ESAB | PKB 250 | Instruction manual | ESAB PKB 250 User manual

ESAB PKB 250 User manual
PKB 250
PKB 400
AH 0480
101103105107109111102021110025108024042106023061104022041100020040060001
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Instruction manual
Betriebsanweisung
0154 117 101
000303
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ÅËËÇÍÉÊÁ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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.
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ENGLISH
1 DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
41
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Connecting the Welding Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
42
5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
6.1
6.2
6.3
6.4
6.5
6.6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily or As Necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
44
44
45
46
7 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
7.1 Checking for air leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TOCe
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GB
1
DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
gun PKB 250, PKB 400 from serial number 933 complies with standard EN 50078, in accordance with
the requirements of directive (73/23/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Laxå 2000--01--03
Anders Birgersson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN
2
Tel: + 46 584 81000
Fax: + 46 584 411924
SAFETY
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS 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 keep fumes and gases 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 ear defenders 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!
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GB
3
INTRODUCTION
3.1
General
PKB is an air--operated welding gun with a pneumatic motor incorporated in the
handle. A wire feed unit is fitted in the gun housing.
Different welding speeds can be selected by way of a valve regulating the speed of
the motor.
The welding gun is available in two models, PKB 250 and PKB 450. In the PKB 450
model the outgoing air is used for forced cooling of the gun.
Swan Neck
The gun can be provided with a swan neck which is turnable 360Ρ when the locking
screws in the wire feed unit have been loosened.
The swan neck provides better access when welding in narrow spaces.
Gun Trigger
When the trigger is pressed into its first position the flow relay of the feed unit is
activated and the operating circuit closes.
When the trigger is pressed as far as it will go the air valve is fully opened and the
wire is fed according to the set value.
By slackening the trigger a little during welding, both the wire feed speed and the
welding current will be decreased and the control of the molten pool will be
improved.
Valve for Setting the Wire Feed Speed
The wire feed speed is proportional to the welding current and is set by way of the
speed regulator on the welding gun.
The wire diameter is of vital importance to the welding current. The coarser the wire,
the higher the amperage.
The speed regulator on the PKB is graded 0--9. The index arrow on the left--hand
side of the gun housing indicates the zero position. The knob can be turned some
2.5 turns.
PKB 400 is provided with a hand shield against the heat radiation.
Welding Hose
The welding hose is available in three lengths: 5, 10 and 16 m.
3.2
Technical Data
Welding gun
PKB 250
PKB 400
’
250 A / 26.5 V
200 A / 24 V
400 A / 34 V
280 A / 28 V
0.6--1.2 mm
0.6--1.6 mm
Air consumption
Max. 280 l/min
Max. 280 l/min
Dimensions l x h
210 x 250 mm
210 x 260 mm
1.2 kg
1.4 kg
Permissible load at 60% duty cycle
Carbon acid CO2
Gas mixture, Argon (Al electrode)
Electrode diameter
Weight
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GB
Welding hose
Permissible load at 60% duty cycle
Length: 5 m, 10 m, 16 m
Electrode diameter
A9--250
A9--400
250 A
400 A
0.6--1.6 mm
0.6--1.6 mm
Working pressure
490 kPa (5
kp/cm2)
490 kPa (5 kp/cm2)
Max. testing pressure
735 kPa (5 kp/cm2)
735 kPa (5 kp/cm2)
NB. Make sure the gun motor has the proper working pressure, 490 kPa (5 kp/cm2). If the pressure is
lower the motor will not get the right speed, resulting in too low wire feed speed and welding current. If
the pressure is higher the welding hose will be exposed to harmful dynamic pressure.
4
INSTALLATION
4.1
General
The installation shall be executed by a professional.
4.2
S
S
S
Connecting the Welding Hose
Press the inlet nozzle (a) -- selected according to the diameter of the wire -- into
the welding hose.
Open the wire feed unit on the bobbin side.
Undo the locking screw (c) on the connecting plate.
Connect the welding hose (b) to the wire feed unit and tighten the locking screw
on the connecting plate.
Remove the plastic cover (d) from the gun housing.
Undo the locking screw (e) and press the other end of the hose into the gun.
Tighten the locking screw and fit the plastic cover.
5
OPERATION
5.1
General
General safety regulations for the handling of the equipment appear from
page 40. Read through before you start using the equipment!
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GB
Welding Gun PKB 250 and PKB 400
Before starting to use of a new welding gun, or after replacement of the motor, the
gun is to be operated at full air pressure (590 kPa, 6 kp/cm2) for a short while.
This causes solidified oil and grease in the pneumatic motor to be dissolved, and
ensures uninterrupted service.
6
MAINTENANCE
6.1
General
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.
6.2
Daily or As Necessary
Nozzles
S
Remove the gas nozzle.
S
Clean the gas nozzle, the
intermediate nozzle and the contact
nozzle of welding spatter so that the
shielding gas can flow freely and the risk of short--circuiting
is eliminated.
S
Check the gas nozzle for damage and wear. Replace the nozzle if damaged or
worn.
S
Select a contact nozzle according to the diameter of the wire.
S
Assemble the parts.
S
Spray with welding spray obliquely into the gas nozzle from two directions.
S
NB. Never spray straight into the nozzle.
Pneumatic Motor
The motor is provided with an oil nipple for its lubrication.
S
Lubricate the motor once a week (normal
operation) using the lubrication gun supplied
with the welding gun.
S
Use oil of the type Shell Super Oil 10 W/50,
ESAB’s order number 0151 370 001.
Feed Unit
S
Take out and clean the feed unit of the gun as
necessary.
S
Lubricate the feed unit with some drops of oil.
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GB
6.3
Replacing the Air Filter
In order to protect the pneumatic motor of the welding gun from impurities the PKB
guns are provided with an air filter.
The filter is fitted in the gun housing in the groove between the two O--rings where
the gas hose is connected.
When a new filter is to be fitted the outer ring must first be removed.
S
Make sure the filter is properly fixed before the O--ring is fitted.
6.4
Replacing the Wire Guide
u
a
Inlet nozzle
u
Inlet end
f
Compression gland
x
Compressed--air inlet
g
Outlet nozzle
y
Shielding gas inlet
h
Wire guide
z
O--rings (inside the tube)
i
O--rings
S
Undo the locking screws on the welding hose connections to the wire feed unit
and the gun, then pull out the welding hose.
S
Pull out the inlet nozzle (a) and screw out the compression gland (f) on the inlet
side and the outlet nozzle (g) on the gun side.
S
Withdraw the wire guide (h) from the inlet end. Make sure the o--rings (i) in the
connecting piece come along.
S
Fit the new wire guide. Stretch out the welding hose and check that the o--rings
at the end of the gun are properly fitted in the grooves. Taper the end of the wire
guide using a file.
S
Insert the new guide through the gun connection. If this proves troublesome,
lubricate the end of the wire guide with a little oil or silicon grease.
S
Fasten the inlet nozzle with screws at the gun end of the welding hose.
S
Adjust the length of the guide at the inlet end of the welding hose. Cut the guide
so as to include an excess length of six mm per metre hose, e.g. for a five--metre
welding hose the wire guide is to be cut 30 mm outside the inlet end of the hose.
S
Insert the o--rings round the wire guide and then fasten the compression gland
with screws.
S
Press in the inlet nozzle.
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GB
6.5
1
Dismantling the Motor
y
d
e
3
2
j
4
5
6
1. Remove the plastic cover (d) on the gun housing. Undo the locking screw (e)
using an Allen key and remove the welding hose.
Unload the spring (y) and undo the screws (j) holding the contact tube.
Remove the tube.
2. Turn the welding gun upside--down. Wire the feed unit (k) can now be easily
removed.
3. Insert a 90 mm long metal rod with a diameter of 2 mm through the hose
connection hole in the gun housing.
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GB
Push out the roll pin (l) in the motor shaft which holds the feed roller of the motor
shaft in place.
Remove the feed roller.
4. Remove the hand shield, if any, then gun trigger (m), rubber handle (n) and
contact tube (o).
Check that the three o--rings of the tube (v) come along.
5. Fasten the motor housing (p) in a screw vice or the like, protected by two
wooden jaws, and tighten moderately.
Screw out the left--threaded gun housing (q).
If the motor is rotating in its housing it cannot be dismounted from the housing of
the gun. Then tighten the right--threaded rear (s) a bit harder, using an open end
wrench with a jaw width of 28 mm.
6. Screw out the gun housing (q).
At the same time remove the protective cap (r) of the gasket ring (a transparent
plastic sleeve) from the motor shaft.
Make sure that the sleeve, which is to be put back on the motor shaft, is not
damaged.
6.6
1
Mounting the Motor
2
1. Place the new motor (p) between the wooden jaws
3
and tighten moderately.
Tighten the rear (s) and provide the motor shaft with
a guide sleeve (t) to protect the gasket ring of the
gun housing during the assembly.
Screw the left--threaded gun housing in place.
2. Loosen the right--threaded rear (s) using an open end
wrench with a jaw width of 28 mm.
Now the gun housing (q) can be turned. Only the
motor shaft is moving. The motor housing is
secured by screws.
Turn the gun housing so that the rear, after having
been tightened, gets into the proper position for
fitting the connection tube (o).
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GB
3. Fit the connection tube (o), rubber handle (n), trigger (m), the protective cap of the
gasket ring, the feed roller of the motor shaft and the wire feed unit.
The connection tube (o) and the three o--rings (v) are to be fitted very snugly.
Cement the rubber handle using Bostik 292 or the like.
7
TROUBLE SHOOTING
7.1
Checking for air leaks
During the test the device is to be run without electrode and shielding gas.
Test 1
S
Turn on the compressed air to the max. pressure of 490 kPa (5 kp/cm2).
S
Submerge the lower part of the gun handle into a container with methylated
spirits.
Smaller leaks in the form of occasional air bubbles need not be attended to.
Test 2
S
Hold the welding gun in such a way that the motor is in vertical position with the
feed unit turned up.
S
Pour methylated spirits on the bottom of the gun housing till the feed unit is
covered.
S
Push the gun trigger checking the gasket ring for air leaks.
After the Test
S
Pour away the methylated spirits.
S
Dry and clean the gun using compressed air.
8
ORDERING OF SPARE PARTS
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 on page 113.
This will simplify dispatch and ensure you get the right part.
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