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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR
EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANU--
FACTURER’S HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from
your breathing zone and the general area.
ARC RAYS -- Can injure eyes and b u rn skin
S Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
NOISE -- Excessive no ise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION
S Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE OPERATING MANUAL
BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
SAFETY
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SAFETY
Users of ESAB welding equipment have u ltim ate responsibility for ensuring that any-
one who works on or near the equipment observes all the relevant safety precau-
tions.
Safety precautions must meet the requirements that apply to this type of welding
equipment.
The following recommendations should be observed in addition to the standard re-
gulations that apply to the work place.
All work m ust b e carried out by trained personnel who are familiar with the operation
of the welding equipment.
Incorrect operation of the equipment may lead to a hazardous situation which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment m u st be familiar with:
S its operation
S the location of emergency stops
S its function
S relevant safety precautions
S welding
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment
when it is started up.
S that no--one is unprotected when the arc is struck
3. The work place must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety
glasses, flame--proof clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified
electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close
at hand.
S Lubrication and maintenance must not be carried out on the equipment dur-
ing its operation.
TECHNICAL DESCRIPTION
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TECHNICAL DESCRIPTION
The A 21 PRI is designed for automatic TIG welding of pipe joints. The pipe welding
tool is intended for use with the PROTIG 315 (cooling unit included).
The A21 PRI series of tools incorporates a wire feed unit and wire reel and can be
used on pipes in the following diameter range:
PRI 36--80 For pipe diameters 36--80 mm
PRI 70--160 For pipe diameters 70--160 mm
PRI 140--220 For pipe diameters 140--220 mm
The following versions are also available for each diameter range:
PRI with floating welding head
PRI with AVC (automatic arc length control through regulation of arc voltage).
PRI with AVC and weaveing
The tools use a gripping mechanism patented by ESAB which allows quick and
accurate positioning of the tool on the pipe. During welding the only part that rotates
is the open gear ring and associated components
The gear ring is driven by a drive unit consisting of a permanent magnet DC motor
which incorporates a planetary gear arrangement. A tachometer generator and feed-
back system is used to achieve the required degree of accuracy of control over rota-
tion speed.
The drive unit drives a pair of cogs which in turn drive the gear ring. The gear ring
can be disengaged.
The weaving action is produced by a ball screw, driven by a geared--down DC motor.
The motor is equipped with a tachometer generator for signal feedback.
On the AVC version the arc length is kept constant by control equipment that is regu-
lated by the output voltage. In other words the arc length is controlled by the voltage
drop across the arc. The electrode gap is adjusted by a DC motor with gears.
TECHNICAL DESCRIPTION
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TECHNICAL DATA
Common data
Rotation
Max. rotor voltage 24 V DC
Max. rotor current 0,5 A DC
Rotor speed at 20 volt 3000 r.p.m.
Gear ratio 91.12:1
Tachometer generator 1.8 V at 3000 r.p.m.
Weave
Max. rotor voltage 48 V DC
Max. rotor current 0.64 A DC
Rotor speed at 48 volt 5500 r.p.m.
Gear ratio 12:1
Max. weave speed 10 mm/s
Min. weave speed 1 mm/s
Setting range 16 mm
Amplitude +/-- 5 mm
Tachometer generator 3.5 V at 5000 r.p.m.
Arc voltage control
Max. rotor voltage 24 V DC
Max. rotor current 60 mA DC
Rotor speed at 10 volt 1700 r.p.m.
Gear ratio 450.6:1
Normal response rate 2.3 mm/s at 10 V
Max. response rate 6.0 mm/s at 24 V
Min. response rate 0.9 mm/s at 4 V
TECHNICAL DESCRIPTION
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Wire feed
Motor, rotor voltage 24 V
Rotor current 0.116 A
Max. speed 8000 r.p.m.
Tachometer generator 1.5 mV/r.p.m.
Min. load resistance, tacho 25 kW
Gear ratio 246:1
Filler wire, diameter
S Steel
S Aluminium
0.8 mm
1.0 mm
Additional data
PRI 36--80 PRI 70 --160 PRI 140 --220
For pipe with outer diameter (mm) 36--80 70--160 140--220
Speed of rotation (r.p.m.) 0.1--1.3 0.04--0.62 0.03--0.57
Max. welding current (A) at 60%
duty cycle
250 250 250
Electrode diameter (mm) 2.4 (1.6) 2.4 (1.6) 2.4 (1.6)
Weight, excl. connecting cables
(kg)
5.9 13.3 16.8
Continuous A--weighted noise level
(dB)
68 68 68
Order number
PRI 36--80 PRI 70 --160 PRI 140 --220
With floating head 442 296--880 442 297--880 442 298--880
With AVC 442 154--880 442 155--880 442 156--880
With AVC and weave unit 442 158--880 442 159--880 442 160--880
OPERATION
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OPERATION
1. Adjust the pipe diameter using the knob (1).
2. Open the tool using the locking lever (2).
3. Reduce the set diameter by tightening the knob (1) one quarter of a turn.
4. Lock the tool on the pipe using the locking lever (2).
5. Free the gear ring using the lever (3) and rotate the gear ring about 1.5 turns in
the direction opposite to the welding direction.
6. Adjust the height and transverse position of the electrode.
7. Set the welding parameters and begin welding.
8. Remove the tool from the pipe by freeing the gear ring, turning it to allow re-
moval and releasing the locking lever.
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OPERATION
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9. Reel holder (4)
S In order to minimise the external dimensions of
the tool for welding in restricted spaces the reel
holder is designed so that it can be tilted in towards
the centre once the tool is mounted on the pipe.
It has three click settings and a range of coarse
adjustment. If the 100 mm outer diameter of the
standard reel is too large, wind the wire on the
smaller reel (D=50 mm).
S File the tip of the wire carefully before feeding
through. If it is still difficult to feed the wire
through, reduce the pressure on the pressure
roller using the adjuster screw (5), but make sure
that sufficient feed pressure remains.
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MAINTENANCE
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MAINTENANCE
WARNING!
Rotating parts can cause injury, take great care.
1. Regularly lubricate all sliding surfaces with
Molycote G Rapid Paste.
2. Check all hoses and hose couplings for leaks
or damage.
3. When cleaning the area around the feed roller,
swing the pressure roller aside by removing the
bolt (6), spring and washers.
4. To remove or replace the feed roller, undo the two
bolts (7).
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