ESAB STA, STB A25 STA, A25 STB User manual

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 EMC−Direktivet 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, SE−695 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 60204−1, Safety of machinery – Electrical equipment of machines – Party 1: General requirements

EN 12100−2, Safety of machinery – Part 2: Technical principles

EN 60974−10 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 manufacturer’s 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 2010−03−25

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. . . . . . . . . . . . . . . . . . . . . . . .

- 17 -

notes

NOTES

.............................................................................................................................................................

- 18 -

notes

NOTES

.............................................................................................................................................................

- 19 -

notes

NOTES

.............................................................................................................................................................

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

ESAB STA, STB A25 STA, A25 STB User manual

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ESAB STA, STB A25 STA, A25 STB User manual

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