ESAB | Pipeweld orbiter | Instruction manual | ESAB Pipeweld orbiter User manual

ESAB Pipeweld orbiter User manual
Pipeweld Orbiter
Instruction manual
0463 487 001 GB 20190204
Valid for: serial no. 18020
TABLE OF CONTENTS
1
SAFETY .......................................................................................................
5
1.1
Meaning of symbols ...............................................................................
5
1.2
Safety precautions .................................................................................
5
2
INTRODUCTION ..........................................................................................
8
3
TECHNICAL DATA ......................................................................................
9
4
INSTALLATION............................................................................................
10
4.1
Adjusting the pipe diameter ..................................................................
10
4.2
Installing the travel band .......................................................................
11
4.3
Adjusting the unit to the band width ....................................................
12
4.4
Mounting the unit on the travel band ...................................................
13
OPERATION ................................................................................................
15
5.1
Overview .................................................................................................
15
5.2
Connections and control devices .........................................................
16
5.2.1
Control box operation ...........................................................................
17
5.2.2
Remote pendant box ............................................................................
18
5.2.3
Programming unit - HHPU....................................................................
18
Weld start ................................................................................................
24
5.3.1
Setting the welding direction ................................................................
24
5.3.2
Adjusting the torch angle ......................................................................
25
5.3.3
Adjusting the spool tension ..................................................................
26
MAINTENANCE ...........................................................................................
27
6.1
Routine maintenance .............................................................................
27
6.2
Replacing the drive wheel .....................................................................
27
6.3
Replacing the Bowden cable.................................................................
28
6.4
Replacing the welding tip ......................................................................
29
6.5
Replacing the wire feed wheels ............................................................
30
6.6
Removing the control box .....................................................................
31
6.7
Removing the stepper motor.................................................................
32
6.8
Removing the drive motor .....................................................................
33
6.9
Removing the tip control motor (near/far) ...........................................
34
6.10
Removing the tip control motor (up/down)..........................................
35
6.11
Removing the tip control lead screw and barrel (near/far).................
36
6.12
Removing the tip control lead screw and barrel (up/down) ...............
37
6.13
Removing the wire feed motor ..............................................................
38
6.14
Removing the bearing housing.............................................................
39
TROUBLESHOOTING .................................................................................
40
7.1
Error codes .............................................................................................
40
7.2
Portable Appliance Testing (PAT) .........................................................
40
ORDERING SPARE PARTS ........................................................................
DIAGRAM ............................................................................................................
41
42
5
5.3
6
7
8
0463 487 001
© ESAB AB 2019
TABLE OF CONTENTS
ORDERING NUMBERS .......................................................................................
WEAR PARTS......................................................................................................
ACCESSORIES ...................................................................................................
47
48
49
Rights reserved to alter specifications without notice.
0463 487 001
© ESAB AB 2019
1 SAFETY
1
SAFETY
1.1
Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual
and follow all labels, employer´s safety practices and
Safety Data Sheets (SDSs).
NOTE!
For product operation instructions please refer to the supplied USB memory stick.
1.2
Safety precautions
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed in addition to the standard regulations that apply to
the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can
result in injury to the operator and damage to the equipment.
1.
2.
3.
Anyone who uses the equipment must be familiar with:
○ its operation
○ location of emergency stops
○ its function
○ relevant safety precautions
○ welding and cutting or other applicable operation of the equipment
The operator must ensure that:
○ no unauthorised person is stationed within the working area of the equipment
when it is started up
○ no-one is unprotected when the arc is struck or work is started with the
equipment
The workplace must:
○ be suitable for the purpose
○ be free from drafts
0463 487 001
-5-
© ESAB AB 2019
1 SAFETY
4.
5.
Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,
flame-proof clothing, safety gloves
○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which
could become trapped or cause burns
General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified
electrician
○ Appropriate fire extinguishing equipment must be clearly marked and close at
hand
○ Lubrication and maintenance must not be carried out on the equipment during
operation
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions
when welding and cutting.
ELECTRIC SHOCK - Can kill
•
•
•
•
Install and ground the unit in accordance with instruction manual.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
Insulate yourself from work and ground.
Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
•
•
•
Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
Welders should use the following procedures to minimize exposure to
EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep welding power source and cables as
far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
FUMES AND GASES - Can be dangerous to health
•
•
Keep your head out of the fumes.
Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.
ARC RAYS - Can injure eyes and burn skin
•
•
Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
Protect bystanders with suitable screens or curtains.
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
0463 487 001
-6-
© ESAB AB 2019
1 SAFETY
MOVING PARTS - Can cause injuries
•
•
•
Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
Stop engine before installing or connecting unit.
Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
•
•
Sparks (spatter) can cause fire. Make sure that there are no inflammable
materials nearby.
Do not use on closed containers.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
WARNING!
Do not use the power source for thawing frozen pipes.
CAUTION!
Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in those locations,
due to conducted as well as radiated disturbances.
NOTE!
Dispose of electronic equipment at the recycling
facility!
In observance of European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.
As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information contact your local ESAB dealer or visit us on
our website.
0463 487 001
-7-
© ESAB AB 2019
2 INTRODUCTION
2
INTRODUCTION
The Pipeweld Orbiter is a light weight bug for orbital welding of pipe and pipelines allowing
the use of 1 system for outside diameters of 200 mm (8 in.) pipe and above without the need
to swap the drivetrain. The Pipeweld Orbiter is not sided and the same unit can weld both
sides of the joint. The unit has its own wire feed system and torch eliminating the need for
secondary feeders, torch hose packs and cables. The only supplies required are control,
power and gas resulting in accurate and precise electrode positioning and unrestricted orbital
travel.
•
•
•
•
•
•
The machine is of lightweight construction to ensure ease of handling by the operator.
Ability to go in either direction and 360° enables one machine to complete a weld joint,
welding direction (up or down) is changed via a rocker switch.
The on board control box enables a wide range of welding parameters to be stored
which are programmed and downloaded from hand held programming unit (HHPU).
The motor, gearboxes, lead screws, and bearings are designed for long life even in
heavy duty.
All of the software for the HHPU with the required data transfer box and controller can
be upgraded on-site or in-house via e-mail.
Two systems can be used on the same band from 16" pipe and above.
For more information, visit esab.com.
0463 487 001
-8-
© ESAB AB 2019
3 TECHNICAL DATA
3
TECHNICAL DATA
Pipeweld Orbiter
Pipe diameters
200 mm (8 in.) to flat plate
Wire diameter solid wire
0.8–1.2 mm (0.031–0.047 in.)
Wire diameter flux cored
1.2 mm (0.047 in.)
Max spool diameter
200 mm (8 in.)
Wire spool capacity
2.7–5.0 kg (5.9–11.02 lb)
Travel speed
0.15–15 m/min (6–59 in./min)
Wire speed
5–15 m/min (196.85–590.55 in./min)
Oscillation width pendulum
action, max
26 mm (1.02 in.)
Oscillation dwell independent
dwells
0–250 ms
Burn back time
0–5 s
Crater fill time
0–2 s
Gas pre-flow
0–20 s
Gas post-flow
0–20 s
Welding torch control
Electronic 50 mm (1.97 in.) vertical, 55 mm (2.17 in.)
horizontal
Weight (without wire and cables)
16 kg (35.3 lb)
60% duty cycle
275 A
100% duty cycle
248 A
0463 487 001
-9-
© ESAB AB 2019
4 INSTALLATION
4
INSTALLATION
CAUTION!
Read and understand the instruction manual before
installing or operating.
The installation must be carried out by a professional.
WARNING!
Risk of electric shock! Before installation or maintenance, ensure that the control
box is switched off and the positive welding cable is disconnected!
Before placing the device on the pipe band, it is necessary to adjust the device to suit the
particular pipe diameters and band widths to be used.
4.1
Adjusting the pipe diameter
The Pipeweld Orbiter has to be adjusted to the pipe diameter before positioning the device
on the pipe.
See the table below for pipe diameters to be used in in. and mm and the corresponding
setting for each leg. Set the same value (Leg setting) on the setting plate for each leg.
Ø Pipe in.
Ø Pipe mm
Leg setting
Ø Pipe in.
Ø Pipe mm
Leg setting
12
31
36
40
102
14
14
36
33.5
42
107
13
16
41
31
44
112
12.5
18
46
28
48
122
11.5
20
51
26
52
132
10.5
22
56
24
56
142
10
24
61
22
60
152
9
26
66
20.5
64
163
8.5
28
71
19
68
173
8
30
76
18
72
183
7.5
32
81
17
76
183
7
34
86
16
80
203
7
36
91
15.5
Straight
0
0
38
97
14.5
0463 487 001
- 10 -
© ESAB AB 2019
4 INSTALLATION
Adjusting the leg setting
1.
2.
3.
4.
5.
Remove spatter guard that covers the legs and setting plates.
Loosen both the leg and setting screws (1) & (2).
Adjust leg to required scale on setting plate with the screw (2).
Tighten the leg and setting screws (1) & (2).
Repeat for other leg.
4.2
Installing the travel band
NOTE!
The Pipeweld Orbiter can be moved or slide down on the band when the power is
off. To enable the motor brake, the power must be turned on.
The Pipeweld Orbiter moves around the pipe by travelling along a band. Follow these steps
to install the travel band.
0463 487 001
- 11 -
© ESAB AB 2019
4 INSTALLATION
1.
2.
Loosen the tensions screw (1) on the travel band and open the latch (2).
Open the band and position it around the pipe, close to the weld joint.
NOTE!
Larger bands may require two people to install it on the pipe.
3.
4.
5.
Tighten the band lightly by closing the latch (2).
Check the position of the band with the band spacing tool at 0°, 90°, 180° and 270°
(12, 3, 6 and 9 o'clock).
Once the position is verified, tighten the tension screw (1) enough to compress the
spring.
4.3
Adjusting the unit to the band width
CAUTION!
Do not let the Pipeweld Orbiter fall around the band when disengaging the unit.
CAUTION!
Excessive drive wheel pressure can result in damage to wheel.
Various band widths can be accommodated, the most common being 127 mm (5 in.) and
120 mm (4.7 in.). To adjust the bandwidth use the setting screw to increase or decrease the
band width and the locking arm to check for adequate tension.
1. Safety lever
2. Adjustment screw
•
•
•
3. Locking arm
Locking arm in position A: The drive wheel is fully extended allowing the device to be
placed on the band.
Locking arm in position B and travel motor lifted: The Pipeweld Orbiter can be moved
around the band.
Locking arm in position C and travel motor engaged: The Pipeweld Orbiter is locked
and ready to weld.
0463 487 001
- 12 -
© ESAB AB 2019
4 INSTALLATION
WARNING!
The unit is attached to the band only when the lever is in position B or C. Ensure
that all 3 wheels are positioned correctly on the band to avoid accidental
dismounting.
To remove the Pipeweld Orbiter from the pipe, return the locking arm to position B, raise the
safety lever and return the arm to position A.
Once the unit is locked on the band, the drive motor can be disengaged from the drive wheel
by pulling the end cap of the drive motor. The Pipeweld Orbiter can now be moved freely
around the band for rapid repositioning.
4.4
Mounting the unit on the travel band
WARNING!
Care must taken to ensure the unit is installed properly on the band to avoid it
falling.
When installing the unit on to the travel band lift the unit using the two handles shown on the
illustration below.
1. Handle
2. Drive roll
3. Idle roll
For ease of installation first position the drive roll to the band and follow with the two idle
rolls. Once located lock in position with the safety lever shown in the last section.
0463 487 001
- 13 -
© ESAB AB 2019
4 INSTALLATION
Both the drive and idle wheels are dual type. When installing the unit onto the band the
uppermost wheel must be mounted on the band. The lower wheel is now located on the latch
plate allowing seamless travel over the joint in the band.
0463 487 001
- 14 -
© ESAB AB 2019
5 OPERATION
5
OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY"
chapter of this manual. Read it through before you start using the equipment!
WARNING!
Always wear recommended personal safety equipment, such as safety glasses,
safety shoes and flame-proof clothing when operating the equipment. The torch, the
unit and its handles may become hot during and after use, safety gloves should be
worn at all times.
5.1
1.
2.
3.
4.
5.
6.
Overview
Wire feed motor
Torch assembly
Stepper motor
Button for manual torch adjustment (*)
Remote pendant box
Tip control motor
7. Control box
8. Hand help programming unit (HHPU)
9. Welding cable
10. Power supply/Gas box
11. Drive motor
12. Spool
(*) When in run-idle mode, pressing this button enables manual adjustment of the torch
position.
WARNING!
Care should be taken to ensure any power source being used is switched to
Mig/Mag mode and has contactor control to avoid the unit becoming live when not
welding.
0463 487 001
- 15 -
© ESAB AB 2019
5 OPERATION
5.2
1.
2.
3.
4.
5.
6.
Connections and control devices
Power input (110/230 V)
DC power lead connection
Gas cylinder connection
Input fuse (4 A)
Power source contactor lead
Gas hose connection to Pipeweld
Orbiter
7. Connection for stepper motor (red)
8. Connection to tip control motor (grey)
9. Connection for travel motor (green)
10. Fuse (6.3 A)
11. Connection for wire feed motor (yellow)
12. Connection for remote pendant
Before starting the welding, it is necessary to connect the system to the power supply/gas
box.
0463 487 001
- 16 -
© ESAB AB 2019
5 OPERATION
5.2.1
1.
2.
3.
4.
5.
Control box operation
Control lamp for operation
Power switch
Display
Program selection switch
Control selection switch
6.
7.
8.
9.
Welding direction switch
Test button
HHPU socket
Warning lamp for errors
Control switch operation
Position
Display text
Test button pushed
RUN
Run
Run mode enables remote pendant control
CAL.T
CalT
Runs travel motor for 12 s
CAL.W
CalW
Runs wire feed motor for 6 s
CAL.O
CalW
Runs oscillator for 15 s
TRAVEL
Travel Speed
Runs travel motor
WIRE
Wire Speed
Runs wire feed motor (used to run wire to torch)
OSC
Osc Parameters Runs oscillator
CONT
Cont
Tests power source contactor circuits
GAS
Gas
Tests gas flow to torch
Starting the control box
Operating the power switch illuminates the display LEDs to indicate the fuse is functioning
and 24 V is present from the power supply unit.
The Run and error LEDs flash and the display scrolls through ESAB Pipeweld Orbiter,
software version number and board number. After approximately 6 s the display is
determined by the position of the control switch.
0463 487 001
- 17 -
© ESAB AB 2019
5 OPERATION
5.2.2
Remote pendant box
Button operation in idle mode
1
Tip up/down, far/near
Provides torch horizontal and vertical control.
2
+ OSC / – OSC
Runs the oscillator at pre-set parameter settings.
3
+ TRAV / – TRAV
Runs travel motor at high speed.
Button operation in weld mode
4
CYCLE
Initiates the welding sequence.
Enables gas flow and after the pre-purge delay starts the
travel and oscillator motors.
Enables the travel and oscillator buttons to allow these
motors to be varied within the pre-set limits.
5
ARC
Outputs the power source contactor signal and starts the
wire feed motor.
6
STOP
Initiates the shut down sequence.
Stops travel motor.
Centralises and stops oscillator motor.
Starts crater fill delay, then stops wire motor.
Starts burn back delay and then removes contactor signal.
Starts post-purge delay then removes the gas signal.
NOTE!
If the stop button is pressed for less than 2 s, the system stops but retains any
modified travel speed or oscillator width variables.
If held for longer than 2 s, the display shows LStp and the system reverts back to
the stored parameter settings.
5.2.3
Programming unit - HHPU
The programming unit provides various system functions including:
0463 487 001
- 18 -
© ESAB AB 2019
5 OPERATION
•
•
•
•
Input of welding parameters
Input of system parameters
Test diagnostic mode
Program updates
The unit is menu driven by using a combination of the cursor control buttons together with
ENT, BACK and HOME.
1. Navigation buttons
2. Home button
3. Back button
4. Display
HHPU screen configurations
The following table shows menus for the configurations that can be made with the
programming unit.
0463 487 001
- 19 -
© ESAB AB 2019
5 OPERATION
1.0 WELD PARAMETERS
1.1 MEASUREMENT
UNITS
INCHES
CENTIMETERS
1.2 VIEW SETTINGS
1.3 EDIT SETTINGS
(password protected)
PASS
0–12 passes
WIRE SPEED
0–14.99 m/min
(0–590 in./min)
TRAVEL SPEED
0–1.50 m/min
(0–59 in./min)
OSC. RATIO
e.g. 10 ( 10 osc. per
in.)
OSC. SIZE NEAR
OSC. SIZE FAR
1.4 COPY SETTINGS
(password protected)
OSC. DWELL NEAR
0–250 ms
OSC. DWELL FAR
0–250 ms
FROM PASS xx
e.g. 01
TO PASS xx
e.g. ALL
1.5 TRANSFER SETTINGS HHPU TO BUG
BUG TO HHPU
2.0 SYSTEM PARAMETRS
0463 487 001
- 20 -
© ESAB AB 2019
5 OPERATION
2.1 MEASUREMENT
UNITS
INCHES
2.2 VARIATION %
NO TRV/OSC LOCK
0=locked, 1=unlocked
TRAVEL MAX
e.g. 25%
TRAVEL BUTTON
e.g. 3% per button
press
OSC WIDTH MAX
e.g. 25%
OSC WIDTH BUTTON
e.g. 3% per button
press
FAST TRAVEL SPEED
e.g. 99%
TIP VERTICAL SPEED
e.g. 50%
TIP HORIZONTAL SPEED
e.g. 50%
BURN BACK
0–4999
ms
5s
CRATER FILL
0–1999
ms
2s
PRE PURGE
0–19999
ms
20 s
POST PURGE
0–19999
ms
20 s
TRAVEL 356:1 GB 1 in. WHEEL
17500
WIRE 33:1 GB 1 in. WHEEL
1750
2.3 SET MOTOR SPEED
2.4 DELAYS
CENTIMETERS
2.5 SET TIME & DATE
2.6 TRAVEL & WIRE
CALIBRATION
2.7 EDIT PASSWORD
3.0 TEST MODE
TEST MODE INPUTS
TEST MODE MOTORS
4.0 PROGRAM UPDATES
HHPU PROGRAM INFO
UPDATE HHPU PROGRAM
BUG PROGRAM INF0
UPDATE BUG PROGRAM
DEFAULT SETTINGS
5.0 BUG LAST CHANGED
HHPU SERIAL No.
DATE
0463 487 001
- 21 -
© ESAB AB 2019
5 OPERATION
Example of setting wire speed
0463 487 001
- 22 -
© ESAB AB 2019
5 OPERATION
Example of reprogramming control box software
Connect the portable USB port to the programming unit and insert memory stick.
0463 487 001
- 23 -
© ESAB AB 2019
5 OPERATION
5.3
Weld start
WARNING!
The unit and its handles may become hot during and after use, gloves should be
worn at all times.
Before weld start, adjust the welding tip angle and set the welding direction.
•
•
Set the welding parameters in the programming unit.
Adjust the welding tip angle.
5.3.1
Setting the welding direction
The Pipeweld Orbiter has to be set for the desired welding direction: clockwise or
counterclockwise. The settings are made for the welding torch and the gas hose connection.
1.
Connect the gas hose with the connection for the welding direction to be used, (a) for
clockwise operation (unit moves up), (b) for counterclockwise operation (unit moves
down).
2.
Adjust the welding torch position for the welding direction to be used, (a) flux core
counterclockwise torch position (unit moves down), (b) flux core clockwise torch
position (unit moves up).
0463 487 001
- 24 -
© ESAB AB 2019
5 OPERATION
3.
Set the welding direction to be used with the welding direction switch on the control
box.
○ Switch to up: Clockwise, unit moves up.
○ Switch to down: Counterclockwise, unit moves down.
5.3.2
Adjusting the torch angle
1. Button for manual torch adjustment
Press the red button to manually adjust the torch angle.
Use the release lever to rotate the torch away from the pipe e.g. for cleaning.
0463 487 001
- 25 -
© ESAB AB 2019
5 OPERATION
5.3.3
Adjusting the spool tension
1. Spool holder tension screw
Spool tension is controlled by adjusting the spool holder tension screw. Set the tension
carefully so the spool does not slip when wire is fed.
0463 487 001
- 26 -
© ESAB AB 2019
6 MAINTENANCE
6
MAINTENANCE
CAUTION!
All warranty undertakings from the supplier cease to apply if the customer attempts
any work to rectify any faults in the product during the warranty period.
NOTE!
Regular maintenance is important for safe and reliable operation.
6.1
Routine maintenance
Daily maintenance during normal conditions:
•
•
Remove splatter, excessive dirt and dust from all moving parts.
Inspect components for wear and safe operation.
The motors and gearboxes are sealed units and require no routine maintenance.
6.2
Replacing the drive wheel
1. Shims
2. Drive wheels
3. Spacer
Follow these steps to replace the drive wheels on the underside of the unit.
1.
2.
3.
4.
5.
6.
Turn off the power on the control box.
Ensure that the drive motor is engaged.
Remove the retaining screw from the end of the shaft with an Allen key (4 mm).
Force the spacers (3), shims (1) and drive wheels (2) off the shaft.
Use two levers to ensure that the drive wheels (2) do not tip over on the shaft and
cause damage.
Change the drive wheels (2).
Reinstall the drive wheels (2) in reverse order.
Use the shims (1) to clamp the middle spacer (3) properly.
0463 487 001
- 27 -
© ESAB AB 2019
6 MAINTENANCE
6.3
Replacing the Bowden cable
1. Spring clip
2. Collet nut
3. Clamp plate screw
4. Bowden cable
Follow these steps to replace the Bowden cable.
1.
2.
3.
4.
Turn off the power on the control box.
Release the spring clip (1) and pull the welding wire back onto the spool.
Loosen the collet nut (2) on the torch and the clamp plate screws (3) on the wire feed
block.
Remove the Bowden cable (4) and replace it.
NOTE!
Ensure the replacement Bowden cable (4) has the correct length (355 mm).
5.
6.
Insert the new Bowden cable into the torch and tighten collet nut (2).
Insert the Bowden cable into the wire feed block and tighten clamp plate screws (3).
CAUTION!
Ensure the Bowden cable does not touch the wire feed wheels.
0463 487 001
- 28 -
© ESAB AB 2019
6 MAINTENANCE
6.4
Replacing the welding tip
Follow these steps to replace the welding tip.
1.
2.
3.
4.
Remove gas nozzle from torch.
Loosen the collet nut (1) with pliers and withdraw the tip (2).
Replace the tip (2).
Tighten the collet nut (1) and put the cover into position.
0463 487 001
- 29 -
© ESAB AB 2019
6 MAINTENANCE
6.5
Replacing the wire feed wheels
1. Spring clip
2. Central screw
3. Insulation bushing
Follow these steps to replace the wire feed wheels.
1.
2.
3.
4.
5.
Turn off the power on the control box.
Release the spring clip (1).
Remove the central screw (2) and the cap.
Force the wire feed wheels and the insulation bushing (3) off the shaft.
Reinstall the wire feed wheels in reverse order.
NOTE!
Make sure the gears of the wire feed wheels are meshing.
0463 487 001
- 30 -
© ESAB AB 2019
6 MAINTENANCE
6.6
Removing the control box
1. Screw
2. Sub-plate
Follow these steps to remove the control box.
1.
2.
3.
Turn off the power on the control box.
Remove the two screws (1) from the sub-plate (2) and slide the control box away for
access to the cable connections on the back.
Remove the four cables.
The control box can be removed.
0463 487 001
- 31 -
© ESAB AB 2019
6 MAINTENANCE
6.7
Removing the stepper motor
1. Pinch bolt
2. Cable gland
3. Screw
Follow these steps to remove the stepper motor.
1.
2.
3.
4.
5.
6.
7.
Turn off the power on the control box.
Disconnect the stepper motor cable (red) from the connection box.
Loosen the pinch bolt (1) on the torch knuckle with an Allen key (3 mm).
Pull out the torch assembly.
Remove the cable gland (2) from the case of the stepper motor.
Remove the two screws (3) on either side of the red release button.
Remove the terminal cover.
Remove the four screws retaining the stepper motor to the case with an Allen key
(2.5 mm).
Carefully withdraw the motor from the case to not damage the cables.
Disconnect the cables from the connector block and the red release button.
0463 487 001
- 32 -
© ESAB AB 2019
6 MAINTENANCE
6.8
1.
2.
3.
4.
Removing the drive motor
Cable cover
Top cap
Cable
Main barrel
5.
6.
7.
8.
Screws
Motor
Engagement barrel
Bottom barrel
Follow these steps to remove the drive motor.
1.
2.
3.
4.
5.
6.
7.
Turn off the power on the control box.
Disconnect the drive motor cable (green) from the connection box.
From the underside of the base, remove the four screws retaining the motor assembly
with an Allen key (4 mm).
Take off the motor assembly.
Remove the cable cover (1).
Unscrew the top cap (2) and reposition the cable (3) from the slot.
Unscrew the main barrel (4).
NOTE!
Ensure the cable (3) is not tangled up.
8.
9.
Disconnect the cable (3) from the motor encoder.
Remove the four screws (5) retaining the motor (6) to the engagement barrel (7) with
an Allen key (2.5 mm) and pull it out of the bottom barrel (8).
10. Remove splined gear and spacer.
11. Reinstall in reverse order.
NOTE!
Ensure the cable slot is facing the torch before fitting the assembly to the
base.
0463 487 001
- 33 -
© ESAB AB 2019
6 MAINTENANCE
6.9
Removing the tip control motor (near/far)
1. Screws
2. Terminal cover plate
3. Screws
4. Cover
5. Tip control body
Follow these steps to remove the tip control motor (near/far).
1.
2.
3.
4.
5.
Turn off the power on the control box.
Remove the four screws (1) and take off the terminal cover plate (2) to gain access to
the connector block.
Disconnect wires from connector block.
Remove the three screws (3) from the motor cover (4) and take the cover (4) off.
Take the assembly out of the tip control body (5).
Remove the gear.
Reinstall in reverse order.
NOTE!
Ensure the distance between the carrier inner face and the middle of the gear
is 65 mm (2.56 in).
0463 487 001
- 34 -
© ESAB AB 2019
6 MAINTENANCE
6.10
Removing the tip control motor (up/down)
1. Pivot bolt
2. Quick release plunger
3. Body
4. Guide rails
Follow these steps to remove the tip control motor (up/down).
1.
2.
3.
Remove the top stop block and power the tip up to maximum position.
Turn off the power on the control box.
Remove the four screws and take off the terminal cover plate to gain access to the
connector block (see figure in section "Removing the tip control motor (near/far)").
Disconnect wires from connector block.
0463 487 001
- 35 -
© ESAB AB 2019
6 MAINTENANCE
4.
5.
6.
7.
8.
9.
Remove the torch pivot bolt (1) and pull back the quick release plunger (2).
Remove the torch assembly.
Take the near/far body (3) off the guide rails (4).
From the underside of the base, remove the four screws retaining the tip control unit
and take it off.
Remove the gear from the motor shaft.
Remove the three screws and take off the vertical body from tip control base.
Remove screws to take out the motor.
6.11
Removing the tip control lead screw and barrel (near/far)
1. Torch fixed arm
2. Helical gear
3. Lead screw
4. Screws
5. Barrel
Follow these steps to remove the tip control lead screw and barrel (near/far).
1.
2.
3.
4.
5.
6.
Turn off the power on the control box.
Take off the torch fixed arm (1) with the brass barrel guides (see section "Removal of
bearing housing", step 2–5).
Remove the helical gear (2) from the lead screw (3).
Remove the two screws (4) and take off the torch fixed arm (1).
Unscrew the lead screw (3) from barrel (5).
Refit in reverse.
NOTE!
The helical gear (2) is secured to the lead screw (3) via a grub screw into a
dimple on the shaft. This will give the correct position relative to the mating
gear.
0463 487 001
- 36 -
© ESAB AB 2019
6 MAINTENANCE
6.12
Removing the tip control lead screw and barrel (up/down)
1. Circlip
2. Screws
Follow these steps to remove the tip control lead screw and barrel (up/down).
1.
2.
3.
4.
5.
6.
7.
Remove the top stop block and power the tip up to maximum position.
Turn off the power on the control box.
Remove the near/far body and the tip control unit (see section "Removal of tip control
motor (up/down)", steps 3–6).
Remove the gear from the lead screw.
Remove the circlip (1) from the lead screw and pull the lead screw out from the
bearing.
On the near/far body, remove the three screws (2) and take off the cover and barrel
nut.
Reinstall in reverse with new circlip.
0463 487 001
- 37 -
© ESAB AB 2019
6 MAINTENANCE
6.13
Removing the wire feed motor
1. Pinch bolt
2. Cap
3. Spring clip anchor
4. Wire straightening mechanism
Follow these steps to remove the wire feed motor.
1.
2.
3.
4.
5.
6.
7.
8.
Turn off the power on the control box.
Disconnect the wire feed motor cable (yellow) from the connection box.
Remove the Bowden cable (see section "Replacing the Bowden cable").
Loosen the pinch bolt (1) on the bracket with an Allen key (5 mm).
Unscrew the cap (2) from the bottom of the barrel and remove the cable from the slot.
Lift the wire feed unit out of the bracket.
Remove the wire feed wheels and the spring clip anchor (3).
Remove the splatter guard and the wire straightening mechanism (4) together with the
insulating strip.
9. Remove the wire feed insulation block.
10. Remove the four screws retaining the motor with an Allen key (2.5 mm).
Disconnect the cables from the motor.
0463 487 001
- 38 -
© ESAB AB 2019
6 MAINTENANCE
6.14
Removing the bearing housing
1. Pivot bolt
2. Quick release plunger
3. Fixed arm
4. Brass barrels
5. Bearing housing
Follow these steps to remove the bearing.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Turn off the power on the control box.
Remove the Bowden cable (see section "Replacing the Bowden cable").
Undo the three screws and remove the wire motor bracket assembly.
Remove the torch pivot bolt (1) and pull back the quick release plunger (2).
Remove the torch assembly.
Remove the lead screw retaining screw at the rear of the tip control.
Pull the torch fixed arm (3) with the brass barrel guides (4) away from the body.
Remove the four screws on the bearing housing (5) and take off the housing (5).
When refitting the bearing housing, tighten the four screws on the bearing housing (5)
finger-tight only.
10. Insert both brass barrels (4) and check the brass barrels slide in and out freely to
ensure correct alignment.
11. Tighten screws on the bearing housing (5) properly and recheck the brass barrels (4)
still slide freely.
0463 487 001
- 39 -
© ESAB AB 2019
7 TROUBLESHOOTING
7
TROUBLESHOOTING
7.1
Error codes
E00l-T-OL
Travel motor overload
E002-T-EN
Travel motor encoder error
E003-W-OL
Wire motor O/L
E004-W-EN
Wire motor encoder error
E007-S-OL
Stepper O/L
E008-EPOM
Eprom error
When the system detects any of the above errors, it initiates a control shut down and
displays the appropriate error message on the display.
Pressing the test button resets the software and allows the system to be restarted. If the
error persists, refer to the maintenance manual for corrective action.
E005-V-OL
Up/Down O/L
E006-H-OL
Near/Far O/L
Current overloads on the tip control motors are used to determine when the mechanisms
reach the end of their travel limits. The corresponding error message is displayed until the
appropriate push button is released. These errors do not initiate a control shut down.
Fuses
Control box 6.3 A
RS 537-1307
Valve box 4 A
RS 563-542
7.2
Portable Appliance Testing (PAT)
In the event that you require to verify continued safe operation of the system insulation within
the valve box, the test method shall be in accordance with BS E 60960–1:2006+A1:2010
para. 5 .2.2 using a DC test voltage of 2121 V between the shorted input mains conductors
and safety earth. The voltage applied to the insulation under test is gradually raised from
zero to 2121 V DC and held at that value for 60 s maximum.
0463 487 001
- 40 -
© ESAB AB 2019
8 ORDERING SPARE PARTS
8
ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Pipeweld Orbiter is designed and tested in accordance with the international and European
standards EN 12100:2010, EN 60974-5 and EN 60974-10. On completion of service or
repair work, it is the responsibility of the person(s) performing the work to ensure that the
product still complies with the requirements of the above standards.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see
esab.com. When ordering, please state product type, serial number, designation and spare
part number in accordance with the spare parts list. This facilitates dispatch and ensures
correct delivery.
0463 487 001
- 41 -
© ESAB AB 2019
DIAGRAM
DIAGRAM
0463 487 001
- 42 -
© ESAB AB 2019
DIAGRAM
0463 487 001
- 43 -
© ESAB AB 2019
DIAGRAM
0463 487 001
- 44 -
© ESAB AB 2019
DIAGRAM
0463 487 001
- 45 -
© ESAB AB 2019
DIAGRAM
0463 487 001
- 46 -
© ESAB AB 2019
ORDERING NUMBERS
ORDERING NUMBERS
Ordering no.
Denomination
0459 990 380
Pipeweld Orbiter
0463 488 001
Spare parts list
Type
Technical documentation is available on the Internet at: www.esab.com
0463 487 001
- 47 -
© ESAB AB 2019
WEAR PARTS
WEAR PARTS
Pipeweld Orbiter
Item Qty Ordering no.
Denomination
Notes
1
0459990402
PipeWeld Drive Wheel
30
0459990403
PipeWeld Bowden cable pack
100 0459990404
PipeWeld Welding Tips
1
0459990405
PipeWeld Shroud Assembly
1
0459990406
PipeWeld Wirefeed Ins Block
1
0459990407
PipeWeld Splatter Cover
1
0459990408
PipeWeld Wirefeed wheel set
10
0459990410
PipeWeld leaf spring
10
0459990415
PipeWeld torch body o-ring
1
0459990519
PipeWeld Orbiter Basic
Consumable Kit
0463 487 001
- 48 -
© ESAB AB 2019
ACCESSORIES
ACCESSORIES
0459 990 381
PipeWeld Orbiter Prog Kit
0459 990 382
PipeWeld Orbiter Tool Kit
0459 990 700
Travel Band 10.75" spaced to 6.625"
0459 990 525
8" ID Pipe 10.75"Orbiter Travel Band
0459 990 383
10.75"Orbiter Travel Band
0459 990 384
12.75"Orbiter Travel Band
0459 990 385
14"Orbiter Travel Band
0459 990 386
16"Orbiter Travel Band
0459 990 387
18"Orbiter Travel Band
0459 990 388
20"Orbiter Travel Band
0459 990 389
22"Orbiter Travel Band
0459 990 390
24"Orbiter Travel Band
0459 990 391
26"Orbiter Travel Band
0459 990 392
28"Orbiter Travel Band
0459 990 393
30"Orbiter Travel Band
0459 990 394
32"Orbiter Travel Band
0459 990 395
34"Orbiter Travel Band
0459 990 396
36"Orbiter Travel Band
0459 990 397
38"Orbiter Travel Band
0459 990 398
40"Orbiter Travel Band
0459 990 399
42"Orbiter Travel Band
0459 990 400
44"Orbiter Travel Band
0459 990 401
48"Orbiter Travel Band
0459 990 656
60" Travel band
0459 990 657
72" Travel band
0459 990 658
86" Travel band
0459 990 521
PipeWeld Orbiter HHPU
0459 990 526
Torch Extension Assemble
0464 562 880
External feeder box - Warrior
0463 487 001
- 49 -
© ESAB AB 2019
For contact information visit esab.com
ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising