ESAB A22 POB Instructions for use

334 771--001 9611
A22 POB
Tubeplate welding tools
Simplified service manual

LIST OF CONTENTS Page
SAFETY 4...........................................................
TECHNICAL DESCRIPTON 5..........................................
INSTALLATION 6.....................................................
OPERATION 10.......................................................
MAINTENANCE 10....................................................
SELECTION TABLE 11.................................................
ACCESSORY SET FOR INTERNAL WELDING 12.........................
ACCESSORY SET FOR EXTERNAL FILLET WELDING 13.................
ACCESSORY SET FOR WELDING TITANIUM 14.........................
WORKING RANGE 15.................................................
DIMENSION DRAWING 16.............................................
DIAGRAM 17.........................................................
CONNECTION DIAGRAM 18...........................................
SPARE PARTS LIST A22 POB 21.......................................
Rights reserved to alter specifications without notice

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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS.
TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY
PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
SInstall and earth the welding unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or both, to keep fumes and gases from
your breathing zone and the general area.
ARC RAYS -- Can injure eyes and burn skin.
SProtect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby.
MALFUNCTION
SCall for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE
INSTALLING OR OPERATING THE EQUIPMENT
PROTECT YOURSELF AND OTHERS!

SAFETY
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SAFETY
Users of ESAB welding equipment have ultimate responsibility for ensuring that any-
one who works on or near the equipment observes all the relevant safety precau-
tions.
Safety precautions must meet the requirements that apply to this type of welding
equipment.
The following recommendations should be observed in addition to the standard re-
gulations that apply to the work place.
All work must be carried out by trained personnel who are familiar with the operation
of the welding equipment.
Incorrect operation of the equipment may lead to a hazardous situation which can
result in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
Sits operation
Sthe location of emergency stops
Sits function
Srelevant safety precautions
Swelding
To make this easier each switch, pushbutton or potentiometer is marked with a
symbol or text that indicates its function when activated.
2. The operator must ensure that:
Sno unauthorized person is stationed within the working area of the equipment
when it is started up.
Sthat no--one is unprotected when the arc is struck
3. The work place must:
Sbe suitable for the purpose
Sbe free from draughts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety
glasses, flame--proof clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified
electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close
at hand.
SLubrication and maintenance must not be carried out on the equipment dur-
ing its operation.

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TECHNICAL DESCRIPTION
The POB tube plate welding tool is intended for TIG--welding of tubes into flat tube plates.
It is suitable for all types of weld joints, in certain cases using extra equipment.
The POB 12--60 welding tool is intended for use together with a spindle and a centering mandrel
according to the selection table on page 11.
POB 12--60 is intended for use with the power sources MECHTIG 315 INVERTER,
PROTIG 315 INVERTER, PROTIG 250 and PROWELDER 250
TECHNICAL DATA A22 POB
Max. continuous welding current 180 A/60 %
Max. pulsed welding current 200 A/60 %
Working range:
base specification
with titanium welding kit
with external fillet welding kit
with internal welding kit
12--60 mm
12--60 mm
12--60 mm
according to designation
Electrode angle for:
butt welding
internal fillet welding
external fillet welding
internal welding
(See page 15)
parallel with tube axis
30_to tube axis
15_to tube axis
90_to tube axis
Electrode diameter 1.6 and 2.4 mm
Speed of rotation 0.3--4.5 r.p.m
Wire feed speed 0.15--1.5 m/min
Wire diameter 0.8 and 0.91 mm
Length of welding cable 8m
Weight
tool
cable and hose bundle
4.5 kg
4.5 kg
Order no.
POB 12--60, base version with wire feed unit 333 893--881
Base version can be fitted with accessory kits for
-- external fillet welding
-- titanium welding
-- internal welding diameter:
9.5--15 mm
15--20 mm
20--30 mm
333 897--880
441 000--880
441 131--880
441 132--880
441 133--880
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When ordering an accessory set for internal welding, please indicate both the inner diameter
(D) of the tube and the distance of the welding joint to the outside (A) of the plate.

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INSTALLATION
1. Welding power source, see separate instruction manual.
2. Dimension drawing, see page 16.
3. Diagram, see page 17.
4. Connection diagram, see page 18 and page 19.
5. Tool dismantling:
It is necessary to dismantle the tool.
SFor adjustment of the ”home” position.
SIn the event of a fault.
Dismantling:
SRemove the three bolts (1) in the support ring (2).
SRemove the screw (4).
SPull off the support tube (3).
SCarefully withdraw the entire inner assembly (5) backwards, being careful not to
damage the microswitch.

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6. Adjusting the ”home” position:
SRemove the four bolts (7).
SWithdraw the gear ring. The lifting cog influencing the microswitch can now be
moved a full turn in 22˚, 5 steps, starting at 11˚, 25 counted from 12 o’clock.
7. Tool reassembly:
SInsert the inner assembly (5) in the outer casing (6). Make sure that the microswitch
is not located just opposite the lifting cog.
SRotate the parts slightly relative to one another, so as to engage the motordrive gear
and the gear ring.
SFit the support tube (3), (lightly grease the contact surface of the sealing ring with a
suitable grease, e.g. Barrierta). Fit the support plate (2) with the screws (1).
SFit the screw (4).

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8. Replacement and fitting of the electrode:
SCut off the electrode to some 45 mm and grind it to the desired angle.
SRemove the gas cup (3).
SRemove the electrode nozzle (2) and the electrode nozzle with gas lens.
SReplace the electrode. When changing to a different electrode diameter it is necess-
ary also to change the electrode nozzle (2) and the collet (1).
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The adjustment of the electrode is important to guarantee the repeatability for continued
welding.
Use ready--ground electrodes of the same length and fit them in the same position.

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9. Adjustment of the welding diameter:
SSlacken the locking screw (8).
SUse a screwdriver to turn the gear wheel (7),
which is mounted on the link arm (3), so
that the correct welding circle diameter is
obtained.
SSlacken the screw (4).
SAdjust the electrode angle by rotating
the electrode holder (6).
STighten the locking screws (4 and 8).
10. Adjusting the arc length:
SAdjust the length of the arc (i.e. the
distance between the tip of the
electrode and the workpiece) by
screwing the spacing tube (9) in or out.
SSecure the setting by means of the
locking nut (10).
11. Inserting the filler wire:
SCut off any bent length of the wire
and file off the end.
SFeed the wire into the nozzle.
SAdvance the wire through the tool
(by running the feed unit manually).
12. Replacing the wire nozzle:
SUndo the screw (5) and remove the nozzle,
which is threaded on to the wire guide.
13. Replacing the wire guide:
SDismantle the tool.
SRemove the wire nozzle from the wire
guide and remove the wire guide from the
inner part of the tool.
SScrew the internally bevelled end of the
new wire guide into the feed unit.
SFit the wire nozzle.
SMount the tool.

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OPERATION
The POB tube welding tool connected to the programmable welding power
source PROTIG 250, PROWELDER 250, PROTIG 315 INVERTER or
MECHTIG 315 INVERTER:
SSet all the welding parameters on the programmable PROTIG 250, PROWELDER 250,
PROTIG 315 INVERTER or MECHTIG 315 INVERTER power source unit.
SAdjust the position and the angle of the electrode.
SStart the automatic welding sequence by pressing the ”Start” button on the power source
or directly on the POB tube welding tool.
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It is important that the tool is suspended according
to the adjoining figure.
For balancing to weightlessness a counterbalancing
device is used. Ordering number 332 330--005
MAINTENANCE
SClean the tool as necessary.
SCheck wearing parts at regular intervals and replace as necessary.
SCheck that all hoses and connections for gas, water, welding current and control current
are undamaged and correctly connected.
SCheck that the correct electrode is being used and that it is properly ground.
By separating the inner and outer parts from each other the equipment is easy to service.

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SELECTION TABLE
Tube diameter Centering mandrel Spindle
Min. mm Max. mm Ordering no. Ordering no.
9,9 10,5 442 634--880 442 714--880
10,3 10,9 442 634--881
10,7 11,3 442 634--882
11,1 11,7 442 634--883
11,5 12,1 442 634--884
11,9 12,7 442 634--885
12,5 13,3 442 634--886
13,1 13,9 442 635--880 332 208--880
13,7 14,5 442 635--881
14,3 15,4 442 635--882
15,2 16,3 442 635--883
16,1 17,6 442 635--884
17,4 19,0 442 635--885
18,8 20,2 442 635--886
19,9 21,7 442 635--887
21,4 23,2 442 636--880 332 209--880
22,9 24,7 442 636--881
24,4 26,6 442 636--882
26,3 28,5 442 636--883
28,1 30,7 442 636--884
30,3 33,1 442 636--885
32,7 36,7 442 636--886
36,2 40,1 442 636--887
39,6 43,7 442 637--880 332 210--880
43,2 47,3 442 637--881
46,7 51,8 442 637--882
51,2 57,2 442 637--883
56,6 63,7 442 637--884
63,0 71,4 442 637--885
70,6 79,0 442 637--886
78,2 86,6 442 637--887

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ACCESSORY SET FOR INTERNAL WELDING
Order number, see on page 5.
Fitting:
1. Dismount the support plate 01 and the support tube 02.
2. Pull of the envelope of the tool 06.
3. Slacken the welding cable clamp 07 (approx. 6 turns) and remove the screws 03 och 04.
4. Pull out the electrode holder and link arm 05 far enough to allow the welding cable to be
disconnected from the electrode holder.
5. Push back the envelope 06 and the support tube 02.
6. Connect the accessory set for internal welding 08 to the welding cable.
7. Pull the accessory set into the correct position by means of the welding cable and secure
it.
8. TIGHTEN THE WELDING CABLE CLAMP 07 THROUGH HOLE 09 IN THE
OUTER CASING 06, OTHERWISE THE ROTATION MOTOR WILL BE DAM-
AGED!
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ACCESSORY SET FOR EXTERNAL FILLET WELDING
Order number, see on page 5.
Fitting:
1. Dismount the spacer tube.
2. Rotate the inner portion, so that the cable is just opposite the group of holes
2xø8 in the envelope.
3. Insert a 2.5 mm Allen key through the holes ø8 and slacken the welding cable clamp
(approx. 6 turns).
4. Dismount the electrode holder and pull it out.
5. Replace the electrode holder and pull into correct position by means of the welding cable.
6. TIGHTEN THE WELDING CABLE CLAMP THROUGH THE HOLES ø8.
OTHERWISE THE ROTATION MOTOR WILL BE DAMAGED!
7. Fit the guide finger mount, the guide fingers, then Allen screw and the locking washer.
8. Replace the electrode nozzle.
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ACCESSORY SET FOR WELDING TITANIUM
Order number, see on page 5.
Welding with the accessory kit for titanium.
1. Cut a hole in the rubber disk (1) so that the rubber rests against the plate at a safe dis-
tance from the arc.
2. Dismount the complete gas shield (2) from the three--point support (3) by means of an
Allen key (4).
3. Adjust the weld diameter and arc length in the normal way (preferably while the tool is
attached to the work piece).
4. Fit the gas shield (2) with the gas connection pointing downwards.
5. Purge the tool with gas to drive out all the air.
6. Tape over the ø8 holes in the outer casing of the tool (6).
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