ESAB EDB-15/30 User manual

EDB-15/30, EIB-15/30,
EDB-60, EIB-60,
EDB-90/120, EDB-120
Rail Cars
Instruction manual
0463 761 001  GB  20210224 Valid for: 026-xxx-xxxx

TABLE OF CONTENTS
0463 761 001 -3- © ESAB AB 2021
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 rail cars .............................................................................. 8
2.3 Terminology used in this manual............................................................................... 8
3 TECHNICAL DATA ..................................................................................................................... 9
3.1 EDB/EIB-15/-30 ............................................................................................................ 9
3.1.1 Drive unit, EDB-15/-30 ....................................................................................... 9
3.1.2 Idler unit, EIB-15/-30 .......................................................................................... 10
3.2 EDB/EIB-60................................................................................................................... 11
3.2.1 Drive unit, EDB-60.............................................................................................. 11
3.2.2 Idler unit, EIB-60................................................................................................. 12
3.3 EDB-90 and EIB-90/-120 .............................................................................................. 13
3.3.1 Drive unit, EDB-90.............................................................................................. 13
3.3.2 Idler unit, EIB-90/-120 ........................................................................................ 14
3.4 EDB-120........................................................................................................................ 14
4 INSTALLATION........................................................................................................................... 16
4.1 Location........................................................................................................................ 16
4.2 Lifting instructions ...................................................................................................... 16
4.3 Installation procedure ................................................................................................. 16
5 OPERATION ............................................................................................................................... 17
5.1 Operating the rail cars ................................................................................................ 17
5.2 Operation safety .......................................................................................................... 18
5.3 Stopping the rail cars.................................................................................................. 18
6 MAINTENANCE.......................................................................................................................... 19
6.1 General ......................................................................................................................... 19
6.2 Storage ......................................................................................................................... 19
6.3 Repair and maintenance ............................................................................................. 19
6.4 Cleaning ....................................................................................................................... 20
6.5 Breakdowns ................................................................................................................. 20
6.6 Gearmotors .................................................................................................................. 20
6.6.1 Gearmotors inspection and maintenance........................................................... 20
6.6.2 Gearbox lubrication ............................................................................................ 20
7 TROUBLESHOOTING ................................................................................................................ 22
8 ORDERING SPARE PARTS ....................................................................................................... 23
WIRING DIAGRAM ................................................................................................................................ 24
ORDERING NUMBERS ......................................................................................................................... 29
SPARE PARTS ...................................................................................................................................... 30
SPARE PARTS - EDB-15/-30 Mechanical parts list - Drive section .................................................. 31
SPARE PARTS - EIB-15/-30 Mechanical parts list - Idler section ..................................................... 32
SPARE PARTS - EDB-60 Mechanical parts list - Drive section ........................................................ 33
SPARE PARTS - EIB-60 Mechanical parts list - Idler section ........................................................... 34

TABLE OF CONTENTS
0463 761 001 -4- © ESAB AB 2021
SPARE PARTS - EDB-90 Mechanical parts list - Drive section ........................................................ 35
SPARE PARTS - EIB-90/-120 Mechanical parts list - Idler section ................................................... 36
SPARE PARTS - EDB-120 Mechanical parts list - Drive section ...................................................... 37
SPARE PARTS - Control cabinet......................................................................................................... 38

1  SAFETY
0463 761 001 -5- © ESAB AB 2021
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 rail cars are not suitable for the following:
• Any work piece which is heavier than the maximum weight limit of the rail
cars.
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
3. The workplace must:
• be suitable for the purpose
• be free from drafts

1  SAFETY
0463 761 001 -6- © ESAB AB 2021
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
0463 761 001 -7- © ESAB AB 2021
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 761 001 -8- © ESAB AB 2021
2 INTRODUCTION
This instruction manual describes the use and maintenance of the optional rail cars EDB-15/-30,
EIB-15/-30, EDB-60, EIB-60, EDB-90, EIB-90/-120 and EDB-120 used together with conventional
roller beds, self-aligning roller beds and/or fit-up units referred to as rail cars in this document. Actions
that must be carried out by the manufacturer are not included in this manual.
This manual is part of the rail cars. Keep a copy of the manual with the rail cars and store the original
in a safe place. If the rail cars are sold, supply the manual with them.
The pictures and diagrams used in this manual are for illustrative purposes only. The supplied
equipment might differ slightly.
2.1 Equipment
The rail car drive unit (EDB) are supplied with:
• 2 × Driven wheel units
• 2 × Idling wheel units
• Contactors (7.3 and 7.4) to be installed in the control panel on the driven roller bed
• Instruction manual
The rail car idler unit (EBI) is supplied with:
• 4 × Idling wheel units
2.2 Purpose and function of rail cars
The rail cars are designed as an accessory to roller beds and/or fit-up units, to make it possible to
move them along floor mounted rails.
Rail cars mounted to the roller beds and/or fit-up units make it possible to join round objects to each
other in a controlled way, for example, wind tower sections, vessels and others.
2.3 Terminology used in this manual
Drive unit Rail car section with powered wheels.
Idler unit Rail car section with free-wheeling wheels.
Rail car driven set
(EDB)
One set consists of two (2) driven wheel units and two (2) idling wheel
units.
Rail car idler set (EIB) One set consists of four (4) idling wheel units.
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 rail car set.

3  TECHNICAL DATA
0463 761 001 -9- © ESAB AB 2021
3 TECHNICAL DATA
3.1 EDB/EIB-15/-30
3.1.1 Drive unit, EDB-15/-30
EDB-15/-30
Max loading capacity 15000kg (33069lb)
Travelling capacity 30000kg (66138lb)
Drive motor 2×0.12kW
Travelling Speed Low / High 200/2000mm/min (5.51/78.74 in./min)
Track width 1730mm (68.11in.)
Mains supply 380–440V, 3phase, 50Hz
Mains fuse 16 A
Wheel type Steel wheels with single flange
Weight (one set of EDB) 436kg (2×128 kg+2×90 kg) / (961 lb (2×282lb+2×198.5 lb))
Extended width to the roller
bed (along the rails)
706mm (2×353mm)
27.8in. (2×13.9in.)
Extended height to the roller
bed
90mm
3.54in.
Control voltage 24V
Operation temperature -15to+40°C

3  TECHNICAL DATA
0463 761 001 - 10 - © ESAB AB 2021
3.1.2 Idler unit, EIB-15/-30
EIB-15/-30
Max loading capacity 15000 kg (33069lb)
Wheel type Steel wheels with single flange
Track width 1730mm (68.11in.)
Weight (one set of EIB) 360kg (4×90kg) / (794lb(4×198.5 lb))
Extended width to the
roller bed (along the rails)
706mm (2×353mm)
27.8in.(2×13.9in.)
Extended height to the
roller bed
90mm
3.54in.