Manual [EN]
precision.
power.
simplicity.
Operating
instructions
BRB 2
BRB 4
Pneumatic
Pneumatic/Auto
Electric
Boiler Pipe Preparation
Machines
Code 790 086 762
│
Machine no.:
Translation of original operating instructions
________________________________
All rights reserved, in particular the rights of duplication and distribution as well as translation.
Duplication and reproduction in any form (print, photocopy, microfilm or electronic) require the written
permission of Orbitalum Tools GmbH.
Operating instructions BRB
Table of contents
Table of contents
Page
0
About these instructions
0.1 Warning messages
0.2 Other symbols and displays
0.3 Abbreviations
1
1
2
2
1
Safety instructions
1.1 Intended use
1.2 Improper use
1.3 Machine constraints
1.4 Safety regulations
1.5 Supervised operation
1.6 Working with safety in mind
1.7 Machine shutdown
1.8 Waste disposal
1.9 Other safety regulations
3
3
3
3
4
4
5
6
7
7
2
Product design
2.1 BRB 2 Pneumatic
2.2 BRB 2 Pneumatic/Auto
2.3 BRB 2 Electric
2.4 BRB 4 Pneumatic
2.5 BRB 4 Pneumatic/Auto
2.6 BRB 4 Electric
2.7 Overview of the BRB clamping systems
2.7.1
"Standard" clamping system
2.7.2
"NC" clamping system
2.8 Accessories
2.8.1
Tool holder and multifunctional tools
2.8.2
Bevel heads for BRB 4 (V-seam)
2.8.3
Bevel heads for BRB 2 (V-/Y-seam)
2.8.4
Brush attachments for BRB 4 (for BRB 2 on
request)
2.8.5
Brushes original equipment kit for BRB 4
2.8.6
Threaded spindles for older machines
2.8.7
Depth setting plate
2.8.8
Mobile air unit with lubricator and water extraction
8
8
9
10
11
12
13
13
14
14
15
15
17
17
Features and scope of application
3.1 Features
3.2 Scope of application
3.2.1
Application range BRB with "standard" clamping
system
3.2.2
Application range BRB with "NC" clamping system
3.2.3
Pipe materials
20
20
21
21
21
21
Technical data
4.1 BRB 2
4.2 BRB 4
22
22
22
3
4
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I
Table of contents
II
Operating instructions BRB
5
Initial operation
5.1 Included with the machine
5.1.1
Standard
5.1.2
Additional parts of the "standard" clamping system
5.1.3
Additional parts of the "NC" clamping system
23
23
23
23
24
6
Transport and storage
25
7
Preparation
7.1 Connection requirements
7.1.1
BRB Pneumatic and BRB Pneumatic/Auto
7.1.2
BRB Electric
26
26
26
27
8
Clamping wedge and mandrel assembly BRB 2
8.1 Overview of clamping wedges and mandrel
8.1.1
BRB 2 with "standard" clamping system
8.1.2
BRB 2 with "NC" clamping system
8.2 Replacing the clamping wedges: BRB 2 "Standard"
8.2.1
Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 12.75
8.2.2
Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 19.05
8.3 Replacing the clamping wedges: BRB 2 "NC"
8.3.1
Replacing the clamping wedges:
BRB 2 "NC" with mandrel Ø 19.05 mm
8.3.2
Replacing the clamping wedges:
BRB 2 "NC" Pneu/Auto with mandrel Ø 19.05 mm
8.4 Replacing the mandrel: BRB 2 "standard"
8.4.1
Removing the mandrel:
BRB 2 "standard" with mandrel Ø 12.75
8.4.2
Fitting the mandrel:
BRB 2 "standard" with mandrel Ø 12.75
8.4.3
Removing the mandrel:
BRB 2 "standard" Auto with mandrel Ø 12.75
8.4.4
Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 12.75
8.4.5
Removing the mandrel:
BRB 2 "standard" with mandrel Ø 19.05
8.4.6
Fitting the mandrel:
BRB 2 "standard" Ø 19.05
8.4.7
Removing the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05
8.4.8
Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05
8.5 Replacing the mandrel: BRB 2 "NC"
8.5.1
Removing the mandrel:
BRB 2 "NC" with mandrel Ø 19.05
8.5.2
Fitting the mandrel:
BRB 2 "NC" with mandrel Ø 19.05
8.5.3
Removing the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05
8.5.4
Fitting the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05
28
28
28
28
29
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Operating instructions BRB
9
Table of contents
Clamping wedge and mandrel assembly BRB 4
9.1 Overview of clamping wedges, clamping attachment and
mandrel
9.1.1
BRB 4 with "standard" clamping system
9.1.2
BRB 4 with "NC" clamping system
9.2 Replacing the clamping wedges: BRB 4 "standard"
9.2.1
Replacing the clamping wedges:
BRB 4 "standard" with mandrel Ø 19.05 and
Ø 31.50
9.3 Replacing the clamping wedges: BRB 4 "NC"
9.3.1
Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 19.05
9.3.2
Replacing the clamping wedges:
BRB 4 "NC" Auto with mandrel Ø 19.05
9.3.3
Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 34.50 and BRB 4 "NC"
Auto with mandrel Ø 34.50
9.4 Replacing the mandrel: BRB 4 "standard"
9.4.1
Replacing the mandrel:
BRB 4 "standard" with mandrel Ø 19.05 and
Ø 31.50
9.4.2
Replacing the mandrel:
BRB 4 "standard" Auto with mandrel Ø 19.05 and
Ø 31.50
9.5 Replacing the mandrel: BRB 4 "NC"
9.5.1
Replacing the mandrel:
BRB 4 "NC" with mandrel Ø 19.05 and Ø 34.50
9.5.2
Fitting the mandrel:
BRB 4 "NC" with mandrel Ø 19.05 and Ø 34.50
9.5.3
Removing the mandrel:
BRB 4 "NC" Auto with mandrel Ø 19.05 and
Ø 34.50
9.5.4
Fitting the mandrel:
BRB 4 "NC" Auto with mandrel Ø 19.05 and
Ø 34.50
10 Machining the pipe
10.1 Mounting the BRB in the pipe to be machined
10.1.1 Distance A
10.1.2 Machining the pipe with BRB Pneumatic and BRB
Electric
10.1.3 Machining the pipe with BRB Pneumatic/Auto
10.2 Fitting the multifunctional tool (MFW) and tool holder (WH)
10.3 Switching on the BRB
10.3.1 EMERGENCY STOP function for BRB Pneumatic
and BRB Pneumatic/Auto
10.3.2 EMERGENCY STOP function for BRB Electric
10.4 Setting the speed
10.4.1 Increasing the speed
10.4.2 Reducing the speed
10.4.3 Determining the speed
10.5 Machining the pipe
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49
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54
55
56
57
58
59
59
59
61
64
65
67
67
68
68
68
69
70
III
Table of contents
Operating instructions BRB
10.6 Switching off the BRB
IV
72
11 Fitting and operating accessories
11.1 Brush attachments
11.1.1 Fitting the "large" brush on the "standard" clamping
system
11.1.2 Fitting the "small" brush on the "standard" clamping
system
11.1.3 Fitting the "large" brush on the "NC" clamping
system
11.1.4 Fitting the "small" brush on the "NC" clamping
system
11.2 Hoist Bracket
11.3 Depth setting plate
11.4 BRB retrofit kits
11.4.1 BRB "dimension extension" retrofit kits
11.4.2 BRB "Pneumatic to Auto" retrofit kits
11.4.3 BRB clamping system "standard to NC" retrofit kits
73
73
12 Maintenance
78
13 What to do if …?
13.1 Troubleshooting
13.2 Servicing/customer service
79
79
80
14 EC Declaration of Conformity
14.1 BRB Pneumatic BRB Pneumatic/Auto
14.2 BRB Electric
81
81
82
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77
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77
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Operating instructions BRB
0 About these instructions
0
About these instructions
For a quick understanding of these instructions and safe operation of the
machine, all the warning messages, notes and symbols used in these
nstructions are presented here along with their meaning.
0.1
Warning messages
In these instructions, warning messages are used to warn you against the
angers of injury or material damage. Always read and observe these warning
messages!
This is a warning symbol. It warns you about dangers of injury.
Please follow all instructions marked with the safety symbol in
order to avoid injuries or death.
Warning
symbol
Meaning
Imminent danger!
Non-observance could result in death or serious injury.
 Restrictions (if applicable).
DANGER
 Risk-prevention measures
Possible danger!
Non-observance could result in serious injury.
 Restrictions (if applicable).
WARNING
 Risk-prevention measures
Dangerous situation!
Non-observance could result in minor injuries.
ATTENTION
ATTENTION
Dangerous situation!
Non-observance could result in material damage.
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1
0 About these instructions
Operating instructions BRB
0.2
Other symbols and displays
Symbol
Meaning
Important, Note Notes: contain particularly important information to clarify
information.
Instruction: you must take note of this symbol.
0.3
1.
Request for action in a sequence of actions: you have to
take action in this case.

Single request for action: you have to take action in this
case.

Conditional request for action: you have to take action if
the specified condition is met.
Abbreviations
Abbr.
Meaning
BRB Pneumatic
Boiler pipe preparation machine with pneumatic drive
BRB Pneumatic/ Boiler pipe preparation machine with pneumatic drive and
Auto
pneumatic clamping
2
BRB Electric
Boiler pipe preparation machine with electric drive
NC
Clamping system with permanently anchored clamping
wedges
MFW
Multifunctional tool
WH
Tool holder
QTC®
Quick Tool Change
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Operating instructions BRB
Important
1 Safety instructions
Warning: when using electrical tools, the following basic safety
measures need to be observed to prevent electric shock, injury or fire.
Read all these instructions before using this electrical tool and keep
them in a safe place.
1
Safety instructions
The boiler pipe preparation machines (hereinafter referred to as BRB 2 or
BRB 4) are state-of the-art machines. Using these machines in a way other
than that described in this manual can lead to personal injuries to the user or
of third parties. It may also damage the machine or other equipment.
Therefore:

always ensure that the machine is in good working order.

Comply with these safety instructions.

Keep complete documentation close by the machine.
1.1

Only use BRB 2 and BRB 4 to process (face and bevel) metallic pipe ends
up to 2 or 4 inches. The machine should only be used on empty,
deenergized pipes. Temperature range: -15°C to 40°C.
1.2
Improper use

The machine is not intended for use by private consumers. Do not use the
machine on energized piping, in explosive atmospheres or on
contaminated pipes.

Do not use the machine outdoors when it is foggy, raining, during a
thunderstorm or when the relative humidity > 80% (measured at 20°C).
Do not use the BRB as a drive for applications other than those listed under
proper use (chapter 1.1).
1.3
orbitalum tools gmbh
Intended use
Machine constraints

Space requirement/freedom of movement: About 1 m of space for people is
required around all sides of the machine.

Lighting for work: min. 300 lux.

Minimum age of operator: 14 years.
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3
1 Safety instructions
Operating instructions BRB
Safety components that are contaminated or worn are defective!
The failure of safety components can cause physical injury.
 Check defective safety components daily to ensure proper operation.
DANGER
 Clean and maintain the machine every day.
 Inspect the machine and its cables daily for visible signs of damage or
defects, which should be repaired by a specialist if necessary.
 Do not misuse the cable, e.g. by hanging it up or using it to carry the
machine.
 Keep cables away from heat, oil, sharp edges and moving equipment parts.
 Inspect the machine daily for visible signs of damage or defects, which
should be repaired by a specialist if necessary.
1.4

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 Orbitalum Tools spare parts and materials.

Work on the electrical equipment may only be carried out by a qualified
electrician.

Only operate the BRB Pneumatic or BRB Pneumatic/Auto with the ON/OFF
switch on the rotating handle for controlling the speed.

Only operate the BRB Electric if the electrical safety equipment/restart
inhibitor is working.
1.5
4
Safety regulations
Supervised operation

Workshop application: The workshop manager 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.

Outdoor/field application: The site manager 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.
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orbitalum tools gmbh
Operating instructions BRB
1 Safety instructions
1.6
Working with safety in mind
"Make your contribution to safety in the workplace."

Report any unusual machine behavior to the person responsible
immediately.

Be aware of safety aspects at all times when working.

When working with the BRB, wear safety shoes that comply with EN ISO
20345 S3, safety goggles compliant with DIN EN 166, safety gloves
compliant with EN 388 and ear protection compliant with DIN EN 352.
Note: The personal protective equipment (PPE) recommendations are
solely and directly related to the described product. 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 operating company
(employer) from its statutory health and safety at work obligations towards
its employees.

After each work process, switch off the machine and let it run to a stop.

BRB Pneumatic and BRB Pneumatic/Auto: before cleaning, maintenance,
adjustment or repair work, turn off the compressed air supply and allow the
machine to run to a stop.

BRB Electric: pull the power plug before cleaning, maintenance or repair
work and allow the machine to run to a stop.

During operation, keep hands away from the tools.
Damaged insulation!
Fatal electric shock.
 Do not screw any indicators or signs to the electrical tool.
DANGER
 Use stickers.
Metal dust can collect in the housing and cause loss of insulation!
Fatal electric shock.
 Clean the machine every week with dry, oil-free compressed air.
DANGER
Electric shock from damaged plugs!
Death.
 The machine connector plug must fit the socket.
DANGER
orbitalum tools gmbh
 Do not use adapter plugs together with electrical tools with protective
grounding.
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5
1 Safety instructions
Operating instructions BRB
Electric shock from grounded elements!
Death.
DANGER
 Avoid contact with grounded surfaces such as pipes, heaters, stoves or ice
boxes.
Machine noise levels > 80 dB (Laeq [dB(A)])!
Irreversible damage to hearing.
 Wear ear protection that complies with DIN EN 352.
WARNING
Parts can be ejected when working!
Irreversible eye injuries.
 Wear safety goggles that comply with DIN EN 166.
WARNING
Falling objects!
Feet can be irreversibly crushed.
 Wear safety shoes that comply with DIN EN 20345-S3.
WARNING
Sharp-edged chips whirling around!
Irreversible cuts.
 Wear safety gloves that comply with EN 388 (protection level 5).
WARNING
Loose clothing and long hair can get caught in the machine!
 During operation, do not wear loose clothing, e.g. neckties.
 Secure long hair to prevent it being caught up.
WARNING
Threat posed by incorrect usage!
Discomfort & tiredness.
Limited ability to react, and cramps.
WARNING
 Run through some relaxation exercises every 10 minutes.
 Assume an upright and relaxed posture when working.
1.7
Machine shutdown
For descriptions of the EMERGENCY STOP functions, see sections 10.3.1,
p. 67 and 10.3.2, p. 67.
6
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orbitalum tools gmbh
Operating instructions BRB
1 Safety instructions
1.8
(as per RL 2002/96/EC)
Waste disposal

Dispose of chips and used gear lubricant oil according to the regulations.

Discarded electrical 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 to the left
may not be disposed of with household waste in accordance with EU
regulations.

By actively using the available return and collection systems, you contribute
to the reuse, recycling and utilization of electrical (electronic) devices.

Electrical (electronic) used devices contain parts, which must be handled
selectively according to EU regulations. Separate collection and selective
treatment is the basis for environment-friendly disposal and the protection
of human health.

Appliances and products that you bought from us after August 13, 2005 will
be disposed of at no cost in accordance with legal standards after they
have been supplied to us.

We may refuse to accept old appliances that pose a risk to human health or
safety due to contamination produced during use.

The user is responsible for the return of used devices that were put into use
before 13 August 2005. Please contact a disposal center near you for this
purpose.

Important for Germany: our products and machines may not be disposed
of in municipal disposal sites as they are used for industrial purposes only.
1.9
Other safety regulations
Observe country-specific regulations, standards and guidelines.
orbitalum tools gmbh
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7
2 Product design
Operating instructions BRB
2
Product design
2.1
2
1
3
4
5
6
BRB 2 Pneumatic
7
8
9
10
1
2
3
4
5
6
8
9
10 11
11
12
12
13
14
13
*
14
15
*
15
BRB 2 Pneumatic with "standard" clamping system BRB 2 Pneumatic with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Hexagon nut
Clamping disc
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping star knob
Threaded spindle
Actuator unit (P)
Speed regulator*
ON/OFF rotary switch*
½" thread for compressed air attachment
*
For older BRB 2 machines: Restricting stop valve / ON/OFF switch / speed regulator
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Stopper
Clamping wedge attachment
Clamping set ("NC" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping nut
Clamping ratchet
Actuator unit (P)
Speed regulator*
ON/OFF rotary switch*
½" thread for compressed air attachment
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Operating instructions BRB
2 Product design
2.2
BRB 2 Pneumatic/Auto
10
8
2
1
12
9
2
7
3
4
5
11
6
8
1
3
4
13
12
14
13
15
5
6
14
*
16
7
10
11
*
15
BRB 2 Pneumatic/Auto with "standard" clamping
system
BRB 2 Pneumatic/Auto with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Hexagon nut
Clamping disc
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Locking wheel
Pneumatic cylinder
Rotary clamping switch
Rotating knob
Threaded spindle
Actuator unit (P)
Speed regulator*
ON/OFF rotary switch*
½" thread for compressed air attachment
*
For older BRB 2 machines: Restricting stop valve / ON/OFF switch / speed regulator
orbitalum tools gmbh
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Stopper
Clamping wedge attachment
Clamping set ("NC" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Locking wheel
Pneumatic cylinder
Rotary clamping switch
Rotating knob
Actuator unit (P)
Speed regulator*
ON/OFF rotary switch*
½" thread for compressed air attachment
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9
2 Product design
Operating instructions BRB
2.3
1
11
2
3
4
5
6
7
BRB 2 Electric
7
8
9
10
10
2
3
4
5
12
12
13
13
14
14
BRB 2 Electric with "standard" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
Hexagon nut
Clamping disc
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping star knob
Threaded spindle
Actuator unit (EL)
ON/OFF slide switch
Speed regulator
6
8
9 10 11
BRB 2 Electric with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Stopper
Clamping set ("NC" clamping system)
Clamping wedge attachment
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping nut
Clamping ratchet
Actuator unit (EL)
ON/OFF slide switch
Speed regulator
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orbitalum tools gmbh
Operating instructions BRB
2 Product design
2.4
1
2
3
4
5
6
BRB 4 Pneumatic
7
8
9
10
1
2
3
11
12
12
13
13
14
14
15
4
5
6
7
8
9
10 11
BRB 4 Pneumatic with "standard" clamping system BRB 4 Pneumatic with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Clamping disc with threaded spindle
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping ratchet
Threaded spindle
Actuator unit (P)
Safety lever
Restricting stop valve / ON/OFF switch / speed regulator
½" thread for compressed air attachment
orbitalum tools gmbh
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Locking screw
Clamping set ("NC" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping nut
Clamping ratchet
Threaded spindle
Actuator unit (P)
Safety lever
Restricting stop valve / ON/OFF switch / speed regulator
½" thread for compressed air attachment
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11
2 Product design
Operating instructions BRB
2.5
1
2
3
4
5
6
7
BRB 4 Pneumatic/Auto
8
9
1
10
2
3
11
11
12
12
13
13
14
14
4
5
6
7
8
9
10
BRB 4 Pneumatic/Auto with "standard" clamping
system
BRB 4 Pneumatic/Auto with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
12
Clamping disc with threaded spindle
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Locking wheel
Pneumatic cylinder
Rotary clamping switch
Rotating knob
Actuator unit (P)
Safety lever
Restricting stop valve / ON/OFF switch / speed regulator
½" thread for compressed air attachment
Locking screw
Clamping set ("NC" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Locking wheel
Pneumatic cylinder
Rotary clamping switch
Rotating knob
Actuator unit (P)
Safety lever
Restricting stop valve / ON/OFF switch / speed regulator
½" thread for compressed air attachment
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
2 Product design
2.6
1
2
3
4
5
6
BRB 4 Electric
7
8
1
10
2
3
5
6
7
8
9 10 11
12
11
13
14
12
BRB 4 Electric with "standard" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
4
Clamping disc with threaded spindle
Clamping set ("standard" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping ratchet
Threaded spindle
Actuator unit (EL)
ON/OFF switch
Speed regulator
2.7
13
BRB 4 Electric with "NC" clamping system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Locking screw
Clamping set ("NC" clamping system)
Mandrel
Tool mounting plate
Housing
Hoist bracket
Switching lever for feed direction (forward/backward)
Feed ratchet
Clamping nut
Clamping ratchet
Threaded spindle
Actuator unit (EL)
ON/OFF switch
Speed regulator
Overview of the BRB clamping systems
There are two different clamping systems available: "Standard" or "NC".
Please keep in mind the different ranges of the interior diameters for
"Standard" and "NC". There are slight deviations here.
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
13
2 Product design
Operating instructions BRB
2.7.1
"Standard" clamping system
In the "Standard" clamping system, the clamping wedges are connected to one
another via 2 springs.
Application ranges
Pipe ID /
clamping range
Ø
BRB 2
BRB 4
Kit 1
Kit 2
Kit 1
Kit 2
Kit 3
Kit 4
Kit 5
[mm]
12.75 - 25.5
19.1 - 46.0
19.1 - 33.8
32.0 - 61.7
32.0 - 110.8
19.1 - 61.7
19.1 - 110.8
[inch]
0.502 - 1.004
0.752 - 1.811
0.752 - 1.330
1.260 - 2.429
1.260 - 4.370
0.752 - 2.429
0.752 - 4.362
[mm]
50.0 / 12.75
50.0 / 16.0
68.0 / 19.0
68.0 / 27.0
120.0 / 27.0
68.0 / 19.0
68.0 / 27.0
68.0 / 19.0
68.0 / 27.0
120.0 / 27.0
[inch]
1.969 / 0.502
1.969 / 0.630
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
2.677 / 0.748
2.677 / 1.063
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
6
8
4
3
6
7
10
19.05
31.5
Tool mounting
plate Ø
Clamping sets
[pieces]
[mm]
12.75
19.05
19.05
31.5
31.5
19.05
31.5
[inch]
0.502
0.750
0.750
1.240
1.240
0.750
1.240
0.750
1.240
114.3
Mandrel-Ø
Pipe OD
Wall thickness
min. - max.
[mm]
16.75 - 41.5
23.0 - 62.0
64.0
73.0
114.3
73.0
[inch]
0.659 - 1.634
0.906 - 2.441
2.51
2.87
4.50
2.87
4.50
[mm]
2-8
2-8
2 - 15
2 - 15
2 - 15
2 - 15
2 - 15
[inch]
0.079 - 0.315
0.079 - 0.315
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
2.7.2
"NC" clamping system
The new "NC" clamping system, with its clamping wedges firmly anchored in
the mandrel, is ideal for applications where no foreign bodies may enter the
inside of the pipe or a container. The "NC" clamping system provides extra
safety particularly for vertical work. The clamping wedges can be quickly
replaced.
Application ranges
Pipe ID /
clamping range
Ø
BRB 2
BRB 4
Kit 2
Kit 1
Kit 2
Kit 3
Kit 4
Kit 5
[mm]
19.1 - 38.0
19.1 - 38.0
35.0 - 64.0
35.0 - 108.0
19.1 - 64.0
19.1 - 108.0
[inch]
0.752 - 1.490
0.752 - 1.490
1.378 - 2.520
1.378 - 4.252
0.752 - 2.520
0.752 - 4.252
[mm]
50.0 / 16.0
68.0 / 19.0
68.0 / 27.0
120.0 / 27.0
68.0 / 19.0
68.0 / 27.0
68.0 / 19.0
68.0 / 27.0
120.0 / 27.0
[inch]
1.969 - 0.630
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
2.677 / 0.748
2.677 / 1.063
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
6
6
7
18 (8+10)
13
24 (14+10)
19.05
34.5
Tool mounting
plate Ø
Clamping sets
[pieces]
[mm]
19.05
19.05
34.5
34.5
19.05
34.5
[inch]
0.750
0.750
1.358
1.358
0.750
1.358
0.750
1.358
114.3
Mandrel-Ø
Pipe OD
Wall thickness
min. - max.
14
[mm]
23.0 - 62.0
64.0
73.0
114.3
73.0
[inch]
0.906 - 2.441
2.51
2.87
4.50
2.87
4.50
[mm]
2-8
2 - 15
2 - 15
2 - 15
2 - 15
2 - 15
[inch]
0.079 - 0.315
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
2 Product design
2.8
Accessories
Danger of using non Orbitalum parts or accessories!
Diverse physical injuries.
WARNING
 Do not use copy parts or accessories, as these may cause damage to the
machine or injury to the operator.
2.8.1
Tool holder and multifunctional tools
Use:

Facing pipe ends

Beveling various joint geometries on the pipe outer and inner diameter
Depending on usage conditions and/or tool mounting plates, REB tool holders
and REB multifunctional tools can also be used.
Combination
possibilities of tool
holder (WH) and
multifunctional tools
(MFW) for REB and
BRB machines
Code No.
Tool holder
Torx screw
Compatible MFW
790 085 031 with R 0
Tools for prepping "I-seam" weld profiles
790 085 234
WH 4–I
790 085 244
790 085 230
WH 5–I
790 093 224
790 085 030 with R 0.4
790 086 210
WH 12–I–H 20 mm
790 086 220
790 086 060 with R 1.2
790 092 202
WH 15–I–H 20 mm
790 093 226
790 093 037 with R 0
790 092 204
WH 15–I–H 27 mm
790 093 226
790 093 037 with R 0
790 093 202
WH 30–I–H 20 mm
790 093 226
790 093 033 with R 0
790 093 204
WH 30–I–H 27 mm
790 093 226
790 093 033 with R 0
790 093 410
WH 15–I–H 16.5–23 mm
(adjustable)
790 093 226 /
790 093 425
790 093 037 with R 0
Tools for prepping "V-seam" and "Y-seam" weld profiles
790 085 236
WH 5–V–30°
790 093 224
790 085 030 with R 0.4
790 086 214
WH 12–V–30°
790 086 220
790 086 060 with R 1.2
790 086 272
WH 12–V–35°
790 086 220
790 086 060 with R 1.2
790 086 216
WH 12–V–37.5°
790 086 220
790 086 060 with R 1.2
790 093 462
WH 12–V–80°
790 086 220
790 086 060 with R 1.2
790 092 210
WH 15–V–30°
790 093 226
790 093 037 with R 0
790 092 216
WH 15–V–37.5°
790 093 226
790 093 037 with R 0
790 092 212
WH 15–V–60°
790 093 226
790 093 037 with R 0
790 093 468
WH 30–V–15°
790 093 226
790 093 033 with R 0
790 093 476
WH 30–V/U–25°
790 093 226
790 093 033 with R 0
790 093 210
WH 30–V–30°
790 093 226
790 093 033 with R 0
790 093 424
WH 30–V–32.5°
790 093 226
790 093 033 with R 0
790 093 216
WH 30–V–37.5°
790 093 226
790 093 033 with R 0
790 093 404
WH 30–V–45°
790 093 226
790 093 033 with R 0
790 093 470
WH 30–V–50°
790 093 226
790 093 033 with R 0
790 093 472
WH 30–V–55°
790 093 226
790 093 033 with R 0
Tools for prepping "U-seam" weld profiles
orbitalum tools gmbh
790 085 228
WH 5–U–20°
790 093 224
790 085 030 with R 0.4
790 086 208
WH 12–U–10°
790 086 220
790 086 060 with R 1.2
790 086 224
WH 12–U–20°
790 086 220
790 086 060 with R 1.2
790 086 212
WH 12–U–25°
790 086 220
790 086 060 with R 1.2
790 093 408
WH 30–U–7°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 220
WH 30–U–10°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 474
WH 30–U–14°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 468
WH 30–V/U–15°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 218
WH 30–U–20°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 478
WH 30–U–25°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
(08.10) MT_BRB_BA_04_790086762_00.doc
15
2 Product design
Operating instructions BRB
Code No.
Tool holder
Torx screw
Compatible MFW
Tools for "beveling / counterboring"
790 085 232
WH 5–ID–14°
790 093 224
790 093 039 with R 0.4
790 093 406
WH 5–ID–14°
790 093 224
790 093 039 with R 0.4
790 086 218
WH 5–ID–45°
790 093 224
790 086 061 with R 0.4
790 093 402
WH 10–ID–14°
790 093 225
790 093 038 with R 0.8 / 790 093 041 with R 3
790 093 466
WH 10–ID–14°/30 mm deep
790 093 225
790 093 038 with R 0.8 / 790 093 041 with R 3
790 086 296
WH 10–ID–60°
790 093 224
790 093 038 with R 0.8 / 790 093 041 with R 3
790 086 275
WH 10–ID–80°
790 086 220
790 086 062 with R 0.4
790 086 280
WH 12–ID–10°
790 086 217
790 086 060 with R 1.2
790 093 494
WH 10–ID–45°
790 086 219
790 093 040 with R 0.8
790 085 031 with R 0
Tools for prepping "I-seam" weld profiles
790 085 234
WH 4–I
790 085 244
790 085 230
WH 5–I
790 093 224
790 085 030 with R 0.4
790 086 210
WH 12–I–H 20 mm
790 086 220
790 086 060 with R 1.2
790 092 202
WH 15–I–H 20 mm
790 093 226
790 093 037 with R 0
790 092 204
WH 15–I–H 27 mm
790 093 226
790 093 037 with R 0
790 093 202
WH 30–I–H 20 mm
790 093 226
790 093 033 with R 0
790 093 204
WH 30–I–H 27 mm
790 093 226
790 093 033 with R 0
790 093 410
WH 15–I–H 16.5–23 mm
(adjustable)
790 093 226 /
790 093 425
790 093 037 with R 0
Tools for prepping "V-seam" and "Y-seam" weld profiles
790 085 236
WH 5–V–30°
790 093 224
790 085 030 with R 0.4
790 086 214
WH 12–V–30°
790 086 220
790 086 060 with R 1.2
790 086 272
WH 12–V–35°
790 086 220
790 086 060 with R 1.2
790 086 216
WH 12–V–37.5°
790 086 220
790 086 060 with R 1.2
790 093 462
WH 12–V–80°
790 086 220
790 086 060 with R 1.2
790 092 210
WH 15–V–30°
790 093 226
790 093 037 with R 0
790 092 216
WH 15–V–37.5°
790 093 226
790 093 037 with R 0
790 092 212
WH 15–V–60°
790 093 226
790 093 037 with R 0
790 093 468
WH 30–V–15°
790 093 226
790 093 033 with R 0
790 093 476
WH 30–V/U–25°
790 093 226
790 093 033 with R 0
790 093 210
WH 30–V–30°
790 093 226
790 093 033 with R 0
790 093 424
WH 30–V–32.5°
790 093 226
790 093 033 with R 0
790 093 216
WH 30–V–37.5°
790 093 226
790 093 033 with R 0
790 093 404
WH 30–V–45°
790 093 226
790 093 033 with R 0
790 093 470
WH 30–V–50°
790 093 226
790 093 033 with R 0
790 093 472
WH 30–V–55°
790 093 226
790 093 033 with R 0
Tools for prepping "U-seam" weld profiles
790 085 228
WH 5–U–20°
790 093 224
790 085 030 with R 0.4
790 086 208
WH 12–U–10°
790 086 220
790 086 060 with R 1.2
790 086 224
WH 12–U–20°
790 086 220
790 086 060 with R 1.2
790 086 212
WH 12–U–25°
790 086 220
790 086 060 with R 1.2
790 093 408
WH 30–U–7°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 220
WH 30–U–10°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 474
WH 30–U–14°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 468
WH 30–V/U–15°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 218
WH 30–U–20°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
790 093 478
WH 30–U–25°
790 093 226
790 093 034 with R 5 / 790 093 035 with R 2
Tools for "beveling / counterboring"
790 085 232
WH 5–ID–14°
790 093 224
790 093 039 with R 0.4
790 093 406
WH 5–ID–14°
790 093 224
790 093 039 with R 0.4
790 086 218
WH 5–ID–45°
790 093 224
790 086 061 with R 0.4
790 093 402
WH 10–ID–14°
790 093 225
790 093 038 with R 0.8 / 790 093 041 with R 3
790 093 466
WH 10–ID–14°/30 mm deep
790 093 225
790 093 038 with R 0.8 / 790 093 041 with R 3
790 086 296
WH 10–ID–60°
790 093 224
790 093 038 with R 0.8 / 790 093 041 with R 3
790 086 275
WH 10–ID–80°
790 086 220
790 086 062 with R 0.4
790 086 280
WH 12–ID–10°
790 086 217
790 086 060 with R 1.2
790 093 494
WH 10–ID–45°
790 086 219
790 093 040 with R 0.8
790 093 493
WH 10–ID–30°
790 086 219
790 093 040 with R 0.8
Please enquire about the availability of further tools.
16
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
2.8.2
2 Product design
Bevel heads for BRB 4 (V-seam)
The bevel heads with 3 cutting edges provide considerable advantages for
heavy chip removal, i.e. for welded material. The bevel heads can be replaced
like a tool mounting plate. They are available for various bevel angles and can
be adapted to all machines (even older ones).
Bevel head comes with:
 3 multifunctional tools, Code 790 086 060
 3 Torx screws
 3 M6x16 fastening screws in each case
Article
Application range in mm
Max. pipe wall thickness Code
[mm]
[inch]
Bevel head 30° ID 36 mm to OD 78 mm (1.417 - 3.071 inch)
in 3 steps of 5 mm (0.197 inch) distance
10
0.394
790 086 500
Bevel head 45° ID 45 mm to OD 73 mm (1.772 - 2.874 inch)
in 2 steps of 5 mm (0.197 inch) distance
10
0.394
790 086 459
2.8.3
Bevel heads for BRB 2 (V-/Y-seam)
Optimized machining, more uniform and quieter cutting. Includes adjustable
tool holder. The bevel heads can be swapped like a tool mounting plate and
are available for different bevel angles. The bevel heads can be adapted for all
machines (including older models).
Bevel head comes with:
 3 multifunctional tools, Code 790 086 060
 1 multifunctional tool, Code 790 085 030
 4 Torx screws
 3 M5x16 fastening screws in each case
Article
Application range
Kit 1 (ID min. – OD max.)
orbitalum tools gmbh
Code
Kit 2 (ID min. – OD max.)
[mm]
[inch]
[mm]
[inch]
Bevel head 30°
14.5 - 48.0
0.570 - 1.890
–
–
790 085 380
Bevel head 37.5°
14.5 - 48.0
0.570 - 1.890
–
–
790 085 381
Bevel head 45°
14.5 - 48.0
0.570 - 1.890
–
–
790 085 382
Bevel head 30°
–
–
18.0 - 44.0
0.708 - 1.732
790 085 383
Bevel head 37.5°
–
–
18.0 - 44.0
0.708 - 1.732
790 085 384
Bevel head 45°
–
–
18.0 - 44.0
0.708 - 1.732
790 085 385
(08.10) MT_BRB_BA_04_790086762_00.doc
17
2 Product design
Operating instructions BRB
2.8.4
Brush attachments for BRB 4 (for BRB 2 on request)
The new brass brush attachments prevent chips and other foreign bodies from
unintentionally falling into the inside of the pipes, making them particularly
useful for vertical work on containers. The brushes are quick and easy to
mount on the threaded spindle of the new BRB. BRB machines built up to the
year 10/2009 can be retrofitted with a new threaded spindle (see chap. 2.8.6,
p. 18). All brushes can be used for both clamping systems (Standard/NC).
1 packaging unit = 5 brushes. For more information, see section 11.1, p. 73.
Article
Brush attachment
Brush M8/25*
10
–
25
–
33
–
[mm]
19.1 - 24.3
[inch]
0.752 - 0.957
790 086 520
Brush M8/28*
–
–
–
22.1 - 27.3
0.870 - 1.075
790 086 521
Brush M8/31*
–
–
–
25.5 - 30.8
1.004 - 1.213
790 086 522
Brush M8/34*
–
–
–
28.5 - 33.8
1.122 - 1.331
790 086 523
Brush attachment 10
x
–
–
–
–
790 086 497
Brush 10/43
x
–
–
32.0 - 42.1
1.260 - 1.657
790 086 524
Brush 10/53
x
–
–
40.9 - 52.0
1.610 - 2.047
790 086 525
Brush attachment 25
–
x
–
–
–
790 086 498
Brush 25/62,5
–
x
–
50.7 - 61.7
1.996 - 2.429
790 086 526
Brush 25/71
–
x
–
59.4 - 70.4
2.339 - 2.772
790 086 527
Brush 25/81
–
x
–
69.2 - 80.2
2.724 - 3.157
790 086 528
Brush attachment 33
–
–
x
–
–
790 086 499
Brush 33/91
–
–
x
79.6 - 90.5
3.134 - 3.563
790 086 529
Brush 33/101
–
–
x
89.4 - 100.4
3.520 - 3.953
790 086 530
Brush 33/112
–
–
x
99.6 - 110.8
3.921 - 4.362
790 086 531
Custom brush**
–
–
–
–
–
790 086 540
*
**
Pipe ID min.-max.
Code
Brush attachment is not necessary because an attachment adapter is included with the brush kit.
When ordering, please specify the required inner diameter of the pipe. The correct brush attachment will
be supplied.
2.8.5
Brushes original equipment kit for BRB 4
Contains all brushes (1 brush per dimension) and attachments as listed in
table, section 2.8.3, p. 17.
Article
Brush attachment
10
25
33
Brushes original equipment kit for
BRB 4
2.8.6
x
x
x
Pipe ID min.-max.
[mm]
[inch]
19.1 - 110.8
0.752 - 4.362
Code
790 086 535
Threaded spindles for older machines
For older machines (up to 10/2009) you can take advantage of the brushes by
replacing the respectiev threaded spindles.
Article
18
Code
Complete threaded spindle for mandrel 19.05 / BRB 4
790 086 190
Complete threaded spindle for mandrel 31.50 / BRB 4
790 086 160
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
2 Product design
2.8.7
Depth setting plate
This depth setting plate ensures uniform depth settings in heat exchanger
applications. The cut-offs can be set flexibly. The spacer is particularly suited
for the BRB Pneumatic/Auto (for assembly information, see section 11.3,
p. 76).
Article
Code
Depth setting plate for BRB 4
790 086 045
Depth setting plate for BRB 2
790 085 055
2.8.8
Mobile air unit with lubricator and water extraction
Can be used together with the BRB Pneumatic and BRB Pneumatic/Auto.
Transportable mobile air unit and connections, consisting of:

Mobile air unit (1), code 790 093 060

Compressed air hose (2), incl. plug nipple (3) with outside thread,
code 790 093 061
1
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
2
3
19
3 Features and scope of application
3
Operating instructions BRB
Features and scope of application
3.1
Features
The BRB 2 and BRB 4 should only be used to process (face and bevel)
metallic pipe ends up to 2 or 4 inches:

Preparation of pipe ends for welding joint geometries that conform with
standards

Replaceable tool mounting plate for machining different pipe diameters
under various operating conditions

QTC® (Quick Tool Change) tool system fastener to attach the tool holder
to the tool mounting plate dia. 120 mm

Tool system with pressure wedges for tool mounting plate dia. 68 mm

Only one multifunctional tool necessary for:
Different machining operations (beveling, facing)
Different pipe wall thicknesses
Different type materials

Additional use of REB tools and holders (see chap. 2.8.1, p. 15).

Tool with multiple cutting edges:
Only one screw is needed to fix and secure each tool
Futura® Balinit tool coating

"Standard" clamping system:
3 wedges flexibly connected to allow a change of dimension without a tool

"NC" clamping system:
3 wedges to allow a change of dimension without a tool

Drive:
BRB Pneumatic and BRB Pneumatic/Auto: compressed air motor with
speed limitation using a compressed air control valve with switch-on
prevention
BRB Electric: speed-controlled electric motor
Low-maintenance gears with grease lubrication
20
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orbitalum tools gmbh
Operating instructions BRB
3 Features and scope of application
3.2
Scope of application
3.2.1
Type of machine
Pipe ID
Wall thickness steel
BRB 2
Wall thickness
aluminum
Kit 2
Kit 1
Kit 2
Kit 3
Kit 4
Kit 5
[mm]
12.75 - 25.5
19.1 - 46.0
19.1 - 33.8
32.0 - 61.7
32.0 - 110.8
19.1 - 61.7
19.1 - 110.8
[inch]
0.502 - 1.004 0.752 - 1.811
0.752 - 1.330
1.260 - 2.429
1.260 - 4.370
0.752 - 2.429
0.752 - 4.362
2.0 - 10.0
2.0 - 10.0
2.0 - 10.0
2.0 - 10.0
2.0 - 10.0
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
[mm]
1.5 - 5.0
[mm]
[inch]
1.5 - 5.0
1.5 - 5.0
Wall thickness
rustproof steel
Wall thickness
aluminum
2.0 - 6.0
0.059 - 0.197 0.079 - 0.236
Type of machine
Wall thickness steel
2.0 - 6.0
0.059 - 0.197 0.079 - 0.236
[mm]
[inch]
2.0 - 6.0
0.059 - 0.197 0.079 - 0.236
3.2.2
Pipe ID
BRB 4
Kit 1
[inch]
Wall thickness
rustproof steel
Application range BRB with "standard" clamping system
Application range BRB with "NC" clamping system
BRB 2, Kit 2
BRB 4, Kit 1
BRB 4, Kit 2
BRB 4, Kit 3
BRB 4, Kit 4
BRB 4, Kit 5
[mm]
19.1 - 38.0
19.1 - 38.0
35.0 - 64.0
35.0 - 108.0
19.1 - 64.0
19.1 - 108.0
[inch]
0.752 - 1.490
0.752 - 1.490
1.378 - 2.520
1.378 - 4.252
0.752 - 2.520
0.752 - 4.252
[mm]
2.0 - 6.0
2.0 - 10.0
2.0 - 10.0
2.0 – 10.0
2.0 - 10.0
2.0 - 10.0
[inch]
0.079 - 0.236
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
0.079 - 0.254
[mm]
2.0 - 6.0
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
2.0 - 8.0
[inch]
0.079 - 0.236
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
0.079 - 0.203
[mm]
2.0 - 6.0
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
2.0 - 15.0
[inch]
0.079 - 0.236
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
0.079 - 0.590
3.2.3
Pipe materials

Unalloyed and low-alloy steels

High-alloy steels (high-grade steel, material no. 1.40. – 1.45. in accordance
with DIN 17 455 and DIN 17 456)

Aluminum
Others on request
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
21
4 Technical data
Operating instructions BRB
4
Technical data
The dimensions and the weight are different for machines with the "standard"
clamping system and machines with the "NC" clamping system.
4.1
BRB 2
BRB 2 Pneumatic
BRB 2 Pneumatic/Auto
BRB 2 Electric
Dimensions with the "standard"
clamping system
[mm]
[inch]
400 x 350 x 50
15.7 x 13.8 x 1.2
400 x 480 x 120
15.7 x 18.9 x 4.7
380 x 350 x 50
15 x 13.8 x 1.2
Dimensions with the "NC"
clamping system
[mm]
[inch]
400 x 360 x 50
15.7 x 14.2 x 1.2
400 x 505 x 120
15.7 x 19.9 x 4.7
380 x 360 x 50
15 x 14.2 x 1.2
Weight gross/net, approx.
[kg]
[lbs]
12.5 / 5.6
27.6 / 12.3
13.8 / 5.6
30.4 / 12.3
13.0 / 4.7
28.7 / 10.4
Power
[kW]
[hp]
0.38
0.51
0.38
0.51
0.5
0.67
Air consumption (at 6 bar)
[m³/min] 0.7
0.7
–
Power supply
[V, Hz]
–
120 V. 50/60 Hz
230 V. 50/60 Hz
Speed max. idling speed
[min–1]
120
120
118
LAeq sound pressure level, 1 m*
[dB (A)]
approx. 82
(mid-range speed)
approx. 82
(mid-range speed)
approx. 76
(mid-range speed)
Vibration level that complies with
EN 28662, Part 1
[m/s²]
2.5
2.5
2.5
–
*) The noise level was measured under normal operating conditions in accordance with EN 23741.
4.2
BRB 4
BRB 4 Pneumatic
BRB 4 Pneumatic/Auto
BRB 4 Electric
Dimensions with the "standard"
clamping system
[mm]
[inch]
533 x 120 x 454
21.0 x 4.7 x 17.9
529 x 120 x 610
20.8 x 4.7 x 24.0
471 x 120 x 380
18.5 x 4.8 x 15.0
Dimensions with the "NC"
clamping system
[mm]
[inch]
531 x 120 x 454
20.9 x 4.7 x 17.9
642 x 120 x 610
25.3 x 4.7 x 24.0
471 x 120 x 378
20.9 x 4.8 x 14.9
Weight gross/net, approx.
[kg]
[lbs]
19.3 / 9.3
42.5 / 20.5
24.4 / 13.3
53.8 / 29.3
26.4 / 11.4
58.2 / 25.1
Power
[kW]
[hp]
1.0
1.34
1.0
1.34
1.53
2.05
Air consumption (at 6 bar)
[m³/min] 1.2
1.2
–
Power supply
[V, Hz]
–
–
120 V. 50/60 Hz
230 V. 50/60 Hz
Speed max. idling speed
[min–1]
0 - 110
0 - 110
17 - 35
LAeq sound pressure level, 1 m*
[dB (A)]
approx. 84
(mid-range speed)
approx. 84
(mid-range speed)
approx. 82
(mid-range speed)
Vibration level that complies with
EN 28662, Part 1
[m/s²]
2.5
2.5
2.5
*) The noise level was measured under normal operating conditions in accordance with EN 23741.
22
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orbitalum tools gmbh
Operating instructions BRB
5 Initial operation
5
Initial operation
 Check delivery for completeness and damage caused by transport.
Checking the parts
of delivery
 Report any missing parts or damage caused by transport to your supplier
immediately.
5.1
Included with the machine
5.1.1
Subject to change
Standard

1 BRB 2 or BRB 4 boiler pipe preparation machine

1 durable storage and shipping case

Tool mounting plates, clamping sets and mandrel, depending on the
machine kit and clamping system (summary tables: section 5.1.2, p. 23 and
section 5.1.3, p. 24).

1 KSS-TOP cooling/cutting lubrication spray pump (Code 790 060 226)

1 tool key set

1 integrated lug for balancer attachment

1 set operating instructions and 1 spare parts list
5.1.2
Additional parts of the "standard" clamping system
For information on replacing the individual components:
 BRB 2: see chapter 8, p. 28.
 BRB 4: see chapter 9, p. 44.
Type of machine
BRB 2, Kit 1
BRB 2, Kit 2
BRB 4, Kit 1
BRB 4, Kit 2
BRB 4, Kit 3
BRB 4, Kit 4
BRB 4, Kit 5
4
-
3
-
3
3 clamping
attachments
4
3
-
4
3
3 clamping
attachments
Clamping sets
[pieces]
6
8
Threaded
spindle (M8)
with clamping
disc-Ø
[mm]
12.0
18.8
18.8
-
30.0
30.0
18.8
30.0
18.8
30.0
[inch]
0.472
0.740
0.740
-
1.181
1.181
0.740
1.181
0.740
1.181
[mm]
12.75
19.05
19.05
-
31.50
31.50
19.05
31.50
19.05
31.50
[inch]
0.502
0.750
0.750
-
1.240
1.240
0.750
1.240
0.750
1.240
[mm]
50.0 / 12.75
50.0 / 16.0
68 / 19
-
68 / 27
-
120 / 27
68 / 19
68 / 27
-
68 / 19
68 / 27
120 / 27
[inch]
1.969 / 0.502
1.969 / 0.630
2.677 / 0.748
-
2.677 / 1.063
-
4.724 / 1.063
2.677 / 0.748
2.677 / 1.063
-
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
Mandrel-Ø
Tool mounting
plate-Ø
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
23
5 Initial operation
Operating instructions BRB
5.1.3
Additional parts of the "NC" clamping system
For information on replacing the individual components:
 BRB 2: see chapter 8, p. 28.
 BRB 4: see chapter 9, p. 44.
Type of machine
Clamping sets
Mandrel-Ø with
clamping wedge
attachment
BRB 2, Kit 2
BRB 4, Kit 2
BRB 4, Kit 3
BRB 4, Kit 4
BRB 4, Kit 5
6
-
8
-
8
2 clamping
attachments
6
8
-
6
8
2 clamping
attachments
[pieces]
6
[mm]
19.05
19.05 (small)
-
34.50 (large)
34.50
19.05
34.50
19.05
34.50
[inch]
0.750
0.750
-
1.358
1.358
0.750
1.358
0.750
1.358
[mm]
50.0 / 16.0
68 / 19
-
68 / 27
-
120 / 27
68 / 19
68 / 27
-
68 / 19
68 / 27
120 / 27
[inch]
1.969 / 0.630
2.677 / 0.748
-
2.677 / 1.063
-
4.724 / 1.063
2.677 / 0.748
2.677 / 1.063
-
2.677 / 0.748
2.677 / 1.063
4.724 / 1.063
Tool mounting
plate-Ø
24
BRB 4, Kit 1
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
6
6 Transport and storage
Transport and storage
BRB Electric:
Danger of death by electric shock.
 Disconnect the BRB from the power supply prior to transport.
DANGER
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Disconnect the BRB from the power supply prior to transport.
The BRB 4 is very heavy when transported in its case (26 kg)!
Risk of overstraining.
ATTENTION
 Use appropriate lifting equipment to transport the BRB 4 over long
distances.
Incorrect machine storage!
Diverse risks.
 Store the machine in its original case in a dry environment.
ATTENTION
The BRB is a portable, hand-operated machine. Special transport aids are not
required.
 For secure transportation, hold the machine as shown below.
Removing the BRB from its case
orbitalum tools gmbh
BRB transportation
(08.10) MT_BRB_BA_04_790086762_00.doc
25
7 Preparation
Operating instructions BRB
7
Preparation
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
Danger from falling machine and pipe.
Danger of bodily injury.
 Check machine condition and secure it to prevent it falling.
ATTENTION
7.1
7.1.1
Connection requirements
BRB Pneumatic and BRB Pneumatic/Auto
To ensure that the BRB Pneumatic or BRB Pneumatic/Auto functions properly
and safely, the compressed air unit must fulfill the following requirements:
Attention
26

The compressed air network must be capable of providing 0.7 m³/min
(BRB 2) and 1.2 m³/min (BRB 4) at 6 bar.

A mobile air unit (Code 790 093 060) must be connected to the BRB with
lubricator, water separator and pressure reducer (see chap. 2.8.8, p. 19).

The compressed air piping (Code 790 093 061) from the mobile air unit to
the BRB must be no more than 5 m in length.

The preset lubricator with 2 – 3 drops/min must not be changed.

The pressure reducer must not be changed.
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
7 Preparation
7.1.2
BRB Electric
The power connection has to fulfill the following requirements:
orbitalum tools gmbh

1-phase alternating current 230 V, 50/60 Hz or 120 V, 50/60 Hz.
Fault current (FI) protection must be provided by the customer.

Power fuse at least 10 A.
(08.10) MT_BRB_BA_04_790086762_00.doc
27
8 Clamping wedge and mandrel assembly BRB 2
8
Operating instructions BRB
Clamping wedge and mandrel
assembly BRB 2
8.1
Overview of clamping wedges and mandrel
8.1.1
BRB 2 with "standard" clamping system
 Select clamping wedges and mandrel according to the interior diameter of
the pipe to be machined.
Kit Clamping range
[mm/inch]
1
2
12.75 - 25.50
0.502 - 1.004
19.05 - 46.00
0.750 - 1.811
Mandrel-Ø
Code
[mm]
085 270
12.75
085 273
19.05
Clamping sets for interior pipe dia.
[inch]
0.502
0.750
Code
Inner spring washer dia.
[mm]
[inch]
Code
[mm]
[inch]
085 276*
12.75 - 15.50
0.502 - 0.610
085 289
9.6
0.378
085 277*
14.50 - 17.50
0.571 - 0.689
085 288
11.0
0.433
085 278*
16.50 - 19.50
0.650 - 0.768
085 288
11.0
0.433
085 279**
18.50 - 21.50
0.728 - 0.846
085 289
9.6
0.378
085 280**
20.50 - 23.50
0.807 - 0.925
085 288
11.0
0.433
085 281**
22.50 - 25.50
0.886 - 1.004
085 288
11.0
0.433
086 256
19.05 - 24.30
0.750 - 0.957
–
–
–
086 257
22.10 - 27.30
0.870 - 1.075
–
–
–
086 258
25.50 - 30.80
1.004 - 1.213
–
–
–
086 259
28.50 - 33.80
1.122 - 1.331
–
–
–
085 258
32.00 - 36.50
1.260 - 1.437
–
–
–
085 259
35.10 - 39.70
1.382 - 1.563
–
–
–
085 260
38.30 - 42.90
1.508 - 1.689
–
–
–
085 263
41.60 - 46.00
1.638 - 1.811
–
–
–
* Clamping sets, each consisting of 3 loose clamping wedges and 1 spring washer.
** Clamping sets, each consisting of 3 connected clamping wedges and 1 spring
washer.
8.1.2
BRB 2 with "NC" clamping system
 Select clamping wedges and mandrel according to the interior diameter of
the pipe to be machined.
Kit Clamping range
[mm/inch]
2
28
19.1 - 38.0
0.752 - 1.490
Mandrel-Ø
Code
085 290
[mm]
19.05
Clamping sets for interior pipe dia.
[inch]
0.750
(08.10) MT_BRB_BA_04_790086762_00.doc
Code
[mm]
[inch]
086 390
19.1 - 23.0
0.752 - 0.906
086 391
22.0 - 26.0
0.866 - 1.024
086 392
25.0 - 29.0
0.984 - 1.142
086 393
29.0 - 32.0
1.142 - 1.260
086 394
31.0 - 35.0
1.220 - 1.378
086 395
34.0 - 38.0
1.339 - 1.496
orbitalum tools gmbh
Operating instructions BRB
8.2
8 Clamping wedge and mandrel assembly BRB 2
Replacing the clamping wedges: BRB 2
"Standard"
 For the clamping wedge overview, see chap. 8.1.1, p. 28.
 For replacing the clamping wedges of a BRB 2 with "NC" clamping system,
see chap. 8.3, p. 32.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work,
disconnect the BRB from the power supply and let it come to a complete
stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
orbitalum tools gmbh
 Prior to assembly, dismantling, maintenance and adjustment work,
disconnect the BRB from the power supply and let it come to a complete
stop.
(08.10) MT_BRB_BA_04_790086762_00.doc
29
8 Clamping wedge and mandrel assembly BRB 2
8.2.1
Removal
3
1
4
6
1.
Operating instructions BRB
Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 12.75
Remove hexagon nut (1) with size 10 open-end wrench.
5
2
8
Mandrel Ø 12.75 (BRB 2 "standard")
Assembly
BRB 2 "standard" Electric
BRB 2 "standard" Pneumatic/Auto
2.
Remove star knob (2).
BRB 2 Pneumatic/Auto, remove ball-head grip (8).
3.
Pull threaded spindle (3) out in direction of arrow as far as the stop.
4.
Remove clamping disc (4) with size 10 open-end wrench.
5.
Detach clamping wedges (5) and spring washer (6).
6.
Push clamping disc (4) onto insertion aid (7) (Code 790 085 299).
7.
Place selected clamping wedges (5) in clamping disc (4). Loose clamping
wedges first push spring washer (6) over the clamping wedges (5).
8.
Push the complete unit onto threaded spindle (3) and rotate clamping disc
(4) onto the threaded spindle up to the end of the thread.
9.
Push clamping wedges (5) into the mandrel groove.
10. Refit star knob (2).
BRB 2 Pneumatic/Auto, refit ball-head grip (8).
11. Refit hexagon nut (1), lightly tighten only.
4
7
4
30
(08.10) MT_BRB_BA_04_790086762_00.doc
6
5
3
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.2.2
1.
Replacing the clamping wedges:
BRB 2 "standard" with mandrel Ø 19.05
Remove star knob (1).
BRB 2 Pneumatic/Auto, remove ball-head grip (6).
1
6
BRB 2 "standard" Pneumatic und
BRB 2 "standard" Electric
BRB 2 "standard" Pneumatic/Auto
2.
Push threaded spindle (2) out of mandrel (3) in direction of arrow.
3.
Detach clamping wedges (4) from clamping disc (5) and push them down
and off the threaded spindle (2).
4.
Push selected clamping wedges over threaded spindle (2) and insert them
in the clamping disc (5).
5.
Push the threaded spindle with clamping wedges back into the mandrel.
6.
Push clamping wedges (4) into the mandrel groove.
7.
Refit star knob (1).
BRB 2 Pneumatic/Auto, refit ball-head grip (6).
5
2
orbitalum tools gmbh
4
2
3
(08.10) MT_BRB_BA_04_790086762_00.doc
31
8 Clamping wedge and mandrel assembly BRB 2
8.3
Operating instructions BRB
Replacing the clamping wedges: BRB 2 "NC"
 For the clamping wedge overview, see chap. 8.1.2, p. 28.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
32
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.3.1
Replacing the clamping wedges:
BRB 2 "NC" with mandrel Ø 19.05 mm
1.
The mandrel should be positioned in the machine housing (1) so that
dimension "X" is approx. 15 mm (0.591 inch).
2.
Remove stopper (2) with size 12 open-end wrench.
3.
Rotate clamping nut (3) in direction of arrow as far as the stop.
4.
The 3 clamping wedges (4) can now be detached from the clamping
wedge attachment guide (5).
1
X
3
5
4
2
5.
ATTENTION
Insert selected clamping wedges into the clamping wedge attachment
guide.
Tool damage!
 The clamping wedges must not be tilted.
 Ensure that the 3 clamping wedges used are always identical.
orbitalum tools gmbh
6.
Use clamping nut (3) to push the clamping wedge attachment as far as the
stop in the opposite direction to the arrow.
7.
Refit stopper (2) with size 12 open-end wrench.
(08.10) MT_BRB_BA_04_790086762_00.doc
33
8 Clamping wedge and mandrel assembly BRB 2
8.3.2
Operating instructions BRB
Replacing the clamping wedges:
BRB 2 "NC" Pneumatic/Auto with mandrel Ø 19.05 mm
1.
Set rotary tensioning switch (6) on the clamping cylinder to the unclamped
position, see chap. 10.1.3, p. 61.
2.
Remove ball-head grip (1).
3.
Remove stopper (2) with size 12 open-end wrench.
6
2
ATTENTION
4
1
1
4.
Move clamping wedge attachment (3) outward with the aid of threaded
spindle (4) as far as the end of the mandrel.
5.
The 3 clamping wedges (5) can now be detached from the clamping
wedge attachment guide (3).
6.
Insert selected clamping wedges into the clamping wedge attachment
guide (3).
Tool damage!
 The clamping wedges must not be tilted.
 Ensure that the 3 clamping wedges used are always identical.
7.
Move clamping wedge attachment (3) in the opposite direction to arrow by
pulling the threaded spindle (4).
8.
Refit the ball-head knob (1).
9.
Refit stopper (2) with size 12 open-end wrench.
5
2
34
3
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8.4
8 Clamping wedge and mandrel assembly BRB 2
Replacing the mandrel: BRB 2 "standard"
 For the mandrel overview, see chap. 8.1.1, p. 28.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
orbitalum tools gmbh
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
(08.10) MT_BRB_BA_04_790086762_00.doc
35
8 Clamping wedge and mandrel assembly BRB 2
8.4.1
Operating instructions BRB
Removing the mandrel:
BRB 2 "standard" with mandrel Ø 12.75
1.
Remove the clamping wedges (see working steps 1 up to 5, chap. 8.2.1,
p. 30).
2.
Loosen the 3 pressure wedges (1). Dimension "X" = approx. 5 - 6 mm
(0.197 - 0.236 inch).
3.
Remove the 3 cylinder screws (2) on the tool mounting plate (3).
4.
Remove tool mounting plate (3) in the direction of the arrow.
5.
Pull the threaded spindle out of the mandrel.
6.
Use feed ratchet (5) to move mandrel (4) in the direction of the arrow.
7.
Pull mandrel (4) out of the housing (7).
X
1
4
3
6
7
5
2
8.4.2
36
3
Fitting the mandrel:
BRB 2 "standard" with mandrel Ø 12.75
1.
Tool mounting plate (3) must be removed.
2.
Push mandrel (4) into the housing.
3.
Use the feed ratchet to move mandrel (4) in the opposite direction to the
arrow.
4.
Fit tool mounting plate (3) in the opposite direction to the arrow.
5.
Refit the 3 cylinder screws (2) on the tool mounting plate (3).
6.
Push the threaded spindle into the mandrel.
7.
Fit the required clamping wedges (see working steps 6 up to 11,
chap. 8.2.1, p. 30).
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.4.3
Removing the mandrel:
BRB 2 "standard" Auto with mandrel Ø 12.75
1.
Remove the clamping wedges (see working steps 1-5, chap. 8.2.1, p. 30).
2.
Loosen the 3 pressure wedges (1). Dimension "X" = approx. 5 - 6 mm
(0.197 - 0.236 inch).
3.
Remove the 3 cylinder screws (2) on the tool mounting plate (3).
4.
Remove tool mounting plate (3) in the direction of the arrow.
5.
Remove PU hose (4) by pressing the washers on the 2 angle screws (5).
6.
Loosen cylinder screw (6) on clamping cylinder (7) until cylinder rotates.
7.
Rotate the clamping cylinder (7) down from the mandrel.
8.
Pull the threaded spindle out of the mandrel in the opposite direction to the
arrow.
9.
Use locking wheel (9) to pull mandrel (8) out of the housing (10) in the
direction of the arrow.
6
10
X
1
8
3
9
7
5
5
2
8.4.4
3
4
Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 12.75
1.
Tool mounting plate (3) must be removed.
2.
Push mandrel (8) into the housing.
3.
Use the locking wheel to rotate the mandrel (8) into the housing in the
opposite direction to the arrow until approx. 15 mm (0.591 inch) of thread
is visible.
4.
Push the threaded spindle into the mandrel (8) in the direction of the
arrow.
5.
Rotate clamping cylinder (7) onto the mandrel as far as the stop.
6.
Tighten cylinder screw (6) on the clamping cylinder. The screw must press
into the mandrel groove.
7.
Fit the PU hose (4) to both angle screws (5).
8.
Refit tool mounting plate (3) in the opposite direction to the arrow.
9.
Refit the 3 cylinder screws (2) on the tool mounting plate (3).
10. Fit the required clamping wedges (see working steps 6 up to 11,
chap. 8.2.1, p. 30).
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
37
8 Clamping wedge and mandrel assembly BRB 2
8.4.5
Operating instructions BRB
Removing the mandrel:
BRB 2 "standard" with mandrel Ø 19.05
1.
Remove the clamping wedges (see working steps 1 up to 3, chap. 8.2.2,
p. 31).
2.
Use feed ratchet (2) to unscrew mandrel (1) out of the housing in the
direction of the arrow.
3.
Remove tool mounting plate (4) (for later assembly of mandrel dia. 12.75
only).
1
4
3
2
8.4.6
38
Fitting the mandrel:
BRB 2 "standard" Ø 19.05
1.
Fit the tool mounting plate (4).
2.
Push mandrel (1) into the housing.
3.
Use the feed ratchet (2) to rotate the mandrel (1) into the housing in the
opposite direction to the arrow until approx. 15 mm (0.591 inch) of thread
is visible.
4.
Fit the required clamping wedges (see working steps 4 up to 8,
chap. 8.2.2, p. 31).
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.4.7
Removing the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05
1.
Remove the clamping wedges (see working steps 1 up to 3, chap. 8.2.2,
p. 31).
2.
Remove PU hose (1) by pressing the washers on the two angle screws
(2).
3.
Loosen cylinder screw (3) on clamping cylinder (4) until the clamping
cylinder rotates.
4.
Rotate the clamping cylinder (4) down from the mandrel.
5.
Rotate mandrel (5) in the direction of the arrow with the locking wheel (6).
6.
Pull the mandrel out of the housing (7).
7.
Remove tool mounting plate (8) (for assembly of mandrel dia. 12.75 only).
5
3
7
8
6
4
2
2
1
8.4.8
orbitalum tools gmbh
Fitting the mandrel:
BRB 2 "standard" Auto with mandrel Ø 19.05
1.
Fit the tool mounting plate (8).
2.
Push mandrel (5) into the housing.
3.
Use the locking wheel (6) to rotate the mandrel (5) into the housing in the
opposite direction to the arrow until approx. 15 mm (0.591 inch) of thread
is visible.
5.
Rotate clamping cylinder (4) onto the mandrel as far as the stop.
6.
Tighten cylinder screw (3) on the clamping cylinder. The screw must press
into the mandrel groove.
7.
Fit the PU hose (1) to both angle screws (2).
8.
Fit the required clamping wedges (see working steps 4 up to 8,
chap. 8.2.2, p. 31).
(08.10) MT_BRB_BA_04_790086762_00.doc
39
8 Clamping wedge and mandrel assembly BRB 2
8.5
Operating instructions BRB
Replacing the mandrel: BRB 2 "NC"
 For the mandrel overview, see chap. 8.1.2, p. 28.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
8.5.1
1.
2.
3.
4.
Removing the mandrel:
BRB 2 "NC" with mandrel Ø 19.05
Remove the clamping wedges (see working steps 1 up to 4, chap. 8.3.1,
p. 33).
Use mounting aid (1) (Code 790 085 490) to unscrew clamping wedge
attachment (2) and detach it. Warning: Left-hand thread!
Rotate clamping nut (3) down from the mandrel.
Use feed ratchet (4) to unscrew mandrel (5) out of the housing (6) in the
direction of the arrow.
1
6
3
5
2
4
40
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.5.2
Note
Fitting the mandrel:
BRB 2 "NC" with mandrel Ø 19.05
The tool mounting plate (1) for mandrel dia. 19.05 must be fitted!
1.
Push mandrel (2) into housing (3). Watch out for the groove position!
2.
Use feed ratchet (4) to move mandrel (2) in the direction of the arrow until
at least 50 mm of the thread is visible.
3.
Rotate clamping nut (5) onto the mandrel as far as the stop.
4.
Push clamping wedge attachment (6) into the mandrel.
5.
Screw it in with the mounting aid (7) (Code 790 085 490) until the
mounting aid (7) is flush up against the mandrel. Warning, left-hand
thread!
6.
Clamping wedge attachment (6) must now be exactly 3 mm from the end
of the mandrel.
7.
The 3 grooves (8) on the clamping wedge attachment (6) must coincide
with the 3 openings (9) on the mandrel.
8.
Fit the required clamping wedges (see working steps 5 up to 8,
chap. 8.3.1, p. 33).
6
2
1
50
3
5
7
6
9
8
4
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
41
8 Clamping wedge and mandrel assembly BRB 2
8.5.3
Operating instructions BRB
Removing the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05
1.
Remove clamping wedges (1) (see working steps 1 up to 4, chap. 8.3.2,
p. 34).
2.
Remove clamping wedge attachment (2) from the mandrel.
3.
Remove PU hose (3) by pressing the washers on the two angle screws
(4).
4.
Loosen cylinder screw (5) on clamping cylinder (6) until clamping cylinder
(6) rotates.
5.
Rotate the clamping cylinder (6) down from the mandrel.
6.
Loosen headless screw (7) on sleeve (8).
7.
Push sleeve (8) downwards away from the mandrel.
8.
Move the mandrel in the direction of the arrow with the locking wheel (9).
9.
Pull the mandrel out of the housing (10).
10. Remove tool mounting plate (11) (for later assembly of mandrel dia. 12.75
only).
10
7
5
1
2
11
4
4
8
6
9
3
42
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
8 Clamping wedge and mandrel assembly BRB 2
8.5.4
Note
Important
Fitting the mandrel:
BRB 2 "NC" Auto with mandrel Ø 19.05
The tool mounting plate (1) for mandrel dia. 19.05 must be fitted!
1.
Push mandrel (2) into housing (3). Watch out for the groove position!
2.
Use locking wheel (4) to move mandrel (2) in the direction of the arrow
until least 50 mm of the thread is visible.
3.
Push sleeve (5) onto the mandrel thread.
4.
Rotate clamping cylinder (6) onto the mandrel as far as the stop.
5.
Fasten clamping cylinder (6) with cylinder screw (7), press the cylinder
screw into the mandrel groove, if necessary rotating the clamping cylinder
back slightly.
6.
Fix sleeve (5) to the clamping cylinder flange and fasten it with the
headless screw (9).
7.
Push clamping wedge attachment (10) into the mandrel.
The 3 grooves on the clamping wedge attachment must coincide with the
3 openings on the mandrel.
8.
Fit the required clamping wedges (11) (see working steps 5 up to 8,
chap. 8.3.2, p. 34).
1
11
9
2
5
4
orbitalum tools gmbh
7
50
3
10
6
(08.10) MT_BRB_BA_04_790086762_00.doc
43
9 Clamping wedge and mandrel assembly BRB 4
9
Operating instructions BRB
Clamping wedge and mandrel
assembly BRB 4
9.1
Overview of clamping wedges, clamping
attachment and mandrel
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
9.1.1
BRB 4 with "standard" clamping system
 Select clamping wedges, clamping attachment and mandrel according to
the interior diameter of the pipe to be machined.
Overview
Kit 1, Kit 2
Clamping range
[mm]
[inch]
19.1 – 33.8
0.752 – 1.330
32.0 – 61.7
1.260 – 2.429
61.7 – 110.8
2.429 – 4.362
Kit 1
Kit 3
Kit 4
x
x
x
x
x
x
x
x
Kit 5
x
Kit 1: Clamping range 19.1 – 33.8 mm
Kit 2: Clamping range 32.0 – 61.7 mm
Interior pipe Ø wedges [mm]
Interior pipe Ø wedges [mm]
19.1 – 24.3
32.0 – 42.1
Code 790 086 256
Code 790 086 169
22.1 – 27.3
Code 790 086 257
25.5 – 30.8
Code 790 086 258
28.5 – 33.8
Code 790 086 259
44
Kit 2
(08.10) MT_BRB_BA_04_790086762_00.doc
40.9 – 52.0
Code 790 086 170
50.7 – 61.7
Code 790 086 171
–
orbitalum tools gmbh
Operating instructions BRB
9 Clamping wedge and mandrel assembly BRB 4
Kit 3
Interior pipe Ø
wedges [mm]
Clamping range 32.0 – 110.8 mm
Clamping
Clamping
attachment for
attachment for
interior Ø [mm]
interior Ø [mm]
32.0 – 42.1
–
Code 790 086 169
Clamping
attachment for
interior Ø [mm]
–
–
40.9 – 52.0
59.4 – 70.4
79.6 – 90.5
Code 790 086 170
Code 790 086 251
Code 790 086 252
–
50.7 – 61.7
69.2 – 80.2
89.4 – 100.4
99.6 – 110.8
Code 790 086 171
Code 790 086 251
Code 790 086 252
Code 790 086 253
Kit 4
Clamping range 19.1 – 61.7 mm
Interior pipe Ø wedges [mm]
Mandrel [mm]
19.1 – 24.3
Code 790 086 256
22.1 – 27.3
Code 790 086 257
 19.05
25.5 – 30.8
Code 790 086 258
Code 790 086 176
28.5 – 33.8
Code 790 086 259
32.0 – 42.1
Code 790 086 169
40.9 – 52.0
Code 790 086 170
 31.5
50.7 – 61.7
Code 790 086 130
Code 790 086 171
Kit 5
Clamping range 19.1 – 110.8 mm
Interior pipe Ø
wedges [mm]
Clamping
attachment for
interior Ø [mm]
Clamping
attachment for
interior Ø [mm]
Clamping
attachment for
interior Ø [mm]
19.1 – 24.3
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Mandrel
[mm]
Code 790 086 256
22.1 – 27.3
Code 790 086 257
25.5 – 30.8
 19.05
Code 790 086 176
Code 790 086 258
28.5 – 33.8
Code 790 086 259
32.0 – 42.1
Code 790 086 169
40.9 – 52.0
59.4 – 70.4
79.6 – 90.5
Code 790 086 170
Code 790 086 251
Code 790 086 252
50.7 – 61.7
69.2 – 80.2
89.4 – 100.4
99.6 – 110.8
Code 790 086 171
Code 790 086 251
Code 790 086 252
Code 790 086 253
9.1.2
 31.5
Code 790 086 130
BRB 4 with "NC" clamping system
 Select clamping wedges, clamping attachment (can be screwed onto the
clamping wedge) and mandrel (dia. 19.05 or dia. 34.5) according to the
interior diameter of the pipe to be machined.
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
45
9 Clamping wedge and mandrel assembly BRB 4
Overview
Kit 1, Kit 2
Operating instructions BRB
Clamping range
[mm]
[inch]
19.1 – 38.0
0.752 – 1.490
35.0 – 64.0
1.378 – 2.520
63.0 – 108.0
2.480 – 4.252
Kit 1
Kit 2
Kit 3
Kit 4
x
x
x
x
x
x
x
Kit 5
x
x
Kit 1:
Clamping range 19.1 – 38.0 mm
Kit 2:
Clamping range 35.0 – 64.0 mm
Interior pipe Ø wedges [mm]
Interior pipe Ø wedges [mm]
19.1 – 23.0
35.0 – 40.0
Code 790 086 390
Code 790 086 311
22.0 – 26.00
39.0 – 44.0
Code 790 086 391
Code 790 086 312
25.0 – 29.0
43.0 – 48.0
Code 790 086 392
Code 790 086 313
29.0 – 32.0
47.0 – 52.0
Code 790 086 393
Code 790 086 314
31.0 – 35.0
51.0 – 56.0
Code 790 086 394
Code 790 086 315
34.0 – 38.0
55.0 – 60.0
Code 790 086 395
Code 790 086 316
59.0 – 64.0
–
Code 790 086 317
Kit 3
Clamping range 35.0 – 108.0 mm
Interior pipe Ø
wedges [mm]
Clamping
attachment A for
interior Ø [mm]
Clamping
attachment B for
interior Ø [mm]
–
–
–
–
–
–
35.0 – 40.0
Code 790 086 311
39.0 – 44.0
Code 790 086 312
43.0 – 48.0
Code 790 086 313
Mandrel [mm]
47.0 – 52.0
67.0 – 72.0
87.0 – 92.0
Code 790 086 314
Code 790 086 319
Code 790 086 324
 34.5
51.0 – 56.0
71.0 – 76.0
91.0 – 96.0
Code 790 086 441
Code 790 086 315
Code 790 086 319
Code 790 086 324
55.0 – 60.0
75.0 – 80.0
95.0 – 100.0
Code 790 086 316
Code 790 086 319
Code 790 086 324
59.0 – 64.0
79.0 – 84.0
99.0 – 104.0
Code 790 086 317
Code 790 086 319
Code 790 086 324
63.0 – 68.0
83.0 – 88.0
103.0 – 108.0
Code 790 086 317
Code 790 086 319
Code 790 086 324
Kit 4
Clamping range 19.1 – 64.0 mm
Interior pipe Ø wedges [mm]
Mandrel [mm]
19.1 – 23.0
Code 790 086 390
22.0 – 26.00
Code 790 086 391
25.0 – 29.0
Code 790 086 392
 19.05
Code 790 086 381
29.0 – 32.0
Code 790 086 393
31.0 – 35.0
Code 790 086 394
46
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
9 Clamping wedge and mandrel assembly BRB 4
Clamping range 19.1 – 64.0 mm
Interior pipe Ø wedges [mm]
Mandrel [mm]
34.0 – 38.0
Code 790 086 395
35.0 – 40.0
Code 790 086 311
39.0 – 44.0
Code 790 086 312
43.0 – 48.0
Code 790 086 313
 34.5
47.0 – 52.0
Code 790 086 314
Code 790 086 441
51.0 – 56.0
Code 790 086 315
55.0 – 60.0
Code 790 086 316
59.0 – 64.0
Code 790 086 317
Kit 5
Clamping range 19.1 – 108.0 mm
Interior pipe Ø
wedges[mm]
19.1 – 23.0
Code 790 086 390
22.0 – 26.00
Code 790 086 391
25.0 – 29.0
Clamping
attachment B for
interior Ø [mm]
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
47.0 – 52.0
67.0 – 72.0
87.0 – 92.0
Code 790 086 314
Code 790 086 319
Code 790 086 324
51.0 – 56.0
71.0 – 76.0
91.0 – 96.0
Code 790 086 315
Code 790 086 319
Code 790 086 324
Code 790 086 392
29.0 – 32.0
Code 790 086 393
31.0 – 35.0
Code 790 086 394
34.0 – 38.0
Code 790 086 395
35.0 – 40.0
Code 790 086 311
39.0 – 44.0
Code 790 086 312
43.0 – 48.0
Code 790 086 313
orbitalum tools gmbh
Clamping
attachment A for
interior Ø [mm]
55.0 – 60.0
75.0 – 80.0
95.0 – 100.0
Code 790 086 316
Code 790 086 319
Code 790 086 324
59.0 – 64.0
79.0 – 84.0
99.0 – 104.0
Code 790 086 317
Code 790 086 319
Code 790 086 324
63.0 – 68.0
83.0 – 88.0
103.0 – 108.0
Code 790 086 317
Code 790 086 319
Code 790 086 324
(08.10) MT_BRB_BA_04_790086762_00.doc
Mandrel [mm]
 19.05
Code 790 086 381
 34.5
Code 790 086 441
47
9 Clamping wedge and mandrel assembly BRB 4
9.2
Operating instructions BRB
Replacing the clamping wedges: BRB 4
"standard"
 For the clamping wedge overview, see chap. 9.1.1, p. 44.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
9.2.1
Replacing the clamping wedges:
BRB 4 "standard" with mandrel Ø 19.05 and Ø 31.50
1.
Remove clamping ratchet with clamping ratchet nut (1).
BRB 4 Pneumatic/Auto, remove ball-head grip (2).
2.
Pull threaded spindle with clamping disc (3) from mandrel (4) in the
direction of the arrow.
3.
Replace the clamping set (5).
4.
Push the threaded spindle with clamping wedge (3) back into the mandrel.
5.
Refit clamping ratchet with clamping ratchet nut (1).
BRB 4 Pneumatic/Auto, refit ball-head grip (2).
3
4
1
5
48
2
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
9.3
9 Clamping wedge and mandrel assembly BRB 4
Replacing the clamping wedges: BRB 4 "NC"
 For the clamping wedge overview, see chap. 9.1.2, p. 45.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
9.3.1
Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 19.05
 For all the steps to be carried out, see BRB 2, chap. 8.3.1, p. 33.
9.3.2
Replacing the clamping wedges:
BRB 4 "NC" Auto with mandrel Ø 19.05
 For all the steps to be carried out, see BRB 2, chap. 8.3.2, p. 34.
orbitalum tools gmbh
(08.10) MT_BRB_BA_04_790086762_00.doc
49
9 Clamping wedge and mandrel assembly BRB 4
9.3.3
x
1
Operating instructions BRB
Replacing the clamping wedges:
BRB 4 "NC" with mandrel Ø 34.50 and
BRB 4 "NC" Auto with mandrel Ø 34.50
1.
The machine housing (1) should be positioned on the mandrel so that
dimension "X" is approx. 50 mm (1.969 inches).
2.
BRB 4 Pneumatic and Electric, rotate clamping nut (2) in the direction of
the arrow as far as the stop.
3.
BRB 4 Pneumatic/Auto version, insert the piston rod (3) from the clamping
cylinder (4) in the direction of the arrow as far as the stop. The piston rod
is inserted when only approx. 12 mm (0.472 inch) protrudes from the
cylinder in the unclamped position, see chap. 10.1.3, p. 61.
4.
Remove stopper (5) with size 24 open-end wrench.
2
x
5
1
4
5
3
BRB 4 Electric "NC"
ATTENTION
BRB 4 Pneumatic/Auto "NC"
Piston rod in BRB 4 Pneumatic/Auto
5.
The 3 clamping wedges (6) can now be pushed out of the clamping wedge
attachment guide (7) in the direction of the arrow.
6.
Insert selected clamping wedges into the clamping wedge attachment
guide (7).
Tool damage!

The clamping wedges must not be tilted.

Ensure that the 3 clamping wedges used are always identical.
7.
Refit stopper (5) with size 24 open-end wrench.
5
6
7
8
7
50
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orbitalum tools gmbh
Operating instructions BRB
9.4
9 Clamping wedge and mandrel assembly BRB 4
Replacing the mandrel: BRB 4 "standard"
 For the mandrel overview, see chap. 9.1.1, p. 44.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
orbitalum tools gmbh
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
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51
9 Clamping wedge and mandrel assembly BRB 4
9.4.1
Removal
Operating instructions BRB
Replacing the mandrel:
BRB 4 "standard" with mandrel Ø 19.05 and Ø 31.50
1.
Remove clamping wedges (1) (see chap. 9.2.1, p. 48).
2.
Remove clamping ratchet with clamping ratchet nut (2).
3.
Pull threaded spindle with clamping disc (3) from mandrel (4) in the
direction of the arrow.
4.
If the mandrel dia. is 19.05 mm, remove the tool mounting plate (5).
5.
Unscrew the mandrel (4) out of the housing (7) with the feed ratchet (6).
6.
Pull mandrel (4) out of the housing (7).
3
4
5
7
6
2
1
Assembly
52
1.
If the mandrel dia. is 31.5 mm, first fit the tool mounting plate (5).
2.
Push mandrel (4) into housing (7). Watch out for the groove position!
3.
Rotate the mandrel (4) into the housing (7) with the feed ratchet (6).
4.
If the mandrel dia. is 19.05 mm, now fit the tool mounting plate (5).
5.
Push the threaded spindle with clamping wedge (3) into the mandrel (4).
6.
Fit the clamping ratchet with clamping ratchet nut (2).
7.
Fit the required clamping wedges (1) (see chap. 9.2.1, p. 48).
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
9 Clamping wedge and mandrel assembly BRB 4
9.4.2
Removal
Replacing the mandrel:
BRB 4 "standard" Auto with mandrel Ø 19.05 and Ø 31.50
1.
Set the rotary tensioning switch (1) to the unclamped position
(see chap. 10.1.3, p. 61).
2.
Remove the clamping wedges (see chap. 9.2.1, p. 48).
3.
Remove PU hose (2) by pressing the washers on the 2 angle screws (3).
4.
Remove ball-head grip (4).
5.
Loosen cylinder screw (5) on clamping cylinder (6) until the clamping
cylinder rotates.
6.
Rotate the clamping cylinder (6) down from the mandrel (7).
7.
If the mandrel dia. is 19.05 mm, remove the tool mounting plate (8).
8.
Move the mandrel (2) in the direction of the arrow using the locking wheel
(9).
9.
Pull mandrel (2) out of the housing (10).
11
7
10 9
1
5
3
4
8
6
9
2
3
Assembly
orbitalum tools gmbh
1.
The tool mounting plate (8) for mandrel dia. 31.5 mm, must already be
fitted.
2.
Push mandrel (7) into housing (10). Watch out for the groove position!
3.
Rotate mandrel (7) with the locking wheel (9) into the housing (10) in the
direction of the arrow until dimension "X" = 15 mm (0.591 inch).
4.
If the mandrel dia. is 19.05 mm, fit the tool mounting plate (8).
5.
Rotate clamping cylinder (6) onto mandrel (7) as far as the stop.
6.
Fasten clamping cylinder (6) with cylinder screw (5). Cylinder screw (5)
must press into the mandrel groove, if necessary rotate the clamping
cylinder back slightly.
7.
Push the threaded spindle with clamping wedges (11) into the mandrel (7).
8.
Refit the ball-head knob (4).
9.
Reconnect the PU hose (2) to both angle screws (3).
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53
9 Clamping wedge and mandrel assembly BRB 4
9.5
Operating instructions BRB
Replacing the mandrel: BRB 4 "NC"
 For the mandrel overview, see chap. 9.1.2, p. 45.
BRB Electric:
Danger of death by electric shock.
DANGER
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
 Prior to assembly, dismantling, maintenance and adjustment work, disconnect the BRB from the power supply and let it come to a complete stop.
9.5.1
Replacing the mandrel:
BRB 4 "NC" with mandrel Ø 19.05 and Ø 34.50
1.
Remove the clamping wedges (for mandrel dia. 19.05, see chap. 8.3.1,
p. 33 and for mandrel dia. 34.5 see chap. 9.3.3, p. 50).
2.
If the mandrel dia. is 19.05 mm, the tool mounting plate must now be
removed; if the mandrel dia. is 34.5 mm, no tool mounting plate must be
removed.
3.
Use mounting aid (1) (Code 790 085 490) to unscrew clamping wedge
attachment (2) in the direction of the arrow and remove it. Warning,
lefthand thread!
4.
Rotate clamping nut (3) down from the mandrel (5).
5.
Rotate mandrel (5) in the direction of the arrow with the ratchet wheel (4).
6.
Pull mandrel (5) out of the housing (6).
6
3
5
4
1
54
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2
orbitalum tools gmbh
Operating instructions BRB
9 Clamping wedge and mandrel assembly BRB 4
9.5.2
Important
Fitting the mandrel:
BRB 4 "NC" with mandrel Ø 19.05 and Ø 34.50
1.
The tool mounting plate (1) for mandrel dia. 34.5 must already be fitted;
the tool mounting plate for mandrel dia. 19.05 can only be fitted at the end.
2.
Push mandrel (2) into housing (3). Watch out for the groove position!
3.
Use feed ratchet (4) to move mandrel (2) in the direction of the arrow until
least 60 mm of the thread (5) is visible.
4.
Rotate the clamping nut (6) onto the mandrel thread (2) as far as the stop.
5.
Push clamping wedge attachment (7) into mandrel (2) and screw it in with
the mounting aid (8) (Code 790 085 490) until the mounting aid is flush up
against the mandrel. Warning, left-hand thread!
The clamping wedge attachment (7) must now be exactly 12 mm
(0.472 inch) from the end of the mandrel. If the mandrel dia. is 19.05 mm,
this dimension is 3 mm (0.118 inch).
6.
The 3 grooves (9) on the clamping wedge attachment (7) must coincide
with the 3 openings (10) on the mandrel.
7.
Fit the required clamping wedges (see chap. 8.3.1, p. 33 and chap. 9.3.3,
p. 50).
1
7
6
3
10
5
2
4
8
orbitalum tools gmbh
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9
55
9 Clamping wedge and mandrel assembly BRB 4
9.5.3
Operating instructions BRB
Removing the mandrel:
BRB 4 "NC" Auto with mandrel Ø 19.05 and Ø 34.50
1.
Set the rotary tensioning switch (1) to the unclamped position
(see chap. 10.1.3, p. 61).
2.
Remove the clamping wedges (see chap. 8.3.2, p. 34 and chap. 9.3.3,
p. 50).
3.
Pull the clamping wedge attachment (2) out of the mandrel (3).
4.
Loosen PU hose (4) by pressing the washers on the two angle screws (5).
5.
Loosen cylinder screw (6) on clamping cylinder (7) until the clamping
cylinder rotates.
6.
Rotate the clamping cylinder (7) down from the mandrel (3).
7.
Loosen headless screw (8) on sleeve (9).
8.
Push the sleeve (9) down from the mandrel (3).
9.
Mandrel dia. 19.05: remove the tool mounting plate (10).
10 Move the mandrel (3) in the direction of the arrow with the locking wheel
(11).
11. Pull mandrel (3) out of the housing (12).
2
3
12
6
9
1
5
7
10
11
8
4
5
56
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orbitalum tools gmbh
Operating instructions BRB
9 Clamping wedge and mandrel assembly BRB 4
9.5.4
Important
Fitting the mandrel:
BRB 4 "NC" Auto with mandrel Ø 19.05 and Ø 34.50
1.
The tool mounting plate (1) for mandrel dia. 34.05 must already be fitted;
the tool mounting plate for mandrel dia. 19.05 must be fitted at the end.
2.
Push mandrel (2) into housing (3). Watch out for the groove position!
3.
Use locking wheel (4) to move mandrel (2) in the direction of the arrow
until least 70 mm (2.756 inches) of the thread (5) is visible.
4.
Push the sleeve (6) onto the mandrel (2).
5.
Rotate clamping cylinder (7) onto mandrel (2) as far as the stop.
6.
Attach clamping cylinder (7) with cylinder screw (8). The cylinder screw
must press into the mandrel groove, if necessary rotate the clamping
cylinder back slightly.
7.
Fix sleeve (6) to the clamping cylinder flange (7) and fasten it with the
headless screw (9).
8.
Push clamping wedge attachment (10) into mandrel (2) and screw it in
with the mounting aid (11) (Code 790 085 490) until the mounting aid (11)
is flush up against the mandrel. Warning, left-hand thread!
Clamping wedge attachment (10) must now be exactly 12 mm from the
end of the mandrel. If the mandrel dia. is 19.05 mm, this dimension is
3 mm (0.118 inch)
The 3 grooves (12) on the clamping wedge attachment (10) must coincide
with the 3 openings (13) on the mandrel!
9.
Fit the required clamping wedges (see chap. 8.3.2, p. 34 and chap. 9.3.3,
p. 50).
10. Refit the ball-head knob.
13
10
2
1
3
5
4
orbitalum tools gmbh
9
8
6
7
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11
12
57
10 Machining the pipe
Operating instructions BRB
10 Machining the pipe
Note
Because operation of our BRB machines is largely identical, the figures in this
chapter show the steps to be carried out only using the example of a BRB 4
machine.
Danger of bodily injury by trapping fingers between clamping wedges
and pipe!
Clamping wedges trap fingers.
WARNING
 Do not put your fingers between the clamping wedges and the pipe.
BRB Electric:
Pulling the plug as an EMERGENCY STOP is not correct!
Diverse risks.
WARNING
 Do not use cables bent at right angles.
 Under no circumstances use blue, locking CEE plugs..
 Ensure that the plug is easily accessible.
 Simulate an emergency by trying to loosen the plug from a distance.
Risk of falling when screwing cutters into clamping wedges!
The machine can become detached from the pipe and fall to the floor
unchecked.
ATTENTION
 Always return the feed unit to the starting position with the motor switched
off.
Hot surfaces!
Risk of burns.
 Do not touch the pipe surfaces or the cutters.
ATTENTION
Vapor when working with lubricants!
Damage to lungs, skin and the environment.
 Use only KSS-TOP lubricant.
ATTENTION
Poor lighting!
Diverse risks.
ATTENTION
58
 Ensure that the minimum lighting rating is 300/200 lux (working area/
surrounding area).
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orbitalum tools gmbh
Operating instructions BRB
10 Machining the pipe
10.1
Mounting the BRB in the pipe to be machined
10.1.1
Note
Distance A
Distance A (pipe end – clamping wedges) depends on the machining method.
Processing the exterior diameter of the pipe:
Distance A as small as possible but it least 10 mm
Processing the interior diameter of the pipe:
Distance A = length of the tool cutting edge plus 5 mm
A
10.1.2
1.
Neutral position
Machining the pipe with BRB Pneumatic and BRB Electric
Bring the BRB to the neutral position using the feed ratchet.
Thread run out from the mandrel (1) is flush with the feed ratchet.
flush
1
orbitalum tools gmbh
2.
Insert the BRB into the pipe.
3.
Set distance A (see chap. 10.1.1).
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59
10 Machining the pipe
Attaching the
BRB Pneumatic and
BRB Electric to
the pipe
Operating instructions BRB
When the BRB is correctly positioned:
4.
Tighten the threaded spindle (2) by turning the clamping ratchet (3).
2
Detaching the
BRB Pneumatic and
BRB Electric from
the pipe
60
3
To remove the machine from the pipe at a later time:

Loosen the threaded spindle (2) by turning the clamping ratchet (3).
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
10 Machining the pipe
10.1.3
Machining the pipe with BRB Pneumatic/Auto
For the BRB Pneumatic/Auto, the machine is clamped to the pipe pneumatically by means of the rotary switch. The 3 possible lever positions are described
in the figures below:
BRB Standard:
BRB NC:
Neutral position
Neutral position
1.
Neutral position
Clamped position
Unclamped
Unclamped
Clamped position
Rotate the BRB Pneumatic/Auto back to the neutral position with the
locking wheel (1).
Thread run out from the mandrel is flush with the hand wheel.
2.
Turn the rotary switch for clamping (2) to the "Unclamped" position.
1
2
orbitalum tools gmbh
3.
Connect the compressed air and check for minimum pressure (6 bar).
4.
Insert the BRB Pneumatic/Auto into the pipe.
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61
10 Machining the pipe
Operating instructions BRB
Danger of bodily injury!
For clamping with the "standard" clamping variant, the machine is pulled in the
axial direction against the pipe.
DANGER
 Keep body parts from the area between the pipe and tool holder.
 Wear safety gloves.
 Hold the machine as shown below when clamping.
5.
Attaching the
BRB Pneumatic/Auto
to the pipe
Set distance A (see chap. 10.1.1, p. 59).
When the BRB Pneumatic/Auto is correctly positioned:
6.
Turn the rotary switch to the "Clamped position".
7.
Place the tools in the tool holder if necessary (see chap. 10.2, p. 64).
8.
Process the pipe.
Risk of injury!
Danger if the machine inadvertently unclamps.
 Do not touch the rotary tensioning switch during machining.
DANGER
 Wear safety gloves.
 Hold the machine as shown below during machining.
9.
62
Put the feed into the neutral position.
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orbitalum tools gmbh
Operating instructions BRB
Loosening the
BRB Pneumatic/Auto
from the pipe
10 Machining the pipe
To unclamp the machine from the pipe:
10. Hold the machine as shown below. Set the rotary switch to the unclamped
position.
11. Place the machine in a secure place and stop the supply of compressed
air immediately.
BRB Pneumatic and BRB Pneumatic/Auto:
Piping under pressure!
Diverse risks.
ATTENTION
orbitalum tools gmbh
 Hold the hose firmly when detaching it from the pneumatic piping and wear
safety gloves.
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63
10 Machining the pipe
Operating instructions BRB
10.2
Fitting the multifunctional tool (MFW) and
tool holder (WH)
Sharp edges and cutters!
Risk of cuts.
 Wear safety gloves that comply with EN 388 (protection level 5).
ATTENTION
ATTENTION
Tool fracture!
Parts can be ejected.
 Ensure that the cutting tools are correctly mounted.
Up to 3 tool holders can be clamped into the BRB tool mounting plate. This
means that the following types of machining can be carried out simultaneously:

Facing

1. Beveling

2. Beveling / counterboring
Joint preparation is therefore reproducible for other pipe ends.
Mounting
MFW and WH
1.
Select the appropriate multifunctional tool according to the type of
machining (split/combined) indicated in chap. 2.8.1, p. 15).
2.
Screw the multifunctional tool (1) onto the tool holder (2) using a Torx
screwdriver.
3.
Insert the tool holder (2) with fitted multifunctional tool into the guiding
groove (3) and position it.
4.
Tighten the screw (4), at the same time press the tool holder against the
bearing surface of the tool holder.
4
2
2
1
3
Note
To speed up the setup process for the same job in the future:
 Take a reading of the value on the tool holder and make a note of it.
64
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orbitalum tools gmbh
Operating instructions BRB
10.3
10 Machining the pipe
Switching on the BRB
BRB Electric:
Electric shock from bypassing the armature shaft insulation!
Danger of death.
DANGER
 Do not connect anything other than the stipulated safety equipment
between the socket and the machine.
 Connect to a RCD (Residual current device).
Risk of injury if body parts get between the tool bits and the pipe!
Tool bits injure body parts.
 Do not put body parts between the tool bits and the pipe.
WARNING
Machine noise levels > 80 dB (A value)!
Irreversible damage to hearing.
 Wear ear protection that complies with DIN EN 352.
WARNING
Parts can be ejected when working!
Irreversible eye injuries.
 Wear safety goggles that comply with DIN EN 166.
WARNING
Falling objects!
Feet can be irreversibly crushed.
 Wear safety shoes that comply with DIN EN 20345-S3.
WARNING
Sharp-edged chips whirling around!
Irreversible cuts.
 Wear safety gloves that comply with EN 388 (protection level 5).
WARNING
BRB Pneumatic and BRB Pneumatic/Auto:
Dirty pneumatic piping connections!
Diverse risks from uncontrolled detaching of pneumatic piping.
WARNING
orbitalum tools gmbh
 Ensure that the connecting lines are clean.
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65
10 Machining the pipe
Operating instructions BRB
BRB Pneumatic and BRB Pneumatic/Auto:
Threat posed by consistently holding the compressed-air valve in an
unergonomic way!
ATTENTION
Limited ability to react, and cramps.
 Always return the feed unit to the starting position when the deadman's
handle has been triggered.
Attention
Tool damage
A pipe that is not sawn off at right-angles can damage the tool if the distance
between the cutting edge and the pipe end is too small.
 Before switching on the BRB, ensure that there is sufficient distance
between the cutting edge and the pipe end.
66
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orbitalum tools gmbh
Operating instructions BRB
BRB Pneumatic and
BRB Pneumatic/Auto
10 Machining the pipe
1.
Connect the BRB (for information on the connection requirements, see
chap. 7.1.1, p. 26).
2.
Press the ON/OFF switch (1) while simultaneously releasing the safety
lever (2) in the direction of the arrow.
The BRB starts.
10.3.1
EMERGENCY STOP function for BRB Pneumatic and BRB
Pneumatic/Auto
 BRB 4: Activate by releasing the ON/OFF switch (1).
 BRB 2: Activate by releasing the rotating ON/OFF switch (1).
BRB Electric
1.
Connect the BRB (for information on the connection requirements,
see chap. 7.1.2, p. 27).
2.
Actuate the ON/OFF switch (3).
The BRB starts.
10.3.2
EMERGENCY STOP function for BRB Electric
BRB Electric:
Pulling the plug as an EMERGENCY STOP is not correct!
Diverse risks.
WARNING
 Do not use cables bent at right angles.
 Under no circumstances use blue, locking CEE plugs.
 Ensure that the plug is easily accessible.
 Simulate an emergency by trying to loosen the plug from a distance.
 Activate by turning the ON/OFF switch (3) to position "0".
2
1
3
3
ON/OFF switch
BRB Pneumatic and BRB Pneumatic/Auto
Note
ON/OFF switch
BRB 4 Electric
ON/OFF switch
BRB 2 Electric
If the tool vibrates after starting, the cutting speed is too high.
 Reduce the speed (see chap. 10.4.2, p. 68).
orbitalum tools gmbh
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67
10 Machining the pipe
Operating instructions BRB
10.4
Note
The cutting speed recommended by Orbitalum Tools can be found in
chap. 10.4.3, p. 69 and thus used to determine the speed.
10.4.1
BRB Pneumatic and
BRB Pneumatic/Auto
BRB Electric
BRB Electric
2
1
Increasing the speed
1.
Press the ON/OFF switch (1) while simultaneously releasing the safety
lever (2) in the direction of the arrow.
2.
Turn the rotating handle (3) counterclockwise.

Turn the regulator (4) to a higher number.
10.4.2
BRB Pneumatic and
BRB Pneumatic/Auto
Setting the speed
Reducing the speed
1.
Press the ON/OFF switch (1) while simultaneously releasing the safety
lever (2) in the direction of the arrow.
2.
Turn the rotating handle (3) clockwise.

Turn the regulator (4) to a lower number.
3
4
4
Controlling the speed for
BRB Pneumatic and BRB Pneumatic/Auto
68
Controlling the speed for
BRB 4 Electric
(08.10) MT_BRB_BA_04_790086762_00.doc
Controlling the speed for
BRB 2 Electric
orbitalum tools gmbh
Operating instructions BRB
10 Machining the pipe
10.4.3
1.
You can take the recommended cutting speed from the table below.
2.
Determine actual speed.
3.
Increase/reduce the determined speed and compare with the
recommended cutting speed.
Standard values for
speed (n) and cutting
speed (v)
Determining speed(s)
Determining the speed
Exterior pipe Ø
OD
Nominal
width DN
Non-alloy and lowalloy steel
High-alloy steel
[mm]
[inch]
[inch]
v [m/min]
n [1/min]
v [m/min]
n [1/min]
26.9
1.305
¾
approx. 8
94
approx. 5 – 6
65
33.7
1.315
1
approx. 8
76
approx. 5 – 6
52
42.4
1.660
1¼
approx. 8
60
approx. 5 – 6
41
48.3
1.900
1½
approx. 8
53
approx. 5 – 6
36
60.3
2.375
2
approx. 8
42
approx. 5 – 6
29
76.1
2.875
2½
approx. 8
34
approx. 5 – 6
23
88.9
3.500
3
approx. 8
29
approx. 5 – 6
20
101.6
4.000
3½
approx. 8
25
approx. 5 – 6
17
114.3
4.500
4
approx. 8
22
approx. 5 – 6
15
4.
Measure the number of revolutions of the tool mounting plate in one
minute (= speed (n)).
5.
Determine the speed using the following formula:
Speed n = v 1000 = 1 / min 
πd
v
d
n
Note
orbitalum tools gmbh
Cutting speed (m/min)
Exterior pipe Ø DA (mm)
Speed (rpm)
A lower speed reduces the tendency to vibrate.
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69
10 Machining the pipe
Operating instructions BRB
10.5
Machining the pipe
Risk of injury to eyes and hands!
Hot and sharp-edged chips.
 Always wear protective goggles, ear protection and safety shoes.
WARNING
 Remove chips only with safety gloves and using a chips mandrel.
Machine noise levels > 80 dB (A value)!
Irreversible damage to hearing.
 Wear ear protection that complies with DIN EN 352.
WARNING
Parts can be ejected when working!
Irreversible eye injuries.
 Wear safety goggles that comply with DIN EN 166.
WARNING
Falling objects!
Feet can be irreversibly crushed.
 Wear safety shoes that comply with DIN EN 20345-S3.
WARNING
Sharp-edged chips whirling around!
Irreversible cuts.
 Wear safety gloves that comply with EN 388 (protection level 5).
WARNING
70
Note
For cutting, only use the KSS-TOP cooling and cutting liquid recommended by
Orbitalum Tools. Cutting with KSS-TOP increases the service life of multifunctional tools.
Note
Do not exceed feed of 0.4 mm.
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
Feed control for
BRB Pneumatic and
BRB Electric
10 Machining the pipe
Feed is carried out with the feed ratchet (1) for BRB Pneumatic and BRB
Electric:
1.
Move the tool towards the pipe using the feed ratchet (1).
2.
Carefully guide the tool using the feed ratchet (1) until the tool touches the
pipe.
If the cutting edge of the tool is cutting on the entire circumference of the pipe:
3.
Feed control for
BRB Pneumatic/Auto
Continue to guide the tool applying pressure evenly.
Feed is controlled by means of a hand wheel (2) for the BRB Pneumatic/Auto:
1.
Move the tool towards the pipe using the hand wheel (2).
2.
Carefully guide the tool using the hand wheel (2) until the tool touches the
pipe.
If the cutting edge of the tool is cutting on the entire circumference of the pipe:
3.
Continue to guide the tool applying pressure evenly.
2
1
orbitalum tools gmbh
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71
10 Machining the pipe
Operating instructions BRB
10.6
Switching off the BRB
BRB Pneumatic and
BRB Pneumatic/Auto
 Release the ON/OFF switch (1).
BRB Electric
 Actuate the ON/OFF switch (2).
The BRB stops.
The BRB stops.
1
2
2
ON/OFF switch
BRB Pneumatic and BRB Pneumatic/Auto
ON/OFF switch
BRB 4 Electric
ON/OFF switch
BRB 2 Electric
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury from the compressed air valve being actuated inadvertently
so that the machine is started.
WARNING
72
 After every operation and prior to assembly, dismantling, maintenance and
adjustment work, disconnect the BRB from the power supply and let it
come to a complete stop.
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orbitalum tools gmbh
Operating instructions BRB
11 Fitting and operating accessories
11 Fitting and operating accessories
11.1
Brush attachments
These brass brush attachments prevent chips and other foreign bodies from
inadvertently falling into the inside of the pipes, making them particularly useful
for vertical work on containers.
 Select the brush attachment using the interior diameter of the pipe to be
machined (for an overview of brushes, see chap. 2.8.4, p. 18).
Please select the
"large" brush for pipe ID 32.0 – 110.8 mm (1.260 – 4.362 inch),
see chap. 11.1.1, p. 73 or chap. 11.1.3, p. 74.
"small" brush for pipe ID 19.1 – 33.8 mm (0.752 – 1.331 inch),
see chap. 11.1.2, p. 74 or chap. 11.1.4, p. 75.
Risk of injury through fanned out brush tips!
Brush tips that penetrate the skin can cause injury.
 Wear safety gloves.
ATTENTION
11.1.1
Fitting the "large" brush on the "standard" clamping system
1.
Attach discs (1, 2) to the inside of the brush ring (3).
2.
Screw the complete brush attachment onto the thread lug (4) of the
threaded spindle.
3.
Attach brush by screwing on the self-securing nut (4).
5
4
3
1
orbitalum tools gmbh
2
5
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73
11 Fitting and operating accessories
11.1.2
Operating instructions BRB
Fitting the "small" brush on the "standard" clamping system
1.
Screw the adapter ring (1) onto the brush (2).
2.
Screw the complete brush attachment onto the thread lug (3) of the
threaded spindle.
2
1
3
3
11.1.3
Fitting the "large" brush on the "NC" clamping system
1.
Attach discs (1, 2) to the inside of the brush ring (3).
2.
Screw the hexagon socket screw (4) into the brush attachment.
3.
Screw the complete brush attachment onto the locking screw (5) on the
mandrel.
5
5
3
1
74
2
4
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Operating instructions BRB
11 Fitting and operating accessories
11.1.4
1.
Fitting the "small" brush on the "NC" clamping system
Screw the brush (1) onto the locking screw (2).
1
Note
2
The brushes may become loose as a result of machining. Check brush
attachment every time after machining.
11.2
Hoist Bracket
Can only be used in combination with the BRB Pneumatic/Auto.
The use of a hoist bracket (machine hangs on a cable) is recommended,
particularly for continuous processing. All BRB machines built since 11/2009
already have an integrated hoist bracket. This is already mounted on the
machine when delivered. Older BRB models can be retrofitted with a hoist
bracket.
Hoist bracket for machines
built since 11/2009
orbitalum tools gmbh
Hoist bracket (retrofit kit) for older
machines
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75
11 Fitting and operating accessories
Mounting the
hoist bracket on
BRB Pneumatic/Auto
Operating instructions BRB
 Place the halves of the hoist bracket (1) around the BRB Pneumatic/Auto
housing and screw then together with M8 cylinder screws on both sides.
1
1
 A cable can now be suspended in the lug of the hoist bracket.
11.3
Depth setting plate
This depth setting plate ensures repeatable machining, improving heat
exchanger and boiler applications. Depth settings can be easily adjusted.
The spacer is particularly suited for use with the BRB Pneumatic/Auto.
Mounting the spacer
1.
Loosen tool mounting plate. The removal procedure depends on the drive
variant, the clamping system and the mandrel:




for BRB 2 "standard" see chap. 8.4, p. 35.
for BRB 2 "NC" see chap. 8.5, p. 40.
for BRB 4 "standard" see chap. 9.4, p. 51.
for BRB 4 "NC" see chap. 9.5, p. 54.
2.
Clamp spacer (1) with slightly loosened screw (2) via the drilling head (3).
3.
When the spacer is flush, tighten the screw (2).
1
3
4.
76
2
Reassemble tool mounting plate.
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orbitalum tools gmbh
Operating instructions BRB
11.4
11 Fitting and operating accessories
BRB retrofit kits
Existing and older BRB machines can be retrofitted with a different clamping
system, drive system or a different dimension range ("kit") (for an overview of
the different retrofit kits, please refer to our current product catalog).
Assembly and
removal
For assembly and removal, according to mandrel dia. and machine type,
see the table of contents.
11.4.1
BRB "dimension extension" retrofit kits
For upgrading from BRB kit 1 to 2, for example, thus extending the pipe
dimension range. Consisting of mandrel, tool mounting plate(s) and clamping
wedges, depending on the kit.
11.4.2
BRB "Pneumatic to Auto" retrofit kits
For converting to pneumatic clamping, which is particularly suited to
continuous processing, e.g. heat exchanger applications. Only possible to
retrofit on pneumatic machines. Quick and simple to fit.
11.4.3
BRB clamping system "standard to NC" retrofit kits
The new "NC" clamping system, with its clamping wedges firmly anchored in
the mandrel, is ideal for applications where no foreign bodies may enter the
inside of the pipe or a container.
orbitalum tools gmbh
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77
12 Maintenance
Operating instructions BRB
12 Maintenance
Note
Should the machine not work as previously described, it must be sent to an
authorized Orbitalum Tools service centre.
Fatal electric shock as a result of poor electrical assembly!
Death.
 Do not meddle with the machine electrics.
DANGER
 Send the machine to an authorized Orbitalum Tools service centre.
BRB Electric:
Danger of death by electric shock
 Disconnect the power supply before carrying out any maintenance work.
DANGER
BRB Pneumatic and BRB Pneumatic/Auto:
Risk of injury when loosening pressurized parts!
 Disconnect the compressed air supply before maintenance work.
WARNING
 Before maintenance work, let the BRB run to a standstill with the
compressed air supply disconnected.
Time
Activity
Before starting work
 Check the pipe clamping if the machine is already mounted in the pipe.
For the BRB Pneumatic:
 Check system pressure.
 Check mobile air unit.
 Set the mobile air unit lubricator.
 Approx. 6 drops per minute (oil types SAE 5 W to SAE 10 W)
At low temperatures:
 Use lubricant with anti-freeze.
Every week
For the BRB Pneumatic:
 Check the compressed air line for leaks.
 Check that the hose clips are secure.
For every cleaning
 Clean clamping wedges and tool mounting plates (mandrel and head).
Every time the tool is
change
 Clean tool holder and multifunctional tool.
78
 Remove cutting material and dirt from the bearing surface of the tool
holder.
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Operating instructions BRB
13 What to do if …?
13 What to do if …?
13.1
Troubleshooting
The following table shows you the causes of possible problems and how to fix
them.
Problem
Possible causes
Remedy
Plates in the compressed air
 Set the throttle to max. speed, then
BRB compressed air is
switch on and adjust downwards.
not running even though motor are in the wrong position.
it is connected to the
Plates are stuck in the rotor.
 Unscrew the BRB's pressure regulator
compressed air supply.
and add thin-viscosity oil, then
reconnect the compressed air supply.
 Dismantle the compressed air motor
and clean the plates.
System pressure too low
 Increase system pressure to 6 bar.
The BRB Pneumatic
motor is not supplying
the necessary power.
Pressure too low in primary
network (below 6 bar).
 Disconnect other consumers from the
network.
Tool (MFW) is catching
during machining.
Feed too large.
 Increase system pressure to 6 bar.
 For the BRB Pneumatic:
 Turn off the machine, disconnect the
compressed air supply, and loosen the
pipe clamping.
 For the BRB Pneumatic and Electric:
 Disassemble tool holder and take the
machine out of the pipe.
 Remove chip using side cutting pliers
and file off section.
 Feed carefully for further machining.
Multifunctional tool is loose.
 Tighten the multifunctional tool.
The restart inhibitor has been
activated.
 Turn the BRB Electric off and back on
again.
Overheating.
 Turn the BRB Electric off, let it cool
down and then turn it back on again.
Carbon brushes worn out.
 Have the carbon brushes replaced by a
specialist.
Tool tends to vibrate.
Cutting speed too high.
 Adjust speed (cutting speed) in
accordance with table.
Strong tendency to
vibrate.
Axial or radial play in the
components.
 Check machine for adequate clearance.
BRB Electric motor is
not running.
Multifunctional tool is loose.
orbitalum tools gmbh
 Check that the multifunctional tool is
securely positioned.
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79
13 What to do if …?
Operating instructions BRB
13.2
Servicing/customer service
For ordering spare parts, refer to the separate spare parts list.
For troubleshooting, please contact the branch responsible directly.
Please provide the following details:
80

Type of machine:
BRB 2 Pneumatic
BRB 2 Pneumatic/Auto
BRB 2 Electric
BRB 4 Pneumatic
BRB 4 Pneumatic/Auto
BRB 4 Electric

Machine no.: (see type plate)
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orbitalum tools gmbh
Operating instructions BRB
14 EC Declaration of Conformity
14 EC Declaration of Conformity
14.1
BRB Pneumatic
BRB Pneumatic/Auto
EG – Konformitätserklärung
Declaration of conformity
Dichiarazione di conformità
Déclaration de conformité
Declaración de conformidad
Orbitalum Tools GmbH
Josef-Schüttler-Straße 17
78224 Singen, Deutschland
Tel.: +49 (0) 77 31 792-0
Fax: +49 (0) 77 31 792-524
As in appendix II A of the EC Machinery Directive 2006/42/EC
Die Bauart der Maschine:
The following product:
Il seguente prodotto:
Le produit suivant:
El producto siguiente:
Seriennummer:
Series number:
Numero di serie:
Nombre de série:
Número de serie:
Baujahr / Year / Anno / Année
/ Año:
Boiler Pipe Preparation Machine BRB 2 Pneumatic
Boiler Pipe Preparation Machine BRB 2 Pneumatic/Auto
Boiler Pipe Preparation Machine BRB 4 Pneumatic
Boiler Pipe Preparation Machine BRB 4 Pneumatic/Auto
ist entwickelt, konstruiert and gefertigt in Übereinstimmung mit folgenden EG-Richtlinien:
was designed, constructed and manufactured in accordance with the following EC guidelines:
è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive:
a été dessiné, produit et commercialisé selon les Directives suivantes:
ha sido proyectado construido y comercializado bajo observación de las siguientes Directivas:
EG-Maschinen-Richtlinie 2006/42/EG (MaschR)
Folgende harmonisierte Normen sind angewandt:
The following harmonized norms have been applied:
Le seguenti norme armonizzate ove applicabili:
Les normes suivantes harmonisées où applicables:
Las siguientes normas armonizadas han sido aplicadas:
EN ISO 13849-1 : 2008
EN ISO 13849- 2 : 2008
EN ISO 12100-1: 2003
EN ISO 12100-2: 2003
EN ISO 14121-1: 2007
EN 349:2008
EN 166:2002
EN 388:2003
EN 13857:2008
EN 13850:2008
EN 1037: 2008
EN 983:2009
Singen, Jan. 22, 2010
Markus Tamm
CEO
orbitalum tools gmbh
Andreas Lier
Head of Energy Division
(08.10) MT_BRB_BA_04_790086762_00.doc
81
14 EC Declaration of Conformity
Operating instructions BRB
14.2
BRB Electric
EG – Konformitätserklärung
Declaration of conformity
Dichiarazione di conformità
Déclaration de conformité
Declaración de conformidad
Orbitalum Tools GmbH
Josef-Schüttler-Straße 17
78224 Singen, Deutschland
Tel.: +49 (0) 77 31 792-0
Fax: +49 (0) 77 31 792-524
As in appendix II A of the EC Machinery Directive 2006/42/EC and the EMC Machinery Directive
2004/108/EC
Die Bauart der Maschine: Boiler Pipe Preparation Machine BRB 2 Electric
The following product: Boiler Pipe Preparation Machine BRB 4 Electric
Il seguente prodotto:
Le produit suivant:
El producto siguiente:
Seriennummer:
Series number:
Numero di serie:
Nombre de série:
Número de serie:
Baujahr / Year / Anno / Année
/ Año:
ist entwickelt, konstruiert and gefertigt in Übereinstimmung mit folgenden EG-Richtlinien:
was designed, constructed and manufactured in accordance with the following EC guidelines:
è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive:
a été dessiné, produit et commercialisé selon les Directives suivantes:
ha sido proyectado construido y comercializado bajo observación de las siguientes Directivas:
EG-Maschinen-Richtlinie 2006/42/EG (MaschR)
EMV-Richtlinie 2004/108/EG
Folgende harmonisierte Normen sind angewandt:
The following harmonized norms have been applied:
Le seguenti norme armonizzate ove applicabili:
Les normes suivantes harmonisées où applicables:
Las siguientes normas armonizadas han sido aplicadas:
EN ISO 13849-1 : 2008
EN ISO 13849- 2 : 2008
EN ISO 12100-1: 2003
EN ISO 12100-2: 2003
EN ISO 14121-1: 2007
EN 349:2008
EN 166:2002
EN 388:2003
EN 13857:2008
EN 13850:2008
EN 1037: 2008
EN 60947-3:2010
EN 60745: 2010
Singen, Jan. 22, 2010
Markus Tamm
CEO
82
Andreas Lier
Head of Energy Division
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
orbitalum tools gmbh
14 EC Declaration of Conformity
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83
14 EC Declaration of Conformity
84
Operating instructions BRB
(08.10) MT_BRB_BA_04_790086762_00.doc
orbitalum tools gmbh
Operating instructions BRB
orbitalum tools gmbh
14 EC Declaration of Conformity
(08.10) MT_BRB_BA_04_790086762_00.doc
85
Orbitalum Tools GmbH
Josef-Schüttler-Str. 17
78224 Singen, Deutschland
Tel. +49 (0) 77 31 792-0
Fax +49 (0) 77 31 792-524
[email protected]
www.orbitalum.com
790 086 762_00/01 (08.10)
© Orbitalum Tools GmbH
D-78224 Singen 2010
Printed in Germany
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