PRC 17-49 PRC 33-90 PRC 60-170 A21 Instruction manual 0443 934 201 GB 061219 Valid for serial no. 538 -xxx -xxxx
1 DIRECTIVE... 3 2SAFETY... 3 3 INTRODUCTION... 4 4 TECHNICAL DATA... 5 5 INSTALLATION... 6 5.1 Connection... 6 5.2 Assembly instructions... 7 6 OPERATION... 7 6.1 Securing the welding tool for welding... 8 6.2 Adjustments... 8 6.3 Welding in confined spaces... 9 7 MAINTENANCE... 12 7.1 Daily... 12 7.2 As necessary... 12 7.3 Replacing wear parts... 14 7.4 Fitting of tungsten electrode... 14 7.5 Dismounting the tongs from the tool... 14 8 ORDERING OF SPARE PARTS... 14 ORDERING NUMBER... 15 WEAR PARTS... 16 ACCESSORIES... 18 Rights reserved to alter specifications without notice. TOCe - 2 -
1 DIRECTIVE DECLARATION OF CONFORMITY ESAB AB Welding Equipment, 695 81 Laxå, Sweden, declares that tube welding tool PRC 17--49 / 33--90 / 60--170 from serial number 538 onwards, conforms to standard IEC/EN 60204--1/ IEC/EN 12100--2 in accordance with the requirements of directive (98/37/EEC) and standard IEC/EN 60974--10 in accordance with the requirements of directive (89/336/EEC). -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ---- Laxå 2006--12--15 Kent Eimbrodt Global Director Equipment and Automation ESAB AB 695 81 LAXÅ SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924 2 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. - 3 -
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 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. - 4 -
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 17-49 PRC 33-90 PRC 60-170 Max welding current at 100% duty cycle (A) 250 250 250 Tube, external diameter (mm) 17--49 33--90 60--170 Rotary speed (r.p.m.) 0.12 -- 2.4 0.08 -- 1.6 0.05 -- 0.95 Weight without cable, hose package, AVC-- and 2.8 3.2 4.4 weaving--unit (kg) Length of hose bundle (m) 7 7 7 Tungsten electrode, diameter (mm) 1.6 / 2.4 1.6 / 2.4 1.6 / 2.4 Filler wire, diameter (mm) Fe, SS 0.6 / 0.8 / 0.9 0.6 / 0.8 / 0.9 0.6 / 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 0,5 6950 246:1 24 0.2 12 2 20 6 1.8 12 0.2 2 0.5 24 0,5 6950 246:1 24 0.2 12 2 20 6 1.8 12 0.2 2 0.5 24 0,5 6950 246:1 24 0.2 12 2 20 6 2.2 12 0.2 2 0.5-5 -
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 -
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. - 7 -
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 8--17 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). - 8 -
6.3 Welding in confined spaces PRC 17-49 with AVC PRC 17-49 with AVC and weaving unit PRC 17-49 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 0443 880 880. D±34 34±D±49 56+ D/2 39+D - 9 -
PRC 33-90 with AVC PRC 33-90 with AVC and weaving unit PRC 33-90 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 -
PRC 60-170 with AVC PRC 60-170 with AVC and weaving unit PRC 60-170 D C-C min S Complete. D±170 137+D/2-11 -
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). - 12 -
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 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 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). - 13 -
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 17-49 / 33-90 / 60-170 is designed and tested in accordance with the international and European standards IEC/EN 60204-1 / 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. - 14 -
PRC 14-49, PRC 33-90, PRC 60-170 Ordering number Ordering no. Denomination Type Notes 0443 751 881 Tube welding tool PRC 17--49 AVC, Water cooled 0443 752 881 Tube welding tool PRC 17--49 AVC, weaving unit, water cooled 0443 761 881 Tube welding tool PRC 33--90 AVC, Water cooled 0443 762 881 Tube welding tool PRC 33--90 AVC, weaving unit, water cooled 0443 771 881 Tube welding tool PRC 60--170 AVC, Water cooled 0443 772 881 Tube welding tool PRC 60--170 AVC, weaving unit, water cooled 0443 934 990 Spare parts list PRC 17--49, PRC 33--90, PRC 60--170 Instruction manuals and the spare parts list are available on the Internet at www.esab.com dsa9o - 15 - Edition 061219
PRC 14-49, PRC 33-90, PRC 60-170 Wear parts Item no. Qty Ordering no. Denomination Notes 0443807880 Wear parts 1 0332811001 Clamping sleeve 1,6 2 0332811003 Clamping sleeve 2,4 3 0443785001 Electrode nozzle 1,6 4 0443785002 Electrode nozzle 2,4 5 0151574002 Tungsten electrode 1,6 6 0151574003 Tungsten electrode 2,4 7 0443787001 Sealing washer 8 0443786001 Gas lens 9 0332801880 Torch cover 10 0365310049 Torch cover 11 0365310050 Torch cover medium 12 0443788001 Gas cup 13 0333420880 Journal 14 0443813001 Ball pressure screw dsa8w - 16 - R0443 934/E061219/P20
PRC 14-49, PRC 33-90, PRC 60-170 Item no. Qty Ordering no. Denomination Notes 0443815880 Wire setting parts 1 1 0443789001 Wire attachment 2 1 0443790001 Wire rock 3 1 0443791001 Wire knob 44 mm 1 0443791002 Wire knob 62 mm 1 0443791003 Wire knob 72 mm 4 1 0443792001 Spring 5 1 0192238219 Screw IN6 M3 x 5, DIN 912 6 1 0212204343 Screw M5 x 6 7 2 0190509321 Screw M5 x 6 8 1 0332792001 Joural dsa8w - 17 - R0443 934/E061219/P20
PRC 14-49, PRC 33-90, PRC 60-170 Accessories Angular support... 0443 875 880 PRC 17--49 wire conduit for welding in confined spaces... 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 - 18 - Edition 061219
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ESAB subsidiaries and representative offices 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:+4536300111 Fax:+4536304003 FINLAND ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71 FRANCE ESAB France S.A. Cergy Pontoise Tel:+33130755500 Fax:+33130755524 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 NORWAY AS ESAB Larvik Tel:+4733121000 Fax:+4733115203 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:+421744882426 Fax:+421744888741 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:+4631509500 Fax:+4631509222 ESAB international AB Gothenburg Tel:+4631509000 Fax:+4631509360 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 Asia/Pacific CHINA Shanghai ESAB A/P Shanghai Tel: +86 21 5308 9922 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 3 5296 7371 Fax:+81352968080 MALAYSIA ESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 8027 9869 Fax:+60380274754 SINGAPORE ESAB Asia/Pacific Pte Ltd Singapore Tel:+6568614322 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 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 HUNGARY ESAB Kft Budapest Tel:+3612044182 Fax:+3612044186 ITALY ESAB Saldatura S.p.A. Mesero (Mi) Tel:+3902979681 Fax:+390297289181 THE NETHERLANDS ESAB Nederland B.V. Utrecht Tel: +31 30 2485 377 Fax: +31 30 2485 260 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 ESAB AB SE -695 81 LAXÅ SWEDEN Phone +46 584 81 000 www.esab.com 061127