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

All rights reserved, in particular the rights of duplication and distribution as well as translation. Duplication and reproduction in any form (print, photo-
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 [phone]
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 [phone]
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.
1.
2.
3.
...
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.

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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.
Position the forming system correctly.Position the forming system correctly.
Use only permissible materials in the welding areaUse only permissible materials in the welding area..
2.7.7 Tripping over the hose package and lines
CAUTION!
If the hose package and lines are under tension, there is the danger that persons may trip over them
and be injured.
WARNING!
Tripping over could cause the plug to be pulled out so that in the worst case an arc may arise be-
tween the plug and the Orbital weld system and the turntable ground connection. Burns and glaring
light may be the result.
Ensure that under no circumstances can people trip over the hose package.
Do not place the hose package under tension. Ensure that the hose package is connected properly and that the
strain relief is attached.

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DVR | Operating instructions Owner information and safety instructions
2.7.82.7.8 Electric shockElectric shock
The relevant standards and regulations have been considered.The relevant standards and regulations have been considered.
There are no additional dangers for the user in case of proper use of the equipment and without force majeure.There are no additional dangers for the user in case of proper use of the equipment and without force majeure.
The turning gear is grounded. Since with the exception of the protective hoses and lines no components which canThe turning gear is grounded. Since with the exception of the protective hoses and lines no components which can
absorb static electricity during normal operation were installed and under consideration of the operation location, noabsorb static electricity during normal operation were installed and under consideration of the operation location, no
danger to the user is to be expected.danger to the user is to be expected.
Two electrical potentials are applied during the welding process:Two electrical potentials are applied during the welding process:
•• Potential 1: Electrode.Potential 1: Electrode.
•• Potential 2: Remaining components of the welding turntablePotential 2: Remaining components of the welding turntable incl. pipeincl. pipe..
WARNING!
Danger of an electric shock at simultaneous contact with both potentials during the high-frequencyDanger of an electric shock at simultaneous contact with both potentials during the high-frequency
ignition.ignition.
DANGER! Risk of death for people with heart problems or cardiac pacemakers.Risk of death for people with heart problems or cardiac pacemakers.
From the start of the welding process avoid contact with the tube and the housing of the Orbital weld headFrom the start of the welding process avoid contact with the tube and the housing of the Orbital weld head..
2.7.92.7.9 Damage to eyes through radiationDamage to eyes through radiation
WARNING!
During the welding process infrared, glaring and ultraviolet rays arise that can seriously damage
the eyes.
Wear eye protection according to EN170.Wear eye protection according to EN170.
2.7.102.7.10 Dangers through electromagnetic fieldsDangers through electromagnetic fields
DANGER! Depending on the form of the workplace, life-threatening electromagnetic fields can arise in the directDepending on the form of the workplace, life-threatening electromagnetic fields can arise in the direct
vicinity.vicinity.
People with heart problems or cardiac pacemakers mayPeople with heart problems or cardiac pacemakers may notnot operate the welding system.operate the welding system.
The owner has to ensure safe design of the workplace in accordance with the EMF Directive 2013/35/EU.The owner has to ensure safe design of the workplace in accordance with the EMF Directive 2013/35/EU.
2.7.112.7.11 Dangers through faulty mountingDangers through faulty mounting
WARNING!WARNING!
An unsafe standing position or the installation on an incline may result in a dangerous situation forAn unsafe standing position or the installation on an incline may result in a dangerous situation for
the user!the user!
Holes to anchor the turntables with a suitable surface are located on the base frameHoles to anchor the turntables with a suitable surface are located on the base frame..
2.7.122.7.12 Danger through loose or dangerous structuresDanger through loose or dangerous structures
WARNING!WARNING! Improper installation of structures and workpieces can lead to very dangerous situations!Improper installation of structures and workpieces can lead to very dangerous situations!

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Owner information and safety instructions DVR | Operating instructions
2.7.132.7.13 Risk of suffocation through an excessive argon share in the airRisk of suffocation through an excessive argon share in the air
DANGER! If the argon share in the air rises above 50%, lasting damage or risk of death can arise through suffo-
cation.
Ensure sufficient ventilation in rooms.Ensure sufficient ventilation in rooms.
If necessary, monitor the oxygen level in the air.If necessary, monitor the oxygen level in the air.
2.7.142.7.14 General injuries through toolsGeneral injuries through tools
CAUTION! Injuries can occur during dismantling for proper disposal of the welding turntablewelding turntable through uncertain-
ties in handling tools.

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DVR | Operating instructions Description
3. DESCRIPTION
0101
0202
2222
1010
0707
0303
0404
0707
0606
0505
0505
0505
2222
1717
1111
1919
1212
0101
0808
0909
0909
0909
1212
2121
2121
1010
0909
0909
0606
0303
0404
0303
2121
2121
1111
2020
1818
1313
1414
1515
1616

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Description DVR | Operating instructions
1TIG machine welding torchTIG machine welding torch
2Compound slidesCompound slides
3Position limit stop torch swivelPosition limit stop torch swivel
armarm
4Clamping chuckClamping chuck
5Locking lever swivel adjustmentLocking lever swivel adjustment
6Signal distribution boxSignal distribution box
7Ground plugGround plug
8Swivel blockSwivel block
9Fastening holeFastening hole
10 Stand armStand arm
11 Torch swiveling armTorch swiveling arm
12 Securing clampSecuring clamp
13 Connection socket motorConnection socket motor
14 Connection socket limit switchConnection socket limit switch
15 Connection socket cold wire
16 Connection socket remote con-Connection socket remote con-
troltrol
17 Connection socket control cable
18 Switch, turning plate direction of
rotation
19 Chuck key lock
20 Chuck key
21 Clamping lever clamping block
22 Adjustment knob compound
slide
3.1 Warning signs
The warning and safety instructions attached to the machine must be observed.
The warning signs are part of the machine. They must not be removed or changed. Missing or illegible warn-
ing signs must be replaced immediately.
FIGURE POSITION ON MACHINE MEANING CODE
Base plate of the clamping chuck Read the safety instructions! 871 001 057

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
DVR | Operating instructions Scope of application
4. SCOPE OF APPLICATION
Welding processWelding process Direct current tungsten inert gas (TIG-DC).Direct current tungsten inert gas (TIG-DC).
MaterialsMaterials All materials that are fundamentally suitable for the TIG-DC welding process.All materials that are fundamentally suitable for the TIG-DC welding process.
4.1 Clamping range three-jaw lathe chuck (optionally)
TYPETYPE ODOD D1D1 D2D2 D3 MAX.D3 MAX. D4 MAX. D5 MAX.
DVR 50DVR 50 200 mm200 mm 4 - 90 mm4 - 90 mm 52 - 135 mm52 - 135 mm 120 - 202 mm120 - 202 mm 60 - 145 mm 130 - 200 mm
DVR 100DVR 100 250 mm250 mm 5 - 118 mm5 - 118 mm 62 - 174 mm62 - 174 mm 145 - 256 mm145 - 256 mm 77 - 188 mm 160 - 250 mm
DVR 100DVR 100 300 mm300 mm 10 - 131 mm10 - 131 mm 78 - 200 mm78 - 200 mm 172 - 299 mm172 - 299 mm 90 - 215 mm 190 - 315 mm

16 Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (15.09.23) OW_DVR_BA_855060202_00_EN
Technical specifications DVR | Operating instructions
5. TECHNICAL SPECIFICATIONS
ARTART DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC
CodeCode 855 000 011855 000 011 855 000 012855 000 012 855 000 001855 000 001 855 000 002855 000 002
TURNTABLETURNTABLE DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC
Max. load in horizontal position (workpieceMax. load in horizontal position (workpiece
+ lathe chuck), max.+ lathe chuck), max.
[kg][kg] 5050 5050 100100 100100
[lbs][lbs] 110110 110110 220220 220220
DimensionsDimensions [mm][mm] 300 x 300 x 395300 x 300 x 395 300 x 300 x 395300 x 300 x 395 600 x 570 x 695600 x 570 x 695 600 x 570 x 695600 x 570 x 695
[inch][inch] 11.8 x 11.8 x 15.611.8 x 11.8 x 15.6 11.8 x 11.8 x 15.611.8 x 11.8 x 15.6 23.6 x 22.4 x23.6 x 22.4 x
27.427.4
23.6 x 22.4 x23.6 x 22.4 x
27.427.4
Distance floor to rotating axisDistance floor to rotating axis [mm][mm] 279279 279279 590590 590590
[inch][inch] 1111 1111 23.223.2 23.223.2
Turntable can be tilted steplesslyTurntable can be tilted steplessly
from 0 to 90°from 0 to 90°
Locking via two clamping leversLocking via two clamping levers
Turning plate Ø ODTurning plate Ø OD [mm][mm] 300300 300300 400400 400400
[inch][inch] 11.8111.81 11.8111.81 15.7515.75 15.7515.75
Hollow shaft Ø IDHollow shaft Ø ID [mm][mm] 3030 3030 125125 125125
[inch][inch] 1.181.18 1.181.18 4.94.9
Built-in weld power coupling for mass transfer toBuilt-in weld power coupling for mass transfer to
turning plateturning plate
Weld current built-in plug for ground cable connec-Weld current built-in plug for ground cable connec-
tiontion
Limit switch for zero setting and speed calibrationLimit switch for zero setting and speed calibration
Stand console for mounting the standStand console for mounting the stand
directly on the turntabledirectly on the turntable
Mounting holes for floor fasteningMounting holes for floor fastening
Signal distribution box with connecting option forSignal distribution box with connecting option for
control cable ORBIMAT-DVR, turntable motor, limitcontrol cable ORBIMAT-DVR, turntable motor, limit
switch, cold wire feed and remote control OWHswitch, cold wire feed and remote control OWH
BASICBASIC
Tilt lever for selecting the direction of rotationTilt lever for selecting the direction of rotation
STANDSTAND DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC
Weld torch stand mounted on consoleWeld torch stand mounted on console
Weld torch stand to be fastened separatelyWeld torch stand to be fastened separately
Base clamp with mounting holes for fastening atBase clamp with mounting holes for fastening at
point of usepoint of use
Dimensions stand tube OD x L:Dimensions stand tube OD x L: [mm][mm] 50 x 120050 x 1200 50 x 120050 x 1200 50 x 120050 x 1200 50 x 120050 x 1200
[inch][inch] 2 x 47.22 x 47.2 2 x 47.22 x 47.2 2 x 47.22 x 47.2 2 x 47.22 x 47.2
Dimensions extension arm OD x L:Dimensions extension arm OD x L: [mm][mm] 50 x 80050 x 800 50 x 80050 x 800 50 x 80050 x 800 50 x 80050 x 800
[inch][inch] 2 x 31.52 x 31.5 2 x 31.52 x 31.5 2 x 31.52 x 31.5 2 x 31.52 x 31.5
Extension swivel unit with magnetic stop for lockingExtension swivel unit with magnetic stop for locking
the welding positionthe welding position
Rough adjustment possible without tools via clamp-Rough adjustment possible without tools via clamp-
ing lever, incl. cross-clamping uniting lever, incl. cross-clamping unit
Three-coordinate support for torch fine adjustment.Three-coordinate support for torch fine adjustment.
Linear adjustment path:. each 50 mm (2")Linear adjustment path:. each 50 mm (2")
Torch holder with ball headTorch holder with ball head
MACHINE TORCHMACHINE TORCH DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC
Liquid-cooled machine torch with hose packageLiquid-cooled machine torch with hose package
length 4 m (13.12 ft)length 4 m (13.12 ft)
Current carrying capacity DC:Current carrying capacity DC:
250 A, AC: 180 A at 100% ED250 A, AC: 180 A at 100% ED
Incl. standard torch equipment for electrode diame-Incl. standard torch equipment for electrode diame-
ter 2.4 mm (0.09")ter 2.4 mm (0.09")
AVC LINEAR UNIT*AVC LINEAR UNIT* DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
DVR | Operating instructions Technical specifications
Arc gap control unit for automatic controlling andArc gap control unit for automatic controlling and
holding of the arc gapholding of the arc gap
Linear stroke: 55 mmLinear stroke: 55 mm
= Function included = Function not included = Function only conditionally includ-
ed
*Can only be used in combination with the
orbital welding power sources ORBIMAT 300
CA AVC/OSC as well as ground cable for 300
CA AVC/OSC power sources

18 Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (15.09.23) OW_DVR_BA_855060202_00_EN
Storage and transport DVR | Operating instructions
6. STORAGE AND TRANSPORT
6.1 Gross weights
ITEMITEM DVR 50DVR 50 DVR 50 AVCDVR 50 AVC DVR 100DVR 100 DVR 100 AVCDVR 100 AVC
WEIGHT*WEIGHT* [kg][kg] 4545 5050 100100 105105
[lbs][lbs] 9999 110110 220220 232232
* Incl. torchIncl. torch
6.26.2 TransportingTransporting the welding turntablethe welding turntable
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!
WARNING!WARNING! Danger of injury through pointed electrode!Danger of injury through pointed electrode!
IfIf the weld turntable is handled incorrectly, there is the danger that you may touch the pointedthe weld turntable is handled incorrectly, there is the danger that you may touch the pointed
electrodeelectrode..
6.3 Preparing storage
NOTES!NOTES! Storage:Storage:
Dry placesDry places
Safe against vibrations and damageSafe against vibrations and damage
Carry out the following steps before storage:
1.1. Disconnect the welding turntable from the welding power supplyDisconnect the welding turntable from the welding power supply
2.2. Remove the electrode.Remove the electrode.
3.3. Place the end caps for cooling liquid over the cooling liquid connectionsPlace the end caps for cooling liquid over the cooling liquid connections..
4.4. Store the welding turntable properly. Ensure that the hose package is not twisted or squeezedStore the welding turntable properly. Ensure that the hose package is not twisted or squeezed..
Carry out the following steps additionally before longer storage periods:Carry out the following steps additionally before longer storage periods:
5.5. Fully remove cooling liquid from the torch hose packageFully remove cooling liquid from the torch hose package..
6.6. Clean the surfacesClean the surfaces..
7.7. Lightly grease the chuck and turning plateLightly grease the chuck and turning plate
Further care and maintenance advice, see chap. 10, p.32

(15.09.23) OW_DVR_BA_855060202_00_EN Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
DVR | Operating instructions Commissioning
7. COMMISSIONING
The welding turntable consists of a drive unit, provided with a turning plate as well as a swivel unit for the rotating unit.The welding turntable consists of a drive unit, provided with a turning plate as well as a swivel unit for the rotating unit.
The two function units are combined on a stable machine frame in a welded structure.The two function units are combined on a stable machine frame in a welded structure.
The drive unit is a DC motor, provided with a spur gear.The drive unit is a DC motor, provided with a spur gear.
The tilting device is used to set the tilt of the rotating axis. For turntables of the DVR 100 the tilt adjustment is realizedThe tilting device is used to set the tilt of the rotating axis. For turntables of the DVR 100 the tilt adjustment is realized
by means of two clamping devices and can be set continuously from 0° to 90°. The tilt for turntables of the type DVR 50by means of two clamping devices and can be set continuously from 0° to 90°. The tilt for turntables of the type DVR 50
can be set continuously via the lateral clamping lever in a range of 0° to ± 90°.can be set continuously via the lateral clamping lever in a range of 0° to ± 90°.
Mechanical safety devices, which ward off dangerous situations caused by the rotary movement of the turntable are notMechanical safety devices, which ward off dangerous situations caused by the rotary movement of the turntable are not
included in the scope of delivery of the welding turntableincluded in the scope of delivery of the welding turntable..
7.1 Scope of delivery
SCOPE OF DELIVERYSCOPE OF DELIVERY DVR 50DVR 50 DVR 50DVR 50
AVCAVC DVR 100DVR 100 DVR 100DVR 100 AVCAVC
Welding turntable of the DVR series (without latheWelding turntable of the DVR series (without lathe
chuck)chuck)
PCS.PCS. 11111111
StandStand PCS.PCS. 11111111
Signal distribution boxSignal distribution box PCS.PCS. 1111––––
Machine torch with equipmentMachine torch with equipment PCS.PCS. 11111111
AVC linear unitAVC linear unit PCS.PCS. ––11––11
Operating instructions and spare part listOperating instructions and spare part list SetSet 11111111
7.2 Checking the scope of delivery
Check the delivery for completeness and damage caused by transport.
Report any missing parts or damage caused by transport to your supplier immediately.
7.3 Accessories (optionally available)
•• Three-jaw lathe chuck*Three-jaw lathe chuck*
•• Control cable (required for use with DVR welding turntables)*Control cable (required for use with DVR welding turntables)*
•• Ground cable (required for use with DVR welding turntables)*Ground cable (required for use with DVR welding turntables)*
•• Remote control OWH BASICRemote control OWH BASIC
•• Cold-wire feeds DVRCold-wire feeds DVR
* Obligatory accessories* Obligatory accessories
7.4 Setting up
WARNING! Danger of accidents through impermissible transport of devices that cannot be transported by
crane!
Using a crane and suspending the device not permissible! The device may fall down and injure per-
sons! Handles and mounts are solely suitable for transport by hand!
The device is not suitable for transporting by crane or suspension!

20 Orbitalum Tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (15.09.23) OW_DVR_BA_855060202_00_EN
Commissioning DVR | Operating instructions
CAUTION!CAUTION! Danger of accidents through tripping hazards and unsuitable setup location!Danger of accidents through tripping hazards and unsuitable setup location!
Persons might be endangered through an incorrect setup location of the device.Persons might be endangered through an incorrect setup location of the device.
Cables or hoses packages which are not properly laid represent tripping hazards and can causeCables or hoses packages which are not properly laid represent tripping hazards and can cause
accidents.accidents.
Set up the device in such a way that sufficient space is available to set the control elements.
Do not block escape routes!
Do not lay cables or hose packages in the danger zone of the device!
Lay cables or hose packages in a straight line or bundled up (use cable ducts or other aids, if necessary)!
Anchoring the turntable and weld torch stand (DVR50/DVR100)
Anchor the turntable and stand through the attachment holes (01) on a suitable, stable and level substrate.
0101 0101
0101
0101
0101
0101