Valid for serial no. 140--xxx--xxxx0444 100 001 020627
A21 PRD 160
Tube welding
105109108024106104022100060
Bruksanvisning
Instruction manual
Betriebsanweisung
Manuel d’instructions
Instrucciones de uso
Istruzioni per l’uso
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Rätt till ändring av specifikationer utan avisering förbehålles.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
SVENSKA 3..............................................
ENGLISH 21..............................................
DEUTSCH 39.............................................
FRANÇAIS 57.............................................
ESPAÑOL 75..............................................
ITALIANO 93..............................................
ENGLISH
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TOCe
1 DIRECTIVE 22........................................................
2SAFETY 22...........................................................
3 I NTRODUCTION 23...................................................
3.1 General 23..................................................................
4 TECHNICAL DATA 24.................................................
5 INSTALLATION 26....................................................
5.1 Installation of track 27.........................................................
5.2 Dismantling the track 27.......................................................
5.3 Adjusting the track 28.........................................................
5.4 Possible fine adjustment of the track after usage for a period of time 28.............
5.5 Adjusting the tool for the track 29...............................................
5.6 Installing the tool on the track 30...............................................
5.7 Replacing wear parts 31.......................................................
5.8 Fine adjustment 32...........................................................
5.9 Adjusting electrode and wire contact tip 33.......................................
5.10 Possible adjustments 34......................................................
5.11 Replacing wire 35............................................................
5.12 Starting welding 35...........................................................
6 OPERATION 36.......................................................
6.1 Connections 36..............................................................
7 MAINTENANCE 36....................................................
7.1 Daily 36.....................................................................
8 ACCESSORIES 37....................................................
8.1 Complete tools 37............................................................
8.2 Installation of accessories 37..................................................
9 ORDERING SPARE PARTS 38..........................................
6.2 Conexión 90.................................................................
DIAGRAM 111............................................................
DIMENSION DRAWING 112................................................
SPARE PARTS LIST 115...................................................
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1 DIRECTIVE
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
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!
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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.
3 INTRODUCTION
3.1 General
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.
During pipe welding, the tool runs along a track. The tracks are available in a large
number of dimensions, see table on page 25.
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 37.
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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
within 37 + 8 mm
AVC, Arc Voltage Control
Speed
1.7 mm/s
37 + 8 mm
Weight 8 kg without cables and track,
14.5 kg with cables and track
Standard toothed tracks See page 25
Scale factor, rotation 846024
Scale factor, wire feed 127478
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 b e executed by a profession al.
General safety regulations for the handling of the equipment can be found on
page 22. Read through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
S Welding power source LTP 450, see user instructions 0456 634 xxx, used when
weaving and AVC are applied.
S Welding power source LTS 160/250, see user instructions 0458 343 xxx or
welding power source LTS 320, see user instructions 0457 690 xxx, may be
used for pipe welding tool PRD160 without weaving and AVC.
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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.
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.
8.
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
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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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 22. 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 warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
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 and list on page 116 =
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 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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