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

(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
On request can be supplied:
• Cage with support ring for welding of flush tubes.
• Internal bore welding torch (L= up to 400 mm), tube diam 9,5 to 80 mm.
• Front dual flow cage for second gas (for titanium welding e.g.), at request with three point support.
We would like to remind you that our staff is able to design special torches for special applications or welding geome-
tries as well as prolonged torches for welding in hardly accessible areas.
3.3.1 Main body and rotating coupling
This group is composed of the following main items or subassemblies:
• Connection block to the main cable for cooling water, welding current and protection gas.
• Electric socket for connection to the welding programmer.
• Rotation joint spindle and main distributor for cooling water, protection gas and welding current. The electrical
contact between the parts is obtained by means of a lamellar joint.
• Self-lubrificating bearings for supporting the rotation joint spindle.
• Standard rotation gear motor. (On request with tachometer feedback).
• Coupling between crown wheel-pinion for transmission of rotation from the gear-motor to the welding head.
• Electro mechanic pulse-counter for controlling the welding cycle with respect to the torch position. The microswitch
is actuated by a wheel with 20 cams which supplies 60 impulses during a 360° rotation of the torch.
• External body with hook. (Standard for welding in horizontal position).
• Mandrel support vessel machined out of stainless steel.
• Ball bearing which allows the rotation of the mandrel support vessel and the front group for external and internal
bore welding.
• Socket.
• Start/Stop button for starting the welding cycle or act the emergency stop (if pushed during the cycle).
3.3.2 Filler wire group
• Filler wire gear-motor.
• Pair of wire feed rollers. On the machine usually are mounted rollers for wire 0,6 - 0,9 mm.
• Wire spool support Standard spool has following dimensions:
- external diameter: 100 mm
- min. wire coiling diameter: 40 mm
• Elastic (spring loaded) blocking device which avoids by a clutch-disc system the unrolling of the spool.
• Filler wire arrival group which is composed of:
- guide nozzle
- wire exit guide
- wire entry guide and rear entry nipple
- rear wire guide hose
- front wire guide hose
- shaft with insulating bushing
- shaft support

12 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
3.3.3 Front body and torch
• Brass slide body with sliding guide for the torch support. Inside the brass body is running the cooling water and the
protection gas. Three Viton hoses start from here to the torch.
• Torch body with threated hole for the gas diffusor (gas lens). The torch is covered by a special insulating painting in
order to insulate the piece against high frequency.
• Torch support with split for adjusting the welding distance. The support is insulated like the torch body. Attached to
the support is the shaft for supporting the filler wire arrival group.
• Radial torch position adjustment device by special screws.
• Insulating body
• Three point support
• Mandrel support vessel
At request front cage with stainless steel support ring.
3.3.4 Centering feature for external tube sheet weldings
Is needed in order to maintain the welding gun perfectly in axis with the tube to be welded.
It consists of a spindle which is mounted by means of 5 screws on the support vessel. On this spindle (mandrel) are
mounted the centering cartridges which will be located into the tube to be welded (bayonette attachment and blocked
by a spring loaded ball).
The centering cartridge is equipped with four rows of spring loaded balls guaranteeing in this way a perfect centering of
the welding head.
All mandrels and centering cartridges must be chosen with respect to the internal diameter of the tube to be welded.
Article Group Cartridge
size/no.
Tube ID
[mm]
Tube ID
[inch]
Code kg
Retaining arbor for centering tools for group A 832 020 003 0.060
Centering tool A 1 10.0 - 10.5 0.394 - 0.413 832 020 004 0.040
Centering tool A 2 10.5 - 11.0 0.413 - 0.433 832 020 005 0.050
Centering tool A 3 11.0 - 11.5 0.433 - 0.452 832 020 006 0.070
Centering tool A 4 11.5 - 12.0 0.452 - 0.472 832 020 007 0.070
Centering tool A 5 12.0 - 12.5 0.472 - 0.492 832 020 008 0.080
Centering tool A 6 12.5 - 13.0 0.492 - 0.512 832 020 009 0.100
Centering tool A 7 12.8 - 14.0 0.504 - 0.551 832 020 011 0.110
Retaining arbor for centering tools for group B 832 020 010 0.070
Centering tool B 8 13.8 - 15.0 0.543 - 0.591 832 020 012 0.120
Centering tool B 9 14.8 - 16.0 0.583 - 0.630 832 020 013 0.140
Centering tool B10 15.8 - 17.0 0.622 - 0.669 832 020 014 0.150
Centering tool B11 16.8 - 18.0 0.661 - 0.709 832 020 015 0.180
Centering tool B12 17.8 - 19.0 0.701 - 0.748 832 020 016 0.190
Centering tool B13 18.8 - 20.0 0.740 - 0.787 832 020 017 0.200
Centering tool B14 19.8 - 22.5 0.780 - 0.886 832 020 018 0.250
Retaining arbor for centering tools for group C 832 020 019 0.115
Centering tool C15 22.3 - 25.0 0.878 - 0.984 832 020 020 0.340
Centering tool C16 24.5 - 27.0 0.965 - 1.063 832 020 021 0.350
Centering tool C17 26.5 - 29.0 1.043 - 1.142 832 020 022 0.360
Centering tool C18 28.5 - 31.0 1.122 - 1.220 832 020 023 0.400
Centering tool C19 30.5 - 33.0 1.201 - 1.299 832 020 024 0.500

(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
Article Group Cartridge
size/no.
Tube ID
[mm]
Tube ID
[inch]
Code kg
Centering tool C20 32.5 - 36.0 1.280 - 1.417 832 020 025 0.510
Centering tool C21 33.5 - 39.0 1.319 - 1.535 832 020 026 0.530
Centering tool C22 38.5 - 42.0 1.516 - 1.654 832 020 027 0.550
Centering tool C23 41.5 - 45.0 1.634 - 1.772 832 020 028 0.560
Centering tool C24 44.5 - 48.0 1.752 - 1.890 832 020 029 1.000
Centering tool C25 47.5 - 51.0 1.870 - 2.008 832 020 030 1.200
Retaining arbor for centering tools for group D 832 020 031 0.215
Centering tool D26 50.5 - 54.0 1.988 - 2.126 832 020 032 1.500
Centering tool D27 53.5 - 58.0 2.106 - 2.283 832 020 033 1.800
Centering tool D28 57.5 - 62.0 2.264 - 2.441 832 020 034 1.900
Centering tool D29 61.5 - 66.0 2.421 - 2.598 832 020 035 2.100
Centering tool D30 65.5 - 70.0 2.579 - 2.756 832 020 036 2.400
Centering tool D31 69.5 - 74.0 2.736 - 2.913 832 020 037 2.600
Centering tool D32 73.5 - 78.0 2.894 - 3.071 832 020 038 2.800
Centering tool D33 77.5 - 82.0 3.051 - 3.228 832 020 039 3.100
Centering tool D34 82.0 - 87.0 3.228 - 3.425 832 020 045 3.100
Centering tool D35 87.0 - 91.0 3.425 - 3.582 832 020 046 -
Centering tool D36 91.0 - 95.0 3.582 - 3.740 832 020 047 -
Centering tool D37 95.0 - 99.0 3.740 - 3.897 832 020 048 -
Centering tool D38 99.0 - 103.0 3.897 - 4.055 832 020 049 -
Centering tool D39 103.0 - 107.0 4.055 - 4.212 832 020 050 -
Centering tool D40 107.0 - 111.0 4.212 - 4.370 832 020 051 -
Centering tool D41 111.0 - 115.0 4.370 - 4.527 832 020 052 -
Centering tool D42 115.0 - 120.0 4.527 - 4.724 832 020 053 -
3.4 Connections
Together with weld head is supplied a connection cable L=8m which allows the connection to the welding programmer/
power supply.
The cable contains the following tubes:
• cooling water in hose (blue)
• water return and current hose (red)
• protection gas hose (yellow)
• gas 2 (eventually to be used for double gas)
• plug of the electrical signals from welding programmer to the welding head

14 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Accessories and modifications P16, P16 AVC, P20 | Operating instructions
4. ACCESSORIES AND MODIFICATIONS
4.1 Internal bore welding without filler wire
A modification kit for the standard welding head can be supplied in order to perform internal bore welding (TIG process)
without filler wire for the following dimension:
• Length std < 400 mm
• Minimum tube internal diameter 9,5 mm
Orbitalum can supply even torches longer than 400 mm and corresponding to special welding geometries.
The standard torches cover the diameter range from 9,5 -80 mm.
Referring to the diameter the torches are subdivided into 5 groups:
• Group "A" : for ID 9.5 - 13 mm
• Group "B" : for ID 3.1 - 18 mm
• Group "C" : for ID 18.1 - 30 mm
• Group "D" : for ID 30.1 - 50 mm
• Group "E" : for ID 50.1 - 80 mm
(On request even larger diameters)
Each group is composed of the following components:
Water cooled torch with front centering bushings (ceramic), gas nozzle (ceramic), electrode holder with gas diffusor.
Ceramic nozzle and electrode holder are fixed to the torch by means of a threaded bush. The electrode is fixed by a
screw.
Front cage with stainless steel centering bush to support the weld head on the tube plate.
It is possible to mount distance rings on the torch in order to reduce the length of the torch in case there are several
welding depths with the same internal diameter. These distance rings are available on request in all dimensions.
In any case we recommend to attach with the order for an internal bore welding torch the drawing of the welding geom-
etry in order to fit out the torch the best way possible.
4.2 Front cage for dual gas flow
For welding special material (e.g. titanium) it is necessary to obtain a completely inert environment. For this reason it is
possible to fit on welding head a front cage with a transparent glass which allows to create an inert environment around
the electrode. This cage can be equipped with a three point support to render easier the positioning of the weld head
on the tube plate in case of slightly protruding tubes.
The accessory is supplied complete with:
• Front cage with stainless steel front ring
• Pyrex glass
• Gas hose
• Nipples
• Upon request three point support

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P16, P16 AVC, P20 | Operating instructions Use and maintenance
5. USE AND MAINTENANCE
5.1 Use of weld head
The high technology achieved with weld head puts this model as response on top of the international market demands.
This welding head is extremely simple and allows easily to perform all necessary adjustments for a proper welding,
guaranteeing a high standard of reproducibility.
Anyhow it is recommended, before starting production, to prepare a sufficient number of welding samples (about 50)
which correspond the later welding geometry. We recommend to adjust the wire arrival about 0,5 - 1,0 mm below the
electrode. The wire should arrive perpendicularly to the electrode and tangentially to the tube.
The welding head should be hooked up with an elastic balancer.
The orbital weld head allows to perform a great number of high quality weldings. 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 and shaped).
• Prepare ceramic nozzles, wire nozzles, gas lenses, collets and wire spools.
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.
5.2 Positioning of the welding head
The low weight and the efficient centering devices allow an easy and economic way of using the welding head.
Hook up the welding machine on a balancer (size up to 15 kg).
In order to obtain an efficient support on the tube sheet it is recommended to have to rope about 2 meters long and that
it may be angled 15 - 20° towards the tube sheet. In this case the welding head is slightly pressed on the tube plate.
5.3 Starting of the welding heads
In case the welding head is connected to a Orbitalum controller, pushing start / stop button the welding cycle will start (real
cycle or simulation).Pushing a second time the same button the welding will be stopped (cycle end with downslope).
5.4 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 the replacement of the electrode unscrew the cover the collet and collet body. In this way you can extract the elec-
trode to be replaced.

16 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Use and maintenance P16, P16 AVC, P20 | Operating instructions
Electrode collets for the following diameters are available: 1; 1.6; 2; 2.4 mm.
L veränderlich
Schlifflächen
D d
Tungsten Thorium 2 % Argon
Electrode
diameter
Top
diameter
Angle DC current
max. val.
Pulsed
current range
D (mm) D (mm) in ° max. A A
1.0 0.12 12 15 2 - 25
1.0 0.25 20 30 5 - 60
1.6 0.50 25 50 8 - 100
1.6 0.75 30 70 10 - 140
2.05 0.75 35 80 10 - 160
2.4 0.75 35 90 12 - 180
2.4 1.1 45 150 15 - 250
3.2 1.1 60 200 20 - 300
3.2 1.5 90 250 25 - 350
NOTE: The protrusion of the electrode from the ceramic nozzle geometric value to guarantee the reproducibility of the
welding. It influences as well the distance electrode-workpiece.
We recommend to prepare a certain number of electrodes allready cut and sharpened as soon as you have determined
the electrode size.
5.5 Adjustment of welding diameter
The welding diameter can be adjusted by means of the screw with the key supplied together with the tool box.
5.6 Adjustment of the Arc distance
The distance electrode-workpiece can be defined after having determined the protrusion of the electrode from the
ceramic nozzle.
Rotating the counter-ring of the three-point-support you may change the distance electrode-workpiece.
Unscrewing the screw on the torch support you may move the torch forwards or backwards parallel to the machine's
axis. the stroke is 6 mm.

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P16, P16 AVC, P20 | Operating instructions Use and maintenance
5.7 Adjustment of the filler wire arrival
The wire arrival group is assembled on the torch support following this way all radial and axial movements. To move the
wire nozzle you just have to untighten the M3 screws on the hinges.
While adjusting the nozzle position you must keep in mind that the wire should pass about 0.5 - 1.0 mm under the
electrode and that the wire arrival should be perpendicular to the tube axis and tangentially to the tube to be welded.
5.8 Replacement of the wire nozzle
It is necessary to replace the wire nozzle when the exit hole has become ovaly due to the wear or if you want to change
the filler wire diameter.
In this way exact guiding of the wire to the welding bath is no longer guaranteed.
Nozzles for wire diameter 0.6 ; 0.8 ; 1.0 mm are available.
For the replacement unscrew screw, extract the nozzle and remove the nozzle from the wire liner.
5.9 Replacement of the wire spool
Act as follows:
• Cut the wire left on the spool.
• Press the wire forward button on the remote control in order to push forward the wire.
• The wire will advance until it has passed the wire feed rollers. Take a pair of pliers and tear the remaining wire out
of the liner.
• Unscrew handle and remove the spool.
• Take a new spool and round off the top of the wire with a file in order to prevent cutting of the Teflon wire liner.
• Remove the wire exit nozzle near the torch.
• Introduce the wire into the guide until it arrives to the wire feed rollers.
• Act on screw in order to adjust the pressure of the rollers for feeding the wire.
• The right pressure is achieved when the wire is feeded regularly and without interruptions.
• Excessive pressure on the rollers will lead to an early wear. In order to adjust the pressure on the rollers it is neces-
sary to act as follows.
• Switch on the welding equipment.
• In case the wire as stopped in front of the rollers which are too closed act on screw in order to open the rollers.
• Press the manual wire button on the remote control and tight screw until the wire starts to be pushed. Now tight
screw half turn. The pressure will be correct now.
• Place the spool on the shaft and put handle on it.
• Push the manual filler wire button until the wire gets out on the top.
• Place again the wire end nozzle on the liner and fix it on its support.
NOTE: The wire group is equipped with a special friction which allows to keep the filler wire tight on the spool.

18 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
Use and maintenance P16, P16 AVC, P20 | Operating instructions
5.10 Removement or assembly of wire group
As mentioned before, the weld head allows to perform Tig weldings with or without filler wire. In case you intend to per-
form only TIG weldings you may remove the filler wire group in order to reduce dimensions and weight of the weld head.
Hereafter are explained all operations to assemble the wire group on the welding head.
• assemble the front wire group fixing it by means of screw
NOTE: The insulating bushing must not be removed when disassembling the wire unit.
• remove rear tap.
• put into position the wire unit paying attention to:
- the front wire liner must be inserted into the hole on the welding head and pushed through
- connect the electric sockets for feeding the wire motor.
• fix the wire unit to the machine body by means of screws.
• add the wire spool as described before and adjust the front wire nozzle.
5.11 Replacement of the wire liner
This operation is necessary due to the wear of the wire liner itself. The wear depends on the roughness of the wire sur-
face. This operation can be programmed periodically after about 10-15 wire spools. As the cost of the wire liner is very
low it is recommended to forcast the replacement before the liner is actually damaged.
Hereafter will be described the necessary replacement of the wire liner.
5.11.1 Replacement of the front wire liner
Act as follows:
• Cut the wire left on the spool.
• Press the button on the remote control in order to push forward the wire.
• The wire will advance until it has passed the wire feed rollers. Take a pair of pliers and tear the remaining wire out
of the liner.
• Remove the wire nozzle from the support and remove it from the liner.
• Loosen screws disconnect electrical connectors and remove the whole wire unit. This way the front wire liner will be
extracted from the welding head.
• Remove the liner from nozzle.
• With the help of a pencil-sharpener round off the extreme parts of the liner and screw it again on nozzle.
• Proceed as described in 3.10.
5.11.2 Replacement of the rear wire liner
Act as follows:
• Cut the wire left on the spool.
• Press the button on the remote control in order to push forward the wire.
• The wire will advance until it has passed the wire feed rollers. Take a pair of pliers and tear the remaining wire out
of the liner.
• Remove the spool as illustrated in the previous paragraph.
• Unscrew the liner to be replaced from its guiding nozzle.
• Remove nozzle.
• With the help of a pencil-sharpener round off the extreme parts of the liner.
• Screw nozzle on the new liner (the liner is self-threading).
• Place again the new liner in its guiding nozzle.

(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 General safety rules
6. GENERAL SAFETY RULES
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.
Welding cables
WARNING
DO NOT overload cables.
WARNING
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 certainly uneconomical.
WARNING
DO NOT use worn-out or poorly connected cables.
WARNING
INSPECT cables frequently. Repair immediately all breaks in insulation with rubber and friction tapes.
Tighten and adequately insulate all cable connections. It is dangerous when exposed sections of
cable come in contact with grounded metallic objects causing an arc. Unprotected eyes may be
injured and fire may result if combustible materials such as oil or grease are in the vicinity.
Polarity switch
WARNING
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.
Ground power circuit
WARNING
DO NOT use welding machine without grounding frame of case.
WARNING
GROUND 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.
ATTENTION BE SURE that conductors can safely carry the ground current.

20 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (12.03.18) OW_P16_P20_BA_831060202_03_EN
General safety rules P16, P16 AVC, P20 | Operating instructions
Welding operations
WARNING
NEVER weld pieces without cleaning or inerting materials which, when heated, give off inflammable
or toxic vapors.
ATTENTION USE steam to clean superficial material.
ATTENTION USE a strong cleaning solution to clean out heavy oils or grease.
ATTENTION BE SURE to remove any residues of inflammable gas or liquid.
WARNING
NEVER use oxygen to ventilate the welding piece.
WARNING
CAUTION when cleaning with steam or caustic soda.
ATTENTION WEAR goggles and gloves.
WARNING
DO NOT clean where there is poor ventilation.
WARNING
Ventilation is necessary to divert harmful or explosive vapors.
WARNING
DO NOT clean in the presence of opes flames of arc.
WARNING
USE a wet tool to avoid sparks, when scaring or hammering to remove heavy sludge or scale.
WARNING
KEEP head and arms distant from work as possible.
Explosion hazards
DANGER
NEVER weld in or near explosive atmospheres.
Such atmospheres ca be created by inflammable gas leaks or by vapors from inflammable liquids
or by combustible dusts.
Ventilation
WARNING
DO NOT weld in enclosed spaces without adequate ventilation.
When welding in enclosed spaces always provide adequate ventilation with fans, air pipes, etc.
WARNING
NEVER use compressed oxygen.
Heat and fumes from welding could cause sever discomfort or serious illnesses.
WARNING
When toxic fumes from lead or cadmium content materials or any other substances are present in
proportions that could be harmful always use a gas mask.