Welding & Cutting · PDF fileUSED IN WELDING EQUIPMENTS?ELECTRODE SELECTION ... Customized...

W e l d i n g & C u t t i n g E q u i p m e n tEngineered to Perfection

WELDERS TO THE NATION SINCE 1951

(Formerly Known as Advani-Oerlikon Ltd.)www.adorwelding.com

W e l d i n g & C u t t i n g E q u i p m e n tEngineered to Perfection

Regd. & Corp. OTel: +91 22 6623 9300 / 2284 2525. Fax: +91 22 2287 3083 / 2596 6562 / 2596 6062. Email: [email protected]

ffice (Corp. Identity Number : L70100MH1951PLC008647): Ador House, 6, K. Dubash Marg, Fort, Mumbai 400 001. INDIA.

www.adorwelding.com


(Formerly Known as Advani-Oerlikon Ltd.)

Corporate Marketing Office: P.B. No 2, Akurdi, Chinchwad, Pune - 411 019, Maharashtra Tel. No.: (020) 4070 6000. Fax No. : (020) 4070 6001. Email: [email protected]

Sharjah Airport International Free Zone ( SAIF Zone) Q3 – 216, P.O.Box No. : 120025 Sharjah - U.A.E.Tel. : 00971 6 5578601. Fax : 00971 6 5578602. E-mail : [email protected]

CONTENTS

A SOME BASICS TO KNOW

B SMAW EQUIPMENT

C GMAW WELDING EQUIPMENT

?MOST COMMON TYPES OF INSULATION CLASSES USED IN WELDING EQUIPMENTS

?MOST COMMON TYPES OF ENCLOSURE PROTECTIONS USED IN WELDING EQUIPMENTS

?MOST COMMON TYPES OF DUTY CYCLES USED IN WELDING EQUIPMENTS

?ELECTRODE SELECTION TABLE

?HELP ME CHOOSE

? AC ARC WELDING TRANSFORMERS

?RED 403 / RED 503

?TPA 303 / TPA 403

?DOUBLE MUSTANG / DOUBLE RACER / DOUBLE HORSE / DOUBLE STALLION

?E-WELMAC 150 / E-WELMAC 190

? DC ARC WELDING RECTIFIERS / WELDERS

?GL SERIES RECTIFIERS

?THYROLUXE SERIES RECTIFIERS

THYROLUXE 401 / THYROLUXE 600 / THYROLUXE 1000 / THYROLUXE 1200

? CHAMP SERIES RECTIFIERS

?CHAMP 160 / CHAMP 200

?CHAMP T400

?CHAMP 250 / CHAMP 400 / CHAMP 500 / CHAMP 600

? MOTOR GENERATOR WELDING SETS

?SUPERGEN 320

? ENGINE DRIVEN WELDING SETS

?SILENT CHALLENGER SERIES

SC 301 / SC 401 / SC 501 / SC MULTI 2x301

?SILENT CHALLENGER 400 K3

? MAXIMIG SERIES OUTFITS

?MAXIMIG 251

?MAXIMIG 400

? RANGER SERIES OUTFITS

?RANGER 600

?RANGER 403

?RANGER MULTI 600

? CHAMP MIG SERIES OUTFITS

?CHAMP MIG 250 / CHAMP MIG 400 / CHAMP MIG 600

?CHAMP MIG 400 (R) / CHAMPMIG 600 (R)

? CHAMP MULTI SERIES OUTFITS

CHAMP MULTI 400 / CHAMP MULTI 400 SSPW

? MULTI OPERTAOR WELDING PAYLOADS FOR GMAW / FCAW PROCESSES

AUTOMATED MIG TROLLEY

? HF CONTROL TIG UNITS

?

? CHAMP TIG SERIES TIG OUTFITS

?CHAMP TIG 300 AD?CHAMP TIG 300 P ?CHAMP TIG 400 P

? MAESTRO SERIES

?MAESTRO 800 (F) / MAESTRO 1000 (F) / MAESTRO 1200 (F)

?MAESTRO 800 T(F) / MAESTRO 1000 T(F) / MAESTRO 1200 T(F)

?MAESTRO 1000 (I)

?PLASMA CUT 25?CHAMPCUT 25

?ELECTRODE DRYING OVEN?MIG / MAG TORCHES

MTG SERIES TORCHES, ADOR TW SERIES?TIG TORCHES, HIPROTIG SERIES TORCHES?GOUGING TORCHES

? MIG-WIRE FEEDERS FEEDLITE SERIES INCLUDING HEAVY DUTYRETROFIT WIREFEEDERS - UNIFEED / WF SERIES

?RETROFIT OF SAW WEDLING HEAD WH 15 (F)?MECHANISED ATTACHMENT - MIG / SAW

WELDING?ADOR ARC-ON?ENERGY SAVING DEVICE (WELDING RECTIFIER)

?COLUMNS & BOOMS

?POSITIONERS

?ROTATORS

?HYBRID PLASMA MIG WELDING

?SPECIAL PURPOSE WELDING SYSTEMS

?ROBOTIC WELDING SOLUTIONS

?ROBOTICS WELDING SOLUTIONS

?

HF 2000 / HF 2000 AD / HF 3000 / HF 3000 AD

D GTAW WELDING EQUIPMENT

E SAW WELDING EQUIPMENT

F AIR PLASMA CUTTING EQUIPMENT

G WELDING ACCESSORIES

I WELDING AUTOMATION PRODUCTS & SYSTEMS (WAPS)

WELDING & CUTTING EQUIPMENT AND SYSTEMS

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WELDERS TO

THE NATION SINCE 1951

WELDING CONSUMABLES

l Electrodes

l Wires & Fluxes

l Customized Consumables

WELDING & CUTTING EQUIPMENT

l

l

l Gas Cutting Products & Accessories

Welding & Cutting Accessories

Welding & Cutting Spares

WELDING AUTOMATION

l

l Welding Positioners

l Welding Rotators

Columns & Booms

PROJECT ENGINEERING

l

l Incinerators (for Industrial Applications)

l Pressure Vessels

Flares and Flare Tips/Burners

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ADOR WELDING ACADEMY PVT. LTD.

Corporate Marketing Office:

Tel. No.: (020) 4070 6000. Fax No. : (020) 4070 6001. Email: [email protected] Marketing Office: P.B. No 2, Akurdi, Chinchwad, Pune - 411 019, Maharashtra

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WELDING & CUTTING

EQUIPMENT AND SYSTEMS



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SOME BASICS TO KNOW

SOME BASICS TO KNOW

SOME BASICS TO KNOW



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SOME BASICS TO KNOW

SOME BASICS TO KNOW



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WeldingCurrent

orLoad

1 Load Cycle

ONTime

OFFTime

4 min6 min

FINDING CURRENT FOR THE REQUIRED DUTY CYCLE WHEN CURRENT IS SPECIFIED AT DIFFERENT DUTY CYCLE

Present specs. are 310 A @ 100 % duty cycle• Follow following steps to find the

welding current at 60% duty cycle• Losses @ d1 = Losses @ d2

2 2• (I1) x r x t1 = (I2) x r x t22• (310x310) x 10 = (I2) x 6

2• (I2) = (10/6) x 310 x 310• I2 = sq. root of (10/6) x 310• I2 = sq. root of 1. 66 x 310• I2 = 1.29 x 310• I2 = 400.2• I2 = 400

Present specs. are 400 A @ 60 % duty cycle• Follow following steps to find the

welding current at 100% duty cycle• Losses @ d1 = Losses @ d2

2 2• (I1) x r x t1 = (I2) x r x t22• (400x400) x 6 = (I2) x 10

2• (I2) = (6/10)x400x400• I2 = sq. root of (6/10) x 400• I2 = sq. root of 0.6 x 400• I2 = 0.7746 X 400• I2 = 309.8• I2 = 310

MOST COMMON TYPES OF DUTY CYCLES USED IN WELDING EQUIPMENTS

DUTY CYCLES OF WELDING EQUIPMENTS

Welding equipments are never used continuously for manual or semiautomaticwelding processes. The common duty cycles observed for majority of welding applications are 25%, 35%, 40%, 60%. However all welding equipments are also supposed to be specified for 100% duty cycles. The duty cycle of the machine or application indicates how severely machines will be used to complete the jobs to be welded. A typical duty cycle is explained on next page, which indicate the WELD time and OFF time observed during the welding of job. The total CYCLE TIME consists of one WELD time and one OFF time associated with the respective WELD time. The CYCLE TIMES are 5 minute and 10 minute as per Indian and International standards respectively.

1

The most common types of Insulation Classes, for which welding equipments are designed, are basically B, F and H. However electrical machines have following range of Insulation classes as per National and International standards. The maximum allowable temperatures are given below for these Insulation classes

MOST COMMON TYPES OF INSULATION CLASSES USED IN WELDING EQUIPMENTS

DEGREE OF INGRESS PROTECTION CLASS FOR ENCLOSURES OF WELDING EQUIPMENTS

FIRST DIGIT Indicates protection against the ingress of foreign body or the particle

SECOND DIGIT Indicates protection against the ingress of dripping or vertically falling water

USED

The most common Ingress Protection classes (IP class) used for the enclosure of the welding equipments are IP 21, IP 23 and IP44. These protections classes of enclosures provide different degree of protection against Ingress of foreign body or particle and vertically falling water to the machines

• IP 21 • IP 23 • IP 44

–

• 2 = Protection against ingress of foreign body / particle > 12 mm dia • 4 = Protection against ingress of foreign body / particle > 1 mm dia

–

• 1 = Protection against ingress of water i.e.dripping or vertically falling water• 3 = Protection against ingress of spraying or splashing water up to 60 degrees• 4 = Protection against the ingress of the splashing water from any direction i.e. all round the machine

• • F = Class of Insulation –155 Deg. Centigrade

• E = Class of Insulation –120 Deg. Centigrade • H = Class of Insulation –180 Deg. Centigrade

• B = Class of Insulation –130 Deg. Centigrade • C = Class of Insulation --220 Deg. Centigrade

A = Class of Insulation --105 Deg. Centigrade

MOST COMMON TYPES OF ENCLOSURE PROTECTIONS USED IN WELDING EQUIPMENTS

2

DUTY CYCLE

• For detailed technical specifications please refer respective leaflet

• Due to continuos development AWL reserves the right to modify / change the design and /or the specifications without notice


• Due to continuos development AWL reserves the right to modify / change the design and /or the

specifications without notice

t

(ON Time) X 100(ON Time + Off Time)6 x 100 = 60%(6 + 4)

% Duty cycle =

=

ELECTRODE SELECTION TABLE

SOME BASICS TO KNOW

HELP ME CHOOSE

SOME BASICS TO KNOW

ELECTRODE TYPES / SIZES VS. RECOMMENDED WELDING CURRENTS

GUIDING NOTES :

1. Recommended Polarities

2. Recommended Welding Positions

3. Current Selection Generally Adapted

a) Superbond, Superbond-S, Superbond-SS = AC, DC (-)b) Supabase, Supabase-X-Plus = AC (70 OCV), DC (+)c) Celwel 60, Celwel 70G = DC(+) (for all passes), DC(-) (for root pass only)

a) Superbond, Superbond-S, Superbond-SS, Celwel 60, Celwel 70G = All including vertical down (Vertical - Top to Bottom)b) Supabase, Supabase-X-Plus = All except vertical down (Vertical - Top to Bottom)

A) For Downhand flat, horizontal and overhead positions = Current at middle of the range is used.b) For Vertical up (Bottom to Top) = Current at maximum of the range is used.c) For vertical down (Top to Bottom) = Current at maximum of the range or slightly more than maximum is used.d) For the same diameter, as the thickness of parent material increases, employed current is increased.

SELECTION GUIDESN.

1.

2.

3.

4.

5.

6.

7.

ELECTRODE TYPE

Superbond

Superbond-S

Superbond-SS

Supabase

Supabase-X-Plus

Celwel 70G

Celwel 60

AWS TYPE

E6013

E6013

E6013

E7018

E7018

E7010-G

E6010

WELDING CURRENTS (AMPS)FOR ELECTRODE SIZE (DIA)

1.6MM 2.0MM 2.5MM 3.2MM 4.0MM 5.0MM 6.3MM

30-50

30-50

30-50

40-60

40-60

-

-

5540-60

5540-60

40-60

50-70

50-70

-

-

8060-90

8060-90

9060-90

8060-90

8060-90

5550-70

5550-70

125100-130

125100-140

135100-140

125100-140

12590-140

10080-120

10080-120

170140-180

170140-180

180140-190

170150-200

170150-190

130110-160

130110-160

220180-240

220180-250

240190-250

200200-240

225200-250

180140-210

-

275

250-330

300250-330

275270-360

300270-320

-

-

WELDING & CUTTING EQUIPMENT&

PROCESSES

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HELP ME CHOOSE

SOME BASICS TO KNOW

HELP ME CHOOSE

SOME BASICS TO KNOW

• Stable / Unstable / Very Low / Very High voltage condition• Chemical (Acidic) Contamination. Conducting Dust Contamination.

• Economy

1. POWER SUPPLY CONDITIONS*2. ENVIRONMENTAL CONDITIONS*3. BUDGET

STEP 3 ADDITIONAL CHECK LIST

STEP 4 SELECTION OF WORK LOAD AND DUTY CYCLE

Thus after selecting the process, duty cycle, and going through the additonal checklist, please verify once again the steps completed so far as per following FLOW CHART as a QUICK RE-CHECK and select the model for your welding/cutting need from the model selection table

STEP 5 MODEL SELECTION TABLE

* Consult factory / Technical Marketing Team for extreme supply and environmental conditions

THE BEST WELDING EQUIPMENT FOR DESIRED APPLICATION

Also check for following along with above mentioned process advantages

THE BEST WELDING EQUIPMENT FOR DESIRED APPLICATION

Select a process for a given metal you want to join or cut from the table given below

STEEL

STAINLESS STEEL

ALUMINIUM

CAST IRON

COPPER, BRASS

TITANIUM

MAGNESIUM ALLOYS

SKILL LEVEL MODERATE MODERATE MODERATE MODERATE LOW LOW HIGH HIGH

MIGMETAL TYPE STICK FCAW SAW AC-TIG DC-TIG CAC-A-AC CAC-A-DC

WELDING PROCESS CUTTING PROCESS

HIGH

PLASMA

It is possible that more than one welding process can be used for a given requirement. Hence to facilitate selection, study and understand the advantages of each process as given below.

STEP 2 WELDING PROCESS SELECTION

STEP 1 METAL JOINING AND CUTTING PROCESS SELECTION

B GMAW/MIG/MAG/SEMIAUTOMATIC/CONTINUOUS WELDING

Suitable for high welding productivityMost suitable for relatively thinner sheetsVery neat and clean welding without slag removableEasy to learn for welders

D SUBMERGED ARC WELDING (SAW)

Most suitable where excellent mechanical properties are requiredIdeally suitable for heavy duty longitudinal structures like girdersHigh deposition rates gives higher welding productivityGives excellent weld bead shape

C FLUX CORED (FCAW) MIG/MAG

Suitable for deep penetration for welding thick sections with less nos. of runsProvides higher welding deposition ratesGives excellent weld bead shape

E TIG WELDING (GTAW)

Used where highest quality welding requiredGives precise welding with very good welding finishMost suitable for thinnest sheets where better heat input controls are required and very minimaldistortions allowed

Most suitable for outside/opendoor useOne of jobs or less volume jobs.Better accessibility for intricate jointsIdeal for dirty/rusty surfaces

SMAW / MMAW / STICK WELDINGA

Used with almost all electrical conducting metals.Distortion free, dross free, burr free, narrow kert with clean cuts, compared to carbon ARC cutting.

F AIR PLASMA ARC CUTTING

Workload/usage/duty Likely Duty Cycle Welding Current Range Recommended

Light Duty - Single Shift 20 % to 35 % Upto 225 Amps

Heavy Duty - Two or Three Shift >60% to 100 % More than 300 Amps

Medium Duty - Single or Two Shift >35 % to 60 % 225 Amps to 300 Amps

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EQUIPMENT SELECTION GUIDELINES-QUICK RE-CHECK

1 CHECK AND VERIFY THE WELDING/CUTTING PROCESS FOR THE METALS TO BE JOINED OR CUT FROM THE TABLE GIVEN

2SELECT WELDING / CUTTING PROCESS DEPENDING ON WELDING (OR CUTTING) PROCESS DESIGN (WELD PARAMETERS / ELECTRODE/WIRE DIA etc) AND PRODUCTION VOLUME REQUIREMENT, TARGET etc, AFTER CONSIDERING THE MERITS OF EACH PROCESS

3CARRY OUT ADDITIONAL CHECKS FOR POWER SUPPLY AND EVIRONMENT CONDITIONS, CONSULT FACTORY / TECHNICAL MARKETING FOR ANY SPECIAL / CUSTOMISED REQUIREMENT OF APPLICATION IF ANY.

4CHECK AND DECIDE WORK LOAD, DUTY CYCLE AND SEVERITY OF USAGE AS PER GUIDELINES GIVEN IN THE TABLE

ONCE ABOVE STEPS ARE COMPLETED, CHECK AC OR DC TYPE OF POWER SOURCE FOR SMAW/TIG PROCESSES AND THEN SELECT THE MODEL FROM THE TABLE GIVEN BELOW

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SMAW EQUIPMENT

SALIENT FEATURES

• Forced Air cooled transformers with better cooling of transformer coils resulting lower internal temperature

• Welding current adjustment/regulation through horizontal, modern moving core design

• Stepless, smooth and infinitely variable current adjustment possible even while welding is in progress

• Higher Open Circuit Voltage (80 V) enables welding with all types of special electrodes including low hydrogen types for AC welding applications and also enables the use of longer welding cable lengths

• Optimised design - Excellent dynamic characteristics ensure smooth and optimum metal transfer

• Robust design to withstand rough handling at site as well as easily maneuverable from job to job at project sites

• Welder friendly usage - easy to operate since all controls like ON-OFF switch, welding current controlling handle, current scale on the same side i.e. front side

RED 403 / RED 503

APPLICATIONS

• AC Arc welding Transformers for light, Medium, and Heavy structural welding, machine building and fabrication work

• Ideal for both Shop and site fabrication welding

• RED series transformers are single phase machines, which can be connected on 2 lines of 3 phase, 415V input supply

• Also recommended as power sources for Gas Tungsten Arc Welding (GTAW-AC) applications of Aluminium, Magnesium and their alloys

BRIEF SPECIFICATIONS:

AC ARC WELDING TRANSFORMERS

SMAW EQUIPMENTS



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Supply voltage Volt 415 415

Input KVA @ 100% Duty cycle KVA 19 25

Open circuit voltage Volt 80 80

Welding current range Amp 60-400 80-500

Welding current @ 60% Duty cycle Amp 300 400

Welding current @ 100% Duty cycle Amp 230 300

Class of insulation Class F F

Type of cooling Type Forced Air Forced Air

Dimensions (LxWxH) mm 720x460x750 745x500x780

Weight (approx.) Kg 110 132

MODELS UNIT RED 403 RED 503

Phase No 2 LINES OF 3 PHASE

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SALIENT FEATURES

• Forced Air cooled transformers with better cooling of transformer coils resulting lower internal temperature

• Welding current adjustment through horizontal, modern moving core design. Stepless, smooth and infinitely variable current adjustment possible even while welding is in progress

• "Open delta" design enables conversion of 3phase input in to single phase output

• Optimised Open Circuit Voltage (66V), enables welding with most commonly used general purpose AC and AC/DC electrodes for structural welding applications, both within the shopfloor as welll as project sites

• Special design - Excellent dynamic characteristics ensure smooth and optimum metal transfer

• Robust design to withstand rough handling at site as well as easily maneuverable from job to job at project sites

• Compact and light weight transformers


APPLICATIONS

• AC Arc welding Transformers for light, Medium, and Heavy structural welding, machine building and fabrication work

• Ideal for both Shop and site fabrication welding

• TPA series transformers are 3 phase machines and recommended for applications where, as far as possible, balanced 3 phase load is desired on input supply lines



SMAW EQUIPMENTS

TPA 303 / TPA 403

TPA 303 TPA 403UNITMODELS

380/415 380/415VoltSupply voltage

3 3NoPhase

16.5 21.0KVAInput KVA @ 100% Duty cycle

66 66VoltOpen circuit voltage

40-300 60-400AmpWelding current range

225 300AmpWelding current @ 60% Duty cycle

175 230AmpWelding current @ 100% Duty cycle

A AClassClass of insulation

Forced Air Forced Air TypeType of cooling

720x500x800 720x500x800mmDimensions (LxWxH)

125 163KgWeight (approx.)


SMAW EQUIPMENTS

DOUBLE MUSTANG / DOUBLE RACERDOUBLE HORSE / DOUBLE STALLIONTHOROUGHBRED SERIES TRANSFORMERS

SALIENT FEATURES

• Light weight and compact transformers with robust construction - Ideal choice for site usage

• Natural air cooled transformers - coils designed for natural air cooling which eliminates the use of fan and thus risk of coil burning whenever fan fails

• Specially designed transformer coils with minimum joints and better interlayer insulation -eliminates the coil failure and enhances service life of transformer

• Stepless, infinitely variable current adjustment through sturdy and smooth moving core mechanism

• Stepless, smooth and infinitely variable current adjustment possible even while welding is in progress

• Ensures the fine control of welding current to minimise the heat input to the job which reduces the HAZ

• Dynamic output characteristics ensures smooth and uninterrupted arc resulting excellent welding performance througout the entire welding range

• Provided with input power ON-OFF switch


APPLICATIONS

• AC arc welding transformers for every applications from medium to heavy duty welding both within shopfloor as well as project sites

• Most recommended for site maintenace welding and medium/heavy structural welding like tankages, AC arc welding with special material like 9% nickel alloy etc

• Most reliable and dependable, natural air cooled transformes - ideal choice for most project sites


MODELS UNITDOUBLE

MUSTANGDOUBLE HORSE

DOUBLE STALLON

DOUBLE RACER

Phase No

Supply voltage Volt 230/400 415 415415

Input KVA @ 100% Duty cycle KVA 10.8 21.0 25.516.0

Open circuit voltage Volt 66 80 8080

Welding current range Amp 35-250 60-400 80-50050-300

Welding current @ 60% Duty cycle Amp 190 300 375225

Welding current @ 100% Duty cycle Amp 150 230 300175

Class of insulation Class H H HH

Weight (approx.) Kg 92 140 170120

650x500x725Dimensions (LxWxH) mm 590x425x660 650x550x755650x475x700

Type of cooling Type Natural Air Natural Air Natural Air Natural Air

2 LINES OF 3 PHASE

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SMAW EQUIPMENTS

SALIENT FEATURES

• Welding rectifiers based on most simple, reliable and maintenance free diode based technology

• These welding rectifiers are built with most robust and rugged mechanical construction which withstand rough handling at construction and project sites

• Welding current adjustment and regulation through electromagnetic transductor resulting stepless and smooth current control

• These welding rectifiers are welder friendly - Very easy to use and operate, maintain and service by ordinary electricians

• Single knob current control from the front panel or remote control unit (provided optionally)

• Easy parallel connection of these welding rectifiers possible for high current gouging applications

• These welding rectifiers can be also used for DC TIG welding applications by connecting suitable TIG control units

APPLICATIONS

• Most simple, robust and reliable welding rectifiers ideally recommended for heavy duty structural welding of construction equipments like crane, steel foundries, steel and fertiliser plants, shipyards etc

• These welding rectifiers are ideally suitable for heavy fabrication shops, project sites with harsh environment, where maintenance staff is not well equipped and qualified

• GL 601 is most recommended for heavy duty welding and gouging applications in foundries, steel plants, heavy engineering workshops etc

DC ARC WELDING RECTIFIERS / WELDERS

SMAW EQUIPMENTS


MODELS UNIT GL 601GL 401

Supply voltage Volt 400 / 440400 / 440

Phase NO. 33

Input KVA @ 60% Duty cycle KVA 38.526

Open circuit voltage Volt 8080

Welding current range Amp 80-60050-400

Welding current @ 60% Duty cycle Amp 600400


Class of insulation Class BB

Dimensions (LxWxH) mm 960x750x1005840x705x905

Weight Kg 430275

APPLICATIONS

• All light and medium duty structural welding applications both within shopfloor and project sites

• Most recommended for site maintenace welding and light structural welding like window grill or similar jobs at construction sites

• Welding applications where only single phase supply is available

E-WELMAC 150 / E-WELMAC 190

SALIENT FEATURES

• Light weight, compact AC arc welding transformers - easy to mobilise at sites

• Single phase, natural air cooled transformers with robust construction

• Most reliable and simple transformers - very convenient and welder friendly to use at sites

• Infinitely variable current adjustment through sturdy and smooth moving core mechanism

• Welding current adjustment possible even while welding is in progress

• Provided with input power ON-OFF switch

• Dynamic output characteristics ensures smooth and uninterrupted arc resulting excellent welding performance througout the entire welding range


UNIT E-WELMAC 190MODELS E-WELMAC 150

Kg 39Weight (approx.)

Volt 230Supply voltage 230

No 1Phase 1

KVA 5.5Input KVA @ 100% Duty cycle 4.3

Volt 50Open circuit voltage 50

Amp 30-200Welding current range 30-150

Amp 200Welding current @ 20% Duty cycle 150



Class HClass of insulation H

Type Natural Air Type of cooling Natural Air

mm 340x315x500Dimensions (LxWxH) 340x315x500

33

GL SERIES RECTIFIERS

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THYROLUXE SERIES RECTIFIERS THYROLUXE 401 / THYROLUXE 600THYROLUXE 1000 / THYROLUXE 1200

SALIENT FEATURES

• Reliable and superior performance thyristorised welding Rectifier for projects, engineering fabrication, construction work and pipe welding

• Robust mechanical construction and good ventilated power components like transformer, IPT, choke etc with sufficient fan size - Ideal for site use

• Full wave full control thyristor bridge construction, Constant Current (CC) characteristics with stepless current control within +/-1% and immune to +10% & -15% voltage fluctuation

• High OCV for easy arc start/restart. Bult-in booster circuit saves power consumption

• Excellent dynamic characteristic helps to deliver stable arc, good welding performance over the entire current range

• Welding rectifier protected against abnormal supply/service conditions like Single phase, Short circuit, Thermal overload, Under voltage and Over voltage conditions etc

• Built-in HOT start / Antistick and Self controlled arc force dynamics provided as standard feature

• Suitable for TIG welding by connecting external HF unit (available as optional supply with main rectifier unit)

• Provided with Remote control unit for easy adjustment/stepless current control of welding current

APPLICATIONS

• These fully thyristor controlled, electronically regulated, transformer rectifier units are suitable for Manual Metal Arc welding (SAMW) process

• Ideally suitable for light, Medium and Heavy duty, all purpose industrial, structural welding applications both within shopfloor and at project sites

• These welding rectifiers can be also used for DC TIG welding applications by connecting suitable TIG control units (HF 2000 / 2000 AD / 3000 / 3000 AD)

• Higher current rating welding rectifiers like 600A/1000A/1200A can also be used for GOUGING applications by using suitable gouging torch


UNIT THYROLUXE 401

MODELS

mm 835x495x820Dimensions (LxWxH)

Volt 415Supply voltage

NO. 3Phase

KVA 19.5Input KVA @ 100% Duty cycle

Volt 100Open circuit voltage

Amp 10-400Welding current range

Amp 400Welding current @ 60% Duty cycle

Amp 310Welding current @ 100% Duty cycle

Class HClass of insulation

Kg 147Weight (approx.)

THYROLUXE 1200

1200x770x1175

415

3

31.5

100

20-600

600

465

H

THYROLUXE 600

980x550x960

415

3

54

100

100-1000

850

650

H

THYROLUXE 1000

1230x770x1080

H

415

3

72

100

100-1200

1200

930

450216 403

DC ARC WELDING RECTIFIERS / WELDERS

SMAW EQUIPMENTS

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CHAMP SERIES RECTIFIERS

SMAW EQUIPMENTS



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CHAMP 160 / CHAMP 200

DC TIGAPPLICATIONS

• Single phase inverter based, High efficiency DC Welders

• High frequency IGBT based PWM Inverter

• TIG Welding possible with Lift Arc technique

• Light weight, compact and portable for easy handling

• Compatible to power generator supply

• n the condition of rated duty cycle being exceeded by user and thermal indication ON, the machine still continues to run at 100% duty cycle rating without shutting downI

SALIENT FEATURES

• Latest PWM inverter technology

• IGBT based

• Smooth and stable arc with minimum spatter

• Hot start feature available as a standard

• TIG welding with scratch / Lift arc start


TECHNICAL SPECIFICATIONS UNIT

Supply voltage Volt

Phase No

Input KVA @100% Duty cycle KVA

Open circuit voltage @ 240 Vac Volt

Welding current range Amp

Welding current @ 60% Duty cycle Amp


Type of cooling Type

Class of insulation Class

Dimensions (LxWxH) mm

Weight (approx.) Kg

CHAMP 160

240, +10%, -15%

1

4

68 +/-3

10-160

130

90

Forced Air

F

375x145x290

6

CHAMP 200

240, +10%, -15%

1

5

68 +/-3

10-200

150

120

Forced Air

F

415x155x300

7

14


SMAW EQUIPMENTS



www.adorwelding.com




CHAMP T400

DC TIGAPPLICATIONS

• These Energy Efficient, latest Inverter based rectifier units are suitable for Manual Metal Arc welding (SMAW) process with all general purpose and special electrodes like 7018 type etc

• Ideally suitable for light, Medium and Heavy duty, all purpose industrial, structural welding applications both within shopfloor and at project sites including construction of power plants, Refineries and cement plants etc


• Most recommended for project site applications, where easy portability/mobility, light weight compact machines are desired due to space constraints etc as well as when they are to be used at some heights above the ground level

SALIENT FEATURES

• Inverter (IGBT) based, energy efficient welding rectifiers for heavy duty structural welding applications

• High power factor, high efficiency resulting energy savings up to 35% over thyristorised rectifiers

• Provided with protections against Over voltage, Under Voltage, Overload and Single phasing

• Welder friendly operation-Arc force adjustments provided on the front panel

• Enhanced reliability due to SMD technoloy in PCB design and manufacturing

• Robust mechanical construction - recommended for hostile operating conditions and heavy duty usage at project sites

• Suitable for TIG welding at site by using external HF control unit like HF 2000 / HF 3000


MODELS UNIT CHAMP T400

Supply voltage Volt 415

Phase No 3

Input KVA @100% Duty cycle KVA 11


Welding current range Amp 10-400



Type of cooling Type Forced Air

Class of insulation Class H

Dimensions (LxWxH) mm 610x295x520

Weight (approx.) Kg 32

15


SMAW EQUIPMENTS



www.adorwelding.com

CHAMP 250 / CHAMP 500 / CHAMP 600

DC TIGAPPLICATIONS

• These Energy Efficient, latest Inverter based rectifier units are suitable for Manual Metal Arc welding (SMAW) process with all elelctrodes including specials like 6010, 7010G and 8010G electrodes

• Ideally suitable for light, Medium and Heavy duty, all purpose industrial, structural welding applications both within shop floor and at project sites


• Most recommended for project site applications where easy portability / mobility light weight compact machines are desired due to space constraints etc

SALIENT FEATURES

• Inverter (IGBT) based, energy efficient welding rectifiers for heavy duty structural welding applications

• High power factor, high efficiency resulting energy savings up to 35% over thyristorised rectifiers

• Provided with protections against Over voltage, Under Voltage, Overload and Single phasing

• Welder friendly operation-Arc force adjustments provided on the front panel

• Enhanced reliability due to SMD technoloy in PCB design and manufacturing

• Robust mechanical construction - recommended for hostile operating conditions and heavy duty usage at project sites

• Suitable for TIG welding at site by using external HF control unit like HF 2000 / HF 3000


MODELS UNIT CHAMP 500CHAMP 250 CHAMP 600

Supply voltage

Phase

Input KVA @ 100% Duty cycle

Open circuit voltage

Welding current range

Welding current @ 60% Duty cycle


Class of insulation

Actual Dimensions (LxWxH)

Volt

No

KVA

Volt

Amp

Amp

Amp

Class

mm

415

3

7.5

72

10-250

250

195

H

520x260x450 700x460x630

415

3

22.0

89

20-600

600

465

H

700x460x630

415

3

17.5

89

20-500

500

387

H

Weight (approx.) Kg 26 5858



Suitable for CELLULOSIC

Electrodes & Long Welding cables

16



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SALIENT FEATURES

• Brushless Technology with no windings, brushes, rotating diodes on the rotor assembly, makes it maintenance free generator and eliminates frequent maintenance and down time - Ideally suitable for all project site welding applications

• Totally enclosed generator body with IP44 construction prevents the entry of dust and dirt inside the windings - makes it the ideal choice for all site conditions

• Light weight, compact generator with easy mobility, compared with old generation DC generator set. Weight of 265 kgs as compared with 330 kgs of old generation, conventional DC generator sets

• Close loop feedback control to deliver constant welding current even with longer cable lengths (100mtr)

• 'H' Class insulation -provides longer service life

• Low power consumption -Energy Efficient motor generator set superior to old generation DC type generator set - reduces energy bills by 30%. Saves upto Rs 46000/- in a year, over energy bill of old generation DC generator sets.These sets have even better POWER FACTOR than conventional thyristorised welding rectifiers

• Higher Open Circuit Voltage (100) guarantees excellent welding performance even with longer cable lengths up to 100 mtrs

APPLICATIONS

• Suitable for welding with Cellulosic electrodes, particularly for cross country petroleum and gas pipelines as well as building Thermal and Nuclear power plants, heavy duty critical structural welding at prestigeous project sites

• Ideally suitable for project sites where welding with longer cable lengths is involved, like welding within the tunnel in mountain areas or laying underground water pipelines within the metro cities

• Most recommended for all project sites/open yards, where atmospere is very dusty, dirty and heavily contaminated with conducting particles

SUPERGEN 320

MOTOR GENERATOR WELDING SETS

SMAW EQUIPMENTS


UNIT SUPERGEN 320

Volt 415

No 3

Kw/HF 15.5/20.78

Volt 100

Amp 35-320

Amp 320

Amp 250

Type Forced Air

Class H

mm 1065x540x840

Kg 265

MODELS

Supply voltage

Phase

Power





Type of cooling

Class of insulation

Dimensions (LxWxH)

Weight (approx.)

DC TIG

17



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ENGINE DRIVEN WELDERS SETS

SMAW EQUIPMENTS

SILENT CHALLENGER SERIESSC 301 / SC 401 / SC 501 / SC MULTI 2x301

DC TIG

APPLICATIONS• Recommended for all versatile welding applications at project sites like, construction of refineries, power

plants, cement plants, constructions sites, Inplant pipeline welding, city gas pipeline, cross country pipeline welding, pipeline welding from jetty to storage tanks for oil, petroleum and gas etc

• ED sets SC 301 / SC 401 / SC 501 are specially recommended for Manual (SMAW) welding applications from medium to heavy duty site fabrication welding, maintenance welding with all types of electrodes and city gas pipeline and cross country pipeline welding with 6010, 7010G, 8010G electrodes

• Double Operator ED set, model SC Multi 2x301, specially recommended for Manual (SMAW) welding for heavy duty site fabrication with all types of electrodes and city gas pipeline, cross country pipeline welding with cellulosic 6010, 7010G, 8010G elelctrodes as well as Semiautomatic welding (FCAW) of cross country pipeline welding applications, and places where more numbers of ED sets can not be accommodated and more numbers of welders are required to be deployed with minimum numbers of ED sets

SALIENT FEATURES• New generation, High frequency Brushless welding generators -resulting Efficient and Excellent welding

performance at project sites• Totally maintenance free welding welding generators with windingless, commutatorless, slipringless, magnetless

ROTOR construction - Ideal for site duty and cross country pipeline welding applications• Direct monobloc closed coupled engine-generator sets with single bearing generator coupled to the engine by

noncorrossive metallic flexible coupling plates and the antivibration mounting with protective cups to protect them against dust and dirt - less maintenance headache

• Highly reliable even in hostile site conditions• Minimum numbers of spare parts required at project sites compared to the conventional ED sets• Most compact, CPCB complient ED set, with super silent acoustic canopy• Higher open circuit voltage for easy arc striking• Provided with suitable auxilliary power source unit to deliver adequate capacity of single phase and three

phase power for auxilliary uses like grinding, drilling, floodlighting etc• Provided with remote control unit to enable welder to adjust/set the welding parameters from the welding

point, while welding is in progress

MODELS

Nos of operators at a time

Characteristic

Open circuit voltage (Max / Min)




Class of insulation

Type of cooling

Engine Type

Rated Speed

Aux. power source

Dimensions (LxWxH) - Skid mounted

Dimensions (LxWxH) - 2 Wheel mounted


Weight (Skid mounted)

Weight (2 Wheel mounted)


Optional Wire feeder for FCAW welding

UNIT

Type

Volt

Amp

Amp

Amp

Class

Type

Type

rpm

mm

mm

mm

Kg

Kg

Kg

Model

No

SILENT CHALLENGER

301

CC

100/45

40-300

300

230

H

Forced Air

S217

1800

2000X820X1375

2910X1455X1908

2910X1555X1908

960

1100

1200

NA

1

SILENT CHALLENGER

401

CC

100/45

50-400

400

310

H

Forced Air

S433

1800

2500x820x1460

3410X1455X1990

3900x1455x1990

1130

1270

1370

NA

1

1285

1385

NA

3410X1455X1990

SILENT CHALLENGER

501

CC

100/45

50-500

500

400

H

Forced Air

S433

1800

2500x820x1460

3900x1455x1990

1145

1

SILENT CHALLENGER MULTI 2X301

1800

2 cc/cv 1

CC/CV CC

15-300 each operator 30-600

300 @40% 600 @40%

200 each operator 400

Forced Air Forced Air

92

H

S433

WF 40 Multi NA

Optional Torch for FCAW welding (3/4.5 mtrs.) Model NA NA NASuper SSPW

350NA

1160

2500x820x1460

1300

1400

3410X1455X1990

3900x1455x1990

18KVA, 3PH, 415V / 6KVA,1PH, 240V


10KVA, 3 PH, 415V / 3.5KVA, 1PH, 230V



18

ENGINE DRIVEN WELDERS SETS

SMAW EQUIPMENTS



www.adorwelding.com




SILENT CHALLENGER 400 K3


MODELS

Nos of operators at a time

CharacteristicOpen circuit voltage (Max / Min)




Class of insulation

Dimensions (LxWxH) -Skid mounted


Weight (Skid mountedl)




DC TIG

Engine type

Rated Speed

UNIT SILENT CHALLENGER 400 K3

No 1Type CC

Volts 100 / 40Amp 40-400Amp 400Amp 310

Class H

mm 2000x820x1150

mm 3400x1455x1700Kg 980Kg 1120Kg 1220

mm 2950x1455x1700

Type HA 394 (Air Cooled)rpm 1500

8KVA, 3 PH, 415V /

3.0KVA, 1PH, 240VAux. power source

UNIQUE DESIGN!!!

DESIGNED AND BUILT

WITH AIR COOLED ENGINE

FOR EXTRA RELIABILITY

AND FUEL SAVINGS!

SALIENT FEATURES

• Virtually maintenance free Engine driven, Brushless welding set with windingless rotor and Air cooled Diesel Engine, requiring very minimal maintenance

• Fully integrated cooling system both for engine and welding generator-needs only one cooling medium, no need of water, antifreeze, or inhibitors, require just air from the atmosphere

• Light weight and most compact Engine driven CPCB compliant welding set available in domestic market

• Most recommended for versatile site welding applications including cross country pipeline, city gas pipeline and inplant pipeline welding etc

• Ideal for heavy fabrication, rebuilding and maintenance welding applications at site -works efficiently in all climatic conditions

• Robust mechanical design makes it highly reliable even in hostile site conditions

• Big savings in fuel consumption and longer runs before next refueling - lesser operating cost

• Specially proven with cellulosic 6010, 7010G and 8010G and other special electrodes

• Fewer spare parts required-no brushes, rotor windings, water hoses, water pumps, radiators etc

• Super silent operation

APPLICATIONS

• Recommended for all versatile welding applications at project sites like, construction of refineries, power plants, cement plants, constructions sites, Inplant pipeline welding, city gas pipeline, cross country pipeline welding, pipeline welding from jetty to storage tanks of oil, petroleum and gas etc

• Specially recommended for Manual (SMAW) welding applications from medium to heavy duty site fabrication welding, maintenance welding with all types of electrodes and city gas pipeline and cross country pipeline welding with 6010, 7010G, 8010G electrodes

• Ideal choice for round the clock (24x7hrs) working in the most demanding and hostile site conditions

www.adorwelding.com

GMAW WELDING EQUIPMENT




19

GMAW WELDING EQUIPMENTS

MAXIMIG 251



www.adorwelding.com




MODELS UNIT MAXIMIG 251


Phase No 3



Open circuit voltage Volt 16-36

No. of steps No 16

Welding current/volts @ 60% Duty cycle A / V 250 / 26.5

Welding current/volts @ 100% Duty cycle A / V 195 / 23.8



Class of Insulation Class F


Wire feeder Type Feedlite 20 (NEL)

Wire feed motor Type PMDC

Wire feed speed m / min 1.2-18


Wire feeder weight Type 8

Torch (3mtr) Model Ador TW 150 E / Ador TW 180 E / Ador TW 250 E

MAXIMIG SERIES OUTFITS

SALIENT FEATURES• Most reliable and dependable workhorse welding machines with proven economy• Rugged design, reliable performance and superior arc characteristics• Diode based power source with traditional tapped transformer, provided with switch

on front panel for step control of voltage enabling welder to obtain the desired arc voltage with ease

• User friendly selection of 2track / 4track operation for zero defect GMAW welding• Good and consistent weld quality with low hydrogen content• Dependable thyristorised wirefeeder system ensures long, uninterrupted welding• Built-in spot welding timer provided for easier and faster tack welding incase of

(MAXIMIG 251 CD) - ideal for repetitive tack welding applications• Quick release wire feed roller mechanism enables operator to change the wire spool

quickly, minimising the unproductive time and thus increasing the productovty on the shop floor

APPLICATIONS• Recommended for All position MIG / MAG welding applications• Suitable for wedling of wide range of metals like Carbon Steel, Stailess Steel,

Aluminum and it's alloys, with appropriate or recommended consumable• High volume thin sheet metal fabrication welding as in Auto Industries and other

engineering industries, maintenance and repair workshops• Most ideal for Auto Ancillary units - for increased productivity and quality welding

applications



www.adorwelding.com

20


MAXIMIG SERIES OUTFITS



APPLICATIONS

• Recommended for All position MIG / MAG welding applications

• Suitable for wide range of metals like Carbon Steel, Stainless Steel, Aluminum and it's alloys, with appropriate or recommended consumable

• Ideally recommended for heavy duty MIG / MAG welding applications like crane structure components manufacturing, 3 shift use, rough handling on the shopfloor and fabrication shops where maintenance staff is not very qualified

SALIENT FEATURES

• Most reliable and dependable workhorse MIG / MAG welding machines proven for wide range of applications

• Rugged design, reliable performance and superior arc characteristics -minimum maintenance requirements

• Diode based power source with traditional tapped transformer, provided with switch on front panel for step control of voltage enabling welder to obtain the desired arc voltage with ease

• User friendly selection of 2track / 4track operation for zero defect GMAW welding

• Good and consistent weld quality with low hydrogen content

• Dependable thyristorised wirefeeder system ensures long, uninterrupted welding

• Quick release wire feed roller mechanism enables operator to change the wire spool quickly, minimising the unproductive time and thus increasing the productivity on the shop floor

MAXIMIG 400

UNIT MAXIMIG 400


MODELS

Supply voltage

Phase

Volt 415

No 3

Welding current rangeOpen circuit voltage

No. of steps

Welding current/volts @ 60% Duty cycle

Welding current/volts @ 100% Duty cycle

Dimensions (LxWxH)

Class of Insulation

Weight (approx)

Wire feeder

Wire feed motor

Wire feed speed

Torch (3mtr)

Dimensions (LxWxH)

Wire feeder weight

Amp 50-400

Volt 18-54

No 32

A / V 400/34

A / V 310/29.5

mm 835x435x820

Class H

Kg 136

Type Feedlite 40 (FEM / NEM)

Type PMDC

m / min 1.2-18

Model Ador TW 250 E / Ador TW 400 E / MTG 400 E

mm 8

Type 130x180x310


21




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www.adorwelding.com

22

RANGER SERIES OUTFITS


RANGER 600

APPLICATIONS

• Suitable for ALL position MIG / MAG welding applications -both within shopfloor as well as at open yards and project sites (with due protection or shield against windy air)

• Suitable for wide range of metals like Carbon Steel, Stailess Steel, Aluminum and it's alloys, with appropriate or recommended consumable

• Specifically designed for heavy duty, structural welding, machine building applications

SALIENT FEATURES• Most reliable and dependable thyristor based power source for high quality MIG/MAG

semiautomatic manual and semiautomatic mechanised welding applications• Hexa phase, full wave full control bridge rectification circuit reduces ripple in the

welding output - resulting spatter free welding• Special design and construction of Transformer - resulting faster response time and

excellent Arc dynamics• Light weight, Compact design of power source, wire feeder and Torch• Adjustmnet of Crater Voltage, Crater Current possible with regulating pots provided

on the front panel• Fesh Tip Transfer technique keeps the tip ready for next welding cycle• Choice of 2 roll and 4 roll wirefeeders and different torches available for different

industrial applications• Quick release wire feed roller mechanism enables operator to change the wire spool

quickly, minimising the unproductive time and thus increasing the productovty on the shopfloor

• Power source protected from Over Voltage, Under Voltage supply, Single phasing, Over load/over heating and very high secondary short circuit current

PhaseInput KVA @ 100% Duty cycle Welding current rangeOpen circuit voltageWelding current / volts @ 60% Duty cycle Welding current / volts @ 100% Duty cycle Type of cooling

Class of InsulationDimensions (LxWxH)Weight (approx.)

Wire feed motor

Wire feed speed

DimensionsWire feeder weight

Torch (3 mtrs)

Wire feeder options


MODELS

Supply voltage

NO.KVAAmp

VoltA / VA / VType

ClassmmKg

Type

m / minmmkg

Model

Models

UNIT

Volt3

31.760-600

65600/44465/37

Forced AirH

950x550x960230

RANGER 600

415

TW 501(E) / MTG 600 E

8/9500x180x310

Feedlite 40(NEM) / Feedlite 40 (PEH)

PMDC / PCB Servo

1.2-18




RANGER 403

SALIENT FEATURES• Most reliable and dependable thyristor based power source for high quality MIG/MAG

semiautomatic manual and semiautomatic mechanised welding applications• Hexa phase, full wave full control bridge rectification circuit reduces ripple in the

welding output - resulting spatterfree welding• Special design and construction of Transformer - resulting faster response time and

excellent Arc dynamics• Light weight, Compact design of power source, wire feeder and Torch • Selection and adjsutmnet of Crater Voltage, Crater Current possible with ON-OFF

switch and regulating pots provided on the front panel • Fesh Tip Transfer technique keeps the tip ready for next welding cycle• Flux cored , solid wire selection switch, gas check toggle switch provided on the front

panel• Quick release wire feed roller mechanism enables operator to change the wire spool

quickly, minimising the unproductive time and thus increasing the productivity on the shopfloor


APPLICATIONS• Suitable for ALL position MIG / MAG welding applications -both within shopfloor as well

as at open yards and project sites (with due protection or shield against windy air)• Suitable for wide range of metals like Carbon Steel, Stailess Steel, Aluminum and it's

alloys, with appropriate or recommended consumable• Most recommended for MIG/MAG welding applications where high metal depositon

rates, high productivity and quality is a must


MODELS UNIT RANGER 403

Phase NO. 3Input KVA @ 100% Duty cycle KVA 20Welding current range Amp 60-400Open circuit voltage Volt 62V +/-3VWelding current/volts @ 60% Duty cycle Amp 400Welding current/volts @ 100% Duty cycle Amp 310Type of cooling Type Forced AirClass of Insulation Class HDimensions (LxWxH) mm 440x705x835Weight (approx.) Kg 160

Feedlite 20 (PNM)Feedlite 40 (PNM)

Wire feed motor TypeWire feed speed m / min 1.2-18Dimensions mm 460x200x280Wire feeder weight Type 9Torch (3mtr) Model

Wire feeder options Type


PCB Servo

Ador TW 400 (E) / MTG 400 (E)

23





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24





www.adorwelding.com




DC TIG

RANGER MULTI 600

SALIENT FEATURES

• Rugged construction -most reliable and dependable thyristor based power source for high quality welding processes

• Hexa phase, full wave full control bridge rectification circuit reduces ripple in the welding output - resulting spatterfree welding

• Special design and construction of Transformer - resulting faster response time and excellent Arc dynamics

• Adjustmnet of Crater Voltage, Crater Current possible with regulating pots provided on the front panel

• Fesh Tip Transfer technique keeps the tip ready for next welding cycle

• Choice of 2 roll and 4 roll wirefeeders and different torches available for different industrial applications

• Quick release wire feed roller mechanism enables operator to change the wire spool quickly, minimising the unproductive time and thus increasing the productovty on the shopfloor


APPLICATIONS

• Suitable for multi process welding applications like SMAW / GMAW / FCAW / GTAW / SAW and GOUGING processes within shopfloor as well as at open yards and project sites (with due protection or shield against windy air)

• Suitable for wide range of metals like Carbon Steel, Stailess Steel, Aluminum and it's alloys, with appropriate or recommended consumable

• Specifically designed for heavy duty, structural welding, machine building applications


Supply voltage Volt 415Phase NO. 3Input KVA @ 100% Duty cycle KVA 31.7Characteristics Type CC/CVWelding current range Amp 20-600 / 75-600Open circuit voltage Volt 80/65Welding current / volts @ 60% Duty cycle A / V 600/44Welding current / volts @ 100% Duty cycle A / V 465/37Type of cooling Type Forced AirClass of Insulation Class HDimensions (LxWxH) mm 955x685x940Weight (approx.) Kg 245

Feedlite 40 (FEH / NEH) / Feedlite 40 (PEH)

Wire feed motor Type PMDC/PCB ServoWire feed speed m / min 1.2-18Dimensions mm 500x180x310Wire feeder weight Kg 8/9Torch (3 mtrs) Model Ador TW 400 E/ MTG 600 E

Wire feeder options Models

MODELS UNIT RANGER MULTI 600

GOUGING

CHAMP MIG 250 / CHAMP MIG 400 / CHAMP MIG 600

SALIENT FEATURES

•

•

•

•

•

•

•

•

•

Digital Panel for adjusting the welding parameters

30% more Energy efficient than conventional machines.

Maximum Power factor is 0.94

Excellent dynamic response enables superior arc characteristics.

2T, 4T operating modes

Electronic choke adjustment for better arc control

Crater voltage and Crater current adjustment through digital panel.

Unique feature of Fresh Tip Transfer (FTT) to avoid globule formation.

Automatic “Weld Stop” facility.

APPLICATIONS

• Inverter based GMAW outfit

• High efficiency and high power factor – resulting energy saving

• Auto “Weld Stop” when welding torch is taken away from weld job

• Compatible to Power Generator Supply


Supply voltage

PhaseInput KVA @ 100% Duty cycle Welding current rangeOpen circuit voltageWelding current / volts @ 60% Duty cycle

Type of coolingDimensions (LxWxH)Weight (approx.)Wire feed speed

MODELS

m / min

VoltNO.KVAAmp

Volt +/-5%AmpAmpTypemmKg

UNIT

1.5-18

415 V +15 %, -10 %

3 Ø6.5

50-25065

195Forced Air

500x260x47026

CHAMP MIG 250

Welding current / volts @ 100% Duty cycle

1.5-18

415 V +15 %, -10 %

3 Ø12

50-40065

310Forced Air

700x450x60044

CHAMP MIG 400

400

1.5-18

415 V +15 %, -10 %

3 Ø21.5

65-60065

465Forced Air

670x450x62056

CHAMP MIG 600

600

26

TIG

APPLICATIONS• Suitable for ALL position MIG / MAG welding applications -both within shopfloor as well as at

open yards and project sites (with due protection or shield against windy air) • Suitable for wide range of metals like Carbon Steel, Stailess Steel, Aluminum and it's alloys, with

appropriate or recommended consumable• Most recommended for Railway workshops, wagon manufacturing and fabrication factories, ship

building and other heavy industrial applications • Champ Multi 400sspw is proven with cellulosic 6010, 7010G, 8010G and other special

electrodes, shelf shielded flux cored wires such as AWS 5.29, ASME SFA 5.29, E71T8K2 and E81T8G for Manual welding(rootpass and hot pass) and Semiautomatic welding processes for cross country pipeline welding applications

SALIENT FEATURES• Inverter based, digitally controlled, programmable, multiprocess power source for synergic

GMAW, self shielded FCAW, SMAW and GTAW (with external HF unit), welding applications • Excellent dynamic response resulting superior ARC characteristics• High Efficiency, High power factor, resulting energy savings and reduced energy bills up to 35%,

over conventional thyristorised power sources• Light weight compact MIG / MAG, FCAW, SMAW and GTAW welding outfit• Enhanced Reliability - latest PCB designs with SMD technology, PCBs and connectors protected

against harsh environment like contaminated air with conducting dust, dirt etc • Feather touch front panel for easy selection of welding process, 2track/4track mode, time

adjustments for gas preflow/ postflow and burnback time, electronic choke adjustment, crater voltage and current adjustments and arc force adjustments etc

• Power source protected against Over voltage, Under voltage, Single Phasing, Over temperature etc• Compatible for Automation


CHAMP MULTI SERIES OUTFITS




www.adorwelding.com



MODELS UNIT

MMA MODE MIG/FCAW MODE

Supply voltage Volt 415 415

Phase No 3 3

Input KVA @ 100% Duty cycle KVA 14 13

Welding current range Amp 50-400 40-400

Open circuit voltage Volt 75 55

Welding current / volts @ 60% Duty cycle Amp

Welding current / volts @ 100% Duty cycle Amp


Class of Insulation Class

Actual Dimensions (LxWxH) mm

Weight (approx.) Kgs

Feedlite 20 (FEM / NEM)

Feedlite 40 (FEM / NEM)

WF - 40 Multi (i)

Wire feed motor Type PMDC

Wire feed speed m/min 1.5-18 / 1.0-6.0

Dimensions mm 450x170x275

Torch (3/4.5mtr) options Model ADOR TW 400(E) / MTG 400 EGMAW Appln

FCAW Appln Model SUPER SSPW 350

Wire feeder optionsType

Kg

520x240x360

GMAW Appln

FCAW Appln

Feedlite

SUPER SSPW

8

20

Feedlite

SUPER SSPW

CHAMPMULTI 400 / CHAMPMULTI 400 SSPW

730x480x730

67

310

H

400

Forced Air

mm

GMAW / FCAW

Type

KgWire feeder weight


25




www.adorwelding.com




CV3PhaseSALIENT FEATURES

• MIG 400 rated at 400 AMPS @ 60% and 310 AMPS @100% Duty cycle

• MIG 600 rated at 600 AMPS @ 60% and 465 AMPS @100% Duty cycle

• Maximum Power Factor 0.94.

• Excellent dynamic response enables superior arc characteristics.

• Stepless Electronic Inductance adjustment for better arc control.

• 7 Segment LED display.

• Hardwire interface for Robots and PLC.

CHAMP MIG 400 (R) / 600 (R)

CHAMP MIG 400 (R) / 600 (R)


MODELS UNIT CHAMPMIG 400 (R) CHAMPMIG 600 (R)

Input KVA

65

12 KVA @ 100% Duty cycle. 0.24 KVA @ No load 12.5 KVA @ 100% Duty cycle. 0.31 KVA @ No load

65Open Circuit voltage Volts +/-5%

Welding current / Crater Current range Amp 50-400 65-600Welding Voltage / Crater Voltage Range Volt 16-39 16-45Mode of operation 2 track, 4 track, Gas check, OCV check facility 2 track, 4 track, Gas check, OCV check facility

Power Factor Max 0.93 Max 0.94Efficiency 87% @ 100% duty cycle 89% @ 100% duty cycleCompatibility to International Standaed As per Std. EN609741 As per Std. EN609741Wire feed speed m / min 1.5-18 1.5-18Suitable Welding Wire Diameter mm Aluminum 1.2 - 1.6 Steel 0.8 1.0, 1.2 & 1.6 Aluminum 1.2 - 1.6 Steel 0.8 1.0, 1.2 & 1.6

IP23 IP23

Weight Kg 46 58Audio Noise Emission dB

Ingress Protection Class

Input Supply 415 V + 15 %, -10 %, 50 / 60 HzC 415 V + 15 %, -10 %, 50 / 60 Hz3 Ø

70 70

Dimensions (approx.) L x W x H mm 650 X 450 X 570 700 X 460 X 630

Interfacing Connection Details Between Champ MIG (R) And Robot PLC.

10 PIN CONNECTORON CHAMPMIG (R)

10 CORE INTERFACE CABLE

I / O CARDCONNECTOR

MIG TROLLEY

APPLICATIONS

• Recommended for fillet, butt and lap welding joints of longitudinal jobs in ship yards and site structural fabrication projects – Enhances welding productivity multifold

• Ideally suitable for fillet joints using mechanised semiautomatic GMAW/FCAW welding processes of longitudinal jobs like girders, beams and other sections etc

• Can be used for fillet welding in either vertical or horizontal directions

SALIENT FEATURES

• Light weight and compact design, easy to carry anywhere on the shopfloor

• Easy to use - Welder friendly operations

• Strong magnet inside provides grip while trolley is traveling

• Four wheel chain drive provides steady traveling

• Rubberised four wheel chain drive provides constant speed whithout sleepage of wheel

• Input supply Protection in case of short circuit of supply cable


AUTOMATED MIG TROLLEY


ITEM UNIT SPECIFICATION

Motor power Watt 6

Supply frequency Hz 50/60

Motor RPM RPM 1200/1500

Gear reduction ratio Ratio 100:1

Input supply Volts AC 230

I/P supply cable length Mtr 5

Torch inclination mm Longitudinal and

transversal 30mm each

Torch adjustment angle Degree 38°- 60°

Traveling speed mm / min 0-1000

Dimension L×W×H mm 210×250×280

Weight Kg 6


APPLICATIONS• Multioperator and multiprocess based welding outfits recommended for cross country gas and

peroleum pipeline welding applications with SMAW (manual) and FCAW (semiautomatic) welding processes

• Specially designed and recommended for Manual (SMAW) welding of root pass / hot pass weld joints using 6010/7010G/8010G electrodes and Semiautomatic (FCAW) welding of filling / capping weld joints using self shielded flux cored wire

27

MULTI OPERTAOR WELDING PAYLOADS FOR GMAW / FCAW PROCESSES





SALIENT FEATURES• Multioperator and multiprocess based outfits designed and built for handling on cross country

gas and petroleum pipeline welding applications• Inverter based, digitally controlled, programmable, multiprocess power source for synergic self

shielded FCAW, SMAW welding applications • Excellent dynamic response resulting superior ARC characteristics• High Efficiency, High power factor, resulting energy savings and reduced energy bills up to

35%, over conventional thyristorised power sources • Light weight and compact SMAW, FCAW welding outfit • Enhanced Reliability - latest PCB designs with SMD technology, PCBs and connectors

protected against harsh environment like contaminated air with conducting dust, dirt etc • Feather touch front panel for easy selection of welding process, 2track/4track mode, time

adjustments for gas preflow/ postflow and burnback time, electronic choke adjustment, crater voltage and current adjustments and arc force adjustments etc

• Power source protected against Over voltage, Under voltage, Single Phasing, Over temperature etc

• Compatible for Automation

CHAMPMULTI 2X400 SSPW

CHAMPMULTI 4X400 SSPW

MODELS UNIT

Supply voltage Volts 415 415Phase No 3 3Max Input power @ 100% KVA 2x14 4x14Welding current range Amps 10-400 40-400Open circuit voltage (SMAW / FCAW) Volts 75/62 75/62Welding current/volts @ 60% Duty cycle Amps 400 400Welding current/volts @ 100% Duty cycle Amps 310 310Class of Insulation ClassDimensions mms 900x900 1060 900x900x1820Weight Kgs 164 324Wirefeeder Type

Wirefeed motor TypeWire feed speed m / minDimensions mmsWirefeeder weight Kg 2x25 4x25Torch (3/4.5mtr) Model

H

WF MULTI 40(I)

PMDC1.0-6.0

520x240x360

SUPER SSPW 350

WELDING PAYLOADS AVAILABLE WITH RECTIFIERS FOR SMAW WELDING PROCESS



www.adorwelding.com

THYROLUXE 2x401THYROLUXE 4x401THYROLUXE 2x600THYROLUXE 4x600

CHOPREC 2X401CHOPREC 4X401CHAMP 2X250CHAMP 4X250

CHAMP 2XT400CHAMP 2XT400CHAMP 2X400CHAMP 4X400

CHAMP 2X600CHAMP 4X600

CC/CV TIG


28



www.adorwelding.com



www.adorwelding.com

GTAW WELDING EQUIPMENT

HF 2000 / HF 2000 AD / HF 3000 /HF 3000 AD

SALIENT FEATURES

• Light weight, compact and portable HF units for greater flexibility in operation at project sites

• Suitable for DC and AC TIG welding applications with SMAW power sources of any make

• Gas pre flow and post flow time adjustments provided on the front panal

• Gas flow actuated through solenoide valve for economical consumption of Argon gas

• HF “ON/OFF” switch provided to prevent high frequency interference (in DC TIG mode only)

• Auto HF cut off facility if arc does not start within 10 seconds

APPLICATIONS

• HF 2000 and HF 3000 controls units are recommended for using alongwith dioded based, thyristor based or Inverter based DC rectifiers for DC TIG welding applications, for both indoor and outdoor use at project sites

• HF 2000 units are used for light and medium duty DC TIG welding applications where as HF 3000 units (bult in with water cooling unit), are used for continuous heavy duty DC TIG welding for full shift and regular production jobs

• HF 2000AD and HF 3000AD controls units are recommended for using alongwith AC power sources like RED / DH / DS / DR type transformers for AC TIG wedling applications for both indoor and outdoor use at project sites

• HF 2000AD units are used for light and medium duty AC TIG welding applications where as HF 3000AD units (built in with water cooling unit), are used for continuous heavy duty DC TIG welding for full shift and regular production jobs


HF CONTROL TIG UNITS

GTAW WELDING EQUIPMENTS



www.adorwelding.com

MODELS UNIT

Supply voltage Volt

Phase No

Welding current DC @ 60% Duty cycle Amp

Welding current DC @ 100% Duty cycle Amp

Welding current AC @ 60% Duty cycle Amp

Welding current AC @ 100% Duty cycle Amp

Gas Pre flow Time Sec.

Gas Post flow Time Sec.

Arc striking Type

Class of Protection Class


Weight (approx.) Kg

Mode of operation

Torch model Type

HF 2000 HF 2000 AD HF 3000 HF 3000 AD

230 230230230

1 111

200 200 300 300

150 230150 230

- 150 - 250

- 110 - 180

0.1-5 0.1-5 0.1-5 0.1-5

1-30 1-301-301-30

2T/4T 2T/4T2T/4T2T/4T

HF/ Touch start HF/ Touch startHF/ Touch startHF/ Touch start

IP 23 IP 23IP 23IP 23

614x400x580440x165x315 560x290x438 614x400x880

10 25 45 50

Type

HIPROTIG 301-4/HIPROTIG 301-8HIPROTIG 201-4/HIPROTIG 201-8



29

31

CHAMPTIG 300 P

SALIENT FEATURES

• Inverter (IGBT) based, energy efficient TIG welding outfit with built-in HF, for medium and heavy duty welding applications

• High power factor, high efficiency power soources, resulting over 30% energy savings compared to conventional inverter power sources

• Power source provided with protections against Over voltage, Under Voltage, Over load and Single phasing

• Most compact and light weight TIG outfits ideally suitable for within shopfloor and project sites - easy mobility at project sites

• Welder friendly operation - easy selection of processes like MMA, DC TIG, adjustment of welding parameters including upslope/downslope, pulse frequency etc provided on the front panel

• Option of foot control switch available for easy adjustment of current while welding to control the heat input for precision welding applications

APPLICATIONS

• Recommended for Pulsed DC TIG welding applications of ferrous metals and alloys like MS, SS and alloys etc

• Suitable for uses within fabrication shops like railway workshops, coach building factories, Shipyards, Steel plants, Construction of Power plants, Refineries, Cement plants etc as well as project sites

• TIG welding equipments and process are ideally recommended for precision welding of thin sheets, tube to tube and tube to sheet welding, X-ray quality welding and other welding applications where finish of welded jobs is very important

CHAMP TIG SERIES TIG OUTFITS


CCDC TIG


MODELS UNIT

Volt

Phase No

Input KVA @ 100% TIG)Duty cycle (MMA, DC KVA

Open circuit voltage Volt

Welding current range (MMA, DC TIG) Amp

Welding current @ 60% Duty cycle (MMA, DC TIG) Amp



Weight (approx.) Kg

Water cooling unit Model

TIG Torch Model

7.5 / 7.0

70

CHAMPTIG 300 P

415

3

HIPROTIG 301 / 4

HIPROTIG 301 / 8

WCU 302

52-250 / 5-300

250 / 300

H

38

560x325x285

Welding current @ 100% Duty cycle (MMA, DC TIG) Amp 195/230

Supply voltage



www.adorwelding.com

CHAMPTIG 300 AD

SALIENT FEATURES

• Inverter (IGBT) based, energy efficient TIG welding outfit with built-in HF, for medium and heavy duty welding applications

• High power factor, high efficiency power soources, resulting over 30% energy savings compared to thyristorised power sources

• Power source provided with protections against Over voltage, Under Voltage, Over load and Single phasing

• Most compact and light weight TIG outfits ideally suitable for within shopfloor and project sites - easy mobility at project sites

• Welder friendly operation -easy selection of processes like MMA, DC TIG, AC TIG and MIX TIG processes, adjustment of welding parameters provided on the front panel

• Option of foot control switch available for easy adjustment of current while welding to control the heat input for precision welding applications

APPLICATIONS

• Recommended for DC TIG welding of ferrous metals and alloys like MS, SS and AC TIG welding applications of nonferrous metals like Aluminum, Magnesium etc

• Suitable for uses within fabrication shops like railway workshops, coach building factories, Shipyards, steel plants, construction of power plants, refineries, cement plants etc as well as project sites

• TIG welding equipments and process are ideally recommended for precision welding of thin sheets, tube to tube and tube to sheet welding, X-ray quality welding and other welding applications where finish of welded jobs is very important




MODELS UNIT

Supply voltage Volt

Phase No

Input KVA @ 100% TIG, AC TIG)Duty cycle (MMA, DC KVA


Welding current range (MMA,DC TIG, AC TIG) Amp

Welding current @ 60% Duty cycle (MMA,DC TIG, AC TIG) Amp




Weight (approx.) Kg


TIG Torch Model

11.8, 11.0, 12.0

90

CHAMPTIG 300 AD

415

3

Forced Air

TIG 300-4.5

WCU 30

20-250, 10-300, 25-300

250, 300, 300

F

50

615x315x570

DC TIG AC TIG

CCCC

30



www.adorwelding.com






32






www.adorwelding.com

CHAMPTIG 400 P

SALIENT FEATURES

•

•

•

•

Latest PWM Inverter Technology

High Efficiency (> 85%)

Smooth and stable arc with spatter less welding

Pulse TIG for precision welding

APPLICATIONS

• Three phase inverter based, High efficiency and High Power Factor Pulse TIG/ MMA DC Welder

• Useful for wide variety of material types and thickness.

• Full featured TIG controls possible

• HF ignition

• Intelligent protection: over / under voltage, over current / temperature

• Water cooled Torch with water cooling unit option.



CCDC TIG


MODELS UNIT

Volt

Phase No

Input KVA @ 100% TIG)Duty cycle (MMA, DC KVA


Welding current range (MMA, DC TIG) Amp



Weight (approx.) Kg


TIG Torch Model

13 / 10

70

CHAMPTIG 400 P

415, +15%, -10%

3

HIPROTIG 401 / 4

HIPROTIG 401 / 8

WCU 302

50-400 / 10-400

310

46

660x315x485


Supply voltage

www.adorwelding.com

SAW WELDING EQUIPMENT

www.adorwelding.com

SAW WELDING EQUIPMENT



www.adorwelding.com

34



MAESTRO 800 (F) / 1000 (F) / 1200 (F) APPLICATIONS• These welding equipments / outfits are recommended for SAW welding of heavy duty longitudinal

structuares like girder, I-beams, plus beam welding applications, where high deposition rates and welding productivity are desired

• Ideal choice for butt weld, fillet weld, double V joint welding of plates as required in ship building industry, railway, construction of bridges, components of earth moving equipments etc

• Most suitable for thick plate welding applications where X ray quality welding with excellent mechanical properties and good finish of weld beads are essential

S A W

SALIENT FEATURES• Rugged and strong power source, tractor or boom mounted welding head, wire feed mechanism,

spool holder, horizontal & vertical slides and feather touch control panel• Highly reliable DIODE based power source and THYRISTOR thyristor controlled wire feeder, carriage

drive and X / Y / Z axis motion controls in case of boom mounted head, makes these outfits a real work horse SAW welding outfits for heavy fabrication workshops and project site

• Trouble-free operation - Negligible maintenance required for power source and welding head• Option of Tractor mounted or Boom mounted heads are available depending on different

application requirements. Precise setting of weld parameter - Voltage adjustments through coarse and fine selector switches and stepless control of wirefeed speed as well as tractor speed

• Swivelling and Tilting arrangement of weld head ensures access to difficult welding areas, specially for fillet welding and jobs with wide range of dimensions/sizes. Strong horizontal and vertical slides - smooth and jerkfree movements enables precise adjustment of welding head along the seam even during welding

• Flux hopper of adequate capacity (10kgs / 7litr) ensures long and interrupted weld seams• Operator friendly controls - Wire inch push button, OCV check push button, set/weld switch, carriage

ON / OFF, UP / DOWN switch, Voltmeter / Ammeter, carriage speed adjustments provided on the control panel. Facilty to check carriage speed and OCV prior to start of welding sequence

• Burn back control incorporated as a standard feature, prevents freezing of wire in the weld pool when welding ends


MAESTRO SERIES

SAW WELDING EQUIPMENTS

MODELS

Supply voltage / Phase

Welding Current Range

Input KVA @ 100% Duty cycle




Type of cooling

Class of insulation

Dimensions (LxWxH) 1225x800x900

Weight (approx.)

Welding Head - Tractor mounted

Welding Head - Boom mounted

UNIT

Volt / NO.

KVA

Volt

Amp

Amp

Tye

Class

mm

Kg

Model

Model

Power Source Model

BOOM mounted SAW welding heads available with 3 options, namely WH 15-01 (F) / WH 15-02 (F) and WH 15-03 (F)

Amp

MAESTRO 800 (F)

37

35-63

800

650

Forced Air

H

350

WH 15 (F)

PS 800 (F)

415 / 3

150 - 800

MAESTRO 1000 (F)

45

35-63

1000

800

Forced Air

H

1225x800x900

365

WH 15 (F)

PS 1000 (F)

415 / 3

200 - 1000

MAESTRO 1200 (F)

57

35-63

1200

1000

Forced Air

H

1225x800x900

390

WH 15 (F)

PS 1200 (F)

415 / 3

200 - 1200



www.adorwelding.com

33

MAESTRO 800 T(F) / 1000 T(F) / 1200 T(F) APPLICATIONS• These welding equipments/outfits are recommended for SAW welding of heavy duty

longitudinal structuares like girder, I-beams, plus beam welding applications, where high deposition rates and welding productivity are desired


• Most suitable for thick plate welding applications where X ray quality welding with excellent mechanical properties and good finish of weld beads are essential good finish of welded joints/jobs is very important

S A W

SALIENT FEATURES• Rugged and strong power source, tractor or boom mounted welding head, wire feed

mechanism, spool holder, horizontal & vertical slides and feather touch control panel• Highly reliable THYRISTOR based power source and THYRISTOR controlled wire feeder, carriage

drive and X / Y / Z axis motion controls in case of boom mounted head, makes these outfits a real work horse SAW welding outfits for heavy fabrication workshops and project site

• Trouble-free operation - Negligible maintenance required for power source and welding head• Option of Tractor mounted or Boom mounted heads are available depending on different

application requirements• Precise setting of weld parameter - Stepless infinitely variable Voltage adjustments through

potentiometer stepless control of wirefeed speed as well as tractor speed• Swivelling and Tilting arrangement of weld head ensures access to difficult welding areas,

specially for fillet welding and jobs with wide range of dimensions/sizes • Strong horizontal and vertical slides - smooth and jerkfree movements enables precise

adjustment of welding head along the seam even during welding• Flux hopper of adequate capacity (10kgs/7litr) ensures long and interrupted weld seams• Operator friendly controls - Wire inch push button, OCV check push button, set/weld switch,

carriage ON / OFF, UP / DOWN switch, Voltmeter/Ammeter, carriage speed adjustments provided on the control panel. Facilty to check carriage speed and OCV prior to start of welding sequence


MAESTRO SERIES


MODELS UNIT

Supply voltage / Phase Volt / NO.

Input KVA @ 100% Duty cycle KVA






Weight (approx.) Kg

Welding Head - Tractor mounted Model

Welding Head - Boom mounted Model

Power Source Model

Welding Current Range Amp

MAESTRO 800 T(F)

44

62

800

650

H

1225x800x900

350

WH 15 T(F)

PS 800 T (F)

415 / 3

150 - 800

MAESTRO 1000 T(F)

50

62

1000

800

H

1225x800x900

365

WH 15 T(F)

PS 1000 T (F)

415 / 3

200 - 1000

MAESTRO 1200 T(F)

63

1200

1000

H

1225x800x900

390

WH 15 T(F)

PS 1200 T (F)

62

415 / 3

200 - 1200

BOOM mounted SAW welding heads available with 3 options, namely WH 15-01 T (F)/ WH 15-02 T (F) and WH 15-03 T (F)




35



www.adorwelding.com

39



www.adorwelding.com

MAESTRO 1000 (I)

S A W

APPLICATIONS

• These welding outfits are incorporated with Inverter based ENERGY EFFICIENT power source and hence recommended for SAW welding applications where energy cost of power consumed by equipment is very critical / important for the overall project cost

• These welding equipments/outfits are recommended for SAW welding of heavy duty longitudinal structuares like girder, I-beams, plus beam welding applications, where high deposition rates and welding productivity are desired



SALIENT FEATURES

• Inverter based Energy Effiicient power source saves power consumption and reduces energy bill up to 30% over convenetional thyristorised power sources

• High efficiency, High power factor power source

• Inverter based digitally controlled power source and welding head

• Light weight compact power source occupies 35% less floor space

• Userfriendly interface including push buttons, LED indicator lamps, micro controller based controllers ensures real time response for every set parameter, wire diameter selection through fuzzy logic control

• Enhanced reliability due to PCB construction with SMD technology

• Power source protected against Over voltage, Under voltage, Overload/over temperature conditions

• Apart from SAW welding application, power source is also suitable for Gouging application


MAESTRO SERIES


GOUGING

MODELS UNIT MAESTRO 1000 (I)


Phase No 3

Input KVA @ 100% Duty cycle KVA 55




Welding Voltage range Volt 26-44





Welding Head Model WH 15(I)






MAESTRO 1000 (I)

S A W

APPLICATIONS

• These welding outfits are incorporated with Inverter based ENERGY EFFICIENT power source and hence recommended for SAW welding applications where energy cost of power consumed by equipment is very critical / important for the overall project cost

• These welding equipments/outfits are recommended for SAW welding of heavy duty longitudinal structuares like girder, I-beams, plus beam welding applications, where high deposition rates and welding productivity are desired



SALIENT FEATURES

• Inverter based Energy Effiicient power source saves power consumption and reduces energy bill up to 30% over convenetional thyristorised power sources

• High efficiency, High power factor power source

• Inverter based digitally controlled power source and welding head

• Light weight compact power source occupies 35% less floor space

• Userfriendly interface including push buttons, LED indicator lamps, micro controller based controllers ensures real time response for every set parameter, wire diameter selection through fuzzy logic control

• Enhanced reliability due to PCB construction with SMD technology

• Power source protected against Over voltage, Under voltage, Overload/over temperature conditions

• Apart from SAW welding application, power source is also suitable for Gouging application


MAESTRO SERIES


GOUGING

MODELS UNIT MAESTRO 1000 (I)


Phase No 3





Welding Voltage range Volt 26-44





Welding Head Model WH 15(I)

www.adorwelding.com

AIR PLASMA CUTTING EQUIPMENT

37



www.adorwelding.com



APPLICATIONS

• Recommended for air plasma cutting applications of all electrically conducting sheet metal up to 25 mm thick in the industries like sheet metal fabrication, Bus and coach body building workshops, Railway and transport workshops, power stations, chemical & fertiliser plants, construction & maintenance workshops, food processing and pharmaceutical equipments using SS, scrap cutting & demolition, ship breaking etc

• Most recommended for applications where good cutting finish with minimum distortion and HAZ, burrfree, drossfree clean cuts with narrow curf, are required

• Ideally suitable for metal cutting applications where Oxy Acytelene cutting process is not feasible or Oxy/Acetylene gases are not available, good clean cuts with higher cutting productivity are desired

SALIENT FEATURES

• Inverter based air plasma cutting outfit for heavy duty production jobs

• Energy Efficient outfit, built in with high efficiency and high power factor power source, saves power consumption and reduces energy bills up to 30%

• Light weight, compact, portable air plasma cutting system - ideal choice for efficient cutting of all metals up to 25 mm thick plates

• "Air pressure meter" with "selector switch", MCB, LED indicators for "power on", "cutting on", warning trip indicators" provided on the front panel

• Power source provided with Under voltage, Over voltage, Single phase and thermal overloads

CHAMPCUT 25

AIR PLASMA CUTTING EQUIPMENTS


MODELS UNIT PLASMACUT 25


Phase No 3



Cutting current range Amp 20-60

Cutting current @ 60% Duty cycle Amp 60


Class of insulation Class F



Cutting Torch Model CCT 25

www.adorwelding.com

AIR PLASMA CUTTING EQUIPMENT

PLASMACUT 25

APPLICATIONS

• Recommended for air plasma cutting applications of all electrically conducting sheet metal up to 25 mm thick in the industries like sheet metal fabrication, Bus and coach body building workshops, Railway and transport workshops, power stations, chemical & fertiliser plants, construction & maintenance workshops, food processing and pharmaceutical equipments using SS, scrap cutting & demolition, ship breaking etc

• Most recommended for applications where good cutting finish with minimum distortion and HAZ, burrfree, drossfree clean cuts with narrow curf are required

• Ideally suitable for metal cutting applications where Oxy Acytelene cutting process is not feasible or Oxy/Acetylene gases are not available, good clean cuts with higher cutting productivity are desired

SALIENT FEATURES

• Air plasma cutting outfit with Rugged, Robust design and well established diode based power source

• User friendly controls on the front panel, requires minimum training to the operator

• Provided with special "Safety -Interlock" for operator protection

• Light weight and flexible torch with 8 mtr long hose assembly

• Provided with Air pressure safety switch for "fail safe' cutting

• Provided with double air filter cum pressure regulator unit to ensure clean compressed air for excellent cut quality

AIR PLASMA CUTTING EQUIPMENTS


36



www.adorwelding.com

SPECIFICATION

Under CO2

ORDERING CODE

Max. current capacity @ 60% duty cycle:

Length

Cooling Type

Air to be used (Plasma+Cooling)

Flow Rate

Pressure

Maximum thickness

M.S. / S.S.

Aluminium

UNIT

Amps

Ltrs./Min.

Bar

Mtrs.

-

MM

MM

CCT - 25

25

100 at 110 Volts

120-150 (Max. 180)

6

S15.01.002.0708

20

5

Air

20

Air

100 at 110 Volts

120-150 (Max. 180)

6

5

CCT - 25A

S15.01.002.0716

25

PLASMA CUTTING SERIES TORCHES




www.adorwelding.com

WELDING ACCESSORIES

•For detailed technical specifications please refer respective leaflet

•Due to continuos development AWL reserves the right to modify / change the design and /or the


SALIENT FEATURES

•

•

Temperature control - Provided with thermostat control for precise setting of drying temperature required for various types of electrodes

Flawless welds - Totally dry welding consumables yield radio graphic quality welds

MODELS: ADORPORT / ADORDRY-I /ADORDRY-II

ELECTRODE DRYING OVEN

WELDING ACCESSORIES


GENERAL SPECIFICATIONS

TECH. SPECS. ADORPORT ADORDRY-I ADORDRY-II

INPUT

Voltage 230 V/AC

Current (Amps) 2 7.6

Phase Single Phase

Frequency 50 Hz

Temperature 50ºC - 250ºC

Capacity (approx.) About 4 kg of 450 mm electrodes

Working Space 80 mm dia. x 445 mm

depth (approx.)

No. of shelves -

Air Circulation

Convection

S10.64.001.0030 S10.64.001.0031 S10.64.001.0032

230 V/AC

Single Phase

50 Hz 50 Hz

Single Phase

230 V/AC

9.5

0.5 kw 1.75 kw 2.25 kw

Natural Natural

50ºC - 250ºC 130ºC - 350ºC

440 x 450 x 490 mm (HWD) 440 x 450 x 490 mm (HWD)

height (approx.) height (approx.)

FIVE FIVE

Convection Convection

THERMOSTAT THERMOSTATTemperature Control

Ordering Code

ELECTRODE DRYING OVEN TYPES

38



www.adorwelding.com

About 25 kg of 450 mm electrodes About 25 kg of 450 mm electrodes

Watts

OUTPUT

THERMOSTAT

with electronic

controller &

digital temperature

indicator



www.adorwelding.com

WELDING ACCESSORIES

39



www.adorwelding.com




SALIENT FEATURES

•

•

•

•

•

•

•

•

Customized design with insulated torch head for longer and trouble free service life

New stainless steel wire-spiral eliminates problem of rust build-up and consequent wire feeding problems

Plug-in connections for easy interchangeability

Varieties of nozzle sizes available to suit welding joint configurations

Special models to fit ‘Euro’ and other wire-feeders

Ergonomic handle to reduce operator fatigue

Improved heavy-duty contact tips for long life and greater operational economy

Easy availability of spares


TORCHES - MTG SERIES

MIG / MAG TORCHES

WELDING ACCESSORIES

MIG SERIES TORCHESMTG 250 / 400 / 600

UNIT

Max. current carrying

Suitable for wires:

ORDERING CODE No. S15.01.002.0047 S15.01.002.0052 S15.01.002.0083

Cooling Type Gas

Amps 250 400 500

Gas Gas

Length Mtrs. 3.0 3.0 3.0

Under Argon Amps 200 300 350

Under CO2

duty cycle:

capacity @ 60%

Steel (Ømm) 0.8, 1.2 0.8, 1.2, 1.6 0.8, 1.2, 1.6. 2.0

Aluminium 1.2 1.2, 1.6 1.2, 1.6

Torch end connector

(Ømm)

Type Euro Euro Euro

SPECIFICATION MTG-250 (E) MTG-400 (E) MTG-600 (E)



www.adorwelding.com

40

WELDING ACCESSORIES



SALIENT FEATURES

• Light weight sleek design –Reduced fatigue to welders

• Ergonomically designed handle.

• Can be adapted to any international make MIG / MAG outfit.

• Ex-stock availability of spares and consumables ADOR-TW 402 E

ADOR-TW 252 E

The new world class Ergonomically designed

MIG / MAG Welding Torches


ADOR-TW SERIES MIG / MAG WELDING TORCHES

ADOR TW SERIES TORCHESADOR-TW 252 (E) / ADOR-TW 402 (E)

Max. current carrying capacity @ 60% Duty cycle

Under CO2under Argon rich mixture

Amps. 250 400

Amps.

Cable - Co-axial Co-axial

Torch length * Mtrs. 3 3

Cooling Type Gas Gas

Suitable for wires DiameterSteelAluminium

MM 0.8 & 1.2 0.8 , 1.2 , 1.6MM - 1.2 , 1.6

Torch end connector Euro

ORDERING CODE

TYPE ADOR-TW 402 E ADOR-TW 252 E PARAMETER

Euro

S15.01.002.0115 S15.01.002.0117

MIG / MAG TORCHES



www.adorwelding.com

41




TIG TORCHES

WELDING ACCESSORIES

SALIENT FEATURES

•

•

•

•

•

•

Flexible cable assembly for easy access

Co-axial cable with special rubber sheathing for longer life

Lightweight torches for maximum comfort and productivity with swivelling handle

Float type switch assembly for positive contact & longer life

Ergonomically designed handle

Optional custom-built torches for specific applications

HIPRO SERIES TORCHESHIPRO TIG180 TV-4 / 201 / 301 / 302 / 401


SPECIFICATION UNIT HIPRO TIG 180 TV-4 HIPRO TIG-201 HIPRO TIG-301 HIPRO TIG-302 HIPRO TIG-401

Max. Current carrying

capacity

@ 60 % duty cycle

AC

DC

@ 100 % duty cycle

AC

DC

Cable Length

Cooling Type

Electrode Capacity

ORDERING CODE

Amp

Amp

Amp

Amp

Meters

-

MM

4-Mtrs

8-Mtrs

200

160

155

125

4

Gas

1.6,2.4

S15.01.002.0156

-

150

200

115

150

4/8

Gas

1.6,2.4,3.2

S15.01.002.0322

S15.01.002.0323

250

300

180

230

4/8

Water

1.6,2.4,3.2,4.0

S15.01.003.0574

S15.01.003.0575

250

300

180

230

4/8

Water

1.6,2.4,3.2,4.0

S15.01.003.0001

S15.01.003.0002

400

320

250

310

4/8

Water

1.6,2.4,3.2,4.0

S15.01.003.0326

S15.01.003.0327

42



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WELDING ACCESSORIES

MODEL: CAG-9/15


MODEL \ UNIT CAG-9 CAG-15COOLING

AIR AIR

Recommended

Air Pressure Kg/Cm2 5.5-7 5.5-7

Air flow whenvalve Min Lit./Min 1.0 1.0

in fully closed condition Max. Lit./Min 2.0 2.0

Max current carrying

capacity AMP 600 600

Suitable for electrode

Diameters MM 6-9 6-15

Length MTR 2 2

Weight (approx) KG 2.7 3.15

ORDERING CODE No 0150103532 0150103533

SALIENT FEATURES

• Gouging torches consist of an electrode holder fitted to a flexible cable-hose assembly. The cable-hose assembly serves the dual purpose of carryingthe compressed air and the gouging current. It is provided with suitableend connection for connecting to the power source by a suitable cable andto the compressed air mains by a suitable air hose. (I.D. of hose should be12.5 mm). The electrode held between the upper arm and the swivel head,can be positioned by adjusting the position of the swivel head. The flow ofminimum 1 ltr./minute and maximum 2 ltrs./minute are purposely adjustedin the closed condition of the valve for better cooling of torch.

APPLICATIONS

•

•

•

•

Fabricators, Tank Shop, Shipyards, Heavy Industrial Plants,Construction Firms, etc.,

Back gouging of welds, removal of old or defective welds.

Steel foundries to cut off risers & gate pads

To remove old welds from most metal

Gouging Current (Amp) 150-300 200-450 300-600 400-700 500-800

RECOMMENDED CURRENT CONDITIONS

6 8 9 12 15Electrode Dia (mm)

GOUGING TORCHES

GOUGING TORCHES

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WELDING ACCESSORIES

MIG-WIRE FEEDERS

MODELS: FEEDLITE-20(FE) / 20(FD) /20 (PD) / 20(PE) / 40(FE) / 40(FD) / 40(FE)H

SALIENT FEATURES

•

•

•

•

Totally enclosed permanent magnet motor for maintenance-free performance

Thyristorised DC Speed Drive ensures smooth and precise wirefeeding

Quick Change Mechanism & Easy plug-in connection

Choice of permanent magnet - Servo Motor type and conventional type motor.


Note: • FE - Wire Feeders with PMDC motor• PE - Wire Feeders with PCB / Servo motor

Wirefeed speed

Suitable for Wires

Wire roll drive

Dimensions:

Length

Width

Height

Torch connection

Drive motor

Weight (approx.)

ORDERING CODE

m/min.

(Ø mm)

No.

mm

mm

mm

Type

Kg.

No.

SPECIFICATION UNIT

12-18

0.8, 1.0, 1.2, 1.6

2

500

180

310

Euro

42V, 60W

PMDC

8

S15.01.001.0517

FEEDLITE-20(FE)

0.8, 1.0, 1.2, 1.6

2

430

180

310

Euro

18V, 65W

PCM

9

S15.01.001.0322

12-18

FEEDLITE-20(PE)

0.8, 1.0, 1.2, 1.6

4

500

180

310

Euro

42V, 90W

PMDC

9

S15.01.001.0519

12-18

FEEDLITE-40(FE)

FEEDLITE SERIES INCLUDING HEAVY DUTY

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WELDING ACCESSORIES

MODELS: UNIFEED – 20/40, WF - 20/40

MODEL UNIFEEED-20 (FD)/(FE) UNIFEED-40 (FD)/(FE)UNIFEEED-20 (FD-AWL)/(FE-AWL) UNIFEED-40 (FD-AWL)/(FE-AWL) UNIFEED-20(PE/(PD)

Suitable for wire sizes 0.8 mm, 1.2 mm & 1.6 mm 0.8 mm, 1.2 mm & 1.6 mm 0.8 m, 1 mm, 1.2mm & 1.6 mmWire feed speed 1.2 M to 18 M/Min 1.2 to 18 M/Min Wire roll drive Two roll Four roll Two rollWire drive motor Permanent magnet Permanent magnet Printed Circuit MotorMotor rating DC 42V, 60 watt DC 42V, 90 watt DC 18V, 65 wattDimensions (l x w x h) mm 430 x 180 x 310 430 x 180 x 310 430 x 180 x 310Weight (w/o spool) 8 Kg. (Approx.) 9 Kg. (Approx.) 9 Kg. (approx.)Construction of Wirefeeder Open type Open type Open Type

MODEL WF-20 (F) with Euro end connection/ WF-20 (F) with AWL end connection (F)

WF-40 (F) with Euro end connectionWF-40 with AWL end connection WF-20 (PE)/(PD)

Suitable for wire sizes 0.8 mm, 1.2 mm & 1.6 mm 0.8 mm, 1.2 mm & 1.6 mm 0.8 mm,1mm,1.2 mm & 1.6 mmWire feed speed 1.2 to 18 M/Min 1.2 to 18 M/Min 1.2 M to 18 M/MinWire roll drive Two roll Four roll Two rollWire drive motor Permanent magnet Permanent magnet Printed Circuit MotorMotor rating DC 42V, 60 watt DC 42V, 90 watt 18V, DC 65 wattDimensions (l x w x h) mm 520 x 240 x 360 520 x 240 x 360 520 x 240 x 360Weight (w/o spool) 20 Kg. (Approx.) 20 Kg. (Approx.) 20 Kg. (approx.)Construction of Wirefeeder Close type Close type Close type

SR. NO. MODEL

WIRE FEEDERS01 UNIFEED-20 (FD)02 UNIFEED-20 (FE)03 UNIFEED-20 (PD)04 UNIFEED-20 (PE)05 UNIFEED-40 (FD)06 UNIFEED-40 (FE) 07 UNIFEED-20 (FD-AWL) 08 UNIFEED-20 (FE-AWL) 09 UNIFEED-40 (FD-AWL) 10 UNIFEED-40 (FE-AWL) 11 (F) WF-20 with Euro end connection 12 (F) WF-20 with AWL end connection 13 (PD) WF-20 with AWL end connection 14 WF-20 (PE) with Euro end connection 15 WF-40 (F) with Euro end connection 16 WF-40 (F) with AWL end connection

SR. NO. MODEL PRODUCT CODEMAGNA RETROFIT WIRE FEEDERS

01 FEEDLITE-20 (FD) RT02 FEEDLITE-20 (FE) RT03 FEEDLITE-40 (FD) RT04 FEEDLITE-40 (FE) RT

SALIENT FEATURES

• ••••••

Reliable permanent magnet motor which works years together without any maintenanceLong life of carbon brushes - hence least maintenanceTotally enclosed motorWire feeder is ruggedly designed to work under demanding shopfloorconditionsThyristorised DC drive for speed control which ensures smooth & pre-cise wire feedingQuick change mechanism for ease & convenience in changing wire size Two track/four track facilityIn-built feature of spot welding timer


Note :• FE - with Euro Connector & PMDC motor • PE - with Euro Connector & PCB / Servo motor• FD - with Standard AWL Connector & PMDC motor • PD - with Standard AWL Connector & PCB / Servo motor

S15.01.001.0528

PRODUCT CODE

S15.01.001.0529S15.01.001.0323S15.01.001.0324

S15.01.001.0531S15.01.001.0532S15.01.001.0533S15.01.001.0534S15.01.001.0535S15.01.001.0524S15.01.001.0525S15.01.001.0325S15.01.001.0326S15.01.001.0526S15.01.001.0527

S15.01.001.0522S15.01.001.0523S15.01.001.0520S15.01.001.0521

S15.01.001.0530

1.2 to 18 M/Min

RETROFIT WIREFEEDERS-UNIFEED / WF SERIES



MIG-WIRE FEEDERS

45



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WELDING ACCESSORIES

RETROFIT OF SAW WEDLING HEAD WH 15 (F)

APPLICATIONS

• This retrofit box is recommended for interphasing standard SAW welding head WH 15 (F), with AWL make old SAW power source CPR-1204/CPR-1205 and PS 1200(T) available with customer

• This is the ideal solution for replacing old SAW head model UP 15CP with new SAW welding head WH 15 (F)

SALIENT FEATURES

• Economical solution for using old SAW welding power sources available with customer, which otherwise are not useful, since old SAW welding head is beyond repairs

• Saves cost of SAW power source since new power source is not required

RETROFIT OF SAW WEDLING HEADMODEL-WH 15 (F) WITH CPR 1204 / CPR 1205 POWER SOURCES FROM OLD ADORSUBARC SERIES OUTFITS

RETROFIT HEAD WH 15 (F)

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APPLICATIONS

• Mechanised attachement is ideally recommended for mechanised GMAW / FCAW / SAW welding processes using existing MIG outfits available with users for fabrication of medium thickness structural/vessel/cylindrical jobs

SALIENT FEATURES

• Mechanised attachement is ideally recommended for mechanised GMAW / FCAW / SAW welding processes using existing MIG outfits available with users for fabrication of medium thickness structural /vessel/cylindrical jobs

• Optimum use of existing MIG welding machines

• Economical - Minimum investment since there is no need to buy complete SAW outfit

• Flexibility in machine utilization for GMAW/FCAW and SAW welding processes

• Increased welding productivity wherever possible, by using SAW welding process instead of GMAW or FCAW process

• Increase in welding productivity even in GMAW/FCAW welding process by using mechanized MIG torch travel instead of manual MIG torch travel used in semiautomatic GMAW/FCAW welding

WELDING ACCESSORIES

MECHANISED ATTACHMENT - MIG / SAW WELDING


PARAMETER UNIT

Amp 600

Amp 465

1.2/1.6/2.0

Welding current @ 60%

Welding current @ 100%

Suitable for wire dia mm

mtr/min 1.2 - 18

Carriage speed mtr/min 0.1 - 1.5

Vertical adjustment mm 140

Transverse adjustmnet (Horizontal) 140

Swivel-

Transverse to head travel degree 45

Parallel to head travel degree 30

Horizontal open swing degree 270

Weight of spool Kg 15

Flux hopper capacity Kg/Ltr 10/7


Total weight (without wire and flux) Kg 95

Wirfeed speed

mm

VALUE

COMBO MS 600 - MECHANISED ATTACHMENT



47(Formerly Known as Advani-Oerlikon Ltd.)

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ADOR ARC-ON

WELDING ACCESSORIES


SR. NO. PARAMETERS SPECIFICATIONS

1 Input Supply 100-30V DC

Directly Works on Welding output Voltage

2Maximum ARC On Time Measurement from the instant of Reset

999 Hours 99 minutes and 59 sec

3Maximum Cumulative Time measurement from the time of Installation

99999 Hours 99 minutes

4 Dimensions in mms (LxWxH) 130 x 165x 80

5 Weight (kg.) 1.0

SALIENT FEATURES

•

•

•

•

•

•

•

Easy to install, can be mounted inside or outside the machine depending on users choice.

It shows present arc on time from the instant of reset as well as total cumulative time from the installation of instrument.

Password protection for resetting the arc on time measured..

No external power supply is required. Works on welding output voltage.

Memory facility is available to store the arc on time counts.

User friendly password setup as well as password reset facility.

Maximum count is 999 hrs 99 min. and 59 Sec. from the instant of reset and cumulative can be 99999 hrs 99 min.

CONNECTION DIAGRAM

ARC ON TIME MEASURING INSTRUMENT

48(Formerly Known as Advani-Oerlikon Ltd.)

www.adorwelding.com

SALIENT FEATURES

•

•

•

•

•

•

Safe voltage to protect from electric shock when welding is not going on.

Instant Start of welding operation

Reduction in machine heating

Compact assembly.

Easy for mounting.

Welding performance unaffected

WELDING ACCESSORIES

ENERGY SAVING DEVICE (WELDING RECTIFIER)

APPLICATIONS

• Energy Saving application.

• Confined Spaces such as vessels, mine shafts

• Wet or damp conditions.

• Hot and humid conditions.

• Working at heights.


1. Input Supply.

415V AC, 1- Ph, 50Hz

3.Adjustab (100msec-5 minute)

– factory set value is 3 minute.le by trimmer on PCB

2.

Voltage across welding terminals at which machine switch to Energy Saving Mode. <12V & >50V

4.No load voltage at OCV terminal (Voltage reducing / Energy Saving Mode). Between 10.0 -11.5 Vdc

WIRING DIAGRAM ENERGY SAVER UNIT

ENERGY BILL SAVING DUE TO ENERGY SAVER

For 400A Thyroluxe or CHOPREC machine No load power = 0.35kWMachine is continuously ON for 24 Hour a day.Out of 24 hours ,if the arc time is 33% then non arc time (No load condition) per day = 16 Hours.Hence with energy saving device the energy saved per day = 16 Hr. x 0.35 kW

= 5.6kWhr.Saving on Energy Bill per day = Rs. 5.5 x 5.6 = Rs. 31Yearly saving (On an average for 300 working days/year) = Rs. 31 x 300

= Rs. 9300

Time to switch to Energy Saving Mode.

INTRODUCTION:

About Energy Saving cum Voltage reducing device and its working principle:

In a Welding rectifier, the primary winding of the transformer is always energized. Even if welding is not going on, the machine always draws some current from the supply to meet the no load losses. Although arc welding can be performed safely, there are circumstances where there is a substantial risk of electric shock where workers need to weld in tight areas where heat and humidity can be a factor. The severity of the shock received when a person becomes part of an electric circuit is affected by several factors.

These include:

1) The amount of current flowing through the body of the person.

2) The path of the current through the body, and the length of time the body is in the circuit.

3) The current level (measured in mA, milli-amperes) is a function of both the voltage at the electrodes and the resistance of the person's body.

This energy saving cum voltage reducing device is designed to operate on any constant DC current welding machine (stick welder) with an open circuit voltage of 60 - 100 volts. Until the arc is struck the output voltage is maintained lesser than 12 volts. This prevents the operator from receiving a shock. Also the input supply to primary of transformer is cut when the output voltage is 12V, hence there is no power loss during this idle condition. Thus it performs energy saving action.

This device is connected between the input supply of the welding rectifier and it continuously monitor the welding output terminal voltage. On striking the arc, full selected output is available instantaneously. Energy saving cum voltage reducing device senses the stoppage in welding and cuts off the supply to the primary winding within the predetermined time (approx. 100mili-second to 5 minute) and safe voltage of 12 Volts will be appeared on the Welding terminals until the next arc strike. This device reenergizes the primary winding instantly without affecting the welding quality as soon as the electrode comes in contact with the job.

ENERGY SAVING CUM VOLTAGE REDUCER DEVICE FOR WELDING RECTIFIER



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WELDING AUTOMATION

PRODUCTS & SYSTEMS (WAPS)

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WELDING AUTOMATION


www.adorwelding.com

WELDING AUTOMATION


COLUMNS & BOOMSSystems ranging from 2020 to 6060 in various permutations and combinationsAPPLICATIONS• The range of Columns and Booms offered by ADOR are ideally recommended for manipulating /

positioning of welding head to facilitate SAW and MIG/MAG welding processes of long and circumferential seams of tanks, barrels / shells pressure vessels, process equipments, tubular components etc

• Ideally recommended for enhancing productivity with quality for repetitive jobs in heavy equipment fabrication/manufacturing industries, Railway workshops, shipyards, steel plants, process equipment manufacturers for sugar mills, cement and fertiliser plants etc

COLUMNS & BOOMS

WELDING AUTOMATION PRODUCTS & SYSTEMS (WAPS)

SALIENT FEATURES• Robust design and construction, accurately machined guides for both vertical and horizontal

travel for longer service life and minimum maintenance• Boom payload capacity of 250 Kgs• Base of column: Pedestal or Trolley type• 360 degree manual rotation of the column ensure 360 degree radial accessibility to

welding head, conveying vast area in shop• Fixed speed AC motor drive for vertical lift of the boom with lift speed of

750mm/min or 1000 mm/min depending on application• Variable speed horizontal boom travel using VFD drives with horizontal

speed infinitely variable from 150 to 1500mm/min• Anti-fall safety mechanism in case of chain failure• Roller bearings with eccentric pin mounting for easy adjustment of guiding pressure.• Electrical and mechanical limiting mechanism against overriding• Precise jerk free vertical & horizontal movement • Extra optional features like seam tracking / oscillation, twin wire feed drive for

SAW welding, mini flux recovery unit, grinding/buffing attachments can be provided on welding head depending on application requirement

• Over rated, pre-loaded & dust protected bearing arrangement• Trolley car mounted version gives accessibility to full shop length• Assure high quality welding with non-dependent on operator skills

Model Stroke (mm)

Stroke (mm) “C”Minimum “A” Maximum “B”

Length“L”

Width“W’

Height“H”

CBM 2020(P) 2000 2000 850 2850 4000 1800 3750 N.A.

CBM 2020(T) 2000 2000 875 2875 4000 1800 3775 1000

CBM 2525(P) 2500 2500 850 3350 4500 1800 4250 N.A.

CBM 2525(T) 2500 2500 875 3375 4500 1800

4275

1000

CBM 3030(P) 3000 3000 1100 4100 5300 2100 5000 N.A.

CBM 3030(T) 3000 3000 1150 4150 5300 2100 5050 1440

CBM 4040(P) 4000 4000 1200

5200

6700 2500

6100

N.A.

CBM 4040(T) 4000 4000 1250 5250 6700 2500 6150 1440

CBM 5050(P) 5000 5000 1200 6200 7700 2500 7100 N.A.

CBM 5050(T) 5000 5000 1250 6250 7700 2500 7150 1600

CBM 6060(P) 6000 6000 1300 7300 8700 2500 8200 N.A.

CBM 6060(T) 6000 6000 1350 7350 8700 2500 8250 1600

NOTE1 In view of continuous development, we reserve the right to modify the design & dimensions without notice.2 Any model not mentioned here can be designed manufactured & supplied as per the customer requirement.

Rail

TECHNICAL SPECIFICATIONS

Vertical Horizontal Height Under Boom (mm) Over all Dimension (mm) Inner dist between

OPTIONAL FEATURES • Integration of control panel with welding head, seam tracker, FRU etc• Slewing ring for the Column rotation, instead of TR Bearings• CCTV camera feedback system for controlling of welding head location • Operator chair, walkway for all models of C&B

from ground level• Motorized column swivelling from 0 to 360 degree

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www.adorwelding.com

WELDING AUTOMATION




www.adorwelding.com

POSITIONERSModels range from 50 kgs to 30,000 kgs

APPLICATIONS• The range of Welding Positioners offered by ADOR are ideally recommended for

manipulating/rotating/ positioning of round or cylindrical jobs to facilitate SAW and MIG/MAG welding processes of tanks, barrels/shells, process equipments, round/tubular components etc

SALIENT FEATURES• All wedling positioners are designed for longer service life and trouble free operation• The main frame is rugged fabricated structure supporting all other subassemblies and

designed for free standing in unloaded condition • The work table is mounted on antifriction bearing arrangement and especially designed to take

overhung loads • The work table is provided with T slots for clamping of work or workholding fixtures• The work table rotation is by a drive mechanism using AC motor, precision cut gears and

worm reduction gearbox • The tilt drive mechnism allows the work table to be positioned and locked at the desired

angle within the specification of the positioner• The positioner is also provided with a special direct earthing arrangement which prevents

the return current from passing through the bearing, shaft gear or gears• Mechanical stoppers in case of limit switch failure• Once the job is loaded it can be manipulated conveniently to complete all the welding

operation in down hand position. This reduce handling time & frequent use of crane• Positioner can be conveniently used for complete circumferential welding, strip cladding for

down hand position welding to set the job conveniently for easy accessibility to intricate assemblies etc along with CBM, a positioner can carry out any welding tasks which are impossible otherwise


POSITIONERS

ModelWPL

50WPL 100

WPM 250

WPM 500

WPH 1000

WPH 2000

WPH 3000

WPH 5000

WPH 8000

WPH 10000

WPH 15000

WPH 20000

WPH 30000

Capacity in all position (Kg) 50 100 250 500 1000 2000 3000 5000 8000 10000 15000 20000 30000

Face plate OD " ФD " (mm) 300 500 600 750 1000 1200 1400 1600 1800 2200 2400 2800 2800

Eccentricity " E "(mm) 40 40 100 150 150 150 150 150 150 200 250 300 300

C.G. (mm) 40 40 100 150 150 200 250 300 300 300 300 300 300

Speed Range (RPM) 0.45 to 8.4 0.1 to 1.5 0.1 to 1.0 0.02 to 0.2 0.02 to 0.25 0.01 to 0.15

Tiltin range (Degree)

+ 60 to -120 0 to 135

Tilting Speed (Sec)

Manual 60 60 90 90 120 120 150 150 150 180 180

Overall Length "L" (mm) 580 580 1100 1300 1400 1600 1700 2200 2300 2700 2900 3400 3700

Overall Width "W" (mm) 590 590 680 900 1100 1250 1500 1750 1900 2300 2500 3200 3200

Overall Height "H" (mm) 500 500 900 1000 1000 1050 1300 1400 1500 1750 2200 2650 2650


OTHER OPTION• Head stock- tail stock setup• Elevating type positioners.• Turn tables


OPTIONAL FEATURES• Face plate diameters more than standard version can be provided against specific

requirement• External arms required to accommodate increase diameter• A.C. variable frequency drive for tilt drive• Optional walkway/ platform at rear side of positioner can be provided• Table rotation start/ stop controls can be given on foot switch




50

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WELDING AUTOMATION


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WR SERIESWR Models 5T to 150T


ROTATORS

APPLICATIONS

• The range of Rotators offered by ADOR are ideally recommended for manipulating/rotating/ positioning of round or cylindrical jobs to facilitate SAW and MIG/MAG welding processes of long and circumferential seams of tanks, barrels/shells, pressure vessels, process equipments, tubular components etc

• Three types (i.e. WR/RSCLA/SAR) of rotators are available for different applications and requirement of rotating and handling of jobs

WELDING ROTATORS

Model Turning Capacity

(Ton)

Load Capacity per unit

(Ton)

Shell Diameter (mm) Over all dimension of Drive & Idler Unit (mm)

Minimum "d"

Maximum "D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T

20

10

450

4500

2850 2650 650

525

610

WR 30 T

30

15

500 5000

3100 2900 700

525 690

WR 40 T

40

20

3175 2975 800

600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100 50 3900 3500 1200 950 910

WR 120 T

120 60

800

6500

4150 3750 1250 950 1010

WR 150 T 150 75 4250 3850 1250 975 1110

SALIENT FEATURES OF WR (Manual Indexing) TYPES

• All Rotators are designed for longer service life and trouble free Operation

• Typically Rotator set consists of one drive unit and one idler unit

• Surface speed sleeplessly variable from 150 to 1500 mm/min

• Speed regulation through VFD drive system

• Forward and reverse rotation along with inching facility provided

• Overload discs are provided (if required) to protect polyurethane wheels from Rupturing

• Pendant control for forwards, reverse and stop push button operation

• Roller bracket to have to be manually moved as per the job diameter

• The fixing holes for the bracket on the bed are precisely factory set

• Ideal version to start with new fabrication line



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ROTATORS

APPLICATIONS



WELDING ROTATORS


(Ton)


(Ton)


Minimum "d"

Maximum "D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T

20

10

450

4500

2850 2650 650

525

610

WR 30 T

30

15

500 5000

3100 2900 700

525 690

WR 40 T

40

20

3175 2975 800

600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100 50 3900 3500 1200 950 910

WR 120 T

120 60

800

6500

4150 3750 1250 950 1010

WR 150 T 150 75 4250 3850 1250 975 1110
















52



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RSCLA TYPES (Self centering lead screw adjustment type) RSCLA Models 5T to 150T

ROTATORS

SALIENT FEATURES

• All rotators are designed for longer service life and trouble free operation• Torque free axle shaft enables easy maintenance and easy replacement of worn out wheels• Optimum positioning of jobs possible since wheel distance adjustment is infinitely variable• Gear drive system is spur type which reduces the friction losses• LH-RH lead screw arrangement allows the wheels to move simultaneously either towards or away from each other• Surface speed sleeplessly variable from 150 to 1500 mm/min• Speed regulation through VFD drive system• Forward and reverse rotation along with inching facility provided• Overload discs are provided, (if required) to protect polyurethane wheels from rupturing• Pendant control for forwards, reverse and stop push button operation


Model Turning

Capacity (Ton)


(Ton)


Minimum "d"

Maximum

"D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T 20 10 450 4500 2850 2650 650 525 610

WR 30 T 30 15

500

5000

3100 2900 700 525 690

WR 40 T 40 20 3175 2975 800 600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100

50

3900

3500 1200

950

910

WR 120 T

120

60 800 6500

4150 3750 1250 950

1010

WR 150 T 150 75 4250 3850 1250 975 1110






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ROTATORS

APPLICATIONS



WELDING ROTATORS


(Ton)


(Ton)


Minimum "d"

Maximum "D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T

20

10

450

4500

2850 2650 650

525

610

WR 30 T

30

15

500 5000

3100 2900 700

525 690

WR 40 T

40

20

3175 2975 800

600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100 50 3900 3500 1200 950 910

WR 120 T

120 60

800

6500

4150 3750 1250 950 1010

WR 150 T 150 75 4250 3850 1250 975 1110

















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ROTATORS

SALIENT FEATURES



Model Turning

Capacity (Ton)


(Ton)


Minimum "d"

Maximum

"D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T 20 10 450 4500 2850 2650 650 525 610

WR 30 T 30 15

500

5000

3100 2900 700 525 690

WR 40 T 40 20 3175 2975 800 600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100

50

3900

3500 1200

950

910

WR 120 T

120

60 800 6500

4150 3750 1250 950

1010

WR 150 T 150 75 4250 3850 1250 975 1110





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ROTATORS

SALIENT FEATURES



Model Turning

Capacity (Ton)


(Ton)


Minimum "d"

Maximum

"D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

WR 5T 5 2.5 400 4000

2500 2300 500 400 515

WR 10T 10 5 2600 2400 625 500 610

WR 20 T 20 10 450 4500 2850 2650 650 525 610

WR 30 T 30 15

500

5000

3100 2900 700 525 690

WR 40 T 40 20 3175 2975 800 600 750

WR 50 T 50 25 3200 3000 800 650 800

WR 60 T 60 30

600 6000

3750 3500 850 700 800

WR 80 T 80 40 3750 3500 1100 900 910

WR 100 T 100

50

3900

3500 1200

950

910

WR 120 T

120

60 800 6500

4150 3750 1250 950

1010

WR 150 T 150 75 4250 3850 1250 975 1110





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SAR TYPES (SELF ALIGNING TYPES) SAR Models 10T to 30T

SALIENT FEATURES

• All rotators are designed for longer service life and trouble free operation• Each unit is provided with pairs of rollers mounted on pivoted bracket,

which self align with each other to suit different job diameters• These rotators enhances shop floor productivity, since the self aligning

arrangement permits the roller brackets to align themselves to vessel or job loading, without any pre-adjustments

• Surface speed stepless variable from 150 to 1500 mm/min• Speed regulation through VFD drive system• Forward and reverse rotation along with inching facility provided• Overload discs are provided (if required) to protect polyurethane wheels

from rupturing• Pendant control for forwards, reverse and stop push button operation• Accepts complete range of job in one or two setting

ROTATORS


Model

Turning Capacity

(Ton)

Load Capacity

(Ton)


Minimum "d"

Maximum "D"

Drive Length

"L"

Idler Length

"L1"

Drive Width "W"

Idler Width "W1"

Height "H"

SAR 5T 5 T 2.5 400 2500 2250 2050 500 350 890

SAR 10T 10 T 5 400 3000 2700 2200 550 400 980

SAR 20 T 20 T 10 500 4000 2700 2200 700 500 1050

SAR 30 T 30 T 15 500 4000 2800 2300 800 500 1055

SAR 40 T 40 T 20 600 5000 3000 2300 800 550 1150

SAR 50 T 50 T 25 600 5000 3000 3000 800 550 1200

SAR 60 T 60 T 30 800 5500 3000 2300 900 600 1200

SAR 80 T 80 T 40 900 6000 3050 2300 1100 750 1210

SAR 100 T 100 T 50 900 6000 3300 2650 1150 800 1260

SAR 120 T 120 T

60

1000

6000

3350 2700 1300

850

1370

SAR 150 T 150 T 75 1000 6500 4400 3500 1400 900 1530


OPTIONAL FEATURES FOR ALL ABOVE ROTATOR MODELS:

• Extra features like hardened steel rollers, extra idlers for longer job lengths, foot control switch, and radio remote control unit can be provided optionally at extra cost

• All type of Rotator can be designed/ supplied with either manual or motorized trolley

• The rotation lead screw in case of RSCLA can be made motorized.• Higher diameter range for the entire Rotators model• Height adjustment for idler to accommodate the taper pole/ taper job in

case of wind tower application• Anti-drift arrangement for all Rotator which is the method of opposing

axial drift of cylindrical work pieces available in manual/ automatic version (Drift control range: +/- 1 mm)

“IDLER UNIT”

ØD Ød

“ L1 ” “ W1 ”

H

ØD

Ød

“H”

“W”“L”

“DRIVE UNIT”




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AUTOMATED ORBITAL WELDING SYSTEMS FOR TUBES, PIPES & TUBESHEETSFROM AMI, USA

SPECIAL WELDING SYSTEMS IN CO-OPERATION WITH AMET-USA, FOR SPECIFIC HIGH END APPLICATIONS

APPLICATIONS

• Microprocessor and CNC controller welding system with advanced Digital Signal Processing (DSP) for providing consistent quality and repeatability

• Aerospace: Cariable Polarity Welding systems with special welding head & manipulator system

• Nuclear : Fuel Rods, Nuclear Battery, Underwater testing facility etc

• Oil & Gas / Petrochemicals.: Hot wire Valve body welding & cladding, matrix drill, Sub-sea cladding etc

• Stainless Steel Fabrication : Dual Arc process for Polar Tank, Brenner Tank etc

• Wind Tower Production : Linear Seam & Circumferential joints

ORBITAL WELDING SYSTEMS

• Orbital tube to tube sheet Weld head / Power source combinations are Model 96 / Model 6 and Model 227 - Model 96 is fusion type tube to tube sheet weld head for flush types for thin tubes upto 3 mm wall thickness - Model 6 is tube to tube sheet weld head for projected joints with filler wire and auto height adjustment (AVC control). The locating

fixture helps for easy and fast locating of weld head. The key advantage of the weld head is that it can weld across the centre line

• Specialised Orbital weld heads-Custom designed for specific applications-AAMI is also capable to design and engineer & design any special weld head that may be required to do uncommon welds like ID weld repair of a 2" pipe at 5m inside from the end, or specially designed weld head for welding remotely the containment chamber for nuclear spent fuel.

Model -96 WeldHead Model -6 WeldHead Model -227 Powersource

Nuclear Fuel Rods WeldingAluminium Fuel Tank fabrication


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AMET MANUFACTURING & ENGINEERING SOLUTIONS

Under water testing facility. ID Cladding with intelligent controls

Narrow Gap SAW Welding with AC/ DC Tandem head

Long Seamer with GTAW application for Titanium Shells

Some more applications


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SPECIAL PURPOSE WELDING SYSTEMS


These special purpose welding systems are custom designed for jobs like Plus Beam, Star Beam and H-Beam of different sections, shells, barrels, idler rollers, axles etc.

2” to 6” OD PIPE WELDING SPECIAL PURPOSE MACHINE


SQUARE AXLE WELDING MACHINE L SEAM WELDING SPM

CIR SEAM WELDING SPM





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HYBRID PLASMA MIG WELDING

ADOR-PLT SUPER-MIG® SYSTEM

• combining two reliable standard welding processes, Plasma arc and MIG arc, into one hybrid process.

• The Super-MIG® process is capable of replacing and improving most standard MIG, SAW or Plasma/TIG, as well as many other applications (i.e. true lap welds-continuous or stitch/spot configurations).

• The advanced Plasma Technology of PLT is integrated with ADOR's Advanced MIG Inverters to provide a superior and advanced technology to replace / enhance the manufacturing (welding) process capabilities in the highly automated process industries

• This association will ensure that the customers get the best of support in terms of training, spares and services. Ador will provide the integration service of this new system into the user's expansion plan for Robotic/Hard Automation system to harness the benefits of this superior product line.

The Super-MIG® system is a new, innovative robotic welding technology developed by

HYBRID PLASMA MIG WELDING

Super MIG Welding Snapshots

Plasma Controller Torch Torch Cleaning Device

Super-MIG® Benefits vs. Standard MIG/MAG• • Maintains high welding speeds under variable gap conditions• Capable of producing true lap welds; continuous or stitch/spot configurations• Reduced part distortion due to a narrower Heat Affected Zone• Meets same weld specs. as standard MIG/MAG• Higher quality of welds for the same range of weldable materials• Significant reduction in weld spatter

Higher welding speeds (2-3 times faster than MIG) and penetration (by +50%)




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ROBOTICS WELDING SOLUTIONS

ADOR introduces Robotic Welding Automation Solution with ABB Robots in India.


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ROBOSTUDIO SOFTWARE: - WELDING USING ROBOT WITH A ROTARY POSITIONER

ROBOSTUDIO SOFTWARE WORKPIECE POSITIONERS FOR ARC WELDING

Robotics:In order to widen it's horizons, Ador Welding Ltd has added a new feather to it's cap by including "Automated welding with Robots" in it's existing solution range of WAPS. Ador is all geared up to give the ultimate solution in welding against demand of productivity, quality & repeatability. A robot has been installed to showcase & demonstrate automated welding on components using 7 or 8 axis motion.




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ADOR introduces Robotic Welding Automation Solution with ABB Robots in India.





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[email protected] / [email protected]

Bharat Nirman is a far-reaching Nation building plan launched by the Central Government with the aim of developing critical infrastructure, including transportation,

energy, ports, telecommunication, urban infrastructure etc.

For every infrastructure project, welding is a vital component. As India's pioneers in welding for over a century, Ador, through its educational thrust Ador Welding Academy Pvt. Ltd. (AWA) will play a crucial role in empowering India.

Empowering Welding. Empowering Bharat.

Welding for Bharat Nirman

OVER SIX DECADES OF

KNOWLEDGE, TECHNOLOGY & EDUCATION

MIS

SION - W

BN

www.adorwelding.com

Ador Welding Academy Pvt. Ltd.

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