GB
Valid for serial no. 306-xxx-xxxx0444 291 101 GB 100315
A21
PRH 3-38
PRH 6-76
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Complete tool 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Welding head 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Generated noise level 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Electrodes 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Requirements for the place of installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Storing the system 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Clamping jaw collets 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Equipment functions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Rotor 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Locking lever 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.3 Clamping jaw collets 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.4 Electrodes 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Attaching the tube welding tool 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Welding 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Removing the tube welding tool 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 After each 10th welding seam 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Daily 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Weekly 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 FAULT TRACING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSION DRAWING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB Welding Equipment, 695 81 Laxå, Sweden, declares that tube welding tool
PRH 3-38 /
PRH 6-76 from serial number 306 (2003 w.6) onwards, conforms to standard EN 60204-1/ EN
12100-2 in accordance with the requirements of directive (98/37/EEC) and standard EN 60974-10
(Class A) in accordance with the requirements of directive (2004/108/EG).
--------------------------------------------------------------------------------------------------------------
Kent Eimbrodt
Global Director
Equipment and Automation
Laxå 2008-08-18
2 SAFETY
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. Note! Do not use safety gloves when replacing wire.
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 precausions 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!
CAUTION!
Read and understand the instruction manual before
installing or operating.
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.
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Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
3 INTRODUCTION
The PRH 3-38/ / PRH 6-76 is a series of enclosed tube welding tools designed for
TIG-welding of tube joints.
Enclosed here means 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 means of clamping jaw
collets. The clamping jaw collets are exchangeable so as to fit different tube
dimensions.
3.1 Equipment
3.1.1 Complete tool
Welding head
For a detailed description see on page 6.
Indicating lamp
Lights up when the electrode is not in home
position.
Locking lever
By means of the locking lever the workpiece
is fixed in position.
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 welding head body.
1 Welding head
2 Indicating lamp
3 Locking lever
4 Handle
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3.1.2 Welding head
Rotor
The rotor carries the electrode. As well, there
are provisions 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.
Clamping jaw
The clamping jaws work as holders for the
clamping jaw collets.
The workpieces become fixed in working
position by closing the upper clamp jaws and
tightening them with the locking levers.
1 Rotor
2 Clamping jaw
3 Clamping jaw collets
4 Electrode
Clamping jaw collets
By means of the collets, welding head and workpiece are attached together.
Electrode
See on page 7.
ESAB's accessories for the product can be found on page 20.
4 TECHNICAL DATA
PRH 3-38 PRH 6-76
Max. pulsed welding current: 100 A 100 A
Max. continuous welding current at
100% duty cycle : 50 A 60 A
Tube outer diameter:
max.
min.
38,1 mm
3 mm
76,2 mm
6 mm
Weight: 8 kg 9 kg
Electrode diameter: 1,6 mm or 2,4 mm 1,6 mm or 2,4 mm
Electrode adjustment length: 10 mm 10 mm
Rotor-turning-drive, power, max.: 19 W 19 W
Rotor-turning-drive, nominal voltage: 48 VDC 48 VDC
Rotor speed:
max.
min.
9,5 (1/min)
0,5 (1/min)
6,15 (1/min)
0,31 (1/min)
Control mode: Speed control by means of pulse transducer
Gas flow,
max.
min.
10 l/min
5 l/min
10 l/min
5 l/min
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PRH 6-76PRH 3-38
Coolant: 50% water / 50% mono-ethylene glycol.
Circulation to be provided externally
Pressure, max. 3,5 bar 3,5 bar
Content of coolant 0,25 l 0,3 l
Weld head-housing-temperature, max* 50 ° C 50 ° C
Operating temperature -10 to +40° C -10 to +40° C
Transportation temperature -20 to +55° C -20 to +55° C
* In case of exceeding the permissible housing temperature, operation breaks have to be added for
this weld head.
4.1 Generated noise level
The noise level generated by the system is below 70 dB (A) with operating coolant
circulation. The measurement assumes a distance of 1 m from the welding tool.
4.2 Electrodes
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
1,5 mm
Electrode length: For determination of the electrode length, please regard page 11
Tip angle:
30° -45°
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
5 INSTALLATION
The installation must be executed 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.
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5.1 Requirements for the place of installation
Place the tube welding tools 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 %
5.2 Storing the system
If the tube welding tools are not to be used for a long period of time, remove it and
place it in the delivery box.
Make sure that no corrosive conditions can occur during the time of storage.
In case of high humidity we recommend humidity-absorbing material to be used in
the storing box.
Before storage we recommend the following procedure:
S Clean the welding head.
S Remove all cooling agent.
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.
5.3 Connections
Electrical ground connection
The supply of welding power to the welding 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 the contact.
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5.4 Clamping jaw collets
Adding the collets
S Place the collet (2) behind the small pin (1).
S Push the collet until it clicks into place.
N.B. Use the two collets with the plunger
pins (screws with the spring loaded ball)
only in the upper position.
The collets are in the right position, if
the ESAB LOGO can be seen from
the outside of all the collets.
Removing the collets
S Pull the screw (3) in the direction shown by the arrow.
S Remove the collet (4).
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING!
Electric shock!
Do not touch the workpiece or the welding head during operation!
WARNING!
During the welding the tool can be very hot. Take therefore great care!
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.
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6.1 Equipment functions
6.1.1 Rotor
An opening in the rotor (1) circumference
permits you to put the welding head into
welding position and to remove it afterwards.
N.B. To position and remove the welding
head the rotor must be in “HOME position
(See the programming manual).
6.1.2 Locking lever
To open the welding head the locking levers
(2) must be released.
Note that to remove the welding head from the
workpiece the upper clamping jaws (3) must be
open.
N.B. Before opening the locking levers,
hold the welding head to avoid
dropping.
Adjustment of the locking levers
If the attachment between the workpiece
and welding head is not tight enough, the
tube may be beyond the tolerances.
But there may also be some maladjustment
or “wear“ on the locking levers, which are
adjustable.
To make the adjustment, use the grub screw (4). The grub screw is located in the
counter-part of the locking lever.
6.1.3 Clamping jaw collets
Each tube diameter has its own set of collets (5). .
The set consists of two upper and two lower parts.
Both upper parts also have two integrated
spring-plunger-set screws.
N.B. The upper parts should only be
mounted into the upper clamping jaws (3).
Attachment takes place automatically by
spring snappers.
For release, push the spring snappers aside
by means of a tool or your finger nails.
Spring plungers
Inside the upper collets, spring-plunger-set screws are incorporated. Their function is
the compensation of tube tolerances in a range of 0,1 to 0,2 mm.
Adjustment of the spring-plunger-set screws can be made even with mounted tube
and top-clamp side closed by simply using the screwdriver supplied.
Adjustment should be carried out in such a way, that the full spring distance
becomes usable.
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6
6
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6.1.4 Electrodes
Electrode fastening screw
By means of this screw (6) the electrode is
tightened after sliding it into one of the
electrode holder holes.
The screw is reached by way of a
screwdriver from the sprocket side
of the rotor.
N.B. that separate holder holes are
provided for 1,6 and 2,4 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 sprocket area of the gear and block the
welding head. Extra length has to be cut off.
For correct electrode preparation, please see on page 7.
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
adjusting the electrode position.
Electrode change
Slide the electrode after preparing the length
into the right electrode hole and tighten it by
means of the electrode fastening screw (6)
at the rotor (1).
To remove the electrode, loosen the screw and pull the electrode out of the rotor.
6.2 Attaching the tube welding tool
1. Check that the weld preparation is done according to the task.
Adjust as necessary
2. Check if a welding procedure is preset or selected
3. Check that the rotor (1) is in home position
If it is not, move it.
4. Insert the clamping jaw collets (5)
a. Position the welding head at the workpiece
b. Make sure, that the electrode is positioned exactly at the welding joint
c. Close and tighten the upper clamping jaw (3).
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5. Check that the arc length has been adjusted correctly.
Adjust the electrode according to page 11.
6. Make sure that the welding tool is securely fixed, otherwise it could slip off.
7. Bring the tube counter-piece into position and tighten the upper
clamping jaw (3b).
CAUTION!
Danger of over pressure! Make sure, that no pressure-rise can occur inside the tube by
means of backup-gas.
8. Check that the backup gas is ready.
6.3 Welding
WARNING!
Danger to your health! Avoid breathing the welding vapours!
S The start of the welding program is initiated from 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 the welding can be stopped from the welding tool or the
programming unit.
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6.4 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 welding head has cooled down before removing.
S After termination of the welding program, check that the rotor is in 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 Open the welding head by releasing the locking levers (2) and opening the upper
clamping jaws (3).
The tube welding tool can now be removed.
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
CAUTION!
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.
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Never use lubricants!
The use of lubricants leads to loss of warranty.
Damage caused by particles in the gear are also excluded from the warranty!
7.1 After each 10th welding seam
S Change or regrind the electrode.
7.2 Daily
S Check the rotor contact surface. If necessary, clean with red “Scotchbrite“
7.3 Weekly
S Check the spring-plunger-bolts inside the collets for correct position;
(The springs should permit full penetration of the spring-plunger-balls.)
S Check all bolts for tight seating.
8 FAULT TRACING
In the event of a serious fault, contact your nearest ESAB retailer or service shop
authorised by ESAB.
1. Symptom Welding head is not in fixed position on the tube after
tightening:
Cause 1.1 Tube dimension beyond tolerances
Action Use adapted collets
Cause 1.2 Locking levers are wrongly adjusted
Action Adjust the grub screw on top-clamp side
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
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Cause 2.6 Cable broken
Action Exchange
Cause 2.7 Conductivity of coolant is too high
Action Exchange the non-functional coolant!
3. Symptom Arc is pulled 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
4. Symptom Arc ignites against parts of the welding head:
(can lead to heavy damage at the welding head)
Cause 4.1 Electrode not OK
Action Exchange
Cause 4.2 Electrode gap too big
Action Adjust
Cause 4.3 Welding chamber dirty
Action Clean
Cause 4.4 Pre-purge time too short
Action Increase
Cause 4.5 No electrode
Action Assemble electrode
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 Welding head cannot be removed from tube:
Cause 6.1 HOME position not achieved
Action Move to HOME position
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9 ORDERING OF SPARE PARTS
PRH 3-38, PRH 6-76 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 pro
duct still conforms to the said standard.
Repair and electrical work should be performed by an authorized ESAB serviceman.
Use only ESAB original spare and wear parts.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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Edition 100315
Dimension drawing
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PRH 3-38
* Width with collets 34 mm
Width without collets 34 mm
Edition 100315
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PRH 6-76
* Width with collets 42,4 mm
Width without collets 38 mm
PRH 3-38, PRH 6-76
Edition 100315
Ordering number
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Ordering no. Denomination Type
0444 301 880 Tube welding tool PRH 3-38, A21
0444 302 880 Tube welding tool PRH 6-76, A21
0444 291 990 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
PRH 3-38, PRH 6-76
Edition 100315
Accessories
Collets
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Collets PRH3-38 PRH 6-76
Collets, one set, four halves
Collets blanks 0444 312 001 0444 313 001
Collets 6.0 mm 0444 312 002 0444 313 002
Collets 6.35 mm 0444 312 003 0444 313 003
Collets 8.0 mm 0444 312 004 0444 313 004
Collets 9.53 mm 0444 312 005 0444 313 005
Collets 10.0 mm 0444 312 006 0444 313 006
Collets 12.0 mm 0444 312 007 0444 313 007
Collets 12.7 mm 0444 312 008 0444 313 008
Collets 13.5 mm 0444 312 009 0444 313 009
Collets 17.2 mm 0444 312 010 0444 313 010
Collets 18.0 mm 0444 312 011 0444 313 011
Collets 19.05 mm 0444 312 012 0444 313 012
Collets 21.3 mm 0444 312 013 0444 313 013
Collets 22.0 mm 0444 312 014 0444 313 014
Collets 25.4 mm 0444 312 015 0444 313 015
Collets 26.9 mm 0444 312 016 0444 313 016
Collets 28.0 mm 0444 312 017 0444 313 017
Collets 29.0 mm 0444 312 018 0444 313 018
Collets 31.8 mm 0444 312 019 0444 313 019
Collets 33.7 mm 0444 312 020 0444 313 020
Collets 34.0 mm 0444 312 021 0444 313 021
Collets 35.0 mm 0444 312 022 0444 313 022
Collets 38.1 mm 0444 312 023 0444 313 023
Collets 40.0 mm 0444 313 024
Collets 41.0 mm 0444 313 025
Collets 42.4 mm 0444 313 026
Collets 48.3 mm 0444 313 027
Collets 50.8 mm 0444 313 028
Collets 52.0 mm 0444 313 029
Collets 53.0 mm 0444 313 030
Collets 60.3 mm 0444 313 031
Collets 63.5 mm 0444 313 032
Collets 70.0 mm 0444 313 033
Collets 76.1 mm 0444 313 034
Collets 76.2 mm 0444 313 035
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