Orbitalum ORBIMAT 180 SW Operating Instructions Manual
Operating instructions
For responsible bodies and persons using the machine
Orbital Welding Power Supply
ORBIMAT 180 SW
Machine No.:
Code 850 060 202 | EN | Translation of original o perating instr uctions
To ensure safe working read the operating
instructions before commissioning.
Retain the operating instructions
for future reference.
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.
ORBIMAT 180 SW | Operating instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Ph one +49 (0) 77 31 792-0 3
1. About these instructions ......................................5
1.1 Warning messages .....................................5
1.2 Further symbols and displays .....................5
1.3 Abbreviations ............................................5
1.4 Further applicable documents ....................5
2. Information and safety instructions ......................6
2.1 Requirements for the responsible body .......6
2.2 Using the machine .....................................6
2.2.1 Proper use .......................................6
2.2.2 Machine constraints .........................7
2.3 Environmental protection/disposal .............7
2.3.1 Coolant ............................................7
2.3.2 Electric tools and accessories ...........7
2.4 Personnel qualification ..............................7
2.5 Fundamental information on operational
safety ........................................................8
2.6 Personal protective equipment ...................8
2.7 Remaining risks .........................................8
2.7.1 Injury through high weight ...............8
2.7.2 Burns and danger of fire through
high temperatures ...........................9
2.7.3 Tripping over the hose package ........9
2.7.4 Long-lasting physical damage
through wrong posture .....................9
2.7.5 Electric shock ..................................9
2.7.6 Danger through incorrect handling
of pressure tanks ........................... 10
2.7.7 Damage to eyes through radiation .. 10
2.7.8 Dangers through electromagnetic
fields ............................................. 10
2.7.9 Risk of suffocation through an
excessive argon share in the air ...... 11
2.7.10 Health problems ............................11
2.7.11 Danger of system tipping over ........11
2.7.12 Danger of explosion and fire ........... 11
2.7.13 General injuries through tools ........11
3. Description ........................................................12
3.1 ORBIMAT 180 SW .....................................12
3.2 Operating concept ....................................14
3.2.1 Operation via push switches
(softkeys) ......................................14
3.2.2 Operation via touch screen .............14
3.2.3 Operation via rotary knob...............14
3.2.4 Operation via an external
keyboard .......................................15
3.3 Warning signs ..........................................16
4. Scope of application...........................................17
4.1 Accessories .............................................17
4.1.1 ORBICAR W trolley..........................17
4.1.2 ORBICOOL Active ...........................17
4.1.3 ORBITWIN switching unit ................18
4.1.4 ORBmax oxygen meter ................... 18
4.1.5 Remote control with cable ..............18
4.1.6 OCL-30 coolant ............................... 18
4.1.7 ORBIPURGE forming set..................18
4.1.8 Paper rolls and ribbon cartridges ...18
5. Technical specifications .....................................19
6. Storage and transport ........................................20
6.1 Gross weight ............................................20
6.2 Preparing storage ....................................20
6.2.1 Removing the weld head from the
orbital welding power supply ..........20
6.2.2 Pumping out coolant ......................20
7. Commissioning ..................................................23
7.1 Scope of delivery .....................................23
7.2 Checking the scope of delivery .................23
7.3 Accessories (optionally available) .............23
7.4 Connecting the welding power supply .......24
7.4.1 Setting up machine ........................24
7.4.2 Connecting a gas bottle .................24
7.4.3 Connecting weld heads ..................25
7.4.4 Detaching coolant hoses ................25
7.4.5 Pumping out coolant ......................25
7.4.6 Closing off gas hose .......................25
7.5 Commissioning ........................................25
7.5.1 Topping up coolant .........................26
7.5.2 Connecting Remote control/dummy
plug ...............................................26
7.5.3 Switching on the power source .......27
7.5.4 Setting the language ......................28
7.5.5 Setting the measuring units ...........28
8. Operation ..........................................................29
8.1 Auto programming ...................................29
8.1.1 Setting parameters ........................29
8.1.2 Configuring weld head ...................29
8.1.3 Configuring material ......................30
8.1.4 Configuring protective gas .............30
8.1.5 Configuring pipe diameter ..............31
8.1.6 Configuring wall thickness .............31
8.1.7 Configuring wire feed .....................31
8.1.8 Calculating procedure ....................31
8.2 Testing the procedure ...............................32
8.2.1 Preparing weld head ......................32
8.2.2 Preparing electrode .......................32
8.2.3 Turning weld head ..........................32
8.2.4 Connecting forming gas .................34
8.2.5 Welding .........................................34
8.2.6 Interrupting the welding process ....36
8.3 Adjusting the procedure ...........................37
8.3.1 Reasons and steps for adjusting
procedure ......................................37
8.3.2 Making percental changes ..............37
TABLE OF CONTENTS
ORBIMAT 180 SW | Operating instructions
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8.3.3 Adjusting individual parameters .....38
8.3.4 Digital gas management.................38
8.3.5 Adjusting gas times .......................38
8.3.6 Adjusting ignition current, final
current and current slope-off ..........39
8.3.7 Adjusting the pool formation time ..39
8.3.8 Adjusting welding current and
transition times ("Slope") .............. 40
8.3.9 Adjusting pulse times ....................41
8.3.10 Adjusting weld speed and
transition time ("Slope") ................42
8.3.11 Changing the sector ...................... 44
8.4 Saving and calling up a procedure ........... 46
8.4.1 Saving a procedure ....................... 46
8.4.2 Calling up a procedure .................. 46
8.5 Locking machine with a login .................... 47
8.6 Tacking function ...................................... 48
8.7 Using the second gas pressure level
("Flow Force") ..........................................49
8.8 Connecting supplementary devices ..........51
8.8.1 ORB Residual Oxygen Meter ........... 51
8.8.2 Connecting and configuring the
BUP control unit ............................. 51
8.8.3 TIG manual welding torch ...............51
8.8.4 External remote control .................. 53
8.8.5 External printer (A4) .......................53
8.8.6 External monitor /HDMI ................. 53
8.9 Monitoring functions ................................ 53
8.9.1 General information ....................... 53
8.9.2 Adjusting limit values .....................54
8.10 Data documentation and data
management ............................................55
8.10.1 Managing data ............................... 55
8.10.2 Entering comments and application
data ("Process details") .................57
8.10.3 Working using USB ........................58
8.10.4 Viewing and printing data ..............59
8.10.5 Editing data on a PC with the
"OrbiProgCA" supplementary
software ....................................... 60
8.11 Updating and backup functions for the
software ................................................. 60
8.12 Updating software components ................ 61
8.13 Saving software components ...................61
8.14 Restoring software components ...............61
8.15 Working in other languages ...................... 61
8.15.1 Changing the language ..................61
8.15.2 Printing data in another language ...62
8.15.3 Creating a new operating
language .......................................62
8.16 Importing programs from other
Orbitalum power sources .........................62
8.16.1 Impor ting procedures ..................... 63
8.17 Special keyboard commands ....................63
8.18 Operation of the system with other mains
voltages ...................................................63
9. Service and troubleshooting .............................. 64
9.1 Performing service work .......................... 64
9.1.1 Pumping out coolant ..................... 64
9.1.2 Performing motor calibration ......... 64
9.1.3 Adjusting an external printer ......... 66
9.1.4 Switching on an internal printer ..... 66
9.1.5 Printing a test page ........................67
9.1.6 Service screen ...............................67
9.1.7 Info............................................... 68
9.2 Possible application/operating errors ...... 68
9.2.1 Uneven weld seam ("current
fluctuations") ............................... 68
9.2.2 Annealing colors inside/outside .... 68
9.2.3 Wide seam and no weld
penetration .................................... 69
9.2.4 Uneven seam/hole formation at
the end of welding .........................69
9.2.5 Ignition problems ...........................70
9.2.6 Machine does not start ..................70
9.3 List of error messages ..............................71
9.4 Status LED indicators ...............................75
9.5 Temporarily deactivating sensors and
monitoring functions ................................ 75
9.5.1 Sensors .........................................75
9.5.2 Monitoring limits ...........................75
9.5.3 External input for aborting .............75
9.6 Setting the date and time ......................... 76
10. Maintenance and troubleshooting ......................77
10.1 Instructions for care .................................77
10.2 Maintenance and care ..............................77
10.2.1 Storage..........................................78
10.3 Servicing/Customer service ......................78
11. EC Declaration of Conformity ....................79
ORBIMAT 180 SW | Operating instructions About these instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Ph one +49 (0) 77 31 792-0 5
1. ABOUT THESE INSTRUCTIONS
1.1 Warning messages
The warning messages used in these instructions warn you of injuries or damage to property.
Always read and observe these warning messages!
This is the warning symbol. It should warn you against dangers of injury. In order to avoid injuries or
death observe the measures marked with a safety sign.
WARNING LEVEL MEANING
DANGER!
Imminently hazardous situation that results in death or serious injuries if the safety measures are
not observed.
WARNING!
Potentially hazardous situation that may result in death or serious injuries if the safety measures
are not observed.
CAUTION!
Potentially hazardous situation that may result in slight injuries if the safety measures are not
observed.
NOTE! Potentially hazardous situation that may result in material damage if the safety measures are not
observed.
1.2 Further symbols and displays
SYMBOL MEANING
Important information for comprehension.
1.
2.
3.
...
Request for action in a sequence of actions: Action is required here.
Single request for action: Action is required here.
1.3 Abbreviations
ABBREVIATION MEANING
OM, SW ORBIMAT, Type "SmartWelder"
1.4 Further applicable documents
The following documents apply together with these operating instructions:
• Operating instructions of the orbital weld head
Information and safety instructions ORBIMAT 180 SW | Operating instructions
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orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 (17.09.18) OW_OR BIMAT_180SW_ BA_850 060202_00 _EN
2. INFORMATION AND SAFETY INSTRUCTIONS
2.1 Requirements for the responsible body
Workshop/outdoor/field use: The responsible body 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 in the danger zone.
Employee safety: The operator has to observe the safety regulations described in this chapter as well as has to work
safety-consciously and with all prescribed safety equipment.
The employer undertakes to give the employees clear notice of the dangers arising that are specified in the EMF directives and to evaluate the workplace correspondingly.
Requirements for special EMF evaluations with regard to general activities, working materials and workplaces*:
TYPE OF WORKING MATERIALS OR
WORKPLACE
EVALUATION REQUIRED FOR:
Employees without
particular risk
Employees at particular
risk (with the exception
of those with active im-
plants)
Employees with active
implants
(1) (2) (3)
Arc welding, manual (including MIG (Metal
Inert Gas), MAG (Metal Active Gas), TIG (Tungsten Inert Gas)) under observance of triedand-tested procedures and without physical
contact to the line
No No Yes
* According to Directive 2013/35/EU
2.2 Using the machine
2.2.1 Proper use
The orbital welding power supply is intended solely for the following utilization:
• Utilization in combination with an orbital weld head of the company Orbitalum Tools GmbH or with
a compatible third-part device in combination with a weld head adapter of the company Orbitalum
Tools GmbH.
• TIG welding of materials that are specified in these operating instructions (see chap. 4, p. 17).
• Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.
Intended use also includes the following points:
• Permanent supervision of the machine during operation. The operator must always be able to stop the process.
• Observing all safety instructions and warning messages in these operating instructions.
• Observing of the further applicable documents.
• Complying with all inspection and maintenance work.
• Use of the machine solely in its original state.
• Usage solely of original accessories as well as original spare parts and operating materials.
• Usage solely of protective gases that are classified for TIG welding process in accordance with EN ISO 14175.
• Usage solely of coolant OCL-30 of the company Orbitalum Tools GmbH.
• Checking of all the safety-relevant items and functions before commissioning.
• Processing of those materials named in the operating instructions.
ORBIMAT 180 SW | Operating instructions Information and safety instructions
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• Purpose usage of all components involved in the welding processes as well as of all further factors that have an
influence on the welding process.
• Solely commercial usage.
2.2.2 Machine constraints
• The workplace can be in the tube preparation, in plant construction or in the plant itself.
• The machine is operated by one person.
• Erect the machine solely on a solid surface.
• A radial space requirement/freedom of movement of approx. 2 m around the machine is required for people.
• Work lighting: min. 300 Lux.
• Climate conditions: –10 °C to 40 °C; < 80% rel. humidity.
• Only work with the machine in dry surroundings (not in misty, rainy or stormy conditions). If appropriate use a welding tent.
• Cooling is only ensured with a full coolant tank.
2.3 Environmental protection/disposal
2.3.1 Coolant
Dispose of coolant in accordance with the local statutory regulations.
2.3.2 Electric tools and accessories
Used-up power tools and accessories contain a large amount of valuable raw materials and plastics which can be recycled.
(as per RL 20 02/96/EC)
• Used electronic devices marked with the adjacent symbol may not be disposed of with household waste in accordance with EU directives.
• By actively using the offered return and collection systems, you are doing your part to reuse and recycle used electronic devices.
• Used electronic devices contain parts that must be handled selectively according to the EU directive. Separate
collection and selective treatment are the basis for environmentally responsible disposal and protection of human
health.
• We will properly dispose of devices and machines from Orbitalum Tools GmbH purchased after August 13th, 2005
if they are sent to us postage-paid.
• In the case of used electronic devices which may represent a risk to human health or safety due to contamination
during use, we have the option of refusing return.
• The user is responsible for disposing of used electronic devices purchased before August 13th, 2005. Bitte wenden
Sie sich hierfür an einen Entsorgungsfachbetrieb in Ihrer Nähe.
• Important for Germany: Devices and machines of Orbitalum Tools GmbH may not be disposed of at communal
dumps, as they are only used in the commercial sector.
2.4 Personnel qualification
CAUTION!
The orbital welding power supply may only be used by instructed personnel.
• Minimum age: 18 years old.
• No physical impairments.
• Operation of the machine by underage persons only under supervision by a person authorized to issue instructions.
• A basic knowledge of TIG welding process is advisable.
Information and safety instructions ORBIMAT 180 SW | Operating instructions
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2.5 Fundamental information on operational safety
CAUTION!
Observe valid safety and accident prevention regulations.
Improper usage can impair safety. This can result in life-threatening injuries.
X Never leave an welding power supply unattended when it is switched on.
X The operator has to ensure that no 2nd person is inside the danger zone.
X Do not modify or convert the orbital welding power supply.
X Use the orbital welding power supply only in proper operating order.
X Use only genuine tools, spare parts and accessories as well as specified operating materials.
X In case of changes in the operating behavior stop operation immediately and have the fault eliminated.
X Do not remove safety devices.
X In order to increase safety a customer-provided SPE-PRCD or a universal-current residual-current circuit-breaker 30
mA or an isolating transformer between the mains network and the welding power supply is required.
X Do not pull the machine at the hose package or the cable.
X Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
X Do not carry the machine by the hose package or the cable and do not use the machine to pull out the plug (except
in an emergency). Protect the cable against heat, oil and sharp edges (chips).
2.6 Personal protective equipment
The sole act of operating the welding power supply does not require personal protective equipment:
X When connecting and using a weld head observe the respective safety instructions and warning messages of the
weld head.
X Observe the remaining risks.
2.7 Remaining risks
2.7.1 Injury through high weight
The orbital welding power supply has a weight of 28 kg (61.73 lbs). A significant health hazard exists during lifting.
Danger of impact and crushing exists in the following situations:
CAUTION!
Falling of the orbital welding power supply during transportation or setting up.
CAUTION!
Falling of the orbital welding power supply caused by it being put down improperly.
X Use a suitable transport medium to transport the orbital welding power supply.
X Always use 2 persons to lift and remove the orbital welding power supply from the packaging.
X When lifting the machine do not exceed the permissible total weight of 25 kg for men and 15 kg for women.
X Place the orbital welding power supply on a stable base.
X Wear safety shoes.
ORBIMAT 180 SW | Operating instructions Information and safety instructions
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2.7.2 Burns and danger of fire through high temperatures
CAUTION!
The orbital weld head is hot after welding. Very high temperatures arise in particular after several
consecutive welding processes. There is a danger of burns or damage to the points of contact when
working on the orbital weld head (for example when changing clamps or mounting/removing the electrodes). Materials without thermal resistance (for example foam inlay of the transport packages) can
be damaged when coming into contact with the hot orbital weld head.
X Wear safety gloves.
X Wait until the surfaces have cooled down to below 50 °C before working on the orbital weld head or before packing
into the transport packaging.
WARNING!
Thermal problems can arise in the case of incorrect positioning of the forming system or the use of
impermissible materials in the welding area. In the worst case a fire will be started. Observe the
local general fire protection measures.
X Position the forming system correctly.
X Use only permissible materials in the welding area.
WARNING!
Danger of scalding through hot emitted liquids as well as hot plug connections during heavy operation.
X Heed the safety precautions of the technical supervisor/person in charge of safety.
2.7.3 Tripping over the hose package
CAUTION!
If a hose package is connected, there is the danger that persons may trip over it and be injured.
WARNING!
Tripping over could cause the plug to be pulled out so that in the worst case an arc may arise between
the plug and the orbital weld system. Burns and glaring light may be the result.
X Ensure that under no circumstances can people trip over the hose package.
X Do not place the hose package under tension.
X Ensure that the hose package is connected properly and that the strain relief is attached.
2.7.4 Long-lasting physical damage through wrong posture
X Use the machine so that an upright and comfortable body position can be achieved during operation.
2.7.5 Electric shock
WARNING!
The danger exists of unintentionally operating the ignition function when connecting or disconnecting a weld head from the welding power supply.
X Switch off the orbital welding power supply when connecting or disconnecting a weld head.
X Do not play with weld head.
X If the weld head is not ready for operation, switch it to the "Test" function.
WARNING!
Electrical hazards through contact.
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X Do not touch energized parts (workpieces), especially when igniting the arc.
X From the start of the welding process avoid contact with the tube and the housing of the orbital weld head.
X Wear dry safety shoes, dry metal-free (grommet-free) leather gloves and dry safety suits to minimize the electrical
hazard.
X Work on a dry surface.
DANGER!
Risk of death for people with heart problems or cardiac pacemakers.
X Do not allow persons with increased sensitivity to electrical hazards (e.g. weakness of the heart) to work with the
machine.
DANGER!
Danger of an electric shock in the case of improper reaching in into and opening of the machine.
X Allow only a professional electrician to access the electrical system.
DANGER!
The danger of an electric shock exists through non-compatible or damaged connectors.
X Do not use adapter plugs together with protectively grounded power tools.
X Ensure that the connecting plugs of the machine fit into the outlet.
X When connecting use a residual-current circuit breaker 30 mA.
2.7.6 Danger through incorrect handling of pressure tanks
WARNING!
Various injuries and damage to property.
X Heed safety regulations for pressure tanks.
X Heed safety data sheets for pressure tanks.
2.7.7 Damage to eyes through radiation
WARNING!
During the welding process infrared, glaring and ultraviolet rays arise that can seriously damage
the eyes.
X Keep the flip cover and swivel clamp closed during the welding process.
X During operation, wear eye protection to EN 170 and skin-covering safety clothing.
X At closed weld heads ensure proper working order of the eye protection.
2.7.8 Dangers through electromagnetic fields
DANGER!
Depending on the form of the workplace life-threatening electromagnetic fields can arise in the direct
vicinity.
X People with heart problems or cardiac pacemakers may not operate the welding system.
X The operator has to ensure safe design of the workplace in accordance with the EMF Directive 2013/35/EU.
X Use only electrical devices with protective insulation in the working area of the welding system.
X Observe electromagnetically-sensitive devices when igniting the system.
ORBIMAT 180 SW | Operating instructions Information and safety instructions
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2.7.9 Risk of suffocation through an excessive argon share in the air
DANGER!
If the argon share in the air rises above 50%, lasting damage or risk of death can arise suffocation.
X Ensure sufficient ventilation in rooms.
X If necessary, monitor the oxygen level in the air.
2.7.10 Health problems
WARNING!
Poisonous vapors and substances during the welding process and handling of the electrodes!
X Use extraction devices in accordance with the professional association regulations (e.g. BGI: 7006-1).
X Extra caution is required with chrome, nickel and manganese.
X Do not use electrodes containing thorium.
2.7.11 Danger of system tipping over
WARNING!
Manifold injuries and damage to property through system (for example ORBICAR welding carriage,
gas bottle, welding power supply, cooling unit) tipping over from the application of force from outside!
X Set up the machine so that it stands securely against external influences.
X Keep moving masses at least 1 meter away from the machine.
2.7.12 Danger of explosion and fire
DANGER!
Danger of explosion and fire through flammable materials near the welding zone or solvent in the
room air.
X Do not weld near solvents (for example where painting is being carried out) or explosive substances.
X Do not use flammable substances as a base in the welding area.
X Ensure that no flammable materials or soiling is located near the machine.
2.7.13 General injuries through tools
CAUTION!
Injuries can occur during dismantling for the proper disposal of the orbital welding power supply
through uncertainties in handling tools.
X In case of uncertainties send the orbital welding power supply to Orbitalum Tools – proper disposal is carried out
here.
Description ORBIMAT 180 SW | Operating instructions
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orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 (17.0 9.18) OW_OR BIMAT_180SW_ BA_850 060202_00_ EN
3. DESCRIPTION
3.1 ORBIMAT 180 SW
1
4
2
5
6
7
8 9 10 11 12 13 14 15 16 17 18 19
20
3
26
27
31
32
2524
28
29
30
21 2322
33
34
ORBIMAT 180 SW | Operating instructions Description
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ITEM DESIGNATION FUNCTION
1 Color touch display Operating the welding power supply, see chap. 3.2, p. 14
2 Push switches (softkeys) Operating the welding power supply, see chap. 3.2, p. 14
3 Cover, hinged Protects the operating elements
4 Connection socket, "USB", front Connection possibility for USB devices (2x) (optional)
5 Integrated system printer For printing actual values and welding data reports
6 Rotary knob Operating the welding power supply, see chap. 3.2, p. 14
7 Carry handles Transporting the welding power supply
8 Main switch (green) Switch on the welding power supply; lights up green during operation
9 Off button (red) Switch off the welding power supply; lights up red during operation and
in "Stand-by" mode
10 Connection socket "BUP" Connection possibility for "BUP Control Box", forming gas pressure con-
troller (optional)
11 Connection socket "ORBmax" Connection possibility for "ORBmax", residual oxygen meter (optional)
12 Connection socket "Remote" Connection for remote external control (optional) or dummy plug
13 Connection socket "Weld head" Connection for weld head signal line
14 Connection socket "Gas" Connection for gas hose to the weld head
15 Coolant connection, blue Connection for coolant supply line
16 Eye, strain relief Strain relief weld head to the power source
17 Coolant connection, red Connection for coolant return line
18 Weld current socket Connection weld head
19 Weld current connection Connection weld head
20 Ventilation slot Venting the welding power supply
21 Connection socket "LAN", rear Connection possibility for LAN cable
22 Connection socket "USB", rear Connection possibility for USB devices (2x) – see Item 4
23 Connection socket "HDMI", rear Connection possibility for HDMI cable
24 Coolant level indication Indicates the fill level of the coolant in the tank
25 Tank opening with lid Holding of up to 2.2 liter coolant for cooling the connected weld tongs
and heads
26 Rating plate Indication of the machine data
27 Gas connection Weld gas input
28 Connection socket "External cooling" Connection of external cooling unit signal line
29 Connection socket "ORBITWIN" Connection for ORBITWIN Switching Unit
30 Power input socket Connection for power line
31 Connection socket Connection possibility superordinate control system
32 Connection socket Connection possibility CAN-compatible components
33 Surface for keyboard The optionally available keyboard can be placed before the softkeys.
34 LED display Display of operating states and coolant flow
Description ORBIMAT 180 SW | Operating instructions
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3.2 Operating concept
The main control elements are the 6 push switches, whose current function assignment is displayed at the bottom margin of the display, the touch screen and the rotary knob. Direct access to standard functions (e.g. "Start" and "STOP")
is always possible. The entry of text is optionally possible using a keyboard that can be connected externally. If faults
occur (e.g. failure of the rotary knob or softkeys), the machine can be operated completely using the external keyboard.
3.2.1 Operation via push switches (softkeys)
The five push switches (Items 1 - 6) are assigned with
standard functions as softkeys.
Examples:
The push switch (Item 6) is usually assigned the "Menu"
function, meaning pressing it brings you directly to the
main menu, regardless of which sub-menu currently appears in the display. The push switch
(Item 3) is assigned the "Save" function. This allows a procedure change to be saved rapidly.
1
2
3
4
5
6
3.2.2 Operation via touch screen
Rapid and efficient operation via touch screen. Directly
touch the values to be changed. A virtual keyboard is
displayed. Operation while wearing protective gloves only
possible to a limited extent and not recommended.
7
3.2.3 Operation via rotary knob
The rotary knob (Item 8) has either a fine or rough detent
when being turned, depending on whether you are
navigating between menu items/fields (rough detent) or
setting parameter values (for example weld current) (fine
detent).
Navigating to a menu item/field in the display:
X Turn the rotary knob.
The menu item/field appears in blue.
8
ORBIMAT 180 SW | Operating instructions Description
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools Gmb H, D-78224 Singe n, www.orb italum.com, P hone +49 (0) 77 31 792-0 15
Select the menu item/field:
X Briefly press the rotary knob. The menu item is selected.
Exiting the menu and navigating to the next-higher menu level:
X Press the rotary knob long (> 2 seconds). The menu of the next-higher level appears in the display.
Setting a parameter/Entering a value:
X Highlight a field. The field appears in red.
X Change the value within the specified limit values: Turn the rotary knob.
X Saving the value and exiting the field: Briefly press the rotary knob.
3.2.4 Operation via an external keyboard
Navigating to a menu item/field in the display:
X Press the UP and DOWN arrow buttons.
Selecting the menu item/field:
X Press the ENTER key.
Setting a parameter/Entering a value:
X Highlight a field. The field appears in red.
X Entering a value: Change with the arrow buttons or enter directly with the number keys.
X Saving the value and exiting the field: Press the ENTER key.
Entering comments on procedures:
X Select a comment field.
X Enter the text using the keyboard.
Using push switches (softkeys) on the keyboard:
Function keys F1 through F6 on the external keyboard correspond to push switches 1 through 6.
Description ORBIMAT 180 SW | Operating instructions
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orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 (17.09.18) OW_OR BIMAT_180SW_ BA_850 060202_00 _EN
3.3 Warning signs
The warning signs and safety signs located on the machine must be observed.
Image Position on machine Meaning Code
Hood inside Read the safety instructions! 871 001 057
Rear panel Before opening the unit disconnect the
mains plug.
850 060 025
Side, left Caution: Only use Orbitalum coolant! 884 001 001
ORBIMAT 180 SW | Operating instructions Scope of application
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools Gmb H, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 17
4. SCOPE OF APPLICATION
The ORBIMAT 180 SW is characterized by the following scope of application and functions:
• For welding using the Tungsten Inert Gas (TIG) process
• Can be used for all materials that are fundamentally suitable for the TIG welding process.
• Simple and convenient operation thanks to multifunctional rotary knob or touch screen
• DC current welding source
• WIDE RANGE input voltages for safe operation of power sets or voltage networks with extreme fluctuations in voltage
• "Flow Force" function to reduce the gas pre-flow and post-flow time
• "Permanent gas" function
• Digital regulation of the weld gas quantity
• Monitoring of coolant and weld gas
• Control option for cold wire feed
• Possibility of connecting an external remote control
• Constant or pulsed wire feed motion and rotation
• Optimal visibility and operating conditions thanks to clearly laid-out 12.4" swivel monitor
• Graphically-supported operating interface and multilingual menu navigation via color display
• Metric and imperial measuring units
• Process-oriented, stable and real-time operating system without power-down sequence
• Automatic weld head recognition and resulting parameter modification
• Motor current monitoring of the drive motors
• Capacity to store over 5.000 welding procedures, providing systematic and clear procedure management thanks to
the creation of folder structures
• Welding data logging and printout of actual values
• Integrated system printer
• Possibility of connecting a monitor or printer (through HMDI/USB/LAN)
• Optional PC software (OrbiProg CA) for welding procedure management and logging
• Integrated, folding carrying grips
• Option to program up to 99 sectors
• Power and motor slope adjustment between the individual sectors
• Integrated liquid cooling system for cooling the connected weld heads
• Can only be used in combination with separately available liquid cooling system
4.1 Accessories
Optionally available:
WARNING!
Danger presented by using accessories that have not been approved.
Various injuries and damage to property.
X Use only original tools, spare parts, materials, and accessories from Orbitalum Tools.
4.1.1 ORBICAR W trolley
Thanks to its integrated liquid cooling function the ORBICAR W trolley
is the perfect supplement to the ORBIMAT 180 SW power source.
Beside the liquid cooling, the trolley is equipped with a practical holder for gas
bottles.
4.1.2 ORBICOOL Active
Very efficient compressor cooling device.
Particularly suitable for welding units in series production.
Scope of application ORBIMAT 180 SW | Operating instructions
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orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 (17.0 9.18) OW_OR BIMAT_180SW_ BA_850 060202_00_ EN
4.1.3 ORBITWIN switching unit
To increase productivity, the ORBITWIN switching unit is available which allows the
alternately operation with 2 weld heads on the ORBIMAT.
4.1.4 ORBmax oxygen meter
For optical oxygen measurement using fluorescence extinction.
The ORBmax does not require any heating-up time. It recognizes the oxygen percentage reliably, rapidly and precisely during the entire welding process.
4.1.5 Remote control with cable
For transferring all the commands important for welding to the power source.
It is not required when working with enclosed orbital weld heads.
4.1.6 OCL-30 coolant
1 canister already included in the scope of delivery of the ORBIMAT 180 SW power
source.
Anti-freeze pre-mix for ORBIMAT power sources and cooling units to avoid freezing of
the cooling water. Protects up to –30 °C (-22°F) outside temperature. Increased service life of components of the cooling system through very high corrosion protection
and high pH-value. Excellent ignition characteristics due to low conductivity. Clear
cooling liquid.
4.1.7 ORBIPURGE forming set
For rapid and efficient internal forming during pipe and molded part weld connections
while at the same time reducing gas consumptions.
4.1.8 Paper rolls and ribbon cartridges
For internal system printer.
Suitable for all ORBIMAT orbital welding power supplies.
ORBIMAT 180 SW | Operating instructions Technical specifications
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH , D-78224 Singen , www.orbit alum.com, Pho ne +49 (0) 77 31 792-0 19
5. TECHNICAL SPECIFICATIONS
PARAMETER UNIT ORBIMAT 180 SW REMARKS
Code 850 000 001
Weld system type Welding rectifier (inverter)
Input (mains)
Mains system 1 phase + PE
Mains input voltage [V (AV)] 110 - 230
Permissible voltage tolerance [%] +/–10
Mains frequency [Hz] 50/60 –
Continuous input current [A (AC)] 15.3
Continuous input [kVA] 3.6
Current consumption, max. [A (AC)] 19.5
Connection value, max. [kVA] 13.5
Power factor [cos ϕ] 1.0 (with 180 A)
Output (welding circuit)
Setting range weld current [A (DC)] 3 - 180 In 0.1 A increments
Weld current reproducibility [%] +/– 0.5
Rated current at 100% duty cycle [A (DC)] 160
Rated current at 60% duty cycle [A (DC)] 180
Weld voltage, min. [V (DC)] 10
Weld voltage, max. [V (DC)] 20
Open-circuit voltage, max. [V (DC)] 85
Ignition power, max. [Joule] 0.9
Ignition voltage, max. [kV] 10
Output (control)
Rotation motor voltage, max. [V (DC)] 24 PWM signal
Wire feeding motor voltage, max. [V (DC)] 24 PWM signal
Rotation motor current, max. [A (DC)] 1.5
Wire feeding motor current, max. [A (DC)] 1.5
Rotation tacho voltage [V (DC)] 0 - 10 Rotation speed, actual value
Other
Degree of protection IP 23 S
Cooling type AF
Insulation class F
Dimensions (wxdxh) [mm]
[inch]
600 x 400 x 310
23.6 x 15.7 x 12.2
300 CA without cooling unit
Weight [kg]
[lbs]
24.6
54.23
Gas input pressure [bar] 3 - 10 Via pressure reducer
Recommended gas input pressure [bar] 4 Via pressure reducer
Coolant volume [l] 2.2
Coolant pressure, max.
[bar] 4
Sound level, max. [dB (A)] 70
Storage and transpor t ORBIMAT 180 SW | Operating instructions
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6. STORAGE AND TRANSPORT
6.1 Gross weight
ARTICLE WEIGHT*
ORBIMAT 180 SW [kg] 28.0
[lbs] 61.73
* incl. transpor t packaging
WARNING!
Damage of electronic components with personal harm and damage to property.
If coolant is still located in the machine during transportation, coolant can enter from the tank into
the machine interior if tilted strongly.
X Pump out coolant before transporting.
WARNING!
Danger of injury through high weight of the orbital welding power supply!
The orbital welding power supply has a weight of 28.0 kg (61.73 lbs).
X Always lift the orbital weld head with two persons or use a suitable means of transport.
X When lifting the machine do not exceed the permissible total weight of 25 kg for men and 15 kg
for women.
6.2 Preparing storage
Carry out the following steps before storage:
6.2.1 Removing the weld head from the orbital welding power supply
For procedure see operating instructions of weld head.
6.2.2 Pumping out coolant
1. Connect the drain hose to the coolant connection,
blue.
2. Hold the end of the drain hose into a collecting vessel
(min. 3 liter).
1
ORBIMAT 180 SW | Operating instructions Storage and transport
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH , D-78224 Singen , www.orbit alum.com, Pho ne +49 (0) 77 31 792-0 21
Carry out the following steps in the menu of the welding power supply:
To protect the pump against possible dry running, the
software stops pumping out after approx. 30 seconds.
3. In the main menu, call up the "System settings" menu
item by turning the rotary knob.
4. Briefly press the rotary knob.
The "System settings" sub-menu appears.
Fig. 1: Main menu (long form)
5. Navigate to the "Service" menu item.
6. Briefly press the rotary knob.
The desired selection appears.
Fig. 2: Sub-menu – System settings
7. Select the "Coolant pump on" menu item.
8. Briefly press the rotary knob.
The "Pumping coolant out" message appears.
The "Cancel" button is highlighted in blue.
Fig. 3: Sub-menu – Service
Storage and transpor t ORBIMAT 180 SW | Operating instructions
22
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9. Confirm "Cancel" by briefly pressing the rotary knob.
The coolant pump is switched off.
10. Check the fill level indication and abort the process
when the tank is empty.
NOTE! When the pump runs dry, this is accompa-
nied by an audible increase in speed.
X Abort the process immediately.
Fig. 4: Coolant – Pumping out
If the coolant does not exit the hose within a maximum of 10 seconds:
11. Stop drainage, as prolonged dry running can damage the pump.
12. Check the coolant level.
13. Check whether the pump is started and a pumping sound can be heard.
ORBIMAT 180 SW | Operating instructions Commissioning
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH , D-78224 Singen, w ww.orbit alum.com, Phon e +49 (0) 77 31 792-0 23
7. COMMISSIONING
7.1 Scope of delivery
SCOPE OF DELIVERY CODE QUANTITY UNIT
ORBIMAT 180 SW Welding Power Supply 850 000 001 1 Pc.
Hose connection set ORBIMAT 875 030 018 1 Pc.
Dummy plug for remote control socket 875 050 006 1 Pc.
3.5 liter coolant OCL-3018 850 030 010 1 Bottle
Operating instructions with calibration certificate 850 060 201 1 Set
QuickStart guide 850 060 020 1 Pc.
Subject to modifications.
7.2 Checking the scope of delivery
X Check delivery for completeness and damage caused by transport.
X Report any missing parts or damage caused by transport to your supplier immediately.
7.3 Accessories (optionally available)
• ORBICAR W carriage with integrated liquid cooling
• ORBICOOL Active compressor cooling unit
• ORBITWIN Switching Unit
• Remote control with cable
• ORBmax residual oxygen meter
• Double pressure reducer
• TIG manual welding torch for ORBIMAT
Commissioning ORBIMAT 180 SW | Operating instructions
24
orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, P hone +49 (0) 77 31 792-0 (17.09.18) OW _ORBIMAT_180 SW_BA _850060202_ 00_EN
7.4 Connecting the welding power supply
CAUTION!
Damage to the orbital welding power supply through the mains supply voltage being exceeded.
X Check whether the mains supply voltage corresponds to the specifications in chap. 5.
X Observe requirements for the power supply: RCCB 30 mA.
DANGER!
Faulty ignition in case of unmounted or incorrectly positioned weld head!
Electric shock, bodily injury and damage to property also at other devices.
X If the weld head is not ready for operation, switch the machine to the "Test" function.
DANGER!
Improper access to and opening of the ORBIMAT system.
Electric shock.
X Disconnect the system from the mains.
X Remove all the external devices connected to the system (weld heads, etc.).
X If the machine was in operation beforehand, allow it to cool down sufficiently.
X Allow only a professional electrician to access the electrical system.
[ Never connect an opened system to the mains network.
DANGER!
Liquid in the housing due to improper use and transport.
Electric shock.
[ Do not place liquids (beverages) on the system.
X Do not block ventilation slots.
X Check housing interior for moisture after transporting the machine and leave it open to air it out
if necessary.
WARNING!
Ultraviolet radiation from the arc while welding.
Damage to eyes and burning of skin.
X During operation, wear eye protection to EN 170 and skin-covering safety clothing.
X At closed weld heads ensure proper working order of the eye protection.
WARNING!
Hot leaking liquids and hot plug connections during heavy operation.
Danger of scalding.
X Heed the safety precautions of the technical supervisor/person in charge of safety.
CAUTION!
Hot surfaces of the weld head and weld points, including for a period of time after welding.
Danger of burns.
X Wear safety gloves.
7.4.1 Setting up machine
X First set up the system for connection in such a way that it is as accessible as possible from the front and rear.
X Ensure that the machine is disconnected from the mains network on all sides.
X Secure the machine against being switched on unintentionally.
X Place the machine on a stable, fixed and plane base.
7.4. 2 Connecting a gas bottle
DANGER!
Exceeding the maximum permissible operating pressure of the forming gas can result in lethal
injuries.
X A pressure reducer must be used.
1. Check the stability of the gas bottle. Secure the gas bottle against falling over.
2. Ensure that the union nut on the pressure reducer fits the thread on the valve of the gas bottle.
3. Mount the pressure reducer on the gas bottle.
4. Connect the gas distributor (there is no gas distributor if a double pressure reducer is used).
5. Screw both included gas hoses onto the gas distributor or the double pressure reducer respectively..
6. Insert the gas hose (which is intended for connection to the power source and is identified by the plug-in nipple
made of brass on the end) into the provided connection socket on the rear back of the power source.
7. Connect the weld head.
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