ESAB A21 PRH 6-76 User manual

Brand: ESAB

Model: A21 PRH 6-76

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB PRH 3-38, PRH 6-76 - A21 PRH 3-38, A21 PRH 6-76 are tube welding tools. They are used for orbital TIG welding of tubes and pipes. These air-cooled tools can weld tubes ranging from 3 to 76 mm in diameter with a wall thickness of up to 5 mm. They are equipped with a color display for programming and monitoring welding parameters, an infinitely variable welding speed, and automatic weld-end detection. The tools have a modular design, are easy to install, and can be upgraded with different options and accessories.

Valid for serial no. 3060444 291 001 2004--09--24

A21 PRH 3-38

A21 PRH 6-76

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Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

Èíñòðóêöèÿ ïî ýêñïëóàòàöèè

Instrukcja obs³ugi

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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.

Îñòàâëÿåì çà ñîáîé ïðàâî èçìåíÿòü ñïåöèôèêàöèþ áåç ïðåäóïðåæäåíèÿ.

Zastrzegamy sobie prawo do wprowadzenia zmian.

SVENSKA 5..............................................

DANSK 23................................................

NORSK 41................................................

SUOMI 59................................................

ENGLISH 77..............................................

DEUTSCH 95.............................................

FRANÇAIS 113.............................................

NEDERLANDS 131.........................................

ESPAÑOL 149..............................................

ITALIANO 167..............................................

PORTUGUÊS 185..........................................

ÅËËÇÍÉÊÁ 203.............................................

POLSKI 221.................................................

Ðóññêèé 239...............................................

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Esab Welding Equipment AB, 695 81 Laxå, Sverige, försäkrar under eget ansvar att

rörsvetsverktyg A21 PRH 3--38/ A21 PRH 6-- 76 från serienummer 306 är i överens-

stämmelse m ed standard EN 60292 enligt villkoren i d ir ektiv (89/392/EEG) med til-

lägg (93/68/EEG).

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OVERENSSTEMMELSEERKLÆRING

Esab Welding Equipment AB, 695 81 Laxå, Sverige, erklærer på eget ansvar, at

rørsvejseværktøj A21 PRH 3--38/ A21 PRH 6--76 fra serienummer 306 er i overens-

stemmelse med standarden EN 60292 ifølge betingelserne i direktiv (89/392/EØF)

med tillæg (93/68/EØF).

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FORSIKRING OM SAMSVAR

Esab Welding Equipment AB, 695 81 Laxå, Sverige, forsikrer på eget ansvar at rørs-

veiseverktøy A21 PRH 3--38/ A21 PRH 6--76 fra serienummer 306 er i overensstem-

melse med standard EN 60292 i følge vilkårene i direktiv (89/392/EF) med tillegg

(93/68/EF).

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VAATIMUSTENMUKAISUUSVAKUUTUS

Esab Welding Equipment AB, 695 81 Laxå, Ruots, vakuuttaa omalla vastuullaan, et-

tä putkihitsaustyökalu A21 PRH 3--38/ A21 PRH 6--76 alkaen sarjanumerosta 306

täyttää standardin EN 60292 vaatimukset d irektiivin (89/392/ETY) ja sen lisäysten

(93/68/ETY).

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DECLARATION OF CONFORMITY

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

A21 PRH 3--38/ A21 PRH 6--76 from serial number 306 onwards, conforms to stan-

dard EN 60292, in accordance with the requirements of directive (89/392/EEC) and

appendix (93/68/EEC).

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KONFORMITÄTSERKLÄRUNG

Esab Welding Equipment AB, 695 81 Laxå Schweden, bestätigt hiermit in Eigenver-

antwortung, daß die Rohrschweisswerkzeuge A21 PRH 3--38/ A21 PRH 6--76 ab

Seriennummer 306 dem Standard EN 60292 gemäß den Bedingungen der Direktive

(89/392/EEG) mit Z usatz (93/68/EEG).

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CERTIFICAT DE CONFORMITÉ

Esab Welding Equipment AB, S--695 81 Laxå Suède, certifie que l’outil de soudage

de tubes A21 PRH 3--38/ A21 PRH 6--76 à partir du numéro de série 306 est confor-

me à la norme EN 60292 selon les conditions de la directive (89/392/CEE) avec ad-

ditif (93/68/CEE).

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VERKLARING VAN OVEREENSTEMMING

Esab Welding Equipment AB, 695 81 Laxå Sweden, verklaart geheel onder eigen

verantwoordelijkheid dat buizenlasgereedschap A21 PRH 3--38/ A21 PRH 6--76 van

het serienummer 306 in overeenstemming is met norm EN 60292 conform de bepa -

lingen in richtlijn ( 89/392/EEG) met annex (93/68/EEG).

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DECLARACIÓN DE CONFORMIDAD

Esab Welding Equipment AB, S--695 81 Laxå, Suecia, garantiza bajo propia respon -

sabilidad que la herramienta de soldadura de tubos A21 PRH 3--38/ A21 PRH 6--76

a partir del número de serie 306 concuerda con la norma EN 60292 conforme a la

directiva (89/392/CEE) con el suplemento (93/68/CEE).

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DICHIARAZIONE DI CONFORMITA

Esab Welding Equipment AB, S--695 81 Laxå Svezia, dichiara sotto la propria re -

sponsabilità che le saldatr ice per tubi A21 PRH 3--38/ A21 PRH 6--76 con numero d i

serie a partire da 306 è conforme alla norma EN 60292 come previsto dalla direttiva

(89/392/CEE) e successive integrazioni (93/68/CEE).

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DECLARAÇÃO DE CONFORMIDADE

Esab Welding Equipment AB, S--695 81 Laxå, Suécia, garante sob responsabilidade

própria que a equipamento de soldadura de tubos A21 PRH 3--38/ A21 PRH 6--76 a

partir do número de série 306 está em conformidade com a norma EN 60292 se-

gundo os requisitos da directiva (89/392/CEE) com o suplemento (93/68/CEE).

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ÂÅÂÁÉÙÓÇ ÓØÌÖÙÍÉÁÓ

Ç Esab Welding Equipment AB, 695 81 Laxå Sweden, âåâáéþíåé ìå äéêÞ ôçò

åõèýíç oôé ç ðçãÞ óùëçíïêïëëçôÞò A21 PRH 3--38/ A21 PRH 6--76 áðü ôïí

áñéèìü óåéñÜò 306 âñßóêåôáé óå óõìöùíßá ìå ôï óôáíôáñô ÅÍ 60292 óýìöùíá

ìå ôïõ üñïõò ôçò ïä çãßáò (89/392/EEC) êáé ôçí ðñïóèÞêç (93/68/EEC).

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ZAPEWNIENIE ZGODNO¦CI Z NORMA

Firma Esab Welding Equipment AB, SE--695 81 Laxå , S zwecja, gwarantuje pod

rygorem odpowiedzialno¶ci, ¿e przyrz±d do spawania rur A21 PRH 3--38/ A21 PRH 6--76

od numeru seryjnego 306 spe³nia wymagania normy EN 60292 wed³ug dyrektywy

(89/392/EEG) z poprawkami (93/68/EEG).

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ÃÀÐÀÍÒÈß ÑÎÎÒÂÅÒÑÒÂÈß

Esab Welding Equipment AB, SE-695 81 Laxå, Sweden ñîáñòâåííîðó÷íî

ãàðàíòèðóåò, ÷òî èíñòðóìåíò äëÿ ñâàðêè òðóá A21 PRH 3--38/ A21 PRH 6--76,

íà÷èíàÿ ñ ñåðèéíîãî íîìåðà 306, ñîîòâåòñòâóåò ñòàíäàðòó EN 60292 ñîãëàñíî

òðåáîâàíèÿì äèðåêòèâû (89/392/EEG) ñ ïðèëîæåíèåì (93/68/EEG).

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Martin Andersson

Manager Control Systems & Software

Automation Products

ESAB AB, Welding Automation

695 81 LAXÅ

SWEDEN Te l: + 46 584 81000 Fax: + 46 584 411721

Laxå 2003--05--08

ENGLISH

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TOCe

1SAFETY 78...........................................................

2 INTRODUCTION 80...................................................

2.1 General 80..................................................................

2.2 Technical data 80............................................................

2.3 Equipment 82................................................................

3 INSTALLATION 84....................................................

3.1 General 84..................................................................

3.2 Requirements for the place of installation 84.....................................

3.3 Storing the system 84.........................................................

3.4 Connections 85..............................................................

3.5 Clamping jaw collets 85.......................................................

4 OPERATION 86.......................................................

4.1 General 86..................................................................

4.2 Equipment functions 87.......................................................

4.3 Attaching the tube welding tool 90..............................................

4.4 Welding 91..................................................................

4.5 Removing the tube welding tool 91.............................................

5 MAINTENANCE 92....................................................

5.1 General 92..................................................................

5.2 After each 10th welding seam: 92..............................................

5.3 Daily 92.....................................................................

5.4 Weekly 92...................................................................

6 FAULT TRACING 93...................................................

6.1 General 93..................................................................

6.2 Fault Tracing 93..............................................................

7 ORDERING OF SPARE PARTS 94......................................

ACCESSORIES 258.......................................................

DIMENSION DRAWING 260................................................

SPARE PARTS LIST 263...................................................

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1SAFETY

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 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 s uitable 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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2 INTRODUCTION

2.1 General

The A21 PRH 3-38/ A21 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.

The tube welding tools are designed for use together with welding power sources

LTS 160, LTS 250, LTS 320 and LTP 450.

2.2 Technical data

2.2.1 General

PRH 3--38 PRH 6--76

Max. continuous welding current at

100% duty cycle :

50 A 60 A

Max. pulsed welding current: 100 A 100 A

Tube outer diameter:

max.

min.

38,1 mm

3mm

76,2 mm

6mm

Weight: 8kg 9kg

Electrode diameter: 1,6mmor2,4mm 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.

(

)

0,5 (1/min)

(

)

0,31 (1/min)

Control mode: Speed control by means of pulse transducer

Gas flow,

max.

min.

20 l/min

5l/min

20 l/min

5l/min

Coolant: W ater with Glycol as anti--freeze. Custom Glycol with

corrosion protection can lead to ignition problems!

N.B. Cooling water with order no. 0007 810 012

must be used.

Glycol--part %: 25 -- 50 % 25 -- 50 %

Circulation: to be provided externally

Pressure, max. (bar): 3,5 bar 3,5 bar

Content of coolant (l): 0,25 l 0,3 l

Weld head --housing--temperature, max.:* 50 ˚C 50 ˚C

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* In case of exceeding the permissible housing temperature, operation breaks have to be added for

this weld head.

2.2.2 Generated noise level

The noise level generated by the system is below 70 dB (A) with operating coolant

circulation. The m easurement assumes a distance of 1 m from the welding tool.

2.2.3 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

2mm

Electrode length: For determination of the electrode length, please regard page 89

Tip angle: 30˚-- 6 0 ˚

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

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2.3 Equipment

2.3.1 Complete tool

Welding head (1)

For a detailed description see on page 83.

Indicating lamp ( 2)

Lights up when the electrode is not in home position.

Locking lever (3)

By means of the locking lever the workpiece is fixed in position.

Handle (4)

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.

PRH 3- 38 PRH 6-76

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2.3.2 Welding head

Rotor (1)

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 (2)

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.

Clamping jaw collets (3)

By means of the collets, welding head and workpiece are attached together.

Electrode (4)

See on page 81.

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3 INSTALLATION

3.1 General

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

WARNING

Rotating parts can cause injury, take great care.

3.2 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 %

3.3 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 r ecommend 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.

Attention! 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.

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3.4 Connections

S Power source LTS 320, see instruction manual 0457 690 xxx.

S Power source LTS 160/ LT S 250, see instruction manual 0458 343 xxx.

S Power source LTP 450, see instruction manual 0456 634 xxx.

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.

3.5 Clamping jaw collets

Adding the collets

S First step (1)

Place the collet behind the small pin

S Second step (2)

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 First step (3)

Pull the screw in the direction shown by the arrow

S Second step (4)

Remove the collet

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4 OPERATION

4.1 General

Caution:

Have you read and understood the safety information ?

You must not operate the machine before then !

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

page 78. Read through before you start using the equipment!

Warning! Danger of electric shock!

Do not touch workpiece and/ or weld--head during ignition!

Warning!

During the welding the tool can be very hot, so take great care!

Read the instruction manual for the welding power source.

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4.2 Equipment functions

4.2.1 Rotor (1)

An opening in the r otor 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).

4.2.2 Locking lever (2)

To open the welding head the locking levers 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 th e lo ckin g 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 (6).Thegrubscrewislocatedinthe

counter--part of the locking lever.

PRH 3- 38

PRH 6- 76

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4.2.3 Clamping jaw collets (5)

Each tube diameter has its own set of collets.

The set consists of 2 upper and 2 lower parts.

Both upper parts also have 2 integrated spring--plunger--set screws.

The upper parts should only be m ounted 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 r ange 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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4.2.4 Electrodes

Electrode fasten in g screw ( 4)

By means of this screw 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 (1).

Please note, that separate holder holes are p rovided 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 81.

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 ch an g e

Slide the electrode after preparing the length into the right electrode hole and tighten

it by means of the electrode fastening screw (4)attherotor(1).

To remove the electrode, loosen the screw (4) and pull the electrode out of the

rotor (1).

PRH 3- 38

PRH 6- 76

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4.3 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).

5. Check that the arc length has been adjusted correctly.

Adjust the electrode according to page 89.

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 ).

Warning! 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.

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4.4 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.

4.5 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.

PRH 3- 38

PRH 6- 76

-- 9 2 --

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5 MAINTENANCE

5.1 General

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.

The actual safety regulations must be followed precisely when

measures with regard to the Installation/ Operation and

Maintenance are taken!

Never use lub ricants!

The use of lubricants leads to loss of warranty.

Damage caused by particles in the gear are also excluded from the warranty!

5.2 After each 10th welding seam:

S Change or regrind the electrode.

5.3 Daily

S Check the rotor contact surface. If necessary, clean with red “Scotchbrite“

5.4 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.

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ESAB A21 PRH 6-76 User manual

Brand: ESAB

Model: A21 PRH 6-76

Category: Welding System

Type: User manual

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ESAB A21 PRH 6-76 User manual

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