ESAB ERD-5/ERI-5 User manual

Instruction manual

Original instructions

0463 635 001 GB 20181218

Valid for: serial no. 827-, 851-xxx-xxxx

ERD-5/ERI-5, ERD-10/ERI-10,

ERD-20/ERI-20, ERD-30/ERI-30,

ERD-30X/ERI-30X,

ERD-60/ERI-60,

ERD-100/ERI-100

Conventional Roller Beds

TABLE OF CONTENTS

0463 635 001 © ESAB AB 2018

1

SAFETY .......................................................................................................

5

1.1 Meaning of symbols ...............................................................................

5

1.2 Non-compliant operation .......................................................................

5

1.3 Safety precautions .................................................................................

5

2

INTRODUCTION..........................................................................................

9

2.1 Equipment ...............................................................................................

9

2.2 Purpose and function of roller beds.....................................................

9

2.3 Nomenclature used in this manual .......................................................

9

3

TECHNICAL DATA ......................................................................................

10

3.1 ERD/ERI-5................................................................................................

10

3.1.1 Drive unit ..............................................................................................

10

3.1.2 Idler unit................................................................................................

11

3.1.3 Inverter parameter settings ..................................................................

11

3.2 ERD/ERI-10..............................................................................................

12

3.2.1 Drive unit ..............................................................................................

12

3.2.2 Idler unit................................................................................................

13

3.2.3 Inverter parameter settings ..................................................................

13

3.3 ERD/ERI-20..............................................................................................

14

3.3.1 Drive unit ..............................................................................................

14

3.3.2 Idler unit................................................................................................

15

3.3.3 Inverter parameter settings ..................................................................

15

3.4 ERD/ERI-30..............................................................................................

16

3.4.1 Drive unit ..............................................................................................

16

3.4.2 Idler unit................................................................................................

17

3.4.3 Inverter parameter settings ..................................................................

17

3.5 ERD/ERI-30X ...........................................................................................

18

3.5.1 Drive unit ..............................................................................................

18

3.5.2 Idler unit................................................................................................

19

3.5.3 Inverter parameter settings ..................................................................

19

3.6 ERD/ERI-60..............................................................................................

20

3.6.1 Drive unit ..............................................................................................

20

3.6.2 Idler unit................................................................................................

21

3.6.3 Inverter parameter settings ..................................................................

21

3.7 ERD/ERI-100............................................................................................

22

3.7.1 Drive unit ..............................................................................................

22

3.7.2 Idler unit................................................................................................

23

3.7.3 Inverter parameter settings ..................................................................

23

4

INSTALLATION............................................................................................

24

4.1 Location...................................................................................................

24

4.2 Lifting instructions .................................................................................

24

4.3 Adjusting the wheel brackets................................................................

25

TABLE OF CONTENTS

0463 635 001 © ESAB AB 2018

4.4 Adjusting the included angle ................................................................

25

4.5 Installation procedure ............................................................................

26

4.6 First time run-in ......................................................................................

26

4.7 PEK set up...............................................................................................

26

4.8 Roller bed configurations ......................................................................

27

5

OPERATION ................................................................................................

29

5.1 Machine details.......................................................................................

29

5.2 Control panel ..........................................................................................

29

5.3 Pendant ...................................................................................................

30

5.4 Switch the mains power on ...................................................................

30

5.5 Operating the roller beds.......................................................................

31

5.6 Operation safety .....................................................................................

31

5.7 Welding....................................................................................................

33

5.8 Stopping the roller beds ........................................................................

34

6

MAINTENANCE AND SERVICE .................................................................

35

6.1 General ....................................................................................................

35

6.2 Storage ....................................................................................................

35

6.3 Repair and maintenance ........................................................................

35

6.4 Cleaning ..................................................................................................

36

6.5 Breakdowns ............................................................................................

36

6.6 Gearbox...................................................................................................

36

6.6.1 Gearbox inspection and maintenance..................................................

36

6.6.2 Gearbox lubrication ..............................................................................

36

7

TROUBLESHOOTING .................................................................................

38

8

ORDERING SPARE PARTS ........................................................................

39

WIRING DIAGRAM..............................................................................................

40

ORDERING NUMBERS.......................................................................................

66

SPARE PARTS ....................................................................................................

68

ACCESSORIES ...................................................................................................

86

Rights reserved to alter specifications without notice.

1 SAFETY

0463 635 001

- 5 -

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 tyres: 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 SAFETY

0463 635 001

- 6 -

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

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

• Install and ground the unit in accordance with instruction manual.

• 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.

1 SAFETY

0463 635 001

- 7 -

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.

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 engine.

• Stop engine 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 that there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

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.

1 SAFETY

0463 635 001

- 8 -

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 635 001

- 9 -

2 INTRODUCTION

This Instruction manual describes the use and maintenance of the Conventional 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 machine. Keep a copy of the manual with the machine 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

• Pendant

• Base frame

• Instruction manual

The roller bed idler is supplied with:

• Idler units

• Base frame

• Instruction manual

2.2 Purpose and function of roller beds

The roller beds are designed to aid the welding of cylindrical vessels.

By using 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

baseframe to accommodate different vessel diameters.

2.3 Nomenclature used in this manual

Drive unit Roller bed section with powered wheels.

Idler unit Roller bed section with free wheeling wheels.

Roller bed set A set consists of 1 drive unit and 1 or more idler units.

Baseframe The frame the drive or idler wheels are mounted on. These are

pre-drilled so that the wheel brackets can be positioned for different

vessel diameters.

Wheel bracket The bracket which houses the roller bed wheels. This is bolted down

to the baseframe.

Control panel Electrical control box mounted on the drive unit.

Pendant Operator hand control pendant.

Vessel Any component or device that is handled on the roller bed set.

3 TECHNICAL DATA

0463 635 001

- 10 -

3 TECHNICAL DATA

3.1 ERD/ERI-5

3.1.1 Drive unit

ERD-5

Max loading capacity 2500kg (5512lb)

Turning capacity 7500kg (16535lb)

Turning drive motor 1×0.55kW

Turning speed 140-1500mm/min (5.51-59.05in./min)

Workpiece diameter minimum Ø200mm (7.87in.) at 80° included angle

Workpiece diameter maximum Ø3500mm (137.79in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Rubber (100°C / 85°A Shore)

Roller width / diameter 127mm (5in.) / 381mm (15in.)

Dimensions (L×W×H) 2150×610×620mm (84.64×24.01×24.41in.)

Weight 590kg (1301lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK settings ERD-5

Gear 1 N1:N2 1025:2

Gear 2 N1:N2 48:18

Gear 3 N1:N2 1:1

Wheel diameter 381mm

High manual speed 150cm/min

Frequency ratio N1 61Hz

Frequency ratio N2 50Hz

Max motor rpm 1400

3 TECHNICAL DATA

0463 635 001

- 11 -

3.1.2 Idler unit

ERI-5

Max loading capacity 2500kg (5512lb)

Roller type Rubber (100°C / 85°A Shore)

Roller width / diameter 127mm (5in.) / 381mm (15in.)

Dimensions (L×W×H) 2150×440×620mm (84.64×17.32×24.41in.)

Weight 470kg (1036lb)

3.1.3 Inverter parameter settings

Factory settings:

Parameter number Value

1 2.5

2 61

3 2

4 2

5 AI.AV

6 1.7

7 1370

8 400

9 0.85

10 L3

11 1

22 A

41 FD

For programming instructions, see the Inverter manual. All other values are set at factory by

the inverter manufacturer and do not need to be altered.

NOTE!

Rotation motor overloads are set to 2.8A, and force vent overloads to 0.4A.

3 TECHNICAL DATA

0463 635 001

- 12 -

3.2 ERD/ERI-10

3.2.1 Drive unit

ERD-10

Max loading capacity 5000kg (11023lb)

Turning capacity 15000kg (33069lb)

Turning drive motor 2×0.55kW

Turning speed 140-1500mm/min (5.51-59.05in./min)

Workpiece diameter minimum Ø350mm (13.78in.) at 80° included angle

Workpiece diameter maximum Ø3500mm (137.79in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 76mm (3in.) / 381mm (15in.)

Dimensions (L×W×H) 2850×610×625mm (112.2×24.01×24.61in.)

Weight 675kg (1488lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK settings ERD-10

Gear 1 N1:N2 1025:2

Gear 2 N1:N2 48:18

Gear 3 N1:N2 1:1

Wheel diameter 381mm

High manual speed 150cm/min

Frequency ratio N1 61Hz

Frequency ratio N2 50Hz

Max motor rpm 1400

3 TECHNICAL DATA

0463 635 001

- 13 -

3.2.2 Idler unit

ERI-10

Max loading capacity 5000kg (11023lb)

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 76mm (3in.) / 381mm (15in.)

Dimensions (L×W×H) 2850×410×625mm (112.2×16.14×24.61in.)

Weight 400kg (882lb)

3.2.3 Inverter parameter settings

Factory settings:

Parameter number Value

1 2.5

2 61

3 2

4 2

5 AI.AV

6 2.8

7 1500

8 400

9 0.85

10 L3

11 1

22 A

41 FD

For programming instructions, see the Inverter manual. All other values are set at factory by

the inverter manufacturer and do not need to be altered.

NOTE!

Rotation motor overloads are set to 2.8A, and force vent overloads to 0.4A.

3 TECHNICAL DATA

0463 635 001

- 14 -

3.3 ERD/ERI-20

3.3.1 Drive unit

ERD-20

Max loading capacity 10000kg (22046lb)

Turning capacity 30000kg (66139lb)

Turning drive motor 2×0.75kW

Turning speed 140-1500mm/min (5.51-59.05in./min)

Workpiece diameter minimum Ø350mm (13.78in.) at 80° included angle

Workpiece diameter maximum Ø5000mm (196.85in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 127mm (5in.)/ 381mm (15in.)

Dimensions (L×W×H) 2850×610×625mm (112.2×24.01×24.61in.)

Weight 750kg (1653lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK settings ERD-20

Gear 1 N1:N2 1025:2

Gear 2 N1:N2 48:18

Gear 3 N1:N2 1:1

Wheel diameter 381mm

High manual speed 150cm/min

Frequency ratio N1 59Hz

Frequency ratio N2 50Hz

Max motor rpm 1445

3 TECHNICAL DATA

0463 635 001

- 15 -

3.3.2 Idler unit

ERI-20

Max loading capacity 10000kg (22046lb)

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 127mm (5in.)/ 381mm (15in.)

Dimensions (L×W×H) 2850×410×625mm (112.2×16.14×24.61in.)

Weight 500kg (1102lb)

3.3.3 Inverter parameter settings

Factory settings:

Parameter number Value

1 2.5

2 59

3 2

4 2

5 AI.AV

6 3.8

7 1500

8 400

9 0.85

10 L3

11 1

22 A

41 FD

For programming instructions, see the Inverter manual. All other values are set at factory by

the inverter manufacturer and do not need to be altered.

NOTE!

Rotation motor overloads are set to 1.8A, and force vent overloads to 0.4A.

3 TECHNICAL DATA

0463 635 001

- 16 -

3.4 ERD/ERI-30

3.4.1 Drive unit

ERD-30

Max loading capacity 15000 kg (33069lb)

Turning capacity 45000kg (99208lb)

Turning drive motor 2×1.1kW

Turning speed 130-1300mm/min (5.12-51.2in./min)

Workpiece diameter minimum Ø570mm (22.44in.) at 80° included angle

Workpiece diameter maximum Ø6800mm (267.72in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 178mm (7in.) / 521mm (20.5in.)

Dimensions (L×W×H) 3570×755×765mm (140.55×29.72×30.12in.)

Weight 1525kg (3362lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK setting ERD-30

Gear 1 N1:N2 615:1

Gear 2 N1:N2 58:19

Gear 3 N1:N2 1:1

Wheel diameter 521mm

High manual speed 130cm/min

Frequency ratio N1 52Hz

Frequency ratio N2 50Hz

Max motor rpm 1445

3 TECHNICAL DATA

0463 635 001

- 17 -

3.4.2 Idler unit

ERI-30

Max loading capacity 15000 kg (33069lb)

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 178mm (7in.) / 521mm (20.5in.)

Dimensions (L×W×H) 3570×520×765mm (140.55×20.47×30.12in.)

Weight 960kg (2116lb)

3.4.3 Inverter parameter settings

Factory settings:

Parameter number Value

1 2.5

2 52

3 2

4 2

5 AI.AV

6 3.8

7 1500

8 400

9 0.85

10 L3

11 1

22 A

41 FD

For programming instructions, see the Inverter manual. All other values are set at factory by

the inverter manufacturer and do not need to be altered.

NOTE!

Rotation motor overloads are set to 1.8A, and force vent overloads to 0.4A.

3 TECHNICAL DATA

0463 635 001

- 18 -

3.5 ERD/ERI-30X

3.5.1 Drive unit

ERD-30X

Max loading capacity 15000 kg (33069lb)

Turning capacity 45000kg (99208lb)

Turning drive motor 2×1.1kW

Turning speed 130-1400mm/min (5.12-55.12in./min)

Workpiece diameter minimum Ø300mm (11.81in.) at 80° included angle

Workpiece diameter maximum Ø5500mm (216.54in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 250mm (9.84in.) / 330mm (12.99in.)

Dimensions (L×W×H) 2500×620×605mm (98.43×24.41×23.82in.)

Weight 700kg (1543.24lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK setting ERD-30X

Gear 1 N1:N2 600:1

Gear 2 N1:N2 27:14

Gear 3 N1:N2 1:1

Wheel diameter 300mm

High manual speed 140cm/min

Frequency ratio N1 55Hz

Frequency ratio N2 50Hz

Max motor rpm 1400rpm at 50Hz

3 TECHNICAL DATA

0463 635 001

- 19 -

3.5.2 Idler unit

ERI-30X

Max loading capacity 15000 kg (33069lb)

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 250mm (9.84in.) / 330mm (12.99in.)

Dimensions (L×W×H) 2500×480×605mm (98.43×18.90×23.82in.)

Weight 400kg (881.85lb)

3.5.3 Inverter parameter settings

Factory settings:

Parameter number Value

1 0

2 55

3 2

4 2

5 AV

6 5.6

7 1500

8 400

9 0.85

10 All

41 FD

06.004 0

12.041 Relay

For programming instructions, see the Inverter manual. All other values are set at factory by

the inverter manufacturer and do not need to be altered.

NOTE!

Rotation motor overloads are set to 2.8A, and force vent overloads to 0.4A.

3 TECHNICAL DATA

0463 635 001

- 20 -

3.6 ERD/ERI-60

3.6.1 Drive unit

ERD-60

Max loading capacity 30000 kg (66139lb)

Turning capacity 90000kg (198416lb)

Turning drive motor 2×1.5kW

Turning speed 130-1300mm/min (5.12-51.2in./min)

Workpiece diameter minimum Ø570mm (22.44in.) at 80° included angle

Workpiece diameter maximum Ø6800mm (267.72in.) at 50° included angle

Incoming supply 380-440V, 3 phase, 50Hz

Roller type Polyurethane (90°C / 92°A Shore)

Roller width / diameter 256mm (14in.) / 521mm (20.5in.)

Dimensions (L×W×H) 3570×880×765mm (140.55×34.65×30.12in.)

Weight 2050kg (4519lb)

Control pendant Yes

Control voltage 24V

IP classification IP65 (Control cabinet) IP 55 (Motor)

PEK settings ERD-60

Gear 1 N1:N2 615:1

Gear 2 N1:N2 58:19

Gear 3 N1:N2 1:1

Wheel diameter 521mm

High manual speed 130cm/min

Frequency ratio N1 52Hz

Frequency ratio N2 50Hz

Max motor rpm 1445

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