ESAB PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170 User manual

Brand: ESAB

Model: PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170

Category: Welding System

Type: User manual

This manual is also suitable for

Valid for serial no. 538-xxx-xxxx0443 808 201 GB 100301

A21

PRB 17-49

PRB 33-90

PRB 60-170

Instruction manual

DECLARATION OF CONFORMITY

according to the Machinery Directive 98/37/EC, according to the EMC Directive 2004/108/EC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt Maskindirektivet 98/37/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.

PRB 17−49, 33−90, 60−170, from Serial number 538 xxx xxxx (2005 week 38)

PRB 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 2010−02−24

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 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Securing the welding tool for welding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Adjustments 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Welding in confined spaces 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Daily 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 As necessary 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Replacing wear parts 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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!

Read and understand the instruction manual before

installing or operating.

CAUTION!

This product is solely intended for arc welding.

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

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 MechTig 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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3 TECHNICAL DATA

Tube welding tool PRB 17−49 PRB 33−90

Water−

cooled

Air−cooled Water−

cooled

Air−cooled

Max welding current at 100% duty

cycle (A)

250 100 250 100

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)

2,8 3,2

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 V(r.p.m.)

Mechanical gear ratio

0,5

6950

246:1

0,5

6950

246:1

Operating temperature -10 to +40° C -10 to +40° C

Transportation temperature -20 to +55° C -20 to +55° C

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

0,5

6950

246:1

Operating temperature -10 to +40° C

Transportation temperature -20 to +55° C

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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.

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.

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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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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 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

21) 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 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

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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).

5.4 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

adjustment.

S The torch cover (3) and distance bolt (4)

may need to be replaced by shorter

variants.

D49 D70+D/2 D40

40tD49

70+D/2

50+D

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) and distance bolt (4)

may need to be replaced by shorter

variants.

S With filler wire nozzle (accessories)

D34

34tD49

56+ D/2

39+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

68tD90

94+D/2

60+D

D68

68tD90

94+D/2

60+D

S Without wheel (1) for precise wire

adjustment.

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

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) and distance bolt (4)

may need to be replaced by shorter

variants.

D90 82+ D/2 D64

64tD90

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

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 21.

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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).

6.3 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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6.4 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).

6.5 Dismounting the tongs from the tool

The tongs can also be fitted reversed to the tool, i.e. the locking lever downwards.

7 ORDERING OF SPARE PARTS

PRB 17-49 / 33-90 / 60-170 is designed and tested in accordance with the international

and European standards EN 60204-1 / EN 12100-2 and EN 60974-10 . It is the obliga

tion 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.

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

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

Edition 100301

Ordering number

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Ordering no. Denomination Type Notes

0443 750 882 Tube welding tool PRB 17-49 Water cooled

0443 750 883 Tube welding tool PRB 17-49 Air cooled

0443 760 882 Tube welding tool PRB 33-90 Water cooled

0443 760 883 Tube welding tool PRB 33-90 Air cooled

0443 770 882 Tube welding tool PRB 60-170 Water cooled

0443 770 883 Tube welding tool PRB 60-170 Air cooled

0443 808 990 Spare parts list PRB 17-49, PRB 33-90,

PRB 60-170

Instruction manuals and the spare parts list are available on the Internet at www.esab.com

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

Edition 100301

Wear parts

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Item

no.

Qty Ordering no. Denomination Notes

0443 807 880 Wear parts Water cooled

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

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

Edition 100301

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Item

no.

Qty Ordering no. Denomination Notes

Wear parts Air cooled

1 0443 813 001 Ball pressure screw

2 0443 812 880 Distance screw

3 0365 310 029 Clamping sleeve 1,6

0365 310 030 Clamping sleeve 2,4

4 0151 574 002 Tungsten electrode 1,6

0151 574 003 Tungsten electrode 2,4

5 0332 801 880 Torch cover

6 0365 310 049 Torch cover

7 0365 310 050 Torch cup medium

8 0443 787 001 Sealing washer

9 0157 121 017 Gas lens 1,6

0157 121 018 Gas lens 2,4

10 0157 121 033 Gas cup 8,0

11 0157 121 034 Gas cup 9,8

12 0157 121 040 Gas cup 12,7

13 0333 420 880 Journal

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

Edition 100301

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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

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ESAB PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170 User manual

Brand: ESAB

Model: PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170

ESAB PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170 User manual

This manual is also suitable for

ESAB PRB 17-49, PRB 33-90, PRB 60-170 - A21 PRB 17-49, A21 PRB 33-90, A21 PRB 60-170 User manual

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