ESAB EFU 30 User manual

EFU 30, EFU30IB
Fit-up unit
Instruction manual
0463 760 101  GB  20230428
Valid for: Serial number:
LX246-xxxx-xxxx

TABLE OF CONTENTS
0463 760 101 -3- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols.................................................................................................... 4
1.2 Non-compliant operation ............................................................................................ 4
1.3 Safety precautions ...................................................................................................... 4
2 INTRODUCTION......................................................................................................................... 7
2.1 Equipment.................................................................................................................... 7
2.2 Purpose and function of EFU ..................................................................................... 7
2.3 Terminology used in this manual............................................................................... 7
3 TECHNICAL DATA ..................................................................................................................... 8
3.1 EFU 30 .......................................................................................................................... 8
3.2 EFU 30 IB ..................................................................................................................... 9
4 INSTALLATION........................................................................................................................... 10
4.1 Location........................................................................................................................ 10
4.2 Lifting instructions ...................................................................................................... 10
4.3 Adjusting the wheel stands ........................................................................................ 10
4.4 Adjusting the included angle ..................................................................................... 12
4.5 Installation procedure ................................................................................................. 12
5 OPERATION ............................................................................................................................... 13
5.1 EFU unit details ........................................................................................................... 13
5.2 Control panel ............................................................................................................... 13
5.3 Wireless remote - control pendant ............................................................................ 14
5.4 Switch the mains power on ........................................................................................ 15
5.5 Operating the fit up unit.............................................................................................. 15
5.6 Operation safety .......................................................................................................... 16
5.7 Welding......................................................................................................................... 17
5.8 Stopping the EFU ........................................................................................................ 18
6 MAINTENANCE.......................................................................................................................... 18
6.1 General ......................................................................................................................... 18
6.2 Storage ......................................................................................................................... 18
6.3 Repair and maintenance............................................................................................. 18
6.4 Cleaning ....................................................................................................................... 19
6.5 Breakdowns ................................................................................................................. 19
6.6 Electromechanical cylinder........................................................................................ 19
6.6.1 Lubrication trapezoid spindle/tube MCT 75(standard) / MCT 75 WE................. 20
6.6.2 Lubricant............................................................................................................. 20
6.6.3 Bearings ............................................................................................................. 21
6.6.4 PU Wheels ......................................................................................................... 21
7 TROUBLESHOOTING ................................................................................................................ 21
7.1 Mechanical malfunctions............................................................................................ 22
7.2 Electrical malfunctions ............................................................................................... 22
8 ORDERING SPARE PARTS ....................................................................................................... 23
ORDERING NUMBERS......................................................................................................................... 24
WIRING DIAGRAM................................................................................................................................ 25
ACCESSORIES ..................................................................................................................................... 31

1  SAFETY
0463 760 101 -4- © ESAB AB 2023
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!
This handling equipment is not suitable for the following:
• Any vessel which is heavier than the maximum weight limit of the handling
equipment
• Any vessel that is larger/smaller than the maximum/minimum diameter
supported
• If the handling equipment have polyurethane or rubber tires, do not use them
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 760 101 -5- © ESAB AB 2023
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
• 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 760 101 -6- © ESAB AB 2023
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 the roller beds.
• Stop the handling equipment 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.

2  INTRODUCTION
0463 760 101 -7- © ESAB AB 2023
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
This Instruction manual describes the use and maintenance of the fit-up unit EFU30 and EFU30IB,
referred to as EFU in this document. Actions that must be carried out by the manufacturer are not
included in this manual.
This manual is part of the EFU. Keep a copy of the manual with the EFU and the original in a safe
place. If the EFU is sold, supply the manual with it.
The illustrations 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 EFU is supplied with:
• Lifting units
• Mounted control cabinet
• Wireless remote - control pendant
• Base frame
• Instruction manual
2.2 Purpose and function of EFU
The EFU is designed to aid the joining and welding of cylindrical vessels.
By placing and adjusting the independent lifting units on the EFU, vessels with varying diameters can
be placed on the EFU in combination with a suitable roller bed (ECD or ESD). The wheels can be
adjusted on the base frame to accommodate different vessel diameters.
2.3 Terminology used in this manual
Base frame The frame where wheel stands are mounted on. These are pre-drilled so
that the wheel stands can be positioned for different vessel diameters.
Wheel stand The stand which houses the EFU wheels. This is bolted down to the base
frame. It also houses a powered electrical cylinder that lift or lower the
wheel.
Control panel Electrical control box mounted on the base frame end.

3  TECHNICAL DATA
0463 760 101 -8- © ESAB AB 2023
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 roller bed set.
3 TECHNICAL DATA
3.1 EFU 30
EFU 30
Max loading capacity 15000kg (33069 lb)
Vertical workpiece adjustment ±40mm (±1.57in.)
Workpiece diameter Ø, conventional
Roller Bed
480mm (18.90in.) up to 5700mm (224.41in.)
Workpiece diameter Ø, self-aligning
Roller Bed
1420mm (55.91in.) up to 5000mm (196.85in.)
Mains supply 380–440V, 3 phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90°C / 92°A Shore)
Roller width / diameter Ø 2×90mm (2×3.54in.) / 400mm (15.74in.)
Dimensions (L×W×H),max 4619×700×1249mm (181.85× 27.56× 49.17in.)
Weight 1285kg (2834lb)
Wireless remote - control pendant Wireless
Control voltage 24V
Operation temperature 0 to +40°C (+32 to +104 °F)

4  INSTALLATION
0463 760 101 -9- © ESAB AB 2023
3.2 EFU 30 IB
EFU 30 IB
Max loading capacity 15000kg (33069 lb)
Turning capacity 45000 kg (99208 lb)
Turning drive motor 2×0.37 kW
Turning speed 200–2000 mm/min (5.51-78.74 in./min)
Vertical workpiece adjustment ±40mm (±1.57in.)
Workpiece diameter Ø, conventional
Roller Bed
480mm (18.90in.) up to 5700mm (224.41in.)
Workpiece diameter Ø, self-aligning
Roller Bed
1420mm (55.91in.) up to 5000mm (196.85in.)
Mains supply 380–440V, 3 phase, 50Hz
Mains fuse 16A
Roller type Polyurethane (90°C / 92°A Shore)
Roller width / diameter Ø 2×90mm (2×3.54in.) / 400mm (15.74in.)
Travelling capacity 30 000 kg (66 138 lb
Traveling drive motor 2×0.12 kW
Travelling Speed Low / High 200/2000 mm/min (5.51/78.74 in./min)
Assembled for track width1) 1730 mm (68.11 in.) or 2500 mm (98.43 in.)
Dimensions (L×W×H),max 4619×700×1249mm (181.85× 27.56× 49.17in.)
Weight 1285kg (2834lb)
Wireless remote - control pendant Wireless
Control voltage 24V
Operation temperature 0 to +40°C (+32 to +104 °F)
1) EFU 30 IB is available in two different track widths variants.

4  INSTALLATION
0463 760 101 - 10 - © ESAB AB 2023
4 INSTALLATION
4.1 Location
WARNING!
Always ensure that there is sufficient space around the EFU.
Ensure to have suitable access and enough space around the EFU, including the vessel when loaded.
Position it to allow unhindered loading and unloading of vessels onto the EFU by overhead crane or
other lifting devices.
4.2 Lifting instructions
WARNING!
When a direction button (upward or downward) is pressed, the EFU begin to lift or lower the
vessel.
NOTE!
Use correctly rated overhead cranes or forklift trucks to move the EFU.
Lifting by crane
Lift the EFU by using the lifting points on the EFU wheel stands. Use one lifting point on each side of
the wheel stand, four lifting points in total. The recommended angle between the chain and the lifting
points on the roller beds is 60°.
Place the EFU on a smooth, level, hard floor capable of taking the weight of the EFU and vessel over
the contact area of the EFU with the floor.
The distances between the base frames should match the vessel dimensions. If the vessel is perfectly
symmetrical and one drive with one idler is used, place the drive unit and the idler unit on one-third of
the way along the vessel's length to ensure that each section carries an equal load.
If one end of the vessel is heavier, move the drive or idler section closer to this end to balance the
loading on each section.
4.3 Adjusting the wheel stands
NOTE!
Adjust the wheel stands so that the axis of rotation of the vessel is on the centre line of the
EFU frame.
The positions of the two wheel stands on the base frame must be adjusted to load vessels of different
diameters.