ESAB PRD 160 A21 User manual

Brand: ESAB

Model: PRD 160 A21

Category: Power tools

Type: User manual

ESAB PRD 160 A21 is a pipe welding tool designed for TIG welding of pipes in combination with MechTig welding power sources. It features a quick-locking system for attaching to tracks, ensuring a tight grip and eliminating play. The tool offers adjustable electrode and wire contact tip, allowing for precise positioning. With the basic unit, simple fusion welding is possible. Additional options include a wire feed unit, AVC (Arc Voltage Control), and weaving capability for more advanced welding tasks.

Valid for serial no. 340-xxx-xxxx0444 100 201 GB 20110526

A21™

PRD 160

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Installation of track 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Dismantling the track 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Adjusting the track 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Fine adjustment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Adjusting the tool for the track 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Installing the tool on the track 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Fine adjustment 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Adjusting electrode and wire contact tip 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Possible adjustments 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 Installation of accessories 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Daily 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Replacing wear parts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Replacing wire 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 DISASSEMBLY AND DISPOSAL 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING SPARE PARTS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIMENSION DRAWING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEAR PARTS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 ob

served 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 equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

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 drafts

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 precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the 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!

ESAB can provide you with all necessary welding protection and accessories.

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.

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2 INTRODUCTION

The PRD 160 pipe welding tool is designed for TIG welding of pipes in combination

with the MechTig welding power sources.

There are several variants available: see on page 23.

During pipe welding, the tool runs along a track. The tracks are available in a large

number of dimensions, see table on page 7.

PRD 160 is attached to the track by a quick locking system, which grips the tool

tightly against the track and ensures that it is free from play.

The tool is available in five different versions. With the basic unit, only simple fusion

welding may be carried out. A wire feed unit, AVC (Arc Voltage Control) and weaving

may be selected to go with the basic version.

3 TECHNICAL DATA

Pipe welding tool PRD 160

Maximum welding power (100% duty cycle) 315 A continuous DC

400 A pulsed DC

Working range,

external from Ø 160 mm

Clearance height 120 mm for all ISO 336 pipes

Minimum distance to flange

18 mm at 0_ skew

Rotation speed 2 - 40 cm/min

Electrode holder, water-cooled with gas lens

wire size

angular adjustment

Ø 1.6 - 3.2 mm

- 30_ to + 45_ (15° per division_)

Filler wire,

Feed speed

Diameter

Contact tip

Bobbin

15 - 150 cm/min

Ø 0.8 - 0.9 mm

adjustable in the X, Y and Z direction

Ø 100 mm

Weaving

Speed

Amplitude

2-12 mm/s

within 37 + 8 mm

AVC, Arc Voltage Control

Speed

1.7 mm/s

Weight without cables and track

with cables and track

8 kg

14.5 kg

Standard toothed tracks See page 7

Scale factor, rotation 846024

Scale factor, wire feed 120700

Scale factor, weaving 119048

Weaving - pulses/mm 84

Scale factor, volts 30

Continuous A-weighted noise pressure < 70 db (A)

Operating temperature -10 till +40° C

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Standard tracks

External diameter of pipe Rotation length Order number

mm inches

161-177 6 113 542 0444 063 880

185-201 127 167 0444 063 881

209-225 8 140 792 0444 063 882

225-241 149 875 0444 063 883

249-265 163 500 0444 063 884

265-281 10 172 583 0444 063 885

289-305 186 208 0444 063 886

313-329 12 199 833 0444 063 887

329-345 208 917 0444 063 888

345-361 14 218 000 0444 063 889

361-377 227 083 0444 063 890

385-401 240 708 0444 063 891

401-417 16 249 792 0444 063 892

425-441 263 417 0444 063 893

449-465 18 277 042 0444 063 894

473-489 290 667 0444 063 895

497-513 20 304 292 0444 063 896

513-529 313 375 0444 063 897

537-553 327 000 0444 063 898

553-569 22 336 083 0444 063 899

577-593 349 708 0444 063 900

601-617 24 363 333 0444 063 901

625-641 376 958 0444 063 902

649-665 26 390 583 0444 063 903

665-681 399 667 0444 063 904

689-705 413 292 0444 063 905

705-721 28 422 375 0444 063 906

729-745 436 000 0444 063 907

753-769 30 449 625 0444 063 908

777-793 463 250 0444 063 909

801-817 32 476 875 0444 063 910

817-833 485 958 0444 063 911

841-857 499 583 0444 063 912

857-873 34 508 667 0444 063 913

881-897 522 292 0444 063 914

905-921 36 535 917 0444 063 915

929-945 549 542 0444 063 916

953-969 36 563 167 0444 063 917

969-985 572 250 0444 063 918

993-1009 585 875 0444 063 919

1009-1025 40 594 958 0444 063 920

The table shows standard sizes in accordance with ISO 336. Tracks can also be supplied for intermediate

sizes.

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4 INSTALLATION

The installation must be carried out by a professional.

WARNING

Rotating parts can cause injury, take great care.

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.

4.1 Installation of track

Take care when installing and dismantling the track, due to the risk of crushing

injuries.

S Use the Allen key (1) supplied to hold the track as illustrated in fig. 1.

Figure 1

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S Place the track around the pipe and lock as illustrated in fig. 2.

Figure 2

The track should now be securely fastened to the pipe and should not be visibly out

of shape; if this is not the case, see under point 5.3.

4.2 Dismantling the track

S Dismantle the track in the reverse order.

4.3 Adjusting the track

On delivery of the track, the thrust bolts

are pre-set to that the track fits

concentrically on the pipe.

When adjusting the pipe dimension, it

is therefore important that every thrust

bolt is changed by the same amount.

There is a special, numbered Allen key

for this (1), see fig. 3.

S Always lock the thrust bolt with a polygon

wrench (2).

The above adjustments do not normally needs to be

performed until you come to a new batch of pipes.

Figure 3

4.4 Fine adjustment

Possible fine adjustment of the track

after usage for a period of time

S Adjust with wrench (1) as illustrated

in fig. 4 so that the parts (2) are

securely pressed in place by both

halves of the track, although

without the transition between the

halves deviating from the round

shape as a result.

Figure 4

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S Adjust the other joint as illustrated in fig. 5

according to the same premise.

Note! that both halves of the hinge

may need to be adjusted in order to keep

the centre of the hinge (the pin) directly

above the track's joint.

Figure 5

4.5 Adjusting the tool for the track

S Undo screws (1) and (2) on both sides of the trolley and adjust so that the centre

of the rollers (3) is pointing towards the centre of the track.

S Lock the screws (1) and (2), see fig. 6.

Incorrectly adjusted tools can result in excessively high motor current, which

produces a fault code (see programming manual MechTig for further information).

IMPORTANT!

Major deviations when adjusting the tool for the track increase the wear

on the track and rollers, and also cause the drive unit to be overloaded.

In order to protect the drive unit, there is a shear pin which breaks off in

the event of too high a load.

If the shear pin breaks off:

1. Dismantle the drive unit.

2. Remove the remnants of the shear pin with a mandrel.

3. Replace the shear pin with a new one.

NOTE that only original shear pins may be used!

Figure 6

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4.6 Installing the tool on the track

S Open and secure the rear rollers (2) using the plate springs (3) in accordance

with the arrows (4) and (5). See fig. 7.

S Incline the tool so that the front rollers (1) can be laid against the edge of the

track (6) (the electrode holder may have to be raised with set screw (7) or with

AVC).

S Fold carefully down the tool so that the gear wheels (8) engage in the intended

holes (9).

Figure 7

When the rear rollers (2) are in contact with the track (6), the tool is locked with the

aid of the plate springs (3) in accordance with the arrows (10), (11) and (12).

See fig. 8.

Dismantling is carried out in the reverse order.

Figure 8

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4.7 Fine adjustment

The rollers setting may need to be adjusted as follows:

S Loosen the support roller a little to tighten with Allen key as illustrated in fig. 9.

S Install the tool to the track and lock the rollers.

Figure 9

The measurement between plate spring and safety rail should now be 3 mm as

illustrated in fig. 10, If not, repeat the procedure.

Figure 10

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4.8 Adjusting electrode and wire contact tip

Adjustment is carried out as illustrated in fig. 11 below.

2 Adjusting the longitudinal position of the wire contact tip

3a Approximate vertical adjustment of the wire contact tip

3b Fine vertical adjustment of the wire contact tip

4 Lateral adjustment of the wire contact tip

5 Vertical adjustment of electrode and wire guide

6 Angling of electrode and wire contact tip

7 Adjustment of electrode distance before start-up

a) use the spacer screw (7) or AVC to adjust the electrode so that it points

towards the centre of the pipe (Alternatively edge (8) parallel with edge (9)).

b) then use set screw (5) to adjust the electrode distance to the item.

Figure 11

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4.9 Possible adjustments

The spring pressure on the electrode holder arm is adjusted as illustrated in fig. 12.

Figure 12

4.10 Installation of accessories

1. The wire feed unit is installed as illustrated in fig. 13 below.

Figure 13

1 Wire feed unit

2 Bobbin holder

3 Wire setting components

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2. Weaving unit is installed as illustrated in fig. 14.

Figure 14

Cables for the accessories are placed in the casing which is supplied with a draw

chain.

5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read 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.

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5.1 Connections

1. Connection of protection gas 6. Connection of wire conduit

2. Connection of cooling water out - RED 7. Connection of weaving unit

3. Connection of cooling water in - BLUE 8. Connection of AVC

4. Connection of welding cablel 9. Connection of measurement cable

5. Connection of rotation

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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 attempts any

work to rectify any faults in the product during the guarantee period.

After a while, the edges of the track can develop a “beard”

(sharp edges). Remove these with a fine file, as there is

otherwise a risk of cutting injuries.

6.1 Daily

S Check all cables and hoses for damage.

S Clean the pipe welding tool.

6.2 Replacing wear parts

The electrode holder can be folded up as

illustrated in fig. 15 in order to replace the

electrode, gas lens and gas cover more easily.

Figure 15

6.3 Replacing wire

S Ease the pressure on the press roller by screwing in screw (1) as illustrated in fig. 16.

S Insert the wire by hand and release the press roller by screwing out screw 1.

Figure 16

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7 DISASSEMBLY AND DISPOSAL

The equipment is manily made from steel, plastics, and non-ferrous metal and must

be disposed of in compliance with local environmental regulations.

The disposal of coolant is also subject to local reguirements.

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.

8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

PRD 160 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.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

Dimension drawing

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ESAB PRD 160 A21 User manual

Brand: ESAB

Model: PRD 160 A21

Category: Power tools

Type: User manual

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ESAB PRD 160 A21 User manual

ESAB PRD 160 A21 User manual

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