ESAB PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170 Instruction manual
A21 PRB 17- 49
A21 PRB 33- 90
A21 PRB 60- 170
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ПдзгЯет чсЮуещт
Valid for serial no. 803--xxx--xxxx0443 808 001 051222
SVENSKA 3..............................................
DANSK 16................................................
NORSK 29................................................
SUOMI 42................................................
ENGLISH 55..............................................
DEUTSCH 68.............................................
FRANÇAIS 81.............................................
NEDERLANDS 94.........................................
ESPAÑOL 107..............................................
ITALIANO 120..............................................
PORTUGUÊS 133..........................................
ЕЛЛЗНЙКБ 146.............................................
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.
ДйбфзсеЯфбй фп дйкбЯщмб фспрпрпЯзузт рспдйбгсбцюн ЧщсЯт рспейдпрпЯзуз.
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ENGLISH
1 DIRECTIVE 56........................................................
2SAFETY 56...........................................................
3 INTRODUCTION 57...................................................
4 TECHNICAL DATA 58.................................................
5 INSTALLATION 58....................................................
5.1 Connections 59..............................................................
6 OPERATION 60.......................................................
6.1 Securing the welding tool for welding 60.........................................
6.2 Adjustments 61..............................................................
6.3 Welding start 61..............................................................
6.4 Welding in confined spaces 62.................................................
7 MAINTENANCE 64....................................................
7.1 Daily 64.....................................................................
7.2 As necessary 64.............................................................
7.3 Replacing wear parts 66.......................................................
7.4 Fitting of tungsten electrode 67.................................................
7.5 Dismounting the tongs from the tool 67..........................................
8 ORDERING OF SPARE PARTS 67......................................
SPARE PARTS LIST 161...................................................
ACCESSORIES 191.......................................................
TOCe
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that tube welding tool A21 PRB 17--49 / 33--90 / 60--170 from serial number 645
complies with standard EN 60292, in accordance with the requirements of directive
89/392/EEA and addendum.
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Laxå 97--09--22
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
2SAFETY
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 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 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
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
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.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3 INTRODUCTION
A21 PRB 17--49 / 33 --90 / 60--170 is designed for TIG welding of tube joints.
The tube welding tools are adapted for connection to the LTO 160, LTO 250,
LTP 450, LT S 160, LTS 250, LT S 320 power source. If a filler wire is required, use
the MEI 21 wire feed unit.
The tube welding tools incorporate a special
gripping principle facilitating rapid and
accurate securing and location of the
tool on the tube. The pair of gripping
jaws (4) clamp the tool to the tube
when the locking lever (1) on the
handle is pressed in. Only the gear
collar (3) with the fitted details
rotates during welding.
The collar is powered by a drive
unit (2) consisting of a perm. magnet
DC motor and a pulse transmitter for speed
control. The motor is powered by the control equipment (power source).
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4 TECHNICAL DATA
Tube welding tool PRB 17--49 PRB 33--90
Water-cooled
Max welding current at
100% duty cycle (A)
Tube, external diameter (mm) 17--49 33--90
Rotary speed (r.p.m.) 0,12 -- 2,4 0,08 -- 1,6
Weight without cable and hose
package (kg)
Length of hose bundle (m) 7 7
Tungsten electrode, diameter (mm) 1,6 / 2,4 1,6 / 2,4
Filler wire, diameter (mm) 0,6 / 0,8 / 0,9 Fe, SS 0,6 / 0,8 / 0,9 Fe, SS
Drive unit
Max armature voltage (V DC)
Max armature current (A DC)
Armature speed at
20 volt (r.p.m.)
Mechanical gear ratio
250 100 250 100
Air--cooled Water--
cooled
2,8 3,2
48
0,5
6950
246:1
246:1
Air--cooled
48
0,5
6950
Tube welding tool PRB 60--170
Water--cooled Air--cooled
Max welding current at 100% duty cycle (A) 250 100
Tube, external diameter (mm) 60--170
Rotary speed (r.p.m.) 0,05 -- 0,95
Weight without cable and hose package (kg) 4,4
Length of hose bundle (m) 7
Tungsten electrode, diameter (mm) 1,6 / 2,4
Filler wire, diameter (mm) 0,6 / 0,8 / 0,9 Fe, SS
Drive unit
Max armature voltage (V DC)
Max armature current (A DC)
Armature speed at 20 volt (r.p.m.)
Mechanical gear ratio
48
0,5
6950
246:1
5 INSTALLATION
The installation must be execu ted by a p rofessional.
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WARNING!
Rotating parts can cause injury, take great care.
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S Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx.
S Welding power source LTP 450, see instruction manual 0456 634 xxx.
S Welding power source LTS 160, LTS 250, see instruction manual 0458 343 xxx.
S Welding power source LTS 320, see instruction manual 0457 690 xxx.
S Wire feed unit MEI 21, see instruction manual 0443 831 xxx
5.1 Connections
Water--cooled welding tool
A Motor cable -- rotation D Cooling-- water hose in
B Wire conduit E Welding cable
C Cooling-- water hose out F Gas hose
Air--cooled welding tool
A Motor cable -- rotation E Welding cable
B Wire conduit F Gas hose
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 56. Read through before you start usin g the equipment!
S Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx.
S Welding power source LTP 450, see programming manual 0456 638 xxx.
S Welding power source LTS, see programming manual 0457 706 xxx.
WARNING!
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.
6.1 Securing the welding tool for welding
S Set the correct tube diameter using the adjusting screw (3), keeping the
locking lever (1) in the closed position.
S Open the welding tool by means of the locking
lever (1).
S For correct pre--clamping, turn
another quarter of a turn using
adjusting screw (3).
N.B. Harder clamping can deform
the tongs leading to centre
displacement and weld defects.
For welding using equipment for
tube diameters 8-- 17 mm (see
accessories, page NO TAG) the
welding tool is to be fixed with the drive
unit in vertical position, as an alternative a support or relief could be placed under
the drive unit to prevent the welding tool turning round the tube.
S Close the welding tool again by means of the locking lever (1).
S Disengage the gear collar by way of the disengagement arm (2).
S Turn the gear collar (4) about 1.5 turns so as to wind up the connection cable.
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6.2 Adjustments
Adjusting the position of the tungsten electrode
in the weld joint
S Adjust the electrode distance radially
using distance bolt (2).
S Adjust the wire nozzle (1) radially
by way of an Allen key and for
fine adjustment with wheel (2).
The spring load of the arm of the
electrode holder is preset on delivery.
If adjustment is necessary, please
contact your nearest ESAB
representative for information.
Inserting the filler wire
S See instruction manual for wire feed
unit MEI 21 (0443 831 xxx).
Adjusting the filler wire
S Adjust the filler wire nozzle (1) radially
by way of an Allen key. For fine adjustment
use the wheel (2).
6.3 Welding start
S Recall the welding program to be used to the working area (see the program-
ming manual)
S Press the start button (A) on the control unit.
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6.4 Welding in confined spaces
PRB 17--49
Tube welding tool PRB 17--49
Water--cooled Air--cooled
D C--C min D C--C min
S Complete. D±49 70+D D±49 70+D
S Without wheel (1) for precise wire adjust-
ment.
S The torch cover (3) and distance bolt (4)
may need to be replaced by shorter variants.
S Without wheel (1) for precise wire adjust-
ment.
S Without end plates (2).
S With room for cables in axial direction.
S The torch cover (3) and distance bolt (4)
may need to be replaced by shorter variants.
S With filler wire nozzle 0443 880 880.
D±49 70+D/2 D±40
40<D±49
D±34
34<D±49
56+ D/2
39+D
70+D/2
50+D
D±40 50+D
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PRB 33--90
Tube welding tool PRB 33--90
Water--cooled Air--cooled
D C--C min D C--C min
S Complete. D±68
68<D±90
S Without wheel (1) for precise wire adjust-
ment.
S The torch cover (3) and distance bolt (4)
may need to be replaced by shorter variants.
S Without wheel (1) for precise wire adjust-
ment.
S Without end plates (2).
S With room for cables in axial direction.
S The torch cover (3) and distance bolt (4)
may need to be replaced by shorter variants.
D±90 94+D/2 D±90 94+D/2
D±90 82+ D/2 D±64
94+D/2
60+D
D±68
68<D±90
64<D±90
94+D/2
60+D
82+D/2
50+D
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PRB 60--170
Tube welding tool PRB 60--170
Water--cooled Air--cooled
D C--C min D C--C min
S Complete D±170 137+D/2 D±170 137+D/2
7 MAINTENANCE
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.
7.1 Daily
Make sure that all cables and hoses are undamaged.
7.2 As necessary
Clean and grease all sliding surfaces using fresh grease, article no. 0444 044 001
(BP Energrease LS EP 00).
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Changing the complete electrode holder.
S Open the protective cover (1).
S Disassemble the connection blocks (2) and (3) by removing the Allen screws.
S Dismount the clamp (6).
S Withdraw the old electrode holder (5) through the protecting cover (1). Send it
together with clamp (6) to your nearest ESAB representative for exchange
according to our exchange system.
S Fit the new electrode holder in reverse order.
S Make sure the o--rings are properly fitted between the connection blocks (2) and
(3).
Repair of multi--conductor
NOTE! This should be done by authorised ESAB service people.
S Loosen the clamps (4) and (6) at the damaged end and withdraw the hose (7).
S Unsolder the current nipples (11) from the electrode holder (12) / connection
block (2).
S Cut off the damaged part of the hose, but leave a couple of extra centimetres of
the current litzes.
S Fit a tape (8) round the current litzes (9) in level with the hose end to mark the
length of the hose.
S Draw the current litzes (9) some 60--70 mm out of the hose and prevent the
litzes slipping back, using a safety pin or a metal wire (10).
S Cut the litzes (9) about 15 mm shorter than the hose.
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S Fit new current nipples (11) using a pair of cable pliers or other suitable device.
S Solder the current nipples (11) against the electrode holder (12) / connection
block (2) using tin solder.
S Remove the safety pin/metal wire (10).
S Wet the current nipples (11) and push over the hose (7).
S Fit the clamps (4) and (6).
7.3 Replacing wear parts
Water--cooled welding tool
S Remove the torch cover (1).
S Remove the tungsten electrode (5).
S Removetheclampingsleeve(2).
S Remove the gas cup (6).
S Unscrew the electrode nozzle (4) from the gas
lens (3) by means of an Allen key.
S Fit the parts in the reverse order
Note: Make sure the gas lens (3) is fitted with the smooth
side against the sealing washer (7).
Air--cooled welding tools
S Remove the torch cover (1).
S Remove the tungsten electrode (4).
S Removetheclampingsleeve(2).
S Remove the gas cup (5).
S Unscrew the gas lens (3).
S Fit the parts in the reverse order.
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7.4 Fitting of tungsten electrode
Water--cooled welding tool
File off the tungsten electrode and fit it into the
electrode holder as follows:
S Remove the torch cover (1).
S Insert the tungsten electrode (5) into the
electrode nozzle (4) and clamping sleeve.
S Clamp the tungsten electrode with the torch cover (1).
Air--cooled welding tool
File off the tungsten electrode and fit it into the
electrode holder as follows:
S Remove the torch cover (1).
S Insert the tungsten electrode (4) into the gas
lens (3) and clamping sleeve (2).
S Clamp the tungsten electrode with the torch
cover (1).
7.5 Dismounting the tongs from the tool
The tongs can also be fitted reversed to the tool, i.e. the locking lever downwards.
8 ORDERING OF SPARE PARTS
A21 PRB 17--49 / 33--90 / 60--170 is designed and tested in accordance with
the EN 60 292 (IEC 292) international standard.
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 are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as designation and spare part number as shown in the spare parts list.
This will simplify dispatch and ensure you get the right part.
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