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Orbitalum MOBILE WELDER OC PLUS, Operating Instructions Manual

The Orbitalum MOBILE WELDER OC PLUS provides precision welding capabilities in a portable package. To ensure optimal usage, a comprehensive Operating Instructions Manual is available for free download from our website. Unlock the full potential of this exceptional product by accessing the manual at manualshive.com.

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MOBILE WELDER OC PLUS

SPARE PARTS

ORBITALUM TOOLS GmbH 

, D-78224 Singen www.orbitalum.com

187

POS.

NO.

CODE

PART NO.

STK.

QTY.

BEZEICHNUNG

DESCRIPTION

POS.

NO.

CODE

PART NO.

STK.

QTY.

BEZEICHNUNG

DESCRIPTION

1

307 001 075

2

Linsenschraube ISO7380-M2.5x6-A2

Oval-head screw ISO7380-M2.5x6-A2

11

854 020 015

2

Stoßschutzbügel, Rückwand MW

Shock protection bracket, rear panel MW

2

854 010 005

1

Einbaudrucker, Thermo MW

Built-in printer, thermal MW

12

500 602 309

2

Sechskantmutter ISO4032-M4-A2

Hexagon nut ISO4032-M4-A2

3

854 020 055

1

IP Abdeckung EIN/AUS Einbauschalter

IP Cover ON/OFF Built-in switch

13

542 500 318

2

Scheibe DIN125-ISO7089-d4.3-A2

Washer DIN125-ISO7089-d4.3-A2

4

303 305 010

2

Senkschraube ISO14581-Tx10/M3x8-A2

Countersunk screw ISO14581-Tx10/

M3x8-A2

14

302 301 114

4

Senkschraube DIN7991-M4x10-A2

Countersunk screw DIN7991-M4x10-A2

5

854 010 006

1

EIN/AUS Einbauschalter

ON/OFF Built-in switch

15

871 020 032

3

Distanzrolle ohne Gewinde, L 5 mm

Spacing roller w/o thread, L 5 mm

6

854 010 004

1

LAN RJ45 Einbaubuchse

LAN RJ45 jack

16

860 020 090

3

Abstandsbolzen, Kunststoff 15 mm, M3

Distance bolt, plastic 15 mm, M3

7

854 010 003

1

USB-Einbaubuchse 2xUSB-A 0.5m

USB built-in socket 2xUSB-A, 0.5m

17

854 010 002

1

Platine, Kühleinheitsignale MW/OC

Board, cooling unit signals MW/OC

8

854 010 052

1

IEC Einbaustecker C20

IEC Panel Connector C20

9

854 020 002

1

Rückwand MW

Back panel MW

10

871 020 033

2

Sperrkantscheibe A4 K für Gewinde M4

Retaining washer A4 K for thread M4

Summary of Contents for MOBILE WELDER OC PLUS

Page 1: ...en Orbital Welding Power Supply Translation of original operating instructions and spa re parts list 854 060 201 MOBILE WELDER OC PLUS 00 2022 REV ...

Page 2: ...4 Personnel qualification 13 2 5 Fundamental information on operational safety 13 2 6 Personal protective equipment 14 2 7 Remaining risks 15 2 7 1 Injury through high weight 15 2 7 2 Burns and danger of fire through high tem peratures 16 2 7 3 Tripping over wires and cables 16 2 7 4 Long lasting physical damage through wrong posture 17 2 7 5 Electric shock 17 2 7 6 Danger from incorrect handling ...

Page 3: ...put devices and con trol elements 50 7 14 2 1 Softkey buttons 50 7 14 2 2 Touchscreen 50 7 14 2 3 Rotary actuator 53 7 14 2 4 USB keyboard 56 7 14 2 5 USB code scanner 59 7 15 Setting the system language and language of the documen tation 60 7 16 Setting the units of measure 61 8 Operation 62 8 1 Main menu 64 8 1 1 Program Manager 70 8 1 1 1 Loading the welding procedure 73 8 1 1 2 Saving the weld...

Page 4: ...enance schedule 169 10 6 Service and customer support 170 10 6 1 Customer support 170 10 6 2 Technical support application engineer ing 170 10 6 3 Operator and service training 171 11 Storage and decommissioning 172 12 Upgrade options 173 13 Accessories 174 14 Consumables 176 15 SPARE PARTS LIST 178 15 1 Grundaufbau MW Frontan sicht Basic structure MW front view 178 15 2 Grundaufbau MW Rückan sich...

Page 5: ...sults in death or serious in juries 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 safet...

Page 6: ...lding tongs Closed orbital weld head This function is only available with the UPGRADE ORBICOOL MW Software MW Plus Connectivity LAN IoT VNC option 1 4 Further applicable documents The following documents apply together with these operating instructions Declaration of Conformity Calibration certificate Operating instructions for weld head manual welding torch Operating instructions for ORBICOOL MW ...

Page 7: ...rescribed 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 WORKPLACE OR WORK EQUIP MENT EVALUATION REQUIRED FOR Employees without particular risk E...

Page 8: ...ENGLISH MOBILE WELDER OC PLUS 8 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com ...

Page 9: ...f 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 suitable for the TIG welding process Empty unpressurized tubes that are free of contaminations explosive atmospheres or liquids Proper use also includes the following points Permanent supervision of the machine durin...

Page 10: ... C 50 at 40 C Ambient conditions during storage and transport Ambient temperature 20 C to 55 C Relative humidity 90 at 20 C 50 at 40 C The device may only be installed and operated in a dry environment according to IP 23 not in fog rain thunderstorms etc If appropriate use a welding tent Cooling is only ensured with a full coolant tank Smoke steam oil vapors and grinding dust must be avoided Avoid...

Page 11: ...materials potentially present in indicative quantities greater than 1 gram at the component level Critical raw materials potentially present in indicative quantities greater than 1 gram at the com ponent COMPONENT CRITICAL RAW MATERIAL Printed circuit boards Barite bismuth cobalt gallium germanium hafnium indium heavy rare earths light rare earths Niobium platinum group metals scandium silicon met...

Page 12: ...ied in the REACh SVHC candidate list exceeding 0 1 percent by mass of the object On June 27 2018 lead CAS 7439 92 1 EINECS 231 100 4 was included in the SVHC candidate list This inclusion activates an obligation to inform along the chain of delivery We herewith inform you that individual partial components of our products contain lead in quantities ex ceeding 0 1 by mass of the object as an alloy ...

Page 13: ...gust 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 Important note 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...

Page 14: ...embly or the cable Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician Do not carry the machine by the hose assembly or the cable Do not pull the plug on the cable out of the socket except in an emergency Protect the cable against heat oil and sharp edges chips Do not transport the device by crane Use handles straps or holders for hand transpo...

Page 15: ...ring transportation or setting up CAUTION Falling of the power supply as the result of being set down improperly When lifting the power supply do not exceed the permissible total weight of 25 kg for men and 15 kg for women Use a suitable transport medium to transport the welding power supply Always use 2 persons to lift and remove the welding power supply from the packaging Place the welding power...

Page 16: ...positioned incorrectly or if unap proved materials are used in the welding area Observe the local general fire protection measures Position the forming system correctly 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 Heed the safety precautions of the technical supervisor person in char...

Page 17: ...n igniting the arc From the start of the welding process avoid contact with the tube and the housing of the orbital weld head Wear dry safety shoes dry metal free grommet free leather gloves and dry safety clothing to minimize the electrical hazard Work on a dry surface DANGER Risk of death for people with heart problems or cardiac pacemakers Do not allow persons with increased sensitivity to elec...

Page 18: ...of the workplace life threatening electromagnetic fields can arise in the direct vicinity People with heart problems or cardiac pacemakers must not operate the welding system The owner has to ensure safe design of the workplace in accordance with the EMF Directive 2013 35 EU Use only electrical devices with protective insulation in the working area of the welding system Observe electromagnetically...

Page 19: ...2 Danger of explosion and fire DANGER Danger of explosion and fire through flammable materials near the welding zone or solvent in the room air Do not weld near solvents for example where degreasing painting is being carried out or ex plosive substances Do not use flammable substances as a base in the welding area Ensure that no flammable materials or soiling is located near the machine 2 7 13 Gen...

Page 20: ...ENGLISH MOBILE WELDER OC PLUS 20 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com ...

Page 21: ...1 2 10 3 4 5 6 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 9 NO DESIGNATION FUNCTION 1 Sheet metal guard operating el ements MW Protects the operating elements 2 Shoulder strap MW Relieves the load when carrying the welding power supply 3 Bumper bar front MW Protects the operating elements and front connections ...

Page 22: ...en 50 13 Connection socket USB Connection possibility for USB devices 2x 14 Connection socket LAN Connection possibility for LAN cable service interface 15 Handle MW Transporting the welding power supply 16 Paper feed button on built in printer Starts paper feed 17 Paper feed stop button on built in printer Stops paper feed 18 Paper discharge on built in printer For removal of printouts 19 ON OFF ...

Page 23: ...ns are part of the machine They must not be removed or modified Missing or illegible warning signs must be replaced immediately IMAGE POSITION ON MACHINE MEANING CODE Front cover inside Read the safety instruc tions 871 001 057 Rear panel Before opening the unit 850 060 025 3 2 Cooling unit See operating instructions for the ORBICOOL MW Download links PDF https www orbitalum com de download html ...

Page 24: ... visual and operating conditions thanks to clearly laid out 7 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 moto...

Page 25: ...Current consumption max A AC 19 5 Connection value max kVA 4 5 Power factor 0 99 with 140 A Output welding circuit Setting range weld current A DC 5 180 Weld current reproducibility 0 5 Rated current at 100 duty cycle A DC 140 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 90 Ignition power max Joule 0 9 Ignition voltage max ...

Page 26: ... x 20 2 Weight power supply only kg lbs 15 6 33 06 Weight without coolant with cooling unit ORBICOOL MW kg lbs 20 9 46 1 Gas input pressure bar 3 10 Via pressure reducer Recommended gas input pressure bar 4 Via pressure reducer Cooling unit ORBICOOL MW For further technical specifications see ORBICOOL MW operating instructions Download link https www orbitalum com de download html Coolant volume l...

Page 27: ... nothing attached to the valve on the shielding gas bottle Avoid heating the shielding gas bottle CAUTION Risk of tipping When moving and setting up the device it may tip over and be dam aged or injure people Tipping resistance is guaranteed up to an angle of 10 to IEC 60974 1 Set up or transport the device on a level solid surface Use suitable means to secure the attachment parts CAUTION Risk of ...

Page 28: ...tal welding power supply weighs a max of 23 20 kg 51 15 lbs Carry the orbital welding power supply by the carrying handle and shoulder strap Wear safety shoes to EN ISO 20345 Class SB When lifting the machine do not exceed the permissible total weight of 25 kg for men and 15 kg for women WARNING Danger of accident from loose fastening screws The cooling unit can detach from the power supply and ca...

Page 29: ... PLUS ENGLISH ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 29 1 2 Illustration Transporting the Mobile Welder 1 Carry handle 2 Shoulder strap See also the chapter Adjusting the length of the shoulder strap 30 ...

Page 30: ...f the shoulder strap 1 2 Illustration Adjusting the length of the shoulder strap 1 Buckle 2 Strap loop Lengthening the shoulder strap Move the strap through the buckle 1 so that the strap loop 2 becomes shorter Shortening the shoulder strap Move the strap through the buckle 1 so that the strap loop 2 becomes longer ...

Page 31: ...ip hazard Attach the strain relief Mechanically secure hose assembly connection Do not work near highly flammable substances 7 1 Unpacking the power supply 1 Remove the cardboard cover insert from the cardboard carton 2 Remove the cardboard protective corners 4 x from the cardboard carton 3 Lift the power supply out of the cardboard carton by the handle with both hands and place it upright on a fl...

Page 32: ...e right to make changes Check the delivery for completeness and damage caused by transport Report any missing parts or damage caused by transport to your supplier immediately 7 3 Setting up the power supply CAUTION Risk of tipping When moving and setting up the device it may tip over and be dam aged or injure people Tipping resistance is guaranteed up to an angle of 10 to IEC 60974 1 Set up or tra...

Page 33: ... welding torch CAUTION Danger of burns from improper welding current connection Unsecured welding current plugs or dirty workpiece connections dust corrosion can heat up and cause burns if touched Check welding current connections daily and ensure cable socket latch is engaged Clean the workpiece connection point thoroughly and fasten it se curely Do not use structural parts of the workpiece as we...

Page 34: ...torch is set in the power supply software NOTICE In order to use the complete range of functions of the digital gas control we recommend setting the incoming volume flow from the pressure reducer higher than the welding gas volume actually required at the torch Recommended incoming volume flows Welding gas 8 18 l min 30 l min The welding gas displaces oxygen in the welding area outside the pipe to...

Page 35: ...se diameter AD 6 mm 1 2 7 7 Mains connection For detailed information on the mains input voltage see the chapter Technical specifications 25 Ensure that the mains connection at the place of use complies with local regulations Ensure that only original ORBITALUM power supply cables are used for the mains connection Ensure that the electrical outlet is properly rated and grounded Check the power cab...

Page 36: ...uries can result Do not use adapter plugs together with protectively grounded power tools Ensure that the connecting plug of the machine fit into the outlet When connecting use a standards compliant residual current circuit breaker rated at 30 mA WARNING Risk of electric shock from faulty or damaged insulation Normally protected parts of the power supply e g housing may be live If touched death or...

Page 37: ... the power supply Set the ON OFF switch 4 on the rear of the power supply to position I ON ð The ON OFF switch red 4 lights up as soon as the power supply is connected to the mains mains voltage is present and switched on ð The operating system boots and the reduced main menu 5 appears in the display 4 5 ...

Page 38: ...tionally purchased software upgrades can be unlocked via an activation key in the power supply software Procedure From the main menu of the power supply navigate to System Settings Activation 4 3 2 1 5 1 Enter the activation key 2 in the text input field 3 2 Confirm the entry by pressing the Activation button 4 ð Successful activation is indicated by a plus sign and a teardrop icon 5 in the menu h...

Page 39: ...supply You can find the activation key and the matching power supply serial num ber on the purchased activation document 4 Activation button button to confirm the activation key entered After successful confirmation the acquired additional func tions are available in the power supply software See also the chapter Main menu 64 NOTICE If an error message is displayed Check whether the activation key...

Page 40: ... with the range of functions relevant for the user 2 Administration level with extended range of functions 7 12 1 Login 1 2 Perform the following steps on the login screen 1 Enter the password in the Password input field 1 2 Confirm the entry by pressing the Login button 2 NOTICE For initial passwords see the chapters Administration level 44 and User level 44 ...

Page 41: ...bH D 78224 Singen www orbitalum com 41 7 12 2 Changing a password The Change Password button 3 can be used to change the user level passwords for users and ad ministrators NOTICE The user password can only be changed by entering the admin password 3 ...

Page 42: ...rm the following steps 1 Press the Change Password button 4 on the login screen 2 Press the Change Admin Password button 3 Enter the current admin password in the Old Password input field 4 Enter the new admin password in the New Password input field 5 Enter the new admin password again in the Confirm Password input field ð The admin password has been changed ...

Page 43: ...erform the following steps 1 Press the Change Password button on the login screen 2 Press the Change User Password button 5 3 Enter the admin password in the Admin Password input field 4 Enter the new user password in the New Password input field 5 Enter the new user password again in the Confirm Password input field ð The user password has been changed ...

Page 44: ...3 User levels The power supply supports two user levels 1 Administration level Full range of functions 2 User level Limited range of functions The distinction between the levels is made by means of the login password 7 13 1 Administration level At the administration level the unrestricted range of function of the power supply is enabled Any system and program settings can be made and welding param...

Page 45: ...tem language and units of measure Welding comments Welding current adjustment via Scale Weld across levels Test mode Welding Blocked functions Create welding procedures Adjust welding parameters Delete rename copy move welding procedures Delete copy move weld logs Change system settings Change program settings Blocked functions and menu items are hidden or grayed out ...

Page 46: ...ment to execute assigned function 3 Dropdown list Control element to open a selection list and select a given value or function 4 Slide control Control element to enable ON or disable OFF assigned function Activated slider buttons are highlighted in blue 5 Number input field Input element to enter numerical values Activated fields are highlighted in blue 6 Touch actuated softkey button Variable co...

Page 47: ...9 NO DESIGNATION FUNCTION 7 Text input field Input element to enter text values Activated text input fields are highlighted in blue 8 Information field Information element that displays various information 9 Touch actuated action field Touch actuated control element to execute assigned func tion ...

Page 48: ...rbitalum com 12 10 11 11 NO DESIGNATION FUNCTION 10 Menu tree element Element to open expand or close a menu tree 11 Checkbox Control element for making a selection Selected checkboxes are marked with a check mark 12 Status icons Display the system status of various functions ...

Page 49: ...lds highlighted in yellow mark all values currently changed in the welding procedure that deviate from the cur rent memory value By saving the welding procedure again the changed values are applied and highlighted in gray NOTICE The function serves as an orientation aid for the user when creating and adjusting the welding procedure 16 Gobal Change softkey If the Gobal Change softkey is pressed the...

Page 50: ... label on the softkey buttons above it on the touchscreen and can be executed by pressing the physical or virtual softkey buttons 1 2 3 4 5 6 Examples The softkey button 6 is usually assigned to the Menu function meaning pressing it brings you directly to the main menu regardless of which sub menu currently appears in the display The softkey button 3 is assigned to the Save function in the Program...

Page 51: ...utomati cally when a corresponding input field is touched Menu buttons Touching the desired slide control executes the function Slide control Touching the desired slide control activates ON or deactivates OFF the function Dropdown list fields Touching the dropdown list field opens the list Touching the desired parameter again selects it Touching the dropdown list field again closes the list ...

Page 52: ...he Fin ished button or canceled using the Cancel field Touch actuated softkey buttons Touching a softkey button executes the stored function Text input fields By touching a text input field the virtual alphanu meric touch actuated keyboard appears for input The entry can be confirmed by means of the Fin ished button or canceled using the Cancel field Touch actuated action fields Touching an action...

Page 53: ...n removes the check mark 7 14 2 3 Rotary actuator The rotary actuator is operated by turning and pressing it Rotate it to select the desired software control ele ment or field The control element or field on which the menu cursor is located is outlined in blue The function is activated or executed by pressing the rotary actuator Clockwise rotation The menu cursor moves down ...

Page 54: ...r moves up Pressing and holding the rotary control for a long time 2 seconds returns you to the higher menu level 2 sec Menu buttons Pressing the rotary actuator executes the function of the highlighted menu button Slide control Pressing the rotary actuator activates ON or de activates OFF the function of the highlighted slider ...

Page 55: ...his is also possible by pressing the dropdown list field again Number input field Pressing the rotary actuator opens the highlighted number input field The desired numerical value can be selected by turning the rotary actuator and confirmed by press ing it again Depending on the direction of rotation the input value increases or decreases The entry can be canceled by pressing and holding longer 2 ...

Page 56: ...SC key and the F1 to F6 keys as well as the numeric and alphanumeric keypad The desired control element or field can be selected with the menu cursor by means of the up and down arrow keys The control element or field on which the menu cursor is located is highlighted in yellow The function is activated or executed by pressing the ENTER key By pressing the ESC key you can revoke the entry or switc...

Page 57: ...g the ENTER key opens the highlighted dropdown list field The desired parameter can be selected by means of the up and down arrow keys and confirmed with the ENTER key The selection can be canceled with the ESC key By selecting again with the arrow keys and con firming with the ENTER key the dropdown list is closed Number input field Pressing the ENTER key opens the highlighted number input field ...

Page 58: ...key 4 Key F5 Softkey 5 Key F6 Softkey 6 Text input fields Pressing the ENTER key activates the selected text input field Text can be entered with the alphanumeric keys and confirmed with the ENTER key The entry can be canceled by pressing the ESC key Touch actuated action fields Operation via the USB keyboard not possible Checkboxes Pressing the ENTER key activates the selected checkbox and places...

Page 59: ...rs into corresponding input fields Bar codes and QR codes can be read Text input fields Number input fields Transferring text and numbers Procedure 1 Select the desired input field by means of an input device 2 Align the scanner with the code to be read and press the Scanner key ð The input field is now activated 3 Press the Scanner key again ð The code content is read in ...

Page 60: ...e is German If a language incomprehensible to the operator has been set the dropdown list of languages can be accessed from the main menu by selecting the last menu item Settings Language Changing system documentation language from the main menu Select the System Settings menu item 1 Select the dropdown list field System Lan guage 1 or Language of the Documenta tion 2 2 Select the desired language...

Page 61: ...tory setting for the units of measure is metric English units of measure OFF Changing the units of measure from the main menu 1 Select the System Settings menu item 2 Select the System Adjustments menu item 3 Select the slide button Display Inch Sizes and make the desired setting 1 ON ð Display imperial units of measure 2 OFF ð Display metric units of measure See the chapter System adjustments 123...

Page 62: ...a dry environment WARNING Danger of burns and fire from arcs Tripping over the hose assembly can cause the welding current plugs to be pulled out of the welding power supply and cause an arc Lay the lines and cables so that they are not under tension Ensure that lines and cables do not pose a trip hazard Attach the strain relief Mechanically secure hose assembly connection Do not work near highly ...

Page 63: ...lt of suffocation Use only in well ventilated areas Monitor oxygen if necessary WARNING Damage to health from toxic emissions in the ambient air No welding of coated workpieces and of pressurized media con taining pipes objects Clean workpieces before welding Weld only materials suitable for the TIG welding process TIG DC WARNING Health hazard from inhalation of radioactive particles Do not use el...

Page 64: ...scriptions in the main menu NO DESIGNATION FUNCTION 1 Program Manager menu button Opens the Program Manager menu where welding programs can be loaded and managed For detailed information see the chapter Program Manager 70 2 Protocol Manager menu button Opens the Protocol Manager menu where welding reports can be displayed printed and managed For detailed information see the chapter Protocol Manage...

Page 65: ... Opens the Weld Mode menu where the welding torch can be con trolled welding parameters adjusted and the welding process started For detailed information see the chapter Weld mode 153 9 Test Mode softkey Opens the Test Mode menu where the welding torch can be con trolled manually welding parameters can be adjusted and a simula tion without arcing can be started in order to test all process relevan...

Page 66: ...es If there are no messages the softkey button is grayed out and cannot be pressed 13 Menu softkey Takes you directly to the main menu 14 Welding procedure in formation The Welding Procedure Information field displays information about the currently loaded welding procedure Program name Displays the file name of the loaded welding procedure Folder Name Displays the name of the folder where the loa...

Page 67: ...manufacturer power supply type and serial number 18 Software status icons The software status icons indicate the currently enabled functionality and scope of the software Enhancements can be purchased and activated as an option For detailed information see the chapter Upgrade options 173 SYMBOL STATUS Enhanced scope of software activated For detailed information see the chapter Activation 38 ORBIC...

Page 68: ...in at the administrator level Button function Log out activate the login screen No communication Power supply Inverter No communication HMI IO board One storage medium connected Active access to the storage medium Multiple storage media connected Active access to one storage medium Network drive s connected Active access to network drive s Internal printer selected Print weld data logs function ac...

Page 69: ...dynamically depending on the number of segments and segment length as well as on the welding parameters of the respec tive active welding procedure During the welding process it is used to determine the position of the electrode and to display the current welding process In the main menu the process graphic is also a touch actuated action field that can be used to access the welding parameter leve...

Page 70: ... procedure 5 Touch actuated action field Level X Touching the touch actuated action field takes you directly to the welding parameter level of the respective segment of the currently loaded welding procedure 6 Touch actuated action field Basic Adjustments Touching the touch actuated action field Basic Adjustments takes you directly to the Basic settings welding parameter level of the cur rently lo...

Page 71: ...ding procedure folders created in the parent location are displayed at this level 3 Welding procedure level All the welding procedures located in the folder are displayed at this level Welding procedures are indicated by the blue file icon 4 Favorites folder The welding procedures marked as favorites in this folder are linked for quick access 5 Favorite icon The star icon indicates that a folder h...

Page 72: ...g the printer set in the sys tem settings For detailed information see the chapter System adjustments 123 14 Save As softkey The Save As softkey can be used to save the currently active weld ing procedure to the desired storage location NOTICE The Save As softkey function is only displayed if a welding procedure is highlighted at the welding procedure level For detailed information see the chapter...

Page 73: ... key After successful entry the power supply switches back to the main menu The newly loaded welding procedure is displayed in the Welding procedure information information field 8 1 1 2 Saving the welding procedure NOTICE Welding procedures can only be saved in folders at the folder level It is not possible to save individual welding procedures at the drive level To save a welding procedure follo...

Page 74: ...low From the main menu 1 Select the Program Manager menu item 2 At the drive level mark the desired drive with the menu cursor 3 Press the New Folder softkey A new folder is created the folder name is highlighted in yellow and the software keyboard is displayed 4 Rename the folder via Touchscreen Enter folder name and confirm with the Finished keyboard button USB keyboard Pressing a key on the ext...

Page 75: ...Copy softkey The Copy softkey can be used to copy welding procedures and folders For detailed information see the chapter Copying welding proce dures and folders 77 6 Move softkey The Move softkey can be used to move welding procedures and folders between the storage locations For detailed information see the chapter Moving welding procedures and folders 78 Remove Favorites softkey The Remove Favo...

Page 76: ...en Spe icherort erhalten Aus dem Hauptmenü 1 Menüpunkt Programm Manager auswählen 2 Softkey Verwalten auswählen Programm Manager 3 Checkboxen der zu entfernenden Schweißprogramme im Favoritenordner oder Programmordner aktivieren Schweißprogramme verwalten 4 Softkey Fav entfernen Programm Manager auswählen 8 1 1 4 3 Renaming welding procedures and folders From the main menu 1 Select the Program Man...

Page 77: ...confirm the entry with the Enter key 8 1 1 4 4 Copying welding procedures and folders Copying creates a copy of the selected welding procedure s or folder s at the destination NOTICE The Copy function can be used within and across drives NOTICE If welding procedures are saved to an external drive USB LAN a PDF of the procedure s content is automatically generated and saved together with the weldin...

Page 78: ...ifferent folders From the main menu 1 Select the Program Manager menu item 2 Select the Manage softkey Main menu 64 3 Activate the checkboxes for the welding procedures or folders to be copied Managing welding procedures 74 4 Mark the destination drive or folder with the menu cursor 5 Select the Copy softkey 6 System prompt Do you wish to copy the selected files Confirm with Yes 8 1 1 4 5 Moving w...

Page 79: ...it The following items cannot be moved Complete drives Welding procedures directly to the drive level Welding procedures within a folder Selections of welding procedures from different folders From the main menu 1 Select the Program Manager menu item 2 Select the Manage softkey Main menu 64 3 Activate the checkboxes for the welding procedures or folders to be copied Managing welding procedures 74 ...

Page 80: ...Eine Auswahl von Schweißprogrammen aus einem Ordner Es können nicht gelöscht werden Komplette Laufwerke Aus dem Hauptmenü 1 Menüpunkt Programm Manager auswählen 2 Softkey Verwalten auswählen Schweißprogramme verwalten 3 Checkboxen der zu löschenden Schweißprogramme oder Ordner aktivieren Schweißprogramme verwalten 4 Ziellaufwerk oder Zielordner mit den Menücursor markieren 5 Softkey Löschen auswäh...

Page 81: ... All active and connected drives are displayed at this level Possible drive include Internal memory External storage media connected via USB LAN network storage locations 2 Menu cursor Drives folders or welding procedures marked with the menu cursor are highlighted in blue in the Program Manager 3 Remove Share soft key The Remove Share softkey can be used to remove network shares or storage locati...

Page 82: ... Drive Information field displays information about the drive cur rently marked with the menu cursors Name Displays the drive name Types of drive Indicates whether the drive is internal USB or LAN IP address Displays the IP address of the network storage location Directory path Displays the network path of the network storage location ...

Page 83: ...elding protocol NOTICE Logs can only be stored on external storage media USB LAN The STANDARD folder cannot be deleted 2 3 4 5 6 7 8 9 10 1 NO DESIGNATION FUNCTION 1 Local icon The power supply can display log files from other Orbitalum power supplies among others This is the case for example with a shared LAN location where multiple power supplies store the weld logs The Local icon marks the stor...

Page 84: ...lding recorded in the associated log a warning message or an abort occurred or whether the weld was performed without these SYMBOL MEANING Check mark All measured actual values lie within the monitoring lim its for alarm and abort Exclamation mark An alarm message was generated during welding The alarm limits set in the monitoring limits were violated The process was not aborted X Welding was abor...

Page 85: ...NGLISH ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 85 NO DESIGNATION FUNCTION 10 Welding protocol pre view The welding protocol preview information field shows the content of the currently selected welding protocol ...

Page 86: ...s etc The welding parameters may have to be adjusted subsequently Auto programming only works in conjunction with an orbital weld head or rotary table This function is not available for manual welding torches 8 1 3 1 Using auto programming From the main menu 1 Select the Create New Program menu item 2 Select the Weld Head Model menu item 3 Select Material and parameter set 4 Select Gas Type 5 Ente...

Page 87: ...meter sets are available for programming The selection must be made on the basis of the application Stainless Classic Classic ORBITALUM parameter set suitable for general stainless steels Stainless 4 Level Stainless steel parameter set recommended for ASME stainless steel pipe dimensions Suitable for high purity and pharmaceutical applications Stainless Slope Stainless steel parameter set with lin...

Page 88: ...rgon 5 0 Argon H2 2 Argon shielding gas containing 2 hydrogen Argon H2 5 Argon shielding gas containing 5 hydrogen 4 Tube diameter Enter the tube s outer diameter 5 Wall thickness Enter the tube s wall thickness 6 Wire Feed Possibility to select whether cold wire to be used or not NOTE Function depends on weld head Can only be activated with weld heads that support use of cold wire 7 Calculate men...

Page 89: ... added in the currently loaded welding procedure 1 2 3 4 6 5 NO DESIGNATION FUNCTION 1 List of levels Tabular overview of the levels contained in the currently loaded pro cedure with indication of the number of levels and their angular ranges from to 2 Level segment bound ary Marks the start and or end of a level segment 3 Level segment cursor The level segment cursor can be used to move and reset...

Page 90: ...he new level segment and level segment range is now included the list of levels 1 8 1 4 1 2 Moving a level segment boundary To move a level segment boundary follow the steps below From the main menu 1 Select the Adjust Level Segments menu item 2 Place the level segment cursor 3 on the segment boundary 2 to be moved 5 and select it 6 3 Move the selected level segment boundary 6 to the desired posit...

Page 91: ... GmbH D 78224 Singen www orbitalum com 91 8 1 4 2 Adjusting parameters The Adjust Program Parameters menu can be used to adjust the welding procedure parameters of the currently loaded welding procedure Illustration Adjust Program Parameters menu ...

Page 92: ...highlighted in gray NOTICE The function serves as an orientation aid for the user when creating and adjusting the welding procedure 2 Global Change softkey Pressing the Global Change softkey transfers the parame ter value currently marked with the menu cursor to all subse quent levels and existing values are overwritten NOTICE The function serves the user as a convenience function to adjust identi...

Page 93: ...Documentation fields have been defined and the documentation function has been activated See the chapters Program settings 130 and Overview and documentation list functions 133 The welding procedure parameter Save Data Log Files is activated See the chapter Basic adjustments 94 Marking of documentation fields Documentation fields marked as required are outlined in red Documentation fields marked a...

Page 94: ...cted the connected torch model is deter mined automatically NOTICE For automatic determination the dropdown list must be acti vated once The connected weld head model is highlighted and can be selected 4 Weld Number Consecutive numbering of welds Weld seam numbers can also be assigned individually They serve as an indicator of progress or as an identifier in documentation NOTICE When the welding p...

Page 95: ... Alert When this function is activated you can define the number of welding igni tions after which the operator is prompted via a message window to check or change the electrode Ignitions until electrode replace ment necessary Input field for the number of ignitions after which a message window ap pears prompting the operator to replace the electrode After each ignition the value decreases by 1 Wh...

Page 96: ...5 16 17 18 19 Illustration Basic adjustments middle region of menu 20 21 Illustration Basic adjustments lower region of menu NO PARAMETER FUNCTION 9 Total Time Displays the total time of the welding procedure from the start command of the welding process until the gas post purge time has elapsed in seconds ...

Page 97: ...format to the selected location Off Weld data logging deactivated USB Saves to USB data storage media Prerequisite Data storage media is connected to any USB port If several USB data storage media are connected they are listed individu ally in the dropdown list NET Saves to local network Prerequisite Power supply is included in the network and network directory is set up See the chapter Network En...

Page 98: ... Welds When activated weld data logs are only created when the welding process is completely finished No logs are created in the event of a manual abort This function can be helpful when using the weld head to set tack points by manually moving the electrode position and briefly starting and stopping the welding process 14 Direction of Rotation Dropdown list selection for selecting the desired dir...

Page 99: ...ted This function is useful if the workpiece only needs to be tacked 17 Tack Points Enter the desired number of tack points At least 2 at most 8 18 Tack Current Welding current flowing during the tack time in amperes 19 Pilot Current Pilot current to maintain the arc between the tack points NOTICE This function is used to maintain the arc when moving the electrode between the tack point positions ...

Page 100: ...ay the user can be provided with important information for the reproduction and documentation of welding results The process details can be created individually for each welding procedure 1 2 3 Illustration Process Details NO DESCRIPTION 1 Text and number input fields for values of specific parameters 2 Comment field for free text 3 Save softkey for saving the entries Procedure 1 Mark the desired ...

Page 101: ... D 78224 Singen www orbitalum com 101 NOTICE The Process Details are procedure related and are stored in the data record of the respective welding procedure Print out the process details together with welding procedures see the chapter Documentation 92 ...

Page 102: ... during which the weld head is purged with the process gas quantity See also the chapter Gas overview 156 23 Gas Quantity Process gas quantity with which the welding torch is purged during the welding process and the regular gas pre purge time and gas post purge time See also the chapter Gas overview 156 24 Gas Over view Takes you to the Gas Overview menu See also the chapter Gas overview 156 25 F...

Page 103: ...essurized with the set Flow Force Gas Quantity NOTICE It is recommended that you reduce the welding gas quantity to the actual process gas quantity at least 2 seconds before ignition of the arc to allow the gas flow to stabilize before ignition 27 Flow Force Gas Quantity Welding gas quantity with which the weld head is pressurized during the Flow Force Time in the pre purge and post purges phases ...

Page 104: ...welding current builds up linearly The pool formation process is static without rotation movement 29 Wire Feed ON OFF Activates deactivates cold wire feed to the weld head NOTICE This function is only supported by weld heads with a built in cold wire unit When weld heads without a cold wire unit are used the following parameters are hidden Wire start delay Wire final delay time Wire retract Wire f...

Page 105: ... www orbitalum com 105 NO PARAMETER FUNCTION 32 Wire Retract Time period in seconds during which the wire needs to be retracted after the Wire Final Delay Time has elapsed This function can be useful to prevent the filler wire from becoming stuck at the weld seam end ...

Page 106: ...elding current secondary welding current in amps 38 HP Time High pulse travel time Time period in seconds during which the HP current flows 39 LP Time Low pulse time Time period in seconds during which the LP current flows 40 HP Travel Speed High pulse travel speed Welding speed in mm min in min used during the time period of high pulse current 41 LP Travel Speed Low pulse travel speed Welding spe...

Page 107: ...me period in seconds of linear current reduction starting from the welding current value of the previous level until the set final current is reached 44 Final Current Value of the final current in amperes when it is reached during current re duction the welding arc is extinguished 45 Rotate During Downslope The Rotate During Downslope function can be used to set the rotation be havior of the weld ...

Page 108: ... head is pressurized with the process gas quantity after the arc has been extinguished See also the chapter Gas overview 156 47 Home Delay Time Time period in seconds during which the electrode remains in the last posi tion after the welding arc is extinguished until it is automatically returned to the home position 48 Gas Over view Takes you to the Gas Overview menu See also the chapter Gas overv...

Page 109: ...hen switch to the Flow Force gas quantity 51 Coolant De lay Time period in minutes during which the coolant system is to remain acti vated after the end of the welding process This function can be used to actively cool the weld heads with the liquid cooling system of the power supply after completion of the welding process NOTICE When the coolant system is active the weld head should not be discon...

Page 110: ...torch The orbital process graphic changes to a classic welding ramp view All welding parameters in Adjust Program are adapted to manual welding 1 2 3 4 5 6 NO PARAMETER PROCESS DETAIL ITEM 1 Adjust Program menu in the manual welding mode Welding parameters can be changed in the Adjust Program section For detailed information see the chapter Adjust Program Manual_Welding_Mode 114 2 Orbital Weld Mod...

Page 111: ...rch can be controlled welding parameters adjusted and the welding process started For detailed information see the chapter Welding in the manual welding mode 116 5 Info softkey The Info softkey displays warning and status messages that have been generated with their time and date Any messages that have been generated are indicated by an icon on the left edge of the softkey button Pressing the soft...

Page 112: ...rting with the Gas Pre Purge Time 3 and ending with the Gas Post Purge Time 11 The welding ramp graphically adapts to the constant or pulse welding mode set in the welding parame ters 1 2 4 12 3 7 5 6 8 9 10 11 NO PARAMETER PROCESS DETAIL ITEM 1 Weld current display The weld current display shows the currently flowing average welding current When the current is adjusted via the welding current up ...

Page 113: ... Current phase and the set parameter value 7 HP Time process phase Welding ramp range in seconds during the HP Time phase and the set parameter value 8 LP Time process phase Welding ramp range in seconds during the LP Time phase and the set parameter value 9 Downslope Time process phase Welding ramp range in seconds during the Downslope Time phase and the set parameter value 10 Final Current proce...

Page 114: ...e Welding ramp process graphic by a yellow font color 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Default values of welding parameters NO PARAMETER PROCESS DETAIL ITEM 1 Current Profile Drop down list for selecting the desired current profile Adjusts the behavior of the welding arc Pulsed Pulsed welding current between the welding current values HP Current and LP current within the time intervals of HP time ...

Page 115: ... pulse time Time period in seconds during which the LP current flows Only available with pulsed current waveform 11 Downslope Time Time period in seconds during which the welding current de creases linearly to the programmed Final Current after the stop signal 12 Final Current Final current in amps at which the welding arc is extin guished by the current reduction 13 Post Purge Time Time period in...

Page 116: ... not possible to adjust the welding parameters via the software interface NOTICE The welding process can only be started via the control panel of the manual welding torch Starting via the power supply is not possible in manual welding mode 1 2 3 4 5 Default values of welding parameters NO PARAMETER PROCESS DETAIL ITEM 1 Weld Mode Shows the current status of the manual welding torch whether the sig...

Page 117: ...cess to ensure functional readiness An error message appears in the event of a lack of gas 3 Menu softkey Pressing the Menu softkey takes you directly back to the main menu for the manual welding mode 4 Welding procedure information field The Welding program information field provides an over view of current technical values such as inverter tempera ture average current and arc voltage 5 Welding r...

Page 118: ...pressure is removed they spring back to the center position Hold up down Tap up down Release Basic functions DIRECTION OF ROCKER MOVEMENT BASIC FUNCTION Left rocker down Start stop welding process Right rocker up Reduce welding current Right rocker down Increase welding current Context sensitive function assignment The function assignment of the rocker switches and their direction of movement depe...

Page 119: ...e Purge Time Gas Pre Purge Time Left rocker released Stops the welding process Left rocker held down again Restarts the Gas Pre Purge Time Upslope Time Left rocker released Start of Gas Post Purge Time Gas Pre Purge Time Left rocker held down again Restarts Arc Ignition HP LP Current Left rocker released Start of Downslope Time Downslope Time Left rocker held down Start of Constant Cur rent HP LP ...

Page 120: ...ht rocker tapped down Increase welding current 1 A Tap HP LP Current Right rocker tapped up Decrease welding current 1 A Tap HP LP Current Right rocker held up Constant welding current de crease 15 A second HP LP Current Right rocker released Stop welding current decrease HP LP Current Right rocker held down Constant welding current in crease 15 A second HP LP Current Right rocker released Stop we...

Page 121: ...tes and the Start Current is set ð The Upslope Time starts ð During the Upslope Time the Start Current increases linearly to the HP LP current weld ing current 2 Left rocker released ð The Constant current HP LP current welding phase changes to the we Downslope Time welding phase ð The welding current is reduced linearly until the Final Current is reached ð When the Final Current is reached the ar...

Page 122: ...2 in the main menu ð The Logout screen appears See also the chapter Login screen 39 ð The power supply is protected from unauthorized access 1 2 Illustration Logout buttons on main menu NO DESIGNATION 1 Logout button 2 Logout function button FUNCTION BUTTON VERSION STATUS FUNCTION Logged in at user level Log out activate the login screen Logged in at the administrator level ...

Page 123: ...an be useful for example when the gas sensor is defective and work must be continued tem porarily Flow Sensor ON Welding gas monitoring active Flow Sensor OFF Welding gas monitoring deactivated CAUTION When the welding gas sensor is deactivated the flow of welding gas from the power supply is not actively monitored There fore increased operator attention is required during continued use of the pow...

Page 124: ...s the function is reset to coolant sensor ON each time the power supply is restarted 3 Parameter Limits ON OFF The Parameter Limits function can be used to activate or deactivate the limits defined under Program Settings Parameter Limits See the chapter Limit Adjustments 132 If parameter limits are activated an alarm message is generated or a weld ing process abort is triggered when the defined li...

Page 125: ... sociated general conditions are assigned by the software When the adaptation solution is used for a competitor s weld head the head list must be changed accordingly ORBITALUM Standard headlist includes all ORBITALUM weld head data AMI Includes selected AMI weld head data Cajon_Polysoude Includes selected Cajon Swagelok and Polysoude weld head data NOTICE Modified headlists deviating from the orig...

Page 126: ... Update Printer List option In this case the power supply scans all USB ports and the LAN network for accessible network and USB printers Internal Prints using the internal system printer NET Prints using a network printer USB Prints using a USB printer Update printer list Scans the USB ports and LAN network for acces sible printers 7 Display Inch Sizes Function to change the system s units of mea...

Page 127: ...ng process must be done manually via the Stop key button When the Start key button is pressed again the following message ap pears Should the interrupted welding process be continued The message can be confirmed with Yes or No Yes The welding process resumes with the Gas Pre Purge Time and Rotor Start Delay defined in the welding procedure then changes directly to the level and angle position wher...

Page 128: ... in min can be set there for which the liquid cooling system remains active after the end of the welding process Coolant Delay ON The Coolant Delay program input field is ac tivated Coolant Delay OFF The Coolant Delay program input field is de activated NOTICE Do not disconnect the weld head from the power supply when a liquid cooling system is active 10 Permanent Gas Quantity The Permanent Gas Qu...

Page 129: ...n level Full Range of Functions The password to activate the full range of functions must be entered once Remain Signed In OFF The power supply always starts at the autho rization level Limited Range of Functions See also the chapter SETUP AND COMIS SIONING and Activating the Full Range of Functions 13 Print Prev Log ON OFF When the Print Prev Log function is activated an additional softkey is act...

Page 130: ...ther the stored Limit Adjustments are to be appended to each weld data log Print Limits ON Attach Limit Adjustments activated Print Limits OFF Limit Adjustments attached not activated 3 Process Details See the chapter Process Details 100 4 Prints Notes ON OFF The Print Notes ON OFF slide button can be used to specify whether the information entered under Process Details is to be printed in additio...

Page 131: ... Speed with Slope ON OFF slide button can be used to define whether the rotation speed adjustment between two level segments should be linear or abrupt When this function is activated the behavior is set together with adjustment of the welding current via the Slope welding procedure parameter See also the chapter Level 106 8 Scale weld limit The Scale Weld Limit input field can be used to define t...

Page 132: ...justments menu The limits can be adjusted individually for each welding procedure Changes must be applied via the Save softkey NOTICE The Limit Adjustments are welding procedure based and stored in the data log of the welding procedure CAUTION When the limits are deactivated there is no active monitoring of the welding parameters such as welding current welding voltage and welding speed Continued ...

Page 133: ...either before each welding task or after each restart of the power supply Output occurs together with all welding related SET and ACTUAL values in the form of a weld log file saved on a USB medium or in a network directory or can be printed out by means of the internal or external printer The documentation routine created can be saved on a USB storage medium and transferred to other power supplies...

Page 134: ... saved in the input field until the power supply is restarted This option is recommended for static parameters such as Welder ID Weld head serial number Gas cylinder number Gas type If the function is deactivated the content of the input field is deleted after each ignition and must be reentered This option is recommended for variable parameters such as Batch num ber Workpiece type Welding positio...

Page 135: ...ct the Documentation menu item 4 Select the documentation field to be moved 5 Press the Move softkey 8 1 6 2 2 3 Deleting a documentation field The documentation fields can be removed by pressing the Delete softkey NOTICE Pressing the Delete softkey irrevocably deletes the marked pa rameter From the main menu 1 Select the Settings menu item 2 Select the Program Settings menu item 3 Select the Docu...

Page 136: ...ge files Documentation list Procedure 1 Insert the USB data storage media with the update file into any USB port 2 Select the menu item for the desired system area ð After successful selection the update routine starts 8 1 6 3 2 Backup Individual system areas can be independently backed up to a USB data storage media under the Backup menu item The following system areas are available for backup Au...

Page 137: ...73 All settings for integrating the power supply into a local network can be made under the Network envi ronment menu item Welding procedures and weld data logs can be stored and retrieved decentrally Thanks to the ability to integrated the unit into an MQTT IoT Industry 4 0 network data and control com mands can be exchanged among the network participants NOTICE Configuration of the network is a ...

Page 138: ...NGLISH MOBILE WELDER OC PLUS 138 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com Power supply 1 Windows PC LAN switch Power supply 3 Power supply 2 Windows server or Illustration Connection scheme ...

Page 139: ...by the system and serves as information No action required Broadcast Parameter is set by the system and serves as information No action required Subnet mask Input field for the subnet mask address of the network NOTICE Mandatory network parameter The subnet mask must be identical to the subnet mask of the network Standard gate way Input field for the standard gateway address of the network NOTICE ...

Page 140: ...ted on the destination com puter server beforehand Network sharing with read and write authorization must be set up for the destination directory on the destination computer server Multiple network directories can be set up in the power supply The network directories can be accessed at the same time by multi ple power supplies PARAMETER FUNCTION Add Shared Folder The Add Shared Folder menu button ...

Page 141: ...r name Example Correct ORBINet Welding Data Wrong DESIOTGS0022 ORBINet Welding Data Do not use a forward slash at the beginning of the network path Correct ORBINet Welding Data Wrong ORBINet Welding Data Use only the forward slash for folder separation in the network path Correct ORBINet Welding Data Wrong ORBINet Welding Data Do not use folder names with spaces Correct ORBINet Welding Data Wrong ...

Page 142: ...y and usually does not need to be changed In case of connection problems the SMB version can be adjusted accordingly Then set the SMB version according to the operating system of the destination computer server This setting should preferably be performed by a system administra tor Selection options Version Operating system Default Automatic selection of the correct SMB version 1 0 Windows 2000 Win...

Page 143: ...word hashing ntlmi Use NTLM password hashing and force packet signing ntlmv2 Use NTLMv2 password hashing ntlmv2i Use NTLMv2 password hashing and force packet sign ing ntlmssp Use NTLMv2 password hashing encapsulated in Raw NTLMSSP message Add Shared Folder Menu button for applying the parameters entered NOTICE Following the successful setup of the network directory on the power supply the network ...

Page 144: ...generations and convert them into the current welding procedure format NOTICE Welding procedures for the ORBIMAT CA generation are fully com patible and do not have to be imported They can be copied opened directly via the Program Manager Preparation 1 On a compatible USB stick with the help of a PC create the PROGRAMS folder NOTICE The PROGRAMS folder must be located at the top level in the root ...

Page 145: ...converted to the input masks 1 2 3 4 5 6 7 8 9 Illustration Import Programs menu upper region NO MENU ITEM SETTING OPTIONS 1 Weld Head Model Possibility for selecting the torch model used 2 Display Inch Sizes Function to change the units of measure between Metric and Imperial After the change all fields are displayed with the active unit of measure and existing values are converted accordingly Opt...

Page 146: ...the arc is extinguished 7 Downs lope Time Time period in seconds of linear current reduction starting from the welding current value of the previous level until the set final current is reached 8 Direction of Rota tion Dropdown list for selecting the desired direction of rotation when welding clockwise Standard direction of rotation starts with upslope welding counterclockwise Alternative directio...

Page 147: ... level specific parameters of the AMI welding proce dure entered under the Adjust Levels menu item The input is done in tabular form Before a value is entered the input field must be selected marked NOTICE All of the following parameters can be transferred from existing AMI welding programs as shown without conversion of units 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 148: ...e menu level 6 Levels column Shows the current number of levels and level number in tabular form 7 TIME column Level time in seconds 8 PULSE column Checkbox for pulsating welding current Checkbox activated PULSE ON Checkbox deactivated PULSE OFF 9 ROT CONT column Checkbox for continuous rotation Checkbox activated ROT CONT Checkbox deactivated ROT CONT 10 PRI RPM column Number input field for prim...

Page 149: ... SETTING OPTIONS 11 Import Pressing the Import menu button converts the AMI welding parameters entered for use in an ORBITALUM welding procedure The converted AMI welding procedure is automatically stored in the Program Man ager in the internal memory under the path Internal Memory PROGRAM MPORTS_AMI ...

Page 150: ...inter Setup menu NO MENU ITEM SETTING OPTIONS 1 Small Letters ON Small font size activated OFF Small font size deactivated 2 Distance From The Left Value for distance from the left edge of the page to the beginning of the print area in mm 3 Width of Tex Width of the print area in mm 4 Distance From The Top Value for distance from the top edge of the page in mm to the beginning of the print area 5 ...

Page 151: ...rrent values of the digital inputs 2 Digital Outputs Current values of the digital outputs 3 PWM Out Current actual values for the active process calculated from the analog input information or serial inverter interface 4 Analog In Current values of the analog inputs 5 Analog Out Current values of the analog outputs 8 1 6 5 7 Info The Info menu button opens an overview with information on the curr...

Page 152: ... keyboard layout of the external USB key board 2 Language Of The Documenta tion For setting the language of the documentation logfile independently of the sys tem language 3 System Lan guage For setting the system language of the power supply See also the chapter Setting the system language and language of the docu mentation 60 NOTICE When the language is changed all messages generated parame ter ...

Page 153: ... mains plug must always be assured in order to permit disconnecting the power supply from the mains The Welding procedure information field 5 provides an overview of current technical values such as coolant and gas flows welding voltage temperatures The Process graphic 6 shows an overview of the current progress of the process and the current welding position on the workpiece in the active welding...

Page 154: ...he result of suffocation Use only in well ventilated areas Monitor oxygen if necessary WARNING Danger of burns and fire from arcs Tripping over the hose assembly can cause the welding current plugs to be pulled out of the welding power supply and cause an arc Lay the lines and cables so that they are not under tension Ensure that lines and cables do not pose a trip hazard Attach the strain relief ...

Page 155: ...ly loaded welding procedure NOTICE The weld head model programmed in the welding procedure must match the weld head model connected to the power supply If weld ing procedure parameters are outside the weld head specification it is not possible to start the welding process 3 Gas softkey The Gas softkey opens a softkey submenu with all functions relevant to coolant and welding gas See the chapter Ga...

Page 156: ...an workpieces before welding Weld only materials suitable for the TIG welding process TIG DC WARNING Health hazard from inhalation of radioactive particles Do not use electrodes containing thorium Do not weld radioactive workpieces 8 2 1 Gas softkey The Gas softkey takes you from the Weld Mode menu to a submenu with all the functions relevant to welding gas 8 2 1 1 Gas overview The gas overview pr...

Page 157: ...r and more effi cient purging or removal of residual oxygen from the welding torch In the gas post purge phase the welding torch can be pressurized with a significantly larger gas quan tity in order to obtain faster cooling of the workpiece and weld head Permanent Gas The Permanent Gas function continuously pressurizes the weld head with a constant flow of welding gas to prevent oxygen from enteri...

Page 158: ...uce the welding gas quantity to the actual process gas quantity at least 2 seconds before ignition of the arc in order to allow the gas flow to stabilize before ignition 5 Flow Force Gas Quantity Welding gas quantity with which the weld head is pressurized during the Flow Force Time in the pre purge and post purge phases 6 Post Purge Time Time period in seconds for how long the welding torch is pr...

Page 159: ...on productive time 11 Limit Testing softkey When the Limit Testing softkey is pressed the power supply starts a welding gas flow test to determine the max welding gas quantity available at the gas input connection The gas quantity determined is transferred to the Flow Force Gas Quantity input field taking a safety margin into account NOTE 1 Ensure that the welding gas supply and the weld head are ...

Page 160: ...quantity can be defined in the system settings or in the Gas Overview under the Permanent Gas Quantity menu item For further information see the chapters Gas overview 156 and System adjustments 123 8 2 1 4 Back softkey The Back softkey takes you directly back to the Weld Mode menu 8 2 2 Motor control The Motor Control softkey takes you from the Weld Mode menu to a submenu where the weld head rotat...

Page 161: ...Advances the cold wire NOTICE The softkeys are only displayed if the selected weld head supports wire 8 2 2 3 Global Change softkey Pressing the Global Change softkey transfers the parameter value currently marked with the menu cursor to all subsequent levels and existing values are overwritten NOTICE The function serves the user as a convenience function to adjust identical values across segments...

Page 162: ...e a simulation process can be started and all welding relevant functions can be controlled in order to check and adjust the sequence of the currently loaded welding procedure The entire welding process is started but without Arc ignition welding current Flow of welding gas Cooling Flow Except for the features mentioned above the test mode is identical to the Weld mode In test mode the Start softke...

Page 163: ...MENT FUNCTION 2 Start softkey Starts the simulation process without arc ignition welding current welding gas and cooling flow based on the parameters of the currently loaded welding procedure NOTICE The weld head model programmed in the welding procedure must match the weld head model connected to the power supply For all further functions see the chapter Weld mode 153 ...

Page 164: ... weld pool forms 2 After the weld pool has formed the rotor starts rotating and the welding parameters for the first level are set At a level transition the welding parameters adjust to those of the next level 3 Once the end of the last level has been reached the downslope phase starts from here the weld ing current is decreased linearly until the final current is reached 4 When the value for the ...

Page 165: ...Shows the current welding position 3 Level marking Shows the currently active level 4 STOP softkey Pressing the STOP softkey immediately ends the entire welding process 5 Downslope softkey Pressing the Downslope softkey switches the power supply to the downslope phase of the welding procedure 6 Gas softkey Reduces the welding gas quantity by 1 l min 7 Gas softkey Increases the welding gas quantity...

Page 166: ...e service screen SLO Switches the slope representation in the welding procedure from to seconds RES Restarts the software BMP Creates an image file of the current screen in BMP format Prerequisite USB data storage media must be plugged in 9 2 Special Commands softkey US Reset If a connected USB peripheral does not work as expected you can try to fix the error via a USB reset without having to rest...

Page 167: ...ON Coolant leakage during weld head change Irritation of skin eyes and respiratory tract possible on contact with coolant When changing the weld head switch off the coolant pump and power supply If several weld heads of different types or if all of the same weld heads are identical this is not neces sary because the machine stores one deviation per head type See also the chapter Motor calibration ...

Page 168: ...ISH MOBILE WELDER OC PLUS 168 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com ð A message appears Do you want to save the new calibration data 2 If the deviation is less than 1 Confirm message with No ...

Page 169: ...eplacing the roll of paper 1 2 3 4 3 1 Open the printer cover 3 2 Align the new paper roll 4 as shown and unroll the beginning of the paper so that it can protrude from the cover slot 2 3 Hold the beginning of the paper above the cover slot 2 and close the printer cover 3 4 Tear off excess paper by pulling upwards 10 5 Maintenance schedule INTERVAL ACTIVITY Monthly Clean the machine fully from the...

Page 170: ...ution Service contact at Orbitalum GmbH Singen E mail customerservice itw ocw com Phone 49 0 77 31 792 786 If you require service please download our Service Form from the Orbitalum home page at Service Repairs and enclose the completed form with the shipment of the affected goods 10 6 2 Technical support application engineering Do you have questions about the operation of your Orbitalum system or...

Page 171: ...o each individual participant and address specific ques tions We will gladly conduct training at your facility upon request At the end of each training you will receive a certificate of attendance and a certificate confirming that you have acquired the required knowledge Operators from the plant container and pipeline construction industries are particularly suitable as tar get groups for the vari...

Page 172: ...enclosed spaces Do not store near materials that may cause corrosion Temperature range 20 to 55 C Relative humidity up to 90 at 40 C The operator obligations for proper disposal in the chapter Environmental protection and disposal 11 and the following safety note must be observed CAUTION Risk of injury from improper disassembly The device may only be opened by a qualified electrician ...

Page 173: ...e entered in the system settings See the chapter Activation 38 UPGRADE Connectivity LAN IoT VNC Code 850080001 Software upgrade to activate the following capabilities Integration of the power supply into a LAN network via RJ45 Exchange of data from welding data logs and welding procedures between power supplies and LAN network drives Integration of the power supply into an Industry 4 0 IoT environ...

Page 174: ... application possibilities in order to perform flexible tacking work and to easily produce manual welding connections with orbital weld heads at inaccessible locations Code 854 030 200 ORBmax Residual Oxygen Meter For optical oxygen measurement using fluorescence extinction The ORBmax does not require any heating up time It recognizes the oxy gen percentage reliably rapidly and precisely during th...

Page 175: ...ilization in combination with an orbital welding power supply from the MOBILE WELDER and ORBIMAT series Code 811 050 005 Hose package extensions Suitable for all weld heads from Orbitalum with exception of the AVC OSC versions of the ORBIWELD TP series The weld current connection adapter set may be required for usage with older Orbitalum welding power supplies and heads with green Superior con nec...

Page 176: ...nted by using consumables that have not been ap proved Various injuries and damage to property Use only genuine tools spare parts operating materials and acces sories from Orbitalum Tools Replacement paper rolls For internal thermal printer Suitable for all orbital welding power supplies from the MOBILE WELDER series Code for 3 pack 854 030 001 ...

Page 177: ...MOBILE WELDER OC PLUS ENGLISH ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 177 ...

Page 178: ...SPARE PARTS MOBILE WELDER OC PLUS 178 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 SPARE PARTS LIST 15 1 Grundaufbau MW Frontansicht Basic structure MW front view 3 2 ...

Page 179: ...5x16 A2 3 854 020 004 1 Deckel MW Cover MW 4 500 602 309 4 Sechskantmutter ISO4032 M4 A2 Hexagon nut ISO4032 M4 A2 5 542 5003 18 4 Scheibe DIN125 ISO7089 d4 3 A2 Washer DIN125 ISO7089 d4 3 A2 6 871 020 033 4 Sperrkantscheibe A4 K für Gewinde M4 Retaining washer A4 K for thread M4 7 854 020 005 1 Seitenwand links MW Side panel left MW 8 307 001 126 23 Linsenschraube ISO7380 M3x8 A2 TX Oval head scr...

Page 180: ...SPARE PARTS MOBILE WELDER OC PLUS 180 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 2 Grundaufbau MW Rückansicht Basic structure MW rear view ...

Page 181: ...00 602 309 2 Sechskantmutter ISO4032 M4 A2 Hexagon nut ISO4032 M4 A2 5 542 500 318 2 Scheibe DIN125 ISO7089 d4 3 A2 Washer DIN125 ISO7089 d4 3 A2 6 871 020 033 2 Sperrkantscheibe A4 K für Gewinde M4 Retaining washer A4 K for thread M4 8 307 001 126 23 Linsenschraube ISO7380 M3x8 A2 TX Oval head screw ISO7380 M3x8 A2 TX 9 307 001 131 2 Linsenschraube ISO7380 M3x12 A2 TX Oval head screw ISO7380 M3x1...

Page 182: ...SPARE PARTS MOBILE WELDER OC PLUS 182 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 3 Bodenblech MW Base plate MW ...

Page 183: ...4 020 052 1 Reduziernippel NPFCR R G3 8 G1 4 MF Reduction nipple NPFCR R G3 8 G1 4 MF 15 500 602 311 2 Sechskantmutter ISO4032 M6 A2 Hexagon nut ISO4032 M6 A2 6 854 020 050 1 Reduziernippel lang MS G1 4 a G3 8 i Reduction nipple long MS G1 4 a G3 8 16 871 020 035 2 Sperrkantscheibe A4 K für Gewinde M6 Retaining washer A4 K for thread M6 7 850 020 304 1 Druckreduzierventil 4 bar 1 4 Pressure reduct...

Page 184: ...SPARE PARTS MOBILE WELDER OC PLUS 184 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 4 Frontabdeckung MW Front cover MW ...

Page 185: ...eibe D6 D20 H1 5 Washer D6 D20 H1 5 13 854 010 010 1 Platine 24pol Steuerleitungsbuchse MW Board 24pin control line socket MW 4 790 052 409 1 Druckfeder Pressure spring 14 307 001 129 4 Linsenschraube ISO7380 M3x10 A2 TX Oval head screw ISO7380 M3x10 A2 TX 5 854 010 008 1 Display Rechnereinheit MW Display computer unit MW 15 854 020 031 1 Distanzscheibe ID10 AD23 H1 POM schwarz Spacer ID10 AD23 H1...

Page 186: ...SPARE PARTS MOBILE WELDER OC PLUS 186 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 5 Rückwand MW Rear panel MW ...

Page 187: ...Washer DIN125 ISO7089 d4 3 A2 4 303 305 010 2 Senkschraube ISO14581 Tx10 M3x8 A2 Countersunk screw ISO14581 Tx10 M3x8 A2 14 302 301 114 4 Senkschraube DIN7991 M4x10 A2 Countersunk screw DIN7991 M4x10 A2 5 854 010 006 1 EIN AUS Einbauschalter ON OFF Built in switch 15 871 020 032 3 Distanzrolle ohne Gewinde L 5 mm Spacing roller w o thread L 5 mm 6 854 010 004 1 LAN RJ45 Einbaubuchse LAN RJ45 jack ...

Page 188: ...SPARE PARTS MOBILE WELDER OC PLUS 188 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 6 Gaskomponenten MW Gas components MW ...

Page 189: ...au PU plastic hose 8x6 mm blue 5 850 020 300 1 Steckverschraubung SL 8 mm 1 8 Push in fitting SL 8 mm 1 8 6 850 010 008 1 Proportionalventil Proportional valve 7 860 020 081 1 Dichtring Typ 0 1 8 Seal ring type 0 1 8 8 860 020 015 1 Gerade Einschraubverschraubung 6 mm 1 8Z Straight screw in connection 6 mm 1 8Z 9 823 020 016 0 065 m Gasschlauch Teflon Gas hose Teflon 10 854 020 009 1 Montageblech ...

Page 190: ...SPARE PARTS MOBILE WELDER OC PLUS 190 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 7 Vertikalblech MW Vertical plate MW ...

Page 191: ...003 1 Kabeldurchführung ID30 Cable gland ID30 13 854 020 018 1 Isolationsplatte Inverter MW Insulation plate inverter MW 4 854 070 002 1 Kabeldurchführung ID18 Cable gland ID18 14 307 001 126 7 Linsenschraube ISO7380 M3x8 A2 TX Oval head screw ISO7380 M3x8 A2 TX 5 854 070 005 8 Kabeldriller 6 6 34 9x18 2 Cable twister 6 6 34 9x18 2 6 854 020 007 1 Montageblech vertikal MW Mounting plate vertical M...

Page 192: ...SPARE PARTS MOBILE WELDER OC PLUS 192 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 8 Horizontalblech MW Horizontal plate MW ...

Page 193: ...mme L N PE Main connection terminal L N PE 5 305 501 058 4 Zylinderschraube ISO4762 M3x20 A2 Cylinder screw ISO4762 M3x20 A2 6 500 602 311 2 Sechskantmutter ISO4032 M6 A2 Hexagon nut ISO4032 M6 A2 7 871 020 035 2 Sperrkantscheibe A4 K für Gewinde M6 Retaining washer A4 K for thread M6 8 542 500 320 2 Scheibe DIN125 ISO7089 d6 4 A2 Washer DIN125 ISO7089 d6 4 A2 9 854 070 001 1 Kabeldurchführung ID1...

Page 194: ...SPARE PARTS MOBILE WELDER OC PLUS 194 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 9 Handgriff Abdeckung MW Handle display cover MW ...

Page 195: ...ger MCM ID5 L2 Clip bearing MCM ID5 L2 4 854 020 021 1 Scharnier Schutzblech Bedienelemente MW Hinge protective cover MW 5 305 501 010 2 Senkschraube ISO14581 M3x10 A2 TX Countersunk screw ISO14581 M3x10 A2 TX 6 854 020 012 1 Gurtlasche vorne MW Belt flap front MW 7 854 020 017 1 Handgriff MW Handle 8 854 020 013 1 Gurtlasche hinten MW Belt flap rear MW 9 302 303 116 4 Senkschraube DIN7991 M5x12 A...

Page 196: ...SPARE PARTS MOBILE WELDER OC PLUS 196 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 10 Schweißstrominverter MW Welding current inverter MW ...

Page 197: ...DESCRIPTION 1 850 010 017 1 Schweißstrom Einbaubuchse 400A Weld current built in socket 400A 2 850 010 018 1 Schweißstrom Einbaustecker 400A Weld current built in plug 400A 3 854 020 022 1 Frontblech Schweißstromanschlüsse MW Front plate weld current connections MW 4 854 050 011 1 Schweißstrominverter MW Welding current inverter MW ...

Page 198: ...SPARE PARTS MOBILE WELDER OC PLUS 198 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com 15 11 Verbindungskabel Connection cables ...

Page 199: ... IF Board KE 14 854 040 011 1 Leitung X19 24VDC Drucker Cable X19 24VDC Printer 5 854 040 004 1 Leitung X10 Soft Key Folie Cable X10 Soft Key Foil 15 854 040 008 1 Leitung X16 Temp Sensor IF Platine KE Cable X16 Temp sensor IF Board KE 6 854 040 013 1 Leitung X203 24VDC SV Netzteil MITTE Cable X203 24VDC SV power supply CENTER 16 854 040 012 1 Leitung X201 24VDC SV Netzteil RECHTS Cable X201 24VDC...

Page 200: ...SPARE PARTS MOBILE WELDER OC PLUS 200 ORBITALUM TOOLS GmbH D 78224 Singen www orbitalum com ...

Page 201: ...on Störungen wenden Sie sich bitte direkt an unsere für Sie zuständige Niederlassung Für die Ersatzteilbestellung geben Sie bitte folgende Daten an Maschinentyp Ersatzteilbezeichnung Code For ordering spare parts and for the resolution of faults please contact your branch office directly Please provide the following information when ordering spare parts Machine type Spare parts description Part No...

Page 202: ...sopra specificata è stata costruita e controllata conformemente alle direttive qui di seguito elencate Por la presente confirmamos que la máquina mencionada ha sido fabricada y comprobada de acuerdo con las directivas especificadas a continuación Hiermee bevestigen wij dat de vermelde machine in overeenstemming met de hieronder vermelde richtlijnen is gefabriceerd en gecontroleerd Tímto potvrzujem...

Page 203: ...tikeln von Orbitalum Machinery and type including optionally available accessories from Orbitalum Seriennummer Series number Hiermit bestätigen wir dass die genannte Maschine entsprechend den nachfolgend aufgeführten Richtlinien gefertigt und geprüft worden ist Herewith our confirmation that the named machine has been manufactured and tested in accordance with the following statutory requirements ...

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