A21 PRB 17-49, A21 PRB 33-90,

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Valid for serial no. 803--xxx--xxxx0443 808 001 020321

A21 PRB 17 - 49

A21 PRB 33 - 90

A21 PRB 60 - 170

101103105107109111102021110025108024042106023061104022041100020040060001

BruksanvisningBrugsanvisningBruksanvisningKyttohjeet

Instruction manualBetriebsanweisung

Manuel dinstructionsGebruiksaanwijzingInstrucciones de usoIstruzioni per luso

Manual de instrues

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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. .

SVENSKA 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DANSK 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NORSK 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUOMI 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGLISH 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DEUTSCH 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRANAIS 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEDERLANDS 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ESPAOL 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ITALIANO 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PORTUGUS 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ENGLISH

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1 DIRECTIVE 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SAFETY 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 INTRODUCTION 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TECHNICAL DATA 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 INSTALLATION 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 OPERATION 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Securing the welding tool for welding 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Adjustments 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Welding start 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Welding in confined spaces 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 MAINTENANCE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Daily 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 As necessary 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Replacing wear parts 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Fitting of tungsten electrode 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 Dismounting the tongs from the tool 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 DIRECTIVE

DECLARATION OF CONFORMITYEsab Welding Equipment AB, 695 81 Lax, Sweden, gives its unreserved guaranteethat 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 directive89/392/EEA and addendum.--------------------------------------------------------------------------------------------------------------------------------------

Paul KarlssonManaging DirectorEsab Welding Equipment AB695 81 LAXSWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

Lax 97--09--22

2 SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone whoworks on or near the equipment observes all the relevant safety precautions. Safety precautionsmust 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 weldingequipment. Incorrect operation of the equipment may lead to hazardous situations which can resultin injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:S its operationS location of emergency stopsS its functionS relevant safety precautionsS welding

2. 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 struck3. The workplace must:

S be suitable for the purposeS be free from draughts

4. Personal safety equipmentS 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 precautionsS 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 mustnot be carried out on the equipment during operation.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-TIONS WHEN WELDING. ASK FOR YOUR EMPLOYERS SAFETY PRACTICES WHICH SHOULD BEBASED ON MANUFACTURERS HAZARD DATA.

ELECTRIC SHOCK -- Can killS 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 healthS 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 HAZARDS Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearingS 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.

PROTECT YOURSELF AND OTHERS!

3 INTRODUCTIONA21 PRB 17--49 / 33--90 / 60 --170is 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, usethe MEI 21 wire feed unit.

The tube welding tools incorporate a specialgripping principle facilitating rapid andaccurate securing and location of thetool on the tube. The pair of gripping

jaws (4) clamp the tool to the tubewhen the locking lever (1) on thehandle is pressed in. Only the gearcollar (3) with the fitted detailsrotates during welding.

The collar is powered by a driveunit (2) consisting of a perm. magnetDC motor and a pulse transmitter for speedcontrol. The motor is powered by the control equipment (power source).

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4 TECHNICAL DATA

Tube welding tool PRB 17--49 PRB 33--90

Water--cooled

Air--cooled Water--cooled

Air--cooled

Max welding current at100% duty cycle (A)

250 100 250 100

Tube, external diameter (mm) 17--49 33--90

Rotary speed (r.p.m.) 0,12 -- 2,4 0,08 -- 1,6

Weight without cable and hosepackage (kg)

2,8 3,2

Length of hose bundle (m) 7 7

Tungsten electrode, diameter (mm) 1,6 / 2,4 1,6 / 2,4

Filler wire, diameter (mm) 0,6 / 0,8 / 0,9 Fe, SS 0,6 / 0,8 / 0,9 Fe, SS

Drive unit

Max armature voltage (V DC)Max armature current (A DC)Armature speed at20 volt (r.p.m.)Mechanical gear ratio

480,5

6950

246:1

480,5

6950

246:1

Tube welding tool PRB 60--170

Water--cooled Air--cooled

Max welding current at 100% duty cycle (A) 250 100

Tube, external diameter (mm) 60--170

Rotary speed (r.p.m.) 0,05 -- 0,95

Weight without cable and hose package (kg) 4,4Length of hose bundle (m) 7

Tungsten electrode, diameter (mm) 1,6 / 2,4

Filler wire, diameter (mm) 0,6 / 0,8 / 0,9 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

480,5

6950246:1

5 INSTALLATIONThe installation must be executed by a professional.

WARNING!

Rotating parts can cause injury, take great care.

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S Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx.S Welding power source LTP 450, see instruction manual 0456 634 xxx.S Welding power source LTS 160, LTS 250, see instruction manual 0458 343 xxx.S Welding power source LTS 320, see instruction manual 0457 690 xxx.S

Wire feed unit MEI 21, see instruction manual 0443 831 xxx5.1 Connections

Water--cooled welding tool

A Motor cable -- rotation D Cooling-- water hose in

B Wire conduit E Welding cable

C Cooling-- water hose out F Gas hose

Air--cooled welding tool

A Motor cable -- rotation E Welding cable

B Wire conduit F Gas hose

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6 OPERATION

General safety regulations for the handling of the equipment can be found onpage 56. Read through before you start using the equipment!

S

Welding power source LTO 160, LTO 250, see instruction manual 0456 779 xxx.S Welding power source LTP 450, see programming manual 0456 638 xxx.

S Welding power source LTS, see programming manual 0457 706 xxx.

To avoid the welding tool being damaged, check that the return cable is connected to theworkpiece and that the tungsten electrode is in the start position before the welding commences.

WARNING!

6.1 Securing the welding tool for welding

S Set the correct tube diameter using the adjusting screw (3), keeping thelocking lever (1) in the closed position.

S Open the welding tool by means of the lockinglever (1).

S For correct pre--clamping, turnanother quarter of a turn usingadjusting screw (3).N.B. Harder clamping can deform

the tongs leading to centredisplacement and weld defects.

For welding using equipment fortube diameters 8--17 mm (seeaccessories, page NO TAG) thewelding tool is to be fixed with the driveunit in vertical position, as an alternative a support or relief could be placed underthe 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.

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6.2 Adjustments

Adjusting the position of the tungsten electrodein the weld joint

S Adjust the electrode distance radiallyusing distance bolt (2).

S Adjust the wire nozzle (1) radiallyby way of an Allen key and forfine adjustment with wheel (2).

The spring load of the arm of theelectrode holder is preset on delivery.If adjustment is necessary, pleasecontact your nearest ESABrepresentative for information.

Inserting the filler wireS See instruction manual for wire feed

unit MEI 21 (0443 831 xxx).

Adjusting the filler wire

S Adjust the filler wire nozzle (1) radiallyby way of an Allen key. For fine adjustmentuse the wheel (2).

6.3 Welding start

S Recall the welding program to be used to the working area (see the program-ming manual)

S Press the start button (A) on the control unit.

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6.4 Welding in confined spaces

PRB 17--49


Water -- cooled Air -- cooled

D C--C min D C--C min

S Complete. D49 70+D D49 70+D

S Without wheel (1) for precise wire adjust-ment.

S The torch cover (3) and distance bolt (4)may need to be replaced by shorter variants.

D49 70+D/2 D4040

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PRB 33--90




S Complete. D6868

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PRB 60 --170




S Complete D170 137+D/2 D170 137+D/2

7 MAINTENANCE

Note:All warranty undertakings given by the supplier cease to apply if the customerattempts 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 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 exchangeaccording 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).

Repair of multi--conductor

NOTE! This should be done by authorised ESAB service people.

S Loosen the clamps (4) and (6) at the damaged end and withdraw the hose (7).

S Unsolder the current nipples (11) from the electrode holder (12) / connectionblock (2).

S Cut off the damaged part of the hose, but leave a couple of extra centimetres ofthe current litzes.

S Fit a tape (8) round the current litzes (9) in level with the hose end to mark thelength of the hose.

S Draw the current litzes (9) some 60--70 mm out of the hose and prevent thelitzes slipping back, using a safety pin or a metal wire (10).

S 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 Solder the current nipples (11) against the electrode holder (12) / connectionblock (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 Fit the clamps (4) and (6).

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 gaslens (3) by means of an Allen key.

S Fit the parts in the reverse orderNote:Make sure the gas lens (3) is fitted with the smoothside against the sealing washer (7).

Air--cooled welding tools


S Remove the tungsten electrode (4).

S Remove the clamping sleeve (2).S Remove the gas cup (5).

S Unscrew the gas lens (3).

S Fit the parts in the reverse order.

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7.4 Fitting of tungsten electrode


File off the tungsten electrode and fit it into theelectrode holder as follows:


S Insert the tungsten electrode (5) into theelectrode nozzle (4) and clamping sleeve.

S 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 Remove the torch cover (1).

S Insert the tungsten electrode (4) into the gaslens (3) and clamping sleeve (2).

S Clamp the tungsten electrode with the torchcover (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.

8 ORDERING OF SPARE PARTS

A21 PRB 17--49 / 33--90 / 60--170 is designed and tested in accordance withthe EN 60 292 (IEC 292) international standard.It is the obligation of the service unit which has carried out the service or re-pair 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 desig-nation 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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Documents

A21 PRB 17-49, A21 PRB 33-90,