Related Manuals for Orbitalum P16 EVO
Summary of Contents for Orbitalum P16 EVO
- Page 1 P16 EVO en Tube-to-tube-sheet orbital weld head Translation of original operating instructions and spare parts list An ITW Company...
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Page 2: Table Of Contents
Poisonous vapors and Scope of delivery ..... substances....2.7.6 Tripping over wires Preparing initial operation ..and cables ....Set-up and mounting ....... 2.7.7 Long-lasting physical damage through Procedure ........ wrong posture .... ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 3 ..8.8.2 Finely adjust welding 11.1 P16 EVO | P16 EVO ....diameter ..... 11.2 P16 EVO mit KD | P16 EVO 8.8.3 Adjust torch angle ..with KD........Adjust welding gap....11.3 P16 AVC EVO | P16 AVC EVO 8.10 Position wire nozzle ....
- Page 4 P16, complete....11.10 P16 EVO: Schläuche, Kabel und Anschlüsse | P16 EVO: Hoses, cables and connectors. 11.11 P16 EVO AVC: Schläuche, Ka- bel und Anschlüsse | P16 EVO AVC: Hoses, cables and con- nectors ........12 Declaration of Conformity ....149 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 5: About These Instructions
Request for action in a sequence of actions: Action is required here. Request for action in a sequence of actions: Action is required here. … ► Single request for action: Action is required here. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 6: Further Applicable Documents
P16 EVO Further applicable documents The following documents apply together with these operating instructions: • Instructions for orbital welding power supply ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 7: Information And Safety Instructions For The Owner
Arc welding, manual (in- cluding MIG (Metal Inert Gas), MAG (Metal Active Gas), TIG (Tungsten In- ert Gas) under obser- vance of tried-and-tested procedures and without physical contact to the line * To Directive 2013/35/EU ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 8: Using The Machine
• Processing of those materials named in the operating instructions. • Proper usage of all components involved in the welding processes as well as of all further factors that have an influence on the welding process. • Solely commercial usage. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 9: Machine Constraints
• The device may only be installed and operated in a dry environment according to IP 23 (not in fog, rain, thunderstorms, etc.). If appropriate, use a welding tent. • Smoke, steam, oil vapors and grinding dust must be avoided. • Avoid salty ambient air (sea air). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 10: Environmental Protection And Disposal
Cable and cable assem- Borate, antimony, barite, beryllium, magnesium blies Displays Gallium, indium, heavy rare earths, light rare earths, niobium, platinum group metals, scandium Batteries Fluorspar, heavy rare earths, light rare earths, magnesium ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 11: Personnel Qualification
Discomfort, tiredness and malfunctions in the motor system, restricted ability to react and cramping. • Perform "loosening-up" exercises. • Ensure a varied range of activities. • Assume an upright, fatigue-free and comfortable body position during operation. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 12: Personal Protective Equipment
If the weld head or manual welding torch is not ready for operation, switch it to the "Test" func- tion. DANGER! Electrical hazards through touching as well as incorrect or damp protective equipment. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 13: Dangers Through Electromagnetic Fields
The owner has to ensure safe design of the workplace in accordance with the EMF Directive 2013/35/EU. ► Use only electrical devices with protective insulation in the working area of the welding system. ► Observe electromagnetically-sensitive devices when igniting the system. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 14: Damage To Eyes Through Radiation
► Do not put lines or cables under tension. ► Place the welding tongs in the transport case after dismantling. ► Ensure that the hose assembly is connected properly and that the strain relief is attached. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 15: Long-Lasting Physical Damage Through Wrong Posture
This can result in burns and blindness, in the worst case a fire can be started. ► Wear safety gloves 1/1/1/1 in accordance with EN 388 or 1/2/1/1 EN 407. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 16: Prick Injury Through Pointed Electrode And, If Appropriate, Cold Wire
Before connecting the weld head and before mounting the electrode: Switch off orbital welding system. ► Before moving the rotor with closed weld heads, fit clamping cassette or clamping unit and close flip cover. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 17: 2.7.13 Danger Of Cuts At Sharp Edges
If the system and its components exceed 25 kg in weight, lift using several people or lifting equipment. 2.7.16 General injuries through tools CAUTION! Injuries can occur during dismantling for the proper disposal of the weld head through uncertainties in handling tools. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 18 P16 EVO ► In case of uncertainties send the weld head to Orbitalum Tools – proper disposal is carried out here. ► Allow only a professional electrician to access the electrical system and open the weld head. ORBITALUM TOOLS GmbH...
- Page 19 P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 20: Description
3-point support Spacer between weld head and pipe sheet during welding of protruding pipes. Balance eye Hand the weld head balanced. Bracket Bears the balance eye and allows for it to be horizontally aligned. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 21 Bears model designation, serial and specification number, year of construction and motor type. Torch Bears the electrode for creating the arc. Tungsten electrode Focuses the arc. Cold wire adjustment unit Align cold wire nozzle. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 22: Application Area
P16 EVO Application area APPLICATION P16 EVO P16 EVO KD P16 EVO AVC KD REMARK AREA Code 831 000 003 831 000 001 831 000 002 From pipe ID [mm] 10.0 ... 78.0 12.0 ... 100.0 to pipe OD [inch] 0,394 ... - Page 23 Arbor for centering cartridge for group C 832 020 019 0.115 Centering car- 22.3 - 25.0 0.878 - 0.984 832 020 020 0.340 tridge Centering car- 24.5 - 27.0 0.965 - 1.063 832 020 021 0.350 tridge ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 24 2.736 - 2.913 832 020 037 2.600 tridge Centering car- 73.5 - 78.0 2.894 - 3.071 832 020 038 2.800 tridge Centering car- 77.5 - 82.0 3.051 - 3.228 832 020 039 3.100 tridge ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 25 115.0 - 120.0 4.527 - 4.724 832 020 053 tridge * Smaller and larger dimensions on request. See product catalog "Orbital Welding" for a comprehensive overview of suitable accessories. Download link PDF: https://www.orbitalum.com/de/download.html ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 26: Technical Specifications
P16 EVO Technical specifications MODEL P16 EVO P16 EVO KD P16 EVO AVC KD Code 833 000 003 833 000 001 833 000 002 Weight machine includ- [kg] 16.20 17.50 18.30 ing hose assembly [lbs] 35,715 38,581 40,345 Hose assembly weight [kg] 5.50... - Page 27 P16 EVO MODEL P16 EVO P16 EVO KD P16 EVO AVC KD Cold wire coil diameter (standard) Cold wire diameter (split 0.6 - 0.9 rolls series 1) Supplementary wire di- 0.9 - 1.2 ameter (split rolls series Normally the machine is delivered with split roll series 1 as standard.
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Page 28: Abmessungen
P16 EVO Abmessungen Illustration: P16 EVO without cold wire ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 29 P16 EVO Illustration: P16 EVO with cold wire ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 30 P16 EVO Illustration: P16 EVO AVC with cold wire TYPE P16 EVO P16 EVO KD P16 EVO AVC KD Code 833 000 003 833 000 001 833 000 002 Dimension "A": [mm] 183.00 183.00 184.00 [inch] 7,204 7,204 7,244 Dimension "B"...
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Page 31: Transport And Shipping
P 16 EVO AVC as an example. Procedures or work steps that deviate are, if required, described separately and represented in a separate figure. Gross weight MODEL P16 EVO P16 EVO KD P16 EVO AVC KD Weight* [kg] 27.20 28.50 29.30 [lbs] 59.97... - Page 32 P16 EVO ► Use the handle (1) and balance eye (2) to re- move the weld head from the transport case. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 33: Commissioning
UNIT P16 EVO/ 833 000 003/ PCS. P16 EVO with cold wire/ 833 000 001/ P16 EVO AVC with cold wire 833 000 002 Tool set P16 (AVC) 831 001 164 PCS. General safety instructions, P16 EVO 833 060 101 PCS. -
Page 34: Preparing Initial Operation
Check the working environment for possible sources of danger and, if applicable, eliminate these. ► Fill weld head with cooling liquid (see the chapter Carry out the gas and cooling-liquid function test). ► Check the weld head for loose parts and particles in the transmission. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 35: Set-Up And Mounting
8. Adjust welding gap [} 55] 9. If necessary Position wire nozzle [} 56] 10. Carry out the gas and cooling-liquid function test [} 58] 11. Configure welding procedure (see operating instructions of the welding power source) ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 36 6. Fit wire coil (see chap. Insert wire coil and set wire feed rolls pressure [} 38]). ► To remove the cold wire conveyor unit carry out the work steps in the reverse order. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 37 ► Activate wire feed: Press “MANUAL WIRE FEED” button and hold it until it automatically stops (see chap. Manual wire feed and retraction [} 61]). OR via welding power supply: ► See operating instructions of the welding power source. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 38 1. Unscrew wire nozzle from the holder so that the wire guide hose can be held without bending. See the chapter Replace wire guide nozzle [} 68] 2. Switch on the welding power supply (see operation manual of welding power supply). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 39 Make sure that the locking pin (1) of the outer brake disc is used in a designated hole in the coil. ► Put a sufficiently large hole in position of the locking pin in the plas- tic coil. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 40 ► At the welding power supply set the desired wire feed speed, whereby in a simulated cycle the regularity of the feed can be checked. ► Then check the wire feed direction. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 41 ► Check whether the angle α between the holding rope and pipe sheet is 10°-15° and, if necessary, adjust. The 5 snap-in positions (3) in the balance eye (2) can be used for this and the position of the balance eye itself can be changed on the bracket (1). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 42 "MIN" marking at the tank). NOTICE During initial commissioning: The hose package may be damaged while being unpacked from the packaging foil! ► Carefully sever the cable ties without damaging the hose package. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 43 5. Connect the gas hose. 6. Switch on the welding power supply. 7. Carry out gas and cooling liquid function test. See the chapter Carry out the gas and cooling-liquid function test [} 58] ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 44 Power source, e.g. Type ORBIMAT 300 SW Socket "Gas" (quick lock) Plug "Gas", hose package "Coolant supply line" socket, blue "Coolant supply line" plug, blue, hose assembly "Coolant return line" socket, red "Coolant return line" plug, red, hose assembly ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 45 Workpiece/hose Socket "Ground cable" "Welding current +" plug, power source * For use with older Orbitalum welding power sources and heads with green Superior connections. Newer machine models are already equipped with DINSE-compatible connections. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 46 Rework, if necessary. See the chapter Grinding elec- trodes ► Raise HF spiral (1) on handle (2) and pull from the gas nozzle (4). ► Screw gas nozzle (3) counterclockwise from the gas lens (4). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 47 ► Pull electrode (7) and clamping sleeve (6) or move to the desired position. ► In the event of an electrode replacement, push new electrode into gas lens and carry out work steps in reverse order. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 48 To reach the optimum welding quality a current adjusted to the electrode geometry is necessary. This is defined by the electrode diameter, the tip diameter and the cutting angle. ► The electrode must be replaced every time its geometry clearly deviates from the original. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 49 0.75 0,030 10 - 140 2.05 0,081 0.75 0,030 10 - 160 0,094 0.75 0,030 12 - 180 0,094 0,043 15 - 250 0,126 0,043 20 - 300 0,126 0,059 25 - 350 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 50 ð If the resistance is too high, turn grub screw (5) counterclockwise in the tip of the spindle with a hexagon screwdriver in order to decrease the resistance. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 51 Centering unit is fitted to the weld head. See the chapter Fit centering unit [} 50] ► Position centering cartridge (1) in the center before the pipe opening and push into the pipe until touching the three support feet (2) on the pipe sheet (3). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 52 Depending on application, the mounting position of the gas nozzle/lens can be changed on the torch body. ► Raise bracket (2) of HF spiral (1) and pull from the gas nozzle (3). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 53 [} 41] Centering unit is fitted to the weld head. See the chapter Fit centering unit [} 50] Weld head is taut in workpiece. See the chapter Clamp the weld head in the workpiece [} 51] ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 54 P16 EVO ► Adjust desired radius of the torch to the pipe center with a hexagon screwdriver at the ad- justing screw (4). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 55 Weld head is taut in workpiece. See the chapter Clamp the weld head in the workpiece [} 51] Welding diameter is adjusted. See the chapter Adjust welding diameter [} 52] Welding diameter is finely adjusted. See the chapter Finely adjust welding diameter [} 53] ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 56 Furthermore, the position of the wire nozzle (4) can be adjusted axially via the adjusting screw (1), horizontally via the hexagon socket head screw (2) and vertically via the hexagon socket head screw (3). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 57 ► Release hexagon socket head screw (2) with a hexagon screwdriver, position wire nozzle (4) by hand and retighten hexagon socket head screw. Adjust vertically: ► Release hexagon socket head screw (3), position wire nozzle (4) by hand and retighten. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 58 If several weld heads of the same type are in use, it is recommended that the motors be calibrated be- fore use. This allows identical welding results to be realized with the saved programs and all weld heads. ► See operating instructions of the welding power source ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 59 In the worst case a fire will be started. ► Observe the local general fire protection measures. NOTICE Various risks ► Permanently observe welding process! ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 60 ü The gas post purge time has ended. ► Press and hold “ROTATION CLOCKWISE” but- ton (2). ð Weld head moves to home position. OR via welding power supply: ► See operating instructions of the welding power source. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 61 Manual wire retraction: ► Press and hold “WIRE RETRACTION” button (3). ð The wire is pulled onto the coil. OR via welding power supply: ► See operating instructions of the welding power source. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 62 • Do not store near materials that may cause corrosion. • Temperature range -20 to +55 °C • Relative humidity up to 90 % at 40 °C Further care and maintenance advice, see chap. Maintenance and troubleshooting. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 63 ► Carry out the standard cleaning process of the weld head (see cesses chap. Standard cleaning process [} 64]). ► A shorter cleaning interval can influence the service life of the weld head positively. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 64 Remove foreign matter from the gas nozzle and gas lens. In the case of stubborn soiling, a Scotch-Brite cleaning sponge or a comparable product can be used. Clean contact surfaces: ► Unscrew bolt (2) with Allen key. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 65 ► Take torch holder (3) from the carriage (5). ► Clean carriage (5) of the radial torch adjust- ment with a lint-free cotton cloth. ► To mount carry out work steps in reverse order. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 66 4. Clean friction surfaces of the arbor shaft (8), the coupling (15) and the clutch disc (14) with a lint- free cotton cloth. ► To mount carry out work steps 1– 3 in reverse order. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 67 See chap. Grinding electrode [} 48] Electrode ground incorrectly. ► Regrind the electrode. See chap. Grinding electrode [} 48] Poor electrode quality. ► Use Orbitalum electrodes. See the chapter Incorrect workpiece material ► Change workpiece material. Bad workpiece quality ► Use different material batch.
- Page 68 3. Unscrew nozzle (2) from the wire guide hose (4). 4. Unscrew new nozzle. 5. Place nozzle (2) in the support (1) and tighten hexagon socket head screw (3) with hexagon screw- driver. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 69 4. Cut off approx. 2 mm (0.1 in) of the hose ends with a sharp knife (e.g. with a carpet knife) in order to remove any burrs created. 5. Turn hose through the guide channel (3) of the cold wire supply unit into the guide nozzle (hose is self-cutting). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 70 4. For deburring, cut off approx. 2 mm (0.1 in) of the hose ends with a sharp knife (e.g. with a carpet knife) in order to remove any burrs created. 5. Screw a hose end into the wire guide nozzle (3) of the cold wire supply unit (the hose is self-cut- ting). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 71 Repairs and enclose the completed form with the shipment of the affected goods. 10.6.2 Technical support & application engineering Do you have questions about the operation of your Orbitalum system or do you have a technical prob- lem? Our experienced and qualified product and application specialists will support you in the correct selec- tion and application of products.
- Page 72 Operators from the plant, container and pipeline construction industries are particularly suitable as tar- get groups for the various training courses. E-mail: training@orbitalum.com Phone: +49 (0) 77 31 792-741 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 73 P16 EVO SPARE PARTS ERSATZTEILLISTE / SPARE PARTS LIST ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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- Page 137 P16 EVO SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 138 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 139 P16 EVO SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 140 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 141 P16 EVO SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 142 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 143 P16 EVO SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 144 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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- Page 146 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 147 P16 EVO SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 148 SPARE PARTS P16 EVO ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 149 (including optionally available accessories from Orbitalum): / Machine et type (y compris accessoires (*inkl. Orbitalschweißstromquelle): Orbitalum disponibles en option): / Macchina e tipo (inclusi gli articoli accessori acquistabili opzionalmente P16 EVO da Orbitalum): / Máquina y tipo (incluidos los artículos de accesorios de Orbitalum disponibles...
- Page 150 Josef-Schüttler-Straße 17 78224 Singen, Deutschland Tel. +49 (0) 77 31 792-0 Rohreinschweißköpfe Maschine und Typ (inklusive optional erhältlichen Zubehörartikeln von Orbitalum): / (*inkl. Orbitalschweißstromquelle) Machinery and type (including optionally available accessories from Orbitalum): Tube-to-tube-sheet orbital weld heads (*incl. orbital welding power source):...
- Page 151 P16 EVO Notizen ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 152 Orbitalum Tools GmbH provides global customers one source for the finest in pipe & tube cutting, beveling and orbital welding products. worldwide | sales + service NORTH AMERICA EUROPE ASIA Gulf Coast GERMANY CHINA Sales, Service & Rental Center E.H. Wachs E.H.
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