ESAB A22 POC 12-60 is a professional tool for TIG welding tubes to flat plates. It excels in welding a variety of joints and can be used in combination with the MechTig power source. The tool offers precise control over electrode angle and arc length, enabling operators to achieve high-quality welds. The compact and lightweight design allows for easy maneuvering and handling in tight spaces, making it suitable for both industrial and home workshop applications.
ESAB A22 POC 12-60 is a professional tool for TIG welding tubes to flat plates. It excels in welding a variety of joints and can be used in combination with the MechTig power source. The tool offers precise control over electrode angle and arc length, enabling operators to achieve high-quality welds. The compact and lightweight design allows for easy maneuvering and handling in tight spaces, making it suitable for both industrial and home workshop applications.
Instruction manual
0443 959 101 GB 20131217 Valid for: serial no. 730-xxx-xxxx
A22 POC 12-60
TABLE OF CONTENTS
0443 959 101 © ESAB AB 2013
1 SAFETY ................................................................................................................ 4
2 INTRODUCTION................................................................................................... 7
3 TECHNICAL DATA ............................................................................................... 8
4 INSTALLATION..................................................................................................... 9
5 OPERATION ....................................................................................................... 10
5.1 Connections ....................................................................................................... 10
5.2 Adjustments ....................................................................................................... 11
5.3 Hanging up the welding tool .............................................................................12
6 MAINTENANCE.................................................................................................. 13
6.1 Daily..................................................................................................................... 13
6.2 As necessary ...................................................................................................... 13
6.3 Dismantling the tool...........................................................................................13
6.4 Resetting the starting position .........................................................................13
6.5 Assembling the tool...........................................................................................13
6.6 Replacing and fitting wear parts.......................................................................14
7 ORDERING SPARE PARTS ............................................................................... 16
DIMENSION DRAWING.............................................................................................17
APPLICATIONS .........................................................................................................18
DIAGRAM ..................................................................................................................20
ORDERING NUMBERS.............................................................................................22
ACCESSORIES .........................................................................................................23
Rights reserved to alter specifications without notice.
1 SAFETY
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1 SAFETY
Users of ESAB 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 equipment. The following
recommendations 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
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 equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment when it
is started up
○ no-one is unprotected when the arc is struck or work is started with the equpment
3. The workplace must:
○ be suitable for the purpose
○ be free from drafts
4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could
become trapped or cause burns
5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinquishing equipment must be clearly marked and close at hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
CAUTION!
Read and understand the instruction manual before
installing or operating.
1 SAFETY
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WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting. Ask for your employer's safety practices which should
be based on manufacturers' hazard data.
ELECTRIC SHOCK - Can kill
• Install and earth the unit in accordance with applicable standards
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from earth and the workpiece
• Ensure your working stance is safe
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• 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
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
NOISE - Excessive noise can damage hearing
• Protect your ears. Use earmuffs or other hearing protection. Protect your
ears. Use earmuffs or other hearing protection
• Warn bystanders of the risk
MALFUNCTION - Call for expert assistance in the event of malfunction.
Read and understand the instruction manual before installing or operating.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be potential
difficulties in ensuring electromagnetic compatibility of
class A equipment in those locations, due to conducted
as well as radiated disturbances.
ESAB can provide you with all necessary welding protection and accessories.
1 SAFETY
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© ESAB AB 2013
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2002/96/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical
and/or electronic equipment that has reached the end of
its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved collection
stations.
For further information contact the nearest ESAB dealer.
2 INTRODUCTION
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© ESAB AB 2013
2 INTRODUCTION
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 power source MechTig.
The tube to plate welding tools must be used with the appropriate spindle and centering
mandrel as shown in the table, in the "APPLICATIONS" appendix to this manual.
3 TECHNICAL DATA
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© ESAB AB 2013
3 TECHNICAL DATA
Tube to plate welding tool 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 and 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 and 0.91 mm
Length of welding cable 8 m
Weight:
- tool 4.5 kg
- cable and hose bundle 4.5 kg
Continuous A-weighted noise level 58 dB
Operating temperature -10 to +40°C
Transportation temperature -20 to +55°C
4 INSTALLATION
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© ESAB AB 2013
4 INSTALLATION
The installation must be carried out by a professional.
WARNING!
Rotating parts can cause injury, take great care.
CAUTION!
This product is intended for industrial use. In a domestic environment this product
may cause radio interference. It is the user's responsibility to take adequate
precautions.
CAUTION!
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.
CAUTION!
The coolant must be handled as chemical waste.
5 OPERATION
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5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
WARNING!
Danger to your health! Avoid breathing the welding vapours!
WARNING!
Burning hazard at the workpiece and in the welding-zone of the welding head.
CAUTION!
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.
5.1 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
5 OPERATION
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© ESAB AB 2013
5.2 Adjustments
Adjusting the weld diameter
• Undo the locking screw (8).
• Turn the cog (7) on the link arm (3) using
a screwdriver (5) to give the correct weld
diameter.
• Undo screw (4).
• Adjust the electrode angle by rotating the
electrode holder (6).
• Tighten the locking screws (4 and 8).
Adjusting the arc length
• Adjust the arc length (distance between
electrode tip and work piece) by screwing
the spacer (9).
• Lock in position using nut (10).
Feeding in filler wire
• Trim off the end if bent and file the tip
round.
• Feed the wire into the inlet nozzle (1).
• Feed the wire through the tool (operate
the wire feed unit manually).
5 OPERATION
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© ESAB AB 2013
5.3 Hanging up the welding tool
• Hang up the welding tool according to the
illustration. The starting position is then
11.25° before the 12 o'clock position.
To reset the starting position, see the
"Resetting the Starting Position" section
in the "MAINTENANCE" chapter.
The tool can be balanced to weightlessness
using a balance block, see the
"ACCESSORIES" appendix to this manual.
6 MAINTENANCE
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© ESAB AB 2013
6 MAINTENANCE
NOTE!
Regular maintenance is important for safe, reliable operation.
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer
attempts any work to rectify any faults in the product during the warranty period.
6.1 Daily
• Make sure that all cables and hoses are undamaged.
6.2 As necessary
• Clean and lubricate all sliding surfaces using lubricating grease, see the
"ACCESSORIES" appendix to this manual.
• Regularly check wear components and replace as necessary.
• 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.
For figures in brackets (1), see illustration below.
• Unscrew the three bolts (1) that hold the support plate (2).
• Remove the bolts (4).
• Pull off the support tube (3).
• Carefully withdraw the entire inner unit (5) without damaging the microswitch (9).
6.4 Resetting the starting position
For figures in brackets (1), see illustration below.
• Remove the four bolts (7).
• Withdraw the gear ring (8). The 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
For figures in brackets (1), see illustration below.
• Insert the inner unit (5) in the casing (6). Make sure the microswitch (9) does not strike
the centre of the cam.
• Align the parts so that the cog engages with the gear ring (8).
• 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).
• Finally fit the bolts (4).
6 MAINTENANCE
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6.6 Replacing and fitting wear parts
Tungsten electrode
• Shorten the tungsten electrode (4) to
around 45 mm and grind it to the desired
angle.
• Unscrew the gas shroud (3).
• Unscrew the electrode nozzle (5)
alternatively the gas lens (2).
• 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.
Use pre-ground tungsten electrodes of the same length and fit them in the same position
6 MAINTENANCE
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Contact tip
• Release the contact tip (3) using
screw(5). The contact tip is screwed
onto the wire conduit (2).
Wire conduit
• Dismantle the tool, see the "Dismantling
the tool" section above.
• Unscrew the contact tip (3) from the wire
conduit (2) and loosen the wire conduit
from the wire feed unit (1).
• Screw the internally bevelled end of the
new conduit into the wire feed unit.
• Screw on the contact tip (3).
• Reassemble the tool.
7 ORDERING SPARE PARTS
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© ESAB AB 2013
7 ORDERING SPARE PARTS
POC 12-60 is designed and tested in accordance with the international and European
standards EN 60204-1, 12100-2 and EN 60974-10. 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.
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this
document. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
DIMENSION DRAWING
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DIMENSION DRAWING
APPLICATIONS
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APPLICATIONS
APPLICATIONS
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© ESAB AB 2013
Tube diameter Centering mandrel Spindle
Min mm Max mm Ordering no. Ordering no.
10.0
10.5
11.0
11.5
12.0
12.5
12.8
10.5
11.0
11.5
12.0
12.5
13.0
14.0
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0444 540 882
0444 540 883
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0444 540 885
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0332 207 880
13.8
14.8
15.8
16.8
17.8
18.8
19.8
15.0
16.0
17.0
18.0
19.0
20.5
22.5
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22.0
24.5
26.5
28.5
30.5
32.5
35.5
38.5
41.5
44.5
47.5
25.0
27.0
29.0
31.0
33.0
36.0
39.0
42.0
45.0
48.0
51.0
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50.5
53.5
57.5
61.5
65.5
69.5
73.5
77.5
54.0
58.0
62.0
66.0
70.0
74.0
78.0
82.0
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0444 543 885
0444 543 886
0444 543 887
0444 543 888
0444 543 889
0444 543 890
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DIAGRAM
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DIAGRAM
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ESAB A22 POC 12-60 is a professional tool for TIG welding tubes to flat plates. It excels in welding a variety of joints and can be used in combination with the MechTig power source. The tool offers precise control over electrode angle and arc length, enabling operators to achieve high-quality welds. The compact and lightweight design allows for easy maneuvering and handling in tight spaces, making it suitable for both industrial and home workshop applications.
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