to deep joints

L=120 mm
L=75 mm

Guide tube for twin wire

L=58 mm twin

tractors

A2/A6 Tractor Wear Parts, contd

Flux Nozzles

Contact Tubes
Length
mm (in.)
D20 light-duty system
100 (3.9)
190 (7.5)
260 (10.2)
260, bent 30o (10.2)
500 (19.7)
Contact clamp
Contact device D20 complete GMAW
90 (3.5)
140 (5.5)
Gas nozzle
Insulating sleeve
Contact tube
Plug
Extension
Guide tube
O-ring 22.2x3.0 (0.87x1/8)
O-ring 15.3x2.4 (.60x3/32)
O-ring 5.3x2.4 (.20x3/32)
D-35 heavy-duty system
220 (8.7)
275 (10.8)
400 (15.7)
500 (19.7)
700 (27.5)
Clamp half

Part Number

Part Number

D20 Contact Tube

Tube
Clamp
Flux hose, 0.5 m (16)
Flux hose free length/m
Flux funnel complete
Insulation sleeve
D35 Contact Tube
Flux nozzle, complete
Tube bent
Tube holder
Flux hose 0.5 m (16)
Flux hose free length/m
Flux funnel, complete
Insert
A2 flux gate w/ shut-off valve
Flux gate nozzle (18 mm)

413 510 003

413 510 002
413 510 001
413 511 001
413 510 004
334 571 880
030 465 389
030 465 388
145 227 882
145 226 001
145 534 882
146 099 001
040 979 803 (158mm)
040 979 804 (108mm)
415 032 001
190 680 405
190 680 313
190 680 303
417 959 880
417 959 881
417 959 882
417 959 883
417 959 884
809 342 880

Contact device D35 complete twin wire

220 (8.7)
333 852 880
275 (10.8)
333 852 881
Nozzle holder
333 772 001
Guide tube
415 032 001
Spiral wire guide insert
334 279 001
MTW 600 GMAW light-duty system
200 (7.8)
457 455 005
250 (9.8)
457 455 006
300 (11.8)
457 455 007
400 (15.7)
457 455 008
Contact device MTW 600 complete singe wire
Gas nozzle
457 451 001
Splatter protection
457 452 001
Centering sleeve
457 453 001
O-ring
457 458 001
Nozzle adaptor
808 311 001

332 948 001

333 094 880
443 383 002
443 383 001
145 221 881
333 667 001
153 299 880
153 296 001
153 290 002
443 383 002
443 383 001
254 900 880
254 900 301
0903787
0708876

3
3

D20 Contact Tube

2
1

1
1.
2.
3.

Tube
Clamp
Insert flux hose

1.
2.
3.

Flux funnel
Insulation sleeve
Flux hose
3

4
D35 Contact Tube
1

3
2
1.
2.
3.
4.

Flux nozzle, complete

Tube bent
Tube holder
Flux hose

1.
2.
3.

Flux funnel
Insert
Flux hose

1.
2.

Flux gate
Nozzle

A2 Flux Gate w/ Shut-off Valve

1

19

controllers and power sources

A2-A6 PEH Process Controller

Designed for use with LAF (DC) and TAF (AC)

power sources
Suitable for MIG or SAW processes
Preset all welding parameters by keying values

on front panel; can store up to 10 different data sets in
memory for easy recall during welding
Sub-menus let user decide on welding direction, wire
type/dimension, and weld start/stop
Microprocessor automatically fine tunes arc

characteristics depending on wire type and parameters
selected
Microprocessor controlled system is user friendly and
requires minimal training
Choose between 12 different languages and view heat
input on display

Ordering Information

Options & Accessories

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

Step Regulator Unit & Oscillation Control for PEH.........Contact ESAB

Control cable, 15 m (49 ft.)............................................449 449 880

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

Technical Data
Connection voltage from the power source, 50/60 Hz,VAC
Connection Power, VA
Motor connection adjusted for ESABs A2 and A6 motors
Speed Control
Welding Speed, m/min (ipm)
Min. - Max. Man. Travel Speed, m/min (ipm) (depending on travel unit)
Consumable Wire Feed Speed, m/min (ipm)
Gas Valve/Auxiliary, VAC, A
Inputs
Connection to power source through operating cable max 100 m (328)
Max. Ambient Temperature, oC (oF)
Min. Ambient Temperature, oC (oF)
Relative air humidity
Weight, Kg (lbs.)
Dimensions LxWxH, mm (in.)
Enclosure Class

20

42
max. 900
Motor current 5A continuous max. 10A
Internal EMK-adjustment, alt. with AC-tacho
0.1-2
(4-80)
0.1-2
(4-80)
30-250
(12-984)
42, 0.5
For connection of sensors or limit switch (2 pcs. NC)
Burndy contact, 12-poles
45
(113)
-15
(5)
98%
5.5
(12)
355x210x164 (14x8x6)
IP 23

A2-A6 PEH Controller Sales Literature...........................XA00089320

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

controllers and power sources

A2 PEI Process Controller

Control system for A2 tractors and A2 welding heads

Analog type that can control most brands of power
supplies
Suitable for MIG or SAW processes
Preset travel speed, voltage, and wire speed
by simply turning the three knobs actual data
shown on digital displays during welding
Change welding direction using switch on front panel
Choice of scratch start or direct start methods
Adjustable burn-back time

Ordering Information
A2 PEI Process Controller.............................................449 330 880

Options & Accessories

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

Contact ESAB for more information on control cables for OEM power
sources (Linde/L-Tec/Lincoln/Miller).

Technical Data
Connection voltage from the power source, VAC, Hz
Connection Power, W
Motor connection adjusted for ESABs A2 motors, VDC, A
Speed Control
Welding Speed, cm/min (ipm)
Max. Man. Travel Speed, m/min (ipm)
Consumable Wire Feed Speed, cm/min (ipm)
SAW
GMAW
Burnback Time, s
Pre-gas Flow Time, s
Post-gas Flow Time, s
Gas Valve/Auxiliary, VAC, A
Inputs
Connection to power source through operating cable max 100 m (328)
Welding Voltage Control, VDC
Flow Guard
Limit Switches
External Current Shunt, A/mV

Operating Temperature, oC (oF)

Weight, Kg (lbs.)
Dimensions LxWxH, mm (in.)
Enclosure Class

A2 PEI Process Controller Sales Literature.................... XA00114320

A2 PEI Process Contoller Instruction Manual.................449 331 001

42, 50/60
max. 700
42, 3.5
Internal EMK-adjustment
10-200 (4-79)
200 (79)
0.5-9 (20-355)
0.9-16.2 (35-640)
0-2.0
0.5
1.0
42, 1
For connection of sensors or limit switch (2 pcs. NC)
Burndy contact, 23-poles
0-10
No contact/PNP OC
No contact/PNP OC
1000/60
1500/60
600/100
750/100
-10-40 (14-104)
6.2 (14)
197x227x220 (7.8x9.0x8.7)
IP 23

21

controllers and power sources

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

Used in conjunction with A2-A6 PEH or A2 PEI

process controller
Solid state, SCR-controlled, three phase, fan-cooled
DC welding power sources
Designed for high productivity mechanized SAW or
MIG welding
Excellent welding characteristics throughout the entire
current and voltage range, with particularly good

starting and re-ignition properties
Extremely efficient power usage saves on power costs
Thermal overload protection
Extend current range by connecting two power

sources in parallel

Ordering Information
LAF 635................................................................................... 457 350 880
LAF 1000................................................................................. 456 321 881
LAF 1250................................................................................. 456 323 880
LAF 1600................................................................................. 456 324 880
Primary cable not included

Options & Accessories

LAF to A2-A6 PEH Controller
Control cable, 15 m (49 ft.).................................................... 449 449 880
Control cable, 25 m (82 ft.).................................................... 449 449 881
Control cable, 35 m (115 ft.)................................................... 449 449 882
Control cable, 50 m (164 ft.).................................................. 449 449 883
Control cable, 75 m (246 ft.).................................................. 449 449 884
Control cable, 100 m (328 ft.)................................................ 449 449 885

Technical Data
Voltage, 3ph 60 Hz, VAC
Current 100%, 60 Hz, A
Fuse, slow 60 Hz, A
Max. load at:
100% duty cycle, A/VAC
60% duty cycle, A/VAC
Setting Range
MIG, A/VAC
SAW, A/VAC
Open Circuit Voltage, VAC
Open Circuit Power, W
Efficiency
Weight, Kg (lbs.)
Dimensions, LxWxH, mm (in.)
Enclosure Class*
Application Class**

LAF 635
440
52
63
630/44
800/44
50/17-630/44
30/21-800/44
54
150
0.84
260 (573)
670x490x930 (26x19x36)
IP 23
S

LAF to A2 PEI Controller

Control cable, 15 m (49 ft.)............................................449 500 800
Control cable, 25 m (82 ft.)............................................449 500 881
Control cable, 35 m (115 ft.)...........................................449 500 882
Control cable, 50 m (164 ft.) .........................................449 500 883
Control cable, 75 m (246 ft.)..........................................449 500 884
Control cable, 100 m (328 ft.)........................................449 500 885

LAF 1000
400/440/550
64/64/52
63
800/44
1000/44
50/17-1000/45
40/22-1000/45
52
145
0.84
330 (728)
646x552x1090 (25x22x43)
IP 23
S

LAF 1250
400/440/550
99/99/80
100/100/80
1250/44
60/17-1250/44
40/22-1250/44
51
220
0.87
490 (1080)
774x598x1428 (30x24x56)
IP 23
S

LAF 1600
400/440/550
136/136/108
160/160/125
1600/44
40/22-1600/46
54
220
0.87
585 (1290)
774x598x1428 (30x24x56)
IP 23
S

* Equipment marked IP 23 is designed for indoor and outdoor use.

**The symbol S indicates that the welding power source may be used in areas with an increased electrical hazard, eg/ areas where the electrical
hazard is increased due to damp and/or the proximity to earthed metal objects.

22

LAF Power Source Sales Literature................................XA00090920

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

controllers and power sources

TAF 800 & 1250 AC Power Sources

Used in conjunction with A2-A6 PEH or A2 PEI

process controller
Solid state, SCR-controlled, one phase, fan-
cooled AC welding power sources
Square wave AC output, no arc blow
Capacity for continuous welding
Arc voltage or current feedback
Optimized open circuit voltage
Extremely efficient power usage saves on power
costs
Prepared for Scott connection of two power
sources

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

Options & Accessories

TAF to A2-A6 PEH Controller
Control cable, 15 m (49 ft.)............................................449 449 880
Control cable, 25 m (82 ft.)............................................449 449 881
Control cable, 35 m (115 ft.)...........................................449 449 882
Control cable, 50 m (164 ft.)..........................................449 449 883
Control cable, 75 m (246 ft.)..........................................449 449 884
Control cable, 100 m (328 ft.)........................................449 449 885

TAF to A2 PEI Controller

Control cable, 15 m (49 ft.).................................................... 449 500 880
Control cable, 25 m (82 ft.).................................................... 449 500 881
Control cable, 35 m (115 ft.)................................................... 449 500 882
Control cable, 50 m (164 ft.).................................................. 449 500 883
Control cable, 75 m (246 ft.).................................................. 449 500 884
Control cable, 100 m (328 ft.)................................................ 449 500 885
Arc gouging supplement....................................................... 449 070 880

Technical Data
Voltage, 1ph 60 Hz, VAC
Max. load at:
100% duty cycle, A/VAC
60% duty cycle, A/VAC
Setting Range, A/VAC
Open Circuit Voltage, VAC
Open Circuit Power, W
Efficiency
Weight, Kg (lbs.)
Dimensions, LxWxH, mm (in.)
Enclosure Class*
Application Class**

TAF 800
400/440/550
800/44
1000/44
300/28-800/44
71
230
0.86
495 (1091)
774x598x1428 (30x24x56)
IP 23
S

TAF 1250
400/440/550
1250/44
1500/44
400/28-1250/44
72
230
0.86
608 (1340)
774x598x1428 (30X24X56)
IP 23
S

* Equipment marked IP 23 is designed for indoor and outdoor use.

**The symbol S indicates that the welding power source may be used in areas with an increased electrical hazard, eg/ areas where the electrical
hazard is increased due to damp and/or the proximity to earthed metal objects.

TAF Power Sources Sales Literature...............................XA00088720

TAF Power Sources Instruction Manual...........................456 513 201

23

welding heads

A2S Mini Master

Versatile welding system for single wire SAW, twin

wire SAW or GMAW
Light-weight and compact design allows for greater
flexibility
Modular design allows user to expand, integrate or
modify system quickly and easily
Uses A2-A6 PEH or A2 PEI process controller
Accurate, easy joint-tracking with manual or motorized
slide system and manual PAK or automatic GMD joint
tracking
System attaches to any beam travelling carriage or
Column & Boom system

Ordering Information

Options & Accessories

A2S Mini Master GMAW MTW (4WD) Systems

Pilot 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

Includes the A2-A6 PEH Process Controller and Wire Equipment

A2S Mini Master w/ manual slides, 90x90 mm..................... 449 181 880
A2S Mini Master w/ motorized slides 180x180 mm & PAK................449 181 881
A2S Mini Master w/ motorized slides 180x180 mm & GMD........... 449 181 882

Gas handling equipment, GMAW only

Cooling unit OCE 2H 220 VAC, 50/60 Hz......................414 191 881
Gas hose.........................................................................190 270 101
Water-cooling hose........................................................190 315 104
Arc shield........................................................................334 689 880

Includes the A2 PEI Process Controller and Wire Equipment

A2S Mini Master w/ manual slides, 90x90 mm..................... 449 380 880
A2S Mini Master w/ motorized slides 180x180 mm & PAK................449 380 881
A2S Mini Master w/ motorized slides 180x180 mm & GMD........... 449 380 882

Flux recovery unit OPC..................................................148 140 880

Flux Hopper, 6 L (1.6 gal.)..............................................413 315 881
Concentric flux funnel....................................................145 221 881
Contact tube, bent.......................................................... 413 511 001
Wire reel, plastic 30 Kg (66 lbs.)....................................153 872 880
Wire reel, steel, 30 Kg (66 lbs.)......................................416 492 880
Wire reel, steel 220 mm (8.7 in.)................................671 164 080
Conversion kit from SAW to GMAW A2 (2WD)............413 526 881
Conversion kit from SAW to GMAW MTW (4WD)........449 030 880

A2S Mini Master SAW Systems

Includes the A2-A6 PEH Process Controller and Wire Equipment

A2S Mini Master w/ manual slides 90x90 mm...................... 449 170 880
A2S Mini Master w/ motorized slides 180x180 mm & PAK......... 449 170 881
A2S Mini Master w/ motorized slides 180x180 mm & GMD........ 449 170 881
Includes the A2 PEI Process Controller and Wire Equipment

A2S Mini Master w/ manual slides 90x90 mm...................... 449 370 880
A2S Mini Master w/ motorized slides 180x180 mm, PAK......... 449 370 881
A2S Mini Master w/ motorized slides 180x180 mm, GMD........ 449 370 881

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

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

Technical Data
Wire size, mm (in.)

Steel
Stainless Steel
Cored Wire
Aluminum
Max. wire feed speed, cm/min (ipm)
Flux volume, L (gal.)
Max. permissable load 100%, A
Control voltage, VAC
Linear slides / setting range, mm (in.)
Angular slide setting range

24

Single Wire SAW

1.6-4.0
1.6-4.0
1.6-4.0

(1/16-5/32)
(1/16-5/32)
(1/16-5/2)

900 (354)
6 (1.4)
1000
42
90 (3.5)
360o

Twin Wire SAW

2x1.2-2.5

(2x.045-3/32)

900 (354)
6 (1.4)
1000
42
90 (3.5)
360o

GMAW
0.8-1.6 (.030-1/16)
0.8-1.6 (.030-1/16)
1.2-2.4 (.045-3/32)
1.2-1.6 (.045-1/16)
1600 (630)
- 1000
42
90 (3.5)
360o

GMAW MTW 600

1.0-1.6 (.040-1/16)
1.0-1.6 (.040-1/16)
1.0-2.4 (.040-3/32)
1.0-2.0 (.040-5/64)
2500 (984)
- 1000
42
90 (3.5)
360o

A2S MiniMaster Sales Literature......................................XA00088820

A2S MiniMaster Instruction Manual..................................449 175 060

welding heads

25

welding heads

A6S Arc Master

Flexibility, reliability, and superior performance

capability
Comprehensive component and module system
make process customization easy
A6 VEC motor for reliable and consistent wire feed
Accurate, easy manual PAK or automatic GMD
joint tracking with manual slides or joystick-
controlled motor-operated cross slides
Capable of heavy-duty MIG, single/twin wire SAW,
as well as strip cladding and Synergic Cold Wire
(SCW) welding with optional accessories
Uses A2-A6 PEH process controller fast,
accurate pre-setting of all parameters before
welding starts
Feedback system ensures high and consistent
welding quality - save time and material
The welding heads can be equipped with the
standard wire feed unit (gear ratio 156:1) or with
the high-speed wire feed unit (gear ratio 74:1)

Ordering Information

Technical Data

Single Wire SAW System A6

Welding current and wire dimensions

Submerged arc welding DC or AC, A max.
A6 Feed Unit - High Speed, 74:1
Wire feed speed, cm/min (ipm)
Single wire, mm (in.)
Twin wire, mm (in.)
Single cored wire, mm (in.)
A6 Feed Unit - Low Speed, 156:1
Wire feed speed, cm/min (ipm)
Single wire, mm (in.)
Twin wire, mm (in.)
Single cored wire, mm (in.)
Angular Positioning
Circular slide, crank operated
Straightener

With 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....449 270 881
A6S Arc Master w/ motorized slides 300x300 mm & GMD...449 270 882
With high-speed wire feed unit (gear ratio 74:1)

A6S Arc Master w/ manual slides 210x210 mm...........449 270 890

A6S 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 A6

With high-speed wire feed unit (gear ratio 74:1)

A6S Arc Master w/ manual slides 210x210 mm...........449 271 890

A6S Arc Master w/ motorized slides 300x300 mm & PAK.....449 271 891
A6S Arc Master w/ motorized slides 300x300 mm & GMD...449 271 892

1500
40-800
1.6-4.0
2x1.2-2x2.5
1.6-4.0

(16-315)
(1/16-5/32)
(2x.045-2x3/32)
(1/16-5/32)

20-400
3.0-6.0
2x2.0-2x3.0
3.0-4.0

(8-157)
(1/8-1/4)
(2x5/64-2x1/8)
(1/8-5/32)

+/- 180
+/- 45

Options & Accessories

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

26

A6S Arc Master Sales Literature......................................XA00088920

A6S Arc Master Instruction Manual.................................449 275 060

welding heads

27

welding heads

A6S Tandem Welding Heads

Suitable for heavy construction welding

Capable of welding DC/DC, DC/AC or AC/AC
Uses A2-A6 PEH process controller- quickly and
accurately program welding parameters for each torch
Feedback system gives high and consistent welding
quality from start to finish, saving time and money
Versatile positioning through easy to use,
complete slide assembly for welding torch
position, distance stick-out, and angle on both
leading and trailing torches
Enhance productivity by adding optional

equipment such as twin wire and Synergic Cold
Wire systems
Available in a two basic versions, A6S Tandem
Master and A6DS Tandem Master, with several
configurations to match specific safety, quality and
productivity requirements
Welding heads can be equipped with the standard
wire feed unit (gear ratio 156:1) or with the highspeed wire feed unit (gear ratio 74:1)
A6S Tandem Master is optimized for welding across multiple perpendicular axis and is key in the welding of cylindrical
objects where both longitudinal and circumferential welding is required
Adjustable 90 interval turning bracket and cross slide
Automatic joint tracking keeps in track no matter which direction welding occurs

A6DS Tandem Master is optimized for welding in multiple directions and is key in the automated welding of long weld joints
such as beams and girders
Adjustable 90 interval turning bracket and fixed cross slide
Automatic joint tracking in any direction when integrated to ESAB column and boom M-model systems; simply rotate the

head 180 and weld in the reverse direction

Ordering Information
A6S Tandem Master, standard (156:1)..........................809 940 880
A6S Tandem Master, high-speed (74:1)........................809 940 881
A6DS 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).......................................809 934 880
Twin kit HD (one kit per torch).......................................809 934 881
Bump protection.............................................................451 404 880
GMD, joint tracking.........................................................417 142 880
Pilot lamp, light bulb......................................................153 143 886
Pilot lamp, laser diode...................................................457 788 880
Bracket, (straight) for wire.............................................334 318 880
Brake hub, for wire reel.................................................146 967 880
Wire reel, plastic, 30 Kg (66 lbs.)...................................153 872 880
Wire reel, steel, 30 Kg (66 lbs.)......................................416 492 880

28

A6DS Tandem

A6S Tandem

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

welding heads

1200

min. 385/max. 980

Straight min. 80

max. 170

801
min. 140/max. 495

min. 70

960

(mm)

Technical Data (Basic Components)

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
Total weight, excl. PEH, wire and flux, Kg (lbs.)

730

max. 130

780
max. 935

R920

A6S Tandem

min. 80/max. 675

1480

A6S Tandem Welding Heads, contd

A6DS Tandem

(mm)

A6S Tandem Master

A6DS Tandem Master

*
*
*
*
*
*

*
*
*
*
*
*

*
*
*
*
334 549 880
215 (474)

*
*
*
809 873 880
190 (419)

Tandem MIG Welding Head

Tandem MIG advantages include high speed welding,

low heat input, and increased productivity
Isolated wire contacts allow different parameters,
wire type, and diameter for each wire
Torch has variable wire spacing, angles, electrical
stickout, and various gas shielding cups
Available for robotics or hard automation
Uses either dual AristoMig pulse system or LAF (DC)
power supplies

Contact ESAB for more information.

29

welding heads

A6S Compact Welding Heads for Internal Tube Welding

For welding longitudinal and circumferential butt joints

inside tubes
Two versions available:
A6S Compact 300 for internal welding of tubes
down to 300 mm (12 in.) inside diameter
A6S Compact 500 for internal welding of tubes
down to 500 mm (20 in.) inside diameter
Equipped with reliable, VEC feed motor for superior
weld performance
Supervise and adjust the head position via TV

monitoring system
Use standard mini-cross slide assembly and PAK
manual tracking system or GMD automatic joint

tracking system to easily follow the joint
Add either the FFRS Basic/Super or FFRS 1200/3000
Flux Feed & Recovery System to optimize the welding
process

A6S Compact 300 Welding Head

Ordering Information
A6S Compact 300 Welding Head, standard.................809 280 880
A6S Compact 300 Welding Head, high-speed.............809 280 881
A6S Compact 500 Welding Head*.................................416 967 880
* Contact ESAB for Ordering Information, Options & Accessories and
Technical Data for A6S Compact 500 Welding Heads

Options & Accessories

Flux Valve Control Kit....................................................813 620 880
Includes solenoid valve and 5 m (16.4 ft.) air hose

Inductive Sensor............................................................ 811 178 880

TV Monitoring Equipment . ........................................... 811 176 880
Laser Pointer.................................................................. 811 177 880

A6S Compact 500 Welding Head

Contact Tips, wire size

M12, 3.0 mm (7/64 in.)....................................................154 623 005
M12, 3.5 mm (1/8 in.)......................................................154 623 004
M12, 4.0 mm (5/32 in.)....................................................154 623 003
Feed Rollers, wire size
3.0-3.2 mm (1/8 in.).........................................................218 510 298
4.0 mm (5/32 in.).............................................................218 510 286

Technical Data
Wire Dimensions, mm (in.)
Permissible Load 100%, A
Control Voltage, VAC
Travel Speed, cm/min (ipm)
Linear Slides Setting Range, mm (in.)
Angular Slide Setting Range, o
Wire Feed Speed, standard, cm/min (ipm)
Wire Feed Speed, high-speed, cm/min (ipm)

30

Steel
Stainless Steel

3.0-4.0 (1/8-5/32)
3.2 (1/8)
800
42
10-170 (4-67)
50 (2)
360
20-400 (8-157)
40-800 (15.7-315)

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

welding heads

A6S SAW Strip Cladding Head

Used in combination with standard A6S Arc Master

welding head
Provides an economical solution for surfacing with
high alloyed materials such as stainless steel or
nickel-based alloys
Choose a wider variety of parent materials and
consumables
Stainless steel cladding is widely used in
production of components where additional
strength or corrosion resistance is required
Welding head can be fitted with electrode strips
as wide as 30-100 mm (1.2-4.0 in.) and as thick as
0.5 mm (0.02 in.)

RECOMMENDED POWER SOURCES: LAF 1250, 1600 and A2-A6

PEH Process Controller

ESW* - Electroslag Welding - is a method of strip cladding, but differs from SAW strip cladding in that the arc is created
between the electrode and the work piece. The welding flux that is put into the joint melts and a slag pool is produced,
which then increases in depth. When the temperature of the slag and its conductive capacity thereby increases, the arc is
extinguished and the welding current is conducted via the molten slag where the necessary welding energy is produced
through resistance. This method can be used for joining thicknesses of 25 mm (1 in.) and above.
* Contact ESAB for Options & Accessories and Technical Data for the ESW Welding Head.

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

Electroslag Welding (ESW) Strip Cladding Head................ 772 306 880

Electromagnetic 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.).............................................. 416 492 880

Suction nozzle, flux................................................................ 156 025 001

Technical Data
Current capacity, A max.
1500
Feed roller diameter, mm (in.)
50 (2.0)
Strip width, mm (in.)
30-100 (1.2-4.0)
Strip thickness, mm (in.)
0.5 (0.02)
Strip feed speed: see A6 Mastertrac sales literature XA00109420 or A6S Arc Master
sales literature XA00088920

A6S SAW Strip Cladding Head Sales Literature.............XA00101020

ESW Strip Cladding Head Information.........................Contact ESAB

(mm)

31

welding heads

A6-MHW Manhole Welder

Equipment designed for welding manholes or

nozzles on cyclindrical vessels or flat plates
Fix the machine to the workpiece by manual
clamping with special jaws to ensure safe
constraint of the machine to manholes with
diameters between 250-460 mm (10-18 in.)
Safety clamping beam with tension bar in the
cyclindrical body to prevent tilting
Rotation device for the welding head, with a gear
wheel drive by the VEC 44 gear-motor with a
continuous adjustable speed of 0.1-2.0 rpm
Torch moved along a rigid rail by a light-weight
carriage
Welding head made from A6 components

Ordering Information
A6-MHW...................................................................... Contact ESAB
Includes jaws for diameters between 200-460 mm (8-18 in.)

Options & Accessories

Mini motorized slides, 90x90 mm............................ Contact ESAB
Joystick control panel PAG17.................................. Contact ESAB
Jaws for manholes +460 mm (+18 in.)..................... Contact ESAB

Technical Data
Welding wire diameters, mm (in.)
Manhole diameters, mm (in.) internal minimum
internal maximum
min. wall thickness
Min. depth necessary for correct clamping on the
internal nozzle surface, mm (in.)
Weight, Kg (lbs.)

2.0-4.0
150
1100
50
25
360

(5/64-5/32)
(6)
(43)
(2)
(1)
(794)

A6-MHW VERSION B - comes complete with the tilting control system for the connection with the turning rolls. This
makes it possible to synchronize the welding movement of the torch with the clockwise or counter-clockwise rotation of
the turning rolls in order to get the joint always in a flat position along the whole circumference.
For more information on the standard A6-MHW or the B version, please contact ESAB.

32

accessory components

A6 Synergic Cold Wire

Boost deposition rates up to 50% for any given

current/wire feed speed (utilizes excess heat from arc)
Synergic Cold Wire welding offers less distortion,
reduced flux consumption, and fewer weld beads
Easy to use, requires no additional control units or
separate wire feed mechanisms
Allows flexible process configuration - solid/cored
wire, single, twin wire, tandem and multiple wire

combinations
Synergic Cold Wire has no arc and can be used for
hard to weld alloys with cored wire
Set wire in leading or trailing position depending on
requirement of penetration vs. build-up
Fits all ESAB A6 systems

Ordering Information

Options & Accessories

Synergic Cold Wire Kit, complete......................................... 449 022 880

Flex Conduit SCW................................................................. 500C23

Contact Device, L=400 mm (16 in.) (D35).....................417 959 882
Wire Reel, steel...............................................................416 492 880
Twin Wire Kit...................................................................334 291 889
SCW Motor Kit....................................................................... 500C31
Wear Parts............................................................... see pages 16-19

Includes 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

33

accessory components

Beam Travelling Carriage

Ideal solution for submerged-arc and MIG welding

applications requiring beam-mounted carriage
Can be fitted with any A2 or A6 welding head
For longitudinal welding or welding of circular

workpieces
Place carriage on either a standard l-beam IPE 300 or
specially machined l-beam (contact ESAB for details)
Fast and easy pre-programming of travel motion and
welding parameters using the A2-A6 PEH process
controller

Ordering Information
Beam-Travelling carriage...............................................457 897 880

Track in lengths of 4,500 mm (14.8 ft.).........................145 282 881

Required number of floor columns: 3

Track in lengths of 6,000 mm (19.7 ft.).........................145 282 882

Options & Accessories

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

Required number of floor columns: 3

Track in lengths of 8,000 mm (26 ft.)............................145 282 883

Required number of floor columns: 4

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

6-200
60

(2-79)
(132)

MBVA 330/550 Beam Welding Carriage

Heavy side beam carriage, suitable for multiple

submerged arc weld heads and most options available
on columns and booms
Crossbeams available up to 1.2 m, capacity up to 1.4 ton
VEC motor with gear, rack and pinion, for powerful,
consistent carriage travel
Different travel units for speeds to match process

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

Options & Accessories

Cable length, 1.5 m (5 ft.) - 50 m (164 ft.).................. contact ESAB
Travel unit, speed range 3-80 cm/min (1.2-32 ipm).....150 943 880
Travel unit, speed range 11-125 cm/min (4-49 ipm).....150 943 881
Travel unit, speed range 14-250 cm/min (5.5-98 ipm).......150 943 882
Travel unit, speed range 37-1500 cm/min (14.5-590 ipm)....... 150 943 883
Travel unit, speed range 27-530 cm/min (11-208 ipm)......150 943 884
Beam 330, 300 cm (118 in.), 240 Kg (529 lbs.)..............803 348 880
Beam 330, 450 cm (177 in.), 480 Kg (1058 lbs.)...........803 348 881
Beam 330, 600 cm (236 in.), 720 Kg (1587 lbs.)...........803 348 882
Beam 330, 750 cm (295 in.), 960 Kg (2116 lbs.)............803 348 883
Beam 330, 900 cm (354 in.), 1000 Kg (2204 lbs.).........803 348 884

34

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

Technical Data

MBVA 330

MBVA 550

Rated load, N (kp)

Rated moment, Nm (kpm)
Weight, Kg (lbs.)

10000
3300
95

20000
10000
275

(1000)
(330)
(209)

(2000)
(1000)
(606)

A6B Beam Travelling Carriage Sales Literature.............XA00091920

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

accessory components

Servo Slide Motorized Slide for Linear Motion

Heavy duty capacity with high precision slide for

accurate and rapid joint tracking and positioning
Can be installed in vertical or horizontal positions -
setting lengths up to 1030 mm (41 in.) with a central
point of attachment
Operates jointly with A2 or A6 components
Slides available from 60 mm (2.4 in.) to 1,030 mm
(41 in.) working range
Permissible load of 1500 N (337 lbf/ft.) in any

mounting position
Maximum torque for vertical unit is 400Nm (3540
lbf/in.); maximum torque for horizontal unit is 280
Nm (2480 lbf/in.)

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

Options & Accessories

Technical Data

Connection cable, 2 m (6.5 ft.)............................................... 417 310 887

Connection cable, 5 m (16.4 ft.)............................................ 417 310 888
Connection cable, 10 m (32.8 ft.).......................................... 417 310 889

Control Voltage, V DC
Max. ambient temperature
Axial play, runner, mm
Max. torque-free load, Kg (lbs.)

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

42
80oC (176oF)
0.1
150 (330)

Technical Data, contd

Servo Slide 334 333

-880

Travel length, mm (in.)

# of 60 mm indexings, n
Clearance at limit, mm (in.)

305

Weight, Kg (lbs.)

11.5

(12)
(0)
(25)

-881
365
0
13.2

(14)
(0)
(29)

-882
425
0
15.0

(17)

-883
485

(0)
(33)

0
16.7

Servo Slide Sales Literature.............................................XA00032720

Servo Slide Instruction Manual.........................................443 394 060

(19)
(0)
(37)

-884
545
0
18.5

(21.5)
(0)
(41)

-885
665
0
21.9

(26)
(0)
(48)

-886
785
0
25.4

11

(31)

-887
1025

(0)

24

(56)

30.9

14

(40)

-888
1385

(1)

55

(68)

38.8

21

(54.5)
(2)
(85.5)

35

accessory components

PAK and GMD Joint Positioning and Tracking Systems

Simple and easy to use

Adapt for use with almost any type of welding joint
PAK system is for manual joint tracking; GMD
system is for automatic joint tracking
PAK and GMD work equally well with A2 or A6
welding systems
Motorized servo slides guarantee a reliable and
accurate joint tracking
PAK system available with or without remote
control, and can be integrated into a Column and
Boom submerged arc welding system
GMD automatic joint tracking system is designed
for use in fillet and butt joints using sensor fingers
GMD compensates for irregularities in weld joint,
tracks simple geometric shapes, and avoids
parallax problems

Ordering Information

Technical Data

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

PAK Control Unit

Control and operating voltage, VAC
Power requirement, VA
Enclosure type
Max. ambient temperature, oC (oF)
Weight, Kg (lbs.)
Weight, remote control unit, Kg (lbs.)

Includes 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...................417 587 880

PAK Control Unit, separate remote control.................417 587 882

Options & Accessories*

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

GMD Sensor with Finger

Sensitivity, mm (in.)
Weight, sensor, Kg (lbs.)

+/- 0.1
0.6

(+/- 0.004)
(1.3)

Cross saddle and support for the sensor

Cross saddle, setting length, mm (in.)
Weight, cross saddle, Kg (lbs.)

80
1.3

GMD Joint Tracking Unit

Control and operating voltage, VAC
Power requirement, VA
Enclosure type
Max. ambient temperature, oC (oF)
Weight, Kg (lbs.)

42
460
IP 53
+45 (+113)
2.2 (4.9)

GMD Remote Control Unit

Positioning speed
Weight, Kg (lbs.)

High/Low
2.0 (4.4)

GMD Accessories
Finger with ball, length, mm (in.)
Intermediate transformer, for separate
voltage supply

36

42
460
IP 23
+45 (+113)
4.5 (10)
2.0 (4.4)

(3.1)
(3.5)

100 (3.9)
200/230/440/500V 60 Hz main
to 42V secondary

GMD/PAK Joint Tracking System Sales Literature.........XA00068420

GMD Joint Tracking System Instruction Manual.............443 403 002
PAK Joint Tracking System Instruction Manual..............443 405 002

Accessory components

OPC Flux Recovery Systems

Robust and compact design

Easy to operate and practically maintenance-free
Integrated system for maximum productivity - lower
investment and service costs
Adapts to any A2 or A6 welding system - tractor or
stationary
Uses only compressed air - safe and inexpensive
Can be integrated into complete FFRS flux feeding
and recovery system
Three filter types: filter bag for A2 applications,

cyclone filter with filter bag for most A6


applications, and Tedak filter for heavy-duty

applications
OPC system includes: ejector, cyclone, filter with
attachment hardware, securing strap,


suction hose, and four suction nozzles (for butt

welds, normal and large; fillet welds, left and right)

OPC Basic Flux Recovery System

Works on ejector principle using compressed air
Cyclone separator, on top of flux hopper,efficiently

separates dust from recovered flux
Slag is separated and flux is returned to hopper

OPC Super Flux Recovery System

Similar to Basic system but with stronger ejector
and cyclone provides better suction
Can also be used with pre-heated flux

Ordering Information

Options & Accessories

OPC Basic, with standard filter bag..................................... 148 140 880

OPC Basic, with cyclone filter............................................... 802 415 882
OPC Basic, with Tedak filter.................................................. 802 415 883

Wear Parts...................................................................... see page 38

OPC Super, with standard filter bag..................................... 339 719 880

OPC Super, with cyclone filter.............................................. 802 415 892
OPC Super, with Tedak filter.................................................. 802 415 893

1.
2.
3.
4.
5.
6.
7.

OPC Flux Recovery System Sales Literature.................XA00105020

OPC Flux Recovery System Instruction Manual.............443 407 001

Air pressure hose, 3/8

Air pressure hose, 1/2
Air pressure tube, 63 mm
Air central
Plastic bag
Filter bag
Filter bag, cyclone, tedak

37

accessory components

OPC Flux Recovery System Wear Parts

8a
8b

8a
8b

Hose
D22/12.5

3
4

7
Hose
D16/9.5

5
6

3
4
2

OPC Basic
1
Ejector
2
Spiral hose, D47, 0/38, 1
3
Tension band
4
Cone
5
Tension ring
6
O-ring, 189.3x5.7
7
Ball valve
8a
Filter, paper
8b
Filter, cotton
9
Funnel
10
Rubber lining
11
O-ring 149.2x5.7
12
Cyclone
13
Rubber lining
14
Tension spring
16
Strainer

9
147 640 880
191 813 801
192 855 002
148 143 001*
148 144 001*
215 201 353
145 824 881
155 966 001
332 448 001*
148 142 001
145 565 001
215 201 345
148 141 001
145 073 001
145 815 001
020 301 780

15

OPC Super
1
Ejector
2
Spiral hose D47, 0/38, 1
3
Tension band
4
Cone
5
Tension ring
6
O-ring, 189.3x5.7
7
Ball valve
8a
Filter, paper
8b
Filter, cotton
9
Funnel
10
Rubber lining
11
O-ring 149.2x5.7
12
Cyclone
13
Rubber lining
14
Tension spring
15
Clamp
16
Strainer

10

12

11
13
14
16

339 720 001

191 813 801
192 855 002
332 279 001
148 144 001
215 201 353
333 625 001
155 966 001
332 448 001*
332 280 001
332 282 001
215 201 345
332 281 001
332 283 001
145 815 002
340 612 001
020 301 780

Suction Nozzle
1a
1b
1c
1d
2
3a
3b
4

Butt weld 1
Butt weld 2
Fillet weld left
Fillet weld right
Nozzle bracket
Insulator D20
Insulator D35
Flux hose, D32.0/25.0, free
length / m, length 0.5 m
Pipe bent

Cyclone Filter
1a
Cone basic
1b
Cone super
2
Tension ring
3
Bend
4
Spiral hose D67, 2/63
5
Cyclone
6a
Filter, paper
6b
Filter, cotton
7
Tension band
8
Plastic bag
9
U-screw
10
Bracket
* Optional Item

38

145 501 001

145 502 001
145 504 001
145 505 001
147 384 881
145 131 004
145 131 002
443 383 001
153 296 001

148 143 001

332 279 001
148 144 001
413 576 001
193 125 003
148 141 001
155 966 001
332 448 001*
192 855 002
190 665 004
379 600 001
379 599 880

1a

1b

1d

1c

1a
1b
1c
1d
4

3a
3b
6a
6b

1a
1b
1a
2

2
9, 10

accessory components

FFRS Flux Feed and Recovery Systems

Ideal for continuous and high capacity welding

Minimal manual flux handling
Reduced flux consumption for better welding economy
Fewer weld stops for increased efficiency
Efficient filtration of used air
Flux feeds from a 75 L (20 gal.) capacity TPC-75
pressurized flux tank to the ESAB flux hopper of
your choice: 6 L (1.6 gal.) or 10 L (2.6 gal.)
Flux feed inlet options: straight or bent

FFRS Basic & Super

Built on OPC Basic & Super modules
Basic - for normal welding operation
Super - for increased flux and heat conditions
Based on ejector vacuum principle

Options & Accessories

FFRS 1200 & FFRS 3000

Based upon an electrical suction unit creating a vacuum
For use when extra high recovery force is required
Flux dust separated automatically in a pre-separator

FFRS Basic & Super

Air central........................................................................417 714 880
Flux hopper with bent inlet pipe 10 L (2.6 gal).............156 230 883
left hand side seen from front

Flux hopper with bent inlet pipe 6 L (1.6 gal)...............413 404 883
left hand side seen from front

Flux hopper with bent inlet pipe 10 L (2.6 gal).............156 230 884
front side

Flux hopper with bent inlet pipe 6 L (1.6 gal)...............413 404 884
front side

Flux hopper with bent inlet pipe 10 L (2.6 gal).............156 230 885

Ordering Information

right hand side seen from front

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.......................................................................801 500 921
FFRS 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.

Flux hopper with bent inlet pipe 6 L (1.6 gal)...............413 404 885
right hand side seen from front

FFRS 1200 & 3000

Bent inlet to flux hopper................................................186 961 881
Straight inlet to flux hopper...........................................186 961 880
Extra hopper with inlet...............................see FFRS Basic & Super
Air pressure hose 1/2 in., max. 50 m (164 ft.)***..........190 343 106
Suction hose D47/38, max. 12 m (39 ft.)***...................379 016 001
***Length according to customer requirement

Technical Data
Flux feeding and recovery system
Weight, Kg. (lbs.)*
Dimensions, LxWxH, mm (in.)
* without flux ** suction unit dimensions below
Suction unit
Power, W
Mains supply, V/Hz
Fuse, A
Max. vacuum, kPA
Max. air flow capacity, m3/h
Sound level, dB
Filter area, m2
Filtration efficiency, %
Life-span of filter, work hours
Weight, Kg (lbs.)
Dimensions, LxWxH, mm (in.)
Primary separator
Volume, L (gal.)
Dimensions, LxW, mm (in.)

FFRS 1200
230 (507)
1053x450x2210 (41x18x87)
FFRS 1200 - P160
1200
110-230/50-60
10
-21
156
74
0.6
99.95
5-6000
19 (42)
480x400x1160 (19x16x46)
FFRS 1200
50 (13)
450x700 (18x28)

FFRS Basic/Super Sales Literature.................................XA00104820

FFRS 1200/3000 Sales Literature.....................................XA00104920
TCP 75 Sales Literature....................................................XA00009320

FFRS 3000
400 (882)
750x450x2210** (30x18x87)**
FFRS 3000 - E-PAK 150
3000
400/3~50
16
-25
270
63
3
99.95
4000-6000
194 (428)
1200x690x2000 (47x27x79)
FFRS 3000
50 (13)
450x900 (18x35)

39

accessory components

CRE 30 & CRE 60 Air Drying Units

Designed for use with any flux handling system

System is based on absorption principle - reduces the
risk of hydrogen cracking in weld metal by ensuring
flux remains dry
Built in monitor - warns if the programmed humidity
limit is exceeded
Reduces condensation - less corrosion and malfunctions
Simple system monitoring - manometer on pressurized
dryer bottles with easy-to-read dew point indicator

Ordering Information

Options & Accessories

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

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

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

Technical Data
Supply Voltage, VAC
Max. power rating, W
Net air flow capacity at bar, m3/h (ft3/hr @ 87 psi)
Regenerating flow at 6 bar (87 psi), %
Max. dew point under nominal working conditions, oC (oF)
Desiccant, Type 512
Sodium-Aluminum-Silicate, Kg (lbs.)
Normal pore size, ngstrom
Particle size, mm (in.)
Density, Kg/m3 (lbs./in.3)
Cycle time per container
Max. permissable air flow for oil separation filter, m3/hr
Manifold thread size
Max. working pressure, bar (psi)
Max. air pressure at testing, bar (psi)
Max. inlet air temp under nominal conditions, oC (oF)

CRE 30
230
40
30 Normal (1060)
14
-26 (-14)
10
2.5-5.0
720

(22)
(0.01-0.20)
(0.023)

5
60 Normal
R12
6 (87)
10 (145)
30 (86)

CRE 60
230
50
60 Normal (2120)
14
-26 (-14)
16
2.5-5.0
720

(35)
(0.01-0.20)
(0.026)

5
60 Normal
R12
6 (87)
10 (145)
30 (86)

Flux Oven

Keeps flux at a minimum of 220oF (104.4oC)

where moisture cannot be absorbed
Constructed of stainless steel inside and out
4 ft. (48 in.) high, top-loading with room for flux
bucket underneath
Stand included
Models for 115V, 1ph outlet or 220V, 1ph outlet
FX300 model has capacity of 136 Kg (300 lbs.);
FX600 model has capacity of 272 Kg (600 lbs.)

Ordering Information
Flux Oven, 136 Kg (300 lbs.).............................................. FX300SS
Flux Oven, 272 Kg (600 lbs.).............................................. FX600SS

40

CRE 30/60 Air Drying Unit Sales Literature.....................XA00101920

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

accessory components

Flux Drying Equipment

JS200 Flux Storage silo

Keeps flux dry and clean

Makes it easy to handle flux
Adjustable temperature

JK-50 Powder Dryer

Can dry up to 50 Kg (110 lbs.) of flux at

a maximum temperature of 932 oF (500
o
C) in 3 hours
After drying, temperature falls
automatically to a pre-set dry storage
temperature of 302 oF (150 oC) within 12
hours

Ordering Information
JS200 Storage Silo................................................................. 000 515 090
JK-50 Powder Dryer............................................................... 000 515 091

Technical Data
Capacity, Kg (lbs.)
Storage temperature, oC (oF)
Drying temperature, oC (oF)
Mains voltage, V/phase
Output, W
Dimensions, LxWxH, mm (in.)
Inner diameter, mm (in.)
Weight, Kg (lbs.)

JK-50
50 (110)
<200 (<392)
<500 (<932)
400/3
3700
1720 (68)
190 (419)

JS200
200
50-300

(440)
(122-572)

230/1
2000
510x570x1750 (20x22x69)
115 (254)

Water Circulators
WC-8C

WC-9

For MIG torches up to 600A, TIG

torches up to 500A
Fits cylinder rack of most power source trucks
High-efficiency, fan-cooled radiator
dissipates 6480 BTU/hr
Rust-proof 5.7 L (1.5 gal.) reservoir
Circulates 1 gal./min (3.8 L/min) @ 50
psi (345 kPa)
115/230V, 50/60 Hz., 1ph

Extra heavy-duty circulator

designed for MIG torches, TIG
torches and plasma cutting torches
High-efficiency, fan-cooled radiator
dissipates 8000 BTU/hr
Rust-proof 15 L (4 gal.) reservoir
Circulates 1 gal./min (3.8 L/min) @
50 psi (345 kPa)
115/230V, 50/60 Hz., 1ph

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

41

ACCESSORY COMPONENTS

Rotatable Earth (Rotating Ground) Couplings

For a good connection to the workpiece to obtain

optimal welding performance
For rotating workpieces, an earth connection with
a rotatable earth coupling is the safest choice
To attach the coupling to the workpiece, special
clamps are available, see Earth Clamps below

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

Earth Clamps for Rotating Workpieces

K2 or PZ3 earth clamps can be mounted directly

onto the rotatable earth coupling to create good
contact between the workpiece and the return
cable
Return clamps can also be used toegher with the
GA 800 handle connection to form a complete
earth clamp to handle high current welding on nonrotating workpieces

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

42

accessory components

Camera Systems for Submerged and Open Arc Welding

Together with a laser or pilot lamp, control the welding

process from a convenient location
System consists of a purposeful designed camera with
built-in crosshair generator to provide a continuous
and distinct joint scanning
In combination with the 15 in. flat screen, it becomes a
unit for excellent control and joint tracking
Upon welding, the camera switches over to viewing
the pool, facilitating the supervision of the process
Optional overview camera will reproduce a picture of
the welded joint to get an immediate inspection of the
welding quality

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

A2/A6 SAW camera system with cooling unit..................... 811 412 880
A2/A6 SAW camera system without cooling unit................ 811 412 881
SAW compact camera system with cooling unit................. 811 413 900
SAW compact camera system without cooling unit........... 811 413 901
GMAW camera system with cooling unit............................. 811 414 880
GMAW camera system without cooling unit........................ 811 414 881
Overview SAW camera system without cooling unit.......... 811 413 881
SAW compact basic camera system with cooling unit....... 811 413 880
SAW compact basic camera system without cooling unit....... 811 413 882

Technical Data
TV Standard
Model No.
Resolution
Min. illumination
Electronic Iris
Horizontal field angle
Vertical field angle
Focal length
External terminals
Output resistance
Power supply range
Power consumption
Temperature range
Dimensions, mm (in.)
Weight, Kg (lbs.)

SAW Camera
PAL/NTSC
VUP2.01P/VUP2.01N
480TVL
0.25lx (at F1.6)
Automatic 1/60 (1/50)~1/10000 sec.
approx. 79o at focal 3.5 mm (WIDE)
~approx. 33o at focal 8 mm (TELE)
approx. 63o at focal 3.5 mm (WIDE)
~approx. 25o at focal 8 mm (TELE)
variofocal lens, 3.5 mm - 8 mm
(A) power input +12V DC, (B) GND, (C)
video output, (D) GND
DC 12V
200mA (max.)
-10oC (14oF)~50oC (122oF), (PCB)
60x60x105 (2.4x2.4x4.1)
approx. 0.46 (approx. 1)

GMAW/SAW Compact
Camera

Overview/SAW Compact
Basic Camera

PAL/NTSC
WeldCam/SAWC
480TVL
Automatic 1/50~1/10000 sec.
-

PAL/NTSC
OV3.04
350TVL
3.0lx
1/50~1/10000 sec.
-

75 ohm
DC +/- 0.5V
360mA (max.)
-10oC (14oF)~50oC (122oF), (PCB)
145x24x24 (5.7x0.9x0.9)
approx. 0.46 (approx. 1)

DC + 6.0V~DC + 7.5V
200mA (max.)
18x18x43+lens (0.7x0.7x1.7+lens)
approx. 0.025 (approx. 0.05)

Note: SAW compact basic and Overview camera have the same specifications, but SAW compact basic is used for compact applications. SAW
compact basic is a simpler alternative to SAW compact camera.

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

43

accessory components

WeldocTM WMS 4000 Data Program

Enables welding industry to comply with rigorous

quality requirements in the ISO 9000 standards
Provides necessary documentation for

quality requirements user-specified limit
values facilitates monitoring and process deviation
Use with the following ESAB power sources:
Prowelder 160/320, Protig 450
LUD/AristoMig 450
LAF 635, 1000, 1250, 1600
TAF 800, 1250
No manual settings required automatic recording
of date, time, and reference number of weld joints
Program automatically receives and stores
welding parameter data from power source
SPS 4000 documentation program provides
setting welding data in power source

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

Options & Accessories

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

Technical Data
Weldoc WMS 4000

Software for surveillance of Prowelder 320, Protig 450, LUD 450, AristoMig 450 and the LAF/TAF range
equipped with CAN- and Echelon-bus

Operating system 16-bit

Minimum Windows 95 or Windows NT 4.0

Computer

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 better

Ram memory

16 MB or better

Capacity of the hard disc

1.5 GB minimum recommended

Screen

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 time

Serial data communication

RS-232

Signal transfer

Optical through fiber cable to the serial port to avoid interference from peripheral equipment

44

Weldoc WMS 4000 Sales Literature.................................XA00088020

Weldoc WMS 4000 Instruction Manual.............................457 413 074

handling equipment

5-500 TA Self-Aligning Turning Rolls

Ideal for difficult and demanding workpieces

Even weight distribution for thin-walled work
pieces and heavy objects
Compact and narrow design with durable rollers
Dual drive motors and gears- eliminate need for
interconnect driveshaft
Vector inverter control system for constant and
precise speed control
Equipped with remote control with a 12 m (39.4 ft.)
cable
Plug & play connection to accessories available
including external connection, rail bogies, anti-
creep/fit-up control, start/stop foot pedal, and A2-
A6 PEH process controller
Synchronization control included as standard
component

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

Power

Idler

5 TA..........................................................................................103563
10 TA........................................................................................103564
25 TA........................................................................................103565
40 TA........................................................................................103566
70 TA........................................................................................103567
100 TA......................................................................................103568
150 TA......................................................................................103569
200 TA......................................................................................103570
300 TA......................................................................................103571
500 TA......................................................................................103572

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

Technical Data
5 TA
Max. load, metric ton (U.S. ton)
Rolling capacity, metric ton (U.S.)
Max. rotating force, kN (lbf)
Rotation speed, cm/min (ipm)
Dia. range 75% load min-max, cm (in.)
Dia. range 100% load min-max, cm (in.)
Rollers pcs/axel
Roller dia, cm (in.)
Roller total width, cm (in.)
Roller material
Length, cm (in.)
Power
Idler
Width, mm (in.)
Power
Idler
Weight, Kg (lbs.)
Power
Idler
Primary input voltage, VAC, 60 Hz
Primary input current, A

2.5
7.5
5.5
6-125
50-450
125-450
35
7.5

PU

(2.8)
(8.3)
(1236)
(2.4-49)
(20-177)
(49-177)
(14)
(3)

256 (101)
220 (87)
72 (28)
40 (16)
760 (1670)
585 (1290)
230, 1ph
16

10 TA
5.5
15
11
6-125
50-450
125-450
35
7.5

PU

(5.0)
(16.5)
(2473)
(2.4-49)
(20-177)
(49-177)
(14)
(3)

262.5 (103)
220 (87)
72 (28)
49 (19)
925 (2040)
585 (1290)
460/575, 3ph
16

25 TA
12.5
37.5
20
6-125
50-450
125-450
35
15

PU

(13.8)
(41.3)
(4496)
(2.4-49)
(20-177)
(49-177)
(14)
(6)

266.5 (105)
220 (87)
77.5 (31)
49 (19)
1185 (2610)
751 (1660)
460/575, 3ph
16

40 TA
20
60
32
6-125
100-520
175-520
42.5
15

PU

(22)
(66.1)
(7194)
(2.4-49)
(39-205)
(69-205)

70 TA
35
105
60
6-125
100-780
175-520

(17)
(6)

307 (121)
271 (107)
105 (41)
83 (33)
1770 (3900)
1220 (2685)
460/575, 3ph
16

TA Turning Rolls Sales Literature....................................XA00120320

Accessories for Turning Rolls..........................................XA00120720

42.5
30

PU

(38.6)
(116)
(13490)
(2.4-49)
(39-07)
(69-205)
(17)
(12)

307 (121)
271 (107)
123 (48)
83 (33)
2430 (5357)
1670 (3680)
460/575, 3ph
16

100 TA
50
150
75
6-125
100-780
200-780
58
22

PU

(55.1)
(165)
(16860)
(2.4-49)
(39-307)
(79-307)
(23
(9)

375 (148)
345 (136)
140 (55)
90 (35)
5000 (11030)
4000 (8820)
460/575, 3ph
16

150 TA
75
225
110
6-125
100-780
200-780
58
45

PU

(82.7)
(248)
(24730)
(2.4-49)
(39-307)
(79-307)
(23)
(18)

380 (150)
345 (136)
190 (75)
130 (51)
6200 (13670)
4500 (9920)
460/575, 3ph
16

200 TA
100
300
165
6-125
100-780
200-780

45

(110)
(331)
(37090)
(2.4-49)
(39-307)
(79-307)
(23)
(18)

PU
380 (150)
345 (136)
200 (79)
140 (55)
7000 (15430)
5300 (11690)
460/575, 3ph
16

300 TA
150
450
210
6-125
100-780
200-780
71
52

(165)
(496)
(47210)
(2.4-49)
(39-307)
(79-307)
(30)
(20)

PU
470 (185)
420 (165)
220 (87)
140 (55)
12000 (26460)
9000 (19480)
460/575, 3ph
16

500 TA
250
750
250
6-125
100-780
200-780

(276)
(827)
(56200)
(2.4-49)
(39-307)
(79-307)

4
71 (30)
26 (10)
Steel
550 (217)
440 (173)
220 (87)
140 (55)
18000 (39680)
15000 (33070)
460/575, 3ph
16

45

handling equipment

3-500 TNA Conventional Turning Rolls

Basic solution for handling a variety of workpieces

Easy to use screws for adjusting diameters
Dual drive motors and gears eliminate need for

interconnect driveshaft
Vector inverter control for constant and precise speed
adjustment
Compact and narrow design with durable rollers
Equipped with remote control with 12 m (39.4 ft.) cable
Many accessories available including external

connection, rail bogies, anti-creep/fit-up, start/stop
foot pedal and A2-A6 PEH process controller
Synchronization control included as standard

component

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

Power

Idler

3 TNA............................................................................................... 103584
5 TNA............................................................................................... 103585
10 TNA............................................................................................. 103586
25 TNA............................................................................................. 103587
40 TNA............................................................................................. 103588
60 TNA............................................................................................. 103589
100 TNA........................................................................................... 103590
150 TNA........................................................................................... 103591
200 TNA........................................................................................... 103592
300 TNA........................................................................................... 103593
500 TNA........................................................................................... 103594

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

Technical Data
3 TNA
Max. load, metric ton (U.S. ton)
Rolling capacity, metric ton (U.S.)
Max. rotating force, kN (lbf)
Rotation speed, cm/min (ipm)
Dia. range min-max, cm (in.)
Rollers pcs/axel
Roller dia, cm (in.)
Roller total width, cm (in.)
Roller material
Length, cm (in.)
Power
Idler
Width, cm (in.)
Power
Idler
Weight, Kg (lbs.)
Power
Idler
Primary input voltage, VAC, 60 Hz
Primary input current, A

46

1.5
5
3
6-125
15-320

35
7.5

(1.65)
(5.5)
(670)
(2.4-49)
(6-126)
2

(14)
(3)

PU
231 (91)
195 (77)
63 (25)
400 (16)
455 (1005)
310 (685)
230, 1ph
16

5 TNA
2.5
7.5
5.5
6-125
15-320

35
7.5

(2.8)
(8.3)
(1230)
(2.4-49)
(6-126)
2

(14)
(3)

PU
231 (91)
195 (77)
63 (25)
400 (16)
530 (1170)
310 (685)
230, 1ph
16

10 TNA
5
15
11
6-125
15-450

35
15.5

(5.5)
(17)
(2470)
(2.4-49)
(6-177)
4

(14)
(6)

PU
304 (120)
268 (105)
66 (26)
490 (19)
660 (1455)
385 (850)
460/575, 3ph
16

25 TNA
12.5
37.5
20
6-125
15-450

35
23.5

(14)
(41)
(4500)
(2.4-49)
(6-177)
6

(14)
(9)

PU
304 (120)
268.5 (106)
70 (28)
490 (19)
1035 (2280)
670 (1480)
460/575, 3ph
16

40 TNA
20
60
32
6-125
30-450

42.5
31

(22)
(66)
(7190)
(2.4-49)
(12-177)
4

(17)
(12)
PU
446 (176)
306 (120)
83 (33)
830 (33)
2200 (4850)
1360 (3000)
460/575, 3ph
16

60 TNA
30
90
60
6-125
30-450

42.5
47

(33)
(99)
(13488)
(2.4-49)
(12-177)
6

(17)
(19)
PU
461 (181)
306 (120)
83 (33)
830 (33)
2410 (5313)
1620 (3571)
460/575, 3ph
25

100 TNA
50
150
75
6-125
50-780

58
47

(55)
(165)
(16860)
(2.4-49)
(20-307)
4

(23)
(19)
PU
510 (201)
470 (185)
140 (55)
850 (35)
3500 (7720)
2500 (5515)
460/575, 3ph
25

150 TNA
75
225
110
6-125
50-780

200 TNA

(83)
(248)
(24730)
(2.4-49)
(20-307)

100
300
165
6-125
50-780

(23)
(28)
PU
520 (205)
480 (189)
170 (67)
1100 (43)
6500 (14330)
5500 (12125)
460/575, 3ph
25

58
97

58
72

300 TNA

(110)
(331)
(37090)
(2.4-49)
(20-307)

150
450
210
6-125
50-780

(23)
(38)
PU
520 (205)
480 (189)
200 (79)
1400 (55)
7000 (15432)
6000 (13230)
460/575, 3ph
25

71
113

500 TNA

(165)
(496)
(47210)
(2.4-49)
(20-307)

250
750
250
6-125
50780

(30)
(44)
PU
850 (228)
450 (213)
290 (114)
1600 (63)
10000 (22050)
8800 (19400)
460/575, 3ph
25

71
26

(275)
(827)
(56200)
(2.4-49)
(20-307)
2

(30)
(10)
Steel
720 (283)
680 (268)
210 (83)
1600 (63)
16500 (36380)
15200 (33510)
460/575, 3ph
25

TNA Turning Rolls Sales Literature.................................XA00120220

Accessories for Turning Rolls..........................................XA00120720

handling equipment

TXA Scissor-Type Turning Rolls

Ideal for applications requiring a constant centre

height
Complete with a low voltage remote control unit for
all functions
Available as a motorized or freely rotating idling unit
Easily adjust the diameter with manually operated
hydraulic hand-pumps
Ideal for handling long objects
Plug & play connection to accessories available
including external connection, rail bogies,
start/stop foot pedal, and A2-A6 PEH process
controller
Synchronization control included as standard
component

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

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

Technical Data

1 TXA

Max. load, metric ton (U.S. ton)

Rolling capacity, metric ton (U.S.)
Rotation speed, mm/min (ipm)
Centre height /dia., mm (in.)
Total dia. range, mm (in.)
Roller pcs/axel
Roller dia, mm (in.)
Roller total width, mm (in.)
Roller material
Length, mm (in.)
Power
Idler
Width, mm (in.)
Power
Idler
Height, mm (in.)
Power
Idler
Weight, Kg (lbs.)
Power
Idler
Primary input voltage, VAC, 60 Hz
Primary input current, A

0.5

30-1750

(0.55)

(1.2-69)

200 (7.9)
50 (2)
PU
850 (33.5)
400 (15.7)
500-700 (19.4-27.5)
150 (331)
-

TXA Turning Rolls Sales Literature..................................XA00120420

Accessories for Turning Rolls..........................................XA00120720

3 TXA
1.5
3
60-1200
105-780/800
100-2100

(1.65)
(3.3)
(2.4-47)
(4.1-30.7/31.5)
(4-82.6)

2
350 (13.8)
75 (3)
PU
1685 (66.3)
1445 (56.9)
670 (26.4)
570 (22.4)
610-880 (24-34.6)
610-880 (24-34.6)
490 (1080)
350 (772)
230, 1ph
16

5 TXA
2.5
5
60-1200
105-780/800
100-2100

(2.7)
(5.5)
(2.4-47)
(4.1-30.7/31.5)
(4-82.6)

4
350 (13.8)
75 (3)
PU
1685 (66.3)
1445 (56.9)
770 (30.3)
670 (26.4)
610-880 (24-34.6)
610-880 (24-34.6)
540 (1190)
400 (882)
230, 1ph
16

47

HANDLING EQUIPMENT

250-35000 AHMA Positioners

3-axis positioning: height, angle, and rotation

Unique design allows for a large operating range
All positioners above 250 Kg (551 lbs.) capacity have
AC drives
Improved hydraulics with integrated safety valves for
total safety operation
Vector inverter control system for constant and precise
rotation speed and improved torque at low speeds
Equipped with remote control
Plug & play connection to accessories available

including external connection, start/stop foot pedal,
speed control foot pedal, and A2-A6 PEH process
controller

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

250 AHMA........................................................................................ 103653

750 AHMA........................................................................................ 103654
1500 AHMA...................................................................................... 103655
3500 AHMA...................................................................................... 103656
7000 AHMA...................................................................................... 103657
15000 AHMA.................................................................................... 103658
25000 AHMA.................................................................................... 103659
35000 AHMA.................................................................................... 103660

Technical Data
Max. load, kN (lbs.)
Rotation speed, rpm
Max. rotation torque, Nm (lbs.-f)
Tilting/angle degree
Tilting time: 0o -max angle, s
Max. tilting torque, Nm (lbs.-f)
Max. welding current, A
Table plate dia., cm (in.)
T-slots on table plate
Centre hole dia., cm (in.)
Remote control cable length, m (ft.)
Length, cm (in.)
Width, cm (in.)
Height, cm (in.)
Weight, Kg (lbs.)
Primary input voltage, VAC, 50 Hz
Primary input current, A

48

250
AHMA

750
AHMA

1500
AHMA

3500
AHMA

7000
AHMA

15000
AHMA

25000
AHMA

35000
AHMA

2.5 (562)
0.2-4.5
80 (59)
man 135
manual
300 (221)
350
40 (16)
3 pcs size M10
6 (2.4)
3 (9.8)
94 (37)
53.8 (21)
49-91 (19-36)

7.5 (1686)
0.05-2.0
600 (443)
hy 135
25
1500 (1106)
700
70 (26)
3 pcs size M12
6 (19.7)
157.5 (62)
69.6 (27)
72.5- (29-57)
145
550 (1215)
460/575, 3ph
16

15 (3370)
0.02-1.3
1000 (738)
hy 135
25
3000 (2213)
700
70 (26)
3 pcs size M12
6 (19.7)
164 (65)
81 (32)
77.5- (31-61)
154
730 (1610)
460/575, 3ph
16

35 (7870)
0.05-1.6
2800 (2065)
hy 135
30
7500 (5532)
700
95 (37)
4 pcs size M20
6 (19.7)
218 (86)
103 (41)
98- (36-66)
167.5
1800 (3970)
460/575, 3ph
25

70 (15730)
0.03-1.0
9000 (6638)
hy 135
55
14000 (10325)
1400
110 (43)
4 pcs size M20
8 (26.2)
264 (104)
149 (59)
100- (39-73)
185.5
3150 (6950)
460/575, 3ph
25

150 (33720)
0.01-0.75
18000 (13276)
hy 135
60
70000 (51630)
1400
149 (59)
4 pcs size M24
12 (39.4)
315 (124)
182 (72)
130- (51-92)
232.5
6500 (14350)
460/575, 3ph
32

250 (56200
0.005-0.4
40000 (29500)
hy 120
80
175000 (129000)
2100
195 (77)
8 pcs size M24
12 (39.4)
408 (161)
238 (94)
160- (63-113)
286
15000 (33070)
460/575, 3ph
35

(350 (78700)
0.0005-0.4
55000 (40565)
hy 120
160
280000 (206500)
2100
195 (77)
6 pcs size M24
12 (39.4)
475 (187)
345 (136)
200- (79-138)
350
23000 (50700)
460/575, 3ph
50

170 (373)
230, 1ph
16

AHMA Positioners Sales Literature................................. XA00119320

Accessories for Positioners.............................................XA00120620

handling equipment

75-150 SK Positioners for Small, Light Workpieces

Ideal for small, light and difficult workpieces

Motorized rotation of table plate
Adjustable rotation speeds and large titling angle
produce excellent welding results
Designed and built for tough manufacturing
workshop conditions
Complete with a low voltage remote control unit for
all functions (connected to the frame on 75 SK)
Includes 3-axis manual height adjustment,
manual tilting angle adjustment and motorized
rotation
Easy to maintain; minimal spare parts

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

75 SK.......................................................................................102729
150 SK.....................................................................................102730

Technical Data
Max. load, kN (lbs.)
Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Tilting/angle degree
Tilting time: 0o -max angle, s
Max. tilting torque, Nm (lbf/ft.)
Max. welding current, A
Table plate dia., mm (in.)
T-slots on table plate
Centre hole dia., mm (in.)
Remote control cable length, m (ft.)
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.)
Primary input voltage, VAC, 50 Hz
Primary input current, A

75 SK

150 SK

0.75 (169)
0.4-7.0
30 (265)
360
manual
150 (1327)
350
300 (12)
fixed
750 (30)
610 (24)
500-800 (20-32)
60 (132)
230, 1ph
16

1.5 (337)
0.2-4.5
80 (708)
360
manual
300 (2655)
350
350 (14)
3 pcs size M10
60 (2.4)
3 (0.8)
860 (34)
650 (26)
500-800 (20-32)
90 (198)
230, 1ph
16

SK Positioners Sales Literature....................................... XA00119520

Accessories for Positioners.............................................XA00120620

49

handling equipment

750-10000 SHA Positioners for Heavy Workpieces

For handling large and demanding workpieces in all positions

Equipped with adjustable hydraulics with built-in safety valves
3-axis operation (height, tilting angle, and rotation) for
ideal ergonomic working conditions
Low voltage remote control with all functions
Rotation and tilting speed controlled by vector
inverters for improved accuracy and better rotation torque
Drives equipped with an AC motor
Plug & play connection to accessories available
including external connection, start/stop foot pedal,
speed control foot pedal, and A2-A6 PEH process
controller

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

750 SHA........................................................................................... 105373

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

Technical Data

750 SHA

1500 SHA

3500 SHA

5000 SHA

Max. load, kN (lbs.)

Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Tilting speed, rpm
Tilting torque, Nm (lbf/ft.)
Adjustable tilting axle height, mm (in.)
Offset distance, mm (in.)
Max. welding current, A
Max. work piece dia., mm (in.)
Table plate dia., mm (in.)
T-slots on table plate
Remote control cable length, m (ft.)
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.)
Primary input voltage, VAC, 50 Hz
Primary input current, A

7.5 (1686)
0.05-2.0
600 (443)
0.1-1.5
1500 (1106)
700-1500 (27.5-59)
400 (16)
700
2000 (79)
700 (28)
3 pcs M12
6 (20)
2240 (88.2)
940 (37)
2110 (83)
1200 (2646)
460/575, 3ph
16

15.0 (3371)
0.02-1.3
1000 (738)
0.1-1.5
3000 (2213)
700-1500 (27.5-59)
400 (16)
700
2500 (98)
700 (28)
3 pcs M12
6 (20)
2650 (104)
1160 (46)
2200 (87)
1700 (3748)
460/575, 3ph
20

35.0 (7868)
0.05-1.6
2800 (2065)
0.1-1.0
6000 (4426)
1100-1900 (43-75)
400 (16)
700
3000 (118)
950 (35)
4 pcs M20
6 (20)
3710 (146)
1450 (57)
3060 (120.5)
4950 (10913)
460/575, 3ph
25

50.0 (11236)
0.01-1.5
6000 (4426)
0.1-0.75
10000 (7376)
1200-2000 (47-79)
500 (20)
1400
3200 (126)
1100 (43)
4 pcs M20
6 (20)
4400 (173)
2040 (80)
3200 (126)
9550 (21054)
460/575, 3ph
25

50

7000 SHA
70.0 (15370)
0.03-1.0
9000 (6638)
0.1-0.75
15000 (11064)
1200-2000 (47-79)
500 (20)
1400
3500 (138)
100 (43)
4 pcs M20
12 (39)
4700 (185)
2040 (80)
3200 (126)
10800 (23810)
460/575, 3ph
25

10000 SHA
100.0 (22472)
0.02-0.75
18000 (13276)
0.1-0.75
20000 (14752)
1200-2000 (47-79)
500 (20)
1400
4000 (157.5)
1490 (59)
4 pcs M20
12 (39)
5490 (216)
2140 (84)
4000 (157.5)
13500 (29762)
460/575, 3ph
32

SHA Positioner Sales Literature...................................... XA00119620

Accessories for Positioners.............................................XA00120620

handling equipment

750-50000 VA Positioners for Circumferential Welding

Ideal for large and heavy workpieces

Complete with a low voltage remote control unit for
all functions
Motorized rotation for economical circumferential
welding
Vector inverter control system for constant and
precise speed control
Drives equipped with an AC motor
Plug & play connection to accessories available
including external connection, start/stop foot
pedal,speed control foot pedal, and A2-A6 PEH
process controller

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

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

Technical Data
Max. load, kN (lbf.)
Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Tilting torque, Nm (lbf/ft.)
Max. welding current, A
Table plate dia., mm (in.)
T-slots on table plate
Remote control cable length, m (ft.)
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.)
Primary input voltage, VAC, 50 Hz
Primary input current, A

750 VA

1500 VA

3500 VA

7000 VA

15000 VA

25000 VA

35000 VA

50000 VA

7.5 (1686)
0.05-2.0
600 (443)
1500 (1106)
700
700 (27.5)
3 pcs size M12
6 (20)
725 (29)
580 (23)
690 (27)
350 (772)
460/575, 3ph
16

15 (3371)
0.02-1.3
1000 (738)
3000 (2213)
700
700 (27.5)
3 pcs size M12
6 (20)
725 (29)
580 (23)
690 (27)
390 (860)
460/575, 3ph
16

35 (7868)
0.05-1.6
2800 (2065)
7500 (5532)
700
950 (37)
4 pcs size M20
6 (20)
1050 (41)
1050 (41)
810 (32)
1100 (2424)
460/575, 3ph
25

70 (15736)
0.03-1.0
9000 (6638)
14000 (10326)
1400
1100 (43)
4 pcs size M20
12 (39)
1050 (41)
1050 (41)
810 (32)
1200 (2646)
460/575, 3ph
25

150 (33721)
0.02-0.75
18000 (13276)
70000 (51632)
1400
1490 (58)
4 pcs size M24
12 (39)
1400 (55)
1400 (55)
900 (35)
2300 (5071)
460/575, 3ph
32

250 (56202)
0.01-0.4
40000 (29500
175000 (12908)
2100
1950 (77)
8 pcs size M24
12 (39)
1400 (55)
1400 (55)
900 (35)
3600 (7937)
460/575, 3ph
35

350 (78683)
0.01-0.4
55000 (40565)
280000 (206528)
2100
1950 (77)
6 pcs size M24
12 (39)
1400 (55)
1400 (55)
900 (35)
4500
(9921)
460/575, 3ph
50

500 (112404)
0.004-0.2
75000 (663800)
400000 (295040)
2100
1950 (77)
6 pcs size M24
12 (39)
1400 (55)
1400 (55)
950 (37)
6500
(14330)
460/575, 3ph
50

VA Positioner Sales Literature......................................... XA00119920

Accessories for Positioners.............................................XA00120620

51

handling equipment

25000-50000 CRA Positioners for Large, Heavy Workpieces

Ideal for large and heavy workpieces

Complete with a low voltage remote control unit for all
functions
Adjustable rotation and tilting for ideal positioning
Vector inverter control system for constant and precise
speed
Drives equipped with an AC motor
Plug & play connection to accessories available
including external connection, start/stop foot pedal,
speed control foot pedal, and A2-A6 PEH process
controller

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

25000 CRA....................................................................................... 105430

35000 CRA....................................................................................... 105431
50000 CRA....................................................................................... 105432

Technical Data

25000 CRA

35000 CRA

50000 CRA

Max. load, kN (lbs.)

Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Tilting speed, rpm
Tilting torque, Nm (lbf/ft.)
Offset distance, mm (in.)
Max. welding current, A
Max. work piece dia., mm (in.)
Table plate dia., mm (in.)
T-slots on table plate
Remote control cable length, m (ft.)
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.)
Primary input voltage, VAC, 50 Hz
Primary input current, A

250 (56202)
0.01-0.4
40000 (29502)
0.1-1.5
70000 (51632)
600 (24)
2100
6000 (236)
1490 (59)
8 pcs size M24
12 (39)
9340 (368)
3160 (124)
5100 (201)
22000 (48502)
460/575, 3ph
32

350 (78683)
0.01-0.4
55000 (40566)
0.1-1.5
110000 (81136)
800 (31)
2100
7000 (276)
1490 (59)
8 pcs size M24
12 (39)
10600 (417)
3660 (144)
5400 (213)
34000 (74957)
460/575, 3ph
32

500 (112404)
0.004-0.2
75000 (55317)
0.1-1.0
150000 (110640)
800 (31)
2100
7000 (276)
1950 (77)
8 pcs size M30
12 (39)
10600 (417)
4000 (158)
5600 (221)
43000 (94799)
460/575, 3ph
32)

52

CRA Positioner Sales Literature...................................... XA00119820

Accessories for Positioners.............................................XA00120620

handling equipment

750-50000 Head & Tailstock Positioners for Revolving Workpieces

Ideal for circumferential welding and assembly of

difficult workpieces
Complete with a low voltage remote control unit for
all functions
Use headstock with or without tailstock
Head & tailstock can be equipped with a
stepless height adjustment and tailstock with
hydraulic motorized rail-bogie for various lengths
Plug & play connection to accessories available
including external connection, rail bogies,
start/stop foot pedal, and A2-A6 PEH process
controller
Headstock HSA features motorized rotation and
fixed height
Headstock HSLA features motorized rotation and
stepless height adjustment
Tailstock TSA/TSLA features freely rotating table
plate, and fixed/adjustable height

Ordering Information
All positioners include RC-31H remote control

Motorized Rotation, Fixed Height

Motorized Rotation, Adjustable Height

750 HSA...................................................................................105280
750 TSA...................................................................................105396
1500 HSA.................................................................................105381
1500 TSA.................................................................................105397
3500 HSA.................................................................................105382
3500 TSA.................................................................................105398
7000 HSA.................................................................................105383
7000 TSA.................................................................................105399
1500 HSA.................................................................................105384
15000 TSA...............................................................................105400
25000 HSA...............................................................................105385
25000 TSA...............................................................................105401
35000 HSA...............................................................................105386
35000 TSA...............................................................................105402
50000 HSA...............................................................................105387
50000 TSA...............................................................................105403

750 HSLA......................................................................................... 105388

750 TSLA......................................................................................... 105404
1500 HSLA....................................................................................... 105389
1500 TSLA....................................................................................... 105405
3500 HSLA....................................................................................... 105390
3500 TSLA....................................................................................... 105406
7000 HSLA....................................................................................... 105391
7000 TSLA....................................................................................... 105407
1500 HSLA....................................................................................... 105392
15000 TSLA..................................................................................... 105408
25000 HSLA..................................................................................... 105393
25000 TSLA..................................................................................... 105409
35000 HSLA..................................................................................... 105394
35000 TSLA..................................................................................... 105410
50000 HSLA..................................................................................... 105395
50000 TSLA..................................................................................... 105411

Headstock Height Extension Blocks

Motorized Railbogies

750 HSA/HSLA........................................................................106507
1500 HSA/HSLA......................................................................106507
3500 HSA/HSLA......................................................................106508
7000 HSA/HSLA......................................................................106509
15000 HSA/HSLA....................................................................106510
25000 HSA/HSLA.................................................................... 106511
35000 HSA/HSLA....................................................................106512
50000 HSA/HSLA....................................................................106513

750 RBTSA...................................................................................... 105412

1500 RBTSA.................................................................................... 105413
3500 RBTSA.................................................................................... 105414
7000 RBTSA.................................................................................... 105415
15000 RBTSA.................................................................................. 105416
25000 RBTSA.................................................................................. 105417
35000 RBTSA.................................................................................. 105418
50000 RBTSA.................................................................................. 105419

HSA - Headstock, TSA - Tailstock

Head & Tailstock Positioner Sales Literature................. XA00119320

Accessories for Positioners.............................................XA00120620

HSLA - Headstock, TSLA - Tailstock

53

handling equipment

750-50000 Head & Tailstock Positioners, contd.

Technical Data
Fixed Height
Max. load, kN (lbf.)
Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Max. welding current, A
Max. allowable tilting moment, Nm (lbf/ft.)
Center height, mm (in.)
Table plate dia., mm (in.)
T-slots on table plate
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.) HSA/TSA
Primary input voltage, VAC, 50 Hz
Primary input current, A
Adjustable Height
Max. load, kN (lbf.)
Rotation speed, rpm
Max. rotation torque, Nm (lbf/ft.)
Max. welding current, A
Max. allowable tilting moment, Nm (lbf/ft.)
Adjustable height, mm (in.)
Table plate dia., mm (in.)
T-slots on table plate
Length, mm (in.)
Width, mm (in.)
Height, mm (in.)
Weight, Kg (lbs.) HSLA/TSLA
Primary input voltage, VAC, 50 Hz
Primary input current, A
Extension
Length, mm (in.)
Height, mm (in.)

750
HSA/TSA

1500
HSA/TSA

3500
HSA/TSA

7000
HSA/TSA

15000
HSA/TSA

25000
HSA/TSA

35000
HSA/TSA

50000
HSA/TSA

7.5 (1686)
0.05-2.0
600 (443)
700
1500 (1106)
800 (31.5)
700 (27.5)
3 pcs size M12
940 (37)
900 (35)
1300 (51)
570 (1257)/
470 (1036)
460/575, 3ph
16

15 (3371)
0.02-1.3
1000 (738)
700
3000 (2213)
800 (31.5)
700 (27.5)
3 pcs size M12
940 (37)
900 (35)
1300 (51)
810 (1786)/
720 (1587)
460/575, 3ph
20

35 (7868)
0.05-1.6
2800 (2065)
700
7500 (5532)
800 (31.5)
950 (37)
4 pcs size M20
940 (37)
1060 (42)
1300 (51)
950 (2094)/
850 (1874)
460/575, 3ph
25

70 (15736)
0.03-1.0
9000 (6638)
1400
14000 (10326)
1000 (39)
1100 (43)
4 pcs size M20
1360 (53.5)
1450 (57)
1600 (63)
2100 (4630)/
1950 (4299)
460/575, 3ph
25

150 (33721)
0.02-0.75
18000 (13276)
1400
70000 (51632
1200 (47)
1490 (58)
4 pcs size M24
1900 (75)
2040 (80)
1700 (67)
4900 (10803)/
4700 (10362)
460/575, 3ph
32

250 (56202)
0.01-0.4
40000 (29500)
2100
175000 (129080)
1200 (47)
1950 (77)
8 pcs size M24
2200 (87)
2040 (80)
1700 (67)
6400 (14109.5)/
6200 (13669)
460/575, 3ph
35

350 (78683)
0.01-0.4
55000 (40565)
2100
280000 (206528)
1400 (55)
1950 (77)
8 pcs size M24
2600 (102)
2400 (94.5)
1900 (75)
9000 (19842)/
8500 (18739)
460/575, 3ph
50

500 (112404)
0.004-0.2
75000 (663800)
2100
400000 (295040)
1400 (55)
1950 (77)
8 pcs size M30
2800 (110)
2400 (94.5)
1900 (75)
2000 (26455)/
11500 (25353)
460/575, 3ph
50

750
HSLA/TSLA
7.5 (1686)
0.05-2.0
600 (443)
700
1500 (1106)
700-1500 (27.5-59)
700 (27.5)
3 pcs size M12
940 (37)
900 (35)
2340 (92)
900 (1984)/
800 (1764)
460/575, 3ph
16

1500
HSLA/TSLA
15 (3371)
0.02-1.3
1000 (738)
700
3000 (2213)
700-1500 (27.5-59)
700 (27.5)
3 pcs size M12
940 (37)
900 (35)
2340 (92)
900 (1984)/
800 (1764)
460/575, 3ph
20

3500
HSLA/TSLA
35 (7868)
0.05-1.6
2800 (2065)
700
7500 (5532)
700-1500 (27.5-59)
950 (37)
4 pcs size M20
940 (37)
1060 (42)
2340 (92)
1310 (2888)/
1210 (2667.5)
460/575, 3ph
25

7000
HSLA/TSLA
70 (15736)
0.03-1.0
9000 (6638)
1400
14000 (10326)
1100-1900 (43-75)
1100 (43)
4 pcs size M20
1360 (53.5)
1450 (57)
3060 (120.5)
2900 (6393)/
2750 (6063)
460/575, 3ph
25

15000
HSLA/TSLA
150 (33721)
0.02-0.75
18000 (13276)
1400
70000 (51632)
1200-2000 (47-79)
1490 (58)
4 pcs size M24
1900 (75)
2040 (80)
3200 (126)
7000 (15432)/
6800 (14991)
460/575, 3ph
32

25000
HSLA/TSLA
250 (56202)
0.01-0.4
40000 (29500)
2100
175000 (129080)
1400-2200 (55-87)
1950 (77)
8 pcs size M24
2200 (87)
2040 (80)
3800 (150)
9000 (19842)/
8800 (19400)
460/575, 3ph
35

35000
HSLA/TSLA
350 (78683)
0.01-0.4
55000 (40565)
2100
280000 (206528)
1400-2200 (55-87)
1950 (77)
8 pcs size M24
2600 (102)
2400 (94.5)
4000 (157.5)
15000 (33069)/
14500 (31967)
460/575, 3ph
50

50000
HSLA/TSLA
500 (112404)
0.003-0.2
75000 (663800)
2100
400000 (295040)
1400-2200 (55-87)
1950 (77)
8 pcs size M30
2800 (110)
2400 (94.5)
4200 (165)
18000 (39683)/
17500 (38580)
460/575, 3ph
50

750
HSA/HSLA
1070 (42)
204 (8)

1500
HSA/HSLA
1070 (42)
204 (8)

3500
HSA/HSLA
1070 (42)
204 (8)

7000
HSA/HSLA
1400 (55)
256 (10)

15000
HSA/HSLA
2050 (81)
288 (11)

25000
HSA/HSLA
2400 (94.5)
288 (11)

35000
HSA/HSLA
2800 (110)
288 (11)

50000
HSA/HSLA
3000 (118)
450 (18)

Travel speed, mm/min (ipm)

750
RBTSA
0.2-2.3 (0.08-0.9)

1500
RBTSA
0.2-2.3 (0.08-0.9)

3500
RBTSA
0.2-2.3 (0.08-0.9)

7000
RBTSA
0.2-2.3 (0.08-0.9)

15000
RBTSA
0.2-2.3 (0.08-0.9)

25000
RBTSA
0.2-2.3 (0.08-0.9)

35000
RBTSA
0.2-2.3 (0.08-0.9)

50000
RBTSA
0.2-2.3 (0.08-0.9)

Length, mm (in.)
Height, mm (in.)

1710
204

1710
204

1710
204

2130
256

2450
288

2700
288

3300
288

3600
450

Rail Bogies

54

(67)
(8)

(67)
(8)

(67)
(8)

(84)
(10)

(96.5)
(11)

(106)
(11)

(130)
(11)

(142)
(18)

mechanized tig

Prowelder 160/250/320 & Protig 450 Mechanized

TIG Welding Machines
Prowelder 160/250/320

Prowelder series is designed for tube-to-tube

joining using PRB welding heads, tube-to-tube
sheet welding with the POC welding head or the
A25 modular component system for mechanized
TIG welding for various applications
Programmable welding power source makes it
possible to customize the welding process
Internal memory for program storage
Compatible with Weldoc WMS 4000 parameter
monitoring system or the SPS 4000 for setting
parameter documentation without monitoring

Protig 450

Ordering Information

Protig is designed for tube-to-tube joining using

the A21 welding head, tube-to-tube sheet welding
using the POC welding head and the A25 modular
component system for mechanized TIG welding for
various applications
Split welding programs into a large number of
independent and freestanding units
Internal memory for program storage
Compatible with Weldoc WMS 4000 parameter
monitoring system or the SPS 4000 for setting
parameter documentation without monitoring

Technical Data
Primary input voltage, VAC

Permitted load at:

100% duty cycle, A/V

60% duty cycle, A/V
45% duty cycle, A/V
35% duty cycle, A/V
Welding current range, A
Open circuit voltage, V
No load power, W
Dimensions, LxWxH, mm (in.)
Weight, Kg (lbs.)

Prowelder
Prowelder 160......................................................................... 458 300 800
Prowelder 250......................................................................... 458 300 881
Prowelder 320, 230/400/500V, 3ph......................................... 456 650 883
Protig
Protig 450, 208/230/460/475V, 3ph......................................... 456 650 881

Options & Accessories

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

Prowelder 160

Prowelder 250

230, 1ph, 60 Hz
80/13
110/15
160/16
5-160
50-60
50
515x285x835 (20x11x33)
37 (81.5)

400, 3PH, 50/60 Hz

140/16
180/17
250/20
5-250
50-60
55
515x285x620 (20x11x24)
38 (83)

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

Prowelder 320

Protig 450

208/230/460/475, 3ph, 60Hz

270/20.8
320/22.7
5-320
50-60
520
734x489x695 (29x19x27)
110 (242.5) 156 (344)

208/230/460/475, 3ph, 60 Hz
360/24.4
450/28
5-450
50-60
520
734x489x695 (29x19x27)
113 (249) 159 (350.5)

55

mechanized tig

A21 PRB Tube-to-Tube TIG Welding Head

Small, flexible, and lightweight

Unique pincer action reduces set-up times
Accurately positions and secures around the tube
within seconds
Available in three size for tubes with outer diameters of
17 to 170 mm (0.67-6.7 in.)
Use with Prowelder and Protig power sources
Choose from air-cooled and water-cooled versions
Includes 7 m (23 ft.) of connection cable

Ordering Information
Water-Cooled
A21 PRB, 17-49 mm (0.67-2 in.)............................................. 443 750 880
A21 PRB, 33-90 mm (1-3.5 in.)............................................... 443 760 880
A21 PRB, 60-170 mm (2-6.5 in.)............................................. 443 770 880
Air-Cooled
A21 PRB, 17-49 mm (0.67-2 in.)............................................. 443 750 881
A21 PRB, 33-90 mm (1-3.5 in.)............................................... 443 760 881
A21 PRB, 60-170 mm (2-6.5 in.)............................................. 443 770 881

Options & Accessories

Angular 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)

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
0.04-0.95
Tube 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 water-cooled
250
250
250
air -cooled
100
100
100
@ 100% duty cycle
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.

56

A21 PRB Sales Literature.................................................XA00098520

A21 PRB Instruction Manual.............................................443 808 001

mechanized tig

A21 PRC Tube-to-Tube TIG Welding Head

Choose between arc voltage control (AVC) models

with or without weaving
Zig-zag weaving movement with AVC produces
better weld quality with increased productivity
particularly when welding thick-walled tubes
Available in three size for tubes with outer
diameters of 17 to 170 mm (0.67-6.7 in.)
Use with Protig 450 power source
Includes 7 m (23 ft.) of connection cable
Water-cooled only

Ordering Information
AVC Only
A21 PRC, 17-49 mm (0.67-2 in.).....................................443 751 880
A21 PRC, 33-90 mm (1-3.5 in.).......................................443 761 880
A21 PRC, 60-170 mm (2-6.5 in.).....................................443 771 880
AVC w/ Weaving
A21 PRC, 17-49 mm (0.67-2 in.).....................................443 752 880
A21 PRC, 33-90 mm (1-3.5 in.).......................................443 762 880
A21 PRC, 60-170 mm (2-6.5 in.).....................................443 772 880

Options & Accessories

Angular Support Bracket...............................................443 875 880
Rebuilding kit, PRB/PRC 17-49.....................................442 002 880
For welding tubes with OD of 8-17 mm (0.3-0.7 in)

Rebuilding kit, PRB/PRC 33-90.....................................443 908 880

For welding tubes with OD of 20-33 mm (0.8-1.3 in)

Rebuilding kit PRB/PRC 60-170....................................443 909 880

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

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
Tube dia., mm (in.)
17-49 (0.67-2)
33-90 (1-3.5)
Tube dia. optional, mm (in.)
8-17 (0.3-0.67)
20-33 (0.8-1)
Max. welding current @ 100% duty cycle
250
250
Electrode dia., mm (in.)
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)
Oscillation:
Adjustment range, mm/s (in./s)
20 (0.8)
20 (0.8)
Amplitude, mm (in.)
+/-6 (+/-0.24)
+/-6 (+/-0.24)
Weave speed, mm/s (in./s)
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*)
Weight, Kg (lbs.) AVC
3 (7)
4 (8)
AVC w/ weave unit
5 (11)
5.5 (12)
* 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 Sales Literature.................................................XA00098520

A21 PRC Instruction Manual.............................................443 934 001

0.04-0.95
60-170 (2-6.5)
44-60 (1.5-2)
250
1.6-2.4 (1/16-3./32)
2.5 (0.1)
20 (0.8)
+/-6 (+/-0.24)
2-12 (5/64-0.5)
D/2+137 (D/2+5.4)
5 (11)
7 (15)

57

mechanized tig

A21 PRH Enclosed Tube TIG Welding Head

Designed for welding thin-walled, stainless steel tubes

to provide maximum gas shielding around the tube
Rotating part and tungsten electrodes are enclosed in
a gas chamber formed by the outer casing, which also
constitutes the clamping arrangement for the tube to
be welded
Water-cooled and available in three sizes to weld tubes
between 3-76.2 mm (0.1-3 in.)
Equipped with encoder motors for precise positioning
of each sector when welding with different sets of
parameters
Includes 8 m (26 ft.) connection cable
For use with Prowelder and Protig power sources

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

Options & Accessories

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

Technical Data
Rotation, rpm
Tube outer diameter, mm (in.)
Max. welding current @ 100% duty cycle
Electrode diameter, mm (in.)
Weight, incl. cables, Kg (lbs.)

58

A21 PRH 3-12 mm

0.65-12.6
3-12.7 (0.12-0.50)
15 A continuous 40 A pulsed
1 (0.040)
5 (11)

A21 PRH 3-38 mm

0.5-9.5
3-38.1 (0.12-1.50)
50 A continuous 100 A pulsed
1.6-2.4 (1/16-3/32)
6.5 (14)

A21 PRH 6-76 mm

0.31-6.15
6-76.2 (0.24-3)
60 A continuous 100 A pulsed
1.6-2.4 (1/16-3/32)
7.5 (16.5)

A21 PRH Welding Head Sales Literature......................... XA00115920

A21 PRH Welding Head Instruction Manual.....................444 291 104

mechanized tig

A21 PRD Orbital Tube and Pipe TIG Welding Heads

A21 PRD 100

A21 PRD 160

Designed for tubes with an outer diameter of 100 mm

(4 in.) or more
Requires only 73 mm (3 in.) clearance around the tube
Water-cooled and designed for amperage of up to 400A
All welding parameters are incorporated into the
procedure program, controlled by a microprocessor system
For use with the Protig 450 power source
Includes 8 m (26 ft.) of connection cable

A21 PRD 100 welding head

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

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

A21 PRD 100

A21 PRD 100 welding head................................................... 444 016 880
Narrow gap head, 50 mm (2 in.)............................................ 441 623 880
Narrow gap head, 80 mm (3 in.)............................................ 441 623 881
A21 PRD 160
A21 PRD 160 welding head, basic........................................ 444 151 880
For use only when fusion welding with a floating head

A21 PRD 160 w/ wire feeder.................................................. 444 151 881

A21 PRD 160 w/ AVC.............................................................. 444 151 882

Technical Data

Weaving
AVC
Weight, Kg (lbs.)

Options & Accessories

For A21 PRD 160 only

Wire feed unit..................................................................444 137 880

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

A21 PRD 100

Max. welding current @ 100% duty cycle

Working range, external, mm (in.)
Clearance height, mm (in.)

Filler wire

Designed for pipes with an outer diameter of 160 mm (6 in.) or more

Carriage travels around the pipe on a rack adapted to
match the diameter of the pipe
Basic model for thin-walled pipes includes one motor for travel
Options for thick-walled pipes include wire feed, arc
voltage control (AVC), and weaving modules
For use with Prowelder power sources
For use only with Protig 450 when using AVC and weaving
Includes 8 m (26 ft.) of connection cable

A21 PRD 160 welding head

Ordering Information

Min. distance to flange, mm (in.)

Rotation speed, cm/min (ipm)
Torch, water-cooled with gas lens

Electrode size, mm (in.)

Angular adjustment
Feed speed, cm/min (ipm)
Diameter, mm (in.)
Contact tip
Wire spool dia., mm (in.)
Speed, mm/s (in./s)
Amplitude, mm (in.)
Rest time at end position, s
Speed, mm/s (in./s)
Amplitude, mm (in.)

315 A continuous DC 400 A pulsed DC

160-1025 (6.3-40.4)
111-119 (4.4-4.7)
+37 for handle (+1.5)
18 at 0o skew (0.71)
2-40 (0.8-15.7)
1.6-3.2 (1/16-1/8)
-30o - +45o
15-150 (5.9-59)
0.8-0.9 (0.030-0.035)
Adjustable in X, Y, Z direction
100 (4)
2-12 (0.08-0.47)
+/-15 (+/-0.6)
0.1-10
2.0 (0.08)
8 (17.6)

A21 PRD 100 Sales Literature..........................................XA00091720

A21 PRD 160 Sales Literature.......................................Contact ESAB
A21 PRD 100 Instruction Manual......................................444 061 001
A21 PRD 160 Instruction Manual......................................444 100 001

A21 PRD 160

315 A continuous DC
100 to flat
73 minimum

400 A pulsed DC
(3.94 to flat)
(2.87)

18 at vertical (0.71)
2-40 (0.8-15.7)
1.0-4.0 (0.040-5/32)
-30o - +45o
10-250 (3.9-98)
0.6-1.2 (0.023-0.045)
Adjustable in X, Y, Z direction
100 (4)
2-19 (0.08-0.75)
+/-15 (+/-0.6)
0.1-10
2.0 (0.08)
25 (1.0)
8 (17.6)

59

mechanized tig

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

Precision-built, robust, versatile welding head for

all types of tube-to-tube sheet welding
Working range of 12-60 mm (0.5-2.4 in.) outer
diameter
High centering accuracy
Patented centering mandrels are available for
inner tube diameters from 9.9 mm (0.38 in.)
Water-cooled and capable of pulsing at 200A, 60%
duty cycle
Includes 8 m (26 ft.) of connection cable and wire
feed unit as standard

Ordering Information
A22 POC 12-60 welding head w/ wire feed...................443 930 880

Options & Accessories

Counter-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).........441 131 880
Internal 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)....441 133 880
Spindles and centering cartridges.......................... Contact ESAB

Technical Data
Working range diameter
Rotation, rpm
Electrode diameter, mm (in.)
Rating, A @ 60% duty cycle
Welding cable length, m (ft.)
Weight, welding head only, Kg (lbs.)
Wire feed unit

60

Electrode parallel with tube axis, mm (in.)

Electrode 30o from tube axis, mm (in.)

Filler wire diameter, mm (in.)

Filler wire speed, m/min (ipm)
Wire spool diameter, mm (in.)
Wire reel weight, Kg (lbs.)

12-60 (0.5-2.4)
12-36 (0.5-1.4)
0.2-4.5
1.6-2.4 (1/16-3/32)
180
8 (26.2)
4.8 (10.6)
0.8-0.9 (0.030-0.035)
0.15-1.5 (5.9-59)
100 (4)
0.5 (1.1)

A22 POC 12-60 Welding Head Sales Literature..............XA00087220

A22 POC 12-60 Welding Head Instruction Manual..........443 959 041

mechanized tig

A25 Mechanized TIG Modular Component System

Modular components can be easily combined to

create customized solutions for specific welding
requirements
TIG Narrow Gap method can be used together
with A25 system for extremely small joint angle
and subsequent low joint volume
Choose between different models with arc voltage
control (AVC), weaving slides, manual horizontal
and vertical slides, floating slides, circular slides,
wire feeder and BTE 250M or BTE 500M torch
For use with Prowelder and Protig power sources

Ordering Information
A25 Welding Automat w/ BTE 250M Torch Models
A25 complete system.....................................................443 910 880
Includes A25 welding automat, AVC, weaving slides, wire feed unit,
VEC motor w/ turntable and BTE 250M torch mounted on stand

w/ AVC.............................................................................. 443 911 880

w/ AVC, weaving slides.................................................. 443 911 882
w/ AVC, manual horizontal slides.................................. 443 911 884
w/ manual vertical and horizontal slides...................... 443 911 886
w/ slides for floating head.............................................443 912 880
A25 Welding Automat w/ BTE 500M Torch Models
A25 complete system.....................................................443 910 881
Includes A25 welding automat, AVC, weaving slides, wire feed unit,
VEC motor w/ turntable and BTE 500M torch mounted on stand

w/ AVC.............................................................................. 443 911 881

w/ AVC, weaving slides.................................................. 443 911 883
w/ AVC, manual horizontal slides.................................. 443 911 885
w/ manual vertical and horizontal slides...................... 443 911 887
w/ slides for floating head.............................................443 912 880

Technical Data
AVC slide amplitude, mm (in.)
AVC slide speed, mm/s (ipm)
Weaving slide amplitude, mm (in.)
Weaving slide speed, mm/s (ipm)
Manual slide amplitude, mm (in.)
Floating slide amplitude, mm (in.)
Wire diameter, m/min (ipm)
Wire feed speed, m/min (ipm)
VEC motor with encoder speed, rpm
VEC motor with encoder ratio

76 (3)
2.8 (0.1)
76 (3)
19 (0.75)
93 (3.6)
76 (3)
0.6-1.6 (23.6-63)
0.1-2.6 (4-102)
1000
672:1

A25 Component System Sales Literature.......................XA00089520

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

Options & Accessories

1. Bracket................................................................................ 441 404 880
2. Wire feed unit, dia. 0.6-0.8 mm (0.023-0.030 in.).............. 441 300 882
3. Feed roller, dia. 1.0-1.2 mm (0.040-0.045 in.).................... 369 557 003
4. Feed roller, dia. 1.2-1.6 mm (0.045-1/16 in.)...................... 369 557 007
5. Outlet pipe, dia. 0.8-1.2 mm (0.030-0.045 in.)................... 441 456 881
6. Outlet pipe, dia. 1.6 mm (1/16 in.)..................................... 441 456 882
7. Connection cable, feed unit 8 m (26 ft.)............................ 443 828 880
8. Wire hose, per meter [std. 400 mm (15.75 in.)]................ 192 799 112
9. Wire nozzle, BTE 250M torch............................................. 441 407 880
10. Wire nozzle, BTE 500M torch........................................... 441 407 881
11. BTE 250M TIG torch......................................................... 441 362 880
12. BTE 500M TIG torch......................................................... 441 418 880
13. BTE 250M torch holder.................................................... 441 414 880
14. BTE 500M torch holder.................................................... 441 414 881
15. AVC slide........................................................................... 443 913 880
16. Circular slide..................................................................... 145 945 880
17. Manual slide...................................................................... 413 518 880
18. Weaving slide.................................................................... 443 913 881
19. Floating slide.................................................................... 441 674 881
20. Single guide wheel unit, BTE 250M torch...................... 441 833 880
Single guide wheel unit, BTE 500M torch............................ 441 833 881
21. Double guide wheel unit, BTE 250M torch..................... 442 358 880
Double guide wheel unit, BTE 500M torch........................... 442 358 881
22. Bracket.............................................................................. 441 412 880
23. Brake hub.......................................................................... 146 967 881
24. Bobbin protection............................................................. 157 482 880
Multi-contact plug for connection with Protig..................... 441 600 880
VEC motor with tacho, speed 1000 rpm, ratio 672:1.............457 258 880
Control unit to VEC 457 222 880
Turntable with return cable connection for VEC motor...... 442 712 880
Narrow gap kit for BTE 500M torch....................................... 441 667 880
Motor control unit PAL 3........................................................ 457 870 990

61

mechanized tig

MEI 21/10 Wire Feed Units

MEI 21 Wire Feed Unit

Four wire rollers for orbital TIG welding

Eliminates the need for a wire feed unit and wire spool
mounted on the welding head
Use with 5 Kg (11 lbs.) wire spools
For wire diameters of 0.6 mm (0.023 in.) to 0.8 mm
(0.031 in.)
Includes wire hose

MEI 10 Wire Feed Unit

Developed for mounting PRB 17-170 tools (PRC 17-49

only with AVC)
PRB tools with MEI 10 can be used with Prowelder
power sources
PRC tools with MEI 10 can be used with Protig 450
Ideal for aluminum welding with short wire feed
distance from the reel to the molten pool
Also use for mild steel and stainless steel
For wire diameters of 0.8 mm (0.030 in.) to 1.0 mm
(0.040 in.) for aluminum, 0.8 mm (0.030 in.) for steel
Motor equipped with pulse generator for precise wire
feed speed adjustment

MEI 21

MEI 10

Ordering Information
MEI 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........... 444 212 880
MEI 10 - PRB 60-170/PRC 60-170 w/ AVC and weaving....... 444 213 880

Technical Data
Wire diameter, mm (in.)
Wire feed, m/min (ipm)
Max. spool dimension/weight, mm/Kg (in./lbs.)
Hub width, mm (in.)
Hub hole diameter, m (ft.)
Wire guide length, m (ft.)
Weight, Kg (lbs.)

62

MEI 21
0.6-0.8
0.1-2.6
200/5
60
51.5
4.2
4

(0.023-0.031)
(0.004-0.1)
(8/11)
(2.4)
(169)
(14)
(8.8)

MEI 10
0.8
0.1-1.2
60/0.26
0.1
0.5

(0.031)
(0.004-0.05)
(2.4/0.6)
(0.3)
(1.1)

MEI 21 Wire Feed Unit Sales Literature...........................XA00089020

MEI 10 Wire Feed Unit Sales Literature...........................XA00098620
MEI 21 Wire Feed Unit Instruction Manual.......................443 831 001
MEI 10 Wire Feed Unit Instruction Manual.......................444 215 001

mechanized tig

G-Tech Precision TIG Electrode Grinder

Unique enclosed wet grinding system for tungsten

electrodes
Stable, concentrated TIG welding arc guarantees
accuracy and repeatability
Automatic collection of grinding dust - no risk to
welder or environment
No oxidation of the tungsten electrode when wet
grinding
Contributes to longer life of electrode point
Disposal and recycling system in the grinder

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

Options & Accessories

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

Electrode clamp 2.4 mm (3/32 in.)......................................... 700 009 009

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

OCF 2M Cooling Unit

Cooling unit designed for use with Prowelder 160

Easy to mount under the power source
Maximum working height - 7 m (23 ft.)

Ordering Information
OCF 2M cooling unit.......................................................457 216 882

Technical Data
Primary input, VAC
Max. power consumption, W
Max. water pressure, bar (psi)
Cooling power, degree, L/min, kW
Total water consumption, L (gal)

230
250
3 (43.5)
4
5 (1.32)

G-Tech TIG Electrode Grinder Sales Literature.................... 898C129

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

63

mechanized tig

Welding Parameter Documentation Printer

Printer for documentation of welding parameters

Use with Prowelder 160, 320 and Protig 450
Prints programmed and measured values for speed,
current, voltage, wire and power
Print-out indicates power source used, time, run

number and total welding time

Ordering Information
Parameter 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....................... 459 370 881
Paper 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

Technical Data
Printing principle
Printing speed
Resolution
Paper load
Control voltage
Power consumption @ 12 V DC
Temperature range
Number of sectors

64

Sleep mode
Standby
Printing
Operation mode
Standby mode

Thermoprinter for 58 mm (2.3 in.) thermo paper with fixed printer head
8 lines/s
384 points/line
Automatic and manual feed
9-32 V DC, protected against incorrect polarity and overload/load dump
Max. 10 mA
Max. 100 mA
Max. 2 A
-25-+55oC (-13-131oF)
-40-+70oC (-40-157oF)
Max. 20; change of max. 3 parameters in each sector is possible to secure proper printing of
20 sectors

Parameter Documentation Printer Sales Literature....... XA00114420

robotics

AristoMig Process Packages for Mechanized MIG Welding

Power source with built-in welding knowledge

for storage of many synergic lines for optimal
performance
Special wire feeder versions like Aristo RoboFeed
with capsulated feeder
Standard wire feeders can also be used for robotic
applications
Use with standard spools or bulk pack wire ,max.
475 Kg (1047 lbs.) drums with automatic switching
to new drum for endless wire feed - excellent for
high productivity
Bus splitter simplifies quick change of cables and
apparatus and links the ESAB internal bus with the
robots control system
External bus communication and control cable
controls both the welding process and coincides
with the robot control
Conventional interface needed if not using bus
control systems

Standard AristoMig Welding Components for DeviceNet

Communication

Applied Welding Solutions

When a component or complete welding system for
another robot & communication network solution is
needed, eg/ with CANopen, DeviceNet or ProfiBus,
ESAB has the experience to make customer oriented
components to suit most applications.
For many mechanized applications, ESAB has a
standard solution. ESAB also provides customer adapted
solutions to suit specific applications.

Mechanized MIG Processes

MIG welding
MIG pulse welding
MIG Aristo SuperPulseTM
Short arc/pulse
Pulse/pulse
Pulse/spray arc
MIG brazing

AristoMig Robotic Packages Sales Literature................XA00125020

AristoMig Retrofit Components Sales Literature...........XA00125220
AristoMig Components Sales Literature.........................XA00125320

65

robotics

Standard AristoMig Robot Package Configuration

AristoMig 450
230-575 vac
459 349 890

AristoMig 450w
230-575 vac
459 349 888

AristoMig 500
460 vac
459 230 884

AristoMig U500w
460 vac
459 230 885

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

External Bus Interface

AristoPendant U8 - DeviceNet.......................................... 461 050 880
AristoPendant U8 - CANopen........................................... 461 050 883

Splitter
Bus splitter DeviceNet Harting 24..................................... 461 105 880

Control Cable, Power Source - robot

1.7 m (6 ft.)........................................................................ 456 527 880
5 m (16.5 ft.)...................................................................... 456 527 881
10 m (33 ft.)....................................................................... 456 527 890
15 m (50 ft.)....................................................................... 456 527 882
25 m (80 ft.)....................................................................... 456 527 883
35 m (115 ft.)..................................................................... 456 527 884

Cable Package, Power Source - drive unit

Air-Cooled
Water-Cooled
5 m (16.5 ft.)
740 538 890..................................... 740 538 895
10 m (33 ft.)
740 538 881..................................... 740 538 886
15 m (50 ft.)
740 538 882..................................... 740 538 887
25 m (82 ft.)
740 538 883..................................... 740 538 888
35 m (115 ft.)
740 538 884..................................... 740 538 889

Drive Unit System - External (Assembly bracket incl.)

AristoFeed Control................................................. 461 080 880
7

Aristo Feed Mech 4804w

23p Burndy...................... 461 070 880
12p Burndy...................... 461 070 881

Assembly Bracket
Assembly bracket universal........................... 461 038 880

Cable & Hose Kit, 2m (6.6 ft)

66

Drive Unit System - Enclosed

Aristo RoboFeed 3004w, 23p Burndy............. 461 000 880
Aristo RoboFeed 3004w, 12p Burndy..............461 000 881

Assembly Bracket
Assembly bracket universal........................... 461 038 880

461 135 881

Accessories
3 m (10) Heavy Duty Conduit ( with quick-connect fittings)
4.5 m (15) Heavy Duty Conduit ( with quick-connect fittings)
6 m (20) Heavy Duty Conduit ( with quick-connect fittings)
Heavy Duty Conduit ( per metre)
Quick Connector Adaptor Kit ( connects conduit to feeder)
Quick Conduit Adaptor Kit for Marathon Pac

899F84
899F45
899F85
899F74
899F50
899F71

applied automation

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

Fast and flexible way to increase productivity

Equipped with A2-A6 PEH process controller and
A2 welding equipment for mechanized SAW or MIG
welding
Weld various profiles such as I-, T-, or L- beams,
straight columns, or tapered columns
Available in four versions (width of gantry): 1730mm
(68 in), 2100 mm (83 in.), 2500 mm (94 in.), or 3000
mm (118 in.)
All versions have standard gantry leg height of 1500
mm (59 in.)
Floor mounted rail delivered in standard lengths of 3
m (118 in.) - can be easily extended
Dual-drive motors are standard
Gantry can support a maximum weight of 220 Kg
(485 lbs.) - up to two A2 welding heads, complete
with GMD joint tracking, and OPC flux recovery
systems

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

Options & Accessories

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

Technical Data
Travel speed, m/min (ipm)
Maximum load, Kg (lbs.)
Standard rail length, m (ft.)
Gantry dimensions, WxH, mm (in.)

0.2-1.9
220
3
1730-3000

(8-75)
(485)
(9.8)
(68-118)

Mechtrac 1730/2100/2500/3000 Sales Literature.............XA00101220

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

67

applied Automation

Column & Boom Systems

Modular design concept allows total customization

using standard components
Large selection of available components to
integrate for a custom solution:
Any A2 or A6 weld head system
A2-A6 PEH process controller with LAF or

TAF power sources
ESAB turning rolls and positioners
ESAB flux feeding and recovery systems
GMD and laser joint tracking systems
Monitoring systems, cameras, WMS 4000

quality supervision software
Four basic station designs suitable for most
standard applications
Three different sizes: 300, 460 and 600 [number
refers to boom profile height (mm) which
determines working range and load capability]
Choose from stationary or mobile, rail-travelling
carriage systems
Versatile to respond to any automated welding
demand

Standard CaB Sizes

The manipulators are divided into three different sizes 300, 460 and 600. These sizes are the throat dimensions of the
boom in millimeters. Each size has a corresponding column. The different sizes are not only limited in where it can fit,
but also how far the boom can extend and how much load that can be put on.

Performance Categories

The system is divided into three different categories for performance:

S: Standard
Standard mechanical performance, no cable chain
A few options, camera-system, tacho-regulated speed and flux control
Only for Basic station 1
M: Modular
Standard mechanical performance, including cable chain for column and booms
More than 20 options fully integrated, such as tandem, shift function, transport speed etc
Only for Basic station 1
C: Customized
Based on the same mechanical performance as the S- and M- model
Based on the same electrical system as the M- model
Includes everything that is not a S- or M- model such as:
Basic station 2, 3, and 4
Odd sizes (ex. 4.35 m x 5.15 m)
Option demands not offered in S- or M- model.

68

applied automation

Column & Boom Systems - Basic Stations

Basic station 1
Standard set-up with welding equipment on one or

both ends of the boom
Positioning of welding equipment in 4-axis
Application: Vessels, pipes, profiles and other large

welding constructions.
Perfect for narrow spaces

Basic station 2
Basic station 1 with the added advantages of a

side boom carriage with welding equipment
Boom is movable and simultaneous welding can

be achieved with two heads
Application: vessels and pipes or conical girders

and box profiles

Basic station 3
Welding station with horizontally fixed boom and is

equipped with two side boom carriages supporting

welding equipment on same side of boom
Weld simultaneously with two heads
Application: straight and conical girders, box profiles,

beams, stiffeners and vessels

Basic station 4
Welding station with horizontally fixed boom

featuring double track with boom carriages

supporting welding equipment on both sides of the

boom
Simultaneous welding operation with two heads as

standard
Application: containers, truck platform bodies, box

girders, beams, stiffener section and joining of

plates and sections

69

applied automation

Technical Data
Column - Effective working range, m (ft.)
Max. boom height A, w/ moveable carriage, mm (ft.)
Min. boom height A, w/ moveable carriage, mm (ft.)
Max. boom height B, w/ concrete stand, mm (ft.)
Min. boom height B, w/ concrete stand, mm (ft.)
Max. boom height C, w/ floor plate, mm (ft.)
Min. boom height C, w/ floor plate, mm (ft.)
Total height D, w/ moveable carriage, mm (ft.)
Total height E, w/ concrete stand, mm (ft.)
Total height F, w/ foot plate, mm (ft.)
Lifting speed, m/min (ipm)
Boom - Effective working range, m (ft.)
Max. extension G, mm (ft.)
Min. extension G, mm (ft.)
Permissible loads
total, Kg (lbs.)
one end, Kg (lbs.)
Cross sectional diameter H, mm (in.)
Welding speed, m/min (ipm)
Transport speed, m/min (ipm)
Rail Carriage/Concrete Stand/Foot Plate
Rail carriage track width, inside to inside L, mm (in.)
Rail carriage dimensions,WxL, mm (in.)
Rail carriage height I, mm (in.)
Welding speed, m/min (ipm)
Transport speed, m/min (ipm)
Concrete stand dimensions, WxL, mm (in.)
Concrete stand height J, mm (in.)
Foot plate dimensions, WxL, mm (in.)
Foot plate height K, mm (in.)

70

300S/300M
3
4070
950
3750
610
3955
815
5170
5055
4850
0.7
3
3580
540
300
240
325
0.1-2.0
2

(10)
(13)
(3)
(147)
(24)
(156)
(32)
(17)
(16.5)
(16)
(27.5)
(10)
(11.75)
(2)
(660)
(530)
(13)
(4-79)
(78)

4
5070
950
4750
610
4955
815
6170
6055
5850
0.7

(13)
(16.5)
(3)
(187)
(24)
(195)
(32)
(20)
(20)
(19)
(27.5)

5
6070
950
5750
610
5955
815
7170
7055
6850
0.7

4
4580
540
220
150
325
0.1-2.0
2

(13)
(15)
(2)
(485)
(330)
(13)
(4-79)
(79)

5
5580
540
150
75
325
0.1-2.0
2

1730
2060x2330
365
0.1-2.0
2
2060x2100
250
1100x1100
40

(16.5)
(20)
(3)
(226)
(24)
(234.5)
(32)
(23.5)
(23)
(22.5)
(27.5)
(16.5)
(18)
(2)
(330)
(165)
(13)
(4-79)
(79)

(68)
(81x92)
(14)
(4-79)
(79)
(81x83)
(10)
(43x43)
(1.6)

Column & Boom 300S Sales Literature........................... XA00118720

Column & Boom 300M Sales Literature.......................... XA00118820

applied automation

Technical Data
Column - Effective working range, m (ft.)
Max. boom height A, w/ moveable carriage, mm (ft.)
Min. boom height A, w/ moveable carriage, mm (ft.)
Max. boom height B, w/ concrete stand, mm (ft.)
Min. boom height B, w/ concrete stand, mm (ft.)
Max. boom height C, w/ floor plate, mm (ft.)
Min. boom height C, w/ floor plate, mm (ft.)
Total height D, w/ moveable carriage, mm (ft.)
Total height E, w/ concrete stand, mm (ft.)
Total height F, w/ foot plate, mm (ft.)
Lifting speed, m/min (ipm)
Boom - Effective working range, m (ft.)
Max. extension G, mm (ft.)
Min. extension G, mm (ft.)
Permissible loads
total, Kg (lbs.)
one end, Kg (lbs.)
Cross sectional diameter H, mm (in.)
Welding speed, m/min (ipm)
Transport speed, m/min (ipm)

460S/460M
4
4950
950
4845
845
4510
510
6275
6170
5835
0.7

(13)
(16)
(3)
(16)
(3)
(15)
(1.6)
(20.5)
(21)
(20)
(27.5)

5
5950
950
5845
845
5510
510
7275
7170
6835
0.7

(16.5)
(19.5)
(3)
(19)
(3)
(18)
(1.6)
(24)
(23.5)
(22.5)
(27.5)

6
6950
950
6845
845
6510
510
8275
8170
7835
0.7

(20)
(23)
(3)
(22.5)
(3)
(21.5)
(1.6)
(27)
(27)
(25.5)
(27.5)

4
4850
850
1100
550
630
0.1-2.0
2

(13)
(16)
(3)
(2423)
(1211)
(25)
(4-79)
(78)

5
5850
850
1050
450
630
0.1-2.0
2

(16.5)
(19)
(3)
(2313)
(991)
(25)
(4-79)
(79)

6
6850
850
1000
350
630
0.1-2.0
2

(20)
(22.5)
(3)
(2203)
(771)
(25)
(4-79)
(79)

Rail Carriage/Concrete Stand/Foot Plate

Rail carriage track width, inside to inside L, mm (in.)
Rail carriage dimensions,WxL, mm (in.)
Rail carriage height I, mm (in.)
Welding speed, m/min (ipm)
Transport speed, m/min (ipm)
Concrete stand dimensions, WxL, mm (in.)
Concrete stand height J, mm (in.)
Foot plate dimensions, WxL, mm (in.)
Foot plate height K, mm (in.)

Column & Boom 460S Sales Literature........................... XA00118920

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

1730
2100x2380
485
0.1-2.0
2
2100x2410
380
1600x1600
40

(68)
(83x94)
(19)
(4-79)
(79)
(83x95)
(15)
(63x63)
(1.6)

71

applied automation

Seamers for External Longitudinal Seam Welding

Best solution for high quality longitudinal welds to

plates, tanks or other cylindrical workpieces
Seamers are delivered ready to weld
Available for 1.5-6 m (59-236 in.) long welds and
for diameters 180-1000 mm (7-39 in.)
Easy alignment of plates with help from laser light
Pneumatically operated stoppers for plate
alignment available
Water-cooled backing bar
Copper backing bar equipped with shielding gas
for plasma and TIG processes
Manual and remote control operations with PLC
controller

Technical Data

ED15H10

ED20H10

ED30H10

ED40H10

ED60H10

Nominal length, mm (in.)

Welding length, mm (in.)
Min. diameter, mm (in.)
Max. diameter, mm (in.)1
Plate thickness, not tack-welded mm (in.)
Max. plate thickness, tack-welded, mm (in.)

1500
1750
180
1000
1-8
10

2000
2250
180
1000
1-8
10

3000
3250
250
1000
1-8
10

4000
4250
350
1000
1-8
10

6000
6250
600
1000
1-8
10

(59)
(69)
(7)
(39)
(0.04-0.31)
(0.40)

(78)
(89)
(7)
(39)
(0.04-0.31)
(0.40)

(118)
(128)
(10)
(39)
(0.04-0.31)
(0.40)

(157)
(167)
(14)
(39)
(0.04-0.31)
(0.40)

(236)
(246)
(24)
(39)
(0.04-0.31)
(0.40)

1 extension block available

Seamers for Internal Longitudinal Seam Welding

Best solution for high quality longitudinal welds to

plates, tanks or other cylindrical workpieces
Seamers are delivered ready to weld
Available for welding a max of 6 m (236 in.) long
welds and diameters greater than 1500 mm (60in.)
Easy alignment of plates with help from laser light beam
Pneumatically operated stoppers for plate
alignment available
Copper backing bar equipped with shielding gas
for Plasma and TIG processes
Conserve shielding gas with divided gas valves
Manual and remote control operations with PLC
controller

Technical Data

ID40H10

ID60H10

Nominal length, mm (in.)

Welding length, mm (in.)
Min. diameter, mm (in.)
Plate thickness, not tack-welded mm (in.)
Max. plate thickness, tack-welded, mm (in.)

4000
4250
1500
1-8
10

6000
6250
1500
1-8
10

72

(157)
(167)
(59)
(0.04-0.31)
(0.40)

(236)
(246)
(59)
(0.04-0.31)
(0.40)

ED External Seamers Sales Literature............................XA00120020

ID Internal Seamers Sales Literature...............................XA00120120

Applied automation

Seamers for Longitudinal Seam Welding, contd

Ordering Information
Package*

ED15H10

ED20H10

ED30H10

ED40H10

ED60H10

ID40H10

ID60H10

SAW1
SAW2
MIG1
MIG2
MIG3
TIG1
TIG2

1069500
10630900
10695500
10631400
10631900
10632400
10632900

10695100
10631000
10695600
10631500
10632000
10632500
10633000

10695200
10631100
10695700
10631600
10632100
10632600
10633100

10695300
10631200
10695800
10631700
10632200
10632700
10633200

10695400
10631300
10695900
10631800
10632300
10632800
10633300

10696300
10637600
10696500
10637800
10638000
10638200
10638400

10696400
10637700
10696600
10637900
10638100
10638300
10638500

External Seamers

ED15H10

ED20H10

ED30H10

ED40H10

ED60H10

High extension block, 500 mm (20 in.)

Plate stopper, required amount
Stopper ring

10639200
2
10639800

10639300
2
10639900

10639400
2
10640000

10639500
2
10640100

10639600
2
10640200

* See table below for Package contents

Options & Accessories

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

*Packages
SAW1

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

SAW2

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 torch

MIG2

AristoMig 400 power source, AristoFeed 48-4W, MA6 wire feeder, MIG torch

MIG3

AristoMig 450 power source, AristoFeed 48-4W, MA6 wire feeder, MIG torch

TIG1

AristoTig 400 power source, BTE500M TIG torch

TIG 2

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

73

applied automation

Circotech Compact Girth Welding System

Self propelled three oclock welding system

Designed for on-site erection of large storage
tanks, silos, blast furnaces and cylindrical objects
Available as single or double-sided
Designed to travel along the edge of a tank shell
on a rail temporarily attached to the shell, or on a
stand-alone ring outside the shell
Equipped with caged cabin for maximum safety
and easy to reach welding controls
Standard equipment includes single-wire SAW, or
twin wire SAW on request
Utilizes ESABs flux supply and recovery system

Ordering Information
Circotech complete package.................................... Contact ESAB
System 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 Data
Plate height, mm (ft.)
Plate thickness, mm (in.)
Shell curvature, radius, mm/min (ipm)

74

1000-3000
8-35
4000

(3.3-10)
(0.3-1.4)
(157)

Circotech Sales Literature................................................XA00083620

applied automation

Rototech 80 for Rotary Welding

Programmable welding system for light and

medium weight cylindrical objects
Welding process and parameters are controlled by
modern PLC control technology
Weld components as large as 400 mm (16 in.) in
diameter, 3000 mm (118 in.) in length, and up to
80 Kg (176 lbs.) in weight

Ordering Information
Rototech 80................................................................ Contact ESAB
System 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

Technical Data
Input power, 3 phase
Recommended fuses, A
Max. welding current per gun, A
Air supply, kPa (psi)
Operational voltage, VDC
Contact function (galvanically insulate) for current contactor/cold wire feed unit
Clamping force, Nm (lbf-ft)
Clamping length, pressure cylinder, mm (in.)
Protection class, motor unit
Protection class, electrical cabinet
Rotation speed, rpm
Weld length, o (# of rotations)
# of programs
Max. torque during continuous operation, Nm (lbf-ft.)
Max. diameter of work object, mm (in.)
Weight, Kg (lbs.)
Ambient temperature, oC (oF)
Operational noise, dBA
Total height, mm (in.)
Total length, excluding weld length, mm (in.)
Weld length, mm (in.)

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

As requested
16
450
500 (72.5)
24
2A resistive load, 80 VA inductive load
150 at max. 0.3 MPa (110.6 max. 3.5 psi)
80 (3)
IP 23
IP 55
0.12-7.0
0.1-3600 (0-10)
1
60 (44.3)
400 (16)
80 (176)
5-40 (41-104)
<50
1550 (61)
1300 (51)
500-3000 (19.6-118)

75

special applications

Windmill Tower Manufacturing

Dedicated Solutions for Dedicated Manufacturers

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.

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.

Windmill tower manufacturing using a Column & Boom system.

76

Efficient Welding in Tower Manufacturing Brochure..... XA00126920

special applications

Windmill Tower Manufacturing - Production Line

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

cutting

The plate is roll-formed and tack welded

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

Flanges are welded using the submerged arc process

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

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

77

special applications

Windmill Tower Manufacturing - Production Line, contd

78

Internal joining of the sections is done using a the A2 Tripletrac welding

tractor or a column and boom, depending on the production line
configuration
Turning rolls or a head & tailstock turn the section during internal welding
This process is supervised by the operator inside the workpiece

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

Production of sub-components, such as the gear box housing, are welded

using positioning equipment and manual welding equipment

special applications

Beam Welding
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. ESABs
extensive experience in beam welding ensures optimum straightness and productivity. Some beam welder examples
are shown, please call for further information on specific applications.

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 Welder

With 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

Submerged-Arc Trailer Beam Welder

Available in narrow track or carriage configuration

CaB 300 for trailer beams; CaB 460 for larger beams
Equipped with A2 or A6 welding heads, A2-A6 PEH process
controller, seam tracking, flux delivery and recovery systems
Pivot base allows welding on both sides of the track
Can be equipped with mounting for up to 4 drums, 450 Kg (1000
lbs.) each, of welding wire for dual twin-arc welding heads
Also available for GMAW processes with metalcored of flux cored
wire

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

79

special applications

Beam Welding - Pull Through Welders

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 Welder

Both sides of flange welded simultaneously

Built-in straightening device to compensate for pullback of the
flanges
Optional induction or gas heating equipment to ensure straight
beams; required for T beams
Complete material handling systems available
PLC controlled, uses A6 DC-AC tandem subarc welding heads on
each side for high speed welding
Specs: 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.)

IT 2000 Web Horizontal Pull-Through Beam Welder

80

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.)

For more detailed information about beam welding, please contact ESAB

special applications

Welding Gantries
Gantrac

Rigid legs supported by tacho-controller, DC-driven bogie

carriages as well as a cross beam to ensure uniform,
stable welding speed
Gantry beam is equipped with guides and a rack on both
sides for the two motorized welding carriages
A6 welding heads are mounted on rack-and-pinion slides
with comprehensive working strokes to obtain good
access to the workpieces
Incorporates 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 beam
Options 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

Stable Gantry Station for Stainless Steel

Railway Wagon Roofs

7000 mm (275.5 in.) width

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

Robotic Production Gantry

Designed for shipyard panel line

Also suitable for other plate and stiffener assemblies
such as large earth-moving equipment
Different programming methods available

Teach, welding macros

Offline programming
Vision assisted programming

Vision System - entire assembly is scanned to determine

absolute part position, then macros used for welding
procedures
30 minute programming for 8 hours of welding

For more detailed information and ordering information, please contact ESAB

81

special applications

Shipyard Applications
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
panels
Vacuum clamping securely holds plates in position
during welding, without tack welding
System uses A6 welding heads and 3-wire subarc
systems
Backing flux is automatically and accurately
deposited on the water-cooled backup bar
Plates are fed through the OSW with infeed and
outfeed tables with gripper conveyor system

Stiffener Assembly and Welding

Positions and welds both sides of stiffener

Programmable stitch or continuous
Gantry can carry dual stations (4 weld heads) for
increased productivity
PLC controlled, uses A2 MIG welding components
Various designs and levels of automation are
available.

Vertical up welder

82

A unique system, specifically designed for double

hull construction
A four torch head is lowered into an intersection and
then welds all four joints simultaneously
Extensive programming capabilities allow oscillation,
multi-pass, stitch, as well as ability to sense and skip
cutouts or horizontal stiffeners
Can be fitted with ESAB pulse or cored wire systems
An extremely efficient system, eliminating a difficult
task while improving health and safety of welders.

For more detailed information and ordering information, please contact ESAB

special applications

Custom Welding Solutions

Roll Buildup and Hard Surfacing

Rototech 2000 is an integrated unit for surfacing of

cylindrical objects, such as steel mill rolls
Uses head and tailstock, with PLC controlled
positioning equipment
Weld process can be plasma, MIG, subarc or strip cladding
Program variables include selectable bead
placement style, carriage and rotation speed, bead
width and overlap, oscillation speed and amplitude
Process variables are preset on the A2-A6 PEH
process controller

Electroslag Welding Machine

Machine for longitudinal welding of cylinders for the

pulp industry
Picture shows machine with the welded cylinder in
the vertical position
The assembly is equipped with an inside-cooling
support column for applying a cooling shoe to the
closed joint of the upright cylinder
The 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

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 wires
Advanced controls easily control and monitor the
parameters of all wires
A 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 software
This equipment is designed for retrofit of existing
mills as well as for new mills

Lamp Pole Welder

Various systems available for tapered lamp pole

welding
Photo shows single sheet formed pole, which is
pulled through the welding station
Heavy guide rollers ensure a tight fitup at the seam
Joint tracking keeps the arc centered on the joint
Available with ESAB subarc or MIG equipment
Infeed and outfeed conveyors are also available

83

special applications

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 operation
Integrated 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

Multi-head gantry stations for the energy

and process market

Welding heavy winch drums intended for the ship

and offshore industry
The circumferential weld procedure utlizes twin-wire
flux cored wire
The shell of the drum is joined at various lengths
using butt joints
Simultaneously welded with two welding heads
Dimension 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

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 rotor
The complex 4 m (157.5 in.) longitudinal preparation
is curved into three dimensions
The process is twin-wire SAW
The 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

Boiler Manufacturing Automation

84

ESAB offers a complete line of boiler equipment from tubefin prefab machines, fin-bar and tube-to-tube machines, to
complete membrane wall panel welding and finishing
Membrane welders can be moveable gantry or
stationary pull-through systems
Multiple head A6 subarc welding is normally used

special applications

Hybrid Laser Welding

ESAB offers state-of-the art Hybrid Laser Welding

(HLAW) systems for high production of structural
beam, pipe, vessel and panel applications
Complimented by real-time, closed-loop process
controls and automated quality assurance systems
Technology 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 fabrication
Results include improved welding performance, quality
and reduced downstream costs due to distortion
HLAW combines the best attributes of laser welding
with those of conventional MIG welding

Laser:

Deep weld penetration

Very low heat input
Small heat affected zones (HAZ)

MIG:

Wide tolerance of joint gaps, surfaces and impurities

Gap filling and contouring
Control of weld metallurgy
Slows cooling rate to prevent brittleness

Contact ESAB for more information.

FANG Narrow Gap Welding System

Fully automated longitudinal and circumferential seam

welding
Features: automatic bead placement and uniform fill
functions
Ideal for continuous mass production of products, such as
heavy wall, offshore structural pipes

Contact ESAB for more information

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

85

special applications

HNG Narrow Gap Welding System

Automatic welding process based on two runs-perlayer technology

Equipment 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 tandem
Welding defects such as lack of fusion, undercut,
and slag entrapment are eliminated
Produces 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 ESABs column and boom
systems and turning roll units
Achieve precise and accurate bead placement with
two-axis joint tracking system
System includes all required hardware, software,
and programming information for automatic joint
tracking and bead placement

Contact ESAB for more information.

Technical Data
Wire dimension, mm (in.)
Wire feed motor, A6-VEC
Wire feed speed, m/min (ipm)
Welding current, A
Beads per layer
Electrode angular setting
Flux hopper capacity, L (gal.)
Air consumption, Nm3/min
Working range - slide assembly
Weight, Kg (lbs.)

86

Horizontal, mm (in.)
Vertical, mm (in.)
HNG-S
HNG-T

3-4 (1/8-5/32)
312:1
4 (157)
Max. 1x800/2x800
2
Max. +/- 3.5o
9.5 (2.5)
0.35 af 6 Kp/cm3
300 (12)
420 (16.5)
140 (309)
165 (364)

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

special applications

ESAB Retrofit

ESABs service group can upgrade any brand of

existing equipment to virtually new condition, with the
latest process equipment and accessories
Weld Process: add the versatile A2-A6 PEH process
controller with DC, AC or tandem upgrade to improve
weld quality, speed and operator convenience
Multi-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 speed
The controller will drive an ESAB VEC travel motor,
suitable for boom or carriage
A very economical system for column and boom
manipulator retrofits because it eliminates the need for
an extra drive for the boom
Alternately, a separate analog interface board can
enable the weld controller to interface with most typical
drives used on turning rolls; postioners
Accessories include seam trackers, flux recovery
systems, wire handling equipment, strip cladding
equipment - all can be added to existing equipment
ESAB 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

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

87

special applications

Friction Stir Welding (FSW)

FSW Process

Friction 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.

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 welded
Round 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

welding
Very low distortion and shrinkage
No joint preparation - only de-greasing is required
Environmentally friendly - no fumes, arc glare, spatter
or noise
Extremely reliable process - expect year after year of
defect free welds

Applications:

88

Aluminum production of large extrusions, large panels,

girders and trusses, such as used in fast ferries, ships,
offshore living quarters and railway wagons
Aerospace, such as rocket fuel tanks, aircraft
structures and components
Production of cooling blocks, coolers and housings for
electrical motors
Aluminum 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

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

special applications

Friction Stir Welding Systems

LegioTM Friction Stir Welding System

The modular system makes it possible to assemble

welding stations to suit the most varied Friction Stir
Welding applications
The LEGIOTM system consists of five basic designs
in 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 line
The versatile Legio family includes linear motion
with single or dual (over/under) heads, with or
without tables
Dual axis(x y) model is available with or without
table
Tables include a hole pattern for attaching fixtures
Legio 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

SuperStirTM Friction Stir Welding System

The ESAB SuperStirTM program includes a

variety of machines developed from a
standarized ESAB SuperStirTM base unit and
with working ranges of 0.5x1.5 m (19.7x59 in.)
up to 10x20 m (33x66 ft.) within the same
concept
The program includes customized models of
various designs for specific customer
requirements in different production areas
These different designs are used worldwide in
R&D centers for joining of extrusions to panels,
in production of pressure vessels as well as
small parts for the automotive and electronic
industries

Legio FSW System Sales Literature................................ XA00117820

SuperStir FSW System Sales Literature.........................XA00098320

89

special applications

Mechanized Cutting Systems

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 customers 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.

Oxy-fuel Cutting

Commonly 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-up
For use only on carbon steel - will not cut through aluminum, stainless steel,
brass, or copper
Ideal for multi-torch applications
Oxy-beveling is available

Conventional Plasma

For cutting a variety of metals including carbon steel, stainless steel, aluminum,
brass, and copper
Cuts much faster than oxy-fuel or waterjet cutting, particularly on thin materials
May leave small bevel angle on cut face
Creates smaller heat affected zone for minimal warping
Generally suited for plate thickness of 25 mm (1 in.) or less
Ideal for multi-torch applications
Plasma beveling is available

Precision Plasma

Highly precise form of plasma cutting

Uses proprietary arc technology to constrict plasma arc - provides low dross
and low bevel angle cuts
Creates a very smooth cut face
Ideal for use on carbon steel, stainless steel, and aluminum up to 25 mm (1 in.)
thick

m3 Plasma

90

New generation plasma

Combines conventional plasma, precision plasma and plasma marking in one
torch

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

special applications

Mechanized Cutting Systems, contd

Plasma Bevel Process

ESABs plasma bevel system increases productivity by

applying the benefits of high speed plasma cutting for plate
edge preparation
Fully 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 fly
Cut above or under water
Cut quality maximized though CNC process and motion
control with Vision PC
This tool is essential for high volume plate cutting such as
windmill tower manufacturing

Waterjet Cutting

Uses high velocity, high pressure stream of water and often

combined with powdered abrasives, such as garnet, to
increase cutting ability
Cut any metal as well as paper, cardboard, glass, graphite,
epoxy, fiberglass, and various other materials
No heat involved in the cutting process - no heat affected
zone, warping, cracking or need for secondary machining
operations
Allows for precise contours, intricate shapes, sharp corners,
and low bevel angles
May combine with conventional plasma on a gantry
Waterjet beveling is available

Laser Cutting

Cut carbon steel up to 25 mm (1 in.) thick, stainless steel up to

16 mm (5/8 in.) thick
Extremely accurate cut, very small kerf width, excellent edge
quality
Eliminate the need for a secondary machining process
ESAB Alpharex Gantry system provides cutting capability up to
5 m (16.5 ft.) wide and unlimited length
Provides high accuracy, speed, and innovative process
automation
May combine with conventional plasma on a single gantry
Laser beveling is available

Columbus software

Software developed and maintained by ESAB

Complete integration with ESAB controllers
Upgrade your existing software
Advanced capabilities include: CAD translation and drawing;
automatic nesting; plate and data manager; estimation
software; interactive CNC files
On-line support and training
91

special applications

Mechanized Cutting Systems, contd

Standard Cutting System Selection Guide
Machine Model

Max. Cutting Width Standard Torch Capacity

Speed Range
mm
(in.)
mm/min
(ipm)
Oxy-Fuel
Plasma

Photocell Tracing Numerical Control

Oxy-Fuel Gas & Plasma

Ultra-Line

Straight Line

76.2 - 2794

(3 - 100)

N/A

N/A

Ultra-Graph

2794

(110)

101.6 - 3810

(4 - 150)

N/A

N/A

Silhouette 500

609

(24)

50 - 3000

(2 - 118)

HL-90

Optional

Silhouette 1000

1219 - 1828

(48-72)

50 - 3000

(2 - 118)

HL-90

Optional

Piecemaker 2

1524 - 1828

(60-72)

N/A

50 - 19050

(2 - 750)

Optional

Standard

Piecemaker Plus

1524 - 2133

(60-84)

50 - 19050

(2 - 750)

Optional

Standard

Shadow 2

2438 - 3048

(96-120)

50 - 19050

(2 - 750)

Optional

Standard

Sabre SXE

2133 - 4724

(84-186)*

50 - 35560

(2 - 1400)

Optional

Standard

Acer

1524 - 1828

(60-72)

N/A

100 - 19050

(4 - 750)

Optional

Standard

Acer 2

1828 - 2438

(72-96)

N/A

50 - 35560

(2 - 1400)

Optional

Standard

Avenger X

2438 - 5486

(96-216)*

12

50 - 35560

(2 - 1400)

Optional

Standard

Avenger 2

4267 - 9321

(168-360+)

12

50 - 25400

(2 - 1000)

Optional

Standard

Avenger 3

4267 - 9906

(168-384+)

12

50 - 25400

(2 - 1000)

Optional

Standard

Avenger 3-Telerex

9000-14000

(348-540)

12

50 - 19050

(2 - 750)

N/A

Standard

Avenger 4-Telerex

14000-26000 (540-1020)

50 - 19050

(2 - 750)

N/A

Standard

Waterjet Cutting Systems

Waterjet

Plasma

Hydrocut PR

1219 - 1828

(48-72)

2.5 - 25400 (0.1 - 1000)

Optional

Standard

Hydrocut LR

2438 - 6096

(96-240)*

2.5 - 15240 (0.1 - 600)

Optional

Standard

Hydrocut HR

2438-3657

(96-144)

2.5 - 15240 (0.1 - 600)

Optional

Standard

Laser

Plasma

50 - 25400

Optional

Standard

Laser Cutting Systems

Alpharex
Note:

92

3048-4877

(120-192)

The specifications in the above chart are generalized

*
=
Increments of 48 in. (609.6 mm)
+
=
Increments of 39.6 in. (1005.8 mm)

(2 - 1000)

Welding filler metals

MIG Welding
Process

Process Advantages

Also called Gas Metal Arc Welding (GMAW)

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

Easy to mechanize or adapt to a robot

Cost-effective method for process automation on
thin materials
Available in wide array of diameters and packages
for any requirement
High deposition efficiency (up to 98%)

Selected Product Listing*

Product

AWS Class

Features &Typical Applications

Mild Steel
Spoolarc 65

ER70S-2

Copper-coated triple deoxidized carbon steel wire

Designed for welding over rust and mill scale
Preferred wire for positional welding of small dia. pipe

Spoolarc 29S

ER70S-3

Copper-coated carbon steel wire for general purpose applications including heavy
equipment, automotive applications and sheet metal

Spoolarc 86

ER70S-6

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

MIG-6

ER70S-6

General purpose copper-coated wire

Similar applications to Spoolarc 86

OK Aristorod 12.50

ER70S-6

Non-copper-coated carbon steel wire

ASC (advanced surface characteristic) technology provides lower spatter levels, superior
feedability and welding performance for robotic or automated welding

Spoolarc 87HP

ER70S-7

Copper-coated carbon steel wire with optimized manganese and silicon ratio to produce weld
beads with excellent appearance
Widely used in robotic welding applications in the automotive industry

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

Various

Full range of stainless steel welding wires for any application

All OK Autrod stainless steel solid wires have a matte finish to improve feedability and
provide a smooth stable arc

ER4043, ER5356

Full range of aluminum alloys to meet any requirement

All ESAB wires are manufactured with a patented process to optimize feeding
characteristics

Stainless Steel
OK Autrod 308LSi, 309LSi, 316LSi

Aluminum
OK Autrod 4043, 5356

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

93

filler metals

Cored Wire
Process Advantages

Process

Flux Cored Arc Welding (FCAW) and Metal Cored

Arc Welding (MCAW) are similar to MIG welding
as far as operation and equipment are concerned
Difference is that the wire is not solid, but consists
of a metal sheath surrounding a flux core
Wire begins as a flat metal strip, which is formed
into a U shape
Flux and alloying materials are deposited into the
U, which is then closed into a tube by a series of
forming rolls

High deposition rates

Excellent weld bead appearance with little or no spatter
Deep arc penetration when welding - allows tighter
joint design, reducing quantity of filler metal needed to
fill the joint
Wide selection of alloys available
High 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

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 wire

Single or multi-pass welding on carbon steels
Uses CO2 gas only

Dual Shield 7100 Ultra

E71T-1/1M/9/9M

All-position, low fuming wire

Single or multi-pass welding on carbon steels
Uses CO2 or Ar/ CO2 gas mixtures

Dual Shield II 70 Ultra

E71T-1/1M/9/9M

All-position, low fuming wire

Single or multi-pass welding on carbon steels
Wide operating range
Uses CO2 or Ar/ CO2 gas mixtures

E71T-1MJ/12MJ-H4

All-position, low fuming wire

Provides excellent low temperature toughness in as-welded and/or stress-relieved
condition
Diffusable hydrogen levels < 4 mL/100 g
Weld metal analysis similar to E7018-1 electrode
Uses 75% Ar/25% CO2 gas only

Dual Shield II 70T12-H4

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 position
Ideal for robotic applications
Uses Ar/CO2 gas only

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

Shield-Bright 308L, 309L, 316L

Various

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

Arcaloy MC-308L, 309L, 316L

Various

Full line of stainless steel metal cored wires designed for high production automated and
robotic applications

Stainless Steel Cored Wires

* Small representation of full product line. Please contact ESAB for more information.
94

Filler metals

Submerged Arc Welding

Process Advantages

Process

Arc is struck between the workpiece and the end of a

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

Very high deposition rates and travel speeds

Excellent and consistent weld quality
Deep arc penetration when welding - allows tighter
joint design, increasing productivity and reducing
quantity of filler metal needed to fill the joint
Operating factor can approach 100%
No fumes or arc radiation

Common ESAB Wire/Flux Combinations*

Wire
Spoolarc 29S

Spoolarc 81

Flux
OK Flux 429
OK Flux 10.71

AWS Class
F7A2-EM13K
F7A4-EM13K
F6P4-EM13K

Typical Applications

Carbon steels, multi-pass; good mechanical properties and weld performance for general fabrications
Carbon steels, multi-pass; for general fabrication
Excellent as-welded or stress relieved mechanical properties, combined with good weld performance
Carbon and low-alloy steels, single pass only; high tolerance to rust and mill scale
Applications include water heaters, rail cars and structural steel

OK Flux 231

F7A2-EM12K

OK Flux 350

F7A2-EM12K

Carbon steels, single pass only; high tolerance to rust and mill scale
Suitable for use with AC or DC power, single or multi-wire
Applications include shipbuilding, thin wall pressure vessels and structural applications

OK Flux 429

F7A2-EM12K
F6P4-EM12K

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

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

OK Flux 10.62

F7A6-EM12K

OK Flux 10.71

F7A4-EM12K

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

OK Flux 10.72

F7A8-EM12K

Carbon and low alloy steels, multi-pass

Excellent slag removal in narrow V-joints; excellent low temperature impact properties
Designed for high current-carrying capacity, DC or AC, with single or multi-wire systems
Ideal for windmill tower and pressure vessel construction

OK Flux 10.71

F7A2-EM14K
F7P4-EM14K

OK Flux 10.62

F7A6-EM14K
F7P6-EM14K

Carbon and low alloy steels, multi-pass

Used for welding pressure vessels and other applications requiring good mechanical properties after
stress relieving
Use OK Flux 10.62 for improved impact toughness

Spoolarc 75

OK Flux 429 or
OK Flux 10.71

F8A4-ENi1K-Ni1

Weathering and carbon steels with up to 1% nickel, multi-pass

Ideal for bridge and structural welding

OK Tubrod 14.00S

OK Flux 10.71

F7A2-EC1

Carbon steels, multi-pass

MCAW wire provides higher travel speeds; up to 20% increase in deposition rate compared to solid wire

OK Tubrod 15.00S

OK Flux 10.71

F7A4-EC1

Carbon steels, multi-pass

Basic metal cored wire provides higher travel speeds; up to 30% increase in deposition rate compared to solid wire
Excellent mechanical properties and impact properties at -40oC (-40oF)

OK Autrod 308L, 309L, 316L

OK Flux 10.93

N/A

Provides stainless steel deposit to match corresponding welding alloy

Basic, non-alloying flux providing excellent weld properties and performance

Spoolarc 71

* Small representation of full product line. Please contact ESAB for more information.
95

filler metals

Strip Cladding
Process

ESW Strip Cladding

Submerged arc welding (SAW) or electroslag welding

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

Process Advantages

Reduces requirement of expensive highly-alloyed

base material, such as stainless steel or nickelbase alloys
Can choose a wide variety of parent materials and
consumables
High deposition processes with low dilution
Allows for flexibility in the production of objects of
various shapes and sizes

A development of SAW strip; established as a reliable

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

SAW Strip Cladding

An electric arc is formed between the strip

electrode and the workpiece
Flux is used to form a molten slag to protect the weld
pool from the atmosphere and helps form a smooth
weld bead surface

Common ESAB Strip/Flux Combinations

Consumable

%C

%Si

%Mn

%Cr

%Ni

%Mo

Other

Ferrite

Typical all weld metal composition using OK Flux 10.05

An agglomerated flux for SAW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo austenitic satinless types of strip. Slag removal and overlapping with this flux
is provides excellent results. Use with OK Band 308L, 309L, 316L. Basicity Index: 1.1
1. 308L overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7m/h
OK Band 309L
0.020
0.4
1.9
Weld composition 1st layer
0.027
0.7
1.1
OK Band 308L
0.022
0.3
1.7
Weld composition 2nd layer
0.021
0.6
1.0
2. 316 overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 750A, 28V, 7 m/h
OK Band 309L
0.020
0.4
1.9
Weld composition 1st layer
0.028
0.7
1.1
OK Band 316L
0.017
0.4
1.8
Weld composition 2nd layer
0.018
0.7
1.1

23
19
19.6
18.9

13
11.3
10.1
10.6

FN 5
FN8

23
19
18.2
18

13
11
13.1
12.9

2.8
2.1

FN 5
FN 7

Typical all weld metal composition using OK Flux 10.10

An agglomerated flux for ESW strip cladding. Recommended for cladding with Cr, CrNi and CrNiMo types, with or without Nb-stabilization. Weldability, bead appearance and slag
removal with this flux provides excellent results. Use with OK Band 309L ESW, 309LMo ESW and 309LNb ESW. Basicity Index: 4.0
1. 308L overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+, 1250A, 25V, 9m/h
OK Band 309L ESW
0.015
0.2
1.8
21
Weld composition 1st layer
0.023
0.45
1.2
18.5
2. 316 overlay combination on 2.25Cr 1Mo steel, typical parameters: DC+m 1250A, 25V, 9m/h
OK Band 309LMo ESW
0.015
0.2
1.8
20
Weld composition 1st layer
0.024
0.4
1.2
18

96

11.4
10

FN 6

13.7
12

2.7
2.7

FN 8

filler metals

Packaging Improves Productivity

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

Coils

Standard package for most solid and cored wires

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

Jumbo Coils

Unique bulk solution for SAW wires

90-100 Kg (100-220 lbs.) of wire on a large coil with 570 mm (22.5 in.)
internal diameter
Often used with column & boom systems
Special coil adapter is required

Payoff Pac

Large diameter drum, most often used with SAW wires

Package weights are typically 250-363 Kg (550-800 lbs.)
Efficient solution for high productivity, stationary SAW welding stations

Marathon Pac

Bulk pack for 200-475 Kg (450-1050 lbs.) of solid or cored wire

Wire wound into the drum using special technique
Wire is straight and comes out of the gun without twisting or warping
- ideal for robotic or mechanized welding stations
Stopping for spool changes and maintenance are reduced by almost
95% for increased arc-on time
Improves weld quality with reduced repair and rejects resulting in less
weld defects
Octogon drums are 100% recyclable

BigBag

Unique solution for bulk users of SAW welding flux

500-1000 Kg (1100-2200 lbs.) per bag
Bag is made of layers of fabric, coated on the inside for moisture
protection
Discharge spout in the bottom of the bag with an opening that can be
easily opened and re-closed by a rope
Four strong straps for lifting by forklift or overhead crane
97

esab global offices

Europe

North/South America

Asia/Pacific

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

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

ARGENTIA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313

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

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

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

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

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

CZECH REPUBLIC
ESAB Vamberk s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120

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

CANADA
ESAB Group Canada Inc.
Mississauga, ON
Tel: 1 905 670 0220
Fax: 1 905 670 4879

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

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

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

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

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

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

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

UNITED STATES OF AMERICA

ESAB Welding & Cutting Products
Florence, SC
Tel: 1 843 669 4411
Fax: 1 843 664 4458

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

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

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

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

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

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

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

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

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

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

Representative Offices

ESAB Asia/Pacific Pte Ltd.

Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39

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

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

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

UNITED ARAB EMIRATES

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

ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA-CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
St. Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85

ESAB Welding & Cutting Products

In Canada

In USA

Head Office:
6010 Tomken Road
Mississauga, Ontario L5T 1X9
Phone: 877-935-3226, 905-670-0220
Fax: 905-670-4879

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

25B de Lauzon
Boucherville, Qubec J4B 1E7
Phone: 450-655-4318
Fax: 450-449-6620

801 Wilson Avenue

Hanover, Pennsylvania 17331-1058
Phone: 717-637-8911
Fax: 717-637-9859

6324 Davies Road

Edmonton, Alberta T6E 4M9
Phone: 877-865-6947, 780-466-8323
Fax: 780-466-2682

In Mexico
ESAB MXICO, S.A. DE C.V.:
Ave. Diego Diaz de Berlanga 130
Apartado Postal 4259-F
Monterrey, N.L., 54000
Mexico
Phone: 52-81-8305-3700
Fax: 52-81-8350-5920
Fax: (Sales) 52-81-8350-7554

Call

1-877-935-3226
or visit

www.esabna.com

For the latest product information, special announcements, Material Safety Data Sheets (MSDS) and
company news

898C160

09/06 Printed in Canada