ORBITEC OSK 38 C Operating Instructions Manual

Operating instructions for OSK series S / G

1

OSK S-series

OSK G-series

As of 13.06.2016

Subject to change

ORBITEC GmbH

Willi-Brehm-Straße 8

D-63500 Seligenstadt

Phone: +49 (0)6182 / 78693-0

Fax: +49 (0)6182 / 78693-10

E-Mail: info@orbitec-group.com

Internet: www.orbitec-group.com

Operating instructions for OSK series S / G

2

Table of Contents

1. Preface ........................................................................................................................... 3

2. Safety instructions .......................................................................................................... 4

3. Product overview ............................................................................................................ 5

4. Features/benefits............................................................................................................ 7

5. Measurement chart and scope ....................................................................................... 8

6. Connection to the inverter / control ................................................................................10

7. Instructions ....................................................................................................................11

7.1. assembly of the collets ...........................................................................................11

7.2. Assembly welding head / drive unit ........................................................................13

7.3. Positioning of the electrode ....................................................................................15

7.4. Guidelines for electrode lengths in OSK .................................................................17

7.5. Preparation of pipes ...............................................................................................18

7.6. Tacking of the pipes ...............................................................................................18

7.7. Welding process .....................................................................................................20

8. Maintenance and product care ......................................................................................21

8.1. General instructions ...............................................................................................21

8.2. Cleaning .................................................................................................................22

8.3. Setting the end switch cam .....................................................................................25

8.4. Exchange of the drive shaft ....................................................................................27

8.5. Exchange of graphite nodule ..................................................................................29

8.6. Setting of tension lock ............................................................................................31

9. Type plate key ...............................................................................................................32

10. Accessories (available separately) .............................................................................33

11. Legal notices .............................................................................................................34

12. EC – Declaration of Conformity ..................................................................................35

13. Notes .........................................................................................................................36

Operating instructions for OSK series S / G

3

1. Preface

Thank you for choosing a closed welding head of the OSK series by Orbitec GmbH.

These operating instructions are intended assist in the handling of the OSK.

Please read the operating instructions carefully and completely and keep them for future

reference to avoid misuse.

Orbitec GmbH does not assume any liability for any unauthorised modifications, incorrect

use and repairs, and /or prohibited conversions, which are not expressly authorised by

Orbitec.

The OSK enables the orbital welding of pipes, pipe bends, t-sections etc.

By its closed construction and the interior protective atmosphere, the welding process is

protected from external influences.

The automated welding process facilitates repeatable results and guarantees consistent high

quality.

Furthermore, the welding heads can be changed, therefore welding heads of different sizes

can be used with one single drive unit.

Water cooling is possible for continuous operation and heavy duty applications such as, for

example, high wall thickness.

These operating instructions apply to the G-series, the subsequent S-series, as well as the

compact and water-cooled variants GW, SW, C, CS and CW.

Should you have any question regarding installation, commissioning or operation, please

contact our customer service on telephone number: +49 (0) 6182/78693-0.

Operating instructions for OSK series S / G

4

2. Safety instructions

General Hazard Warnings!

 The same rules as for TIG welding (Tungsten Inert-gas welding, or GTAW - Gas

Tungsten arc welding) apply.

 The tool may only be used by trained personnel.

 The tool may only be used for its intended purpose.

 Orbitec GmbH does not assume any liability for unauthorised / incorrect

modifications, repairs, use and conversions, which are not expressly authorised by

Orbitec.

 Please read and follow the operating instructions for this product and all related

system components.

 Please observe the accident prevention regulations.

 Please observe country-specific provisions.

 Check all components for damage.

 Do not continue to use a product if it is damaged.

 Ensure a safe workplace.

Electrical danger!

 An electrical shock can be fatal!

 Install and earth welding equipment in accordance with local standards.

 Do not touch any live components or electrodes with bare hands or wet protective

equipment.

 Persons must isolate themselves from earth and the workpiece.

 Do not touch any live parts during welding.

Risk of fire and burns!

 Welding beads can lead to fire and burns.

 Prior to switching on the machine, ensure that there are no solvents present in the

room air, for example in paint shops.

 Do not store any flammable objects or cleaning agents at the workspace.

 Dirt can often be flammable.

 Wear suitable protective gloves.

Danger from radiation!

 Ultraviolet and infrared light can cause burns to eyes and skin.

 Protect eyes and body, wear suitable safety helmet with filter insert as well as

protective clothing.

 Never look towards the electric arc without protection.

 Personnel in close proximity must be protected by protective curtains or walls.

Danger from gases and smoke!

 Smoke and gas can endanger your health.

 Do not inhale the welding fumes.

 Ensure sufficient ventilation.

 If necessary, use an extraction system.

 Observe the safety rules for welding work in small spaces and closed containers.

Danger of explosion!

 Caution when using forming gases or gases containing hydrogen.

There is a danger of deflagration.

 Only use gases that are suitable for your uses.

 When using gases containing hydrogen, maximum 10% hydrogen.

 Observe the provisions of the relevant safety data sheets.

Danger of crushing!

 Do not reach into the body aperture when the rotor is running.

 Do not reach into the moving machine parts.

Operating instructions for OSK series S / G

5

3. Product overview

Adapter flange OSK C/G*

Drive unit OSK G

Drive unit OSK C

OSK 115 G

OSK 38 C

OSK 76 G

OSK 53 G

OSK 21 C

OSK 38 C

OSK 21 C

*The adapter flange enables the

connection of a C welding head to a G or S

drive unit

Operating instructions for OSK series S / G

6

The following OSK welding tools are available:

welding head

variant

function

OSK 21

C

gas-cooled

CW

water-cooled

OSK 38

C

gas-cooled

CW

water-cooled

OSK 53

G

gas-cooled

GW

water-cooled

OSK 76

G

gas-cooled

GW

water-cooled

OSK 115

G

gas-cooled

GW

water-cooled

S

gas-cooled

SW

water-cooled

The following drive units are available:

drive unit

compatible with variant:

function

Drive unit OSK C

C

gas-cooled

drive unit OSK CW

CW

water-cooled

drive unit OSK G

G / S

gas-cooled

drive unit OSK GW

GW / SW

water-cooled

drive unit OSK S

G / S

gas-cooled

drive unit OSK SW

GW / SW

water-cooled

Body

Clamping shell housing

Operating instructions for OSK series S / G

7

4. Features/benefits

The closed OSK welding heads have the following features:

 The closed construction and the inert gas atmosphere inside protect the welding

process against external influences and guarantee a qualitative high-grade welding

seam.

 The automated welding process facilitates repeatable results and guarantees

consistent high quality.

 The welding head can be separated from the drive unit.

 Therefore five different welding heads can be used with one drive unit.

 Electrodes with Ø 1.6 mm and Ø 2.4 mm can be used.

 Each welding head is available in a water-cooled variant or can be upgraded to a

water-cooled variant (from S-series onwards also OSK 38 and OSK 21).

 Collets exchangeable by quick-change system.

 Simple assembly and dismantling.

Operating instructions for OSK series S / G

8

5. Measurement chart and scope

The dimensions of the OSK series are as follows:

G-series

welding head

A

B

C

D

E

F

mm

inch

mm

inch

mm

inch

mm

inch

mm

inch

mm

inch

OSK 21 C

70

2.756

40

1.575

150

5.906

370

14.567

33

1.299

16

.630

OSK 38 C

102

4.016

53

2.087

175

6.890

390

15.354

33

1.299

16

.630

OSK 53 G / GW

140

5.512

73

2.874

210

8.268

430

16.929

44

1.732

22

.866

OSK 76 G / GW

160

6.299

83

3.268

230

9.055

445

17.520

44

1.732

22

.866

OSK 115 G / GW

200

7.874

103

4.055

270

10.630

485

19.094

44

1.732

22

.866

S-series

welding head

A

B

C

D

E

F

mm

inch

mm

inch

mm

inch

mm

inch

mm

inch

mm

inch

OSK 21 CW

70

2.756

39.5

1.555

146

5.748

365.5

14.390

35

1.378

17.5

.689

OSK 38 CW

102

4.016

54

2.156

177

6.969

396

15.591

35

1.378

17.5

.689

OSK 115 S / SW

200

7.874

103

4.055

270

10.630

487.5

19.192

40

1.575

20

.787

Operating instructions for OSK series S / G

9

The scopes of the OSK series is as follows:

welding head

scope (outside diameter)

OSK 21

3.17 mm – 21.3 mm

0.125 inch – 0.839 inch

OSK 38

3.17 mm – 38.1 mm

0.125 inch – 1.500 Inch

OSK 53

6 mm – 53 mm

0.250 inch – 2.087 Inch

OSK 76

6 mm – 76.2 mm

0.250 inch – 3.000 Inch

OSK 115

8 mm – 114.3 mm

0.368 inch – 4.500 inch

Clamping jaws are

available in all

common pipe

diameters.

(special sizes on

request)

Operating instructions for OSK series S / G

10

6. Connection to the inverter / control

Gas connection

Connection

control

marked yellow

positive pole

(Mass)

marked red

minus pole

(electrode)

marked blue

Additionally in case of water-cooling:

Water flow

blue

Water return

flow red

Please follow the

relevant instructions

regarding the

commissioning, operation

and the safety

precautions

In case of water-cooling, you will

also require the water cooling unit

Cool 50

Item no. 1.2.0118

Operating instructions for OSK series S / G

11

7. Instructions

7.1. assembly of the collets

As a rule, one set of collets consisting of four identical individual parts is required. These are

inserted into the clamping shell housing and each are held into place and locked by 2

cylinders.

Rear lock (fixed)

Front lock (flexible)

Collets

Recesses for lock

Lock closed

(for the locking of the

collets)

Lock open

(for the insertion and

removal of the collets)

Recess

inside

Recess

outside

Large recesses to the rear

(fixed lock)

Small recesses to the front

(flexible lock)

Operating instructions for OSK series S / G

12

Open the lock and insert the collets as depicted.

Assemble the remaining three collets in the same way.

3. Close lock.

1. Insert collet at the rear

2. Insert collet at the front

1.

2.

3.

Operating instructions for OSK series S / G

13

7.2. Assembly welding head / drive unit

Due to the plug-in principle, different welding heads can be connected to the same drive unit.

Overview of the media:

Coupling

(The coupling must be aligned with

each other during assembly!)

2x power

connection

2x power

connection

3x contacts for limit switch

2x water connection with water stop

coupling

(only with water-cooled variant,

these connections are not present

with gas-cooled variant)

Gas

connection

Gas

connection

Attention!

The water-cooled variants OSK 38 CW and

OSK 21 CW as well as their drive unit OSK CW

do not have a water stop coupling.

When disconnecting the welding head from the

drive unit, beware of water leakage

Operating instructions for OSK series S / G

14

Connect the welding head with the drive unit.

Fit in the knurled-head screw

and tighten it by hand.

Attention!

Ensure that the couplings are

aligned, otherwise the welding

head cannot be completely

assembled.

Do not use force.

There are no knurled-head screws in the

water-cooled variant OSK 38 CW and OSK

21 CW. The connection is made with four

cylinder head screws. The remaining

assembly is identical.

4x cylinder screw hexagon socket ISO 4762 M4x12

Operating instructions for OSK series S / G

15

7.3. Positioning of the electrode

Electrodes with a diameter of 1.6mm and 2.4mm can be used.

For supplementary information on control see operating instructions for:

Tigtronic Basic 2, 3, 4

Tictronic COMPACT 200 MV

Position for Ø1.6

mm

Position for Ø2.4

mm

 Never insert two electrodes

simultaneously

 The position of the electrodes can be

inverted, depending on design

Open the clamping shell

housing

Proceed with the rotor as per control, until

the desired clamping screw can be

reached.

Attention!

Danger of crushing

Operating instructions for OSK series S / G

16

Guidelines for electrode gap

wall thickness

Electrode gap

0.5 mm - 1.0 mm

0.8 mm

1.25 mm - 2.0 mm

1.0 - 1.8 mm

2.25 mm - 3.2 mm

2.0 - 2.6 mm

Remove the adjustment pipe again.

Fit electrode

fit suitable pipe diameter and

tighten with one side of the

clamping shell housing.

Set the electrode gap with feeler gauge and fix

with the clamping screw.

The gap is dependent on the wall thickness

(see guidelines)

Attention!

The electrode must not

protrude into the gear

wheel area.

This results in damage of

the gear wheels and

potentially the body.

Operating instructions for OSK series S / G

17

7.4. Guidelines for electrode lengths in OSK

 Heads

OSK-13 S

OSK-21 C

OSK-38 C

OSK-53 G

OSK-76 G

OSK-115 G / S

 Head number

25

17

24

18

19

20

 Rotor outside Ø

D = 32.5

D = 58

D = 86

D = 116

D = 136

D = 176

 Gas volume

4-6 L/min

6-8 L/min

10-12 L/min

12-16 L/min

14-18 L/min

 Electrodes Ø

1.0 / 1.6

1.6 / 2.4

Pipe OD

3.17 mm

14 mm

26 mm

40 mm

6 mm

12 mm

25 mm

39 mm

54 mm

64 mm

6.35 mm

12 mm

25 mm

39 mm

53 mm

63 mm

8 mm

11 mm

24 mm

38 mm

53 mm

63 mm

83 mm

9.53 mm

10 mm

23 mm

37 mm

52 mm

62 mm

82 mm

10 mm

23 mm

37 mm

52 mm

62 mm

82 mm

12 mm

9 mm

22 mm

36 mm

51 mm

61 mm

81 mm

12.7 mm

9 mm

21 mm

35 mm

50 mm

60 mm

80 mm

13 mm

21 mm

35 mm

50 mm

60 mm

80 mm

16 mm

20 mm

34 mm

49 mm

59 mm

79 mm

18 mm

32 mm

47 mm

57 mm

77 mm

19 mm

17 mm

31 mm

46 mm

56 mm

76 mm

19.05 mm

17 mm

31 mm

46 mm

56 mm

76 mm

21.3 mm

16 mm

30 mm

45 mm

55 mm

75 mm

23 mm

15 mm

29 mm

44 mm

54 mm

74 mm

25.4 mm

14 mm

28 mm

43 mm

53 mm

73 mm

26.9 mm

27 mm

42 mm

52 mm

72 mm

28 mm

27 mm

42 mm

52 mm

72 mm

29 mm

26 mm

41 mm

51 mm

71 mm

33.7 mm

24 mm

39 mm

49 mm

69 mm

35 mm

23 mm

38 mm

48 mm

68 mm

38.1 mm

22 mm

37 mm

47 mm

67 mm

41 mm

35 mm

45 mm

65 mm

42.4 mm

34 mm

44 mm

64 mm

44.5 mm

33 mm

43 mm

63 mm

48.3 mm

31 mm

41 mm

61 mm

50.8 mm

30 mm

40 mm

60 mm

53 mm

29 mm

39 mm

59 mm

54 mm

39 mm

59 mm

60.3 mm

35 mm

55 mm

63.5 mm

34 mm

54 mm

70 mm

31 mm

51 mm

76.1 mm

28 mm

48 mm

85 mm

43 mm

88.9 mm

41 mm

101.6 mm

35 mm

104 mm

34 mm

108 mm

32 mm

114.3 mm

28 mm

For special sizes, use the following formula:

Electrode length = 

 

Operating instructions for OSK series S / G

18

7.5. Preparation of pipes

The quality of the welding seam depends on the preparation.

The following must be noted:

Preparation of the pipe:

square cut, good surface quality, cleanliness, burr-free, free from fat and oil

Recommendation: 1.2.4503 tube saw ORS 115

1.3.4101 Planfix 40

1.2.4005 Planfix 115

7.6. Tacking of the pipes

The components must be tacked on prior to the orbital welding.

It is necessary to use forming gas depending on the application.

Manual tacking:





Align the pipes centrally and

gap-free

Manually set 4 spot welds,

each offset by 90°

Recommendation: 1.2.0129 prism DA 5 – 30 mm

1.2.0130 prism DA 10 – 65 mm

1.2.0131 prism DA 20 – 115 mm

Operating instructions for OSK series S / G

19

Tacking with the OSK:

It is also possible to tack with the orbital welding head.

Insert the prepared pipes in the welding head, so that the joint with the electrode forms a line.

Close the welding head and start the tacking process.

It is mandatory to use forming gas depending on the application.

Parameter

Welding head:

OSK 21 C

OSK 38 C

OSK 53 G

OSK 76 G

OSK 115 G / S

Head number

17

24

18

19

20

Gas volume

6-8 L/min

10-12 L/min

12-16 L/min

14-18 L/min

Attention!

Only recommended for short pieces of pipe, approximately 50 -

100mm.

For longer pieces of pipe, the manual tacking is indispensable.

The own weight of the pipe otherwise causes a gap formation.

Operating instructions for OSK series S / G

20

7.7. Welding process

Rotor back in basic position

Completely open the clamping

shell housing

Insert the tacked pipe and align

central to the electrode.

Close clamping shell housing and weld together.

It is mandatory to form depending on the

application.

Attention!

Danger from burns!

The welding head gets hot.

Gloves should be worn.

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ORBITEC OSK 38 C Operating Instructions Manual

ORBITEC OSK 38 C Operating Instructions Manual

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