Related Manuals for ESAB ESD 7.5
Summary of Contents for ESAB ESD 7.5
- Page 1 ESD 7.5/ESI 7.5, 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 Valid for: 015-xxx-xxxx, LX130-xxxx-xxxx 0463 751 001 GB 20230428...
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Page 3: Table Of Contents
Control panel ................Wireless remote - control pendant ..................Switch the mains power on .................... Operating the roller beds ......................Operation safety ......................... Welding ..................... Stopping the roller beds .......................... MAINTENANCE 0463 751 001 - 3 - © ESAB AB 2023... - Page 4 ............................. ACCESSORIES ............................SPARE PARTS ............SPARE PARTS - ESD 7.5 Mechanical parts list - Drive section ............SPARE PARTS - ESI 7.5 Mechanical parts list - Idler section ............SPARE PARTS - ESD 15 Mechanical parts list - Drive section ............
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Page 5: Safety
°C. 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. - Page 6 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 0463 751 001 - 6 - © ESAB AB 2023...
- Page 7 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. 0463 751 001 - 7 -...
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Page 8: Introduction
A wireless operator hand control pendant. 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. 0463 751 001 - 8 - © ESAB AB 2023... -
Page 9: Technical Data
550 kg (1213 lb) Wireless remote - control Wireless pendant Control voltage 24 V Operation temperature -15 to +40 °C (53.5 to 104 °F) PEK settings, ESD 7.5 Gear 1 N1:N2 100:1 0463 751 001 - 9 - © ESAB AB 2023... -
Page 10: Idler Unit, Esi 7.5
Dimensions (L × W × H) 2200 × 500 × 721 mm (86.61 × 19.69 × 28.39 in.) 650, 910, 1170, 1430, 1690 mm (25.59, 35.83, 46.06, 56.30, 66.54 in.) Weight 400 kg (882 lb) 0463 751 001 - 10 - © ESAB AB 2023... -
Page 11: Esd/Esi 15
Wireless remote - control Wireless pendant Control voltage 24 V Operation temperature -15 to +40 °C PEK settings, ESD 15 Gear 1 N1:N2 100:1 Gear 2 N1:N2 10:1 Gear 3 N1:N2 Wheel diameter 400 mm 0463 751 001 - 11 - © ESAB AB 2023... -
Page 12: Idler Unit, Esi 15
2830 × 600 × 803 mm (111.42 × 23.62 × 31.61 in.) 760, 1140, 1520, 1900, 2280 mm C - C (29.92, 44.88, 59.84, 74.8, 89.76 in.) Weight 600 kg (1323 lb) 0463 751 001 - 12 - © ESAB AB 2023... -
Page 13: Esd/Esi 30
Wireless remote - control Wireless pendant 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 Wheel diameter 400 mm 0463 751 001 - 13 - © ESAB AB 2023... -
Page 14: Idler Unit, Esi 30
Dimensions (L × W × H) 2848 × 700 × 859 mm (112.1 × 27.6 × 33.8 in.) 995, 1375, 1755, 2135 mm (39.17, 54.12, 69.09, 84.06 in.) Weight 850 kg (1874 lb) 0463 751 001 - 14 - © ESAB AB 2023... -
Page 15: Drive Unit, Esd 60
Wireless remote - control Wireless pendant 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 Wheel diameter 580 mm 0463 751 001 - 15 - © ESAB AB 2023... -
Page 16: Idler Unit, Esi 60
Dimensions (L × W × H) 3650 × 800 × 1039 mm (143.7 × 31.5 × 40.91 in.) 995, 1415, 1835, 2255, 2675 mm (39.17, 55.71, 72,24, 88.78, 105.31 in.) Weight 1700 kg (3749 lb) 0463 751 001 - 16 - © ESAB AB 2023... -
Page 17: Esd/Esi 90
Wireless remote - control Wireless pendant 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 Wheel diameter 580 mm 0463 751 001 - 17 - © ESAB AB 2023... -
Page 18: Idler Unit, Esi 90
Dimensions (L × W × H) 3723 × 800 × 1126 mm (146.6 × 31.5 × 44.33 in.) 1470, 1890, 2310, 2730 mm (57.87, 74.41, 90.94, 107.48 in.) Weight 2100 kg (4631 lb) 0463 751 001 - 18 - © ESAB AB 2023... -
Page 19: Esd/Esi 120
Wireless remote - control Wireless pendant 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 Wheel diameter 580 mm 0463 751 001 - 19 - © ESAB AB 2023... -
Page 20: Idler Unit, Esi 120
Dimensions (L × W × H) 3746 × 800 × 1142 mm (147.48 × 31.50 × 44.96 in.) 1470, 1890, 2310, 2730 mm (57.87, 74.41, 90.94, 107.48 in.) Weight 2350 kg (5182 lb) 0463 751 001 - 20 - © ESAB AB 2023... -
Page 21: Installation
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. 0463 751 001 - 21 - © ESAB AB 2023... -
Page 22: Adjusting The Wheel Stands
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 7.5, ESI 7.5 Wheel stand position C- C (mm) Min object Ø (mm) Max object Ø... -
Page 23: Adjusting The Included Angle
The distance between the wheel stands, on both the drive unit and the idler units depends on the diameter of the vessel. To achieve a safe and smooth operation of the roller beds the recommendation is the keep the included angle (α) between 45° and 70°. 0463 751 001 - 23 - © ESAB AB 2023... -
Page 24: Installation Procedure
The following description requires basic knowledge of ESAB welding process PEK control unit . For more information about PEK control unit , refer to the PEK control unit instruction manual. Follow these instructions to set up the PEK control unit when a roller bed is connected to an ESAB CaB. - Page 25 - enter the diameter (mm) of the work piece where the weld will be carried out. If welding on the surface, this value will be equal to the roll diameter. • ROLL DIAMETER - enter the outer diameter (mm) of the actual work piece. 0463 751 001 - 25 - © ESAB AB 2023...
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Page 26: Roller Bed Configurations
Roller bed configurations The figure below shows different setup options for the CaB and roller bed. For further details see section "WIRING DIAGRAM". For interface cable and synchronization cable see section "ACCESSORIES". 0463 751 001 - 26 - © ESAB AB 2023... -
Page 27: Operation
Inside the control panel is an inverter that controls the motors. The roller bed is manually controlled via a wireless remote - control pendant. It can also be connected to a welding manipulator, for example, ESAB CaB, and then controlled by the CaB controller. Control panel 1. -
Page 28: Wireless Remote - Control Pendant
Press again to deactivate it. When the roller bed is connected to and controlled from an ESAB CaB i.e., digital output from the CaB is set to high, this lamp flashes until the signal is set to low again. -
Page 29: Switch The Mains Power On
Switch the mains power on WARNING! Do not operate the roller beds if there are signs of damage. Always have an authorized ESAB service technician to check and make repairs if necessary. Before switching on the roller beds, check that: 1. -
Page 30: Drive Unit, Esd
5) Press the E-stop rest pushbutton. If running as standalone, press the control mode pushbutton (white lamp). In case an ESAB CaB is connected to the roller bed, check and verify that settings in the PEK are correct and match the roller bed parameters. -
Page 31: Welding
Rotation starts again when the pushbutton for continuously rotation is pressed. NOTE! Use the emergency stop button on the control panel and wireless remote - control pendant in case of an emergency only. 0463 751 001 - 31 - © ESAB AB 2023... -
Page 32: Maintenance
Cable damage: mains and any visible cable running from the control panel to the motors. • Correct functioning of the emergency stops and the control panel mains switch. Remove and replace any damaged parts. 0463 751 001 - 32 - © ESAB AB 2023... -
Page 33: Cleaning
Breakdowns If the roller beds stop working, the equipment must be repaired by authorized ESAB service technicians. NOTE! Repeated faults indicate a problem with the roller beds. -
Page 34: Inverters
All inverters are of Siemens brand. More detailed information around maintenance and troubleshooting of Sinamics V20 Inverter can be found at Siemens web site. A new inverter with appropriate application software can be purchased from ESAB as a spare part. Bearings NOTE! Before loosening the screws and nuts holding the bearing hubs, mark their position in relation to the wheel stand beneath, for example with a permanent marker. - Page 35 6 MAINTENANCE the shaft. Before mounting the new PU wheel, make sure that the shaft and keys are undamaged. Replace them if necessary. 0463 751 001 - 35 - © ESAB AB 2023...
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Page 36: Troubleshooting
Wheel centres are too far apart Check that wheel centres are correct to component diameter Out of balance loading has been Check if out of balance loading is acceptable exceeding 0463 751 001 - 36 - © ESAB AB 2023... -
Page 37: Ordering Spare Parts
Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. ESD 7.5 and ESI 7.5, ESD 15 and ESI 15, ESD 30 and ESI 30, ESD 60 and ESI 60, ESD 90 and ESI 90, ESD 120 and ESI 120 are designed and tested in accordance with the international and European standards EN 12100:2010, EN 60204-1:2018, EN 61000-6-2:2019 and... -
Page 38: Wiring Diagram
APPENDIX APPENDIX WIRING DIAGRAM 0463 751 001 - 38 - © ESAB AB 2023... - Page 39 APPENDIX Connections overview 0463 751 001 - 39 - © ESAB AB 2023...
- Page 40 APPENDIX Connections B to A cabinet and primary to secondary 0463 751 001 - 40 - © ESAB AB 2023...
- Page 41 APPENDIX Connections XS1 and XP2 0463 751 001 - 41 - © ESAB AB 2023...
- Page 42 APPENDIX Emergency stop circuit overview 0463 751 001 - 42 - © ESAB AB 2023...
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Page 43: Ordering Numbers
Roller bed idler unit ESI 90 0909 018 880 Roller bed drive unit ESD 120 0909 018 881 Roller bed drive unit ESD 120 C, With digital display 0909 019 880 Roller bed idler unit ESI 120 0463 751 001 - 43 - © ESAB AB 2023... -
Page 44: Accessories
0909 530 901 Synchronization cable, CE 20 m 0909 530 902 Synchronization cable, CE 30 m 0909 530 903 Synchronization cable, CE 40 m 0909 530 904 Synchronization cable, CE 50 m 0463 751 001 - 44 - © ESAB AB 2023... -
Page 45: Spare Parts
Not following the recommendations for replacement parts can have consequences for the safety of the equipment. The manufacturers cannot be held liable for any subsequent problems after fitting non-recommended parts. 0463 751 001 - 45 - © ESAB AB 2023... -
Page 46: Spare Parts - Esd 7.5 Mechanical Parts List - Drive Section
APPENDIX SPARE PARTS - ESD 7.5 Mechanical parts list - Drive section Item Qty Ordering no. Denomination Notes 0909 229 001 Base frame 200×200×12.5 L=2200 0909 248 880 Roller stand 0909 297 001 Side plate 0909 173 001 Slide bearing with flange... - Page 47 APPENDIX 0463 751 001 - 47 - © ESAB AB 2023...
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Page 48: Spare Parts - Esi 7.5 Mechanical Parts List - Idler Section
0909 392 001 Shaft kidney 0909 299 001 Idler shaft 0215 701 321 Key, wheel 12×8×32 0909 249 001 PU wheel 247×50 0909 302 001 Flange bearing 0909 037 001 Side support 0463 751 001 - 48 - © ESAB AB 2023... -
Page 49: Spare Parts - Esd 15 Mechanical Parts List - Drive Section
0215 701 341 Key, wheel 14×9×63 0909 104 001 Bracket 0909 116 001 Bracket 0909 291 001 Cover end Valid for serial no. 015-xxx-xxxx 0909 372 001 Cover end v2 Valid for serial no. LX130-xxxx-xxxx 0463 751 001 - 49 - © ESAB AB 2023... - Page 50 APPENDIX 0463 751 001 - 50 - © ESAB AB 2023...
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Page 51: Spare Parts - Esi 15 Mechanical Parts List - Idler Section
0909 390 001 Shaft kidney 0909 163 001 Idler shaft 0215 701 341 Key, wheel 14×9×63 0909 164 001 PU wheel 300×90 0909 162 001 Flange bearing 0909 037 001 Side support 0463 751 001 - 51 - © ESAB AB 2023... -
Page 52: Spare Parts - Esd 30 Mechanical Parts List - Drive Section
0215 701 420 Key, wheel 20x12x70 0909 104 001 Bracket 0909 117 001 Bracket 0909 292 001 Cover end Valid for serial no. 015-xxx-xxxx 0909 367 001 Cover end v2 Valid for serial no. LX130-xxxx-xxxx 0463 751 001 - 52 - © ESAB AB 2023... - Page 53 APPENDIX 0463 751 001 - 53 - © ESAB AB 2023...
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Page 54: Spare Parts - Esi 30 Mechanical Parts List - Idler Section
0909 386 001 Shaft kidney 0909 132 001 Idler shaft 0215 701 420 Key, wheel 20×12×70 0909 076 001 PU wheel 400×90 0909 136 001 Flange bearing 0909 037 001 Side support 0463 751 001 - 54 - © ESAB AB 2023... -
Page 55: Spare Parts - Esd 60 Mechanical Parts List - Drive Section
0215 701 431 Key, wheel 22x14x160 0909 104 001 Bracket 0909 118 001 Bracket 0909 293 001 Cover end Valid for serial no. 015-xxx-xxxx 0909 376 001 Cover end v2 Valid for serial no. LX130-xxxx-xxxx 0463 751 001 - 55 - © ESAB AB 2023... - Page 56 APPENDIX 0463 751 001 - 56 - © ESAB AB 2023...
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Page 57: Spare Parts - Esi 60 Mechanical Parts List - Idler Section
0909 389 001 Shaft kidney 0909 174 001 Idler shaft 0215 701 431 Key, wheel 22×14×160 0909 057 001 PU wheel 400×90 0909 137 001 Flange bearing 0909 098 001 Side support 0463 751 001 - 57 - © ESAB AB 2023... -
Page 58: Spare Parts - Esd 90 Mechanical Parts List - Drive Section
0215 701 430 Key, wheel 22×14×140 0909 104 001 Bracket 0909 118 001 Bracket 0909 294 001 Cover end Valid for serial no. 015-xxx-xxxx 0909 380 001 Cover end v2 Valid for serial no. LX130-xxxx-xxxx 0463 751 001 - 58 - © ESAB AB 2023... - Page 59 APPENDIX 0463 751 001 - 59 - © ESAB AB 2023...
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Page 60: Spare Parts - Esi 90 Mechanical Parts List - Idler Section
0909 388 001 Shaft kidney 0909 206 001 Idler shaft 0215 701 430 Key, wheel 22×14×140 0909 096 001 PU wheel 580×180 0909 210 880 Flange bearing 0909 098 001 Side support 0463 751 001 - 60 - © ESAB AB 2023... -
Page 61: Spare Parts - Esd 120 Mechanical Parts List - Drive Section
0215 701 448 Key, wheel 28×16×140 0909 104 001 Bracket 0909 118 001 Bracket 0909 295 001 Cover end Valid for serial no. 015-xxx-xxxx 0909 384 001 Cover end v2 Valid for serial no. LX130-xxxx-xxxx 0463 751 001 - 61 - © ESAB AB 2023... - Page 62 APPENDIX 0463 751 001 - 62 - © ESAB AB 2023...
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Page 63: Spare Parts - Esi 120 Mechanical Parts List - Idler Section
0909 391 001 Shaft kidney 0909 221 001 Idler shaft 0215 701 448 Key, wheel 28×16×140 0909 101 001 PU wheel 580×180 0909 211 880 Flange bearing 0909 098 001 Side support 0463 751 001 - 63 - © ESAB AB 2023... -
Page 64: Spare Parts - Control Cabinet
Safety relay, SSR10 24 VDC 0908 800 202 Circuit breaker 1P 4A C 0909 552 885 CPU and software ESD 7.5 0909 505 885 CPU and software ESD 15 0909 506 885 CPU and software ESD 30 0909 507 885 CPU and software ESD 60 0909 508 885 CPU and software ESD 90... - Page 65 APPENDIX Item Qty Ordering no. Denomination Marking Notes 0802 083 085 Terminals + 24 VDC 0802 083 085 Terminals 0 VDC 0802 524 505 AO card, digital display X10.2 If applicable 0463 751 001 - 65 - © ESAB AB 2023...
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Page 66: Spare Parts - Electrical Parts - Control Cabinet
22MM 1NO 0908 800 113 Illuminated pushbutton, GREEN 22MM 1NO 0909 530 950 Plug, male 1XP1 0909 530 951 Plug, female 1XS2 0900 500 887 Digital display with configuration Optional 0463 751 001 - 66 - © ESAB AB 2023... -
Page 67: Spare Parts - Wireless Control System
APPENDIX SPARE PARTS - Wireless control system Item Qty Ordering no. Denomination Notes 0909 500 903 Complete transmitter unit 0463 751 001 - 67 - © ESAB AB 2023... - Page 68 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...
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