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A21 PRB 17- 49 A21 PRB 33- 90 A21 PRB 60- 170

101103105107109111102021110025108024042106023061104022041100020040060001

Bruksanvisning Brugsanvisning Bruksanvisning Kyttohjeet Instruction manual Betriebsanweisung

Manuel dinstructions Gebruiksaanwijzing Instrucciones de uso Istruzioni per luso Manual de instrues

0443 808 001

020321

Valid for serial no. 803-xxx-xxxx

SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 FRANAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 ESPAOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 PORTUGUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Rtt till ndring av specifikationer utan avisering frbehlles. Ret til ndring af specifikationer uden varsel forbeholdes. Rett til endre spesifikasjoner uten varsel forbeholdes. Oikeudet muutoksiin pidtetn. Rights reserved to alter specifications without notice. nderungen vorbehalten. Sous rserve de modifications sans avis pralable. 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 especificaes sem aviso prvio. .

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ENGLISH

1 2 3 4 5

DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 56 57 58 58
59

6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 6.2 6.3 6.4 7.1 7.2 7.3 7.4 7.5 Securing the welding tool for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding in confined spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting of tungsten electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismounting the tongs from the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60
60 61 61 62

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64
64 64 66 67 67

8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

TOCe

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GB 1 DIRECTIVE

DECLARATION OF CONFORMITY Esab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guarantee that tube welding tool A21 PRB 17--49 / 33--90 / 60--170 from serial number 645 complies with standard EN 60292, in accordance with the requirements of directive 89/392/EEA and addendum. -------------------------------------------------------------------------------------------------------------------------------------Lax 97--09--22

Paul Karlsson Managing Director Esab Welding Equipment AB 695 81 LAX SWEDEN

Tel: + 46 584 81000

Fax: + 46 584 12336

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 recommendations 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 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 The workplace must: S be suitable for the purpose S be free from draughts 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. 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.

2.

3.

4.

5.

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WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS 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. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!

INTRODUCTION

A21 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 LTO 160, LTO 250, LTP 450, LTS 160, LTS 250, LTS 320 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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GB 4 TECHNICAL DATA
PRB 17-49 Watercooled Max welding current at 100% duty cycle (A) Tube, external diameter (mm) Rotary speed (r.p.m.) Weight without cable and hose package (kg) Length of hose bundle (m) Tungsten electrode, diameter (mm) Filler wire, diameter (mm) Drive unit Max armature voltage (V DC) Max armature current (A DC) Armature speed at 20 volt (r.p.m.) Mechanical gear ratio Tube welding tool Max welding current at 100% duty cycle (A) Tube, external diameter (mm) Rotary speed (r.p.m.) Weight without cable and hose package (kg) Length of hose bundle (m) Tungsten electrode, diameter (mm) Filler wire, diameter (mm) Drive unit Max armature voltage (V DC) Max armature current (A DC) Armature speed at 20 volt (r.p.m.) Mechanical gear ratio 250 60--170 0,05 -- 0,95 4,4 7 1,6 / 2,4 0,6 / 0,8 / 0,9 Fe, SS 48 0,5 6950 246:1 250 17--49 0,12 -- 2,4 2,8 7 1,6 / 2,4 0,6 / 0,8 / 0,9 Fe, SS 48 0,5 6950 246:1 Air-cooled 100 PRB 33-90 Watercooled 250 33--90 0,08 -- 1,6 3,2 7 1,6 / 2,4 0,6 / 0,8 / 0,9 Fe, SS 48 0,5 6950 246:1 PRB 60-170 Water-cooled Air-cooled 100 Air-cooled 100

Tube welding tool

INSTALLATION

The installation must be executed by a professional.

WARNING!
Rotating parts can cause injury, take great care.

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S S S S S Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx. Welding power source LTP 450, see instruction manual 0456 634 xxx. Welding power source LTS 160, LTS 250, see instruction manual 0458 343 xxx. Welding power source LTS 320, see instruction manual 0457 690 xxx. Wire feed unit MEI 21, see instruction manual 0443 831 xxx

5.1
A B C

Connections
Motor cable -- rotation Wire conduit Cooling-- water hose out D E F Cooling-- water hose in Welding cable Gas hose

Water-cooled welding tool

Air-cooled welding tool A B Motor cable -- rotation Wire conduit E F Welding cable Gas hose

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GB 6 OPERATION

General safety regulations for the handling of the equipment can be found on page 56. Read through before you start using the equipment! S S S Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx. Welding power source LTP 450, see programming manual 0456 638 xxx. Welding power source LTS, see programming manual 0457 706 xxx. WARNING!
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.

6.1
S S S

Securing the welding tool for welding


Set the correct tube diameter using the adjusting screw (3), keeping the locking lever (1) in the closed position. Open the welding tool by means of the locking lever (1). 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 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 S S

Close the welding tool again by means of the locking lever (1). Disengage the gear collar by way of the disengagement arm (2). 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 S Adjust the electrode distance radially using distance bolt (2).

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 MEI 21 (0443 831 xxx). Adjust the filler wire nozzle (1) radially by way of an Allen key. For fine adjustment use the wheel (2).

Adjusting the filler wire S

6.3
S S

Welding start
Recall the welding program to be used to the working area (see the programming manual) Press the start button (A) on the control unit.

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6.4 Welding in confined spaces

PRB 17-49

Tube welding tool Water-cooled D S Complete. 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. 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 0443 880 880. D49 D49

PRB 17-49 Air-cooled D D49 D40 40<D49 D40 C-C min 70+D 70+D/2 50+D 50+D C-C min 70+D 70+D/2

D34 34<D49

56+ D/2 39+D

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GB
PRB 33-90

Tube welding tool Water-cooled D S Complete. 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. 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. D68 68<D90 D90

PRB 33-90 Air-cooled D D68 68<D90 D90 C-C min 94+D/2 60+D 94+D/2 C-C min 94+D/2 60+D 94+D/2

D90

82+ D/2

D64 64<D90

82+D/2 50+D

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PRB 60-170

Tube welding tool D S Complete D170

PRB 60-170 Water-cooled C-C min 137+D/2 D D170 Air-cooled C-C min 137+D/2

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).
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Changing the complete electrode holder.

S S S S

Open the protective cover (1). Disassemble the connection blocks (2) and (3) by removing the Allen screws. Dismount the clamp (6). 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.

Fit the new electrode holder in reverse order. Make sure the o--rings are properly fitted between the connection blocks (2) and (3). Repair of multi-conductor S S NOTE! This should be done by authorised ESAB service people. S S S S Loosen the clamps (4) and (6) at the damaged end and withdraw the hose (7). Unsolder the current nipples (11) from the electrode holder (12) / connection block (2). Cut off the damaged part of the hose, but leave a couple of extra centimetres of the current litzes. Fit a tape (8) round the current litzes (9) in level with the hose end to mark the length of the hose.

S 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). 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 S S S

Solder the current nipples (11) against the electrode holder (12) / connection block (2) using tin solder. Remove the safety pin/metal wire (10). Wet the current nipples (11) and push over the hose (7). Fit the clamps (4) and (6).

7.3

Replacing wear parts


Remove the torch cover (1). Remove the tungsten electrode (5). Remove the clamping sleeve (2). Remove the gas cup (6). Unscrew the electrode nozzle (4) from the gas lens (3) by means of an Allen key.

Water-cooled welding tool S S S S S

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 S S S S S Remove the torch cover (1). Remove the tungsten electrode (4). Remove the clamping sleeve (2). Remove the gas cup (5). Unscrew the gas lens (3). Fit the parts in the reverse order.

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7.4 Fitting of tungsten electrode

Water-cooled welding tool File off the tungsten electrode and fit it into the electrode holder as follows: S S S Remove the torch cover (1). Insert the tungsten electrode (5) into the electrode nozzle (4) and clamping sleeve. 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 S S Remove the torch cover (1). Insert the tungsten electrode (4) into the gas lens (3) and clamping sleeve (2). Clamp the tungsten electrode with the torch cover (1).

7.5

Dismounting the tongs from the tool

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

ORDERING OF SPARE PARTS


A21 PRB 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 repair 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 designation and spare part number as shown in the spare parts list. This will simplify dispatch and ensure you get the right part.

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