GB
Valid for serial no. 538-xxx-xxxx0443 934 201 GB 100215
A21
PRC 17-49
PRC 33-90
PRC 60-170
Instruction manual
DECLARATION OF CONFORMITY
according to the Machinery Directive 2006/42/EC, according to the EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
enligt Maskindirektivet 2006/42/EG, enligt EMC−Direktivet 2004/108/EG
Type of equipment Materialslag
Tube welding tool
Brand name or trade mark Fabrikatnamn eller varumärke
ESAB
Type designation etc. Typbeteckning etc.
PRC 17−49, 33−90, 60−170, from Serial number 538 xxx xxxx (2005 week 38)
PRC Tube welding tools are members of the ESAB product family A21
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:
ESAB AB, Welding Equipment
Esabvägen, SE−695 81 LAXÅ, Sweden
Phone: +46 584 81 000, Fax: +46 584 411 924
The following harmonised standard in force within the EEA has been used in the design:
Följande harmoniserande standarder har använts i konstruktionen:
EN 60204−1, Safety of machinery – Electrical equipment of machines – Party 1: General requirements
EN 12100−2, Safety of machinery – Part 2: Technical principles
EN 60974−10 Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.
Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.
Date / Datum
Laxå 2010−02−12
Signature / Underskrift Position / Befattning
Global Director
Equipment and Automation
Kent Eimbrodt
Clarification
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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Assembly instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Connection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Securing the welding tool for welding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Adjustments 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Welding in confined spaces 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 MAINTENANCE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Daily 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 As necessary 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Replacing wear parts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Fitting of tungsten electrode 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Dismounting the tongs from the tool 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ORDERING OF SPARE PARTS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING NUMBER 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WEAR PARTS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 SAFETY
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 recommen
dations 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 unauthorized 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. Note! Do not use safety gloves when replacing wire.
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.
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.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Read and understand the instruction manual before
installing or operating.
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and returned to an
environmentally compatible recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human
health!
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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.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
PRC 17-49 / 33-90 / 60-170 is designed for TIG welding of tube joints.
The tube welding tools are water-cooled and include weaving function (6) and
automatic arc length control (by control of the arc voltage = AVC) (5). The tools are
adapted for connection to the power source MechTig. When filler wire is required the
MEI 21 wire feed unit is to be used.
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).
ESAB's accessories for the product can be found on page 20.
3 TECHNICAL DATA
Tube welding tool PRC 17-49 PRC 33-90 PRC 60-170
Max welding current at 100% duty cycle (A) 250 250 250
Tube, external diameter (mm) 17-49 33-90 60-170
Rotary speed (r.p.m.) 0.12 - 2.4 0.08 - 1.6 0.05 - 0.95
Weight without cable, hose package, AVC- and
weaving-unit (kg)
2.8 3.2 4.4
Length of hose bundle (m) 7 7 7
Tungsten electrode, diameter (mm) 1.6 / 2.4 1.6 / 2.4 1.6 / 2.4
Filler wire, diameter (mm) Fe, SS 0.6 / 0.8 / 0.9 0.6 / 0.8 / 0.9 0.6 / 0.8 / 0.9
Drive unit
Max armature voltage (V DC)
Max armature current (A DC)
Armature speed at 20 volt (r.p.m.)
Mechanical gear ratio
24
0,5
6950
246:1
24
0,5
6950
246:1
24
0,5
6950
246:1
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Tube welding tool PRC 60-170PRC 33-90PRC 17-49
Weaving
Motor
Max armature voltage (V DC)
Max armature current (A DC)
Max speed, weaving motion (mm/s)
Min speed, weaving motion (mm/s)
Setting range (mm)
Amplitude (mm)
Weight (kg)
24
0.2
12
2
20
"6
1.8
24
0.2
12
2
20
"6
1.8
24
0.2
12
2
20
"6
2.2
AVC (Arc Voltage Control)
Motor
Max armature voltage (V DC)
Max armature current (mA DC)
Normal control speed at 10 V (arc control, mm/s)
Weight (kg)
12
0.2
2
0.5
12
0.2
2
0.5
12
0.2
2
0.5
Operating temperature -10 to +40° C
Transportation temperature -20 to +55° C
4 INSTALLATION
The installation must be executed 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 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.
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4.1 Assembly instructions
AVC unit
Weaving unit
Weaving unit (3) and the tongs (1) can also
be fitted reversed to the tool, i.e. the locking
lever (1c) downwards.
S Dismounting the tongs (1) and weaving
unit (3) from the rotary unit (4).
A special fixture (5) is supplied which is
to be fitted between the gripping jaws
(1b) and the gear collar (4b) before
tightening. This is to avoid centre
displacement when fixing the tongs (1)
to the rotary unit (4).
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5 OPERATION
General safety regulations for the handling of 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 weld 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.
5.1 Connection
A Motor cable - rotation
B Wire conduit
C Cooling- water hose out
D Cooling- water hose in
E Welding cable
F Gas hose
G Motor cable - Weaving unit
H Measurement cable - AVC-unit
I Motor cable - AVC-unit
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5.2 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 preclamping, 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 20) 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.
5.3 Adjustments
Adjusting the position of the tungsten electrode in the weld joint
S Adjust the electrode distance
radially using the control box with
AVC-unit (3).
N.B. When using the tool for the max. tube
diameters 49, 90, 170 mm, the distance
between the periphery of the tube and the gas
cup cannot exceed 7.5 mm.
S Adjust the position of the wire axially with setting
screw (1) or over the programming box with
weaving unit (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.
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).
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5.4 Welding in confined spaces
PRC 17-49 with AVC
PRC 17-49 with AVC and weaving unit
PRC 17-49 D C-C min
S Complete. D49 70+D
S Without wheel (1) for precise wire adjustment.
S The torch cover (3) may need to be replaced by shorter
variants.
D49 70+D/2
S Without wheel (1) for precise wire adjustment.
S Without end plates (2).
S With room for cables in axial direction.
S The torch cover (3) may need to be replaced by shorter
variants.
S With filler wire nozzle (accessories)
D34
34D49
56+ D/2
39+D
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PRC 33-90 with AVC
PRC 33-90 with AVC and weaving unit
PRC 33-90 D C-C min
S Complete. D68
68D90
94+D/2
60+D
S Without wheel (1) for precise wire adjustment.
S The torch cover (3) may need to be replaced by shorter
variants.
D90 94+D/2
S Without wheel (1) for precise wire adjustment.
S Without end plates (2).
S With room for cables in axial direction.
S The torch cover (3) may need to be replaced by shorter
variants.
D90 82+D/2
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PRC 60-170 with AVC
PRC 60-170 with AVC and weaving unit
PRC 60 - 170 D C-C min
S Complete. D170 137+D/2
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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 himself
attempts any work in the product during the guarantee period in order to rectify any faults.
6.1 Daily
Make sure that all cables and hoses are undamaged.
6.2 As necessary
Clean and grease all sliding surfaces using fresh grease, see accessories, page 20.
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).
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Repair of multi-conductor
NOTE! This should be done by authorised ESAB service people.
S Loosen the clamps (4), (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.
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 Put back the clamps (4) and (6).
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6.3 Replacing wear parts
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).
6.4 Fitting of tungsten electrode
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).
6.5 Dismounting the tongs from the tool
See “Weaving unit” on page 8.
7 ORDERING OF SPARE PARTS
PRC 17-49, PRC 33-90, PRC 60-170 is designed and tested in accordance with the inter
national and European standards EN 60204-1, EN 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.
GB
PRC 17-49, PRC 33-90, PRC 60-170
Edition 100215
Ordering number
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Ordering no. Denomination Type Notes
0443 751 881 Tube welding tool PRC 17-49 AVC, Water cooled
0443 752 881 Tube welding tool PRC 17-49 AVC, weaving unit, water cooled
0443 761 881 Tube welding tool PRC 33-90 AVC, Water cooled
0443 762 881 Tube welding tool PRC 33-90 AVC, weaving unit, water cooled
0443 771 881 Tube welding tool PRC 60-170 AVC, Water cooled
0443 772 881 Tube welding tool PRC 60-170 AVC, weaving unit, water cooled
0443 934 990 Spare parts list PRC 17-49, PRC
33-90, PRC 60-170
Instruction manuals and the spare parts list are available on the Internet at www.esab.com
PRC 17-49, PRC 33-90, PRC 60-170
Edition 100215
Wear parts
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Item
no.
Qty Ordering no. Denomination Notes
0443 807 880 Wear parts
1 1 0332 811 001 Clamping sleeve 1,6
2 1 0332 811 003 Clamping sleeve 2,4
3 1 0443 785 001 Electrode nozzle 1,6
4 1 0443 785 002 Electrode nozzle 2,4
5 1 0151 574 002 Tungsten electrode 1,6
6 1 0151 574 003 Tungsten electrode 2,4
7 2 0443 787 001 Sealing washer
8 2 0443 786 001 Gas lens
9 1 0332 801 880 Torch cover
10 1 0365 310 049 Torch cover
11 1 0365 310 050 Torch cover medium
12 2 0443 788 001 Gas cup
13 1 0333 420 880 Journal
14 1 0443 813 001 Ball pressure screw
1 0154 438 001 Hex tool key 2.5 mm
1 0193 387 101 In6 key set 8 pieces 1.5 - 6 mm
1 0334 731 001 Box
1 0444 044 001 Lubrication grease
PRC 17-49, PRC 33-90, PRC 60-170
Edition 100215
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Item
no.
Qty Ordering no. Denomination Notes
0443 815 880 Wire setting parts
1 1 0443 789 001 Wire attachment
2 1 0443 790 001 Wire rock
3 1 0443 791 001 Wire knob 44 mm
1 0443 791 002 Wire knob 62 mm
1 0443 791 003 Wire knob 72 mm
4 1 0443 792 001 Spring
5 1 0192 238 219 Screw IN6 M3 x 5, DIN 912
6 1 0212 204 343 Screw M5 x 6
7 2 0190 509 321 Screw M5 x 6
8 1 0332 792 001 Joural
PRC 17-49, PRC 33-90, PRC 60-170
Edition 100215
Accessories
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Angular support 0443 875 880. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRC 17-49 wire conduit for welding in confined spaces 0443 880 880. . . . . . . . . . . . . . . . . . . . . . . .
Wheel for precise wire adjustment (62 mm) PRC 17-49, 33-90 0443 791 002. . . . . . . . . . . . . . . . .
Conversion kit for PRC 17-49 welding of tube diameters 8-17 mm 0444 002 880. . . . . . . . . . . . . . .
Conversion kit for PRC 33-90 welding of tube diameters 20-33 mm. 0443 908 880. . . . . . . . . . . . .
Conversion kit for PRC 60-170 welding of tube diameters 44-60 mm. 0443 909 880. . . . . . . . . . . .
Driving unit 134:1 0443 544 880. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate for angular support together with conversion kit for smaller diameters 0444 226 880. . . . . .
Wire holder complete with gas lens Ø24 mm with adjustable wire nozzle for
PRC 33-170 0443 923 880. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire nozzle straight for PRC 17-170 complete adjustable holder 0443 988 880. . . . . . . . . . . . . . . .
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