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

101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung

Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções

ПдзгЯет чсЮуещт

Valid for serial no. 538--xxx--xxxx0443 808 101 060209

SVENSKA 3..............................................

DANSK 16................................................

NORSK 30................................................

SUOMI 44................................................

ENGLISH 58..............................................

DEUTSCH 72.............................................

FRANÇAIS 86.............................................

NEDERLANDS 100.........................................

ESPAÑOL 114..............................................

ITALIANO 128..............................................

PORTUGUÊS 142..........................................

ЕЛЛЗНЙКБ 156.............................................

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 59........................................................

2SAFETY 59...........................................................

3 INTRODUCTION 60...................................................

4 TECHNICAL DATA 61.................................................

5 INSTALLATION 62....................................................

5.1 Connections 63..............................................................

6 OPERATION 64.......................................................

6.1 Securing the welding tool for welding 64.........................................

6.2 Adjustments 65..............................................................

6.3 Welding start 65..............................................................

6.4 Welding in confined spaces 66.................................................

7 MAINTENANCE 68....................................................

7.1 Daily 68.....................................................................

7.2 As necessary 68.............................................................

7.3 Replacing wear parts 70.......................................................

7.4 Fitting of tungsten electrode 71.................................................

7.5 Dismounting the tongs from the tool 71..........................................

8 ORDERING OF SPARE PARTS 71......................................

SPARE PARTS LIST 173...................................................

ACCESSORIES 209.......................................................

TOCe

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1DIRECTIVE

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, LTS 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

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5 INSTALLATION

The installation must be executed by a profession al.

WARNING!

Rotating parts can cause injury, take great care.

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

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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 59. Read through before you start using 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 209) 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 Remove the clamping sleeve (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 Remove the clamping sleeve (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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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V .
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Prague
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Copenhagen--Valby
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Utrecht
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax: [phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax: [phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel: [phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

0511118