Orbitalum ORBmax Operating Instructions Manual

Operating instructions

For responsible bodies and persons using the machine

Residual Oxygen Meter

ORBmax

To work safely with this device, please
read through the operating instructions
in full before initial operation.
Retain the operating instructions for
future reference.

Device No.:

Code 882 0 60 202 | EN | Translation of orig inal operating instructions

All rights reser ved, 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.

ORBmax | Operating instructions

TABLE OF CONTENTS

1. About these instructions ......................................4

1.1 Warning messages .....................................4

1.2 Further symbols and displays .....................4

1.3 Abbreviations ............................................4

2. Information and safety instructions for the

responsible body .................................................5

2.1 Requirements for the responsible body .......5

2.2 Using the device .........................................5

2.2.1 Proper use .......................................5

2.2.2 Improper use ...................................5

2.2.3 Limits of the device ..........................5

2.3 Environmental protection/disposal .............6

2.3.1 Electric tools and accessories ..........6

2.4 Basic safety instructions ............................6

3. Product design .....................................................8

3.1 ORBmax ....................................................8

3.2 Accessories and consumables ....................8

3.2.1 Measuring hose set ..........................8

3.2.2 Individual parts for measuring

hose set...........................................9

3.2.3 Power supply unit set .......................9

3.2.4 Interface cable .................................9

3.2.5 SD card ............................................9

3.2.6 Protective cover .............................10

3.2.7 Transport case ...............................10

8.4.3 Evaluating the measurement with

the "O2_Log" evaluation software .... 19

8.5 Connecting the ORBmax to the

power source ...........................................21

9. Servicing, maintenance, troubleshooting ............22

9.1 Maintenance ............................................22

9.2 What to do if? –

General trouble-shooting .........................22

9.3 Service, customer service &

spare parts ..............................................23

10. EU declaration of conformity ...............................24

4. Features ............................................................11

4.1 Properties of the sensor ........................... 11

4.2 Further properties of the ORBmax ............. 11

5. Technical data ....................................................12

6. Included in delivery, storage and transport .........13

6.1 Included in delivery .................................13

6.1.1 Checking the parts of delivery .......13

6.1.2 Included in delivery .......................13

6.2 Storage and transport ..............................13

7. Initial operation .................................................14

7.1 Setting up the device ...............................14

7.2 Connecting the ORBmax ...........................14

8. Operation ..........................................................15

8.1 Touch screen (main display elements) .......15

8.2 Control or setting keys .............................15

8.2.1 "Start logging" key ........................15

8.2.2 "Start pump" key ...........................16

8.2.3 "Menu" key .................................... 16

8.3 Carrying out a measurement ....................17

8.4 Evaluating a measurement .......................17

8.4.1 Evaluating a measurement with

Microsoft Excel ..............................17

8.4.2 Evaluating a measurement with

a text editor ...................................18

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. [phone] 3

About these instructions ORBmax | Operating instructions

1. ABOUT THESE INSTRUCTIONS

To allow quick understanding of these instructions and safe handling of the device, 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

Direct danger!
Non-observance could result in death or critical injury.

DANGER

[ Restrictions (if applicable).

X Measures to prevent danger.

Possible danger!
Non-observance could result in serious injury.

WARNING

ATTENTION

ATTENTION Dangerous situation!

[ Restrictions (if applicable).

X Measures to prevent danger.

Dangerous situation!

X Non-observance could result in minor injuries.

X Non-observance could result in material damage.

1.2 Further symbols and displays

Symbol Meaning

IMPORTANT

NOTE

1. Request for action in a sequence of actions: You have to do something here.

Notes: Contain particularly important information for comprehension.

Instruction: You must take notice of this symbol.

Single request for action: You have to do something here.

Conditional request for action: You have to do something here if the specified condition is met.

1.3 Abbreviations

Abbr. Meaning

ORBmax

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4

Residual Oxygen Meter

ORBmax | Operating instructions Information and safety instructions for the responsible body

2. INFORMATION AND SAFETY 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

device, and should allow only qualified personnel to enter the zone or operate the device 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 device

2.2.1 Proper use

• The device should be exclusively used for measuring the residual oxygen in forming vessels.

• Operate the device only at the voltages specified on the rating plate (Technical data, see chap. 5,

p. 12).

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 speci-

fied constraints shall be considered improper use due to the potential risks involved.

• The responsible body shall be solely responsible for damages that arise through improper use

and the manufacturer shall assume no liability whatsoever.

• Tools or accessories that have not been approved by the manufacturer for this device may not

be used.

• The removal of safety equipment is not permitted.

• Do not misuse the device.

• The device is not intended for use by private consumers.

• The technical values defined for normal operation must not be exceeded.

2.2.3 Limits of the device

• Keep your working area clean. Disorder or unlit working areas can lead to accidents.

• 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 device is required for people.

• Work lighting: min. 300 Lux.

• Operator age: at least 14 years old and without physical impairments.

• Operated by one person.

• Climate conditions: Temperature range for device operation: 0 °C to 40 °C

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. [phone] 5

Information and safety instructions for the responsible body ORBmax | Operating instructions

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 at the side may not be dis-

posed 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 be-

fore 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.

(as per RL 20 02/96/EC)

2.4 Basic safety instructions

The Residual Oxygen Meter (hereinafter referred to as ORBmax) is designed using state-of-the-art technology for safe
use. The risks involved in using the machine 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.

• In addition to these operating instructions the general safety precautions of the welding machines together with

which ORBmax is used apply. Store all documentation near the device.

• Generally valid regulations for the prevention of accidents must be observed.

• Observe country-specific regulations, standards and guidlines.

• Use the device only in proper operating order. Observe the maintenance information (chap. 9, p. 22).

• Use the device only when it has a solid footing. Check whether the substrate is able to take sufficient loads.

• Report deviations in operating behavior of the device to the person in charge immediately.

• Use only original tools, spare parts, materials and accessories from Orbitalum Tools.

• Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.

• Switch the device off and unplug the power plug before carrying out transportation, cleaning, maintenance and

repairs.

• Do not carry the device by the cable and do not use the cable to pull the power plug out of the socket outlet (except

in case of an emergency). Protect the cable against heat, oil and sharp edges (shavings).

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBma x_BA _882.060.202_00 _EN

6

ORBmax | Operating instructions Information and safety instructions for the responsible body

If the mains cable is damaged, live parts may cause death if touched directly!

Fatal electric shock.

DANGER

[ Do not operate the device unattended.
X Keep the power cable away from heat, oil, sharp edges or moving device parts.
X During processing, always keep an eye on the position of the mains cable.
X Keep the device clean, always remove lubricant or other residues from the device.

Damaged insulation!

Fatal electric shock.

DANGER

[ Do not screw signs to the device.
X Use stickers.

Damaged plug!

Fatal electric shock.

DANGER

[ Do not use adapter plugs with ground protected electrical tools.
X Connecting plugs of the device must fit into the outlet.

Grounded body!

Fatal electric shock.

DANGER

X Avoid contact with grounded surfaces such as tubes, heating, cookers or refrigerators.

DANGER

WARNING

Safety components that are contaminated, worn or broken are defective!

The failure of safety components can cause physical injury.

[ Do not misuse the cable, for example by suspending or carrying the device by the cable.
X Replace defective safety components immediately and check them daily to ensure proper operation.
X Replace defective mains cable immediately by a specialist.
X Clean and maintain the device after every use.
X Keep cables away from heat, oil, sharp edges and moving equipment parts.
X Check the device daily for externally visible damage and defects and have them remedied by a

professional if necessary.

Danger caused by vibration and unergonomic, monotonous work!

Discomfort, tiredness and disruptions to the locomotor system.
Limited ability to react, and cramps.

X Do relaxation exercises.
X Ensure activity is varied.
X Assume an upright and relaxed posture when working.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. [phone] 7

Product design ORBmax | Operating instructions

3. PRODUCT DESIGN

3.1 ORBmax

For accessories and consumables (e.g. power supply unit, measuring hose, filter, etc.), see as of chap. 3.2.

1

8

1. Touch screen (description, see chap. 8.1)

2. Gas inlet / Connection measuring hose

3. Gas outlet

4. Connection of interface cable

5. Connection of power supply unit

6. ON/OFF toggle switch

7. Protective cover

8. SD card port

3.2 Accessories and consumables

Danger presented by using poor-quality accessories and tools not approved by Orbitalum Tools!

Diverse physical injuries and material damage.

WARNING

3.2.1 Measuring hose set

Including:

• 1 hose (please specify the hose length in meters when ordering)

• 1 filter for protecting the oxygen sensor against soiling

• 2 filter inserts

• 1 test tip

• 1 hose connector

X Use only original tools, spare parts, materials, and accessories from Orbitalum Tools.

273 4 5

6

All individual parts are already included in the scope of delivery of the ORBmax.

Article Code

Measuring hose set 882 050 006

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBma x_BA _882.060.202_00 _EN

8

ORBmax | Operating instructions Product design

3.2.2 Individual parts for measuring hose set

All individual parts are already included in the scope of delivery of the ORBmax.

Article Code

Hose* 882 012 010
Filter 882 020 003
Filter inserts (5 piece per packing unit) 882 030 002
Test tip 882 012 011
Hose connector 882 012 012

* Please specify the hose length in meters when ordering.

3.2.3 Power supply unit set

100 - 240 VAC / 12 VDC. For connecting the ORBmax to the mains network.
Including diverse country-specific AC adapters.

Article Code
Power supply unit set 882 012 023

3.2.4 Interface cable

For connecting the ORBmax to the ORBIMAT orbital welding power sources of Orbitalum Tools.
Can be set at ORBIMAT so that welding can only be started after the oxygen value has been
underpassed.

1 interface cable is already included in the scope of delivery of the ORBmax.

Article Code
Interface cable 882 012 028

3.2.5 SD card

1 Gbyte. For measured data storage.
Evaluation software "O2_log" included.

1 SD card including evaluation software is already included in the scope of delivery of the ORBmax.

Article Code

SD card (1 GB) 882 050 007

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. [phone] 9

Product design ORBmax | Operating instructions

3.2.6 Protective cover

Practical protective cover that can be converted into a stand when rolled together on the device rear.

1 protective cover is already included in the scope of delivery of the ORBmax.

Article Code
Protective cover 882 001 013

3.2.7 Transport case

Robust transport case with degree of protection IP67.

1 transport case is already included in the scope of delivery of the ORBmax.

Article Code

Transport case 882 050 008

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBma x_BA _882.060.202_00 _EN

10

ORBmax | Operating instructions Features

4. FEATURES

The ORBmax residual oxygen meter is characterized by the following properties:

4.1 Properties of the sensor

• Novel optical sensor technology (patented)

• No heating period required

• High measuring precision

• Measuring of forming gas with variable hydrogen content without switching over

• Measuring of the residual oxygen value in all gas mixtures

• No uncontrolled measured value increase during the welding process through arising ozone

• Measuring of the residual oxygen value during the welding process

• Rapid reaction times

• Water-resistant

• Maintenance-free (we recommend annual calibration of the sensor)

4.2 Further properties of the ORBmax

• SD-card storage of the measured value

• User-friendly touch screen

• Alarm mode with signal (beeper) as well as change in display color (green/red)

• Degree of protection IP32

• Adjustable alarm or limit value and storage interval

• Multi-range voltage supply

• Evaluation software "O2_log" included

• Connection possibility to ORBIMAT orbital welding power sources

• Appealing and compact design

• Transport case with protection class IP67

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. [phone] 11

Technical data ORBmax | Operating instructions

5. TECHNICAL DATA

Dimensions (lxwxh) [mm] 215 x 200 x 74

[inch] 8.46 x 7.87 x 2.91

Weight, approx. [kg] 2

[lbs] 4.4
Protection class device [class] IP32
Protection class transport case [class] IP67
Power connection [V, Hz] AC 100 - 240 V, 50 - 60 Hz
Measuring range [ppm] 1 - 999

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_B A_882.0 60.202_00_EN

12

ORBmax | Operating instructions Included in delivery, storage and transport

6. INCLUDED IN DELIVERY, STORAGE AND TRANSPORT

6.1 Included in delivery

6.1.1 Checking the parts of delivery

• Check delivery for completeness and damage caused by transport.

• Report any missing parts or damage caused by transport to your supplier immediately.

6.1.2 Included in delivery

Subject to modifications.

• 1 ORBmax Residual Oxygen Meter

• 1 transport case

• 1 power unit supply set 100 - 240 VAC / 12 VDC

• 1 measuring hose (with test tip and filter)

• 1 SD card incl. evaluation software "O2_log"

• 1 interface cable

• 2 reserve filter inserts

• 1 operating instructions

6.2 Storage and transport

Fatal electric shock!

X Before each transport or change in the workplace, switch the device off and pull the power plug.

DANGER

ATTENTION

The ORBmax is a portable device. Special resources are not required for transportation.

X Always transport and store the device in the original transport case.

Improper device storage!

Diverse physical injuries and material damage.

X Always transport and store the device in the original transport case.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, ww w.orbitalum.com, Tel. [phone] 13

Initial operation ORBmax | Operating instructions

7. INITIAL OPERATION

IMPORTANT Observe the operator information and safety instructions in chap. 2, p. 5.

7.1 Setting up the device

1. Take the ORBmax out of the transport case and place

it on a sufficiently stable load-bearing base.

2. Fold the protective cover upward and to the rear (see

figure). The protective cover can be converted into a
stand when rolled together on the device rear.

7.2 Connecting the ORBmax

1. Connect the device connection end (gas inlet) of the measuring hose (1) to the ORBmax.

Removing the hose later: Press in the blue ring (2) lightly and pull out the measuring hose (1).

IMPORTANT The measuring hose (1) must be inserted firmly so that it does not slip out when pulled lightly!

2. Connect the power supply unit (3) to the device and

connect the other end to the mains network.

3. The ORBmax can be connected to an ORBIMAT orbital

welding power source with the interface cable (4)
(see chap. 8.5, p. 21). This allows the information
whether the residual oxygen value exceeds or
underpasses the value preset at the ORBmax to be
displayed at the power source (function only possible
at orbital welding power source from Orbitalum
Tools).

4. Use the ON/OFF toggle switch (5) to switch the ORB-

max on.

The main display or the touch screen starts up and the
ORBmax is now ready to use. Measurement can now be
started or the presettings carried out.

1

4

2

5

3

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_B A_882.060.202_00_ EN

14

ORBmax | Operating instructions Operation

8. OPERATION

IMPORTANT Observe the operator information and safety instructions in chap. 2, p. 5.

X The ORBmax is operated solely via the touch screen of the main display.

See chap. 8.1 for a description of the function of the main display elements and chap. 8.2 of the various control

and setting keys.
X Carrying out the presettings such as language, date, time (only during initial commissioning), see chap. 8.2.3.
X Carrying out the measurement, see chap. 8.3, p. 17.
X Evaluating the measurement, see chap. 8.4, p. 17.

8.1 Touch screen (main display elements)

The residual oxygen value (6) is displayed on the screen
in the middle in large numbers in the measuring unit
"ppm" (parts per million). The number "999" is displayed
as a dummy value (placeholder value) whenever the
device is switched on and as long as no measurement is
being carried out.

6

7

The current time (7) is displayed at the top right.

The 3 control and setting keys (8) are used to control the
ORBmax or to preset specific parameters (chap. 8.2).

8.2 Control or setting keys

8.2.1 "Start logging" key

The "Start logging" key (9) is used to start a logging
process.

NOTE This process is not required when a mea-

suring result is only to be displayed on the
ORBmax and not recorded.

The measured value is subsequently stored on the SD
card at a previously defined interval. The value can be
read afterwards at a PC with Microsoft Excel or a text edi­tor or be evaluated with the evaluation software "O2_log"
(see chap. 8.4.3, p. 19).

8

9

After the "Start logging" key (9) has been pressed, a welding seam number (max. 6 digits) under which a measurement is
to be stored afterwards on the SD card has to be entered first.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH , D-78224 Singen, www.o rbitalum.com, Tel. [phone] 15

Operation ORBmax | Operating instructions

8.2.2 "Start pump" key

The "Start Pump" (10) key is used to switch the pump on
and off and the actual measuring process is started.

12

11

The wheel (11) on the main screen rotates while the pump
is running. When the pump is standing still, the wheel
also stands still.
The pump output (12) is only displayed during a measure­ment and can be preset in the menu under "Pump Power"

13

10

(see chap. 8.2.3).

Presettings for a measurement/measuring series are
carried out in the "Menu" (13) (see chap. 8.2.3).

8.2.3 "Menu" key

The "Menu" key (13) – see figure above – is used to
access the main menu.

14

15

16

Several setting options are available:

The menu language can be set to German or English in the

17

18

19

"Language" (14) menu item.

In the case of forming applications with a low volume
flow the pump power can be reduced (for example 50%

20

21 22

pump power = approx. 1.5 l, 100% = approx. 3 l) by
means of the "Pump Power" (15) key (selection options:
100%/80%/50%).

The software version number installed on the device is
displayed under "Version" (16).

The alarm can be activated or deactivated by means of the "Alarm" (17) menu. As long as the measured value (in ppm)
lies over the set alarm value, a red bar is displayed on the main screen and, if this is set, a warning sound is issued
("Alarm On with Beeper"). If the value drops below the alarm value, the bar turns green and the beeper stops.

The value for the "Log interval" (18) and the "Alarm value" (19) of a measuring series can be set via the respective menu
items.

The "Back" key (20) is used to return to the main display.

The "Date" (21) and "Time" (22) can be set or changed by means of the respective keys.

The current date, the time (Central European Time) as well as the menu language (German) are preset in the
factory before the ORBmax is delivered.

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBma x_BA _882.060.202_00 _EN

16

ORBmax | Operating instructions Operation

8.3 Carrying out a measurement

1. Connect the ORBmax and switch it on (see chap. 7.2, p. 14).

2. Insert the measuring hose into the medium to be measured (e.g. pipe).

3. If necessary, carry out the presettings such as "Log Interval" or "Alarm value" under "Menu" (see chap. 8.2.3, p. 16).

4. Turn up the gas connection so that the gas flows into the medium to be measured.

Presettings in the "Menu" can also be carried out during a measurement!

5. If necessary, press the "Start logging" key if a measurement is to be stored on the SD card and evaluated later (see
chap. 8.2.1, p. 15).

6. Switch on the pump with the "Start pump" key.

The measurement is now started. The dummy value "999" in the main display drops to the residual oxygen value actu­ally measured. The fundamental rule: The lower the value, the lower the residual oxygen content.

7. A measurement is terminated by pulling the hose out of the medium to be measured (e.g. pipe).

8. At the end of the measurement switch the device off with the ON/OFF toggle switch.

8.4 Evaluating a measurement

The ORBmax offers the possibility to store measurements on the SD card and read them with Microsoft Excel
(chap. 8.4.1, p. 17) or a text editor (see chap. 8.4.2, p. 18) and evaluate them with the supplied Windows software
("O2_Log", see from chap. 8.4.3, p. 19).

Per measurement one folder is created with the creation data as the folder name and the weld seam number entered
before as the file name with the extension ".CSV " (data exchange format). You can later rename the folder and file name
freely via a PC as well as delete or move files on the SD card.

The Windows software "O2_Log.exe" required for reading out is already stored on the SD card and can be started on
the PC from the SD card.

8.4.1 Evaluating a measurement with Microsoft Excel

1. Remove the SD card from the internal slot at the ORBmax and insert it into a suitable card reading device or if ap­propriate directly into the SD drive of a PC.

2. The "Autoplay" window is opened. Select the "Open folder to..." option to open the directory with the measuring
results. If the "Autoplay" window is not displayed automatically, the directory ("Secure Digital Storage Device") can
also be opened in the Windows Explorer.

The content of the SD card is now displayed in the Windows Explorer.

If one or more measurements were carried out with the ORBmax, a folder with the respective creation date as the folder
name is listed (the directory "O2_Log" contains the "O2_ Log.exe" evaluation software developed specially by Orbitalum
Tools that can be used alternatively to Microsoft Excel or a text editor for the data evaluation (see from chap. 8.4.3, p. 19)).

3. Double-click the folder for the desired measurement to open it.

4. Double-click the ".CSV " file to open it.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH , D-78224 Singen , www.orbitalum.com, Tel. [phone] 17

Operation ORBmax | Operating instructions

Microsoft Excel starts up and the file is opened. The data can now be edited individually.

Column "A"; Row "1" contains the creation date of a mea-
suring series. The measuring times specified at a specific
interval are listed below it (from Row "2") in the format
"hh mm ss".

The starting time of a measurement is listed to the right
of it (Column "B"; Row "1") in the format "hh.mm.ss".
The residual oxygen values measured at the respective
time follow below it (from Row "2") in the format "ppm".

Column "C"; Row "1" lists the interval in which measuring
was carried out (the storage interval can be preset under
"Menu", see chap. 8.2.3, p. 16).

Column "D"; Row "1" contains the weld seam number of a
measuring series.

8.4.2 Evaluating a measurement with a text editor

Opening and further editing of the measured data with a text editor is possible and is described below. However, we
recommend editing the data further with Microsoft Excel or the Orbitalum evaluation software "O2_Log" (see from
chap. 8.4.3, p. 19).

1. Remove the SD card from the internal slot at the ORBmax and insert it into a suitable card reading device or if
appropriate directly into the SD drive of a PC.

2. The "Autoplay" window is opened. Select the "Open folder to..." option to open the directory with the measuring
results. If the "Autoplay" window is not displayed automatically, the directory ("Secure Digital Storage Device") can
also be opened in the Windows Explorer.

The content of the SD card is now displayed in the Windows Explorer.

If one or more measurements were carried out with the ORBmax, 1 folder with the creation date as the folder name is
listed per measurement (the directory "O2_Log" contains the "O2_Log" evaluation software developed specially by
Orbitalum Tools that can be used alternatively to Microsoft Excel or a text editor for the data evaluation (see from
chap. 8.4.3, p. 19)).

3. Double-click the folder for the desired measurement to open it.

4. Right-click the ".CSV" file in the Windows Explorer once.

5. Then click in the "Open with" menu and select "Editor".

Or:

3. Right-click the ".CSV " file in the Windows Explorer once and select "Rename" in the menu.

4. Change the extension ".CSV " to ".txt" and then confirm with the "Return" key.

5. Double-click the ".txt " file to open it.

Microsoft Editor starts up and the file is opened. The data can now be edited individually.

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax _BA_ 882.060.202 _00_EN

18

ORBmax | Operating instructions Operation

8.4.3 Evaluating the measurement with the "O2_Log" evaluation software

System requirements: Operating system "Windows XP" or later.

The "O2_ Log.exe" evaluation software developed by Orbitalum Tools can only be started if the software ".NET Frame­work 4" is installed on the PC.

".NET Framework 4" is a software platform developed by Microsoft for the development and execution of
application programs.

8.4.3.1 Installation of ".NET Framework 4" (if not already installed):

1. Remove the SD card from the internal slot at the ORBmax and insert it into a suitable card reading device or if ap­propriate directly into the SD drive of a PC.

2. The "Autoplay" window is opened. Select the "Open folder to..." option to open the directory with the measuring
results as well as the evaluation software. If the "Autoplay" window is not displayed automatically, the directory
("Secure Digital Storage Device") can also be opened in the Windows Explorer.

3. Double-click the "O2_Log" folder to open it.

4. Double-click the ".NET4 installer" folder to open it.

5. Double-click the file "dotNetFx40_Client_setup.exe".

Installation of ".NET Framework 4" is now started. After successful installation the evaluation software "O2_Log.exe"
can be started by double-clicking it.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Sing en, www.orbitalum.com, Tel. + 49 (0) 77 31 792-0 19

Operation ORBmax | Operating instructions

8.4.3.2 Starting the evaluation software

The evaluation software "O2_Log" is license-free and can be copied as often as wished. "O2_Log" can be
started directly from the SD card or be copied to a PC and started there. If the evaluation is lost or faulty,
please contact Orbitalum Tools directly or order a new SD card including software (see chap. 3.2.5, p. 9).

1. Remove the SD card from the internal slot at the ORBmax and insert it into a suitable card reading device or if
appropriate directly into the SD drive of a PC.

2. In order to start the software, double-click the "O2_Log.exe" file in the corresponding directory in the Windows
Explorer.

3. The program is started and a window called "O2 LOG Oxygenmonitor" is opened:

22

23

24

25 27

26

28

29

(22) Scroll-down menu for the language selection (English/Deutsch (=German)).

ATTENTION: When the language is changed, the current window is closed and a new window opened in the
selected language. In the process all the entries (27) are lost and have to be re-entered!

(23) Representation of the measuring result as the relationship of "ppm Oxygen" (Y-axis) to "Storage interval" (X-axis).

(24) Date and time when the measurement has taken place.

(25) Storage interval ("Sampling rate") under which the measurement has taken place (e.g. "05 s" = measurement

every 5 seconds).

(26) (26) "Open Logfile" to open a measurement or a measurement series.

(27) Individual fields that can be filled by the operator with additional information about the measurement series (e.g.

which gas type was used, pipe dimension that was measured, operator name, etc.).

(28) File path or directory in which the current measurement series is stored.

(29) Print the measurement result with the "Print " key.

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax _BA_882.060.202_0 0_EN

20

ORBmax | Operating instructions Operation

8.5 Connecting the ORBmax to the power source

The ORBmax can be connected to an ORBIMAT orbital
welding power source with the supplied interface cable (4).

This allows the information whether the residual oxygen
value exceeds or underpasses the value preset at the
ORBmax to be displayed at the power source (display only
possible at orbital welding power source from Orbitalum
Tools). The power source cannot be started as long as
the residual oxygen value lies above the set limit value. If
the limit value is exceeded, the process is canceled and a
note is entered in the log.

Connection of interface cable

For information on operating the ORBmax in combination with the power source please read the operating instructions
of the respective orbital welding power source from Orbitalum Tools.

4

ORBIMAT CA series

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Sing en, www.orbitalum.com, Tel. + 49 (0) 77 31 792-0 21

Servicing, maintenance, troubleshooting ORBmax | Operating instructions

9. SERVICING, MAINTENANCE, TROUBLESHOOTING

NOTE Some of the tasks named are heavily dependent on use and ambient conditions. The stated cycles

are minimum values. In individual cases, different maintenance cycles are possible. To ensure
the device safety, have the calibration performed annually by authorized service points with VDE
testing. Should the device not function as described above, it must also be sent to an authorized
service point.

Danger of death by electric shock!

Non-observance could result in death or critical injury.

DANGER

DANGER

X Switch the device off and unplug the power plug before carrying out transportation, cleaning,

maintenance and repairs.

Risk of electric shock due to poor electrics!

Fatal electric shock.

X Switch the device off and unplug the power plug before carrying out transportation, cleaning,

maintenance and repairs.

X Repair and maintenance work on the electrical equipment may only be carried out by a qualified

electrician.

9.1 Maintenance

Interval Activity

Depending on the
degree of soiling

Annually X The oxygen sensor is maintenance-free. However, annual calibration is recommended,

Replacing the filter insert:

X Open the filter at the measuring hose.
X Replace the filter insert.
X Close the filter again.

as for all devices. Please send the device directly to the branch responsible for you.

9.2 What to do if? – General trouble-shooting

Problem Possible cause Remedy

Device cannot be switched on. Power plug not plugged in correctly. X Check whether the device or

the power adapter is plugged in
correctly.

Plug power supply unit defective. X Replace the plug power supply unit.

Oxygen value does not drop dur­ing measuring, but remains at the
dummy value of "999".

Hose connections not plugged
correctly.

Measuring hose is damaged and
leaks.

X Check hose connections.

If necessary, replug.

X Check the measuring hose for dam-

age. If necessary replace the hose.

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_OR Bmax_B A_882.0 60.202_00_EN

22

ORBmax | Operating instructions Servicing, maintenance, troubleshooting

9.3 Service, customer service & spare parts

For troubleshooting, please contact the branch responsible directly.

Please indicate the following details:

• Device type: ORBmax Residual Oxygen Meter

• Device No.: (see type plate)

For information on ordering accessories or consumables please refer to chap. 3.2, p. 8.
Please send the device directly to the branch responsible for you in order to replace spare parts at the electronic equipment.

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] 23

EU declaration of conformity ORBmax | Operating instructions

10. EU DECLARATION OF CONFORMITY

EG-Konformitätserklärung
Declaration of conformity
Dichiarazione di conformità
Déclaration de conformité
Declaración de conformidad

Orbitalum Tools GmbH
Josef-Schüttler-Straße 17
78224 Singen, Deutschland
Tel.: [phone]
Fax: [phone]

as per EC Low-Voltage Directive (2006/95/EC) and EMC Directive 2004/108/EC.

Die Bauart der Maschine:
The fo llowing produ ct:
Il seguente prodotto:
Le produit suivant:
El produ cto siguient e:

Seriennummer:
Series number:
Numero di serie:
Nombre de série:
Número de serie:

Baujahr / Year / Anno / An née / Año:

ist ent wickelt, ko nstruier t und gefer tigt in Übe reinstimmu ng mit folgen den EG-Rich tlinien:
was des igned, cons tructed an d manufact ured in accorda nce with the fo llowing EC gui delines:
è stat a progetta to costrui to e commerciali zzato in osse rvanza de lle seguent i Diretti ve:
a été dess iné, produit e t commercial isé selon les Di rectives s uivantes:
ha sido pr oyectado co nstruido y co mercializad o bajo obser vación de la s siguientes D irectiv as:

Folgende harmonisierte Normen sind angewandt:
The fo llowing harmonized nor ms have been applied:
Le seg uenti norme ar monizzate ove applic abili:
Les normes suivantes harmonisées où applicables:
Las sig uientes nor mas armonizadas han sid o aplicadas:

ORBmax Residual Oxygen Meter

EMC Directive (2004/108/EC)
Low-Voltage Directive (2006/95/EC)

EN 55011
EN 61000
EN 61010 -1

Authorised to compile the technical file is Mr. Gerd Riegraf, Orbitalum Tools GmbH, D-78224 Singen.

Singen, 22.01.2014

Markus Tamm
Managing Director

Marcel Foh
Business Unit Manager Orbital Welding

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_OR Bmax_B A_882.0 60.202_00_EN

24

ORBmax | Operating instructions

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Sing en, www.or bitalum.com, Tel. [phone] 25

EU declaration of conformity ORBmax | Operating instructions

orbitalum tools GmbH, D -78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax _BA_ 882.060.202 _00_EN

26

ORBmax | Operating instructions EU declaration of conformity

(17.07.14) OW_ORBmax_BA_ 882.060.202_00_EN orbitalum tools GmbH, D-78224 Sing en, www.orbitalum.com, Tel. + 49 (0) 77 31 792-0 27

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