Valid for serial no. 730--xxx--xxxx0443 959 001 020321
A22 POC 12-60
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Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones d e uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
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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.
SVENSKA 3..............................................
DANSK 13................................................
NORSK 23................................................
SUOMI 33................................................
ENGLISH 43..............................................
DEUTSCH 53.............................................
FRANÇAIS 63.............................................
NEDERLANDS 73.........................................
ESPAÑOL 83..............................................
ITALIANO 93..............................................
PORTUGUÊS 103..........................................
ÅËËÇÍÉÊÁ 113.............................................
ENGLISH
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TOCe
1 DIRECTIVE 44........................................................
2SAFETY 44...........................................................
3 INTRODUKTION 45...................................................
3.1 Selection table 46............................................................
3.2 Technical data 47............................................................
4 INSTALLATION 47....................................................
4.1 Connections 47..............................................................
5 OPERATION 48.......................................................
5.1 Adjustments 48..............................................................
5.2 Hanging up the welding tool 49.................................................
5.3 Welding start 49..............................................................
6 MAINTENANCE 50....................................................
6.1 Daily 50.....................................................................
6.2 As necessary 50.............................................................
6.3 Dismantling the tool 50........................................................
6.4 Resetting the starting position 50...............................................
6.5 Assembling the tool 50........................................................
6.6 Replacing and fitting of wear parts 51...........................................
7 ACCESSORIES 52....................................................
8 ORDERING OF SPARE PARTS 52......................................
DIMENSION DRAWING 123................................................
APPLICATIONS 124.......................................................
DIAGRAM 125............................................................
SPARE PARTS LIST 127...................................................
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that tube welding tool A22 POC 12--60 from serial number 730 complies with stan-
dard EN 60292, in accordance with the requirements of directive (89/392/EEA) and
addendum.
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 971118
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 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.
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WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT ING.
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 INTRODUKTION
A22 POC 12--60 are designed for TIG welding of tubes into flat plates. These tools
may also be used for welding the full range of welded joints, although this may
require additional equipment in certain cases. It may be used with the following
power sources LTO 160, LTO 250, LTP 450, LTS 160, LTS 250 and LTS 320.
The tube to plate welding tools must be used with the appropriate spindle and
centering mandrel as shown in the selection table, on page 46.
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3.1 Selection table
Tube diameter Centering mandrel Spindle
Min mm Max mm Order no. Order no.
9.9 10.5 0442 634 880 0442 714 880
10.3 10.9 0442 634 881
10.7 11.3 0442 634 882
11.1 11.7 0442 634 883
11.5 12.1 0442 634 884
11.9 12.7 0442 634 885
12.5 13.3 0442 634 886
13.1 13.9 0442 635 880 0332 208 880
13.7 14.5 0442 635 881
14.3 15.4 0442 635 882
15.2 16.3 0442 635 883
16.1 17.6 0442 635 884
17.4 19.0 0442 635 885
18.8 20.2 0442 635 886
19.9 21.7 0442 635 887
21.4 23.2 0442 636 880 0332 209 880
22.9 24.7 0442 636 881
24.4 26.6 0442 636 882
26.3 28.5 0442 636 883
28.1 30.7 0442 636 884
30.3 33.1 0442 636 885
32.7 36.7 0442 636 886
36.2 40.1 0442 636 887
39.6 43.7 0442 637 880 0332 210 880
43.2 47.3 0442 637 881
46.7 51.8 0442 637 882
51.2 57.2 0442 637 883
56.6 63.7 0442 637 884
63.0 71.4 0442 637 885
70.6 79.0 0442 637 886
78.2 86.6 0442 637 887
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3.2 Technical data
Tube to plate welding tool A22 POC 12--60
Max. continuous welding current 180 A/60 %
Max. pulsed welding current 200 A/60 %
Working range 12--60 mm
Max no. of revolutions 1,5 turns
Electrode angle for:
-- butt welding parallel with tube axis
-- internal fillet welding
30_ to tube axis
Electrode diameter 1,6 och 2,4 mm
Speed of rotation 0,22--4,4 r/min
Wire feed speed 0,10--1,5 m/min
Wire diameter 0,8 and0,91 mm
Length of welding cable 8m
Weight
-- tool 4,5 kg
-- cable and hose bundle 4,5 kg
Continuous A--weighted noise level 58 dB
4 INSTALLATION
The in stallatio n must be executed by a professional.
WARNING!
Rotating parts can cause injury, take great care.
S Welding power source LTO 160, LTO 250 see instruction manual 0456 779--xxx
Welding power source LTP 450, see instruction manual 0456 634--xxx,
Welding power source LTS 160, LTS 250, see instruction manual 0458 343--xxx,
Welding power source LTS 320, see instruction manual 0457 690--xxx,
4.1 Connections
A Motor cable -- rotation D Cooling-- water hose in
B Motor cable -- wire feed E Welding cable --
C Cooling -- water hose out F Gas hose
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5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 44. Read through before you start using the equipment!
S Welding power source LTO 160, LTO 250 see instruction manual 0456 779--xxx
Welding power source LTP 450, see programming manual 0456 638--xxx,
Welding power source LTS, see programming manual 0457 706--xxx,
To avoid the welding tool being damaged, check that the return cable is connected to the
workpiece and that the tungsten electrode is in the start position before the welding commences.
WARNING!
5.1 Adjustments
Adjusting the weld diameter
S Undo the locking screw (8).
S Turn the cog (7) on the link arm (3)
using a screwdriver (5) to give the
correct weld diameter.
S Undo screw (4).
S Adjust the electrode angle by r otating
the electrode holder (6).
S Tighten the locking screws (4 and 8).
Adjusting the arc leng th
S Adjust the arc length (distance between
electrode tip and work piece) by
screwing the spacer (9).
S Lock in position using nut (10).
Feeding in f iller wire
S Trim off the end if bent and file the tip
round.
S Feed the wire into the inlet nozzle (1).
S Feed the wire through the tool
(operate the wire feed unit manually).
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5.2 Hanging up the welding tool
S Hang up the welding tool according to the figure. The
starting position is then 11.25° before the 12 o’clock
position.
To reset the starting position, see under Resetting
the Star ting Position on page 50.
The tool can be balanced to weightlessness
using a balance block, see ACCESSORIES
on page 52.
5.3 Welding start
S Recall the welding program to be used to the working area (see the
Programming Manual).
S Press the start button (A) on the control unit or o n the tube--to--plate welding tool
(B).
By moving forward and backward the welding tool will now go to the starting
position, whereafter the welding procedure starts.
When the program is finished the tool automatically moves back to the starting
position, corresponding to the number of revolutions of the welding procedure
(i.e. 1.5 turns of welding = 1.5 turns return motion).
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6 MAINTENANCE
6.1 Daily
S Make sure that all cables and hoses are undamaged.
6.2 As necessary
S Clean and lubricate all sliding surfaces using smörjfett part,nr 0444 044 001
Energrease BP--LS EP 00).
S Regularly check wear components and replace as necessary.
S Make sure the correct tungsten electrode is fitted and that it is properly ground.
6.3 Dismantling the tool
The tool must be dismantled to reset the starting position and repair faults
S Unscrew the three bolts (1) that hold the support plate (2).
S Remove the bolts (4).
S Pull off the support tube (3).
S Carefully withdraw the entire inner unit (5) without damaging the microswitch (9).
6.4 Resetting the starting position
S Remove the four bolts (7).
S Withdraw the gear ring (8). T h e cam that actuates the microswitch can now be
rotated in 22.5_ increments, starting 11.25_ before the 12 o’clock position.
6.5 Assembling the tool
S Insert the inner unit (5) in the casing ( 6). Make sure the microswitch (9) does not
strike the centre of the cam.
S Align the parts so that the cog engages with the gear ring (8).
S Refit the support tube (3) (lightly lubricate the contact surfaces of the sealing ring
using Barrierta grease or an equivalent) and the support plate (2) with bolts (1).
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S Finally fit the bolts (4).
6.6 Replacing and fitting of wear parts
Tungsten electrode
S Shorten the tungsten electrode (4) to around 45 mm and grind it to the desired
angle.
S Unscrew the gas shroud (3).
S Unscrew the electrode nozzle (5) alternatively the gas lens (2).
S Replace the tungsten electrode (4). If fitting an electrode of different diameter,
the contact tip (5) alternatively the gas lens (2) and collet (1) must also be
replaced.
The adjustment of the tungsten electrode is important to ensure consistent results in
subsequent welding.
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Use pre--ground tungsten electrodes of the same length and fit them in the same
position
Contact tip
S Release the contact tip (3) using screw (5).
The contact tip is screwed onto the wire conduit (2).
Wire conduit
S Dismantle the tool, see page 50.
S Unscrew the contact tip (3)
from the wire conduit (2) and
loosen the wire conduit
from the wire feed unit (1).
S Screw the internally bevelled
end of the new conduit into the
wire feed unit.
S Screw on the contact tip (3).
S Reassemble the tool.
7 ACCESSORIES
Balance block 0332 330 005...............................................
Accessory set for external fillet welding < 36mm 0333 897 880.................
36 -- 93 mm 0333 897 883.................
Accessory set for titan welding 0441 000 880.................................
Accessory set for internal bore welding 9.5--15 mm 0441 131 880...............
15--20 mm 0441 132 880.....................
20--30 mm 0441 133 880.....................
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When ordering the internal welding kit please specify the inner diameter of the tube,
D, and the distance of the weld from the outside of the plate, A.
8 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.
This will simplify dispatch and ensure you get the right part.
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