A22 POC 12-60 Instruction manual 0443 959 101 GB 20131217 Valid for: serial no.
TABLE OF CONTENTS 1 SAFETY ................................................................................................................ 4 2 INTRODUCTION ................................................................................................... 7 3 TECHNICAL DATA ............................................................................................... 8 4 INSTALLATION.....................................................................................................
1 SAFETY 1 SAFETY Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
1 SAFETY WARNING! Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.
1 SAFETY NOTE! Dispose of electronic equipment at the recycling facility! In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility. As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.
2 INTRODUCTION 2 INTRODUCTION POC 12-60 are designed for TIG welding of tubes into flat plates. These tools may also be used for welding the full range of welded joints, although this may require additional equipment in certain cases. It may be used with power source MechTig. The tube to plate welding tools must be used with the appropriate spindle and centering mandrel as shown in the table, in the "APPLICATIONS" appendix to this manual.
3 TECHNICAL DATA 3 TECHNICAL DATA Tube to plate welding tool POC 12-60 Max. continuous welding current 180 A / 60 % Max. pulsed welding current 200 A / 60 % Working range 12-60 mm Max no. of revolutions 1.5 turns Electrode angle for: - butt welding parallel with tube axis - internal fillet welding 30° to tube axis Electrode diameter 1.6 and 2.4 mm Speed of rotation 0.22-4.4 r/min Wire feed speed 0.10-1.5 m/min Wire diameter 0.8 and 0.
4 INSTALLATION 4 INSTALLATION The installation must be carried out by a professional. WARNING! Rotating parts can cause injury, take great care. CAUTION! This product is intended for industrial use. In a domestic environment this product may cause radio interference. It is the user's responsibility to take adequate precautions. CAUTION! Danger of hose-burst! Never use pressure of more than 3.
5 OPERATION 5 OPERATION General safety regulations for handling the equipment can be found in the "SAFETY" chapter of this manual. Read it through before you start using the equipment! WARNING! Danger to your health! Avoid breathing the welding vapours! WARNING! Burning hazard at the workpiece and in the welding-zone of the welding head.
5 OPERATION 5.2 Adjustments Adjusting the weld diameter • • • • • Undo the locking screw (8). Turn the cog (7) on the link arm (3) using a screwdriver (5) to give the correct weld diameter. Undo screw (4). Adjust the electrode angle by rotating the electrode holder (6). Tighten the locking screws (4 and 8). Adjusting the arc length • Adjust the arc length (distance between electrode tip and work piece) by screwing the spacer (9). • Lock in position using nut (10).
5 OPERATION 5.3 • Hanging up the welding tool Hang up the welding tool according to the illustration. The starting position is then 11.25° before the 12 o'clock position. To reset the starting position, see the "Resetting the Starting Position" section in the "MAINTENANCE" chapter. The tool can be balanced to weightlessness using a balance block, see the "ACCESSORIES" appendix to this manual.
6 MAINTENANCE 6 MAINTENANCE NOTE! Regular maintenance is important for safe, reliable operation. CAUTION! All warranty undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the warranty period. 6.1 • Daily Make sure that all cables and hoses are undamaged. 6.2 • • • As necessary Clean and lubricate all sliding surfaces using lubricating grease, see the "ACCESSORIES" appendix to this manual.
6 MAINTENANCE 6.6 Replacing and fitting wear parts Tungsten electrode • • • • Shorten the tungsten electrode (4) to around 45 mm and grind it to the desired angle. Unscrew the gas shroud (3). Unscrew the electrode nozzle (5) alternatively the gas lens (2). Replace the tungsten electrode (4). If fitting an electrode of different diameter, the contact tip (5) alternatively the gas lens (2) and collet (1) must also be replaced.
6 MAINTENANCE Contact tip • Release the contact tip (3) using screw (5). The contact tip is screwed onto the wire conduit (2). Wire conduit • • • • • Dismantle the tool, see the "Dismantling the tool" section above. Unscrew the contact tip (3) from the wire conduit (2) and loosen the wire conduit from the wire feed unit (1). Screw the internally bevelled end of the new conduit into the wire feed unit. Screw on the contact tip (3). Reassemble the tool.
7 ORDERING SPARE PARTS 7 ORDERING SPARE PARTS POC 12-60 is designed and tested in accordance with the international and European standards EN 60204-1, 12100-2 and EN 60974-10. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard. CAUTION! Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts.
DIMENSION DRAWING DIMENSION DRAWING 0443 959 101 - 17 - © ESAB AB 2013
APPLICATIONS APPLICATIONS 0443 959 101 - 18 - © ESAB AB 2013
APPLICATIONS Tube diameter Centering mandrel Spindle Min mm Max mm Ordering no. Ordering no. 10.0 10.5 0444 540 880 0332 207 880 10.5 11.0 0444 540 881 11.0 11.5 0444 540 882 11.5 12.0 0444 540 883 12.0 12.5 0444 540 884 12.5 13.0 0444 540 885 12.8 14.0 0444 540 886 13.8 15.0 0444 541 881 14.8 16.0 0444 541 882 15.8 17.0 0444 541 883 16.8 18.0 0444 541 884 17.8 19.0 0444 541 885 18.8 20.5 0444 541 886 19.8 22.5 0444 541 887 22.0 25.0 0444 542 880 24.
DIAGRAM DIAGRAM 0443 959 101 - 20 - © ESAB AB 2013
DIAGRAM 12-pole Burndy 23-pole Burndy 0443 959 101 - 21 - © ESAB AB 2013
ORDERING NUMBERS ORDERING NUMBERS Ordering no. Denomination Type 0443 930 880 Tube plate welding tool A22 POC 12-60 0443 930 990 Spare parts list A22 POC 12-60 Instruction manuals and the spare parts list are available on the Internet at: www.esab.
ACCESSORIES ACCESSORIES 0444 044 001 Energrease BP-LS EP 00 0332 330 005 Balance block 0333 897 880 Accessory set for external fillet welding < 36 mm 0333 897 883 Accessory set for external fillet welding 36 - 93 mm 0441 000 880 Accessory set for titan welding 0441 131 880 Accessory set for internal bore welding 9.
ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85 BELGIUM S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28 BULGARIA ESAB Kft Representative Office Sofia Tel: +359 2 974 42 88 Fax: +359 2 974 42 88 THE CZECH REPUBLIC ESAB VAMBERK s.r.o.
