Orbitalum ORBIWELD OW 65, ORBIWELD OW 115, ORBIWELD OW 170, ORBIWELD OW 38S, ORBIWELD OW 76S Operating Instructions Manual
...
Machine no.:
Operating instructions
for responsible bodies and persons using the machine
Enclosed Orbital Welding Heads
ORBIWELD
OW 65, OW 115, OW 170
OW 38S, OW 76S, OW 115S
OW 12, OW 19
To work safely with this machine, please read through the operating instructions in full before initial operation.
Retain the operating instructions for future reference.
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orbitalum tools GmbH, D -78224 Singen, ww w.orbitalu m.com, Tel. +49 (0) 77 31 792- 0 (24.07.17) OW_BA _ORBIW ELD_821.060 .202_05_EN
ORBIWELD | Operating instructions
1. ABOUT THIS INSTRUCTIONS..................................4
1.1 Warning messages .....................................4
1.2 Abbreviations ............................................4
2. INFORMATION AND SAFET Y INSTRUCTIONS FOR
THE
RESPONSIBLE BODY .......................................................5
2.1 Requirements for the responsible body .......5
2.2 Using the machine .....................................5
2.2.1 Proper use .......................................5
2.2.2 Improper use ...................................5
2.2.3 Machine constraints .........................5
2.3 Environmental protection/disposal .............6
2.3.1 Electric tools and accessories ...........6
2.4 Basic safety instructions ............................6
3. Product design ...................................................10
3.1 ORBIWELD 65 - 170 ..................................10
3.1.1 Front view ......................................10
3.1.2 Welding head view .........................10
3.2 ORBIWELD 38S, 76S .................................10
3.2.1 Front view ......................................10
3.2.2 Welding head view .........................11
3.3 ORBIWELD 115S, 170S .............................11
3.3.1 Front view ...................................... 11
3.3.2 Welding head view .........................11
3.4 ORBIWELD 12, 19 .....................................12
3.4.1 OW 12 - front view ..........................12
3.4.2 OW 12 - clamping cartridge ............12
3.4.3 OW 19 - front view ..........................12
3.5 Accessories .............................................12
3.5.1 Exchangeable clamping cartridges for
OW 12 ...........................................13
3.5.2 Clamping shells for OW 12 (clamping
cartridge, version B) .......................13
3.5.3 Clamping shell for OW 19 ...............13
3.5.4 Clamping shells for OW 38S, OW 76S,
OW 115S, OW 170S ........................13
3.5.5 Special clamping shells for orbital
welding heads ...............................14
3.5.6 Plastic case for clamping shells ...... 14
3.5.7 Cavity shell for moldings (2 shells) .14
3.5.8 Special clamping shell ...................14
3.5.9 Shells for arc welding .....................15
3.5.10 Elect rode adapters .........................15
3.5.11 Clamping shells for OW 65, OW 115,
OW 170 ..........................................16
3.5.12 Special clamping shells for orbital
welding heads ...............................16
3.5.13 Plastic case for clamping shells ...... 16
3.5.14 Cavity shells for moldings (2 shells) 16
3.5.15 Extension cable assembly ..............17
3.5.16 Shells for arc welding .....................17
3.5.17 Elect rode adapters .........................18
4. Features and Scope of Application ......................19
4.1 ORBIWELD 12 ...........................................19
4.2 ORBIWELD 19 ...........................................19
4.3 ORBIWELD 38S, 76S, 115S, 170S ..............19
4.4 ORBIWELD 65, 115, 170 ............................20
5. Technical Data....................................................21
5.1 Technial Data ...........................................21
5.2 Storage of the System ..............................21
5.3 Electrodes ...............................................22
5.4 Generated Noise Level ..............................22
6. Operational Elements and Functions ...................23
6.1 Keys ........................................................23
6.1.1 LED-Indicator .................................23
6.1.2 <START/STOP> ................................23
6.1.3 <GAS/TEST> ....................................23
6.1.4 <END/ 0-POS> .................................23
6.1.5 <MOTOR> ........................................23
6.2 Handle .....................................................23
6.3 Rotor .......................................................24
6.4 Top-Clamp-Side .......................................24
6.4.1 Adjustment of the Clamp-Latches ...24
6.5 Collets .....................................................24
6.5.1 Spring Plungers .............................24
6.6 Electrical Ground Connection ...................25
6.7 Electrodes ...............................................25
6.7.1 Electrode Set Screw .......................25
6.7.2 Electrode Length ............................25
6.7.3 Adjustment of Arc length ................25
6.7.4 Electrode Change ...........................25
7. Initial Operation and Operation Sequence ...........26
7.1 Checking the parts of delivery ..................26
7.2 Included with the machine (subject to
change without notice) .............................26
7.3 Preparations ............................................26
7.4 Attaching the Welding Head .....................26
7.5 Setting-Up the System for Operation ........27
7.6 Welding ...................................................27
7.7 Interrupt Welding .....................................27
7.8 Remove Welding Head ..............................27
TABLE OF CONTENTS
(24.07.17) OW_BA_ORBIWELD_821.060.202_05_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Tel . +49 (0) 77 31 792-0 3
ORBIWELD | 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.
8. Service and Maintenance ...................................29
9. TroubleShooting ................................................30
10. EU Declaration of Conformity ....................31
10.1 ORBIWELD 65 | 115 | 170 | 38S | 76S | 115S |
170S | 12 | 19 ...........................................31
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orbitalum tools GmbH, D -78224 Singen, ww w.orbitalu m.com, Tel. +49 (0) 77 31 792- 0 (24.07.17) OW_BA _ORBIW ELD_821.060 .202_05_EN
ABOUT THIS INSTRUCTIONS ORBIWELD | Operating instructions
1. ABOUT THIS INSTRUCTIONS
To allow quick understanding of these instructions and safe handling of the machine, all the warning messages, notes
and symbols used in these instructions are presented here along with their meaning.
1.1 Warning messages
In these instructions, warning messages are used to warn you against the dangers of injury or material 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
ATTENTION This note refers to dangers, which can cause damage at the system or to the product.
WARNING
This note refers to dangers, which can cause injuries for operators, technical personal or
unconcerned persons in the working area.
DANGER
This note refers to dangers, which can cause danger for life or heavy injuries for
operators, technical personal or unconcerned persons in the working area.
1.2 Abbreviations
Abbr. Meaning
OW ORBIWELD
(24.07.17) OW_BA_ORBIWELD_821.060.202_05_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Tel . +49 (0) 77 31 792-0 5
ORBIWELD | Operating instructions INFORMATION AND SAFET Y INSTRUCTIONS FOR THE RESPONSIBLE BODY
2. INFORMATION AND SAFET Y INSTRUCTIONS FOR THE
RESPONSIBLE BODY
2.1 Requirements for the responsible body
• Workshop/outdoor/field application: 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 safety regulations described in chap. 2 must be observed and work
must be carried out with safety in mind using the prescribed protective equipment.
2.2 Using the machine
2.2.1 Proper use
The orbital welding equipment ( Orbital Welding Power Supplies CA/CB 165/300 and
Orbitwin in connection with the orbital welding heads OW/TP/P/OP/HX and the
manufacturer's recommended accessories) are to be used with metal pipes and tubes up to
the specified pipe/tube dimensions of the heads.
The machine may only be used on pipes and containers that are empty, unpressurized, do
not have explosive atmospheres and are not contaminated.
The cassette (only for ORBIWELD welding heads) is entirely closed and thereby forms a
room, which keeps the atmospheric air away from the welding zone. All necessary power
supply and controls have to be provided by the orbital power supply.
The welding head is clamped by means of collets or clamp jaws onto the tube joint, which
is to be welded. The arrangement is made in such a way, that the welding-electrode is
located radially over the tube joint.
After ignition of the welding arc, the electrode is turned around the tube according to the
preselected speed. Thereby the tube is being welded.
Proper use also includes the following:
• observing all safety instructions and warning messages included in these operating
instructions
• carrying out all inspection and maintenance work
• sole use in the original condition with original accessories, spare parts and materials
2.2.2 Improper use
A use other than that defined under "proper use" or a use that goes beyond this or the specified constraints shall be considered improper use due to the potential risks involved.
The removal of safety equipment is not permitted. DThe machine is not intended for use by
private consumers. The technical values defined for normal operation must not be
exceeded.
2.2.3 Machine constraints
• The workplace can be in pipe preparation, in plant construction or in the plant itself.
• A radial space requirement/freedom of movement of approx. 2 m around the machine is required for people.
• Work lighting: min. 300 lux.
• Maintenance as described in chapter 8.1
• Operated by one person.
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orbitalum tools GmbH, D -78224 Singen, ww w.orbitalu m.com, Tel. +49 (0) 77 31 792- 0 (24.07.17) OW_BA _ORBIW ELD_821.060 .202_05_EN
INFORMATION AND SAFET Y INSTRUCTIONS FOR THERESPONSIBLE BODY ORBIWELD | Operating instructions
• User qualification: instructed operator.
• Climate conditions:
temperature range for machine operation: -10°C to 40°C, (<70% rel. humidity).
temperature range for machine storage: -20°C to 40°C, (<70% rel. rel. humidity).
Do not use outdoors in fog, rain or during a thunderstorm.
The cooling performance is only guaranteed when full water tank.
2.3 Environmental protection/disposal
2.3.1 Electric tools and accessories
Discarded electric 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 actively contribute to
the reuse, recycling and utilization of electrical (electronic) devices.
• Used electrical (electronic) devices contain parts that must be handled selectively
according to EU regulations. Separate collection and selective treatment is the basis
for environmentfriendly disposal and the protection of human health.
• Appliances and products that you bought from us after August 13, 2005 will be
disposed of in accordance with legal standards after they have been supplied to us
at no cost.
• We may refuse to accept old appliances that pose a risk to human health or safety due
to contamination produced during use.
• The end user is responsible for disposing of used appliances introduced to the market
before August 13, 2005. Please contact a disposal center near you for this purpose.
• Important for Germany: our products may not be disposed of in municipal disposal
sites as they are only used for industrial purposes.
(nach RL 20 02/96/EG)
2.4 Basic safety instructions
All products which are produced and market by Orbitalum Tools GmbH are state-of-the-art machines designed for safe
use. The risks involved in using the machines are described in the operating instructions below. Using this machine in a
way other than that described in these instructions can lead to serious physical injury and material damage.
Therefore:
• Observe warning messages at all times.
• Keep complete documentation close by the machine.
• Observe country-specific regulations,accident prevention regulations, standards and guidelines.
• Always ensure that the machine is in good working order. Observe the maintenance information. (chap. 8.1).
• Report any unusual machine behavior to the person responsible immediately.
• Only use the dimensions and materials specified in these instructions. Other materials should be used only after
consulting with Orbitalum Tools customer service.
• Only use tools, spare parts, Ersatzteile, operational materials and accessories of Orbitalum Tools.
• Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician..
• At the end of each working cycle, before transportation, changing tools, cleaning and performing any maintenance,
adjustment or repair work, switch off the machine, allow it to run to a stop and pull the mains plug.
• Do not carry the machine by the cable assembly and protect them from heat, oil and sharp edges.
• During operation, keep hands away from the tools.
• Check that the work piece is correctly clamped.
• Switch on the machine only when the pipe has been clamped.
(24.07.17) OW_BA_ORBIWELD_821.060.202_05_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Tel . +49 (0) 77 31 792-0 7
ORBIWELD | Operating instructions INFORMATION AND SAFET Y INSTRUCTIONS FOR THERESPONSIBLE BODY
• In extreme usage conditions, conductive dust can settle in the machine's interior. For this reason, the installation of
a SPE-PRCD or fault current (FI) protect switch (30 mA) between the main power supply and the machine is required.
Such protection is to be provided by the customer and installed by a qualified electrician.
• When working with the machine, wear safety shoes in accordance with EN ISO 20345 (at leastS1).
NOTE The recommendations concerning "Personal protective equip-
ment" only apply to the product being described
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
responsible body (employer) from its statutory health and
safety at work obligations towards its employees.
WARNING
Danger of unit toppling over (Orbicar welding trolley, gas cylinder, welding power supply,
cooling unit) as a result of external application of force.
Diverse physical injuries and property damage are possible!
X Install machine securely against external force and keep moving masses at minimum
clearance of 1 meter.
DANGER
Danger through operation by more than one person
Diverse physical injuries and property damage are possible!
X Ensure that only one person operates the machine and welder head at a time.
DANGER
Danger through improper maintenance of the unit
Diverse physical injuries and property damage are possible!
X Maintenance work must be performed in accordance with the "Maintenance" section.
DANGER
Electrical forms of danger from contact and/or incorrect or damp personal protective
equipment.
Electric shock!
[ Do not touch any live parts (pipes), especially during arc ignition!
[ Persons with increased sensitivity to electrical forms of danger (e.g. cardiac
insufficiency) must not work with the unit.
X Dry safety shoes, dry metal-free (rivet-free) leather gloves and dry protective suits
minimize the danger presented by electricity.
X Work on dry ground.
DANGER
Accidentally activated ignition function
Electric shock!
X Always switch off the orbital welding power supply when connecting or disconnecting
a welding head.
WARNING
Electromagnetic incompatibility of surrounding devices when conducting high-frequency
ignition and devices without ground conductor in operation
Diverse physical injuries and property damage are possible!
X Only use insulated electrical devices in the working area of the welding unit.
X Observe electromagnetically sensitive devices when the unit is ignited
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orbitalum tools GmbH, D -78224 Singen, ww w.orbitalu m.com, Tel. +49 (0) 77 31 792- 0 (24.07.17) OW_BA _ORBIW ELD_821.060 .202_05_EN
INFORMATION AND SAFET Y INSTRUCTIONS FOR THERESPONSIBLE BODY ORBIWELD | Operating instructions
WARNING
Ultra-violet radiation caused by the arc during welding operation
Damage to eyes and burns to the skin!
X During operation, wear EN 170-compliant visor and protective clothing that covers the
skin.
X In the case of closed heads, check that the visor is in perfect working order.
WARNING
Hot emergent liquids and hot plug connections during intense operation
Danger of scalding!
X Observe safety measures put in place by the supervisor/safety officer.
DANGER
Incorrect handling of pressure containers and other parts of the unit (e.g. forming gas
cylinder)
Diverse physical injuries and property damage are possible!
X Observe safety regulations, especially for pressure containers.
X Observe safety data sheets.
X If > 25 kg, lift unit and its components with the help of several people/hoisting
equipment.
DANGER
Flammable materials in the vicinity of the welding zone or solvents in the ambient air
Danger of explosion and fire!
[ Do not perform welding tasks in the vicinity of solvents (e.g. painting work)
[ Do not perform welding tasks in the vicinity of explosive materials
X Ensure there are no flammable materials or contaminations in the vicinity of the wel-
ding zone or being used as an underlay
ATTENTION
Surfaces of the welding heads and welding point remain hot for some time after welding
Danger of burning!
X Wear protective gloves
WARNING
Toxic vapors and materials in the welding process and handling electrodes
Damage to health, such as cancer!
[ Do not use electrodes that contain thorium
X Use extraction device in accordance with official regulations (e.g. BGI: 7006-1)
X Particular attention should be paid when working with chromium, nickel, or
manganese
DANGER
Incorrect ignition when welding head has not been attached or brought into the correct
position.
Electric shock, physical injury, and property damage to other devices!
[ Do not play with welding heads
X Switch to "test" function if head is not ready for operation
DANGER
Improper access and opening of ORBIMAT unit
Electric shock!
[ Never connect an open unit to the power supply
X Disconnect unit from the power supply
X Remove all devices connected externally to the unit (welding heads, etc.)
X If previously in use, allow to cool
X Only allow qualified electricians to access the electronics
DANGER
Liquid in housing as a result of improper use and/or transport
Electric shock!
[ Do not place any liquids (drinks) on the unit
X Keep vents free
X Check housing for moisture on the inside after transporting the machine and leave
open to dry if necessary.
(24.07.17) OW_BA_ORBIWELD_821.060.202_05_EN orbitalum tools Gmb H, D-78224 Singe n, www.orbi talum.com, Tel . +49 (0) 77 31 792-0 9
ORBIWELD | Operating instructions INFORMATION AND SAFET Y INSTRUCTIONS FOR THERESPONSIBLE BODY
DANGER
Damaged plug!
Fatal electric shock.
[ Do not use adapter plugs with ground protected electrical tools.
X The machine connector plug must fit the socket.
DANGER
Loose/baggy clothing, long hair or jewelry can get caught in rotating machine parts!
Serious injury or death.
[ During operation, do not wear loose/baggy clothing, e.g. neckties.
X Tie up long hair to prevent it from being caught.
DANGER
Safety components that are contaminated or worn are defective!
The failure of safety components can cause physical injury.
X Replace defective safety components immediately and check them daily
to ensure proper operation.
X Inspect the machine daily for visible signs of damage or defects, and have them re-
paired by a specialist if necessary.
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orbitalum tools GmbH, D -78224 Singen, ww w.orbitalu m.com, Tel. +49 (0) 77 31 792- 0 (24.07.17) OW_BA _ORBIWE LD_821.060. 202_05_EN
Product design ORBIWELD | Operating instructions
3. PRODUCT DESIGN
3.1 ORBIWELD 65 - 170
3.1.1 Front view
2
4
3
1
5
6
1. Handle
2. Function keys
3. Clamp latches
4. Collets
5. Latch
6. Viewing window
3.1.2 Welding head view
5
4
2
1
3
1. Clamp
2. Rotor
3. Electrode
4. Collets
5. Clamp latches
3.2 ORBIWELD 38S, 76S
3.2.1 Front view
2
4
3
1
5
1. Handle
2. Operation keys
3. Clamp latches
4. Collets
5. Viewing window
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