ESAB A21 PRB 33-90 User manual

ESAB
Brand
ESAB
Model
A21 PRB 33-90
Category
Welding System
Type
User manual

This manual is also suitable for

GB
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.
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 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!
GB
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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).
GB
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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
48
0,5
6950
246:1
48
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
48
0,5
6950
246:1
Operating temperature -10 to +40° C
Transportation temperature -20 to +55° C
GB
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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.
GB
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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. D49 70+D D49 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.
D49 D70+D/2 D40
40tD49
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)
D34
34tD49
56+ D/2
39+D
D40 50+D
GB
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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. D68
68tD90
94+D/2
60+D
D68
68tD90
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.
D90 94+D/2 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) and distance bolt (4)
may need to be replaced by shorter
variants.
D90 82+ D/2 D64
64tD90
82+D/2
50+D
GB
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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 D170 137+D/2 D170 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.
GB
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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.
GB
PRB 17-49, PRB 33-90, PRB 60-170
Edition 100301
Ordering number
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dsa8o
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 A21 PRB 33-90 User manual

ESAB
Brand
ESAB
Model
A21 PRB 33-90
Category
Welding System
Type
User manual
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