Orbitalum P16 User manual

Operating instructions
For responsible bodies and persons using the machine
Tube-to-tube-sheet orbital weld
heads
P16
P16 AVC
P20
To work safely with this machine, please
read through the operating instructions
in full before initial operation. Retain the
operating instructions for future reference.
Code 831 060 202 | EN | Translation of original operating instructions
Machine no.

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_P16_P20_BA_831060202_03_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
P16, P16 AVC, P20 | Operating instructions
TABLE OF CONTENTS
1. About these instructions ......................................4
1.1 Warning messages.....................................4
1.2 Further symbols and displays.....................4
1.3 Abbreviations ............................................4
2. Information and safety instructions for the
responsible body .................................................5
2.1 Requirements for the responsible body.......5
2.2 Using the machine .....................................5
2.2.1 Proper use .......................................5
2.2.2 Improper use ...................................5
2.2.3 Machine constraints.........................6
2.3 Environmental protection/disposal .............6
2.3.1 Electric tools and accessories ..........6
2.4 Basic safety instructions............................6
3. Technical specifications .......................................9
3.1 P16............................................................9
3.2 P20..........................................................10
3.3 Description of welding head .....................10
3.3.1 Main body and rotating coupling ....11
3.3.2 Filler wire group.............................11
3.3.3 Front body and torch ......................12
3.3.4 Centering feature for external
tube sheet weldings.......................12
3.4 Connections.............................................13
4. Accessories and modifications ...........................14
4.1 Internal bore welding without filler wire....14
4.2 Front cage for dual gas flow......................14
5. Use and maintenance.........................................15
5.1 Use of weld head......................................15
5.2 Positioning of the welding head................15
5.3 Starting of the welding heads...................15
5.4 Preparation and replacement of the
electrode .................................................15
5.5 Adjustment of welding diameter ...............16
5.6 Adjustment of the Arc distance .................16
5.7 Adjustment of the filler wire arrival...........17
5.8 Replacement of the wire nozzle ................17
5.9 Replacement of the wire spool..................17
5.10 Removement or assembly of wire group....18
5.11 Replacement of the wire liner ...................18
5.11.1 Replacement of the front wire
liner...............................................18
5.11.2 Replacement of the rear wire
liner...............................................18
6. General safety rules ...........................................19
7. EG Declaration of Conformity..............................23

4orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
About these instructions P16, P16 AVC, P20 | 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. Abbreviations
OW ORBIWELD

(12.03.18) OW_P16_P20_BA_831060202_03_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
P16, P16 AVC, P20 | Operating instructions Information and safety instructions for the responsible body
2. INFORMATION AND SAFETY INSTRUCTIONS FOR THE
RESPONSIBLE BODY
2.1 Requirements for the responsible body
Workshop/outdoor/field application: The responsible body 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 safety regulations described in chap. 2 must be observed and work must be carried out with
safety in mind using the prescribed protective equipment.
The employer undertakes to give the employees clear notice of the dangers arising that are specified in the EMC direc-
tives and to evaluate the workplace correspondingly.
Requirements for special EMC evaluations with regard to general activities, working materials and workplaces*:
TYPE OF WORKING MATERIALS OR WORK-
PLACE
EVALUATION REQUIRED FOR:
Employees without
particular risk
Employees at particular
risk (with the exception
of those with active
implants)
Employees with active
implants
(1) (2) (3)
Arc welding, manual (including MIG (Metal Inert
Gas), MAG (Metal Active Gas), TIG (Tungsten Inert
Gas)) under observance of tried-and-tested proce-
dures and without physical contact to the line
No No Yes
* According to Directive 2013/35/EU
2.2 Using the machine
2.2.1 Proper use
• The orbital welding equipment ( Orbital Welding Power Supplies CA/CB 165/300 and Orbitwin
in connection with the orbital welding heads OW/TP/P/OP/HX and the manufacturer's recom-
mended accessories) are to be used with metal pipes and tubes up to the specified pipe/tube
dimensions of the heads.
• The machine may only be used on tubes and containers that are empty, unpressurized, do not
have explosive atmospheres and are not contaminated.
Proper use also includes the following:
• observing all safety instructions and warning messages included in these operating instructions
• carrying out all inspection and maintenance work
• sole use in the original condition with original accessories, spare parts and materials
• processing only materials set out in the operating instructions.
2.2.2 Improper use
• A use other than that defined under "proper use" or a use that goes beyond this or the specified
constraints shall be considered improper use due to the potential risks involved.
• The responsible body shall be solely responsible for damages that arise through improper use
and the manufacturer shall assume no liability whatsoever.

6orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Information and safety instructions for the responsible body P16, P16 AVC, P20 | Operating instructions
• No tools should be used that have not been authorized by the manufacturer for this machine.
• The removal of safety equipment is not permitted.
• Do not misuse the machine.
• The machine is not intended for use by private consumers.
• The technical values defined for normal operation must not be exceeded.
• Do not use the machine as a drive for applications other than those listed under proper use.
2.2.3 Machine constraints
• The workplace can be in tube preparation, in plant construction or in the plant itself.
• A radial space requirement/freedom of movement of approx. 2 m around the machine is required for people.
• Work lighting: min. 300 lux.
• Operator age: at least 14 years old and without physical impairments.
• User qualification: instructed operator.
• Operated by one person.
• Climate conditions: temperature range for machine operation: -10°C to 40°C, (<70% rel. humidity).
Temperature range for machine storage: -20°C to 40°C, (<70% rel. humidity).
Do not use outdoors in fog, rain or during a thunderstorm.
The cooling performance is only guaranteed when full water tank.
2.3 Environmental protection/disposal
2.3.1 Electric tools and accessories
Discarded electric tools and accessories contain large quantities of valuable raw and synthetic
materials that can be recycled. Therefore:
• Electrical (electronic) devices that are marked with the symbol at the side may not be
disposed of with household waste in accordance with EU regulations.
• By actively using the available return and collection systems, you actively contribute to the
reuse, recycling and utilization of electrical (electronic) devices.
• Used electrical (electronic) devices contain parts that must be handled selectively accord-
ing to EU regulations. Separate collection and selective treatment is the basis for environ-
ment-friendly disposal and the protection of human health.
• Appliances and products that you bought from us after August 13, 2005 will be disposed of
in accordance with legal standards after they have been supplied to us at no cost.
• We may refuse to accept old appliances that pose a risk to human health or safety due to
contamination produced during use.
• The end user is responsible for disposing of used appliances introduced to the market
before August 13, 2005. Please contact a disposal center near you for this purpose.
• Important for Germany: our products may not be disposed of in municipal disposal sites as
they are only used for industrial purposes.
(as per RL 2002/96/EC)
2.4 Basic safety instructions
The machine (hereinafter referred to as the P16, P16 AVC, P20) is a state-of-the-art machine designed for safe use.
The risks involved in using the machine are described in the operating instructions below. Using this machine in a
way other than that described in these instructions can lead to serious physical injury and material damage.
Therefore:
• Observe warning messages at all times.
• Keep complete documentation close by the machine.
• Observe country-specific regulations, standards and guidelines.

(12.03.18) OW_P16_P20_BA_831060202_03_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
P16, P16 AVC, P20 | Operating instructions Information and safety instructions for the responsible body
• Always ensure that the machine is in good working order. Observe the maintenance information.
• Report any unusual machine behavior to the person responsible immediately.
• Only use the dimensions and materials specified in these instructions. Other materials should be used only after
consulting with Orbitalum Tools customer service.
• Use only original tools, spare parts, materials and accessories from Orbitalum Tools.
• Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
• At the end of each working cycle, before transportation, changing tools, cleaning and performing any maintenance,
adjustment or repair work, switch off the machine, allow it to run to a stop and pull the mains plug.
• Do not carry the machine by the cable assembly and protect them from heat, oil and sharp edges.
• During operation, keep hands away from the tools.
• Check that the tube is correctly clamped.
• Switch on the machine only when the tube has been clamped.
• In extreme conditions of use, conductive dust can settle inside the machine. For this reason and for better safety,
an on-site SPE-PRCD or ground-fault circuit (30 mA) is required between the mains network and the machine, to be
installed and tested if necessary by a professional electrician.
• When working with the machine wear safety shoes (as per EN ISO 20345 at least S1).
NOTE The recommendations concerning "Personal protective equipment" only apply
to the product being described. Other requirements resulting from the ambient
conditions on-site or of other products, or from combining with other products, are
not taken into account. These recommendations do not in any way release the re-
sponsible body (employer) from its statutory health and safety at work obligations
towards its employees.
WARNING
Danger of unit toppling over (Orbicar welding trolley, gas cylinder, welding power supply, cooling unit)
as a result of external application of force!
Diverse physical injuries and property damage are possible.
XInstall machine securely against external force and keep moving masses at minimum clearance
of 1 meter.
DANGER
Danger through operation by more than one person!
Diverse physical injuries and property damage are possible.
XEnsure that only one person operates the machine and welder head at a time.
DANGER
Danger through improper maintenance of the unit!
Diverse physical injuries and property damage are possible!
XMaintenance work must be performed in accordance with the "Maintenance" section.
DANGER
Electrical forms of danger from contact and/or incorrect or damp personal protective equipment!
Electric shock.
[Do not touch any live parts (pipes), especially during arc ignition!
[Persons with increased sensitivity to electrical forms of danger (e.g. cardiac insufficiency) must
not work with the unit.
XDry safety shoes, dry metal-free (rivet-free) leather gloves and dry protective suits minimize
the danger presented by electricity.
XWork on dry ground.
DANGER
Accidentally activated ignition function!
Electric shock.
XAlways switch off the orbital welding power supply when connecting or disconnecting a weld-
ing head.
WARNING
Electromagnetic incompatibility of surrounding devices when conducting high-frequency ignition
and devices without ground conductor in operation!
Diverse physical injuries and property damage are possible.
XOnly use insulated electrical devices in the working area of the welding unit.
XObserve electromagnetically sensitive devices when the unit is ignited.
WARNING
Ultra-violet radiation caused by the arc during welding operation!
Damage to eyes and burns to the skin.
XDuring operation, wear EN 170-compliant visor and protective clothing that covers the skin.
XIn the case of closed heads, check that the visor is in perfect working order.

8orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Information and safety instructions for the responsible body P16, P16 AVC, P20 | Operating instructions
WARNING
Hot emergent liquids and hot plug connections during intense operation
Danger of scalding.
XObserve safety measures put in place by the supervisor/safety officer.
DANGER
Incorrect handling of pressure containers and other parts of the unit (e.g. forming gas cylinder)!
Diverse physical injuries and property damage are possible.
XObserve safety regulations, especially for pressure containers.
XObserve safety data sheets.
XIf > 25 kg, lift unit and its components with the help of several people/hoisting equipment.
DANGER
Flammable materials in the vicinity of the welding zone or solvents in the ambient air!
Danger of explosion and fire.
[Do not perform welding tasks in the vicinity of solvents (e.g. painting work).
[Do not perform welding tasks in the vicinity of explosive materials.
XEnsure there are no flammable materials or contaminations in the vicinity of the welding zone
or being used as an underlay.
ATTENTION
Surfaces of the welding heads and welding point remain hot for some time after welding!
Danger of burning.
XWear protective gloves.
WARNING
Toxic vapors and materials in the welding process and handling electrodes!
Damage to health, such as cancer.
[Do not use electrodes that contain thorium.
XUse extraction device in accordance with official regulations (e.g. BGI: 7006-1)
XParticular attention should be paid when working with chromium, nickel, or manganese.
DANGER
Incorrect ignition when welding head has not been attached or brought into the correct position!
Electric shock, physical injury, and property damage to other devices.
[Do not play with welding heads.
XSwitch to "test" function if head is not ready for operation.
DANGER
Improper access and opening of ORBIMAT unit!
Electric shock.
[Never connect an open unit to the power supply.
XDisconnect unit from the power supply.
XRemove all devices connected externally to the unit (welding heads, etc.).
XIf previously in use, allow to cool.
XOnly allow qualified electricians to access the electronics.
DANGER
Liquid in housing as a result of improper use and/or transport!
Electric shock.
[Do not place any liquids (drinks) on the unit.
XKeep vents free.
XCheck housing for moisture on the inside after transporting the machine and leave open to dry
if necessary.
DANGER
Damaged plug!
Fatal electric shock.
[Do not use adapter plugs with ground protected electrical tools.
XThe machine connector plug must fit the socket.
DANGER
Loose/baggy clothing, long hair or jewelry can get caught in rotating machine parts!
Serious injury or death.
[During operation, do not wear loose/baggy clothing, e.g. neckties.
XTie up long hair to prevent it from being caught.
DANGER
Safety components that are contaminated or worn are defective!
The failure of safety components can cause physical injury.
XReplace defective safety components immediately and check them daily to ensure proper operation.
XInspect the machine daily for visible signs of damage or defects, and have them repaired by a
specialist if necessary.

(12.03.18) OW_P16_P20_BA_831060202_03_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
P16, P16 AVC, P20 | Operating instructions Technical specifications
3. TECHNICAL SPECIFICATIONS
3.1 P16
Welding process: TIG and TIG + filler wire
Welding position: horizontal, vertical, inclined
Positioning of welding head: by means of a series of spring loaded centering cartridges and mandrels
Centering of torch: by means of a spring loaded balancer or positioning frame with x-y-z
movement
Torch cooling: water cooled
Torch inclination: max ± 45°
Welding diameters: 12 - 78 mm electrode parallel to tube axis
10 - 36 mm electrode inclined of 30° tube axis
bigger and smaller diameters at request
Welding current (60% duty cycle): max. 200 A DC pulsed
max. 180 A DC linear
Rotation speed: 0,33 - 6,00 rpm (stepless adjustment)
Front cage with steel ring: Standard
Adjustment of welding distance: 6 mm on torch support slider +/- 5 mm by means of adjustment ring
(micrometric adjustment)
Filler wire group: removable if not used
Filler wire speed: 0,15 - 1,50 m/min (step less adjustment)
Filler wire spool: 1 kg ø spool 100 mm
Wire diameter with rollers type 1: min 0.6 mm - max 0.9 mm
Wire diameter with rollers type 2: min. 0.9 mm - max 1.2 mm
If not specified the machine is delivered with rollers type 1
Dimensions:
Machine body: [mm] 100
Spool protection cage: [mm] 120
Length:
without wire group [mm] 350
with wire group [mm] 480
Weight:
without wire group [kg] 8.0
with wire group [kg] 10.0

10 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Technical specifications P16, P16 AVC, P20 | Operating instructions
3.2 P20
Welding position: horizontal, vertical, inclined
Welding process: TIG and/or TIG + filler wire
Welding current: [A] max. 200
Welding diameters: [mm] 10 - 70
Welding geometries: recessed, flush and protruding tubes
Current transmission: lamellar coupling
Gas and water transmission: rotating coupling
Support on tube sheet: three point support
Torch and wire nozzle: adjustable on three axis according to welding geometry
Centering of torch: by means of a series of spring loaded centering cartridges and mandrels
Cooling of torch: water cooled up to electrode holder
Torch inclination: max. +/- 45°
Rotation and filler: 18 V DC standard motor
Rotation speed: min. 0,33 rpm
max 6,00 rpm
Wire speed: min. 150 mm/min
max 1.500 mm/min
Filler wire spool: 1 kg midget spool, diam. 100 mm, mounted on machine body
Wire diameter with rollers: min. 0,6 mm
max. 0,9 mm
Dimensions:
Machine body [mm] 70
Length [mm] 325 (without wire group)
[mm] 470 (with wire group)
Weight (without centering devices
and connection cable)
[kg] 5,0 (without wire group)
5,5 (with wire group)
3.3 Description of welding head
The weld head can rotate indefinitely as current, cooling water and gas are supplied to the torch by means of a special
designed rotating coupling. In this way cable connections from the power supply to the weld head remain fix.
Electrode and wire nozzle are both completely moveable towards the tube axis. In this way the electrode and the wire
nozzle inclination can be easily optimized.
All normal work operations and small maintenance jobs can easily be performed directly by the operator (replacement
of spool, electrode, wire hose, etc.).
The weld head is composed of these groups:
• Central body and rotating coupling
• Wire group
• Front body and torch