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GB
A21 PRC 17-49 PRC 33-90 PRC 60-170
Instruction manual
0443 934 201 GB 100215 Valid for serial no. 538-xxx-xxxx
DECLARATION OF CONFORMITY
according to the Machinery Directive 2006/42/EC, according to the EMC Directive 2004/108/EC
FÖRSÄKRAN OM ÖVERENSSTÄMMELSE
enligt Maskindirektivet 2006/42/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.
PRC 17 − 49, 33 − 90, 60 − 170, from Serial number 538 xxx xxxx (2005 week 38) PRC 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 − 12 Signature / Underskrift Position / Befattning Global Director Equipment and Automation Kent Eimbrodt Clarification - 2 -
Rights reserved to alter specifications without notice.
TOCe - 3 -
GB 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.
2.
3.
4.
S S S Anyone who uses the welding equipment must be familiar with: S its operation S location of emergency stops its function relevant safety precautions welding 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 The workplace must: S be suitable for the purpose S be free from drafts 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.
S S 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.
Appropriate fire extinquishing equipment must be clearly marked and close at hand.
Lubrication and maintenance must not be carried out on the equipment during operation.
dsa9d1ea - 4 -
GB
WARNING
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.
S S 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.
Insulate yourself from earth and the workpiece.
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!
CAUTION!
This product is solely intended for arc welding.
CAUTION!
Read and understand the instruction manual before installing or operating.
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
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 source MechTig. 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.
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).
ESAB's accessories for the product can be found on page 20 .
3 TECHNICAL DATA
Tube welding tool Max welding current at 100% duty cycle (A) Tube, external diameter (mm) Rotary speed (r.p.m.) Weight without cable, hose package, AVC- and weaving-unit (kg) Length of hose bundle (m) Tungsten electrode, diameter (mm) Filler wire, diameter (mm) 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 PRC 17-49 250 17-49 0.12 - 2.4
2.8
PRC 33-90 250 33-90 0.08 - 1.6
3.2
PRC 60-170 250 60-170 0.05 - 0.95
4.4
7 1.6 / 2.4
0.6 / 0.8 / 0.9
7 1.6 / 2.4
0.6 / 0.8 / 0.9
7 1.6 / 2.4
0.6 / 0.8 / 0.9
24 0,5 6950 246:1 24 0,5 6950 246:1 24 0,5 6950 246:1 - 6 dsa9d1ea
GB
Tube welding tool 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) 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) Operating temperature Transportation temperature PRC 17-49 PRC 33-90 PRC 60-170 24 0.2
12 2 20 " 6 1.8
12 0.2
2 0.5
24 0.2
12 2 20 " 6 1.8
12 0.2
2 0.5
-10 to +40 ° C -20 to +55 ° C 24 0.2
12 2 20 " 6 2.2
12 0.2
2 0.5
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.
dsa9d1ea CAUTION!
The coolant must be handled as chemical waste.
- 7 -
GB
4.1
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).
dsa9d1ea - 8 -
GB 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.
5.1
Connection
G H I A B C D E F Motor cable - rotation Wire conduit Cooling- water hose out Cooling- water hose in Welding cable Gas hose Motor cable - Weaving unit Measurement cable - AVC-unit Motor cable - AVC-unit dsa9d1ea - 9 -
GB
S S S
5.2
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 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 20) 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.
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.
5.3
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.
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).
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5.4
Welding in confined spaces
PRC 17-49 with AVC PRC 17-49 with AVC and weaving unit S S S S S S S S PRC 17-49 Complete.
Without wheel (1) for precise wire adjustment.
The torch cover (3) may need to be replaced by shorter variants.
Without wheel (1) for precise wire adjustment.
Without end plates (2).
With room for cables in axial direction.
The torch cover (3) may need to be replaced by shorter variants.
With filler wire nozzle (accessories) D D D 49 49 34 D D 34 49 - 11 dsa9d1ea C-C min 70+D 70+D/2 56+ D/2 39+D
GB
PRC 33-90 with AVC PRC 33-90 with AVC and weaving unit PRC 33-90 S Complete.
S S S S S S Without wheel (1) for precise wire adjustment.
The torch cover (3) may need to be replaced by shorter variants.
Without wheel (1) for precise wire adjustment.
Without end plates (2).
With room for cables in axial direction.
The torch cover (3) may need to be replaced by shorter variants.
D 68 D D 68 90 D 90 D 90 - 12 dsa9d1ea C-C min 94+D/2 60+D 94+D/2 82+D/2
GB
PRC 60-170 with AVC PRC 60-170 with AVC and weaving unit S Complete.
dsa9d1ea PRC 60 - 170 - 13 D D 170 C-C min 137+D/2
GB 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 20.
Changing the complete electrode holder S S 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).
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S S Repair of multi-conductor NOTE! This should be done by authorised ESAB service people.
S S Loosen the clamps (4), (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.
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).
Put back the clamps (4) and (6).
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6.3
Replacing wear parts
S S S S S 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.
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).
6.4
Fitting of tungsten electrode
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).
6.5
Dismounting the tongs from the tool
7 ORDERING OF SPARE PARTS
PRC 17-49, PRC 33-90, PRC 60-170 is designed and tested in accordance with the inter national and European standards EN 60204-1, EN 12100-2 and EN 60974-10. 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 may be ordered through your nearest ESAB dealer, see the last page of this publication.
dsa9d1ea - 16 -
PRC 17-49, PRC 33-90, PRC 60-170 Ordering number Ordering no.
Denomination 0443 751 881 Tube welding tool 0443 752 881 Tube welding tool 0443 761 881 Tube welding tool 0443 762 881 Tube welding tool 0443 771 881 Tube welding tool 0443 772 881 Tube welding tool 0443 934 990 Spare parts list Type PRC 17-49 PRC 17-49 PRC 33-90 PRC 33-90 PRC 60-170 PRC 60-170 PRC 17-49, PRC 33-90, PRC 60-170 Notes AVC, Water cooled AVC, weaving unit, water cooled AVC, Water cooled AVC, weaving unit, water cooled AVC, Water cooled AVC, weaving unit, water cooled Instruction manuals and the spare parts list are available on the Internet at www.esab.com
dsa9o - 17 Edition 100215
PRC 17-49, PRC 33-90, PRC 60-170 Wear parts 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 11 12 13 14 1 2 3 4 5 6 7 8 9 10 Item no.
Qty Ordering no.
Denomination 0443 807 880 0332 811 001 0332 811 003 0443 785 001 0443 785 002 0151 574 002 0151 574 003 0443 787 001 0443 786 001 0332 801 880 0365 310 049 0365 310 050 0443 788 001 0333 420 880 0443 813 001 0154 438 001 0193 387 101 0334 731 001 0444 044 001 Wear parts Clamping sleeve Clamping sleeve Electrode nozzle Electrode nozzle Tungsten electrode Tungsten electrode Sealing washer Gas lens Torch cover Torch cover Torch cover medium Gas cup Journal Ball pressure screw Hex tool key In6 key set Box Lubrication grease 1,6 2,4 1,6 2,4 1,6 2,4 2.5 mm 8 pieces 1.5 - 6 mm Notes dsa9w - 18 Edition 100215
PRC 17-49, PRC 33-90, PRC 60-170 Item no.
Qty Ordering no.
1 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 2 1 Denomination 0443 815 880 0443 789 001 0443 790 001 0443 791 001 0443 791 002 0443 791 003 0443 792 001 0192 238 219 0212 204 343 0190 509 321 0332 792 001 Wire setting parts Wire attachment Wire rock Wire knob Wire knob Wire knob Spring Screw IN6 Screw Screw Joural 44 mm 62 mm 72 mm M3 x 5, DIN 912 M5 x 6 M5 x 6 Notes dsa9w - 19 Edition 100215
PRC 17-49, PRC 33-90, PRC 60-170 Accessories Angular support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRC 17-49 wire conduit for welding in confined spaces . . . . . . . . . . . . . . . . . . . . . . . . 0443 875 880 0443 880 880 Wheel for precise wire adjustment (62 mm) PRC 17-49, 33-90 . . . . . . . . . . . . . . . . . 0443 791 002 Conversion kit for PRC 17-49 welding of tube diameters 8-17 mm . . . . . . . . . . . . . . . 0444 002 880 Conversion kit for PRC 33-90 welding of tube diameters 20-33 mm.
. . . . . . . . . . . . . 0443 908 880 Conversion kit for PRC 60-170 welding of tube diameters 44-60 mm.
. . . . . . . . . . . . 0443 909 880 Driving unit 134:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0443 544 880 Plate for angular support together with conversion kit for smaller diameters . . . . . . 0444 226 880 Wire holder complete with gas lens Ø24 mm with adjustable wire nozzle for PRC 33-170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0443 923 880 Wire nozzle straight for PRC 17-170 complete adjustable holder . . . . . . . . . . . . . . . . 0443 988 880 dsa9a - 20 Edition 100215
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- 23 notes
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 VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120 DENMARK Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24 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: +36 1 20 44 182 Fax: +36 1 20 44 186 ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44
ESAB subsidiaries and representative offices
NORWAY AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03 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: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41 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: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60 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 2326 3000 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 45 670 7073 Fax: +81 45 670 7001 MALAYSIA ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225 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 ESAB AB SE-695 81 LAXÅ SWEDEN Phone +46 584 81 000 www.esab.com
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.com
081016
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