ESAB STA, STB A25 STA, A25 STB User manual

Category
Welding System
Type
User manual

This manual is also suitable for

GB
Valid for serial no. 751-xxx-xxxx, 838-xxx-xxxx0443 922 101 GB 100325
A25
STA/STB
Instruction manual
DECLARATION OF CONFORMITY
according to the Machinery Directive 2006/42/EC, according to the EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
enligt Maskindirektivet 2006/42/EG, enligt EMCDirektivet 2004/108/EG
Type of equipment Materialslag
Welding station used as carrier of welding heads
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
STA / STB from Serial number 751 xxx xxxx (2007 week 51)
STA / STB are members of the ESAB product family A25
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB, Welding Equipment
Esabvägen, SE695 81 LAXÅ, Sweden
Phone: +46 584 81 000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
EN 602041, Safety of machinery – Electrical equipment of machines – Party 1: General requirements
EN 121002, Safety of machinery – Part 2: Technical principles
EN 6097410 Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: Restrictive use; Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturers authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Date / Datum
Laxå 20100325
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.1 Welding station A25 STA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.2 Automatic tube welding machine A25 STA 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.3 Automatic tube welding machine A25 STB 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1.4 Technical data 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Connection of Welding Station A25 STA to welding power source 10. . . . . . . . . . . . . . . .
4 OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Settings 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 MAINTENANCE 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Maintenance and Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 ORDERING OF SPARE PARTS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR PARTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 SAFETY
Users of ESAB welding 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 welding equipment. The following recommen
dations 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 welding
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 welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from drafts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves. Note! Do not use safety gloves when replacing wire.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precausions when welding.
Ask for your employer's safety practices which should be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S Keep your head out of the fumes.
S 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.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
Read and understand the instruction manual before
installing or operating.
CAUTION!
This product is solely intended for arc welding.
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.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
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ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
A25 is a modular component system for mechanised TIG welding.
The components can be built together for customised solutions and are contained in
the STA/STB automatic tube welding machines and welding station STA.
Typical applications for A25:
S Automatic tube welding machines
S Welding column and booms
S Head and tailstocks
S Tables for circumferential welding
S Fixtures for longitudinal welding
S Customised applications
Welding station A25 STA
The A25 STA welding station is designed for longitudinal welding of tubes and for
welding of tube joints or other types of workpieces.
For rotation of the workpiece the station is provided with a motorised turntable.
Automatic tube welding machines A25 STA / A25 STB
A25 STA/ A25 STB are automatic welding machines designed for longitudinal weld
ing of tubes and for welding of tube joints. They are to be used together with some
type of carrier, for example a column and boom unit or a railborne carriage.
2.1 Equipment
2.1.1 Welding station A25 STA
Welding station A25 STA is equipped with a motorised AVC slide, a motorised
weaving slide and a VEC motor for the rotation of the workpiece.
The station can also be provided with equipment for narrow-gap welding.
The welding station is adapted for connection to the programmable welding
power source.
1. VEC motor with gear
2. Automatic tube welding machine A25
STA with machine torch BTE
250M Automatic tube welding
machine A25 STA with machine
torch BTE 500M
3. Stand
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2.1.2 Automatic tube welding machine A25 STA
The automatic tube welding machines are provided with a motor-driven AVC slide,
and depending on the design, a motor-driven weaving slide or a manual horizontal
slide.
The station can also be provided with equipment for narrow-gap welding of material
up to 80 mm thickness.
The automatic tube welding machines are adapted for connection to the
programmable welding power source.
The automatic tube welding machine A25 STA is available in the following designs,
see page 14.
1. Wire feed unit
2. Wire guide unit
3. Wire bobbin
4. Circular slide
5. Manual horizontal slide
6. Motor-driven AVC slide
7. Motor-driven weaving slide
8. Machine torch BTE 250M
Machine torch BTE 500M
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2.1.3 Automatic tube welding machine A25 STB
The automatic tube welding machines are provided with manually adjustable slides
with gas spring. The spring can easily be dismounted, if desired.
The slides are adapted for connection to the programmable welding power source.
The automatic tube welding machine A25 STB is available in the following designs,
see page 14.
1. Wire feed unit
2. Wire guide unit
3. Wire bobbin
4. Circular slide
5. Slide with gas spring
6. Guide wheel device
7. Machine torch BTE 250M
Machine torch BTE 500M
ESAB's accessories for the product can be found on page 16.
2.1.4 Technical data
Operating temperature -10 to +40° C
Transportation temperature - 20 to +55° C
S The wire feed unit is designed for the wire dimensions 0.6 - 0.8 - 1.0 - 1.2
-1.6mm.
The drive roller for 1.6 mm is only supplied together with machine torch BTE
500M.
Motor voltage (DC) 48 V
Armature rotation speed 70 - 5500 r/min
Gear ratio 159:1
Max. power 50 W
Wire feed speed 0.1 - 2.6 m/min
S The wire guide unit is play-free and is provided with two setting screws for the
adjustment of the filler wire position +/- 4 mm in each direction. The
centre tube is axially adjustable and is secured by way of a stop screw. Nozzles
are available for the wire dimensions 0.6 - 0.8 - 1.0 - 1.2 - 1.6 mm.
S The max. diameter of the wire bobbin is 300 mm and the weight max. 15 kg.
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S Slides
S The circular slide permits optional setting of the angle for fillet welding.
S The setting length of the manual horizontal slide is 93 mm.
S The motor-driven AVC slide and the motor-driven weaving slide are
fitted with a ball screw, driven by a toothed belt over a DC motor.
The motor is connected by way of an 8 m screened cable.
Motor-driven AVC slide Motor-driven weaving slide
Setting length 76 mm 76 mm
Motor voltage (DC) 12 V 48 V
Armature rotation speed 100 - 8000 r/min 70 - 5500 r/min
Gear ratio 159:1 14:1
Control speed max. 2.81 mm/s max. 19 mm/s
S Slide with gas spring - the power of the spring is 40 N.
For fillet welding a slide cross with two gas springs is used. One of the
springs can be dismounted, and a free runner adapted as a cross slide is
obtained.
The setting length of the slide is 76 mm.
S The guide wheel device is provided with two setting screws for vertical and
lateral adjustment of the tungsten electrode in the weld joint.
The lateral adjustment is +/- 3 mm. The
guide wheel device can be used for butt and fillet welding. For the guide wheel to
be used for joint tracking in butt welding, a gap of about 0.5 mm is required
between the workpieces.
Two types of guide wheels are available:
S Guide wheel with pointed tread for butt welding.
S Guide wheel with rounded tread for fillet welding.
The guide wheel device can be combined with the wire guide unit. Using this
combination the filler wire must be fed in slantwise from the front.
S The machine torches BTE 250M and BTE 500M are water-cooled and
designed for welding with up to 250 A and 500 A welding current.
S The VEC motor with gear is a separately magnetised DC motor with a
combined gear/worm gear.
To the VEC motor with gear belong a terminal box and 2 connection cables
(rotation and CAN/42V).
Fit the 4 supplied insulators on the terminal box to avoid that the casing of the
box gets into electrical contact with earth.
Voltage (DC) 42 V
Gear ratio 672:1
Max. permissible torque 50 Nm
Rotation speed 1000 r/min
Output power at rated voltage 36 W
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3 INSTALLATION
The installation must be executed by a professional.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Fasten the equipment - particularly if the
ground is uneven or sloping.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
3.1 Connection of Welding Station A25 STA to welding power
source
B-B Motor cable - wire feed
C-C Motor cable - rotation
E-E Motor cable - AVC unit
F-F Motor cable - weaving unit
G-G Cooling water hose, in
H-H Cooling water hose, out
J-J Welding cable
K-K Measuring cable
M-M Gas hose, out
Q-Q Return cable +
R-R Connection cable - pulse generator VEC
S-S Motor cable - rotation
T-T Connection cable - CAN 42V
U-U Connection cable - armature VEC
V-V Connection cable - CAN 42 V
Z-Z Motor cable - wire feed
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4 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!
WARNING!
Electric shock!
Do not touch the workpiece or the welding head during operation!
CAUTION!
Danger of hose-burst ! Never use pressure of more than 3,5 bar on the coolant hoses!
Blow out all the cooling agent inside the system by means of compressed air into a
container.
CAUTION!
To avoid the welding tool being damaged, check that the return cable is connected to the
workpiece and that the tungsten electrode is in the start position before the welding
commences.
CAUTION!
The coolant must be handled as chemical waste.
4.1 Settings
S Make sure that all gas hoses, return and connection cables are properly fitted.
S Make sure that a correctly ground thorium or tungsten electrode is fitted in the
machine torch.
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5 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any faults.
5.1 Maintenance and Service
S Keep the movable parts of the automatic welding machine free of dust and dirt.
As necessary, clean the machine using dry compressed air (reduced pressure).
S Check that all screws and nuts are tightened.
S Check that all cables and hoses are undamaged and properly connected.
S Clean and grease the slides as necessary using Molycote.
6 ORDERING OF SPARE PARTS
STA/STB is designed and tested in accordance with the international and European
standards 60204-1/12100-2 and 60974-10. It is the obligation of the service unit which
has carried out the service or repair work to make sure that the product still conforms
to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
Edition 100325
Diagram
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STA/STB
Edition 100325
Ordering number
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Ordering no. Product
0443 911 880 Automatic welding machine A25 STA with TIG torch BTE 250M and AVC slide
0443 911 881 Automatic welding machine A25 STA with TIG torch BTE 500M and AVC slide
0443 911 882 Automatic welding machine A25 STA with TIG torch BTE 250M, AVC and weave slide
0443 911 883 Automatic welding machine A25 STA with TIG torch BTE 500M, AVC and weave slide
0443 911 884 Automatic welding machine A25 STA with TIG torch BTE 250M, AVC and manual slide
0443 911 885 Automatic welding machine A25 STA with TIG torch BTE 500M, AVC and manual slide
0443 911 886 Automatic welding machine A25 STA with TIG torch BTE 250M and manual slide
0443 911 887 Automatic welding machine A25 STA with TIG torch BTE 500M and manual slide
0443 912 880 Automatic welding machine A25 STB with TIG torch BTE 250M and slide for floating welding
head
0443 912 881 Automatic welding machine A25 STB with TIG torch BTE 500M and slide for floating welding
head
0443 910 880 Welding station A25 STA with TIG torch BTE 250M
0443 910 881 Welding station A25 STA with TIG torch BTE 500M
0443 922 990 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
STA/STB
Edition 100325
Wear parts
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Item
no.
Qty Ordering no. Denomination Notes
0441 299 880 Wire feed mechanism
1 1 0367 907 003 Inlet nozzle Ø 2.5 mm
2 1 0441 990 001 Guider
3 2 0455 068 001 Shaft
4 4 0455 053 880 Ball bearing
5 1 0441 304 001 Pinion
Item Ordering no. Denomination Wire type Wire dimensions Groove
typ
6 0369 557 001 Feed/pressure rollers Fe, Ss & cored Ø 0.6 & 0.8 mm V
0369 557 003 Feed/pressure rollers Fe, Ss & cored Ø 1.0 & 1,2 mm V
0369 557 005 Feed/pressure rollers Cored Ø 1.4/1.6 & 2.0/2.4 mm V-Knurled
0369 557 007 Feed/pressure rollers Fe, Ss & cored Ø 1.2 & 1,6 mm V
7 0190 725 200 Ball bearing
STA/STB
Edition 100325
Accessories
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Special nozzle for narrow-gap welding 0441 667 880. . . . . . . . . . . .
Wire guide unit for narrow-gap welding 0441 407 882. . . . . . . . . . .
Beam-travelling carriage 0458 002 880. . . . . . . . . . . . . . . . . . . . . . . .
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ESAB AB
SE-695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
081016
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
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.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 45 670 7073
Fax: +81 45 670 7001
MALAYSIA
ESAB (Malaysia) Snd Bhd
USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki-Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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ESAB STA, STB A25 STA, A25 STB User manual

Category
Welding System
Type
User manual
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