Valid for serial no. 803--xxx--xxxx0443 934 001 020321
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 129..............................................
PORTUGUÊS 143..........................................
ÅËËÇÍÉÊÁ 157.............................................
ENGLISH
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TOCe
1 DIRECTIVE 60........................................................
2SAFETY 60..........................................................
3 INTRODUCTION 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 172............................................................
SPARE PARTS LIST 173...................................................
ACCESSORIES 203.......................................................
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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 PRC 17--49 / 33--90 / 60--170 from serial number 732
complies with standard EN 60292, in accordance with the requirements of d irective
(89/392/EEA) and addendum.
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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 OPERAT ING.
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 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!
3 INTRODUCTION
A21 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 sour ce LTP 450. 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. T he 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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The following A21 PRC variants are available:
PRC 17--49 PRC 33--90 PRC 60--170
With AVC 0443 751 880 0443 761 880 0443 771 880
With AVC & weavin g unit 0443 752 880 0443 762 880 0443 772 880
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
T ube, 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
T ungsten 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
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5 INSTALLATION
The in stallatio n must b e executed 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 M EI 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 LTP 450, see programming 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 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 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 MEI 21, 0443 831 xxx.
Adjusting th e filler wire
S Adjust the filler wire nozzle (1)
radially by way of an Allen key. F or
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 and weaving u n it
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 and weaving u n it
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
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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 b y 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 of
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).
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7.3 Replacing wear parts
S Remove the tor ch 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 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 tor ch 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 ordered 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 r ight part.
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