GB
Valid for serial no. 306-xxx-xxxx0444 292 101 GB 100317
A21
PRH 3-12
Instruction manual
DECLARATION OF CONFORMITY
according to the Machinery Directive 2006/42/EC, according to the EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
enligt Maskindirektivet 2006/42/EG, enligt EMC−Direktivet 2004/108/EG
Type of equipment Materialslag
Tube welding tool
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
PRH 3 − 12, from Serial number 306 xxx xxxx (2003 week 06)
PRH Tube welding tool is a member of the ESAB product family A21
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB, Welding Equipment
Esabvägen, SE−695 81 LAXÅ, Sweden
Phone: +46 584 81 000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
EN 60204−1, Safety of machinery – Electrical equipment of machines – Party 1: General requirements
EN 12100−2, Safety of machinery – Part 2: Technical principles
EN 60974−10 Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Additional information: Restrictive use; Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Date / Datum
Laxå 2010−03−08
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Main components 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Description of Main components 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Weld head 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2 Indicating lamp 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3 Thumb screws 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.4 Handle 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Generated noise level 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Electrodes 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Requirements for the place of use 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Storage of the system 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Clamping jaw collets (Cartridge C) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Equipment functions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Rotor 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Locking screws 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3 Clamping jaw Collets for Weld head Cartridge C 11. . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.4 Electrodes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Attaching the tube welding tool 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Welding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Removing the tube welding tool 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 After each 10th weld-seam 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Daily 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Weekly 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 FAULT TRACING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIMENSION DRAWING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 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.
CAUTION!
Read and understand the instruction manual before
installing or operating.
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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!
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.
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!
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2 INTRODUCTION
The PRH 3-12 is an enclosed tube welding tool 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 Welding head
Cartridge A or Welding head Cartridge B.
Welding head Cartridge MF is a cartridge machined for a specific tube size.
When you want to weld a different tube size the whole cartridge is replaced.
Welding head Cartridge C is a cartridge with clamping jaw collets.
When you want to weld a different tube size the clamping jaw collets are changed.
2.1 Main components
1. Weld head
2. Indicating lamp
3. Thumb screws
4. Handle
For a description of the main components
see on page 7.
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2.2 Description of Main components
2.2.1 Weld head
1. Rotor
2. Electrode
3. Cartridge MF
4. Cartridge C
5. Clamping jaw collets
6. Locking screws
Rotor
The rotor is equipped with channels 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.
Electrode
The rotor carries the electrode. See also on page 8.
Cartridge MF
By means of Cartridge MF the tube welding tool is clamped onto the the tube-joint.
The workpiece becomes fixed in working position by closing the upper parts of the
Cartridge and tightening them with the Locking screws (6).
Cartridge C
Cartridge C works as a holder for the clamping jaw collets (5).
The workpieces become fixed in working position by closing the upper parts of the
cartridge and tightening them with the locking screws (6).
2.2.2 Indicating lamp
Lights up when the electrode is not in home position.
2.2.3 Thumb screws
By means of the thumb screws the Welding head Cartridge is fixed into position.
2.2.4 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 weld head-body.
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ESAB's accessories for the product can be found on page 20.
3 TECHNICAL DATA
PRH 3-12
Max. continuous welding current at
100% duty cycle : 15 A
Max. pulsed welding current: 40 A
Tube outer diameter:
max.
min.
12,7 mm
3 mm
Weight: 7 kg
Electrode-diameter: 1,0 mm
Electrode adjustment length: 2 mm
Rotor-turning-drive, power, max.: 4 W
Rotor-turning-drive, nominal voltage: 24 VDC
Rotor-speed:
max.
min.
12,6 rpm
0,65 rpm
Control-mode Speed-control by means of pulse transducer
Gas-flow: 4-5 l/min
(A higher gas-flow can damage the weld head.)
Coolant: 50% water / 50% mono-ethylene glycol.
Circulation to be provided externally
Pressure, max. : 3,5 bar
Content of coolant : 0,25 l
Weld head-housing-temperature, max. 50 ° C
N.B. In case of exceeding the permissible
housing-temperature, operation-breaks have to be
added for this weld head.
Operating temperature -10 to +40° C
Transportation temperature -20 to +55° C
3.1 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 at a height of 1.6 m.
3.2 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
1,0 mm
Electrode-length: For determination of the electrode-length, please regard 12
Tip-angle:
30°
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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4 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.
4.1 Requirements for the place of use
Place the tube welding tool 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 %
4.2 Storage of the system
If the tube welding tool is not to be used for a long period of time remove it and place
in the delivery box.
Make sure that no corrosive conditions can occur during time of storage.
In such cases we recommend humidity-absorbing material for use inside the
delivery-box.
Before storage we recommend the following procedure:
S Clean the weld-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.
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4.3 Connections
Electrical ground connection
The supply of welding-power to the weld-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 this contact.
4.4 Clamping jaw collets (Cartridge C)
Adding the collets
S Loosen the locking screws (1).
S Open the top parts of the Cartridge (2).
S Mount the collets (3). See on page 11.
S Tighten the screws (4) that fix the collets (3) in place.
Removing the collets
S Loosen the locking screws (1).
S Open the top parts of the Cartridge (2).
S Remove the screws (4).
S Remove the collets (3).
5 OPERATION
General safety regulations for the handling of the equipment can be found on
page 4. 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!
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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 Equipment functions
5.1.1 Rotor
An opening within the rotor-circle (1) permits You to put the
weld head into welding-position and to remove it afterwards.
N.B. To position and remove the weld-head the
rotor must be in “HOME”-position (see the
programming manual).
5.1.2 Locking screws
To open the Weld head Cartridge (3) the
Locking screws (2) must be released.
When the top parts of the Cartridge (3)
have been opened the tube welding tool
can be removed from the workpiece
N.B. The tube welding tool must be
secured before opening the Locking
screws (2).
Adjustment of the Locking screws
If the attachment between workpiece and weld head is not tight enough, the tube
may be out of tolerance. But there may also be some maladjustment or “wear“ on
the Locking screws, which is adjustable.
N.B. The Locking screws should only be tightened by hand.
5.1.3 Clamping jaw Collets for Weld head Cartridge C
Each tube-diameter has it's own set of collets (4).
Each collet set consists of 4 parts.
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5.1.4 Electrodes
Electrode-set-screw
By means of this screw (1) the electrode is tightened after sliding it into one of the
electrode-holder-holes.
Please note, that there are two positions available for 1,0 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 gear collar-area.
Extra length has to be ground off.
For correct electrode-preparation please see on page 8.
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 means of adjusting the electrode position.
Electrode Change
Slide the electrode after preparing the length into the electrode-hole and tighten it by
means of the electrode-set-screw (1) at the rotor (2).
To remove an electrode, loosen the set-screw (1) and pull the electrode out of the
rotor (2).
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5.2 Attaching the tube welding tool
1. Check that the weld-preparation are done in accordance to the burdens.
Refinish, if necessary.
2. Check if a welding-procedure is preset or selected.
3. Check that the rotor (1) is in home-position.
If it isn't move it.
4. Insert the clamping jaw collets (2), (only when using Cartridge C).
5. Position the weld-head at the workpiece.
6. Make sure, that the electrode is positioned exactly at the welding-joint.
7. Close and tighten the upper part of the cartridge (3a).
8. Check that the arc-length has been adjusted correctly.
Adjust the electrode according to page 12.
9. Make sure that the welding tool is securely fixed, otherwise it could slip off.
10. Bring the tube-counter piece into position and tighten the upper part of the
cartridge (3b).
CAUTION!
Danger of over pressure! Make sure, that no pressure-rise can occur inside the tube by
means of backup-gas.
11. Check that the root gas is ready.
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5.3 Welding
WARNING!
Danger to your health! Avoid breathing the welding vapours!
S Start of a welding program is initiated on 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 welding is stopped from the welding tool or the
programming unit
5.4 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 tube welding tool has cooled down before removing.
S After termination of the welding-program, check that the rotor (1) 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 Release the Locking screws (2)
S Open the upper parts of the Cartridge (3).
The tube welding tool can now be removed.
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6 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.
Never use lubricants!
Use of lubricants leads to loss of warranty.
Damage, caused by particles in the gear, are also excluded from warranty!
6.1 After each 10th weld-seam
S Change or regrind the electrode.
6.2 Daily
S Check of the rotor-contact-surface, if necessary clean with red “Scotchbrite“.
6.3 Weekly
S Check all bolts for tight seating.
7 FAULT TRACING
In the event of a serious fault, contact your nearest ESAB retailer or service shop
authorised by ESAB.
1. Symptom Weld head is not in fixed position on the tube after tightening:
Cause 1.1 Wrong tube-tolerance
Action Use adapted collets;
Cause 1.2 Locking screws are loose
Action Tighten the Locking screws
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
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Cause 2.4 Electrode-tip is worn
Action Regrind electrode
Cause 2.5 Bad contact between rotor and electrode
Action Clean
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 Weld head:
(can lead to heavy damage at the Weld head)
Cause 4.1 Electrode not OK
Action Exchange
Cause 4.2 Electrode-gap too high
Action Adjust
Cause 4.3 Weld-chamber dirty
Action Clean
Cause 4.4 Pre-purge-time too short
Action Increase
Cause 4.5 No electrode
Action Assemble electrode
Cause 4.6 Gas-flow to high
Action Adjust the gas-flow to 4-5 l/ min
5. Symptom Rotor-turn does not start:
Cause 5.1 Particles inside gear
Action Remove and clean
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Cause 5.2 Electrical connection defective
Action Check plug, check cable, check power-supply
6. Symptom Weld head cannot be removed from tube:
Cause 6.1 Opening-position not achieved
Action Move to HOME-position
8 ORDERING OF SPARE PARTS
PRH 3-12 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.
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.
GB
Edition 100317
Dimension drawing
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A21 PRH 3-12
* Width with collets C: 31 mm
Width without collets: 12,7 mm
PRH 3-12
Edition 100317
Ordering number
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Ordering no. Denomination Type
0444 300 880 Tube welding tool PRH 3-12, A21
0444 292 990 Spare parts list
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
PRH 3-12
Edition 100317
Accessories
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Collets + Cartridge PRH 3-12
Cartridges
Cartridge C 0444310880
Cartridge MF 6.0 mm 0444310881
Cartridge MF 6.35 mm 0444310882
Cartridge MF 8.0 mm 0444310883
Cartridge MF 9.53 mm 0444310884
Cartridge MF 10.0 mm 0444310885
Cartridge MF 12.0 mm 0444310886
Cartridge MF 12.7 mm 0444310887
Collets for cartridge C, one set, four halves
Collets C blanks 0444311001
Collets C 6.0 mm 0444311002
Collets C 6.35 mm 0444311003
Collets C 8.0 mm 0444311004
Collets C 9.53 mm 0444311005
Collets C 10.0 mm 0444311006
Collets C 12.0 mm 0444311007
Collets C 12.7 mm 0444311008
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