Orbitalum GF 4 AVM, Operating Instructions Manual

Page 1: ...precision power simplicity Operating instructions Pipe Cutting and Beveling Machines GF 4 AVM MVM Code 790 142 762 Machine no ________________________________ ...

Page 2: ...ed 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 ...

Page 3: ...4 1 Saw blades and bevel cutters 10 2 4 2 Aluminum clamping shells 11 2 4 3 Special high quality steel clamping jaws 11 2 4 4 Length gauge 11 2 4 5 Quick mounting plate with screw clamps 11 2 4 6 Gear oil 11 2 4 7 Saw blade lubricant GF TOP 12 2 4 8 Saw blade lubricant ROCOL 12 3 Features and scope of application 13 3 1 Features 13 3 2 Scope of application 14 3 2 1 Working range 14 4 Technical dat...

Page 4: ...speed 31 7 6 1 Standard values for spindle speed and feed force level AVM 31 7 7 Processing the pipe with GF 4 AVM 32 7 7 1 Commissioning 32 7 7 2 Cutting the pipe with GF 4 AVM 33 7 7 3 Beveling the pipe with GF 4 AVM 34 7 7 4 Cutting the pipe and beveling it simultaneously GF 4 AVM 35 7 8 Processing the pipe with GF 4 MVM 36 7 8 1 Cutting the pipe with GF 4 MVM 36 7 8 2 Beveling the pipe with GF...

Page 5: ...rial damage Always read and observe these warning messages This is a warning symbol It should warn you against dangers of injury Follow all instructions which are identified with this safety symbol in order to avoid injuries or death Warning Symbol Meaning DANGER Direct danger Non observance could result in death or critical injury Restrictions if applicable X Measures to prevent danger WARNING Po...

Page 6: ... comprehension Instruction You must take notice of this symbol 1 Request for action in a sequence of actions You must do something here X Single request for action You must do something here Z Conditional request for action You must do something here if the specified condition is met 0 3 Abbreviations Abbr Meaning GF 4 Pipe Cutting and Beveling Machine for up to 4 inch pipe outer diameter AVM Auto...

Page 7: ...ls pipe cutter GF 4 The user will be the only person liable for damages caused by improper use GF 4 AVM Only the mains cable of the pipe cutter may be connected to the socket of the AVM 1 2 Safety Regulations Only use the dimensions and materials specified in these instructions Other materials should be used only after consulting the Orbitalum Tools after sales service Only use original Orbitalum ...

Page 8: ...t the mains plug and allow the machine to run to a stop Fault current FI protection in the mains supply line provided by the customer is required When working with the AVM in case of danger immediately press the EMERGENCY OFF button When working with the AVM the AVM will stop automatically after each cutting process If you are working manually switch off the machine after each working cycle ON OFF...

Page 9: ...ips flying around Keep hands away from the running tool X Always wear protective goggles and safety gloves X Remove chips only with safety gloves Danger of being injured by rotating slide housing When switching the motor on the pipe cutter may revolve around the pipe automatically When working with the GF 4 AVM do not stand within swiveling distance of the machine during an automatic revolution of...

Page 10: ...ser beam or view using optical instruments Do not point the laser beam in the direction of others Do not misuse the laser pointer and do not remove from the pipe cutter 1 4 Waste disposal Dispose of chips and used gear lubricant oil according to the regulations Discarded electric tools and accessories contain a large share of valuable raw and synthetic materials which can be recycled Therefore Ele...

Page 11: ...many our products may not be disposed of in municipal disposal sites as they are used for industrial purposes only 1 5 Returning of batteries Some of our products work with batteries Batteries which are marked with one of the symbols on the left may not be disposed of together with household waste according to the applicable EU directive 91 157 EEC With batteries containing hazardous substances th...

Page 12: ...er 12 ON OFF switch 3 Slide housing with cover plate 13 Ergonomic handle 4 Saw blade bevel cutter 14 Retainer for vice handle 5 Opening for meter rule Anti theft protection 6 Saw blade guard Holding fixture for pipe length guage bar 7 Identification plate 15 Quick mounting plate 8 Slide 16 Multifunctional wrench vice handle 9 Motor 17 Vice 10 Rotating speed indicator 18 Turnable clamping jaws 1 2 ...

Page 13: ...s it is possible to preset the desired feed force in 9 levels If the device is ready for operation these buttons may be pressed at any time to set the feed force level or to vary it during processing If one of the buttons remains pressed by the user the display will run to the respective direction selected by the user The machining process is initiated by actuating this button After start up this ...

Page 14: ...imum strain and have a maximum tool life A selection of 4 different saw blades and bevel cutters are available for various uses Economy Series for low and non alloy steels and cast iron casting alloys Performance Series for high alloy steels high quality steel High Performance Series for high performance materials and high alloy steels Premium Series especially for high quality steel use with extr...

Page 15: ...3 108 00 4 252 790 046 367 114 30 4 500 790 046 368 2 4 3 Special high quality steel clamping jaws For GF 4 and RA 4 In pairs Article Code Special high quality steel clamping jaws for GF 4 and RA 4 790 042 201 2 4 4 Length gauge For all GF 4 RA 2 RA 4 RA 6 and RA 8 versions Measuring range up to 680 mm 26 77 inch Article Code Length gauge 790 041 011 2 4 5 Quick mounting plate with screw clamps Wi...

Page 16: ...t with the former food approval USDA H2 The screwable brush guarantees an easy and uniform application of lubricant on the saw blade Article Code Saw blade lubricant GF TOP 790 060 228 2 4 8 Saw blade lubricant ROCOL High performance lubricant for cutting and beveling Increases the tool life of the saw blade Article Code Saw blade lubricant ROCOL Tube 150 ml 790 041 016 Saw blade lubricant ROCOL C...

Page 17: ...with oil lubrication Speed controlled pipe cutter motor Burr free cutting surface and deformation free pipe cross section Cold machining process Quick cutting process The ability to produce V and Y weld preps using a bevel cutter with the option of cutting and beveling simultaneously Cutting of elbows Quick tool change Line laser for optical identification of the cutting area Locking mechanism of ...

Page 18: ...e ID min mm saw blade Ø 63 mm 21 Pipe ID min mm saw blade Ø 68 mm 16 Pipe ID min mm saw blade Ø 80 mm 4 High quality steel any Cr and Mo content High quality stainless steel any Cr and Mo content High quality steel Cr 12 and Mo 2 5 Cr 20 and Mo 0 Case hardened steels High speed steels Heat treated steels Bearing steels Tool steels Black and galvanized steel pipe General structural steel Annealed c...

Page 19: ...rotection class GF 4 GF 4 MVM Double insulated according to class II DIN VDE 0740 Protection class GF 4 AVM Double insulated according to class I DIN VDE 0113 Tool speed 65 215 rpm Speed of the slide housing 0 1 1 8 rpm Torque of the slide housing 100 200 Nm Sound pressure level at the workplace approx 79 dB A Vibration level in accordance with DIN EN 28662 Part 1 2 5 m s2 Mains fuse by customer 1...

Page 20: ...5 1 Included with the machine 1 Pipe Cutting and Beveling Machine GF 4 AVM MVM 1 Transportation case 1 Saw blade 1 Set of clamping jaws made from cast aluminum 1 Quick mounting plate 1 Tool set 1 Tube of saw blade lubricant GF TOP Code 790 060 228 1 Tube of special gear oil Code 790 041 030 1 Set of operating instructions and spare parts list The automatic and manual feed module AVM MVM is already...

Page 21: ...ing and allow the machine to run to a stop 6 1 Transporting the pipe cutter Danger of being injured during transportation Never carry and fit the pipe cutter alone X Transport and fit the pipe cutter with the aid of a second person or a crane or a similar lifting device X Wear safety gloves Position of the machine in the transportation case upon delivery Transport and fit the machine with the aid ...

Page 22: ... quick mounting plate as a template 2 Drill Ø 13 mm 0 51 inch holes 3 Fasten the quick mounting plate with screws 6 2 2 Fitting the pipe cutter to the quick mounting plate 1 Guide the pipe cutter sideways onto the fitted quick mounting plate 2 Bolt the pipe cutter securely in place with the hexagon bolt When using the Orbitalum Tools pipe feeder base unit the pipe cutter is directly fitted to the ...

Page 23: ...he AVM are fastened in the cable clamps Danger of being injured by sharp cutting edges Keep hands away from the tools when inserting or changing the tool X Wear safety gloves Damage to material X The saw blade or bevel cutter must be free from chips and dirt X Only use Orbitalum Tools saw blades and bevel cutters X Using combination saw blade bevel cutters only use the special Orbitalum Tools clam...

Page 24: ...ing generation GF 4 AVM MVM now offers lots of new innovative features and the finest ergonomic design What s new 7 1 1 Multifunctional wrench Detachable It is possible to make 5 different adjustments on the machine using this multifunctional wrench Vice handle Adjusting the clamping jaws Tightening the saw blades and bevel cutters Tightening the GF 4 quick mounting plate Locking mechanism of the ...

Page 25: ...nstruments Do not point the laser beam in the direction of others Do not misuse the laser pointer and do not remove from the pipe cutter To determine the cut off point on the pipe Ideal for checking whether the pipe is adjusted to the desired cut off point A red line marking to determine the cut off point appears on the clamped pipe once the red button on the laser pointer has been actuated If nec...

Page 26: ...tandard feature of the GF 4 AVM MVM Both thin walled pipes OD 12 56 mm and thick walled pipes OD 20 120 mm can be processed by turning the clamping jaws Fitting the clamping jaws see chapter 7 2 p 24 Turnable aluminum cast clamping jaws 7 1 4 Swivel cable with quick disconnect coupler For easy and comfortable replacement of power cables Also prevents cables from twisting Plug connection with quick...

Page 27: ...ngth Optimized saw blade guard 7 1 6 Hand wheel with ratchet adjustment The pipe dimension can also be adjusted by manually turning the hand wheel using a ratchet the ratchet is not in the product contents 1 Insert a number eight nut into the ratchet and slot into the designated opening at the top of the hand wheel 2 Adjust the pipe dimensions by turning the ratchet Adjusting the pipe dimensions u...

Page 28: ...ted aluminum cast are a standard feature of the GF 4 AVM MVM Both thin walled pipes OD 12 56 mm and thick walled pipes OD 20 120 mm can be processed by turning the clamping jaws 1 Unscrew the hexagon bolts 1 on the sides of the vice using the multifunctional wrench 2 2 Fit the clamping jaws 3 Tighten hexagon bolts 1 using the multifunctional wrench 2 Fitting the clamping jaws 2 1 ...

Page 29: ... 3 and saw blade 2 3 Clean the saw blade shaft 6 and vicinity 4 Fit the saw blade 2 or bevel cutter and the clamping plate 3 5 Tighten the hexagon nut 4 6 Move the saw blade guard 1 back to its original position 2 3 4 1 7 3 2 Inserting additional cutters 1 Turn the saw blade guard 1 down for approx 90 2 Loosen the hexagon nut 5 Remove the clamping washer and the saw blade 3 Clean the saw blade sha...

Page 30: ...volve around the pipe automatically In their home position the saw blade or bevel cutter must not touch the pipe X Before switching the motor on make sure that the gap between the saw blade bevel cutter and the pipe is sufficient and that the pipe is securely clamped in the vice It is recommended to support pipes with a length of more than 1 m 39 37 inch using the pipe feeder base unit or the opti...

Page 31: ...4 3 Use the handle to turn the motor upwards for about 30 clockwise until the saw blade is in cutting position 4 Turn the hand wheel 1 until the teeth of the saw blade 3 protrude about 1 to 2 mm 0 039 0 079 inch inside the pipe 2 5 If desired perform a test cut cutting the pipe see chapter 7 7 p 32 check the cut result and readjust the hand wheel 1 if necessary 1 2 mm 2 3 6 Turn the motor back to ...

Page 32: ...using the multifunctional wrench 4 3 Use the handle to turn the motor upwards for about 30 until the saw blade is in cutting position 4 Turn the hand wheel 1 until the teeth of the additional cutter 2 cover the wall thickness of the pipe 5 Perform a test cut cutting the pipe see chapter 7 7 4 p 35 check the cut and bevel result and readjust the hand wheel 1 if necessary 2 6 Turn the motor back to ...

Page 33: ...l wrench 3 3 Use the handle to turn the motor upwards for about 30 until the bevel cutter is in beveling position 4 Turn the hand wheel 1 until the teeth of the bevel cutter 2 cover the wall thickness of the pipe and the desired beveling position is reached 5 If desired perform a test bevel beveling the pipe see chapter 7 7 3 p 34 check the bevel result and readjust the hand wheel 1 if necessary 2...

Page 34: ...dle of the pipe 3 Use a meter rule to extend the gauge to the desired length slot for meter rule see chapter 7 1 5 p 23 4 Position the clamp 3 flush with the housing and turn it so that it rests on the workbench 5 Tighten the clamp 3 6 Move the pipe forward up to the cut off stop and clamp it into place 7 Swivel the cut off stop outward and push it all the way back 8 Cut the pipe see chapter 7 7 p...

Page 35: ...quality steels 2 4 150 1 4 Structural steel 4 6 215 5 9 The feed force level may be varied depending on the thickness and diameter of the pipe wall When first starting to process the pipe with the AVM a low feed force level is recommended which may be increased later Higher levels result in a higher chip production and possibly also in a higher wear of tools The intelligent control system of the A...

Page 36: ...s pipe cutter GF 4 Do not connect any other devices to the socket of the AVM 7 7 1 Commissioning 1 Connect the pipe cutter to the socket 1 of the AVM 2 Connect the main cable of the AVM to the main power supply After unlocking the EMERGENCY OFF button the number of the current software version will appear on the display for approx 1 second After this second has passed the control system will suppl...

Page 37: ...4 Tighten the hexagon nut of the saw blade fixture if necessary see chapter 7 3 p 25 5 Adjust the spindle speed and the feed force level for standard values see chapter 7 6 p 31 6 Push the pipe through the vice up to the desired length and clamp it Support pipes with a length of more than 1 m using a pipe feeder see chapter 7 4 p 26 Pull off the vice handle from the spindle before the slide housin...

Page 38: ...25 4 Adjust the spindle speed and the feed force level for standard values see chapter 7 6 p 31 5 Push the pipe through the vice up to the desired length and clamp it Support pipes with a length of more than 1 m using a pipe feeder see chapter 7 4 p 26 Pull off the vice handle from the spindle before the slide housing starts rotating 6 Apply saw blade lubricant to the bevel cutter up to 2 every 3 ...

Page 39: ...ly cut and beveled If using a combination cutter the cutter motor has to be turned around the pipe more slowly than during normal cutting as two tools are being used at the same time The working procedure is the same as described in chapter 7 7 2 p 33 If necessary lubricate the saw blade and the additional cutter again during work For non stop operation after cutting loosen the hexagon nut on the ...

Page 40: ...e see chapter 7 5 p 30 3 Adjust the saw blade to the pipe diameter see chapter 7 4 1 p 27 4 Tighten the hexagon nut of the saw blade fixture if necessary see chapter 7 3 p 25 5 Adjust the spindle speed see chapter 7 6 p 31 6 Push the pipe through the vice up to the desired length and clamp it Support pipes with a length of more than 1 m using a pipe feeder see chapter 7 4 p 26 Pull off the vice ha...

Page 41: ...s If the pipe cutter was out of operation for a longer time Turn the cutter motor by 180 Switch the pipe cutter on and let it run for about 10 seconds This will lubricate all gear components 1 Set the pipe diameter see chapter 7 4 p 26 2 Adjust the bevel cutter to the pipe diameter see chapter 7 4 3 p 29 3 Tighten the hexagon nut of the bevel cutter fixture if necessary see chapter 7 3 p 25 4 Adju...

Page 42: ...til the pipe wall has been pierced through 9 Continue turning rapidly until the pipe has been beveled completely 10 Switch the motor off and allow the machine to run to a stop 7 8 3 Cutting the pipe and beveling it simultaneously with GF 4 MVM Pipes with a wall thickness of up to 4 5 mm 0 177 inch can be simultaneously cut and beveled If using a combination cutter the cutter motor has to be turned...

Page 43: ...r 7 5 p 30 3 Adjust the saw blade to the pipe diameter see chapter 7 4 1 p 27 4 Tighten the hexagon nut of the saw blade fixture if necessary see chapter 7 3 p 25 5 Adjust the spindle speed see chapter 7 6 p 31 6 Push the pipe through the vice up to the desired length and clamp it Support pipes with a length of more than 1 m using a pipe feeder see chapter 7 4 p 26 Pull off the vice handle from th...

Page 44: ...If the pipe cutter was out of operation for a longer time Turn the cutter motor by 180 Switch the pipe cutter on and let it run for about 10 seconds This will lubricate all gear components 1 Set the pipe diameter see chapter 7 4 p 26 2 Adjust the bevel cutter to the pipe diameter see chapter 7 4 3 p 29 3 Tighten the hexagon nut of the bevel cutter fixture if necessary see chapter 7 3 p 25 4 Adjust...

Page 45: ... until the pipe wall has been pierced through 9 Continue turning rapidly until the pipe has been beveled completely 10 Switch the motor off and allow the machine to run to a stop 7 9 3 Cutting the pipe manually and beveling it simultaneously Pipes with a wall thickness of up to 4 5 mm 0 177 inch can be simultaneously cut and beveled If using a combination cutter the cutter motor has to be turned a...

Page 46: ... work X Remove chips and dirt from the saw blade X Keep the vent holes free from chips Every time the cutter is cleaned Every time the tool is changed Do not use compressed air to clean the area at the end of the shaft marked with an arrow as the rotary shaft seal may otherwise be damaged by chips X Use a cloth or brush to clean the end of the shaft Every week X Clean and oil the spindle of the ha...

Page 47: ... up The gears of the pipe cutters GF 4 AVM MVM have an oil level inspection glass The oil level should be visible in the middle of the inspection glass 1 Check the oil level through the inspection glass 2 and top up if necessary To top up 2 Unscrew the oil filler screw 1 Fill with special Orbitalum Tools gear oil 1 2 3 Re insert and tighten the oil filler screw ...

Page 48: ... slide by pulling it downwards X Always tighten the safety screw when assembling the slide 1 Remove the safety screw 1 2 Turn the slide housing upwards by 180 3 Turn the hand wheel 2 anticlockwise 4 Pull out the slide 3 with the motor upwards 5 Clean the guides of the slide housing and slide Lightly lubricate both parts using HD 30 engine oil 6 Remount the slide Insert and tighten the safety screw...

Page 49: ... 9 2 Error messages trouble shooting AVM In case of faults concerning the AVM the machine will be stopped automa tically The display will flash at 1 second intervals alternately showing F and a figure from 1 to 6 Before restarting the AVM it has to be disconnected from the mains supply by pressing the EMERGENCY OFF button or by pulling the mains plug Error message fault Possible cause Remedy Displ...

Page 50: ...X Correct the adjustment The feed stops at the cut in area Saw blade worn out X Insert new saw blade Light barrier or reflector defective X Replace the defective parts contact the service department if necessary The feed does not stop at the stop position Display No decimal point at the stop position Light barrier or reflector dirty X Clean the dirty parts After having remedied the cause of malfun...

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Page 52: ...reibühlstrasse 19 78224 Singen Deutschland Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 500 tools orbitalum com www orbitalum com An ITW Company 790 142 762_01 04 01 08 Orbitalum Tools GmbH D 78224 Singen 2008 Printed in Germany ...