ESD-15/ESI-15,
ESD-30/ESI-30,
ESD-60/ESI-60,
ESD-90/ESI-90,
ESD-120/ESI-120
Self-aligning Roller Beds
Instruction manual
0463 751 001 GB 20201217
Valid for: 015-xxx-xxxx
TABLE OF CONTENTS
0463 751 001
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© ESAB AB 2020
1 SAFETY
......................................................................................................................................
5
1.1 Meaning of symbols
....................................................................................................
5
1.2 Non-compliant operation
............................................................................................
5
1.3 Safety precautions
......................................................................................................
5
2 INTRODUCTION
.........................................................................................................................
8
2.1 Equipment
....................................................................................................................
8
2.2 Purpose and function of roller beds
..........................................................................
8
2.3 Terminology used in this manual
...............................................................................
8
3 TECHNICAL DATA
.....................................................................................................................
9
3.1 ESD/ESI-15
...................................................................................................................
9
3.1.1 Drive unit, ESD-15
..............................................................................................
9
3.1.2 Idler unit, ESI-15
.................................................................................................
10
3.2 ESD/ESI-30
...................................................................................................................
11
3.2.1 Drive unit, ESD-30
..............................................................................................
11
3.2.2 Idler unit, ESI-30
.................................................................................................
12
3.3 ESD/ESI-60
...................................................................................................................
13
3.3.1 Drive unit, ESD-60
..............................................................................................
13
3.3.2 Idler unit, ESI-60
.................................................................................................
14
3.4 ESD/ESI-90
...................................................................................................................
15
3.4.1 Drive unit, ESD-90
..............................................................................................
15
3.4.2 Idler unit, ESI-90
.................................................................................................
16
3.5 ESD/ESI-120
.................................................................................................................
17
3.5.1 Drive unit, ESD-120
............................................................................................
17
3.5.2 Idler unit, ESI-120
...............................................................................................
18
4 INSTALLATION
...........................................................................................................................
19
4.1 Location
........................................................................................................................
19
4.2 Lifting instructions
......................................................................................................
19
4.3 Adjusting the wheel stands
........................................................................................
20
4.4 Adjusting the included angle
.....................................................................................
21
4.5 Installation procedure
.................................................................................................
21
4.6 PEK setup
....................................................................................................................
22
4.7 Roller bed configurations
...........................................................................................
24
5 OPERATION
...............................................................................................................................
25
5.1 Roller bed details
........................................................................................................
25
5.2 Control panel
...............................................................................................................
25
5.3 Wireless remote - control pendant
............................................................................
26
5.4 Switch the mains power on
........................................................................................
27
5.5 Operating the roller beds
............................................................................................
28
5.6 Operation safety
..........................................................................................................
28
5.7 Welding
.........................................................................................................................
29
5.8 Stopping the roller beds
.............................................................................................
29
6 MAINTENANCE
..........................................................................................................................
30
6.1 General
.........................................................................................................................
30
6.2 Storage
.........................................................................................................................
30
TABLE OF CONTENTS
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© ESAB AB 2020
6.3 Repair and maintenance
.............................................................................................
30
6.4 Cleaning
.......................................................................................................................
31
6.5 Breakdowns
.................................................................................................................
31
6.6 Gearmotors
..................................................................................................................
31
6.6.1 Gearmotors inspection and maintenance
...........................................................
31
6.6.2 Gearbox lubrication
............................................................................................
31
6.7 Inverters
.......................................................................................................................
32
6.8 Bearings
.......................................................................................................................
32
6.9 PU wheels
....................................................................................................................
32
7 TROUBLESHOOTING
................................................................................................................
34
8 ORDERING SPARE PARTS
.......................................................................................................
35
WIRING DIAGRAM
................................................................................................................................
36
ORDERING NUMBERS
.........................................................................................................................
41
ACCESSORIES
.....................................................................................................................................
42
SPARE PARTS
......................................................................................................................................
43
SPARE PARTS - ESD-15 Mechanical parts list - Drive section
........................................................
44
SPARE PARTS - ESI-15 Mechanical parts list - Idler section
...........................................................
46
SPARE PARTS - ESD-30 Mechanical parts list - Drive section
........................................................
47
SPARE PARTS - ESI-30 Mechanical parts list - Idler section
...........................................................
49
SPARE PARTS - ESD-60 Mechanical parts list - Drive section
........................................................
50
SPARE PARTS - ESI-60 Mechanical parts list - Idler section
...........................................................
52
SPARE PARTS - ESD-90 Mechanical parts list - Drive section
........................................................
53
SPARE PARTS - ESI-90 Mechanical parts list - Idler section
...........................................................
55
SPARE PARTS - ESD-120 Mechanical parts list - Drive section
......................................................
56
SPARE PARTS - ESI-120 Mechanical parts list - Idler section
.........................................................
58
SPARE PARTS - Control cabinet
.........................................................................................................
59
SPARE PARTS - Electrical parts - Control cabinet
............................................................................
61
SPARE PARTS - Wireless control system
..........................................................................................
62
1 SAFETY
0463 751 001
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© ESAB AB 2020
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and
follow all labels, employer´s safety practices and Safety Data
Sheets (SDSs).
1.2 Non-compliant operation
CAUTION!
These roller beds are not suitable for the following:
Any vessel which is heavier than the maximum weight limit of the roller beds.
Any vessel that is larger/smaller than the maximum/minimum diameter that can
be supported.
If the roller beds have polyurethane or rubber tires Do not use on preheated
vessels above 60 °C.
1.3 Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be observed
in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
its operation
location of emergency stops
its function
relevant safety precautions
welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
no unauthorised person is stationed within the working area of the
equipment when it is started up
no-one is unprotected when the arc is struck or work is started with the
equipment
1 SAFETY
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© ESAB AB 2020
3. The workplace must:
be suitable for the purpose
be free from drafts
4. Personal safety equipment:
Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves
Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns
5. General precautions:
Make sure the return cable is connected securely
Work on high voltage equipment may only be carried out by a qualified
electrician
Appropriate fire extinguishing equipment must be clearly marked and close
at hand
Lubrication and maintenance must not be carried out on the equipment
during operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
Insulate yourself from work and ground.
Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimize exposure to EMF:
Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
Keep your head out of the fumes
Use ventilation, extraction at the arc, or both, to take fumes and gases away
from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
Protect bystanders with suitable screens or curtains
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
1 SAFETY
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© ESAB AB 2020
MOVING PARTS - Can cause injuries
Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting the roller beds.
Stop the roller beds before installing or connecting unit.
Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
HOT SURFACE - Parts can burn
Do not touch parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the public
low-voltage supply system. There may be potential difficulties in
ensuring electromagnetic compatibility of class A equipment in
those locations, due to conducted as well as radiated
disturbances.
NOTE!
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2012/19/EC on Waste
Electrical and Electronic Equipment and its implementation in
accordance with national law, electrical and/or electronic
equipment that has reached the end of its life must be disposed
of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment for
purchase. For ordering information contact your local ESAB dealer or visit us on our website.
2 INTRODUCTION
0463 751 001
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© ESAB AB 2020
2 INTRODUCTION
This Instruction manual describes the use and maintenance of the self-aligning roller beds, referred to
as roller beds in this document. Actions that must be carried out by the manufacturer are not included
in this manual.
This manual is part of the roller beds. Keep a copy of the manual with the roller beds and the original
in a safe place. If the roller beds are sold, supply the manual with it.
The pictures and diagrams used in this manual are for illustrative purposes only to help explain
instructions in the text. The equipment supplied may differ slightly.
2.1 Equipment
The roller bed drive is supplied with:
Drive units
Mounted control cabinet
Wireless remote - control pendant
Base frame
Instruction manual
The roller bed idler is supplied with:
Idler units
Base frame
2.2 Purpose and function of roller beds
The roller beds are designed to aid the welding of cylindrical vessels.
By using the independent drive and idler units, vessels of varying lengths can be placed on the roller
beds supported on the roller bed wheels. The wheels can be adjusted on the base frame to
accommodate different vessel diameters.
2.3 Terminology used in this manual
Drive unit Roller bed section with powered wheels.
Idler unit Roller bed section with freewheeling wheels.
Roller bed set A set consists of one drive unit and one or more idler units.
Base frame The frame the drive or idler wheels are mounted on. These are pre-drilled
so that the wheel stands can be positioned for different vessel diameters.
Wheel stand The stand which houses the roller bed wheels. This is bolted down to the
baseframe.
Control panel Electrical control box mounted on the drive unit.
Wireless remote -
control pendant
A wireless operator hand control pendant.
Receiver The receiver that communicates with the wireless remote-control pendant.
Vessel Any component or device that is handled on the roller bed set.
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
3 TECHNICAL DATA
3.1 ESD/ESI-15
3.1.1 DRIVE UNIT, ESD-15
ESD-15
Max loading capacity 7500 kg (16535lb)
Turning capacity 22500kg (49604 lb)
Turning drive motor 2×0.18kW
Turning speed 200-2000mm/min (5.51-78.74in./min)
Workpiece diameter minimum Ø1090mm (42.91in.) at 60° included angle
Workpiece diameter maximum Ø4400mm (173.23 in.) at 45° included angle
Mains supply 380-440V, 3phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 90 mm (3.54in.) / 300mm (11.81 in.)
Dimensions (L × W × H) 3365 × 801 × 871 mm (132.48 × 31.54 ×34.29in.)
C-C
760, 1140, 1520, 1900, 2280 mm
(29.92, 44.88, 59.84, 74.8, 89.76 in.)
Weight 703 kg (1550 lb)
Wireless remote - control
pendant
Wireless
Control voltage 24V
Operation temperature -15 to +40 °C
PEK settings, ESD-15
Gear 1 N1:N2 100:1
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
Gear 2 N1:N2 10:1
Gear 3 N1:N2 1:1
Wheel diameter 400mm
High manual speed 200cm/min
Frequency ratio N1 50 Hz
Frequency ratio N2 50Hz
Max motor rpm 1592
3.1.2 Idler unit, ESI-15
ESI-15
Max loading capacity 7500 kg (16535lb)
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 90 mm (3.54in.) / 300 mm (11.81 in.)
Dimensions (L × W × H) 2830 × 600 × 803 mm (111.42 × 23.62 × 31.61in.)
C - C
760, 1140, 1520, 1900, 2280 mm
(29.92, 44.88, 59.84, 74.8, 89.76in.)
Weight 561 kg (1237 lb)
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
3.2 ESD/ESI-30
3.2.1 DRIVE UNIT, ESD-30
ESD-30
Max loading capacity 15000 kg (33069lb)
Turning capacity 45000kg (99208 lb)
Turning drive motor 2×0.37kW
Turning speed 200-2000mm/min (5.51-78.74in./min)
Workpiece diameter minimum Ø1420mm (55.91 in.) at 60° included angle
Workpiece diameter maximum Ø4900mm (192.92 in.) at 45° included angle
Mains supply 380-440V, 3phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 90 mm (3.54in.) / 400mm (15.74in.)
Dimensions (L × W × H) 3358 × 817 × 911 mm (132.2 × 32.17 × 35.87 in.)
C-C
995, 1375, 1755, 2135 mm
(39.17, 54.12, 69.09, 84.06 in.)
Weight 1066 kg (2351 lb)
Wireless remote - control
pendant
Wireless
Control voltage 24V
Operation temperature -15 to +40 °C
PEK settings, ESD-30
Gear 1 N1:N2 100:1
Gear 2 N1:N2 10:1
Gear 3 N1:N2 1:1
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
Wheel diameter 400mm
High manual speed 200cm/min
Frequency ratio N1 50 Hz
Frequency ratio N2 50Hz
Max motor rpm 1592
3.2.2 Idler unit, ESI-30
ESI-30
Max loading capacity 15000 kg (33069 lb)
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 90 mm (3.54in.) / 400mm (15.74in.)
Dimensions (L × W × H) 2848 × 700 × 859 mm (112.13 × 27.55 × 33.82in.)
C-C
995, 1375, 1755, 2135 mm
(39.17, 54.12, 69.09, 84.06 in.)
Weight 847 kg (1868 lb)
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
3.3 ESD/ESI-60
3.3.1 DRIVE UNIT, ESD-60
ESD-60
Max loading capacity 30000 kg (66139lb)
Turning capacity 90000kg (198416 lb)
Turning drive motor 2×0.75kW
Turning speed 200-2000mm/min (5.51-78.74in./min)
Workpiece diameter minimum Ø1420mm (55.91in.) at 60° included angle
Workpiece diameter maximum Ø6300mm (248.03 in.) at 45° included angle
Mains supply 380-440V, 3 phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 2×90 mm (2×3.54 in.) / 400 mm (15.74 in.)
Dimensions (L × W × H) 4161 × 949 × 1158 mm (163.82 × 37.36 × 45.59in.)
C-C
995, 1415, 1835, 2255, 2675mm
(39.17, 55.71, 72,24, 88.78, 105.31in.)
Weight 2031 kg (4478 lb)
Wireless remote - control
pendant
Wireless
Control voltage 24V
Operation temperature -15 to +40 °C
PEK settings, ESD-60
Gear 1 N1:N2 100:1
Gear 2 N1:N2 10:1
Gear 3 N1:N2 1:1
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
Wheel diameter 580mm
High manual speed 200cm/min
Frequency ratio N1 50 Hz
Frequency ratio N2 50Hz
Max motor rpm 1098
3.3.2 Idler unit, ESI-60
ESI-60
Max loading capacity 30000 kg (66139lb)
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 2×90 mm (2×3.54 in.) / 400 mm (15.74 in.)
Dimensions (L × W × H) 3650 × 800 × 1039 mm (143.7 × 31.5 × 40.91in.)
C-C
995, 1415, 1835, 2255, 2675mm
(39.17, 55.71, 72,24, 88.78, 105.31in.)
Weight 1802 kg (3973 lb)
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
3.4 ESD/ESI-90
3.4.1 DRIVE UNIT, ESD-90
ESD-90
Max loading capacity 45000 kg (66139lb)
Turning capacity 135000kg (297624 lb)
Turning drive motor 2×1.0kW
Turning speed 200-2000mm/min (5.51-78.74in./min)
Workpiece diameter minimum Ø2120 mm (83.46in.) at 60° included angle
Workpiece diameter maximum Ø6200mm (244.09 in.) at 45° included angle
Mains supply 380-440V, 3 phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 180 mm (7.09in.) / 580 mm (22.83in.)
Dimensions (L × W × H) 4167 × 1043 × 1142 mm (164.06 × 41.06 × 44.96 in.)
C-C
1470, 1890, 2310, 2730 mm
(57.87, 74.41, 90.94, 107.48 in.)
Weight 2569 kg (5665 lb)
Wireless remote - control
pendant
Wireless
Control voltage 24V
Operation temperature -15 to +40 °C
PEK settings, ESD-90
Gear 1 N1:N2 100:1
Gear 2 N1:N2 10:1
Gear 3 N1:N2 1:1
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
Wheel diameter 580mm
High manual speed 200cm/min
Frequency ratio N1 50 Hz
Frequency ratio N2 50Hz
Max motor rpm 1098
3.4.2 Idler unit, ESI-90
ESI-90
Max loading capacity 45000 kg (99208lb)
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 180 mm (7.09 in.) / 580 mm (22.83in.)
Dimensions (L × W × H) 3746 × 800 × 1126 mm (147.48 × 31.49 × 44.33in.)
C-C
1470, 1890, 2310, 2730 mm
(57.87, 74.41, 90.94, 107.48 in.)
Weight 2130 kg (4697 lb)
3 TECHNICAL DATA
0463 751 001
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© ESAB AB 2020
3.5 ESD/ESI-120
3.5.1 DRIVE UNIT, ESD-120
ESD-120
Max loading capacity 60000 kg (132277 lb)
Turning capacity 180000kg (396832 lb)
Turning drive motor 2×1.5kW
Turning speed 200-2000mm/min (7.87-78.74in./min)
Workpiece diameter minimum Ø2120mm (83.46in.) at 60° included angle
Workpiece diameter maximum Ø6200 mm (244.09 in.) at 45° included angle
Mains supply 380-440V, 3 phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 180 mm (7.08in.) / 580 mm (22.83in.)
Dimensions (L × W × H) 4313 × 1120 × 1220 mm (169.80 × 44.09 × 48.03in.)
C-C
1470, 1890, 2310, 2730 mm
(57.87, 74.41, 90.94, 107.48 in.)
Weight 2894 kg (6381 lb)
Wireless remote - control
pendant
Wireless
Control voltage 24V
Operation temperature -15 to +40 °C
PEK settings, ESD-120
Gear 1 N1:N2 100:1
Gear 2 N1:N2 10:1
Gear 3 N1:N2 1:1
3 TECHNICAL DATA
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© ESAB AB 2020
Wheel diameter 580mm
High manual speed 200cm/min
Frequency ratio N1 50 Hz
Frequency ratio N2 50Hz
Max motor rpm 1098
3.5.2 Idler unit, ESI-120
ESI-120
Max loading capacity 60000 kg (132277 lb)
Roller type Polyurethane (90 °C / 92°A Shore)
Roller width / diameter 180 mm (7.08in.) / 580 mm (22.83in.)
Dimensions (L × W × H) 3746 × 800 × 1142 mm (147.48 × 31.50 × 44.96in.)
C-C
1470, 1890, 2310, 2730 mm
(57.87, 74.41, 90.94, 107.48 in.)
Weight 2207 kg (4866 lb)
4 INSTALLATION
0463 751 001
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© ESAB AB 2020
4 INSTALLATION
4.1 Location
WARNING!
Always ensure that there is sufficient space around the roller beds.
Make sure to have suitable access and enough space around the roller beds, including the vessel
when loaded. Position it to allow unhindered loading and unloading of vessels onto the roller beds by
overhead crane or other lifting devices
4.2 Lifting instructions
Use correctly rated overhead cranes or forklift trucks to move the roller beds.
Lifting by crane
The roller beds can be lifted by using the lifting points on the roller bed wheel stands. Use one lifting
point on each side of the wheel stand, 4 lifting points in all. The recommended angle between the
chain and the lifting points on the roller beds is 60°.
Place the roller beds on a smooth, level, hard floor that is capable of taking the weight of the roller bed
and vessel, over the contact area of the roller bed with the floor.
The distances between the base frames should match the vessel dimensions. If the vessel is perfectly
symmetrical and one drive with one idler is used, place the drive unit and the idler unit on one-third of
the way along the vessel's length to ensure that each section carries an equal load.
If one end of the vessel is heavier, move the drive or idler section closer to this end to balance the
loading on each section.
CAUTION!
Balance the loading equally between the drive and idler sections. Failure to do so can
result in overloading one of the sections, which will cause the wheels slipping when trying
to rotate the vessel. It can also result in back-driving, where the vessel can continue to
rotate after stopping the roller beds. This must be rectified by correctly positioning the drive
and idler section, failure to do so will cause damage to the equipment.
WARNING!
When a direction button (forward or reverse) is pressed, the roller beds begin to turn the
vessel.
4 INSTALLATION
0463 751 001
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© ESAB AB 2020
4.3 Adjusting the wheel stands
The positions of the two wheel stands on the base frame must be adjusted to load vessels of different
diameters.
1. Unbolt the wheel stand from the base frame.
2. Use an overhead crane to lift the wheel stand using the lifting points.
3. Move the wheel stand to the required position for the diameter of the vessel.
4. Bolt the wheel stands back onto the base frame using all the bolts, and tighten to the
correct torque i.e. M12 (8.8) 81 Nm and M16 (8.8) 197 Nm.
5. See tables and the picture below for correct distances between the two wheels
stands.
Suitable centre to centre distance (C -C) in relation to workpiece diameter
NOTE!
Only when the workpiece is resting an all wheels.
ESD-15, ESI-15
Wheelstandposition C- C (mm) Min object Ø (mm) Max object Ø (mm)
A 760 1090 1540
B 1140 1540 2510
C 1520 2510 3500
D 1900 3400 4400
E 2280 4100 5400
ESD-30, ESI-30
Wheelstandposition C- C (mm) Min object Ø (mm) Max object Ø (mm)
A 995 1420 2080
B 1375 2080 2990
C 1755 2910 3900
D 2135 3700 4900
ESD-60, ESI-60
Wheelstandposition C- C (mm) Min object Ø (mm) Max object Ø (mm)
A 995 1420 2010
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