Orbitalum BRB 2 Operating Instructions Manual Download Page 52

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9 Clamping wedge and mandrel assembly BRB 4

Operating instructions BRB

(08.10)

MT_BRB_BA_04_790086762_00.doc

orbitalum tools

gmbh

Clamping range

Kit 1

Kit 2

Kit 3

Kit 4

Kit 5

[mm] [inch]

19.1 – 38.0

0.752 – 1.490

35.0 – 64.0

1.378 – 2.520

63.0 – 108.0

2.480 – 4.252

Kit 1:

Clamping range 19.1 – 38.0 mm

Kit 2:

Clamping range 35.0 – 64.0 mm

Interior pipe Ø wedges [mm]

19.1 – 23.0

Code 790 086 390

35.0 – 40.0

Code 790 086 311

22.0 – 26.00

Code 790 086 391

39.0 – 44.0

Code 790 086 312

25.0 – 29.0

Code 790 086 392

43.0 – 48.0

Code 790 086 313

29.0 – 32.0

Code 790 086 393

47.0 – 52.0

Code 790 086 314

31.0 – 35.0

Code 790 086 394

51.0 – 56.0

Code 790 086 315

34.0 – 38.0

Code 790 086 395

55.0 – 60.0

Code 790 086 316

–

59.0 – 64.0

Code 790 086 317

Clamping range 35.0 – 108.0 mm

Interior pipe Ø

wedges [mm]

Clamping

attachment A for

interior Ø [mm]

Clamping

attachment B for

interior Ø [mm]

Mandrel [mm]

35.0 – 40.0

Code 790 086 311

– –



34.5

Code 790 086 441

39.0 – 44.0

Code 790 086 312

– –

43.0 – 48.0

Code 790 086 313

– –

47.0 – 52.0

Code 790 086 314

67.0 – 72.0

Code 790 086 319

87.0 – 92.0

Code 790 086 324

51.0 – 56.0

Code 790 086 315

71.0 – 76.0

Code 790 086 319

91.0 – 96.0

Code 790 086 324

55.0 – 60.0

Code 790 086 316

75.0 – 80.0

Code 790 086 319

95.0 – 100.0

Code 790 086 324

59.0 – 64.0

Code 790 086 317

79.0 – 84.0

Code 790 086 319

99.0 – 104.0

Code 790 086 324

63.0 – 68.0

Code 790 086 317

83.0 – 88.0

Code 790 086 319

103.0 – 108.0

Code 790 086 324

Clamping range 19.1 – 64.0 mm

Interior pipe Ø wedges [mm]

Mandrel [mm]

19.1 – 23.0

Code 790 086 390



19.05

Code 790 086 381

22.0 – 26.00

Code 790 086 391

25.0 – 29.0

Code 790 086 392

29.0 – 32.0

Code 790 086 393

31.0 – 35.0

Code 790 086 394

Overview

Kit 1, Kit 2

Kit 3

Kit 4

Summary of Contents for BRB 2

Page 1: ...implicity Operating instructions BRB 2 BRB 4 Pneumatic Pneumatic Auto Electric Boiler Pipe Preparation Machines Code 790 086 762 Translation of original operating instructions Machine no ________________________________ ...

Page 2: ...ed in particular the rights of duplication and distribution as well as translation Duplication and reproduction in any form print photocopy microfilm or electronic require the written permission of Orbitalum Tools GmbH ...

Page 3: ... Pneumatic Auto 12 2 6 BRB 4 Electric 13 2 7 Overview of the BRB clamping systems 13 2 7 1 Standard clamping system 14 2 7 2 NC clamping system 14 2 8 Accessories 15 2 8 1 Tool holder and multifunctional tools 15 2 8 2 Bevel heads for BRB 4 V seam 17 2 8 3 Bevel heads for BRB 2 V Y seam 17 2 8 4 Brush attachments for BRB 4 for BRB 2 on request 18 2 8 5 Brushes original equipment kit for BRB 4 18 2...

Page 4: ...ing wedges BRB 2 NC 32 8 3 1 Replacing the clamping wedges BRB 2 NC with mandrel Ø 19 05 mm 33 8 3 2 Replacing the clamping wedges BRB 2 NC Pneu Auto with mandrel Ø 19 05 mm 34 8 4 Replacing the mandrel BRB 2 standard 35 8 4 1 Removing the mandrel BRB 2 standard with mandrel Ø 12 75 36 8 4 2 Fitting the mandrel BRB 2 standard with mandrel Ø 12 75 36 8 4 3 Removing the mandrel BRB 2 standard Auto w...

Page 5: ...h mandrel Ø 19 05 and Ø 31 50 52 9 4 2 Replacing the mandrel BRB 4 standard Auto with mandrel Ø 19 05 and Ø 31 50 53 9 5 Replacing the mandrel BRB 4 NC 54 9 5 1 Replacing the mandrel BRB 4 NC with mandrel Ø 19 05 and Ø 34 50 54 9 5 2 Fitting the mandrel BRB 4 NC with mandrel Ø 19 05 and Ø 34 50 55 9 5 3 Removing the mandrel BRB 4 NC Auto with mandrel Ø 19 05 and Ø 34 50 56 9 5 4 Fitting the mandre...

Page 6: ... 3 Fitting the large brush on the NC clamping system 74 11 1 4 Fitting the small brush on the NC clamping system 75 11 2 Hoist Bracket 75 11 3 Depth setting plate 76 11 4 BRB retrofit kits 77 11 4 1 BRB dimension extension retrofit kits 77 11 4 2 BRB Pneumatic to Auto retrofit kits 77 11 4 3 BRB clamping system standard to NC retrofit kits 77 12 Maintenance 78 13 What to do if 79 13 1 Troubleshoot...

Page 7: ...material damage Always read and observe these warning messages This is a warning symbol It warns you about dangers of injury Please follow all instructions marked with the safety symbol in order to avoid injuries or death Warning symbol Meaning DANGER Imminent danger Non observance could result in death or serious injury Restrictions if applicable Risk prevention measures WARNING Possible danger N...

Page 8: ...e action in this case Single request for action you have to take action in this case Conditional request for action you have to take action if the specified condition is met 0 3 Abbreviations Abbr Meaning BRB Pneumatic Boiler pipe preparation machine with pneumatic drive BRB Pneumatic Auto Boiler pipe preparation machine with pneumatic drive and pneumatic clamping BRB Electric Boiler pipe preparat...

Page 9: ...orking order Comply with these safety instructions Keep complete documentation close by the machine 1 1 Intended use Only use BRB 2 and BRB 4 to process face and bevel metallic pipe ends up to 2 or 4 inches The machine should only be used on empty deenergized pipes Temperature range 15 C to 40 C 1 2 Improper use The machine is not intended for use by private consumers Do not use the machine on ene...

Page 10: ...y regulations Only use the dimensions and materials specified in these instructions Other materials should be used only after consulting with Orbitalum Tools customer service Use only original Orbitalum Tools spare parts and materials Work on the electrical equipment may only be carried out by a qualified electrician Only operate the BRB Pneumatic or BRB Pneumatic Auto with the ON OFF switch on th...

Page 11: ...ndations do not in any way release the operating company employer from its statutory health and safety at work obligations towards its employees After each work process switch off the machine and let it run to a stop BRB Pneumatic and BRB Pneumatic Auto before cleaning maintenance adjustment or repair work turn off the compressed air supply and allow the machine to run to a stop BRB Electric pull ...

Page 12: ...y crushed Wear safety shoes that comply with DIN EN 20345 S3 Sharp edged chips whirling around Irreversible cuts Wear safety gloves that comply with EN 388 protection level 5 Loose clothing and long hair can get caught in the machine During operation do not wear loose clothing e g neckties Secure long hair to prevent it being caught up Threat posed by incorrect usage Discomfort tiredness Limited a...

Page 13: ...ch must be handled selectively according to EU regulations Separate collection and selective treatment is the basis for environment friendly disposal and the protection of human health Appliances and products that you bought from us after August 13 2005 will be disposed of at no cost in accordance with legal standards after they have been supplied to us We may refuse to accept old appliances that ...

Page 14: ... plate 6 Housing 6 Housing 7 Hoist bracket 7 Hoist bracket 8 Switching lever for feed direction forward backward 8 Switching lever for feed direction forward backward 9 Feed ratchet 9 Feed ratchet 10 Clamping star knob 10 Clamping nut 11 Threaded spindle 11 Clamping ratchet 12 Actuator unit P 12 Actuator unit P 13 Speed regulator 13 Speed regulator 14 ON OFF rotary switch 14 ON OFF rotary switch 1...

Page 15: ...5 Tool mounting plate 6 Housing 6 Housing 7 Hoist bracket 7 Hoist bracket 8 Locking wheel 8 Locking wheel 9 Pneumatic cylinder 9 Pneumatic cylinder 10 Rotary clamping switch 10 Rotary clamping switch 11 Rotating knob 11 Rotating knob 12 Threaded spindle 12 Actuator unit P 13 Actuator unit P 13 Speed regulator 14 Speed regulator 14 ON OFF rotary switch 15 ON OFF rotary switch 15 thread for compress...

Page 16: ...dge attachment 4 Mandrel 4 Mandrel 5 Tool mounting plate 5 Tool mounting plate 6 Housing 6 Housing 7 Hoist bracket 7 Hoist bracket 8 Switching lever for feed direction forward backward 8 Switching lever for feed direction forward backward 9 Feed ratchet 9 Feed ratchet 10 Clamping star knob 10 Clamping nut 11 Threaded spindle 11 Clamping ratchet 12 Actuator unit EL 12 Actuator unit EL 13 ON OFF sli...

Page 17: ...sing 5 Housing 6 Hoist bracket 6 Hoist bracket 7 Switching lever for feed direction forward backward 7 Switching lever for feed direction forward backward 8 Feed ratchet 8 Feed ratchet 9 Clamping ratchet 9 Clamping nut 10 Threaded spindle 10 Clamping ratchet 11 Actuator unit P 11 Threaded spindle 12 Safety lever 12 Actuator unit P 13 Restricting stop valve ON OFF switch speed regulator 13 Safety l...

Page 18: ...ool mounting plate 4 Tool mounting plate 5 Housing 5 Housing 6 Hoist bracket 6 Hoist bracket 7 Locking wheel 7 Locking wheel 8 Pneumatic cylinder 8 Pneumatic cylinder 9 Rotary clamping switch 9 Rotary clamping switch 10 Rotating knob 10 Rotating knob 11 Actuator unit P 11 Actuator unit P 12 Safety lever 12 Safety lever 13 Restricting stop valve ON OFF switch speed regulator 13 Restricting stop val...

Page 19: ...st bracket 7 Switching lever for feed direction forward backward 7 Switching lever for feed direction forward backward 8 Feed ratchet 8 Feed ratchet 9 Clamping ratchet 9 Clamping nut 10 Threaded spindle 10 Clamping ratchet 11 Actuator unit EL 11 Threaded spindle 12 ON OFF switch 12 Actuator unit EL 13 Speed regulator 13 ON OFF switch 14 Speed regulator 2 7 Overview of the BRB clamping systems Ther...

Page 20: ...2 15 2 15 inch 0 079 0 315 0 079 0 315 0 079 0 590 0 079 0 590 0 079 0 590 0 079 0 590 0 079 0 590 2 7 2 NC clamping system The new NC clamping system with its clamping wedges firmly anchored in the mandrel is ideal for applications where no foreign bodies may enter the inside of the pipe or a container The NC clamping system provides extra safety particularly for vertical work The clamping wedges...

Page 21: ...86 216 WH 12 V 37 5 790 086 220 790 086 060 with R 1 2 790 093 462 WH 12 V 80 790 086 220 790 086 060 with R 1 2 790 092 210 WH 15 V 30 790 093 226 790 093 037 with R 0 790 092 216 WH 15 V 37 5 790 093 226 790 093 037 with R 0 790 092 212 WH 15 V 60 790 093 226 790 093 037 with R 0 790 093 468 WH 30 V 15 790 093 226 790 093 033 with R 0 790 093 476 WH 30 V U 25 790 093 226 790 093 033 with R 0 790...

Page 22: ...092 212 WH 15 V 60 790 093 226 790 093 037 with R 0 790 093 468 WH 30 V 15 790 093 226 790 093 033 with R 0 790 093 476 WH 30 V U 25 790 093 226 790 093 033 with R 0 790 093 210 WH 30 V 30 790 093 226 790 093 033 with R 0 790 093 424 WH 30 V 32 5 790 093 226 790 093 033 with R 0 790 093 216 WH 30 V 37 5 790 093 226 790 093 033 with R 0 790 093 404 WH 30 V 45 790 093 226 790 093 033 with R 0 790 09...

Page 23: ...45 mm to OD 73 mm 1 772 2 874 inch in 2 steps of 5 mm 0 197 inch distance 10 0 394 790 086 459 2 8 3 Bevel heads for BRB 2 V Y seam Optimized machining more uniform and quieter cutting Includes adjustable tool holder The bevel heads can be swapped like a tool mounting plate and are available for different bevel angles The bevel heads can be adapted for all machines including older models Bevel hea...

Page 24: ...40 9 52 0 1 610 2 047 790 086 525 Brush attachment 25 x 790 086 498 Brush 25 62 5 x 50 7 61 7 1 996 2 429 790 086 526 Brush 25 71 x 59 4 70 4 2 339 2 772 790 086 527 Brush 25 81 x 69 2 80 2 2 724 3 157 790 086 528 Brush attachment 33 x 790 086 499 Brush 33 91 x 79 6 90 5 3 134 3 563 790 086 529 Brush 33 101 x 89 4 100 4 3 520 3 953 790 086 530 Brush 33 112 x 99 6 110 8 3 921 4 362 790 086 531 Cust...

Page 25: ...ited for the BRB Pneumatic Auto for assembly information see section 11 3 p 76 Article Code Depth setting plate for BRB 4 790 086 045 Depth setting plate for BRB 2 790 085 055 2 8 8 Mobile air unit with lubricator and water extraction Can be used together with the BRB Pneumatic and BRB Pneumatic Auto Transportable mobile air unit and connections consisting of Mobile air unit 1 code 790 093 060 Com...

Page 26: ...th pressure wedges for tool mounting plate dia 68 mm Only one multifunctional tool necessary for Different machining operations beveling facing Different pipe wall thicknesses Different type materials Additional use of REB tools and holders see chap 2 8 1 p 15 Tool with multiple cutting edges Only one screw is needed to fix and secure each tool Futura Balinit tool coating Standard clamping system ...

Page 27: ...5 0 2 0 15 0 2 0 15 0 2 0 15 0 inch 0 059 0 197 0 079 0 236 0 079 0 590 0 079 0 590 0 079 0 590 0 079 0 590 0 079 0 590 3 2 2 Application range BRB with NC clamping system Type of machine BRB 2 Kit 2 BRB 4 Kit 1 BRB 4 Kit 2 BRB 4 Kit 3 BRB 4 Kit 4 BRB 4 Kit 5 Pipe ID mm 19 1 38 0 19 1 38 0 35 0 64 0 35 0 108 0 19 1 64 0 19 1 108 0 inch 0 752 1 490 0 752 1 490 1 378 2 520 1 378 4 252 0 752 2 520 0 ...

Page 28: ...nge speed approx 82 mid range speed approx 76 mid range speed Vibration level that complies with EN 28662 Part 1 m s 2 5 2 5 2 5 The noise level was measured under normal operating conditions in accordance with EN 23741 4 2 BRB 4 BRB 4 Pneumatic BRB 4 Pneumatic Auto BRB 4 Electric Dimensions with the standard clamping system mm inch 533 x 120 x 454 21 0 x 4 7 x 17 9 529 x 120 x 610 20 8 x 4 7 x 24...

Page 29: ...nd 1 spare parts list 5 1 2 Additional parts of the standard clamping system For information on replacing the individual components BRB 2 see chapter 8 p 28 BRB 4 see chapter 9 p 44 Type of machine BRB 2 Kit 1 BRB 2 Kit 2 BRB 4 Kit 1 BRB 4 Kit 2 BRB 4 Kit 3 BRB 4 Kit 4 BRB 4 Kit 5 Clamping sets pieces 6 8 4 3 3 3 clamping attachments 4 3 4 3 3 clamping attachments Threaded spindle M8 with clamping...

Page 30: ... 4 Kit 1 BRB 4 Kit 2 BRB 4 Kit 3 BRB 4 Kit 4 BRB 4 Kit 5 Clamping sets pieces 6 6 8 8 2 clamping attachments 6 8 6 8 2 clamping attachments Mandrel Ø with clamping wedge attachment mm 19 05 19 05 small 34 50 large 34 50 19 05 34 50 19 05 34 50 inch 0 750 0 750 1 358 1 358 0 750 1 358 0 750 1 358 Tool mounting plate Ø mm 50 0 16 0 68 19 68 27 120 27 68 19 68 27 68 19 68 27 120 27 inch 1 969 0 630 2...

Page 31: ...e machine is started Disconnect the BRB from the power supply prior to transport The BRB 4 is very heavy when transported in its case 26 kg Risk of overstraining Use appropriate lifting equipment to transport the BRB 4 over long distances Incorrect machine storage Diverse risks Store the machine in its original case in a dry environment The BRB is a portable hand operated machine Special transport...

Page 32: ...hine and pipe Danger of bodily injury Check machine condition and secure it to prevent it falling 7 1 Connection requirements 7 1 1 BRB Pneumatic and BRB Pneumatic Auto To ensure that the BRB Pneumatic or BRB Pneumatic Auto functions properly and safely the compressed air unit must fulfill the following requirements The compressed air network must be capable of providing 0 7 m min BRB 2 and 1 2 m ...

Page 33: ... 10 MT_BRB_BA_04_790086762_00 doc 27 7 1 2 BRB Electric The power connection has to fulfill the following requirements 1 phase alternating current 230 V 50 60 Hz or 120 V 50 60 Hz Fault current FI protection must be provided by the customer Power fuse at least 10 A ...

Page 34: ...88 11 0 0 433 085 281 22 50 25 50 0 886 1 004 085 288 11 0 0 433 2 19 05 46 00 0 750 1 811 085 273 19 05 0 750 086 256 19 05 24 30 0 750 0 957 086 257 22 10 27 30 0 870 1 075 086 258 25 50 30 80 1 004 1 213 086 259 28 50 33 80 1 122 1 331 085 258 32 00 36 50 1 260 1 437 085 259 35 10 39 70 1 382 1 563 085 260 38 30 42 90 1 508 1 689 085 263 41 60 46 00 1 638 1 811 Clamping sets each consisting of ...

Page 35: ...em see chap 8 3 p 32 BRB Electric Danger of death by electric shock Prior to assembly dismantling maintenance and adjustment work disconnect the BRB from the power supply and let it come to a complete stop BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjust...

Page 36: ...of arrow as far as the stop 4 Remove clamping disc 4 with size 10 open end wrench 5 Detach clamping wedges 5 and spring washer 6 6 Push clamping disc 4 onto insertion aid 7 Code 790 085 299 7 Place selected clamping wedges 5 in clamping disc 4 Loose clamping wedges first push spring washer 6 over the clamping wedges 5 8 Push the complete unit onto threaded spindle 3 and rotate clamping disc 4 onto...

Page 37: ... standard Pneumatic Auto BRB 2 standard Electric 2 Push threaded spindle 2 out of mandrel 3 in direction of arrow 3 Detach clamping wedges 4 from clamping disc 5 and push them down and off the threaded spindle 2 4 Push selected clamping wedges over threaded spindle 2 and insert them in the clamping disc 5 5 Push the threaded spindle with clamping wedges back into the mandrel 6 Push clamping wedges...

Page 38: ...h by electric shock Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power su...

Page 39: ...open end wrench 3 Rotate clamping nut 3 in direction of arrow as far as the stop 4 The 3 clamping wedges 4 can now be detached from the clamping wedge attachment guide 5 5 Insert selected clamping wedges into the clamping wedge attachment guide Tool damage The clamping wedges must not be tilted Ensure that the 3 clamping wedges used are always identical 6 Use clamping nut 3 to push the clamping we...

Page 40: ... 4 Move clamping wedge attachment 3 outward with the aid of threaded spindle 4 as far as the end of the mandrel 5 The 3 clamping wedges 5 can now be detached from the clamping wedge attachment guide 3 6 Insert selected clamping wedges into the clamping wedge attachment guide 3 Tool damage The clamping wedges must not be tilted Ensure that the 3 clamping wedges used are always identical 7 Move clam...

Page 41: ... electric shock Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply...

Page 42: ... of the arrow 5 Pull the threaded spindle out of the mandrel 6 Use feed ratchet 5 to move mandrel 4 in the direction of the arrow 7 Pull mandrel 4 out of the housing 7 8 4 2 Fitting the mandrel BRB 2 standard with mandrel Ø 12 75 1 Tool mounting plate 3 must be removed 2 Push mandrel 4 into the housing 3 Use the feed ratchet to move mandrel 4 in the opposite direction to the arrow 4 Fit tool mount...

Page 43: ...ection to the arrow 9 Use locking wheel 9 to pull mandrel 8 out of the housing 10 in the direction of the arrow 8 4 4 Fitting the mandrel BRB 2 standard Auto with mandrel Ø 12 75 1 Tool mounting plate 3 must be removed 2 Push mandrel 8 into the housing 3 Use the locking wheel to rotate the mandrel 8 into the housing in the opposite direction to the arrow until approx 15 mm 0 591 inch of thread is ...

Page 44: ...rew mandrel 1 out of the housing in the direction of the arrow 3 Remove tool mounting plate 4 for later assembly of mandrel dia 12 75 only 8 4 6 Fitting the mandrel BRB 2 standard Ø 19 05 1 Fit the tool mounting plate 4 2 Push mandrel 1 into the housing 3 Use the feed ratchet 2 to rotate the mandrel 1 into the housing in the opposite direction to the arrow until approx 15 mm 0 591 inch of thread i...

Page 45: ...ow with the locking wheel 6 6 Pull the mandrel out of the housing 7 7 Remove tool mounting plate 8 for assembly of mandrel dia 12 75 only 8 4 8 Fitting the mandrel BRB 2 standard Auto with mandrel Ø 19 05 1 Fit the tool mounting plate 8 2 Push mandrel 5 into the housing 3 Use the locking wheel 6 to rotate the mandrel 5 into the housing in the opposite direction to the arrow until approx 15 mm 0 59...

Page 46: ...jury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop 8 5 1 Removing the mandrel BRB 2 NC with mandrel Ø 19 05 1 Remove the clamping wedges see working steps 1 up to 4 chap 8 3 1 p 33 2 Use mounting aid 1 Code 790 085 49...

Page 47: ...ntil at least 50 mm of the thread is visible 3 Rotate clamping nut 5 onto the mandrel as far as the stop 4 Push clamping wedge attachment 6 into the mandrel 5 Screw it in with the mounting aid 7 Code 790 085 490 until the mounting aid 7 is flush up against the mandrel Warning left hand thread 6 Clamping wedge attachment 6 must now be exactly 3 mm from the end of the mandrel 7 The 3 grooves 8 on th...

Page 48: ...rel 3 Remove PU hose 3 by pressing the washers on the two angle screws 4 4 Loosen cylinder screw 5 on clamping cylinder 6 until clamping cylinder 6 rotates 5 Rotate the clamping cylinder 6 down from the mandrel 6 Loosen headless screw 7 on sleeve 8 7 Push sleeve 8 downwards away from the mandrel 8 Move the mandrel in the direction of the arrow with the locking wheel 9 9 Pull the mandrel out of the...

Page 49: ...visible 3 Push sleeve 5 onto the mandrel thread 4 Rotate clamping cylinder 6 onto the mandrel as far as the stop 5 Fasten clamping cylinder 6 with cylinder screw 7 press the cylinder screw into the mandrel groove if necessary rotating the clamping cylinder back slightly 6 Fix sleeve 5 to the clamping cylinder flange and fasten it with the headless screw 9 7 Push clamping wedge attachment 10 into t...

Page 50: ...to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop 9 1 1 BRB 4 with standard clamping system Select clamping wedges clamping attachment and mandrel according to the interior diameter of the pipe to be machined Clamping range Kit 1 Kit 2 Kit 3 Kit 4 Kit 5 mm inch 19 1 33 8 0 752 1 330 x x x 32 0 61 7 1 260 2 429 x x x...

Page 51: ...de 790 086 259 32 0 42 1 Code 790 086 169 40 9 52 0 Code 790 086 170 31 5 Code 790 086 130 50 7 61 7 Code 790 086 171 Clamping range 19 1 110 8 mm Interior pipe Ø wedges mm Clamping attachment for interior Ø mm Clamping attachment for interior Ø mm Clamping attachment for interior Ø mm Mandrel mm 19 1 24 3 Code 790 086 256 19 05 Code 790 086 176 22 1 27 3 Code 790 086 257 25 5 30 8 Code 790 086 25...

Page 52: ...e 790 086 317 Clamping range 35 0 108 0 mm Interior pipe Ø wedges mm Clamping attachment A for interior Ø mm Clamping attachment B for interior Ø mm Mandrel mm 35 0 40 0 Code 790 086 311 34 5 Code 790 086 441 39 0 44 0 Code 790 086 312 43 0 48 0 Code 790 086 313 47 0 52 0 Code 790 086 314 67 0 72 0 Code 790 086 319 87 0 92 0 Code 790 086 324 51 0 56 0 Code 790 086 315 71 0 76 0 Code 790 086 319 91...

Page 53: ...achment B for interior Ø mm Mandrel mm 19 1 23 0 Code 790 086 390 19 05 Code 790 086 381 22 0 26 00 Code 790 086 391 25 0 29 0 Code 790 086 392 29 0 32 0 Code 790 086 393 31 0 35 0 Code 790 086 394 34 5 Code 790 086 441 34 0 38 0 Code 790 086 395 35 0 40 0 Code 790 086 311 39 0 44 0 Code 790 086 312 43 0 48 0 Code 790 086 313 47 0 52 0 Code 790 086 314 67 0 72 0 Code 790 086 319 87 0 92 0 Code 790...

Page 54: ...lve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop 9 2 1 Replacing the clamping wedges BRB 4 standard with mandrel Ø 19 05 and Ø 31 50 1 Remove clamping ratchet with clamping ratchet nut 1 BRB 4 Pneumatic Auto remove ball head grip 2 2 Pull threade...

Page 55: ...t it come to a complete stop BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop 9 3 1 Replacing the clamping wedges BRB 4 NC with mandrel Ø 19 05 For all the steps to be ...

Page 56: ...ping cylinder 4 in the direction of the arrow as far as the stop The piston rod is inserted when only approx 12 mm 0 472 inch protrudes from the cylinder in the unclamped position see chap 10 1 3 p 61 4 Remove stopper 5 with size 24 open end wrench BRB 4 Electric NC BRB 4 Pneumatic Auto NC Piston rod in BRB 4 Pneumatic Auto 5 The 3 clamping wedges 6 can now be pushed out of the clamping wedge atta...

Page 57: ... electric shock Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started Prior to assembly dismantling maintenance and adjustment work dis connect the BRB from the power supply...

Page 58: ... 05 mm remove the tool mounting plate 5 5 Unscrew the mandrel 4 out of the housing 7 with the feed ratchet 6 6 Pull mandrel 4 out of the housing 7 1 If the mandrel dia is 31 5 mm first fit the tool mounting plate 5 2 Push mandrel 4 into housing 7 Watch out for the groove position 3 Rotate the mandrel 4 into the housing 7 with the feed ratchet 6 4 If the mandrel dia is 19 05 mm now fit the tool mou...

Page 59: ...e mandrel 2 in the direction of the arrow using the locking wheel 9 9 Pull mandrel 2 out of the housing 10 1 The tool mounting plate 8 for mandrel dia 31 5 mm must already be fitted 2 Push mandrel 7 into housing 10 Watch out for the groove position 3 Rotate mandrel 7 with the locking wheel 9 into the housing 10 in the direction of the arrow until dimension X 15 mm 0 591 inch 4 If the mandrel dia i...

Page 60: ...aintenance and adjustment work dis connect the BRB from the power supply and let it come to a complete stop 9 5 1 Replacing the mandrel BRB 4 NC with mandrel Ø 19 05 and Ø 34 50 1 Remove the clamping wedges for mandrel dia 19 05 see chap 8 3 1 p 33 and for mandrel dia 34 5 see chap 9 3 3 p 50 2 If the mandrel dia is 19 05 mm the tool mounting plate must now be removed if the mandrel dia is 34 5 mm...

Page 61: ...ow until least 60 mm of the thread 5 is visible 4 Rotate the clamping nut 6 onto the mandrel thread 2 as far as the stop 5 Push clamping wedge attachment 7 into mandrel 2 and screw it in with the mounting aid 8 Code 790 085 490 until the mounting aid is flush up against the mandrel Warning left hand thread The clamping wedge attachment 7 must now be exactly 12 mm 0 472 inch from the end of the man...

Page 62: ...50 3 Pull the clamping wedge attachment 2 out of the mandrel 3 4 Loosen PU hose 4 by pressing the washers on the two angle screws 5 5 Loosen cylinder screw 6 on clamping cylinder 7 until the clamping cylinder rotates 6 Rotate the clamping cylinder 7 down from the mandrel 3 7 Loosen headless screw 8 on sleeve 9 8 Push the sleeve 9 down from the mandrel 3 9 Mandrel dia 19 05 remove the tool mounting...

Page 63: ...stop 6 Attach clamping cylinder 7 with cylinder screw 8 The cylinder screw must press into the mandrel groove if necessary rotate the clamping cylinder back slightly 7 Fix sleeve 6 to the clamping cylinder flange 7 and fasten it with the headless screw 9 8 Push clamping wedge attachment 10 into mandrel 2 and screw it in with the mounting aid 11 Code 790 085 490 until the mounting aid 11 is flush u...

Page 64: ... cables bent at right angles Under no circumstances use blue locking CEE plugs Ensure that the plug is easily accessible Simulate an emergency by trying to loosen the plug from a distance Risk of falling when screwing cutters into clamping wedges The machine can become detached from the pipe and fall to the floor unchecked Always return the feed unit to the starting position with the motor switche...

Page 65: ...terior diameter of the pipe Distance A as small as possible but it least 10 mm Processing the interior diameter of the pipe Distance A length of the tool cutting edge plus 5 mm 10 1 2 Machining the pipe with BRB Pneumatic and BRB Electric 1 Bring the BRB to the neutral position using the feed ratchet Thread run out from the mandrel 1 is flush with the feed ratchet 2 Insert the BRB into the pipe 3 ...

Page 66: ...s correctly positioned 4 Tighten the threaded spindle 2 by turning the clamping ratchet 3 To remove the machine from the pipe at a later time Loosen the threaded spindle 2 by turning the clamping ratchet 3 Attaching the BRB Pneumatic and BRB Electric to the pipe Detaching the BRB Pneumatic and BRB Electric from the pipe 2 3 ...

Page 67: ...ions are described in the figures below BRB Standard Neutral position Clamped position Unclamped BRB NC Neutral position Unclamped Clamped position 1 Rotate the BRB Pneumatic Auto back to the neutral position with the locking wheel 1 Thread run out from the mandrel is flush with the hand wheel 2 Turn the rotary switch for clamping 2 to the Unclamped position 3 Connect the compressed air and check ...

Page 68: ... as shown below when clamping 5 Set distance A see chap 10 1 1 p 59 When the BRB Pneumatic Auto is correctly positioned 6 Turn the rotary switch to the Clamped position 7 Place the tools in the tool holder if necessary see chap 10 2 p 64 8 Process the pipe Risk of injury Danger if the machine inadvertently unclamps Do not touch the rotary tensioning switch during machining Wear safety gloves Hold ...

Page 69: ...s shown below Set the rotary switch to the unclamped position 11 Place the machine in a secure place and stop the supply of compressed air immediately BRB Pneumatic and BRB Pneumatic Auto Piping under pressure Diverse risks Hold the hose firmly when detaching it from the pneumatic piping and wear safety gloves Loosening the BRB Pneumatic Auto from the pipe ATTENTION ...

Page 70: ...Facing 1 Beveling 2 Beveling counterboring Joint preparation is therefore reproducible for other pipe ends 1 Select the appropriate multifunctional tool according to the type of machining split combined indicated in chap 2 8 1 p 15 2 Screw the multifunctional tool 1 onto the tool holder 2 using a Torx screwdriver 3 Insert the tool holder 2 with fitted multifunctional tool into the guiding groove 3...

Page 71: ...he tool bits and the pipe Machine noise levels 80 dB A value Irreversible damage to hearing Wear ear protection that complies with DIN EN 352 Parts can be ejected when working Irreversible eye injuries Wear safety goggles that comply with DIN EN 166 Falling objects Feet can be irreversibly crushed Wear safety shoes that comply with DIN EN 20345 S3 Sharp edged chips whirling around Irreversible cut...

Page 72: ...nomic way Limited ability to react and cramps Always return the feed unit to the starting position when the deadman s handle has been triggered Tool damage A pipe that is not sawn off at right angles can damage the tool if the distance between the cutting edge and the pipe end is too small Before switching on the BRB ensure that there is sufficient distance between the cutting edge and the pipe en...

Page 73: ...on requirements see chap 7 1 2 p 27 2 Actuate the ON OFF switch 3 The BRB starts 10 3 2 EMERGENCY STOP function for BRB Electric BRB Electric Pulling the plug as an EMERGENCY STOP is not correct Diverse risks Do not use cables bent at right angles Under no circumstances use blue locking CEE plugs Ensure that the plug is easily accessible Simulate an emergency by trying to loosen the plug from a di...

Page 74: ...on of the arrow 2 Turn the rotating handle 3 counterclockwise Turn the regulator 4 to a higher number 10 4 2 Reducing the speed 1 Press the ON OFF switch 1 while simultaneously releasing the safety lever 2 in the direction of the arrow 2 Turn the rotating handle 3 clockwise Turn the regulator 4 to a lower number Controlling the speed for Controlling the speed for Controlling the speed for BRB Pneu...

Page 75: ...4 approx 5 6 65 33 7 1 315 1 approx 8 76 approx 5 6 52 42 4 1 660 1 approx 8 60 approx 5 6 41 48 3 1 900 1 approx 8 53 approx 5 6 36 60 3 2 375 2 approx 8 42 approx 5 6 29 76 1 2 875 2 approx 8 34 approx 5 6 23 88 9 3 500 3 approx 8 29 approx 5 6 20 101 6 4 000 3 approx 8 25 approx 5 6 17 114 3 4 500 4 approx 8 22 approx 5 6 15 4 Measure the number of revolutions of the tool mounting plate in one ...

Page 76: ...tion that complies with DIN EN 352 Parts can be ejected when working Irreversible eye injuries Wear safety goggles that comply with DIN EN 166 Falling objects Feet can be irreversibly crushed Wear safety shoes that comply with DIN EN 20345 S3 Sharp edged chips whirling around Irreversible cuts Wear safety gloves that comply with EN 388 protection level 5 For cutting only use the KSS TOP cooling an...

Page 77: ...of the tool is cutting on the entire circumference of the pipe 3 Continue to guide the tool applying pressure evenly Feed is controlled by means of a hand wheel 2 for the BRB Pneumatic Auto 1 Move the tool towards the pipe using the hand wheel 2 2 Carefully guide the tool using the hand wheel 2 until the tool touches the pipe If the cutting edge of the tool is cutting on the entire circumference o...

Page 78: ...ON OFF switch BRB Pneumatic and BRB Pneumatic Auto BRB 4 Electric BRB 2 Electric BRB Pneumatic and BRB Pneumatic Auto Risk of injury from the compressed air valve being actuated inadvertently so that the machine is started After every operation and prior to assembly dismantling maintenance and adjustment work disconnect the BRB from the power supply and let it come to a complete stop BRB Pneumatic...

Page 79: ...ined for an overview of brushes see chap 2 8 4 p 18 Please select the large brush for pipe ID 32 0 110 8 mm 1 260 4 362 inch see chap 11 1 1 p 73 or chap 11 1 3 p 74 small brush for pipe ID 19 1 33 8 mm 0 752 1 331 inch see chap 11 1 2 p 74 or chap 11 1 4 p 75 Risk of injury through fanned out brush tips Brush tips that penetrate the skin can cause injury Wear safety gloves 11 1 1 Fitting the larg...

Page 80: ...rew the adapter ring 1 onto the brush 2 2 Screw the complete brush attachment onto the thread lug 3 of the threaded spindle 11 1 3 Fitting the large brush on the NC clamping system 1 Attach discs 1 2 to the inside of the brush ring 3 2 Screw the hexagon socket screw 4 into the brush attachment 3 Screw the complete brush attachment onto the locking screw 5 on the mandrel 3 1 2 3 1 2 5 3 4 5 ...

Page 81: ... every time after machining 11 2 Hoist Bracket Can only be used in combination with the BRB Pneumatic Auto The use of a hoist bracket machine hangs on a cable is recommended particularly for continuous processing All BRB machines built since 11 2009 already have an integrated hoist bracket This is already mounted on the machine when delivered Older BRB models can be retrofitted with a hoist bracke...

Page 82: ...changer and boiler applications Depth settings can be easily adjusted The spacer is particularly suited for use with the BRB Pneumatic Auto 1 Loosen tool mounting plate The removal procedure depends on the drive variant the clamping system and the mandrel for BRB 2 standard see chap 8 4 p 35 for BRB 2 NC see chap 8 5 p 40 for BRB 4 standard see chap 9 4 p 51 for BRB 4 NC see chap 9 5 p 54 2 Clamp ...

Page 83: ...tension retrofit kits For upgrading from BRB kit 1 to 2 for example thus extending the pipe dimension range Consisting of mandrel tool mounting plate s and clamping wedges depending on the kit 11 4 2 BRB Pneumatic to Auto retrofit kits For converting to pneumatic clamping which is particularly suited to continuous processing e g heat exchanger applications Only possible to retrofit on pneumatic ma...

Page 84: ...mpressed air supply before maintenance work Before maintenance work let the BRB run to a standstill with the compressed air supply disconnected Time Activity Before starting work Check the pipe clamping if the machine is already mounted in the pipe For the BRB Pneumatic Check system pressure Check mobile air unit Set the mobile air unit lubricator Approx 6 drops per minute oil types SAE 5 W to SAE...

Page 85: ...er consumers from the network Increase system pressure to 6 bar Tool MFW is catching during machining Feed too large For the BRB Pneumatic Turn off the machine disconnect the compressed air supply and loosen the pipe clamping For the BRB Pneumatic and Electric Disassemble tool holder and take the machine out of the pipe Remove chip using side cutting pliers and file off section Feed carefully for ...

Page 86: ...mer service For ordering spare parts refer to the separate spare parts list For troubleshooting please contact the branch responsible directly Please provide the following details Type of machine BRB 2 Pneumatic BRB 2 Pneumatic Auto BRB 2 Electric BRB 4 Pneumatic BRB 4 Pneumatic Auto BRB 4 Electric Machine no see type plate ...

Page 87: ...Nombre de série Número de serie Baujahr Year Anno Année Año ist entwickelt konstruiert and gefertigt in Übereinstimmung mit folgenden EG Richtlinien was designed constructed and manufactured in accordance with the following EC guidelines è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive a été dessiné produit et commercialisé selon les Directives suivantes ha si...

Page 88: ...ist entwickelt konstruiert and gefertigt in Übereinstimmung mit folgenden EG Richtlinien was designed constructed and manufactured in accordance with the following EC guidelines è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive a été dessiné produit et commercialisé selon les Directives suivantes ha sido proyectado construido y comercializado bajo observación d...

Page 89: ...Operating instructions BRB 14 EC Declaration of Conformity orbitalum tools gmbh 08 10 MT_BRB_BA_04_790086762_00 doc 83 ...

Page 90: ...14 EC Declaration of Conformity Operating instructions BRB 84 08 10 MT_BRB_BA_04_790086762_00 doc orbitalum tools gmbh ...

Page 91: ...Operating instructions BRB 14 EC Declaration of Conformity orbitalum tools gmbh 08 10 MT_BRB_BA_04_790086762_00 doc 85 ...

Page 92: ...GmbH Josef Schüttler Str 17 78224 Singen Deutschland Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 524 tools orbitalum com www orbitalum com 790 086 762_00 01 08 10 Orbitalum Tools GmbH D 78224 Singen 2010 Printed in Germany ...

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Orbitalum BRB 2, Operating Instructions Manual

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