Orbitalum Dvr 50 (avc) User manual

Operating instructions

For owners and persons using the machine

Welding turntable

DVR 50 (AVC)

DVR 100 (AVC)

Machine No.:

To ensure safe working read the operating

instructions

before commissioning.

Retain the operating instructions

for future reference.

Code 855 060 201 | EN | Translation of Original Operating Instructions

copy, microfilm or electronic) require the written permission of Orbitalum Tools GmbH.

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone +49 (0) 77 31 792-0 3

DVR | Operating instructions

1. About these instructionsAbout these instructions............................................................................55

1.1 Warning messages......................................5

1.2 Further symbols and displays...................5

1.3 Abbreviations...............................................5

1.4 Further applicable documents .................5

2. Owner information and safety instructions......6

2.1 Requirements for the owner.....................6

2.2 Using the machine ......................................6

2.2.1 Intended use .....................................6

2.2.2 Machine constraints........................7

2.3 Environmental protection and disposal .7

2.3.1 Cooling liquid ....................................7

2.3.2 Electric tools and accessories .....8

2.4 Personnel qualification..............................8

2.5 Fundamental information on operational

safety.............................................................8

2.6 Personal protective equipment ...............9

2.7 Remaining risks...........................................9

2.7.1 Injury through high weight.............9

2.7.2 Prick injury through pointed elec-

trode ...................................................9

2.7.3 Danger of crushing through rotat-

ing turntable and chuck..................9

2.7.4 Danger of crushing through being

caught in by moving parts ........... 10

2.7.5 Danger of cuts at sharp edges.... 10

2.7.6 Burns and danger of fire through

high temperatures ......................... 10

2.7.7 Tripping over the hose package

and lines........................................... 10

2.7.8 Electric shock .................................. 11

2.7.9 Damage to eyes through radiation

............................................................ 11

2.7.10 Dangers through electromagnetic

fields .................................................. 11

2.7.11 Dangers through faulty mounting11

2.7.12 Danger through loose or danger-

ous structures ................................. 11

2.7.13 Risk of suffocation through an

excessive argon share in the air . 12

2.7.14 General injuries through tools .... 12

3. Description ............................................................ 13

3.1 Warning signs............................................. 14

4. Scope of application ............................................ 15

4.1 Clamping range three-jaw lathe chuck

(optionally).................................................. 15

5. Technical specifications...................................... 16

6. Storage and transport......................................... 18

6.1 Gross weights ............................................ 18

6.2 Transporting the welding turntable ...... 18

6.3 Preparing storage..................................... 18

7. Commissioning...................................................... 19

7.1 Scope of delivery ...................................... 19

7.2 Checking the scope of delivery .............. 19

7.3 Accessories (optionally available) ......... 19

7.4 Setting up ................................................... 19

7.5 Clamping chuck swivel range setting ... 21

7.6 Preparing initial operation ...................... 21

8. Set-up and mounting ......................................... 22

8.1 Procedure .................................................. 22

8.2 Connect the control cable...................... 22

8.3 Connect the ground cable ..................... 22

8.4 Connecting the welding power supply. 23

8.4.1 DVR connection scheme.............. 24

8.5 Torch arm position setting..................... 26

8.6 Torch arm position setting .................... 27

8.7 Torch fine setting .................................... 28

8.8 Setting up the torch ................................ 28

8.9 Carry out the gas and cooling-liquid

function test.............................................. 29

8.10 Calibrate the welding turntable ............ 29

8.11 Configure the welding procedure ......... 29

9. REMOTE CONTROL (optionally available)...... 30

9.1 Operating elements................................. 30

9.2 Welding........................................................ 31

9.3 Aborting welding....................................... 31

10. Servicing and maintenance............................... 32

10.1 Instructions for care................................ 32

10.2 Maintenance and care............................. 32

10.2.1 Corrosion protection .................... 32

10.2.2 Lubrication.................................. 32

10.2.3 Lubrication of the track ........... 32

10.2.4 Lubrication intervals................. 33

10.2.5 Standard cleaning process of the

weld turntable................................ 33

10.3 Servicing/Customer service.................. 34

TABLE OF CONTENTS

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone +49 (0) 77 31 792-0 5

DVR | Operating instructions About these instructions

1.1. ABOUT THESE INSTRUCTIONSABOUT THESE INSTRUCTIONS

1.11.1 Warning messagesWarning messages

The warnings used in these instructions warn you of injuries or damage to property.The warnings used in these instructions warn you of injuries or damage to property.

Always read and observe these warnings!Always read and observe these warnings!

This is a warning symbol. It warns against dangers of injury. In order to avoid injuries or death ob-

serve the measures marked with a safety sign.

WARNING LEVEL MEANING

DANGER!

Imminently hazardous situation that results in death or serious injuries if the safety measures are

not observed.

WARNING! Potentially hazardous situation that may result in death or serious injuries if the safety measures

are not observed.

CAUTION! Potentially hazardous situation that may result in slight injuries if the safety measures are not

observed.

NOTE! Potentially hazardous situation that may result in material damage if the safety measures are not

observed.

1.21.2 Further symbols and displaysFurther symbols and displays

SYMBOL MEANING

Important information for comprehension.

...

Request for action in a sequence of actions: Action is required here.

Single request for action: Action is required here.

1.31.3 AbbreviationsAbbreviations

ABBREVIATION MEANING

DVRDVR Turning gear/welding turntablesTurning gear/welding turntables

1.41.4 Further applicable documentsFurther applicable documents

The following documents form part of these operating instructions:The following documents form part of these operating instructions:

•• Operating instructions of the welding power source of the ORBIMAT seriesOperating instructions of the welding power source of the ORBIMAT series

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Owner information and safety instructions DVR | Operating instructions

2. OWNER INFORMATION AND SAFETY INSTRUCTIONS

2.1 Requirements for the owner

Workshop/outdoor/field use: The owner 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 in the danger zone.

Employee safety: The owner has to observe the safety regulations described in this chapter as well as has to work safe-

ty-consciously and with all prescribed protective equipment.

The employer undertakes to give the employees clear notice of the dangers arising that are specified in the EMF direc-

tives and to evaluate the workplace correspondingly.

Requirements for special EMF evaluations with regard to general activities, working materials and work-

places*:

TYPE OF WORKING MATERIALS OR

WORKPLACE

EVALUATION REQUIRED FOR:

Employees without

particular risk

Employees at particu-

lar risk

(with the exception of

those

with active implants)

Employees with ac-

tive implants

(1) (2) (3)

Arc welding, manual (including MIG (Metal

Inert Gas), MAG (Metal Active Gas), TIG (Tung-

sten Inert Gas)) under observance of tried-

and-tested procedures and without physical

contact to the line

No No Yes

* To Directive 2013/35/EU

2.2 Using the machine

2.2.1 Intended use

TheThe welding turntableswelding turntablesare intended solely for the following use:are intended solely for the following use:

•• Utilization in combination with an Orbital welding power source of the ORBIMAT series.Utilization in combination with an Orbital welding power source of the ORBIMAT series.

•• TIG welding of materials and tube dimensions that are specified in these operating instructions (see chap. 4, pageTIG welding of materials and tube dimensions that are specified in these operating instructions (see chap. 4, page

15).15).

•• Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.

Only protective gases that are classified for TIG welding in accordance with EN ISO 14175 may be used.Only protective gases that are classified for TIG welding in accordance with EN ISO 14175 may be used.

Proper use also includes the following points:Proper use also includes the following points:

•• Permanent supervision of the machine during operation. The operator must always be able to stop the process.Permanent supervision of the machine during operation. The operator must always be able to stop the process.

•• Observing all safety and warning information in these operating instructions.Observing all safety and warning information in these operating instructions.

•• Observing of the further applicable documents.Observing of the further applicable documents.

•• Complying with all inspection and maintenance work.Complying with all inspection and maintenance work.

•• Use of the machine solely in its original state.Use of the machine solely in its original state.

•• Usage solely of original accessories as well as original spare parts and operating materials.Usage solely of original accessories as well as original spare parts and operating materials.

•• Checking of all the safety-relevant items and functions before commissioning.Checking of all the safety-relevant items and functions before commissioning.

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone +49 (0) 77 31 792-0 7

DVR | Operating instructions Owner information and safety instructions

•• Processing of those materials named in the operating instructions.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 influ-Proper usage of all components involved in the welding processes as well as of all further factors that have an influ-

ence on the welding process.ence on the welding process.

•• Solely commercial usage.Solely commercial usage.

•• The structures on the turning plate must have a secure fixed connection in such a manner that the structures formThe structures on the turning plate must have a secure fixed connection in such a manner that the structures form

a unit with the turning plate. The fact that the welding turntable can be tilted must always be taken into consider-a unit with the turning plate. The fact that the welding turntable can be tilted must always be taken into consider-

ation. Dangerous situations for the operating personnel mayation. Dangerous situations for the operating personnel may notnot result through structures.result through structures.

•• The rotary drive must only be used when the tilting device is in a secured working positionThe rotary drive must only be used when the tilting device is in a secured working position..

•• The welding turntable is used to hold a workpiece support, which must be firmly connected with the turntable. TheThe welding turntable is used to hold a workpiece support, which must be firmly connected with the turntable. The

correspondingly mounted object is only rotated by the device. Additional mechanical connections to the turntablecorrespondingly mounted object is only rotated by the device. Additional mechanical connections to the turntable

must not be established.must not be established.

•• In particular the turning gear must not be used for winding processes or to drive other mechanical structures. TheIn particular the turning gear must not be used for winding processes or to drive other mechanical structures. The

weight of the workpiece must not exceed the permissible overall weight in chap. 5, p. 16 for center of gravityweight of the workpiece must not exceed the permissible overall weight in chap. 5, p. 16 for center of gravity

distance of 100 mm (3.937") to the face plate. The holder as well as the workpiece must be attached centrically ondistance of 100 mm (3.937") to the face plate. The holder as well as the workpiece must be attached centrically on

the turntable.the turntable.

•• The tilting device is used to tilt the rotating axis. The tilting device must only be usedwhen a free movement of theThe tilting device is used to tilt the rotating axis. The tilting device must only be usedwhen a free movement of the

rotating unit including mounted device and workpiece is ensured.rotating unit including mounted device and workpiece is ensured.

•• The control unit does not contain an interface to a power source. For operation with a welding power supply theThe control unit does not contain an interface to a power source. For operation with a welding power supply the

reference potential of the power source must be realized at the provided stud bolt with sufficient cross-section. Thereference potential of the power source must be realized at the provided stud bolt with sufficient cross-section. The

weld current must not exceed the current amperage specified in chap. 5, p. 16. Otherwise the current transmitterweld current must not exceed the current amperage specified in chap. 5, p. 16. Otherwise the current transmitter

might be damaged and the operational safety of the set-up is not ensured.might be damaged and the operational safety of the set-up is not ensured.

•• All work on electronic equipment must only be performed by professional electricians.All work on electronic equipment must only be performed by professional electricians.

•• All structures and attachments have to be designed in such a way thatAll structures and attachments have to be designed in such a way that nono dangerous situations can occur for thedangerous situations can occur for the

personnel .personnel .

2.2.2 Machine constraints

•• The workplace can be in the tube preparation, in plant construction or in the plant itself.The workplace can be in the tube preparation, in plant construction or in the plant itself.

•• The machine is operated by one person.The machine is operated by one person.

•• Erect the machine solely on a solid surface.Erect the machine solely on a solid surface. The device has to be anchored in the floor.The device has to be anchored in the floor.

•• A radial space requirement/freedom of movement for people of approx.A radial space requirement/freedom of movement for people of approx. 2 m around the machine2 m around the machine is required.is required.

•• Work lighting:Work lighting: min. 300 Luxmin. 300 Lux..

•• Climate conditions:Climate conditions: –15 °C to 40 °C; < 80% rel. humidity–15 °C to 40 °C; < 80% rel. humidity..

•• Only work with the machine in dry surroundings (not in misty, rainy or stormy conditions). If appropriate, use aOnly work with the machine in dry surroundings (not in misty, rainy or stormy conditions). If appropriate, use a

welding tent.welding tent.

2.32.3 Environmental protection and disposalEnvironmental protection and disposal

2.3.1 Cooling liquid

Dispose of cooling liquid in accordance with the local statutory regulations.Dispose of cooling liquid in accordance with the local statutory regulations.

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Owner information and safety instructions DVR | Operating instructions

2.3.2 Electric tools and accessories

Used-up power tools and accessories contain a large amount of valuable raw materials and plastics

which can be recycled:

• Used electronic devices marked with the adjacent symbol may not be disposed of with house-

hold waste in accordance with EU directives.

• By actively using the offered return and collection systems, you are doing your part to reuse

and recycle used electronic devices.

• Used electronic devices contain parts that must be handled selectively according to the EU

directive. Separate collection and selective treatment are the basis for environmentally respon-

sible disposal and protection of human health.

• We will properly dispose of devices and machines from Orbitalum Tools GmbH purchased after

August 13th, 2005 if they are sent to us postage-paid.

• In the case of used electronic devices which may represent a risk to human health or safety due

to contamination during use, we have the option of refusing return.

• The user is responsible for disposing of used electronic devices purchased before August 13th,

2005. For this purpose, please contact a professional disposal company in your area.

• Important note for Germany: Devices and machines of Orbitalum Tools GmbH may not be

disposed of at communal dumps, as they are only used in the commercial sector.

(as per RL 2002/96/EC)

2.4 Personnel qualification

CAUTION! TheThe welding turntablewelding turntable may only be used by instructed personnel.may only be used by instructed personnel.

• Minimum age: 18 years old.

• No physical impairments.

• Operation of the machine by underage persons only under supervision by a person authorized to issue instructions.

• A basic knowledge of TIG welding is advisable.

2.5 Fundamental information on operational safety

CAUTION! Observe valid safety and accident prevention regulations.

Improper usage can impair safety. This can result in life-threatening injuries.

NeverNever leave theleave the welding turntablewelding turntable unattended when the welding power source is switched on.unattended when the welding power source is switched on.

The operator must ensure that no 2nd person is located within the danger zone.The operator must ensure that no 2nd person is located within the danger zone.

The operator must ensure that the workpiece can move completely freely.The operator must ensure that the workpiece can move completely freely.

Do notDo not modify or convertmodify or convert the welding turntable.the welding turntable.

Use theUse the welding turntablewelding turntable only in a proper operating condition.only in a proper operating condition.

Use only genuine tools, spare parts and accessories as well as specified operating materials.Use only genuine tools, spare parts and accessories as well as specified operating materials.

Do notDo not remove safety devicesremove safety devices.

In case of changes in the operating behavior, stop operation immediately and have the fault eliminated.In case of changes in the operating behavior, stop operation immediately and have the fault eliminated.

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DVR | Operating instructions Owner information and safety instructions

2.62.6 Personal protective equipmentPersonal protective equipment

The following personal protective equipment must be worn while working at the system:The following personal protective equipment must be worn while working at the system:

Safety gloves 1/1/1/1 in accordance with EN 388 or 1/2/1/1 EN 407.

Safety gloves DIN 12477, Type A for welding operation and DIN 388, Class 4 for mounting the electrode.

Safety shoes to EN ISO 20345, Class SB.

Eye protection to EN 170 and skin-covering safety clothing.

2.72.7 Remaining risksRemaining risks

2.7.12.7.1 Injury through high weightInjury through high weight

Depending on the version, theDepending on the version, the welding turntablewelding turntable can have a weight of up tocan have a weight of up to 100 kg (220 lbs)100 kg (220 lbs) in a packed statein a packed state (including(including

hose package and transport case)hose package and transport case). A significant health hazard exists during lifting.. A significant health hazard exists during lifting.

Danger of impact and crushing exists in the following situations:Danger of impact and crushing exists in the following situations:

CAUTION! Falling of theFalling of the welding turntablewelding turntable duringduring transportation, mounting/dismantling or setting up.

WARNING!WARNING! Danger of injury through high weight of theDanger of injury through high weight of the welding turntablewelding turntable!!

Always lift the welding turntable with two persons or use a suitable means of transportAlways lift the welding turntable with two persons or use a suitable means of transport..

Danger of accidents through impermissible transport of devices that cannot be transported byDanger of accidents through impermissible transport of devices that cannot be transported by

crane! Using a crane and suspending the device is not permissible! The device may fall down andcrane! Using a crane and suspending the device is not permissible! The device may fall down and

injure persons! Handles and mounts are solely suitable for transport by hand!injure persons! Handles and mounts are solely suitable for transport by hand!

The device is not suitable for transporting by crane or suspension!The device is not suitable for transporting by crane or suspension!

The welding turntableThe welding turntable must notmust not be used to transport persons.be used to transport persons.

Wear safety shoes to EN ISO 20345, Class B.Wear safety shoes to EN ISO 20345, Class B.

2.7.22.7.2 Prick injury through pointed electrodePrick injury through pointed electrode

CAUTION!

Danger of being pricked by the electrode for the operator as well as for third parties while graspingDanger of being pricked by the electrode for the operator as well as for third parties while grasping

thethe machine welding torchmachine welding torch.

Do notDo not grasp thegrasp the machine welding torch at the position of the electrode.machine welding torch at the position of the electrode.

Before transporting and storing the welding turntable: Remove the electrodeBefore transporting and storing the welding turntable: Remove the electrode..

2.7.32.7.3 Danger of crushing through rotating turntable and chuckDanger of crushing through rotating turntable and chuck

CAUTION! Danger of crushing!Danger of crushing!

Danger of crushing exists in the following situations:Danger of crushing exists in the following situations:

•• The turning plate and chuck starts up unintentionally during setting up. Hands and fingers are crushed.The turning plate and chuck starts up unintentionally during setting up. Hands and fingers are crushed.

•• Hair and clothes can be caught.Hair and clothes can be caught.

Wear tight-fitting clothes.Wear tight-fitting clothes.

Do notDo not wear open hair, jewelry or other accessories that can be easily drawn in.wear open hair, jewelry or other accessories that can be easily drawn in.

Before connecting the welding turntable and before mounting the electrode: Switch off the control unit of the orbit-Before connecting the welding turntable and before mounting the electrode: Switch off the control unit of the orbit-

al welding system.al welding system.

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Owner information and safety instructions DVR | Operating instructions

2.7.4 Danger of crushing through being caught in by moving parts

CAUTION! Hands and fingers can be caught in and crushed while setting up theHands and fingers can be caught in and crushed while setting up the welding turntablewelding turntable..

2.7.5 Danger of cuts at sharp edges

CAUTION! Danger of cut injuries caused by sharp tube edges when positioning the welding turntable at theDanger of cut injuries caused by sharp tube edges when positioning the welding turntable at the

tube.tube.

Wear safety gloves to EN 388, Performance level 2.

2.7.6 Burns and danger of fire through high temperatures

CAUTION! The welding turntable is hot after welding. Very high temperatures arise in particular after severalThe welding turntable is hot after welding. Very high temperatures arise in particular after several

consecutive welding processes. When working on the welding turntableconsecutive welding processes. When working on the welding turntable

(for example when changing clamps or mounting/removing the electrodes) there is a danger of burns(for example when changing clamps or mounting/removing the electrodes) there is a danger of burns

or damage to the points of contact. Materials without thermal resistance can be damaged when com-or damage to the points of contact. Materials without thermal resistance can be damaged when com-

ing into contact with the hot welding turntable.ing into contact with the hot welding turntable.

WARNING! Thermal problems can arise in the case of incorrect positioning of the forming system or the use of

impermissible materials in the welding area. In the worst case a fire will be started. Observe the

local general fire protection measures.

Wear safety gloves.

Wait until the surfaces have cooled down to below 50 °C before working on the welding turntable or before trans-Wait until the surfaces have cooled down to below 50 °C before working on the welding turntable or before trans-

port.port.