Valid for serial no. 3060444 292 001 2006--02--15
A21 PRH 3-12
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Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
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Instrukcja obs³ugi
-- 2 --
Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
Zastrzegamy sobie prawo do wprowadzenia zmian.
SVENSKA 5..............................................
DANSK 21................................................
NORSK 37................................................
SUOMI 53................................................
ENGLISH 69..............................................
DEUTSCH 85.............................................
FRANÇAIS 102.............................................
NEDERLANDS 118.........................................
ESPAÑOL 135..............................................
ITALIANO 152..............................................
PORTUGUÊS 169..........................................
ÅËËÇÍÉÊÁ 186.............................................
POLSKI 203.................................................
3
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
Esab Welding Equipment AB, 695 81 Laxå, Sverige, försäkrar under eget ansvar att
rörsvetsverktyg A21 PRH 3-12 från serienummer 306 är i överensstämmelse med
standard EN 60292 enligt villkoren i direktiv ( 89/392/EEG) med tillägg (93/68/EEG).
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OVERENSSTEMMELSEERKLÆRING
Esab Welding Equipment AB, 695 81 Laxå, Sverige, erklærer på eget ansvar, at
rørsvejseværktøj A21 PRH 3-12 fra serienummer 306 er i overensstemmelse m ed
standarden EN 60292 ifølge betingelserne i direktiv (89/392/EØF) m e d tillæg
(93/68/EØF).
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FORSIKRING OM SAMSVAR
Esab Welding Equipment AB, 695 81 Laxå, Sverige, forsikrer på eget ansvar at rø r s-
veiseverktøy A21 PRH 3-12 fra serienummer 306 er i overensstemmelse m ed stan -
dard EN 60292 i følge vilkårene i direktiv (89/392/EF) med tillegg (93/68/EF) .
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VAATIMUSTENMUKAISUUSVAKUUTUS
Esab Welding Equipment AB, 695 81 Laxå, Ruots, vakuuttaa omalla vastuullaan, et-
tä putkihitsaustyökalu A21 PRH 3-12 alkaen sarjanumerosta 306 täyttää standardin
EN 60292 vaatimukset direktiivin (89/392/ETY) ja sen lisäysten (93/68/ETY).
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DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, declares that tube welding tool
A21 PRH 3-12 from serial number 306 onwards, conforms to standard EN 60292, in
accordance with the requirements of directive (89/392/EEC) and appendix
(93/68/EEC).
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KONFORMITÄTSERKLÄRUNG
Esab Welding Equipment AB, 695 81 Laxå Schweden, bestätigt hiermit in Eigenver-
antwortung, daß die Rohrschweisswerkzeuge A21 PRH 3-12 ab Seriennummer 306
dem Standard EN 60292 gemäß den Bedingungen der Direktive (89/392/EEG) mit
Zusatz (93/68/EEG).
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CERTIFICAT DE CONFORMITÉ
Esab Welding Equipment AB, S--695 81 Laxå Suède, certifie que l’outil de soudage
de tubes A21 PRH 3-12 à partir du numéro de série 306 est conforme à la norme
EN 60292 selon les conditions de la directive (89/392/CEE) avec additif
(93/68/CEE).
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VERKLARING VAN OVEREENSTEMMING
Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart geheel onder eigen
verantwoordelijkheid dat buizenlasger eedschap A21 PRH 3-12 van het serienum -
mer 306 in overeenstemming is met norm EN 60292 conform de bepalingen in richt-
lijn (89/392/EEG) m et annex (93/68/EEG).
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DECLARACIÓN DE CONFORMIDAD
Esab Welding Equipment AB, S--695 81 Laxå, Suecia, garantiza bajo propia respon-
sabilidad que la herramienta de soldadura de tubos A21 PRH 3-12 a partir del nú-
mero de serie 306 concuerda con la norma EN 60292 conforme a la directiva
(89/392/CEE) con el suplemento (93/68/CEE).
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4
DICHIARAZIONE DI CONFORMITA
Esab Welding Equipment AB, S--695 81 Laxå Svezia, dichiara sotto la propria re-
sponsabilità che le saldatrice per tubi A21 PRH 3-12 con numero di serie a partire
da 306 è conforme alla norma EN 60292 come previsto dalla direttiva (89/392/CEE)
e successive integrazioni (93/68/CEE).
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DECLARAÇÃO DE CONFORMIDADE
Esab Welding Equipment AB, S--695 81 Laxå, Suécia, garante sob responsabilidade
própria que a equipamento de soldadura de tubos A21 PRH 3-12 a partir do núme-
ro de série 306 está em conformidade com a norma EN 60292 segundo os requisi-
tos da directiva (89/392/CEE) com o suplemento (93/68/CEE).
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ÂÅÂÁÉÙÓÇ ÓØÌÖÙÍÉÁÓ
Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, âåâáéþíåé ìå äéêÞ ôçò
åõèýíç oôé ç ðçãÞ óùëçíïêïëëçôÞò A21 PRH 3-12 áðü ôïí áñéèìü óåéñÜò 306
âñßóêåôáé óå óõìöùíßá ìå ôï óôáíôáñô ÅÍ 60292 óýìöùíá ìå ôïõ üñïõò ôçò
ïäçãßáò (89/392/EEC) êáé ôçí ðñïóèÞêç (93/68/EEC).
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ZAPEWNIENIE ZGODNO¦CI Z NORMA
Firma Esab Welding Equipment AB, SE--695 81 Laxå , S zwecja, gwarantuje pod
rygorem odpowiedzialno¶ci, ¿e przyrz±d do spawania rur A21 PRH 3-12 od numeru
seryjnego 306 spe³nia wymagania normy EN 60292 wed³ug dyrektywy (89/392/EEG) z
poprawkami (93/68/EEG).
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Martin Andersson
Manager Control Systems & Software
Automation Products
ESAB AB, Welding Automation
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721
Laxå 2003--05--08
ENGLISH
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TOCe
1SAFETY 70...........................................................
2 INTRODUCTION 72...................................................
2.1 General 72..................................................................
2.2 Technical data 72............................................................
2.3 Main components 73.........................................................
2.4 Description of Main components 74.............................................
3 INSTALLATION 75....................................................
3.1 General 75..................................................................
3.2 Requirements for the place of use 75...........................................
3.3 Storage of the system 75......................................................
3.4 Connections 76..............................................................
3.5 Clamping jaw collets (Cartridge C) 76...........................................
4 OPERATION 77.......................................................
4.1 General 77..................................................................
4.2 Equipment functions 78.......................................................
4.3 Attaching the tube welding tool 80..............................................
4.4 Welding 81..................................................................
4.5 Removing the tube welding tool 81.............................................
5 MAINTENANCE 82....................................................
5.1 General 82..................................................................
5.2 After each 10th weld--seam: 82................................................
5.3 Daily 82.....................................................................
5.4 Weekly 82...................................................................
6 FAULT TRACING 83...................................................
6.1 General 83..................................................................
6.2 Fault--Tracing 83.............................................................
7 ORDERING OF SPARE PARTS 84......................................
ACCESSORIES 220.......................................................
DIMENSION DRAWING 221................................................
SPARE PARTS LIST 223...................................................
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fna1safe
1SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace 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 during operation.
GB
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fna1safe
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ 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 take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn 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 noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB
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2 INTRODUCTION
2.1 General
The A21 PRH 3-12 is an enclosed tube welding tool designed for TIG--welding of
tube joints.
Enclosed here m eans that the tube joint during the welding is surrounded by a
closed chamber in which a gas shield of inert gas protects the tungsten electrode,
the weld joint and the tube from oxidation.
The tube welding tool is clamped onto the the tube--joint by m eans of Welding head
Cartridge A or Welding head Cartridge B.
Welding head Cartridge MF is a cartridge machined for a specific tube size.
When you want to weld a different tube size the whole cartridge is replaced.
Weldin g head Cartridge C is a cartridge with clamping jaw collets.
When you want to weld a different tube size the clamping jaw collets are changed.
The tube welding tools are designed for use together with welding power sources
LTS 160, LTS 250, LTS 320 and LTP 450.
2.2 Technical data
2.2.1 General
PRH 3--12
Max. continuous welding current at
100% duty cycle :
15 A
Max. pulsed welding current: 40 A
Tube outer diameter:
max.
min.
12,7 mm
3mm
Weight: 7kg
Electrode--diameter: 1,0 mm
Electrode adjustment length: 2mm
Rotor--turning-- drive, power, max.: 4W
Rotor--turning-- drive, nominal voltage: 24 VDC
Rotor--speed:
max.
min.
12,6 rpm
0,65 rpm
Control--mode Speed--control by means of pulse transducer
Gas--flow: 4--5 l/min
(A higher gas--flow can damage the weld head.)
Coolant: W ater with Glycol as anti--freeze. Custom Glycol with
corrosion--protection can lead to ignition--problems!
N.B. Cooling water with order no. 0007 810 012
must be used.
Glycol--part : 25–50%
Circulation to be provided externally
Pressure, max. : 3,5 bar
Content of coolant : 0,25 l
Weld head -- housing-- temperature, max. 50 ˚C
N.B. In case of exceeding the permissible housing--
temperature, operation--breaks have to be added for
this weld head.
GB
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2.2.2 Generated noise level
The noise level generated by the system is below 70 dB (A) with oper ating coolant
circulation. The m easurement assumes a distance o f 1 m at a height of 1.6 m.
2.2.3 Electrode s
As electrode--base--material, tungsten is used. To optimize the time of use, we
recommend an electrode--material with 2--4 % Thorium--content.
N.B. Special applications may require different electrode--materials.
Arc--length (distance)
min.
max.
0,8 mm
1,2 mm
Electrode--length: For determination of the electrode--length, please regard 79
Tip-- angle: 30˚
we recommend You break the tip after grinding (see
sketch)
How to make the tip: exclusively by grinding
Direction of grinding: exclusively longitudinal
Recommended tool: ESAB G--Tech Handy or G--Tech
2.3 Main components
1. Weld head
2. Indicating lamp
3. Thumb screws
4. Handle
For a description of the main components
see on page 74.
GB
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2.4 Description of Main components
2.4.1 Weld head
1. Rotor
2. Electrode
3. Cartridge MF
4. Cartridge C
5. Clamping jaw collets
6. Locking screws
Rotor
The rotor is equipped with channels to lead the welding--gas into the welding--
chamber. The rotor is driven around the workpiece during the welding--process with
the preselected, controlled speed.
Electrode
The rotor carries the electrode. See also on page 73.
Cartridge MF
By means of Cartridge MF the tube welding tool is clamped onto the the tube--joint.
The workpiece becomes fixed in working pos ition by closing the upper parts of the
Cartridge and tightening them with the Locking screws (6).
Cartridge C
Cartridge C works as a holder for the clamping jaw collets (5).
The workpieces become fixed in working position by closing the upper parts of the
Cartridge and tightening them with the Locking screws (6).
2.4.2 Indicating lamp
Lights up when the electrode is not in home position.
2.4.3 Thumb screws
By means of the thumb screws the Welding head Cartridge is fixed into position.
2.4.4 Handle
For holding the welding tool.
A vice can also be used for holding the welding head. To avoid damage, this may
only be done carefully at the lower part of the weld head--body.
GB
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3 INSTALLATION
3.1 General
The installatio n must be executed by a profession al.
WARNING
Rotating parts can cause injury, take great care.
3.2 Requirements for the place of use
Place the tube welding tool in a weather--protected location.
Please note the restriction of the relative humidity at 90 % at the place of installation.
Environmental temperature:
S Min. -- 10 ˚C
S Max. + 25 ˚C (at higher temperatures, the duty--cycles must be reduced)
Relative humidity:
S Max. 90 %
3.3 Storage of the system
If the tube welding tool is not to be used for a long period of time remove it and place
in the delivery box.
Make sure that no corrosive conditions can occur during time of storage.
In such cases we recommend humidity--absorbing material for use inside the
delivery--box.
Before storage we recommend the following procedure:
S Clean the weld--head
S Remove all cooling agent.
Attention! Danger of hose-burst!
Never use pressure of more than 3,5 bar on the coolant hoses!
Blow out all the cooling agent inside the system by means of
compressed air into a container.
GB
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3.4 Connections
S Power source LTS 320, see instruction manual 04457 690 xxx.
S Power source LTS 160/ LTS 250, see instruction manual 0458 343 xxx.
S Power source LTP 450, see instruction manual 0456 634 xxx.
Electrical ground connection
The supply of welding --power to the weld--head is ensured by means of the
cable--package. Ground--contacting of the workpiece takes place automatically by
means of the collets.
Please note, that dirt or non--conductive support--items can cause trouble in
operation by losing this contact.
3.5 Clamping jaw collets (Cartridge C)
Adding the collets
S Loosen the locking screws (1).
S Open the top parts of the Cartridge (2).
S Mount the collets ( 3). See on page 78.
S Tighten the screws (4) that fix the collets (3) in place.
Removing the collets
S Loosen the locking screws (1).
S Open the top parts of the Cartridge (2).
S Remove the screw (4).
S Remove the collets (3).
GB
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4 OPERATION
4.1 General
Caution:
Have you read and understood the safety information ?
You must not operate the machine before then !
General safety regulations for the handling of the equipment can be found on
page 70. Read through before you start using the equipment!
Warning! Danger of electric shock!
Do not touch workpiece and/ or weld--head during ignition!
Warning!
During the welding the tool can be very hot, so take great care!
Read the instruction manuals for the
componets included in the equipment!
S Power source LTS 320, see instruction manual 04457 690 xxx.
S Power source LTS 160/ LTS 250, see instruction manual 0458 343 xxx.
S Power source LTP 450, see instruction manual 0456 634 xxx.
S Programm ing box LT S, see program m ing m anual 0457 706 xxx.
S Programm ing box LTP 450, see pr ogr amm ing m anual 0456 638 xxx.
GB
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fna3o1ea
4.2 Equipment functions
4.2.1 Rotor
An opening within the rotor--circle (1) permits You to put the
weld head into welding--position and to remove it afterwards.
N.B. To position and remove the weld--head the
rotormustbein“HOME”--position(seethe
programming manual).
4.2.2 Locking screws
To open the Weld head Cartridge ( 3)the
Locking screws (2) must be released.
When the top parts of the Cartridge ( 3 )
have been opened the tube welding tool
can be removed from the workpiece
N.B. The tube welding tool must be
secured before opening the Locking
screws (2).
Adjustment of the L o cking screws
If the attachment between workpiece and weld head is not tight enough, the tube
may be out of tolerance. But there may also be some maladjustment or “wear“ on
the Locking screws, which is adjustable.
N.B. The Locking screws should only be tightened by hand.
4.2.3 Clamping jaw Collets for Weld head Cartridge C
Each tube--diameter has it’s own set of collets ( 4 ).
Each collet set consists of 4 parts.
GB
-- 7 9 --
fna3o1ea
4.2.4 Electrode s
Electrode--set--screw
By means of this screw (1) the electrode is tightened after sliding it into one of the
electrode--holder--holes.
Please note, that there are two positions available for 1,0 mm electrodes.
Electrode--Length
The necessary length of the electrode can be figured out with the tube in place.
Please note, that the electrode never should reach into the gear collar--area.
Extra length has to be ground off.
For correct electrode--preparation please see on page 73.
Adjustment of Arc--length
The useful length of the arc may be determined depending on parameters like
tube--wall --thickness, tube-- and electrode diameter.
Adjustment of the arc--length is done by means of adjusting the electrode position.
Electrode Change
Slide the electrode after preparing the length into the electrode--hole and tighten it by
means of the electrode--set--screw (1)attherotor (2).
To remove an electrode, loosen the set--screw ( 1 ) and pull the electrode out of the
rotor (2).
GB
-- 8 0 --
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4.3 Attaching the tube welding tool
1. Check that the weld--preparation are done in accordance to the burdens.
Refinish, if necessary
2. Check if a welding--procedure is preset or selected
3. Check that the rotor (1) is in home--position
If it isn’t m ove it.
4. Insert the clam ping jaw collets (2), (only when using Cartridge C)
5. Position the weld--head at the workpiece
6. Make sure, that the electrode is positioned exactly at the welding--joint
7. Close and tighten the upper part of the cartridge (3a).
8. Check that the arc--length has been adjusted correctly.
Adjust the electrode according to page 79.
9. Make sure that the welding tool is securely fixed, otherwise it could slip off.
10. Bring the tube--counter piece into position and tighten the upper part o f the
cartridge (3b).
Warning! Danger of over pressure!
Make sure, that no pressure--rise can occur inside the tube by
means of root gas!
11. Check that the root gas is ready
GB
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4.4 Welding
Warning! Danger to Your health!
Avoid breathing the welding vapours!
S Start of a welding program is initiated on the welding tool or the programming
unit.
S Watch the welding as far as possible.
S When the welding is terminated the tube welding tool automatically returns to
“HOME” --position.
If something is wrong welding is stopped from the welding tool or the
programming unit
4.5 Removing the tube welding tool
Warning!
Burning hazard at the workpiece and in the welding--zone of the
weld head!
N.B. Make sure that the tube welding tool has cooled down before r emoving.
S After termination of the welding--program, check that the rotor (1)isin
HOME--position.
If not, drive the rotor into “HOME“--position (see the programming manual).
S Check that the gas post--purge--time has elapsed.
S Release the Locking screws (2 )
S Open the upper parts of the Cartridge (3).
The tube welding tool can now be removed.
GB
-- 8 2 --
fna3u1ea
5 MAINTENANCE
5.1 General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
The actual safety regulations must be followed precisely when
measures with regard to the In stallatio n/ Operation and
Maintenance are taken!
Never use lub ricants!
Use of lubricants leads to loss of warranty.
Damage, caused by particles in the gear, are also excluded from warranty!
5.2 After each 10th weld--seam:
S Change or regrind the electrode
5.3 Daily
S Check of the rotor--contact--surface, if necessary clean with red “Scotchbrite“
5.4 Weekly
S Check all bolts for tight seating;
GB
-- 8 3 --
fna3f1ea
6 FAULT TRACING
6.1 General
In the event of a serious fault, contact your nearest ESAB retailer or service shop
authorised by ESAB.
6.2 Fault--Tracing
1. Symptom Weld head is not in fixed position on the tube after tightening:
Cause 1.1 Wr ong tube--tolerance
Action Use adapted collets;
Cause 1.2 Locking screws are loose
Action Tighten the Locking screws
2. Symptom Arc does not ignite:
Cause 2.1 Bad or no contact between collets and tube
Action Clean surfaces and/ or remove insulating layers
Cause 2.2 No welding--gas
Action Check on gas--supply
Cause 2.3 Electrode--gap too high
Action Adjust
Cause 2.4 Electrode--tip is worn
Action Regrind electrode
Cause 2.5 Bad contact between rotor and electrode
Action Clean
Cause 2.6 Cable broken
Action Exchange
Cause 2.7 Conductivity of coolant is too high;
Action Exchange the non--functional coolant!
3. Sympto m Arc is pu lled aside:
Cause 3.1 Electrode--tip is worn
Action Regrind electrode
Cause 3.2 Electrode is ground incorrectly
Action Regrind electrode
Cause 3.3 Bad electrode quality
Action Replace electrode
GB
-- 8 4 --
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4. Symptom Arc ignites ag ain st parts of Weld head:
(can lead to heavy damage at the Weld h ead )
Cause 4.1 Electrode not OK
Action Exchange
Cause 4.2 Electrode--gap too high
Action Adjust
Cause 4.3 Weld--chamber dirty
Action Clean
Cause 4.4 Pre--purge--time too short
Action Increase
Cause 4.5 No electrode
Action Assemble electrode
Cause 4.6 Gas--flow to high
Action Adjust the gas--flow to 6--8 l/ min
5. Symptom Rotor--turn does not start:
Cause 5.1 Particles inside gear
Action Remove and clean
Cause 5.2 Electrical connection defective
Action Check plug, check cable, check power--supply
6. Symptom Weld head cannot be removed from tube:
Cause 6.1 Opening --position not achieved
Action Move to HOME--position
7 ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list on page 223.
This will simplify dispatch and ensure you get the righ t part.
GB
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