ESAB A21 PRC 33-90 User manual

Brand: ESAB

Model: A21 PRC 33-90

Category: Welding System

Type: User manual

This manual is also suitable for

Valid for serial no. 538--xxx--xxxx0443 934 101 060208

A21 PRC 17-49

A21 PRC 33-90

A21 PRC 60-170

101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

Ïäçãßåò ÷ñÞóåùò

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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.

Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.

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

DANSK 17................................................

NORSK 31................................................

SUOMI 45................................................

ENGLISH 59..............................................

DEUTSCH 73.............................................

FRANÇAIS 87.............................................

NEDERLANDS 101.........................................

ESPAÑOL 115..............................................

ITALIANO 130..............................................

PORTUGUÊS 144..........................................

ÅËËÇÍÉÊÁ 158.............................................

ENGLISH

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TOCe

1 DIRECTIVE 60........................................................

2SAFETY 60..........................................................

3 I NTRODUCTION 61...................................................

4 TECHNICAL DATA 62.................................................

5 INSTALLATION 63....................................................

5.1 Connection 63...............................................................

5.2 Assembly instructions 64......................................................

6 OPERATION 65.......................................................

6.1 Securing the welding tool for welding 65.........................................

6.2 Adjustments 66..............................................................

6.3 Welding start 66..............................................................

6.4 Welding in confined spaces 67.................................................

7 MAINTENANCE 70....................................................

7.1 Daily 70.....................................................................

7.2 As necessary 70.............................................................

7.3 Replacing wear parts 72.......................................................

7.4 Fitting of tungsten electrode 72.................................................

7.5 Dismounting the tongs from the tool 72..........................................

8 ORDERING OF SPARE PARTS 72......................................

DIAGRAM 173............................................................

SPARE PARTS LIST 175...................................................

ACCESSORIES 224.......................................................

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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 PRC 17--49 / 33 --90 / 60--170 from serial number 732

complies with standard EN 60292, in accordance with the requirements of directive

(89/392/EEA) and addendum.

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------

Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Laxå 97--09--22

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 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 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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS 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 s uitable 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!

3 INTRODUCTION

A21 PRC 17--49 / 33--90 / 60--170 is designed for TIG welding of tube joints.

The tube welding tools a re 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 LT P 450. When filler wir e 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. T he motor is powered by the

control equipment (power source).

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The fo llo win g A21 PRC variants are available:

PRC 17--49 PRC 33--90 PRC 60--170

With AVC 0443 751 881 0443 761 881 0443 771 881

With AVC & weavin g unit 0443 752 881 0443 762 881 0443 772 881

Conversion kits for conversion from A21 PRB to A21 PRC:

PRB 17--49 PRB 33--90 PRB 60--170

AVC unit 0443 936 880 0443 936 881 0443 936 882

Weaving unit 0443 937 880 0443 937 880 0443 938 880

Note that weaving is normally impossible without the AVC unit.

4 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

0,5

6950

246:1

0.5

6950

246:1

0.5

6950

246:1

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)

0.2

6

1.8

0.2

6

1.8

0.2

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)

0.2

0.5

0.2

0.5

0.2

0.5

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5 INSTALLATION

The in stallatio n must be execu ted by a professional.

WARNING!

Rotating parts can cause injury, take great care.

S Welding power source LTP 450, see instruction manual 0456 634 xxx.

S Wire feed unit MEI 21, see instruction manual 0443 831 xxx

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 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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6 OPERATION

General safety regulations for the handling of the equipment can be found on

page 60. Read through before you start using the equipment!

S Welding power source LT P 450, see programm ing manual 0456 638 xxx.

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.

WARNING!

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 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 224) 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 m eans 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 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 f iller wire

S See instruction manual for wire feed

unit MEI 21, 0443 831 xxx.

Adjusting th e 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

programming manual)

S Press the start button (A) on the control unit.

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6.4 Welding in confined spaces

PRC 17--49 with AVC

PRC 17--49 with AVC an d weaving unit

PRC 17--49 D C--C min

S Complete. D±49 70+D

S Without wheel (1) for precise wire adjustment.

S The torch cover (3) may need to be replaced by shorter

variants.

D±49 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 0443 880 880.

D±34

34±D±49

56+ D/2

39+D

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PRC 33--90 with AVC

PRC 33--90 with AVC an d weaving unit

PRC 33--90 D C--C min

S Complete. D±68

68±D±90

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.

D±90 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.

D±90 82+D/2

-- 6 9 --

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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. D±170 137+D/2

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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).

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), (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 o f

the current litzes.

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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).

-- 7 2 --

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7.3 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 r everse order

Note: Make sure the gas lens (3) is fitted with the

smooth side against the sealing washer (7).

7.4 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).

7.5 Dismounting the tongs from the tool

See “Weaving unit” on page 64.

8 ORDERING OF SPARE PARTS

A21 PRC 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 re-

pair work to make sure that the product still conforms to the said standard.

Spare parts are order ed through your nearest ESAB representative, see back cover.

When ordering spare parts, please state machine type and number as well as desig -

nation and spare part number as shown in the spare parts list.

This will simplify dispatch and ensure you get the right part.

ESAB AB

SE--695 81 L AXÅ

SWEDEN

Phone +46 584 81 000

www.esab.co m

0511118

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

THE CZECH REPUBLIC

ESAB V AMBERK s.r .o.

Prague

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Copenhagen-- Valby

Tel:+4536300111

Fax:+4536304003

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel:+33130755500

Fax:+33130755524

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel:+3612044182

Fax:+3612044186

ITALY

ESAB Saldatura S.p.A.

Mesero (Mi)

Tel:+3902979681

Fax:+390297289181

THE NETHERLANDS

ESAB Nederland B.V.

Utrecht

Tel: +31 30 2485 377

Fax: +31 30 2485 260

NORWAY

AS ESAB

Larvik

Tel:+4733121000

Fax:+4733115203

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel:+421744882426

Fax:+421744888741

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel:+4631509500

Fax:+4631509222

ESAB international AB

Gothenburg

Tel:+4631509000

Fax:+4631509360

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem--MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 5308 9922

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 3 5296 7371

Fax: +81 3 5296 8080

MALAYSIA

ESAB (Malaysia) Snd Bhd

Selangor

Tel: +60 3 8027 9869

Fax: +60 3 8027 4754

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

Dokki--Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office

Bucharest

Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB

Moscow

Tel: +7 095 543 9281

Fax: +7 095 543 9280

LLC ESAB

St Petersburg

Tel: +7 812 336 7080

Fax: +7 812 336 7060

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.co m

ESAB A21 PRC 33-90 User manual

Brand: ESAB

Model: A21 PRC 33-90

Category: Welding System

Type: User manual

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ESAB A21 PRC 33-90 User manual

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