Orbitalum BRB 2 User manual

precision.
power.
simplicity.
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.:
________________________________

All rights reserved, 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.

Operating instructions BRB Table of contents
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc I
Table of contents
Page
0About these instructions 1
0.1 Warning messages 1
0.2 Other symbols and displays 2
0.3 Abbreviations 2
1Safety instructions 3
1.1 Intended use 3
1.2 Improper use 3
1.3 Machine constraints 3
1.4 Safety regulations 4
1.5 Supervised operation 4
1.6 Working with safety in mind 5
1.7 Machine shutdown 6
1.8 Waste disposal 7
1.9 Other safety regulations 7
2Product design 8
2.1 BRB 2 Pneumatic 8
2.2 BRB 2 Pneumatic/Auto 9
2.3 BRB 2 Electric 10
2.4 BRB 4 Pneumatic 11
2.5 BRB 4 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
2.8.6 Threaded spindles for older machines 18
2.8.7 Depth setting plate 19
2.8.8 Mobile air unit with lubricator and water extraction 19
3Features and scope of application 20
3.1 Features 20
3.2 Scope of application 21
3.2.1 Application range BRB with "standard" clamping
system 21
3.2.2 Application range BRB with "NC" clamping system 21
3.2.3 Pipe materials 21
4Technical data 22
4.1 BRB 2 22
4.2 BRB 4 22

Table of contents Operating instructions BRB
II (08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
5Initial operation 23
5.1 Included with the machine 23
5.1.1 Standard 23
5.1.2 Additional parts of the "standard" clamping system 23
5.1.3 Additional parts of the "NC" clamping system 24
6Transport and storage 25
7Preparation 26
7.1 Connection requirements 26
7.1.1 BRB Pneumatic and BRB Pneumatic/Auto 26
7.1.2 BRB Electric 27
8Clamping wedge and mandrel assembly BRB 2 28
8.1 Overview of clamping wedges and mandrel 28
8.1.1 BRB 2 with "standard" clamping system 28
8.1.2 BRB 2 with "NC" clamping system 28
8.2 Replacing the clamping wedges: BRB 2 "Standard" 29
8.2.1 Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 12.75 30
8.2.2 Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 19.05 31
8.3 Replacing the clamping 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 with mandrel Ø 12.75 37
8.4.4 Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 12.75 37
8.4.5 Removing the mandrel:
BRB 2 "standard" with mandrel Ø 19.05 38
8.4.6 Fitting the mandrel:
BRB 2 "standard" Ø 19.05 38
8.4.7 Removing the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05 39
8.4.8 Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05 39
8.5 Replacing the mandrel: BRB 2 "NC" 40
8.5.1 Removing the mandrel:
BRB 2 "NC" with mandrel Ø 19.05 40
8.5.2 Fitting the mandrel:
BRB 2 "NC" with mandrel Ø 19.05 41
8.5.3 Removing the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05 42
8.5.4 Fitting the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05 43

Operating instructions BRB Table of contents
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc III
9Clamping wedge and mandrel assembly BRB 4 44
9.1 Overview of clamping wedges, clamping attachment and
mandrel 44
9.1.1 BRB 4 with "standard" clamping system 44
9.1.2 BRB 4 with "NC" clamping system 45
9.2 Replacing the clamping wedges: BRB 4 "standard" 48
9.2.1 Replacing the clamping wedges:
BRB 4 "standard" with mandrel Ø 19.05 and
Ø 31.50 48
9.3 Replacing the clamping wedges: BRB 4 "NC" 49
9.3.1 Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 19.05 49
9.3.2 Replacing the clamping wedges:
BRB 4 "NC" Auto with mandrel Ø 19.05 49
9.3.3 Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 34.50 and BRB 4 "NC"
Auto with mandrel Ø 34.50 50
9.4 Replacing the mandrel: BRB 4 "standard" 51
9.4.1 Replacing the mandrel:
BRB 4 "standard" with 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 mandrel:
BRB 4 "NC" Auto with mandrel Ø 19.05 and
Ø 34.50 57
10 Machining the pipe 58
10.1 Mounting the BRB in the pipe to be machined 59
10.1.1 Distance A 59
10.1.2 Machining the pipe with BRB Pneumatic and BRB
Electric 59
10.1.3 Machining the pipe with BRB Pneumatic/Auto 61
10.2 Fitting the multifunctional tool (MFW) and tool holder (WH) 64
10.3 Switching on the BRB 65
10.3.1 EMERGENCY STOP function for BRB Pneumatic
and BRB Pneumatic/Auto 67
10.3.2 EMERGENCY STOP function for BRB Electric 67
10.4 Setting the speed 68
10.4.1 Increasing the speed 68
10.4.2 Reducing the speed 68
10.4.3 Determining the speed 69
10.5 Machining the pipe 70

Table of contents Operating instructions BRB
IV (08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
10.6 Switching off the BRB 72
11 Fitting and operating accessories 73
11.1 Brush attachments 73
11.1.1 Fitting the "large" brush on the "standard" clamping
system 73
11.1.2 Fitting the "small" brush on the "standard" clamping
system 74
11.1.3 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 Troubleshooting 79
13.2 Servicing/customer service 80
14 EC Declaration of Conformity 81
14.1 BRB Pneumatic BRB Pneumatic/Auto 81
14.2 BRB Electric 82

Operating instructions BRB 0 About these instructions
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc 1
0 About these instructions
For a quick understanding of these instructions and safe operation of the
machine, all the warning messages, notes and symbols used in these
nstructions are presented here along with their meaning.
0.1 Warning messages
In these instructions, warning messages are used to warn you against the
angers of injury or 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!
Non-observance could result in serious injury.
Restrictions (if applicable).
Risk-prevention measures
ATTENTION
Dangerous situation!
Non-observance could result in minor injuries.
ATTENTION
Dangerous situation!
Non-observance could result in material damage.

0 About these instructions Operating instructions BRB
2 (08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
0.2 Other symbols and displays
Symbol Meaning
Important, Note Notes: contain particularly important information to clarify
information.
Instruction: you must take note of this symbol.
1. Request for action in a sequence of actions: you have to
take 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 preparation machine with electric drive
NC Clamping system with permanently anchored clamping
wedges
MFW Multifunctional tool
WH Tool holder
QTC®Quick Tool Change

Operating instructions BRB 1 Safety instructions
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc 3
Warning: when using electrical tools, the following basic safety
measures need to be observed to prevent electric shock, injury or fire.
Read all these instructions before using this electrical tool and keep
them in a safe place.
1 Safety instructions
The boiler pipe preparation machines (hereinafter referred to as BRB 2 or
BRB 4) are state-of the-art machines. Using these machines in a way other
than that described in this manual can lead to personal injuries to the user or
of third parties. It may also damage the machine or other equipment.
Therefore:
always ensure that the machine is in good working 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 energized piping, in explosive atmospheres or on
contaminated pipes.
Do not use the machine outdoors when it is foggy, raining, during a
thunderstorm or when the relative humidity > 80% (measured at 20°C).
Do not use the BRB as a drive for applications other than those listed under
proper use (chapter 1.1).
1.3 Machine constraints
Space requirement/freedom of movement: About 1 m of space for people is
required around all sides of the machine.
Lighting for work: min. 300 lux.
Minimum age of operator: 14 years.
Important

1 Safety instructions Operating instructions BRB
4 (08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Safety components that are contaminated or worn are defective!
The failure of safety components can cause physical injury.
Check defective safety components daily to ensure proper operation.
Clean and maintain the machine every day.
Inspect the machine and its cables daily for visible signs of damage or
defects, which should be repaired by a specialist if necessary.
Do not misuse the cable, e.g. by hanging it up or using it to carry the
machine.
Keep cables away from heat, oil, sharp edges and moving equipment parts.
Inspect the machine daily for visible signs of damage or defects, which
should be repaired by a specialist if necessary.
1.4 Safety 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 the rotating handle for controlling the speed.
Only operate the BRB Electric if the electrical safety equipment/restart
inhibitor is working.
1.5 Supervised operation
Workshop application: The workshop manager is responsible for safety in
the danger zone around the machine and should allow only qualified
personnel to enter the zone or operate the machine.
Outdoor/field application: The site manager is responsible for safety in the
danger zone around the machine and should allow only qualified personnel
to enter the zone or operate the machine.
DANGER