background image

(12.03.18) OW_P16_P20_BA_831060202_03_EN 

 orbitalum tools

 GmbH, D-78224 Singen, www.orbitalum.com, Tel. +49 (0) 77 31 792-0

        11

P16, P16 AVC, P20

  |  Operating instructions  

 

Technical specifications

On request can be supplied:

•  Cage with support ring for welding of flush tubes.
•  Internal bore welding torch (L= up to 400 mm), tube diam 9,5 to 80 mm.
•  Front dual flow cage for second gas (for titanium welding e.g.), at request with three point support.

We would like to remind you that our staff is able to design special torches for special applications or welding geome-
tries as well as prolonged torches for welding in hardly accessible areas.

3.3.1 

Main body and rotating coupling

This group is composed of the following main items or subassemblies:

•  Connection block to the main cable for cooling water, welding current and protection gas.
•  Electric socket for connection to the welding programmer.
•  Rotation joint spindle and main distributor for cooling water, protection gas and welding current. The electrical 

contact between the parts is obtained by means of a lamellar joint.

•  Self-lubrificating bearings for supporting the rotation joint spindle.
•  Standard rotation gear motor. (On request with tachometer feedback).
•  Coupling between crown wheel-pinion for transmission of rotation from the gear-motor to the welding head.
•  Electro mechanic pulse-counter for controlling the welding cycle with respect to the torch position. The microswitch 

is actuated by a wheel with 20 cams which supplies 60 impulses during a 360° rotation of the torch.

•  External body with hook. (Standard for welding in horizontal position).
•  Mandrel support vessel machined out of stainless steel.
•  Ball bearing which allows the rotation of the mandrel support vessel and the front group for external and internal 

bore welding.

•  Socket.
•  Start/Stop button for starting the welding cycle or act the emergency stop (if pushed during the cycle).

3.3.2 

Filler wire group

•  Filler wire gear-motor.
•  Pair of wire feed rollers. On the machine usually are mounted rollers for wire 0,6 - 0,9 mm.
•  Wire spool support Standard spool has following dimensions:
         - external diameter: 100 mm
         - min. wire coiling diameter: 40 mm 
•  Elastic (spring loaded) blocking device which avoids by a clutch-disc system the unrolling of the spool.
•  Filler wire arrival group which is composed of:
        - guide nozzle
        - wire exit guide
        - wire entry guide and rear entry nipple 
        - rear wire guide hose
        - front wire guide hose
        - shaft with insulating bushing
        - shaft support

Summary of Contents for P16

Page 1: ...e sheet orbital weld heads P16 P16 AVC P20 To work safely with this machine please read through the operating instructions in full before initial operation Retain the operating instructions for future reference Code 831 060 202 EN 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: ...ody and rotating coupling 11 3 3 2 Filler wire group 11 3 3 3 Front body and torch 12 3 3 4 Centering feature for external tube sheet weldings 12 3 4 Connections 13 4 Accessories and modifications 14 4 1 Internal bore welding without filler wire 14 4 2 Front cage for dual gas flow 14 5 Use and maintenance 15 5 1 Use of weld head 15 5 2 Positioning of the welding head 15 5 3 Starting of the welding...

Page 4: ...r to avoid injuries or death Warning symbol Meaning DANGER Direct danger Non observance could result in death or critical injury Restrictions if applicable X X Measures to prevent danger WARNING Possible danger Non observance could result in serious injury Restrictions if applicable X X Measures to prevent danger ATTENTION Dangerous situation X X Non observance could result in minor injuries ATTEN...

Page 5: ...plants 1 2 3 Arc welding manual including MIG Metal Inert Gas MAG Metal Active Gas TIG Tungsten Inert Gas under observance of tried and tested proce dures and without physical contact to the line No No Yes According to Directive 2013 35 EU 2 2 Using the machine 2 2 1 Proper use The orbital welding equipment Orbital Welding Power Supplies CA CB 165 300 and Orbitwin in connection with the orbital we...

Page 6: ... electronic devices that are marked with the symbol at the side may not be disposed of with household waste in accordance with EU regulations By actively using the available return and collection systems you actively contribute to the reuse recycling and utilization of electrical electronic devices Used electrical electronic devices contain parts that must be handled selectively accord ing to EU r...

Page 7: ...ody employer from its statutory health and safety at work obligations towards its employees WARNING Danger of unit toppling over Orbicar welding trolley gas cylinder welding power supply cooling unit as a result of external application of force Diverse physical injuries and property damage are possible X X Install machine securely against external force and keep moving masses at minimum clearance ...

Page 8: ...ns e g BGI 7006 1 X X Particular attention should be paid when working with chromium nickel or manganese DANGER Incorrect ignition when welding head has not been attached or brought into the correct position Electric shock physical injury and property damage to other devices Do not play with welding heads X X Switch to test function if head is not ready for operation DANGER Improper access and ope...

Page 9: ...ectrode inclined of 30 tube axis bigger and smaller diameters at request Welding current 60 duty cycle max 200 A DC pulsed max 180 A DC linear Rotation speed 0 33 6 00 rpm stepless adjustment Front cage with steel ring Standard Adjustment of welding distance 6 mm on torch support slider 5 mm by means of adjustment ring micrometric adjustment Filler wire group removable if not used Filler wire spee...

Page 10: ... 6 00 rpm Wire speed min 150 mm min max 1 500 mm min Filler wire spool 1 kg midget spool diam 100 mm mounted on machine body Wire diameter with rollers min 0 6 mm max 0 9 mm Dimensions Machine body mm 70 Length mm 325 without wire group mm 470 with wire group Weight without centering devices and connection cable kg 5 0 without wire group 5 5 with wire group 3 3 Description of welding head The weld...

Page 11: ... spindle Standard rotation gear motor On request with tachometer feedback Coupling between crown wheel pinion for transmission of rotation from the gear motor to the welding head Electro mechanic pulse counter for controlling the welding cycle with respect to the torch position The microswitch is actuated by a wheel with 20 cams which supplies 60 impulses during a 360 rotation of the torch Externa...

Page 12: ...ed balls guaranteeing in this way a perfect centering of the welding head All mandrels and centering cartridges must be chosen with respect to the internal diameter of the tube to be welded Article Group Cartridge size no Tube ID mm Tube ID inch Code kg Retaining arbor for centering tools for group A 832 020 003 0 060 Centering tool A 1 10 0 10 5 0 394 0 413 832 020 004 0 040 Centering tool A 2 10...

Page 13: ...ng tool D 30 65 5 70 0 2 579 2 756 832 020 036 2 400 Centering tool D 31 69 5 74 0 2 736 2 913 832 020 037 2 600 Centering tool D 32 73 5 78 0 2 894 3 071 832 020 038 2 800 Centering tool D 33 77 5 82 0 3 051 3 228 832 020 039 3 100 Centering tool D 34 82 0 87 0 3 228 3 425 832 020 045 3 100 Centering tool D 35 87 0 91 0 3 425 3 582 832 020 046 Centering tool D 36 91 0 95 0 3 582 3 740 832 020 047...

Page 14: ...th gas diffusor Ceramic nozzle and electrode holder are fixed to the torch by means of a threaded bush The electrode is fixed by a screw Front cage with stainless steel centering bush to support the weld head on the tube plate It is possible to mount distance rings on the torch in order to reduce the length of the torch in case there are several welding depths with the same internal diameter These...

Page 15: ...point to achieve a perfect weld is a perfect cleaning of the tubes and the joints to be welded Be sure that there is no oxide chips grease or any impurities 5 2 Positioning of the welding head The low weight and the efficient centering devices allow an easy and economic way of using the welding head Hook up the welding machine on a balancer size up to 15 kg In order to obtain an efficient support ...

Page 16: ... electrode from the ceramic nozzle geometric value to guarantee the reproducibility of the welding It influences as well the distance electrode workpiece We recommend to prepare a certain number of electrodes allready cut and sharpened as soon as you have determined the electrode size 5 5 Adjustment of welding diameter The welding diameter can be adjusted by means of the screw with the key supplie...

Page 17: ...e control in order to push forward the wire The wire will advance until it has passed the wire feed rollers Take a pair of pliers and tear the remaining wire out of the liner Unscrew handle and remove the spool Take a new spool and round off the top of the wire with a file in order to prevent cutting of the Teflon wire liner Remove the wire exit nozzle near the torch Introduce the wire into the gu...

Page 18: ... cost of the wire liner is very low it is recommended to forcast the replacement before the liner is actually damaged Hereafter will be described the necessary replacement of the wire liner 5 11 1 Replacement of the front wire liner Act as follows Cut the wire left on the spool Press the button on the remote control in order to push forward the wire The wire will advance until it has passed the wi...

Page 19: ...ARNING INSPECT cables frequently Repair immediately all breaks in insulation with rubber and friction tapes Tighten and adequately insulate all cable connections It is dangerous when exposed sections of cable come in contact with grounded metallic objects causing an arc Unprotected eyes may be injured and fire may result if combustible materials such as oil or grease are in the vicinity Polarity s...

Page 20: ...ARNING Ventilation is necessary to divert harmful or explosive vapors WARNING DO NOT clean in the presence of opes flames of arc WARNING USE a wet tool to avoid sparks when scaring or hammering to remove heavy sludge or scale WARNING KEEP head and arms distant from work as possible Explosion hazards DANGER NEVER weld in or near explosive atmospheres Such atmospheres ca be created by inflammable ga...

Page 21: ...least 10 m from the arc on the contrary they should be suitably protected by a flame proof shiled Danger of electric shock ATTENTION OPEN power circuits before checking machines WARNING DO NOT touch electrically heated parts WARNING NEVER touch any exposed or insulated part of the cables cable connectors electrodes etc to avoid harmful or fatal electric shock or burns WARNING NEVER work in a damp ...

Page 22: ...y painful Clothing WARNING DO NOT use inadeguate or worn out clothing Proper and dry oil free clothing is essential for weldors protection Clothing must not only keep off sparks and molten particles but must also obstruct the rays from the arc ATTENTION They must insulate the body from harmful electric currents Wear leather or asbestos gloves at all times to protect hand and wrists Dark coloured s...

Page 23: ...ntwickelt konstruiert und 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 de las...

Page 24: ...mbH Josef Schuettler Str 17 78224 Singen Germany Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 500 UNITED KINGDOM Wachs UK UK Sales Rental Service Centre Units 4 5 Navigation Park Road One Winsford Industrial Estate Winsford Cheshire CW7 3 RL United Kingdom Tel 44 0 1606 861 423 Fax 44 0 1606 556 364 ASIA CHINA Orbitalum Tools New Caohejing International Business Centre Room 2801 B Building B No 391 Gui...

Reviews: