ESAB PRC 33-90 User manual

ESAB
Brand
ESAB
Model
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
-- 2 --
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.
GB
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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).
GB
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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
24
0,5
6950
246:1
24
0.5
6950
246:1
24
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)
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
GB
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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
GB
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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).
GB
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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.
GB
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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.
GB
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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
GB
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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
GB
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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
GB
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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.
GB
-- 7 1 --
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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).
GB
-- 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.
GB
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
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ESAB PRC 33-90 User manual

ESAB
Brand
ESAB
Model
PRC 33-90
Category
Welding System
Type
User manual
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