Product description

Assembly and use

Fig. 3​Design

A​Cable assembly input

B​Z axis with welding torch mount

C​Welding torch ABIMIG® MT 305 PIPE

D​Cable assembly output

E​Scale for wire feed roll contact pressure

F​Wire feed unit

G​Running gear – adjusting screw for wire feed

H​Running gear – adjusting screw for welding torch

I​Running gear with guide rail system and drive wheel

J​LED status indication

K​Circular connector, 8-pole remote control

L​Circular connector, 7-pole energy supply

M​Running gear – release lever

N​Retaining clamp quick-release clamp

O​Welding torch mount adjustable catch

P​On/Off switch with LED

Q​Cover for wire spool (D200 / 5 kg)

R​Wire spool mandrel

S​Running gear quick-return button (4×)

T​Retaining frame

U​Welding torch supply lines transfer station


Fig. 4​Function

A​Workpiece

B​Welding torch

C​Cable assembly

D​ABIBUG 300 orbital welding machine

E​Positioning belt

The integrated drive unit guarantees misalignment-free welding. The welding seam can be made to the left and right of the positioning belt. The device is controlled using a remote control.

Power supply unit

Fig. 5​Power supply unit

A​Mains plug (plug type G, B or F)

B​Power connection

C​Emergency switch

D​Gas valve (DN5 connections)

E​Machine safety switch <I>

F​Machine safety switch <O>

G​Connection 16S-1, 7-pole

H​Connection M12, 4-pole

Connection M16S-1, 7-pole

PIN

Description

A

+ 24 V DC

B

GND

C

Analog output

D

2T start/stop

E

Analog output

F

Gas relay

G

Not assigned

Connection M12, 4-pole

PIN

Description

1

2 T start/stop

2

GND

Analog output

3

0–10 V DC

4

2 T start/stop

Power connection

Description

PIN (115 V / 120 V)

PIN (230 V)

Not assigned

3

1

N – neutral conductor

2

2

C – conductor

1

3

PE – protective conductor

4

4

Freedom of movement

Fig. 6​Freedom of movement

Fig. 7​Positions on the pipe

Technical data

ABIBUG 300 orbital welding machine

Tab. 1​General information

Power consumption

240 W (24 V DC/10 A) MAX

Weight without welding torch

13.3 kg

Weight incl. welding torch

14.8 kg/19.8 kg
(depending on the supplied model)

Dimensions without welding torch (L × W × H)

470 × 400 × 270 mm

Dimensions with welding torch (L × W × H)

470 × 400 × 520 mm

Horizontal welding torch adjustability

65 mm

Vertical welding torch adjustability

50 mm

Welding torch tilt angle adjustability

±25°, depending on whether “forehand” or “backhand”

Oscillation width

35 mm

Oscillation speed

0–25 µS/cm oscillation

Speed

0–160 cm/min

Wire feeder speed

0–16 m/min

Flank holding time

Operator defined and separately adjustable 0 – ∞

Supply connections

Welding gas/process gas

Device supply

Remote control

Min. pipe diameter

≥ 10.75"

Tab. 2​General torch data (EN60974-7) only in conjunction with on-board torch

Welding procedure

MIG/MAG

Welding torch

Orbital welding machine

Weight

1.5 kg

Wire types

Solid wire, filler wire

Welding wire diameter

1.0 mm–1.2 mm

Type of cooling

Air-cooled

Gas type

DIN EN ISO 14175

Load

260 A 100% DC/320 A 60% DC
(EN 60974-7)

Tab. 3​Ambient conditions for transport, storage and operation

Ambient temperature
(operation in a closed environment)

−15 °C to +50 °C

Ambient temperature (transport, storage)

−40 °C to +50 °C

Relative humidity

Up to 90% non-condensing

Tab. 4​Trolley dimensions/weight

External

Internal

Length

800 mm

707 mm

Width

600 mm

507 mm

Height

443 mm

393 mm

Empty weight

Approx. 9 kg

Weight incl. device

Approx. 50 kg

Power supply unit

Tab. 5​General information


Input

Phases

1

Nominal input voltage Ue nom.

1× AC 110 ... 240 V

Input voltage range

AC 85 ... 264 V; DC 90 ... 373 V

Nominal line frequency range

47 ... 63 Hz; 0 Hz

Input current Ie

≤ 1.5 A (AC 230 V); ≤ 3 A (AC 115 V)

Leakage current

≤ 3.5 mA

Inrush current

≤ 30 mA

Power factor

≥ 0.94 (AC 230 V); ≥ 0.98 (AC 115 V)

Power factor correction (PFC)

Active

Power failure bypass

≥ 20 ms (AC 230 V)


Output

Output voltage Ua nom.

DC 24 V (SELV)

Output voltage range

DC 22 ... 28 V (adjustable)

Default setting

DC 24 V

Nominal output current Ia nom.

10 A (DC 24 V)

Output rating

240 W

Control deviation

≤ 1%

Residual ripple

≤ 100 mV (peak – peak)

Behavior if overload occurs

Constant power
(in overload range 1.15 ... 1.4 × Ia nom.);
if short circuit, automatic restart switches off


Signaling and communication

Signaling

1 × LED DC O.K. (green)

1 × LED Overload (red)

Operating display

LED green (DC 24 V O.K.)

LED red (overload)

Efficiency/power dissipation

Power dissipation Pv

≤ 37.5 W (AC 230 V; nominal load)

Power dissipation max. Pv max.

53 W (AC 110 V/DC 24 V; 11 A)

Efficiency typ.

86% (AC 230 V)

Fuse protection

Internal fuse

F 5 A / AC 250 V

Necessary back-up fuse

For DC input voltage, an external DC fuse is required.

Recommended back-up fuse

Circuit breaker 10 A, 16 A; characteristic B or C


Safety and protection

Insulation voltage (prim.-sec.)

DC 4.242 kv

Insulation voltage (prim.-PE)

DC 2.2 kv

Insulation voltage (sec.-PE)

DC 0.7 kv

Protection class

I

Protection type

IP20 (according to EN 60529)

Feedback resistance

≤ DC 28 V

Overvoltage category

II

Amount of dirt

2

Transient protection; primary

Varistor

Short circuit proof

Yes

Idle proof

Yes

Parallel switchable

Yes

Switchable in a series

Yes

MTBF

480,000 h (in accordance with IEC 61709)


Connection data

Connection type 1

Input/output

Connection equipment

CAGE CLAMP®

WAGO clamp

WAGO Series 745

Solid conductor

0.08 ... 4 mm²/28 ... 12 AWG

Fine-wire conductor

0.08 ... 4 mm²/28 ... 12 AWG

Stripping length

8 ... 9 mm/0.31 ... 0.35 inch

Note (conductor cross-section)

12 AWG: THHN, THWN


Geometric data

Width

110 mm/4.331 inch

Height

92 mm/3.622 inch

Depth from upper edge of support rail

136 mm/5.354 inch


Mechanical data

Type of support rail installation

35