ESAB PKB 250 User manual

AH 0480

0154 117 201 GB 20110816

PKB™250

PKB™400

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Connecting the welding hose 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Daily or as necessary 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Replacing the air filter 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Replacing the wire guide 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Dismantling the motor 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Mounting the motor 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 TROUBLE SHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Checking for air leaks 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING OF SPARE PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 DISASSEMBLY AND DISPOSAL 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDER NUMBER 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEAR PARTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

ESAB can provide you with all necessary welding protection and accessories.

WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

SInstall and earth the unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

This product is solely intended for arc welding.

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2 INTRODUCTION

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 400. In the PKB 400

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 360°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 TECHNICAL DATA

Welding gun PKB 250 PKB 400

Permissible load at 60% duty cycle

Carbon acid CO2

Gas mixture, Argon (Al electrode)

250 A / 26.5 V

200 A / 24 V

400 A / 34 V

280 A / 28 V

Electrode diameter 0.8-1.2 mm 0.8-1.6 mm

Air consumption Max. 280 l/min Max. 280 l/min

Air pressure, max 590 kPa (6 kp/cm2)590 kPa (6 kp/cm2)

Dimensions l x h 210 x 250 mm 210 x 260 mm

Weight 1.2 kg 1.4 kg

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Welding hose A9-250 A9-400

Permissible load at 60% duty cycle

Length: 5 m, 10 m, 16 m 250 A 400 A

Electrode diameter 0.8-1.2 mm 0.8-1.6 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

The installation must be carried out by a professional.

4.1 Connecting the welding hose

SPress the inlet nozzle (a), - selected according to the diameter of the wire - into

the welding hose.

SOpen the wire feed unit on the bobbin side.

SUndo the locking screw (b) on the connecting plate.

SConnect the welding hose (c) to the wire feed unit and tighten the locking screw

on the connecting plate.

SRemove the plastic cover (d) from the gun housing.

SUndo the locking screw (e) and press the other end of the hose into the gun.

STighten the locking screw and fit the plastic cover.

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5 OPERATION

General safety regulations for handling the equipment can be found on

page 4. Read through before you start using the equipment!

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 for a short while.

This causes solidified oil and grease in the pneumatic motor to be dissolved, and

ensures uninterrupted service.

6 MAINTENANCE

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer attempts any

work to rectify any faults in the product during the guarantee period.

6.1 Daily or as necessary

Nozzles

SRemove the gas nozzle.

SClean 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.

SCheck the gas nozzle for damage and wear. Replace the nozzle if damaged or

worn.

SSelect a contact nozzle according to the diameter of the wire.

SAssemble the parts.

SSpray with welding spray obliquely into the gas nozzle from two directions.

SNB. Never spray straight into the nozzle.

Pneumatic Motor

The motor is provided with an oil nipple for its lubrication.

SLubricate the motor once a week (normal

operation) using the lubrication gun supplied

with the welding gun.

SUse oil, see accessories, page 19.

Feed Unit

STake out and clean the feed unit of the gun as

necessary.

SLubricate the feed unit with some drops of oil.

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6.2 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.

SMake sure the filter is properly fixed before the O-ring is fitted.

6.3 Replacing the wire guide

a Inlet nozzle f Shielding gas inlet

b Compression gland g Compressed-air inlet

c Wire guide h O-rings (inside the tube)

d O-rings i Outlet nozzle

e Inlet end

SUndo the locking screws on the welding hose connections to the wire feed unit

and the gun, then pull out the welding hose.

SPull out the inlet nozzle (a) and screw out the compression gland (b) on the inlet

side and the outlet nozzle (i) on the gun side.

SWithdraw the wire guide (c) from the inlet end. Make sure the o-rings (d) in the

connecting piece come along.

SFit 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.

SInsert 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.

SFasten the inlet nozzle (i) with screws at the gun end of the welding hose.

SAdjust the length of the guide (c) at the inlet end (e) 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.

SInsert the o-rings round the wire guide and then fasten the compression gland

(b) with screws.

SPress in the inlet nozzle (a).

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6.4 Dismantling the motor

1. Remove the plastic cover (a) on the gun housing. Undo the locking screw (b) using

an Allen key and remove the welding hose.

Unload the spring (c) and undo the screws (d) holding the contact tube.

Remove the tube.

2. Turn the welding gun upside-down. Wire the feed unit (e) 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.

Push out the roll pin (f) in the motor shaft which holds the feed roller of the motor

shaft in place.

Remove the feed roller.

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4. Remove the hand shield, if any, then gun trigger (m), rubber handle (n) and

contact tube (h).

Check that the three o-rings of the tube (g) come along.

5. Fasten the motor housing (k), in a screw vice or the like, protected by two

wooden jaws, and tighten moderately.

Screw out the left-threaded gun housing (l).

If the motor is rotating in its housing it cannot be dismounted from the housing of

the gun. Then tighten the right-threaded rear (m) a bit harder, using an open

end wrench with a jaw width of 28 mm.

6. Screw out the gun housing (l).

At the same time remove the protective cap (n) 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.

6.5 Mounting the motor

1. Place the new motor (k) between the wooden jaws

and tighten moderately.

Tighten the rear (m) and provide the motor shaft

with a guide sleeve (o) 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 (m) using an open

end wrench with a jaw width of 28 mm.

Now the gun housing (l) 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.

3. Fit the connection tube (h), the rubber handle (j),

the trigger (i), the protective cap (n) of the gasket ring,

the feed roller (p) of the motor shaft and the wire

feed unit (q)..

The connection tube (h) and the three o-rings (g) are to be fitted very snugly.

Cement the rubber handle using Bostik 292 or the like.

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