advertisement
Pipeweld Orbiter
Instruction manual
0463 487 001 GB 20190204 Valid for: serial no. 18020
TABLE OF CONTENTS
2 3 4 1 5
SAFETY
.......................................................................................................
1.1
...............................................................................
1.2
.................................................................................
INTRODUCTION
..........................................................................................
TECHNICAL DATA
......................................................................................
INSTALLATION
............................................................................................
4.1
..................................................................
4.2
.......................................................................
4.3
4.4
Adjusting the unit to the band width
....................................................
Mounting the unit on the travel band
...................................................
OPERATION
................................................................................................
5.1
.................................................................................................
5.2
Connections and control devices
.........................................................
5.2.1
5.2.2
5.2.3
5.3
5.3.1
5.3.2
5.3.3
Control box operation ...........................................................................
Remote pendant box ............................................................................
Programming unit - HHPU....................................................................
................................................................................................
Setting the welding direction ................................................................
Adjusting the torch angle......................................................................
Adjusting the spool tension ..................................................................
6 7
MAINTENANCE
...........................................................................................
6.1
.............................................................................
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
.....................................................................
.................................................................
......................................................................
Replacing the wire feed wheels
............................................................
.....................................................................
.................................................................
.....................................................................
Removing the tip control motor (near/far)
...........................................
Removing the tip control motor (up/down)
..........................................
Removing the tip control lead screw and barrel (near/far)
.................
Removing the tip control lead screw and barrel (up/down)
...............
..............................................................
.............................................................
TROUBLESHOOTING
.................................................................................
7.1
.............................................................................................
7.2
Portable Appliance Testing (PAT)
.........................................................
8
ORDERING SPARE PARTS
........................................................................
DIAGRAM
............................................................................................................
15
8
9
10
5
27
40
41
42
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 Wire diameter solid wire Wire diameter flux cored Max spool diameter Wire spool capacity Travel speed Wire speed Oscillation width pendulum action, max Oscillation dwell independent dwells 200 mm (8 in.) to flat plate 0.8–1.2 mm (0.031–0.047 in.) 1.2 mm (0.047 in.) 200 mm (8 in.) 2.7–5.0 kg (5.9–11.02 lb) 0.15–15 m/min (6–59 in./min) 5–15 m/min (196.85–590.55 in./min) 26 mm (1.02 in.) 0–250 ms Burn back time Crater fill time Gas pre-flow Gas post-flow 0–5 s 0–2 s 0–20 s 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.
28 30 32 34 36 38
Ø Pipe in.
12 14 16 18 20 22 24 26 71 76 81 86 91 97
Ø Pipe mm
31 36 41 46 51 56 61 66
Leg setting
36 33.5
31 28 26 24 22 20.5
19 18 17 16 15.5
14.5
Ø Pipe in.
40 42 44 48 52 56 60 64 68 72 76 80 Straight
Ø Pipe mm
102 107 112 122 132 142 152 163 173 183 183 203 0
Leg setting
14 13 8 7.5
7 7 0 12.5
11.5
10.5
10 9 8.5
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.
3.
4.
5.
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.
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.
2.
Safety lever 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.
2.
Handle 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
Overview
1.
2.
3.
4.
5.
6.
Wire feed motor Torch assembly Stepper motor Button for manual torch adjustment (*) Remote pendant box Tip control motor 7.
8.
9.
11.
12.
Control box Hand help programming unit (HHPU) Welding cable 10.
Power supply/Gas box Drive motor 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
Connections and control devices
1.
2.
3.
4.
5.
6.
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.
8.
9.
10.
11.
12.
Connection for stepper motor (red) Connection to tip control motor (grey) Connection for travel motor (green) Fuse (6.3 A) Connection for wire feed motor (yellow) 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
Control box operation
1.
2.
3.
4.
5.
Control lamp for operation Power switch Display Program selection switch Control selection switch
Control switch operation
6.
7.
8.
9.
Welding direction switch Test button HHPU socket Warning lamp for errors
Position
RUN CAL.T
CAL.W
CAL.O
TRAVEL WIRE OSC CONT GAS
Display text
Run CalT CalW CalW Travel Speed Wire Speed
Test button pushed
Run mode enables remote pendant control Runs travel motor for 12 s Runs wire feed motor for 6 s Runs oscillator for 15 s Runs travel motor Runs wire feed motor (used to run wire to torch)
Osc Parameters Cont Gas
Runs oscillator Tests power source contactor circuits 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 3 + OSC / – OSC + TRAV / – TRAV
Button operation in weld mode
Runs the oscillator at pre-set parameter settings.
Runs travel motor at high speed.
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 6 STOP Outputs the power source contactor signal and starts the wire feed motor.
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.
2.
Navigation buttons Home button 3.
4.
Back button 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 1.2 VIEW SETTINGS 1.3 EDIT SETTINGS (password protected) INCHES CENTIMETERS PASS WIRE SPEED TRAVEL SPEED OSC. RATIO OSC. SIZE NEAR OSC. SIZE FAR 1.4 COPY SETTINGS (password protected) OSC. DWELL NEAR OSC. DWELL FAR FROM PASS xx TO PASS xx 1.5 TRANSFER SETTINGS HHPU TO BUG BUG TO HHPU 2.0 SYSTEM PARAMETRS
0–12 passes 0–14.99 m/min (0–590 in./min) 0–1.50 m/min (0–59 in./min) e.g. 10 ( 10 osc. per in.) 0–250 ms 0–250 ms e.g. 01 e.g. ALL 0463 487 001
- 20 -
© ESAB AB 2019
5 OPERATION
2.1 MEASUREMENT UNITS 2.2 VARIATION % INCHES CENTIMETERS NO TRV/OSC LOCK TRAVEL MAX TRAVEL BUTTON OSC WIDTH MAX OSC WIDTH BUTTON 2.3 SET MOTOR SPEED 2.4 DELAYS FAST TRAVEL SPEED TIP VERTICAL SPEED TIP HORIZONTAL SPEED BURN BACK CRATER FILL PRE PURGE POST PURGE 2.5 SET TIME & DATE 2.6 TRAVEL & WIRE CALIBRATION 2.7 EDIT PASSWORD 3.0 TEST MODE 4.0 PROGRAM UPDATES 5.0 BUG LAST CHANGED TRAVEL 356:1 GB 1 in. WHEEL WIRE 33:1 GB 1 in. WHEEL TEST MODE INPUTS TEST MODE MOTORS HHPU PROGRAM INFO UPDATE HHPU PROGRAM BUG PROGRAM INF0 UPDATE BUG PROGRAM DEFAULT SETTINGS HHPU SERIAL No.
DATE
0=locked, 1=unlocked e.g. 25% e.g. 3% per button press e.g. 25% e.g. 3% per button press e.g. 99% e.g. 50% e.g. 50% 0–4999 ms 0–1999 ms 5 s 2 s 0–19999 ms 0–19999 ms 20 s 20 s 17500 1750 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.
2.
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).
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.
5.3.2
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.
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.
2.
Shims 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.
2.
Spring clip Collet nut 3.
4.
Clamp plate screw 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.
5.
6.
NOTE!
Ensure the replacement Bowden cable (4) has the correct length (355 mm).
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.
2.
Spring clip 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 Follow these steps to remove the control box.
2.
1.
2.
3.
Sub-plate 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.
2.
Pinch bolt 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
Removing the drive motor
1.
2.
3.
4.
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.
Disconnect the cable (3) from the motor encoder.
9.
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.
2.
3.
Screws Terminal cover plate Screws 4.
5.
Cover 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.
2.
Pivot bolt Quick release plunger 3.
4.
Body 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.
6.11
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.
Removing the tip control lead screw and barrel (near/far)
1.
2.
3.
Torch fixed arm Helical gear Lead screw 4.
5.
Screws 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.
2.
Pinch bolt Cap 3.
4.
Follow these steps to remove the wire feed motor.
Spring clip anchor Wire straightening mechanism 1.
2.
3.
4.
5.
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.
6.
7.
Lift the wire feed unit out of the bracket.
Remove the wire feed wheels and the spring clip anchor (3).
8.
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.
2.
3.
Pivot bolt Quick release plunger Fixed arm Follow these steps to remove the bearing.
4.
5.
Brass barrels Bearing housing 1.
2.
3.
4.
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).
5.
6.
Remove the torch assembly.
Remove the lead screw retaining screw at the rear of the tip control.
7.
Pull the torch fixed arm (3) with the brass barrel guides (4) away from the body.
8.
Remove the four screws on the bearing housing (5) and take off the housing (5).
9.
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
7.1
TROUBLESHOOTING
Error codes
E00l-T-OL E002-T-EN E003-W-OL E004-W-EN E007-S-OL E008-EPOM Travel motor overload Travel motor encoder error Wire motor O/L Wire motor encoder error Stepper O/L 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 E006-H-OL Up/Down O/L 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 Valve box 4 A RS 537-1307 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.
0459 990 380 0463 488 001
Denomination
Pipeweld Orbiter Spare parts list Technical documentation is available on the Internet at: www.esab.com
Type
0463 487 001
- 47 -
© ESAB AB 2019
WEAR PARTS
WEAR PARTS
Pipeweld Orbiter Item Qty Ordering no.
1 30 0459990402 0459990403 100 0459990404 1 0459990405 1 1 1 10 10 1 0459990406 0459990407 0459990408 0459990410 0459990415 0459990519
Denomination
PipeWeld Drive Wheel PipeWeld Bowden cable pack PipeWeld Welding Tips PipeWeld Shroud Assembly PipeWeld Wirefeed Ins Block PipeWeld Splatter Cover PipeWeld Wirefeed wheel set PipeWeld leaf spring PipeWeld torch body o-ring PipeWeld Orbiter Basic Consumable Kit
Notes
0463 487 001
- 48 -
© ESAB AB 2019
ACCESSORIES
ACCESSORIES
0459 990 381 0459 990 382 0459 990 700 0459 990 525 0459 990 383 0459 990 384 0459 990 385 0459 990 386 0459 990 387 0459 990 388 0459 990 389 0459 990 390 0459 990 391 0459 990 392 0459 990 393 0459 990 394 0459 990 395 0459 990 396 0459 990 397 0459 990 398 0459 990 399 0459 990 400 0459 990 401 0459 990 656 0459 990 657 0459 990 658 0459 990 521 0459 990 526 0464 562 880 PipeWeld Orbiter Prog Kit PipeWeld Orbiter Tool Kit Travel Band 10.75" spaced to 6.625" 8" ID Pipe 10.75"Orbiter Travel Band 10.75"Orbiter Travel Band 12.75"Orbiter Travel Band 14"Orbiter Travel Band 16"Orbiter Travel Band 18"Orbiter Travel Band 20"Orbiter Travel Band 22"Orbiter Travel Band 24"Orbiter Travel Band 26"Orbiter Travel Band 28"Orbiter Travel Band 30"Orbiter Travel Band 32"Orbiter Travel Band 34"Orbiter Travel Band 36"Orbiter Travel Band 38"Orbiter Travel Band 40"Orbiter Travel Band 42"Orbiter Travel Band 44"Orbiter Travel Band 48"Orbiter Travel Band 60" Travel band 72" Travel band 86" Travel band PipeWeld Orbiter HHPU Torch Extension Assemble 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
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
advertisement