ESAB PRD 160 A21 User manual

Valid for serial no. 340--xxx--xxxx0444 100 101 GB 050705

A21PRD 160

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 7....................................................

5.1 Installation of track 8.........................................................

5.2 Dismantling the track 8.......................................................

5.3 Adjusting the track 9.........................................................

5.4 Possible fine adjustment of the track after usage for a period of time 9.............

5.5 Adjusting the tool for the track 10...............................................

5.6 Installing the tool on the track 11...............................................

5.7 Replacing wear parts 12.......................................................

5.8 Fine adjustment 13...........................................................

5.9 Adjusting electrode and wire contact tip 14.......................................

5.10 Possible adjustments 15......................................................

5.11 Replacing wire 16............................................................

5.12 Starting welding 16...........................................................

6 OPERATION 17.......................................................

6.1 Connections 17..............................................................

7 MAINTENANCE 17....................................................

7.1 Daily 17.....................................................................

8 ACCESSORIES 18....................................................

8.1 Complete tools 18............................................................

8.2 Installation of accessories 18..................................................

9 ORDERING SPARE PARTS 19..........................................

DIMENSION DRAWING 21................................................

DIAGRAM 24............................................................

ORDERING NUMBER 25.................................................

WEAR PARTS 26........................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

ESAB Welding Equipment AB, 695 81 Laxå, Sweden, declares that tube welding tool

PRD 160 from

serial number

140 onwards, conforms to standard EN 60292, in accordance with the requirements of

directive (89/392/EEC) and appendix (93/68/EEC) and standard EN 50199 in accordance with the

requirements of directive (89/336/EEC) and appendix (93/68/EEC).

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Joakim Cahlin

Vice President

ESAB Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924

Laxå 2001--10--01

2SAFETY

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 unauthorized 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 drafts

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.

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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!

3 INTRODUCTION

The A21 PRD 160 pipe welding tool is designed for TIG welding of pipes in

combination with the LTP 450 and LTS 160/250/320 welding power sources.

There are several variants available: see on page 25.

During pipe welding, the tool runs along a track. The tracks are available in a large

number of dimensions, see table on page 6.

A21 PRD 160 is attached to the track by a quick locking system, which grips the tool

tightly against the track and ensures that it is free from play.

The tool is available in five different versions. With the basic unit, only simple fusion

welding may be carried out. A wire feed unit, AVC (Arc Voltage Control) and weaving

may be selected to go with the basic version, see under accessories on page 18.

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4 TECHNICAL DATA

Pipe welding tool A21 PRD 160

Maximum welding power (100% duty cycle) 315 A continuous DC

400 A pulsed DC

Working range,

external

from ø 160 mm

Clearance height 120 mm for all ISO 336 pipes

Minimum distance to flange

18 mm at 0_ skew

Rotation speed 2 -- 40 cm/min

Electrode holder, water--cooled with gas lens

wire size

angular adjustment

ø1.6--3.2mm

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_ to + 45_ (15 per division_)

Filler wire,

Feed speed

Diameter

Contact tip

Bobbin

15 -- 150 cm/min

ø0.8--0.9mm

adjustable in the X, Y and Z direction

ø 100 mm

Weaving

Speed

Amplitude

2--12 mm/s

within37+8mm

AVC, Arc Voltage Control

Speed

1.7 mm/s

Weight 8 kg without cables and track,

14.5 kg with cables and track

Standard toothed tracks See page 6

Scale factor, rotation 846024

Scale factor, wire feed 120700

Scale factor, weaving 119048

Weaving -- pulses/mm 84

Scale factor, volts 30

Continuous A--weighted noise pressure <70db(A)

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Standard tracks

External diameter of pipe Rotation length Order number

mm inches

161--177 6 113 542 0444 063 880

185--201 127 167 0444 063 881

209--225 8 140 792 0444 063 882

225--241 149 875 0444 063 883

249--265 163 500 0444 063 884

265--281 10 172 583 0444 063 885

289--305 186 208 0444 063 886

313--329 12 199 833 0444 063 887

329--345 208 917 0444 063 888

345--361 14 218 000 0444 063 889

361--377 227 083 0444 063 890

385--401 240 708 0444 063 891

401--417 16 249 792 0444 063 892

425--441 263 417 0444 063 893

449--465 18 277 042 0444 063 894

473--489 290 667 0444 063 895

497--513 20 304 292 0444 063 896

513--529 313 375 0444 063 897

537--553 327 000 0444 063 898

553--569 22 336 083 0444 063 899

577--593 349 708 0444 063 900

601--617 24 363 333 0444 063 901

625--641 376 958 0444 063 902

649--665 26 390 583 0444 063 903

665--681 399 667 0444 063 904

689--705 413 292 0444 063 905

705--721 28 422 375 0444 063 906

729--745 436 000 0444 063 907

753--769 30 449 625 0444 063 908

777--793 463 250 0444 063 909

801--817 32 476 875 0444 063 910

817--833 485 958 0444 063 911

841--857 499 583 0444 063 912

857--873 34 508 667 0444 063 913

881--897 522 292 0444 063 914

905--921 36 535 917 0444 063 915

929--945 549 542 0444 063 916

953--969 36 563 167 0444 063 917

969--985 572 250 0444 063 918

993--1009 585 875 0444 063 919

1009--1025 40 594 958 0444 063 920

The table shows standard sizes in accordance with ISO 336. Tracks can also be supplied for

intermediate and larger sizes.

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5 INSTALLATION

The installation must be execu ted by a p rofession al.

WARNING!

Rotating parts can cause injury, take great care.

S Welding power source LTP 450, see user instructions, used when weaving and

AVC are applied.

S Welding power source LTS 160/250, see user instructions or welding power

source LTS 320, see user instructions, may be used for pipe welding tool

PRD160 without weaving and AVC.

IMPORTANT!

Welding power sources LTP 450, LTS 160, LTS 250 and LTS 320, which are used

with PRD 160, must have program version 2.8x or higher.

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5.1 Installation of track

Take care when installing and dismantling the track, due to the risk of crushing

injuries.

Use the Allen key supplied to hold the track as illustrated in fig. 1.

Fig. 1

Place the track around the pipe and lock as illustrated in fig. 2.

Fig. 2

The track should now be securely fastened to the pipe and should not be visibly out

of shape; if this is not the case, see under point 5.3.

5.2 Dismantling the track

Dismantle the track in the reverse order.

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5.3 Adjusting the track

On delivery of the track, the thrust bolts

arepre--settothatthetrackfits

concentrically on the pipe.

When adjusting the pipe dimension, it

is therefore important that every thrust

bolt is changed by the same amount.

There is a special, numbered Allen key

for this (1), see fig. 3. Always lock the

thrust bolt with a polygon wrench (2).

The above adjustments do not normally need

to be performed until you come to a new

batch of pipes.

Fig. 3

5.4 Possible fine adjustment of the track after usage for a period

of time

Adjust with wrench (1) as illustrated in fig. 4 so that the parts (3) are securely

pressed in place by both halves of the track, although without the transition between

the halves deviating from the round shape as a result.

Adjust the other joint as illustrated in fig. 5 according to the same premise. Note that

both halves of the hinge may need to be adjusted in order to keep the centre of the

hinge (the pin) directly above the track’s joint.

Fig. 4

Fig. 5

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5.5 Adjusting the tool for the track

Undo screws (1) and (2) on both sides of the trolley and adjust so that the centre of

the rollers (3) is pointing towards the centre of the track. Lock the screws (1) and (2),

see fig. 6.

Incorrectly adjusted tools can result in excessively high motor current, which

produces a fault code (see programming manual for LTP 450 or LTS for further

information).

IMPORTANT!

Major deviations when adjusting the tool for the track increase the wear

on the track and rollers, and also cause the drive unit to be overloaded.

In order to protect the drive unit, there is a shear pin which breaks off in

the event of too high a load.

If the shear pin breaks off:

1. Dismantle the drive unit.

2. Remove the remnants of the shear pin with a mandrel.

3. Replace the shear pin with a new one. NOTE that only original shear pins

maybeused!

Fig. 6

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5.6 Installing the tool on the track

Open and secure the rear rollers (2) using the plate springs (3) in accordance with

the arrows (4) and (5). See fig. 7.

Incline the tool so that the front rollers (1) can be laid against the edge of the track

(6) (the electrode holder may have to be raised with set screw (7) or with AVC) and

carefully fold down the tool so that the gear wheels (8) engage in the intended holes

(9).

Fig. 7

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When the rear rollers (2) are in contact with the track (6), the tool is locked with the

aid of the plate springs (3) in accordance with the arrows (10), (11) and (12). See fig.

Dismantling is carried out in the reverse order.

Fig. 8

5.7 Replacing wear parts

The electrode holder can be folded up as illustrated in fig. 9 in order to replace the

electrode, gas lens and gas cover more easily.

Fig. 9

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5.8 Fine adjustment

The rollers’ setting may need to be adjusted as follows:

Loosen the support roller a little and tighten with Allen key as illustrated in fig. 10.

Install the tool on the track and lock the rollers.

Fig. 9

Fig. 10

The measurement between plate spring and safety rail should now be 3 mm as

illustrated in fig. 11. If not, repeat the procedure.

Fig. 11

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5.9 Adjusting electrode and wire contact tip

Adjustment is carried out as illustrated in fig. 13 below.

1 Adjusting the lateral position of the electrode and wire guide

2 Adjusting the longitudinal position of the wire contact tip

3a Approximate vertical adjustment of the wire contact tip

3b Fine vertical adjustment of the wire contact tip

4 Lateral adjustment of the wire contact tip

5 Vertical adjustment of electrode and wire guide

6 Angling of electrode and wire contact tip

7 Adjustment of electrode distance before start--up

a) use the spacer screw (7) or AVC to adjust the electrode so that it points

towards the centre of the pipe (Alternatively edge 8 parallel with edge 9)

b) then use set screw 5 to adjust the electrode distance to the item.

Fig. 13

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5.10 Possible adjustments

The spring pressure on the electrode holder arm is adjusted as illustrated in fig. 14.

Fig. 14

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5.11 Replacing wire

Ease the pressure on the press roller by screwing in screw 1 as illustrated in fig. 16.

Insert the wire by hand and release the press roller by screwing out screw 1.

Fig. 16

5.12 Starting welding

S Set the welding parameters or recall the welding

program to be used to the working area (see

programming manual).

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6OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

6.1 Connections

1 Connection of protection gas

2 Connection of cooling water out -- RED

3 Connection of cooling water in -- BLUE

4 Connection of welding cable

5 Connection of rotation

6 Connection of wire conduit

7 Connection of weaving unit

8 Connection of AVC

9 Connection of measurement cable

7 MAINTENANCE

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

After a while, the edges of the track can develop a “beard”

(sharp edges). Remove these with a fine file, as there is

otherwise a risk of cutting injuries.

7.1 Daily

S Check all cables and hoses for damage.

S Clean the pipe welding tool.

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8 ACCESSORIES

8.1 Complete tools

The tool may be ordered with accessories installed as described below. The basic

unit can also be supplied with the accessories subsequently.

Basic unit intended solely for fusion welding with floating head 0444 151 880.....

Basic unit with wire feed unit complete 0444 151 881..........................

Basic unit with AVC (Arc Voltage Control) 0444 151 882.......................

Basic unit with AVC plus wire feed unit complete 0444 151 883.................

Basic unit with AVC plus wire feed unit complete and weaving unit 0444 151 884..

8.2 Installation of accessories

1. The wire feed unit (item no. 0444 137 880) is installed as illustrated in fig. 12

below.

Fig. 12

1 Wire feed unit

2 Bobbin holder

3 Wire setting components

2. AVC unit (item no. 0443 656 881) as illustrated in figure = main illustration or

compilation illustration.

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3. Weaving unit (item no. 0444 140 880) is installed as illustrated in fig. 17.

Fig. 17

Cables for the accessories are placed in the casing which is supplied with a draw

chain (in accordance with compilation drawing 0444 151).

9 ORDERING SPARE PARTS

PRD 160 is designed and tested in accordance with the international an European

standards IEC/EN 60 292 and EN 50 199.

It is the obligation of the service unit which has carried out the service or repair work

to make sure that the product still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

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ESAB PRD 160 A21 User manual

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