Welding Automation

Item Code: CPRA 1000-T/1200-T
Fully thyristorised heavy duty SAW & gouging
SAW process produces the highest quality welds at speeds higher than MMA or MIG process. Standard single wire SAW can deposit up to 5 kg/hr and automatic multi-wire technique can reach much higher levels

CPRA 1000-T/ 1200 –T are reliable power sources offered with AWM (LW) tractor for single wire SAW applications.

Applications :

• Rugged construction.
• Rubberized wheels for ease of mobility.
• For applications up to 1000A/1200A max
• Precise voltage control.
• Mains voltage compensation.
• Protection against thermal overloading.

Technical Data :

	CPRA 1000-T	CPRA 1200-T
Mains supply, Ph x V, Hz	3 x 415, 50	3 x 415, 50
Fuse rating at 415V, A (Max)	100	125
Input power kVA (Max)	66	82
Open circuit voltage, V DC	59	59
Welding current range	300 A /32 V -1000 A/44 V	300 A /32V -1200 A /44 V
Welding current at 60% duty cycle, A	1000	1200
Welding current at 100% duty cycle, A	850	950
Insulation class	F	F
Type of cooling	Forced Air	Forced Air
Dimensions, l x w x h, mm	830 x 670 x 1400	830 x 670 x 1400
Weight, Kg	440	440

Item Code: A6 Mastertrac A6TF (SAW)
For efficient submerged-arc welding
The A6 Mastertrac is a self-propelled, four-wheel drive automatic welding machine. Fully mobile, the Mastertrac is easily moved from one welding station to another and it can be quickly set-up for different workpieces.

The Mastertrac has ample capacity for heavy production welding and can take up to 6 mm wire using 1500 A direct or alternating current. It is designed to be used together with LAF or TAF power sources.

The Mastertrac can be delivered in three different designs: Single, Twin or Tandem. The Single and Twin designs are available with standard or high- speed motors. To be able to increase the profit- ability there are a number of accessories :

• strip cladding kit
• arc-air gouging kit
• flux funnel for any type of butt joint
• pilot lamp which projects a light spot onto the joint
• extra idler rollers
• flux recovery unit OPC
• extra guide wheels
• guide rail with magnetic fasteners when there is no guiding edge available.

Technical Data :

	A6 Mastertrac A6TF (SAW)
Permissible load 100% (A)	1500
Wire diameter (mm)	3.0-6.0
Wire feed speed (m/min)	0.2-4.0
Wire feed speed high (m/min)	0.4-8.0
Travel speed (m/min)	0.1-2.0
Control voltage (V)	42
Wire reel (kg)	30
Flux capacity (l)	10
Weight excl. wire and flux (kg)	110

Item Code: A2 Multitrac A2TF (SAW)
The universal welding automat for Submerged-Arc Welding
A2 Multitrac is designed to put your Submerged-Arc Welding operation on the right track to increase both the productivity and the quality.

The compact and efficient design makes it easy to move and to set up the A2 Multitrac between different welding workpieces. The mechanical compo- nents are very reliable, even under hard working conditions. Feedback systems on the wire feed and travel unit secures a very good welding result. The A2 Multitrac is designed to be used with LAF or TAF welding power sources.

The simple design makes it possible to adjust the nozzle into numerous positions, to best suit the application. The heavy dimensioned feed unit with an encoder feedback secures an even and stable wire feed, and pre-requisite for top quality and homogenous welding. Another feature which ensures constant welding speed is the four-wheel drive carriage which also has an encoder for feedback.

Pre-setting and control of the welding parameters is done on the operator panel on the A2-A6 Process Controller (PEK). The A2-A6 Process Controller is a digital control system, which is easy to handle by the menus on the display.

The A2 Multitrac for Submerged-Arc Welding can be delivered in two versions, for single or twin wire. When using twin wire the deposit rate is increased by 30-40%. Joint gaps can easily be bridged and there is less risk for burn through. When cladding, the A2 Multitrac with twin wires can easily be set up for a low penetration.

Technical Data :

	Single SAW	Twin SAW
Wire dimensions (mm)
Steel	1.6-4.0	2 x 1.2-2.5
Stainless	1.6-4.0	2 x 1.2-2.5
Cored wire	1.6-4.0
Max wire feed speed (m/min)	9	9
Electrode weight (kg)	30	2 x 15
Flux volume (l)	6	6
Weight excl wire and flux (kg)	47	47
Permissible load 100% (A)	800	800
Control voltage (V)	42	42
Travel speed (m/min)	0.1-1.7	0.1-1.7
Linear slides setting length (mm)	90	90
Rotary slide setting angle (°)	360	360

Item Code: LAF 631 / 1001 / 1251 / 1601
DC power sources for submerged arc welding
The LAF series are three phase, fan- cooled DC welding power sources designed for high productivity mechanized Submerged or high productivity MIG/MAG arc welding.

They are used in combination with ESAB’s A2-A6 equipment range and the A2-A6 Process Controllers (PEK or PEI).

LAF welding power sources have excellent welding characteristics throughout the entire current and voltage range, with particularly good starting and re- ignition properties. These power sources demonstrate good arc stability at both high and low arc voltages.

The welding power source can be adjusted and monitored from the front panel of the process controller (PEK or PEI), which permits easy adjustment of all welding parameters.

The welding current range can be extended by connecting two power sources in parallel for the most demanding application.

Applications:

• Submerged arc welding : The excellent welding characteristics and the capacity of the LAF series make these power sources ideal for continuous submerged arc welding. The LAF power sources are today used by the major manufacturers of wind power compo- nents, nuclear power vessels, boilers and in the ship building industry.
• MIG/MAG welding : LAF power sources produce a stable arc at low currents and voltages. This means that they are also ideal for high productive MIG and MAG weld- ing in automation applications as welding the root pass in heavy pipe production.

Technical Data :

	LAF 631	LAF 1001	LAF 1251	LAF 1601
Voltage, 3 ph 50 Hz, V	400/415	400/415/500	400/415/500	400/415/500
Voltage, 3 ph 60 Hz, V	440	400/440/550	400/440/550	400/440/550
Current A 100%, 50 Hz	52	64/64/52	99/99/80	136/136/108
Current A 100% 60 Hz	52	64/64/52	99/99/80	136/136/108
Cable area mm2, 50 Hz	4x16	4x16	3x35+25/3x35+25/3x25+16	3x70+35/3x70+35/3x50+35
Cable area mm2, 60 Hz	4x16	4x16	3x35+25/3x35+25/3x25+16	3x70+35/3x70+35/3x70+35
Fuse, slow A, 50 Hz	63	63	100/100/80	160/160/125
Fuse, slow A, 60 Hz	63	63	100/100/80	160/160/125
Maximum load at:
Maximum load at:	630/44	800/44	1250/44	1600/44
80% duty cycle A/V	-	-	-
60% duty cycle A/V	800/44	1000/44	-	-
Setting range A/V
MIG/MAG	50/17-630/44	50/17-1000/45	60/17-1250/44
SAW	30/21-800/44	40/22-1000/45	40/22-1250/44	40/22-1600/46
Open circuit voltage, V	54	52	51	54
Open circuit power, W	150	145	220	220
Efficiency	0.84	0.84	0.87	0.86
Power factor	0.90	0.95	0.92	0.87
Enclosure class	IP23	IP23	IP23	IP23
Dimensions LxWxH mm	670x490x930	646x552x1090	774x598x1428	774x598x1428
Weight, kg	260	330	490	585
Application class	S	S	S	S

Item Code: >ESAB CaB 600M
A Modularised Column and Boom for customised weld mechanization
Productivity
In today´s industrial development, the rate of productivity has been brought more and more into focus as a decisive parameter for raised profitability.

This requires individually adapted production solutions, flexible enough to conveniently switch over, without extensive rebuilding, between a variety of applications. In close co-operation with the welding industry ESAB has created an application oriented Column and Boom range with integrated modular functions in order to meet our customers´ demands for purposeful solutions on a competitive market.

Stability and reliability
CaB 600M has a stable and robust design of the profiles and saddle providing large working ranges and heavy load capacity with ample safety margins for reliable operations. Different types of foundations are available; rail carriage (4WD) or concrete stand – to fit any need. The lift drive has a reliable safety factor and is supplied with a security device which, regardless of boom position, immediately locks the boom to prevent unwanted descent in the event of a breakdown. Positioning of the horizontal boom can easily be carried out both in the vertical and horizontal direction. An even and stable welding speed is secured by the rack and pinion drive. The control system has been designed with totally integrated functions; welding head manipulation and operation of the column and boom – of course remote controlled.

Individual solutions:
When dressing up the naked column and boom into a complete welding solution, the optional combinations are almost unlimited.

In order to facilitate the selection process to result in a specification based on customer´s application, there is a computer aided configuration system available.

Together with the ESAB representative the customer is able to build up his welding solution, i.e. a specification of the modular components to be assembled and installed at the customer´s workshop in a most convenient manner.

For all modular components applicable for this column and boom, kindly refer to our range of leaflets available from our representative.

Technical Data :

Effective working range (m)	6	7	8	9	10
Boom height A (max mm)	7000	8000	9000	10000	11000
using movable carriage (min mm)	1150	1150	1150	1150	1150
Boom height B (max mm)	6925	7925	8925	9925	10925
using concrete stand (min mm)	975	975	975	975	975
Total height C (max mm) using movable carriage	8585	9585	10585	11585	12585
Total height D (mm) using concrete stand	8510	9510	10510	11510	12510
Lifting speed (m/min)	2.0	2.0	2.0	2.0	2.0

Item Code: Railtrac 1000
A unique, flexible, multi-purpose system for welding and cutting.

Flexible answer to stiff requirements
Railtrac is a system of components that can be configured to create the optimal solution for your mechanized welding application. To minimize problems associated with harsh environments, most mechanical parts are constructed in aluminum or stainless steel. Railtrac is designed for horizontal and horizontal to vertical (up, not down).

Joint rail system for stiff or flexible rail applications
The extendable Railtrac combi-rail enables the same tractor to run on a flexible rail or the same rail stiffened with a stiffener bar. The stiffener-bar rail fits into the existing holes in the rail. This makes it possible to weld straight as well as curved surfaces. The combi-rail is clean, without a rack for driving the tractor.

Five different versions
The Railtrac can be delivered in different versions. F is the basic version which is a drive unit only. For FR we have added an automatic return function. FW has a weaving unit that can be used when you want to fill up a welding joint. The most advanced unit is the FWR which has both the weaving and return functions. If the welding process requires a lower welding speed there is a version of the FW unit, FW1000 L, with a lower travel speed.

Interval welding and backfill function are standard
Each Railtrac 1000 is supplied with software for programmable interval welding as standard. Only weld length and distance between the welds need to be set. Backfill, i.e. welding in reverse for a preset distance before stopping, is also programmable. Backfill is used as an alternative to crater filling.

Direct connection to all new modern ESAB wire feeders
Railtrac 1000 can be easily connected to most ESAB wire feeders with no major modification.

Five programs can easily be stored
As many as five different programs can be stored. Each program is individual and can be retrieved from the control box or the remote control.

Remote control of welding parameters and immediate program shift
Using two potentiometers on the remote control, both welding current and voltage can be adjusted during welding. Stepping up or down between the alternative motion programs is also easy, depending on welding position.

Resilient programming units with great potential
Straightforward, logically-designed programming units are used to set the values for five different programs. All speeds are calibrated in cm and mm, for the greatest possible precision and welding quality. Membrane push-buttons and weatherproof casings permit use outdoors.

Remote control for the harshest environments
Using the robust and lightweight remote control that comes with the Railtrac FW1000 and Railtrac FWR1000, the operator can access and control every function without lifting his welding visor. Individually shaped buttons for:

• Start and stop
• Shift program
• Travel or welding direction (cutting direction)
• Travel or welding speed (cutting speed)
• Weaving width
• Zero line displacement
• Welding current (wire-feed speed)
• Welding voltage
• Backfill function

Tractor unit
The tractor unit is the motive force. It is available in five different versions, from the simplest (drive only) to a unit featuring driving, weaving and automatic return.

Weaving unit
The W30 weaving unit is mounted as standard on FW and FWR tractors, but can also be used as a separate unit for different automation solutions. Two versions are available, with weaving widths of 30 or 80 mm. Control unit is included.

Control units
Two different types of control units are available for the Railtrac 1000 series: one for the F and FR1000, one for the FW and FWR1000 as well as FW1000L. The first controls travel and programs only, while the latter controls travel, programs and weaving.

Remote control
A remote control may be connected to the FW1000 and FWR1000, for control of key parameters.

Technical specification

Technical specification		Railtrac F1000 Flexi	Railtrac FR1000 Flexi Return	Railtrac FW1000 Flexi Weaver	Railtrac FW1000L Flexi Weaver	Railtrac FWR1000 Flexi Weaver Return
Power supply	VAC/VDC	36-46/40-60	36-46/40-60	36-46/40-60	36-46/40-60	36-46/40-60
Power consumption, max	W	30	30	80	80	80
Weight, excl. rails	kg	6	6	7	7	7
Measurements, LxWxH	mm	170x400x190	170x400x190	170x350x190	170x350x190	170x350x190
Rail measurements – flexi rail	mm	60x5	60x5	60x5	60x5	60x5
Stiffener	mm	40x10	40x10	40x10	40x10	40x10
Minimum bend dia. externally	mm	Ø3000	Ø3000	Ø3000	Ø3000	Ø3000
Slide for height adjustment	mm	±22	±22	±22	±22	±22
Slide for lateral adjustment	mm	±28	±28
Mechanical lateral adjustment	mm			±35	±35	±35
Welding speed	cm/min	10-150	10-150	10-150	10-150	10-150
Quick transport	cm/min	150	150	150	99	150
Preheating time	s	0.0-9.9	0.0-9.9	0.0-9.9	0.0-9.9	0.0-9.9
Interval welding	cm	1-99	1-99	1-99	1-99	1-99
Crater-filling time	s	0.0-9.9	0.0-9.9	0.0-9.9	0.0-9.9	0.0-9.9
“Backfill”	mm	0-99	0-99	0-99	0-99	0-99
Weaving speed	mm/s			6-60	6-60	6-60
Weaving width	mm			1-30	1-30	1-30
Electrical 0-line displacement	mm			±12.5	±12.5	±12.5
Pause time at outer edge	s			0.0-9.9	0.0-9.9	0.0-9.9
Weaving pattern	No.			3	3	3
Number of programs	No.	5	5	5	5	5
Temp. machine and magnets	°C	0-70	0-70	0-70	0-70	0-70
Temp. vacuum attachment	°C	0-90	0-90	0-90	0-90	0-90
Safety class	DIN 40050	IP 23	IP 23	IP 23	IP 23	IP 23

Item Code: POC 12-60
Tube-to-tube sheet welding head
The POC 12-60 welding head in combination with the power source Aristo™MechTigC2002i or power source Aristo™MechTig4000iw in conjunction with Aristo™Mech-Control 2 or 4 is a very economical solution for your tube-to-tube sheet welding.

The POC 12-60 is a precision-built, robust and versatile welding head which can be used for all types of tube-to-tube sheet welding.

The POC welding head has a working range of 12 to 60 mm tube outer diameter. Due to the efficient water cooling of the torch, the POC can take a 200A pulsed current at 60% duty cycle. Its low weight and compact size is a result of a unique design, where the components involved have been used as load bearing elements.

At the rear of the welding head there is a compact wire feed unit designed for 100 mm standard reels. The torch can be set at correct angles, no matter whether the tubes are recessed inside, flush with or protruding from the end plate.

Exact centering
Consistent and perfect welds, time and time again, require exact centering, particularly when it comes to thin walled tubes and fillet welds. The centeringaccuracy for the POC welding head is very high and centeringmandrels are available for the tube inner

Technical specification

Working range
Electrode parallel with tube axis	Ø12-60 mm
Electrode 30°from tube axis	Ø12-36 mm
Rotation	0.2-4.5 rpm
Electrode	Ø1.6-2.4 mm
Rating	180 A at 60%
Welding head weight	4.8 kg without cable
Welding cable length	8 m
Wire feed unit:
Filler wire diameter	Ø0.8-0.9 mm
Filler wire speed	0.15-1.5 m/min
Wire reel diameter	Ø100 mm
Wire reel weight	0.5 kg