PRC PRC PRC

Transcription

1 PRC PRC PRC A21 Instruction manual GB Valid for serial no xxx -xxxx

2 1 DIRECTIVE SAFETY INTRODUCTION TECHNICAL DATA INSTALLATION Connection Assembly instructions OPERATION Securing the welding tool for welding Adjustments Welding in confined spaces MAINTENANCE Daily As necessary Replacing wear parts Fitting of tungsten electrode Dismounting the tongs from the tool ORDERING OF SPARE PARTS ORDERING NUMBER WEAR PARTS ACCESSORIES Rights reserved to alter specifications without notice. TOCe - 2 -

3 1 DIRECTIVE DECLARATION OF CONFORMITY ESAB AB Welding Equipment, Laxå, Sweden, declares that tube welding tool PRC / / from serial number 538 onwards, conforms to standard IEC/EN / IEC/EN in accordance with the requirements of directive (98/37/EEC) and standard IEC/EN in accordance with the requirements of directive (89/336/EEC) Laxå Kent Eimbrodt Global Director Equipment and Automation ESAB AB LAXÅ SWEDEN Tel: Fax: 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 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. 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. ESAB can provide you with all necessary welding protection and accessories. This product is solely intended for arc welding

4 WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU- TIONS 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. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! WARNING! 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! 3 INTRODUCTION PRC / / 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

5 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). 4 TECHNICAL DATA Tube welding tool PRC PRC PRC 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) 1.6 / / / 2.4 Filler wire, diameter (mm) Fe, SS 0.6 / 0.8 / / 0.8 / / 0.8 / 0.9 Drive unit Max armature voltage (V DC) Max armature current (A DC) Armature speed at 20 volt (r.p.m.) Mechanical gear ratio 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) 24 0, : , : , :

6 5 INSTALLATION The installation must be executed by a professional. WARNING! Rotating parts can cause injury, take great care. WARNING! 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. 5.1 Connection A B C D E F G H I 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 - 6 -

7 5.2 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). 6 OPERATION General safety regulations for the handling of the equipment can be found on page 3. Read through before you start using the equipment! 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

8 6.1 Securing the welding tool for welding S S 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). S 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 mm (see accessories, page 18) 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. 6.2 Adjustments Adjusting the position of the tungsten electrode in the weld joint S GB 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)

9 6.3 Welding in confined spaces PRC with AVC PRC with AVC and weaving unit PRC D C-C min S Complete. D±49 70+D S Without wheel (1) for precise wire adjustment. S The torch cover (3) may need to be replaced by shorter variants. D±49 70+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) may need to be replaced by shorter variants. S With filler wire nozzle D±34 34±D± D/2 39+D - 9 -

10 PRC with AVC PRC with AVC and weaving unit PRC D C-C min S Complete. D±68 68±D±90 S Without wheel (1) for precise wire adjustment. S The torch cover (3) 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) may need to be replaced by shorter variants. 94+D/2 60+D D±90 94+D/2 D±90 82+D/2-10 -

11 PRC with AVC PRC with AVC and weaving unit PRC D C-C min S Complete. D± D/2-11 -

12 7 MAINTENANCE Regular maintenance is important for safe, reliable operation. Note! 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. 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, see accessories, page 18. 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)

13 Repair of multi -conductor NOTE! This should be done by authorised ESAB service people. S Loosen the clamps (4), (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 S Draw the current litzes (9) some 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 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 Put back the clamps (4) and (6)

14 7.3 Replacing wear parts 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). 7.4 Fitting of tungsten electrode 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). 7.5 Dismounting the tongs from the tool See Weaving unit on page 7. 8 ORDERING OF SPARE PARTS PRC / / is designed and tested in accordance with the international and European standards IEC/EN / and EN 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

15 PRC 14-49, PRC 33-90, PRC Ordering number Ordering no. Denomination Type Notes Tube welding tool PRC AVC, Water cooled Tube welding tool PRC AVC, weaving unit, water cooled Tube welding tool PRC AVC, Water cooled Tube welding tool PRC AVC, weaving unit, water cooled Tube welding tool PRC AVC, Water cooled Tube welding tool PRC AVC, weaving unit, water cooled Spare parts list PRC , PRC , PRC Instruction manuals and the spare parts list are available on the Internet at dsa9o Edition

16 PRC 14-49, PRC 33-90, PRC Wear parts Item no. Qty Ordering no. Denomination Notes Wear parts Clamping sleeve 1, Clamping sleeve 2, Electrode nozzle 1, Electrode nozzle 2, Tungsten electrode 1, Tungsten electrode 2, Sealing washer Gas lens Torch cover Torch cover Torch cover medium Gas cup Journal Ball pressure screw dsa8w R /E061219/P20

17 PRC 14-49, PRC 33-90, PRC Item no. Qty Ordering no. Denomination Notes Wire setting parts Wire attachment Wire rock Wire knob 44 mm Wire knob 62 mm Wire knob 72 mm Spring Screw IN6 M3 x 5, DIN Screw M5 x Screw M5 x Joural dsa8w R /E061219/P20

18 PRC 14-49, PRC 33-90, PRC Accessories Angular support PRC wire conduit for welding in confined spaces Wheel for precise wire adjustment (62 mm) PRC , Conversion kit for PRC welding of tube diameters mm Conversion kit for PRC welding of tube diameters mm Conversion kit for PRC welding of tube diameters mm Driving unit 134: Plate for angular support together with conversion kit for smaller diameters Wire holder complete with gas lens Ø24 mm with adjustable wire nozzle for PRC Wire nozzle straight for PRC complete adjustable holder dsa9a Edition

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20 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges.m.b.H Vienna -Liesing Tel: Fax: BELGIUM S.A. ESAB N.V. Brussels Tel: Fax: THE CZECH REPUBLIC ESAB VAMBERK s.r.o. Vamberk Tel: Fax: DENMARK Aktieselskabet ESAB Herlev Tel: Fax: FINLAND ESAB Oy Helsinki Tel: Fax: FRANCE ESAB France S.A. Cergy Pontoise Tel: Fax: GERMANY ESAB GmbH Solingen Tel: Fax: GREAT BRITAIN ESAB Group (UK) Ltd Waltham Cross Tel: Fax: ESAB Automation Ltd Andover Tel: Fax: NORWAY AS ESAB Larvik Tel: Fax: POLAND ESAB Sp.zo.o. Katowice Tel: Fax: PORTUGAL ESAB Lda Lisbon Tel: Fax: SLOVAKIA ESAB Slovakia s.r.o. Bratislava Tel: Fax: SPAIN ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: Fax: SWEDEN ESAB Sverige AB Gothenburg Tel: Fax: ESAB international AB Gothenburg Tel: Fax: SWITZERLAND ESAB AG Dietikon Tel: Fax: North and South America ARGENTINA CONARCO Buenos Aires Tel: Fax: BRAZIL ESAB S.A. Contagem -MG Tel: Fax: Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: Fax: INDIA ESAB India Ltd Calcutta Tel: Fax: INDONESIA P.T. ESABindo Pratama Jakarta Tel: Fax: JAPAN ESAB Japan Tokyo Tel: Fax: MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: Fax: SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel: Fax: SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel: Fax: UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel: Fax: Representative offices BULGARIA ESAB Representative Office Sofia Tel/Fax: EGYPT ESAB Egypt Dokki -Cairo Tel: Fax: ROMANIA ESAB Representative Office Bucharest Tel/Fax: RUSSIA LLC ESAB Moscow Tel: Fax: LLC ESAB St Petersburg Tel: Fax: Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page HUNGARY ESAB Kft Budapest Tel: Fax: ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel: Fax: THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: Fax: CANADA ESAB Group Canada Inc. Missisauga, Ontario Tel: Fax: MEXICO ESAB Mexico S.A. Monterrey Tel: Fax: USA ESAB Welding & Cutting Products Florence, SC Tel: Fax: ESAB AB SE LAXÅ SWEDEN Phone