Orbitalum HX 16P User manual

Operating instructions
For responsible bodies and persons using the machine
Enclosed orbital weld head
HX 16P
Machine no.:
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 848 060 202 | 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, photocopy, microfilm or electronic) require the written permission of Orbitalum Tools GmbH.

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions
1. About these instructions .................................................................................................................................. 4
1.1 Warning messages................................................................................................................................. 4
1.2 Further symbols and displays................................................................................................................. 4
1.3 Abbreviations ........................................................................................................................................ 4
2. General information ......................................................................................................................................... 5
2.1 Technical specifications ......................................................................................................................... 5
3. Description ...................................................................................................................................................... 6
3.1 Machine body ........................................................................................................................................ 6
3.2 Pneumatic clamping system ................................................................................................................... 6
3.3 Connections........................................................................................................................................... 6
4. Use and maintenance....................................................................................................................................... 7
4.1 General information ............................................................................................................................... 7
4.2 Positioning of the weld head................................................................................................................... 7
4.3 Starting of the orbital weld head ............................................................................................................ 7
4.4 Preparation and replacement of the electrode......................................................................................... 8
4.5 Adjustment and replacement of microswitch........................................................................................... 8
4.6 Cleaning the orbital weld head ............................................................................................................... 9
4.6.1 Equipment ................................................................................................................................... 9
4.6.2 Procedure .................................................................................................................................... 9
5. General safety rules ........................................................................................................................................11
5.1 Welding cables......................................................................................................................................11
5.2 Polarity switch......................................................................................................................................11
5.3 Ground power circuit .............................................................................................................................11
5.4 Welding operations ...............................................................................................................................12
5.5 Explosion hazards.................................................................................................................................12
5.6 Ventilation ............................................................................................................................................12
5.7 Solvents ...............................................................................................................................................12
5.8 Fire hazards..........................................................................................................................................13
5.9 Dangers of electric shock ......................................................................................................................13
5.10 Face protection .....................................................................................................................................13
5.11 Eye protection.......................................................................................................................................13
5.12 Clothing................................................................................................................................................14
5.13 Hot metals burns ..................................................................................................................................14
TABLE OF CONTENTS

4orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
About these instructions HX 16P | Operating instructions
1. ABOUT THESE INSTRUCTIONS
To allow quick understanding of these instructions and safe handling of the machine, all the warning messages, notes
and symbols used in these instructions are presented here along with their meaning.
1.1 Warning messages
In these instructions, warning messages are used to warn you against the dangers of injury or material damage.
Always read and observe these warning messages!
This is a warning symbol. It should warn you against dangers of injury.
Follow all instructions which are identified with this safety symbol in order to avoid injuries or death.
Warning symbol Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
[Restrictions (if applicable).
XMeasures to prevent danger.
WARNING
Possible danger!
Non-observance could result in serious injury.
[Restrictions (if applicable).
XMeasures to prevent danger.
ATTENTION
Dangerous situation!
XNon-observance could result in minor injuries.
ATTENTION Dangerous situation!
XNon-observance could result in material damage.
1.2 Further symbols and displays
Symbol Meaning
IMPORTANT
NOTE
Notes: Contain particularly important information for comprehension.
Instruction: You must take notice of this symbol.
1. Request for action in a sequence of actions: You have to do something here.
Single request for action: You have to do something here.
Conditional request for action: You have to do something here if the specified condition is met.
1.3 Abbreviations
Abbr. Meaning
HX 16P Enclosed orbital weld head, type "16 P" for Heat Exchanger (HX) applications

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions General information
2. General information
The recent technological advances in the design and manufacturing processes of the heat exchangers and equipment
for chemical, nuclear and mechanical industry has been the extensive use of new materials which require sophisticated
and, therefore, highly precise and efficient welding system.
These critical weld joints must be sound and safe because the smallest defect may have serious consequences.
The welding process commonly applied for welding tubes to tubes is TIG carried out with fully automatic equipment.
This system allows the welding operation to be completely unaffected by the skill of the welder and produces perfectly
repeatable high quality welds.
The family of weld heads HX16 model has been specially designed to meet these requirements, in particular the new
version HX16P has been implemented with a pneumatic system for clamping to reduce cycle times.
2.1 Technical specifications
Enclosed orbital weld head HX 16P
Welding process TIG
Welding position Horizontal, vertical, inclined
Welding current (60%) max. 70 A DC pulsed
Rotation gear motor Standard 1,6 mm
Torch rotation speed 0,3 - 5 rpm
Tube diameters 13 - 16 mm
Dimensions HX 16P
Radial clearance 71 mm
Height 240 mm
Min. straight part tube + bend 72 mm
Max. height tube + bend 195 mm
Weld point bei 30 mm
Weight 1,1 kg (without cable)

6orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
Description HX 16P | Operating instructions
3. DESCRIPTION
The HX 16P is composed of the following groups:
• Machine Body
• Pneumatic System
• Connecting cable to welding power source
3.1 Machine body
This group encloses:
• Connection to machine cable for water out / welding current, water out protection gas
• Rotation gear motor
• Conical gears group for the rotation movement with gear wheels for transmission of rotation to the rotor
• The electrode, Standard, 1.6 mm ø is fixed with dowel
• The microswitch which is actioned by a cam wheel or a cogwheel
• Lower and upper seat for clamping the tube/bend with pneumatically controlled pistons to keep the weld head in
place during the weld
• Start blue button to clamping the weld head to the tube
• Start red button to initiate the welding cycle
• The protective allows to create a closed chamber for the shielding gas
3.2 Pneumatic clamping system
This group encloses:
• The pressure regulator is powered by means of the quick coupling by high pressure air (max. 16 bar), this device is
equipped with a pressure gauge for the control and a knob setting
• The solenoid valve powered by the air coming from the pressure regulator serves, by means of the quick coupling,
the pistons installed on the weld head
• The relay receives the signal from the blue button and controls the solenoid valve
• The connector is connected to the cable machine.
3.3 Connections
The HX 16P will be delivered with a cable (length 5 m) which allows connections of the weld head to a welding program-
mer/power supply.
This cable is composed of:
• Cooling water to torch hose (blue)
• Cooling water return hose (red) with copper plait for welding current
• Protection gas hose (yellow)
• The multiple cable for transmission of electrical signals from the welding programmer to the weld head
• The multiple cable for transmission of electrical signals from the welding programmer to the Pneumatic Box

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions Use and maintenance
4. USE AND MAINTENANCE
4.1 General information
The high technology achieved with the orbital weld head HX 16 puts this models on the top of the international market
demands. This weld heads are extremely simple and it is easy to perform all necessary adjustments for a proper weld-
ing, guaranteeing a high standard of reproducibility.
The HX 16P allows to perform a great number of high quality welding.
In order to take advantage of this feature it is recommended to organize in advance the welding position:
• Be sure to have enough gas bottles.
• Be sure to have enough electrodes (pre-cut).
• Prepare tools for replacement of electrode.
The most important 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.
4.2 Positioning of the weld head
With the introduction of pneumatic part (in the model HX16P) placement has been completely revolutionized, much
faster and more accurate than the standard versions. The low weight and efficient clamping systems allows a easy plac-
ing of the weld head on the tube to be welded. Using the new adjustment slide (OPTIONAL), the weld head have to be
only positioned on the curve to be welded bringing into contact the slide previously regulated and start the pneumatic
locking by pushing start/stop button, avoiding loss of time for the search of the correct position as in the case of welds
on the border of the overlay.
4.3 Starting of the orbital weld head
Pushing start/stop button on the handle, the welding cycle will start (real cycle or simulation).
Pushing a second time the same button will cause a cycle end with current down slope and final gas.

8orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
Use and maintenance HX 16P | Operating instructions
4.4 Preparation and replacement of the electrode
A correct geometry of the electrode is very important in order to guarantee a good quality of the welding. This geometry
depends on the current you have chosen. For your reference see the enclosed table.
The electrode must be replaced every time you can see differences from the original geometry. In this case the welding
parameters will change and the reproducibility is no longer guaranteed.
For replacement move the rotor with the open weld head forwards until you can reach dowel.
NOTE: The distance electrode work piece influences the arc voltage.
We recommend to prepare a certain number of electrodes already cut and sharpened as soon as you have determined
the electrode size.
4.5 Adjustment and replacement of microswitch
Adjustment of replacement is necessary when we realize that the pulse counting is no longer regular.
Act as follows:
• Remove the screws and remove cover
• Loose screw from basis
In case of replacement:
• Remove screw and un-weld the two wires
• Remove microswitch and replace it

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions Use and maintenance
4.6 Cleaning the orbital weld head
4.6.1 Equipment
• Compressed air (compressor)
• Brush with metal bristles
• Scotch-Brite 3M A-VFN 150x115mm (or similar)
• Cleaner for electrical contacts LOCTITE 7039
4.6.2 Procedure
1. Without disassembling the weld head, turn the gear wheel
(rotor) into position as shown in Fig. 1.
Fig. 1 Starting position for the cleaning of the gear
2. Once the gear wheel (rotor) has reached the position, spray
the cleaner contacts in the direction shown in Fig. 2, continu-
ously during the rotation on the gear. Continue for the entire
extension of the gear.
Fig. 2 Cleaning using spray
3. Brushing the toothing with the wire brush as shown in Fig. 3.
Fig. 3 Brushing teeth

10 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
Use and maintenance HX 16P | Operating instructions
4. Repeat step 2. If you need to run step 2 until you get a shiny
finish of the gear.
5. Exhaust the carbonaceous deposits with a vacuum cleaner.
6. Clean the inside of the gear using scotch brite as shown in
Fig. 5 and Fig. 6.
Fig. 5 Cleaning inside gear with scotch brite
Fig. 6 Cleaning inside gear with scotch brite
7. Repeat step 2 by spraying abundantly product. Both inside
and outside of the gear. Repeat immediatly after step 5, tak-
ing care to remove all residual traces on all sides of the gear.

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions General safety rules
5. GENERAL SAFETY RULES
WARNING
These rules apply to AC and DC welding generators, AC transformers, AC/DC welding machines
and DC transformer welding rectifiers. In arc welding operations, where electrically charged parts
are exposed, the following rules should be observed to assure maximum safety and protection to
operator and surroundings.
Failure to observe these safety precautions may expose, not only the operator himself, but also
fellow workers, to serious injuries. Once these rule are studied and well kept in mind, proceed, in
any case with maximum care.
5.1 Welding cables
XAlways read and observe the following warning messages!
[DO NOT overload cables.
[DO NOT use welding cables at excessive current rates compared to their capacity. It will cause overheating and
rapid deterioration of their insulation. It is uneconomical.
[DO NOT use worn-out or poorly connected cables.
XINSPECT cables frequently. Repair immediately all breaks in insulation with rubber and friction tapes. Tighten and
adequately insulate all cable connections.
XIt is dangerous when exposed sections of cable come in contact with grounded metallic objects causing an arc.
XUnprotected eyes may be injured and fire may result if combustible materials such as oil or grease are in the vicinity.
5.2 Polarity switch
XAlways read and observe the following warning messages!
[DO NOT operate the polarity switch under load.
The polarity switch, when supplied, is provided for changing the electrode lead mutually from positive to negative.
Operate this switch only while the machine is not in use and the welding circuit is open.
Potential dangers of opening the circuit while charged with current are the following:
• An arc could form between contact surfaces of the switch.
• The person using the switch may receive a severe burn from this arc.
5.3 Ground power circuit
XAlways read and observe the following warning messages!
[DO NOT use welding machine without grounding frame of case.
XGROUND every power circuit to prevent accidental shock by stray current.
[DO NOT ground to pipelines carrying gas or inflammable liquids and lines carrying electrical conductors.
XBE SURE that conductors can safely carry the ground current.

12 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
General safety rules HX 16P | Operating instructions
5.4 Welding operations
XAlways read and observe the following warning messages!
[NEVER weld pieces without cleaning or inert materials which, when heated, give off inflammable or toxic vapours.
XUSE steam to clean superficial material.
XUSE a strong cleaning solution to clean out heavy oils or grease.
XBE SURE to remove any residues of inflammable gas or liquid.
[NEVER use oxygen to ventilate the welding piece.
XCAUTION when cleaning with steam or caustic soda.
XWEAR goggles and gloves.
[DO NOT clean where there is poor ventilation. Ventilation is necessary to divert harmful or explosive vapours.
[DO not clean in the presence of open flames of arc.
XUSE a wet tool to avoid sparks, when scaring or hammering to remove heavy sludge or scale.
XKEEP head and arms distant from work as possible.
5.5 Explosion hazards
XAlways read and observe the following warning messages!
[NEVER weld in or near explosive atmosphere. Such atmosphere can be created by inflammable gas leaks or by
vapours from inflammable liquids or by combustible dust.
5.6 Ventilation
XAlways read and observe the following warning messages!
[DO NOT weld in enclosed spaces without adequate ventilate.
XWhen welding in enclosed spaces always provide adequate ventilation with fans, air pipes, etc.
[NEVER use compressed oxygen. Heat and fumes from welding could cause sever discomfort or serious illnesses.
XWhen toxic fumes lead or cadmium content materials or any other substance are present in proportions that could
be harmful always use a gas mask.
5.7 Solvents
XAlways read and observe the following warning messages!
[DO NOT weld in the presence of even a small amount of vapour from solvents such as perchloroethylene or trichlo-
roethylene. Ultraviolet light from the electric arc can decompose the vapours forming phosgene, a poisonous gas.

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions General safety rules
5.8 Fire hazards
XAlways read and observe the following warning messages!
[DO NOT weld near inflammable or combustible materials. Fire can be caused by the arc, on contact with heated
metal, by slag or sparks.
XKEEP combustibles at least 10 m from the arc, on the contrary they should be suitably protected by a flame-proof
shield.
5.9 Dangers of electric shock
XAlways read and observe the following warning messages!
XOPEN power circuits before checking machines.
[DO NOT touch electrically heated parts.
[NEVER touch any exposed or insulated part of the cables, cable connectors, electrodes, etc. to avoid harmful or
fatal electric shock or burns.
[NEVER work in a damp area without suitable insulation.
XKEEP hands, feet and clothing dry at all the times.
5.10 Face protection
XAlways read and observe the following warning messages!
[DO NOT use cracked or defective helmets or shields.
XKEEP helmet and face shield in good condition.
XIf cracks occur in fibre material, replace shield, since leakage of arc rays may cause serious burns.
5.11 Eye protection
XAlways read and observe the following warning messages!
[DO NOT under any circumstances, view an electric arc without eye protection.
XMAKE sure that flash goggles are used under the welding helmet at all times.
In some types of arc welding, such as TIG welding, ultra-violet and infrared radiation from the arc is particularly intense
and requires constant attention to avoid arc flashes reaching welder or other exposed persons.

14 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_HX 16P_BA_848060202_01_EN
General safety rules HX 16P | Operating instructions
5.12 Clothing
XAlways read and observe the following warning messages!
[DO NOT use inadequate or worn-out clothing. Proper and dry, oil-free clothing is essential for welders protection.
Clothing must not only keep off sparks and molten particles, but must also obstruct the rays from the arc. They
must insulate the body from harmful electric currents.
XWear leather or asbestos gloves at all times to protect hand and wrists.
XDark coloured shirts are preferred to light ones since arc rays readily penetrate light-coloured fabrics.
[In case of gas-shielded arc welding, light colours are more reflective and may cause eye burns due to intense
ultra-violet rays given off by the process.
[Avoid cotton fabrics with gas shielded arc welding.
5.13 Hot metals burns
[DO NOT touch hot metals.
[DO NOT touch pieces of metal which have just been welded or heated.
[DO NOT substitute electrodes or centering cartridges immediately after welding.

(12.03.18) OW_HX 16P_BA_848060202_01_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
HX 16P | Operating instructions

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