Orbitalum ORBIMAT 165 CA Operating Instructions Manual Download

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orbitalum tools

GmbH, D-78224 Singen, www.orbitalum.com, Tel. +49 (0) 77 31 792-0

(01.2012) OM_BA_ORBIMAT_CA_01_EN

OWNER INFORMATION AND SAFET Y PRECAUTIONS

ORBIMAT CA

| Operating instructions

DANGER

Dangers of improper maintenance of the system.

Various injuries and damage to property!

Carry out maintenance as described in the "Maintenance" chapter.

DANGER

Electrical hazards through touching and incorrect or damp safety equipment.

Electric shock!

[

Do not touch energized parts (pipe), especially when igniting the arc.

[

Do not allow persons with increased sensitivity to electrical hazards
(e.g. weakness of the heart) to work with the machine.

Wear dry safety shoes, dry metal-free (grommet-free) leather gloves and dry safety
suits to minimize the electrical hazard.

Work on a dry surface.

DANGER

Accidental ignition.

Electric shock!

Switch off the orbital welding power source when connecting or disconnecting
a weld head.

WARNING

Electromagnetic incompatibility of surrounding devices during high-frequency ignition
and devices in operation without a protective ground.

Various injuries and damage to property!

Use only electrical devices with protective insulation in the working area of the
welding system.

Observe electromagnetically-sensitive devices when igniting the system.

WARNING

Ultraviolet radiation from the arc while welding.

Damage to eyes and burning of skin!

During operation, wear eye protection as per EN 170 and skin-covering safety
clothing.

With closed weld heads, ensure proper working order of the eye protection.

WARNING

Hot leaking liquids and hot plug connections during heavy operation.

Danger of scalding!

Heed the safety precautions of the technical supervisor/person in charge of safety.

DANGER

Incorrect handling of pressure tanks and other parts of the system
(e.g. forming gas bottle).

Various injuries and damage to property!

Heed safety regulations, especially those for pressure tanks.

Comply with safety data sheets.

If the system and its components exceed 25 kg in weight, lift using several people or
lifting equipment.

DANGER

Flammable material near the welding zone or solvent in the room air.

Danger of explosion and fire!

[

Do not weld near solvents (e.g. where painting is being carried out).

[

Do not weld near explosive substances.

[

Do not use flammable materials as a base in the welding area.

Ensure that no flammable materials or soiling is located near the machine.

CAUTION

Hot surfaces of the weld head and weld points, including for a period of time after
welding.

Danger of burns!

Wear safety gloves.

Summary of Contents for ORBIMAT 165 CA

Page 1: ...sers Orbital Welding Power Supplies ORBIMAT CAdvanced ORBIMAT 165 CA ORBIMAT 300 CA Machine No Please read all operating instructions before commissioning this machine so that you can work with it safely Retain the operating instructions for future use ...

Page 2: ...MAT 300 CA Compact 16 4 2 3 ORBIMAT 300 CA AC DC 16 4 2 4 ORBIMAT 300 CA AC DC Compact 16 4 2 5 ORBIMAT 300 CA AVC OSC 16 4 3 Functional description 16 5 TECHNICAL DATA 17 5 1 System data 17 5 1 1 Components and parts 17 5 1 2 Technical Data 17 6 COMMISSIONING 19 6 1 Checking scope of delivery 19 6 2 Scope of delivery 19 7 SETUP AND ASSEMBLY 20 7 1 Control elements 20 7 1 1 Overview of the main co...

Page 3: ...1 Updating and backup functions for the software 55 8 12 Updating software components 56 8 13 Saving software components 56 8 14 Restoring software components 56 8 15 Working in other languages 56 8 15 1Changing the language 56 8 15 2Printing data in another language 57 8 15 3Creating a new operating language 57 8 16 Importing programs from other ORBIMATIC power sources 57 8 17 Special keyboard co...

Page 4: ...compliance can result in death or very serious injury Prohibited activities if applicable X Measures for avoiding danger WARNING Possible danger Non compliance can result in serious injury X Prohibited activities if applicable Measures for avoiding danger CAUTION Dangerous situation Non compliance can result in minor injury X Measures for avoiding danger CAUTION Dangerous situation Non compliance ...

Page 5: ...CTIONS 1 4 Warning signs X Heed all warnings and safety precautions found on the machine The following information is also found on the machine Image Machine model Position on the machine Meaning Code No ORBIMAT 165 CA ORBIMAT 300 CA Rear Danger Danger of injury from electric shock ORBIMAT 165 CA ORBIMAT 300 CA Rear Warning Danger of injury from electric shock ...

Page 6: ...ply with inspection and maintenance intervals X Use machine only in its original state Use only genuine accessories spare parts and operating materials X Do not remove safety devices or modify their function X Use the machine only on empty unpressurized pipes and containers in a non explosive atmosphere 2 2 2 Improper use Any use that differs from or goes beyond the use specified under Intended pu...

Page 7: ...orting it before changing tools and before carrying out cleaning adjustment and repair work Do not carry machine by the hose assembly Protect machine cabling from heat oil and sharp edges Do not reach into the tools during operation Ensure that the workpiece is clamped properly Only switch on the machine if a pipe is clamped When working with the machine wear safety shoes as per EN ISO 20345 at le...

Page 8: ...orking area of the welding system X Observe electromagnetically sensitive devices when igniting the system WARNING Ultraviolet radiation from the arc while welding Damage to eyes and burning of skin X During operation wear eye protection as per EN 170 and skin covering safety clothing X With closed weld heads ensure proper working order of the eye protection WARNING Hot leaking liquids and hot plu...

Page 9: ...low machine to cool down sufficiently before opening X Allow only a professional electrician to access the electrical system Never connect an opened system to the mains network DANGER Liquid in the housing due to improper use and transport Electric shock Do not place liquids drinks on the system X Do not block ventilation slots X Check housing interior for moisture after transporting the machine a...

Page 10: ... OF THE PRODUCT ORBIMAT CA Operating instructions 3 LAYOUT OF THE PRODUCT 3 1 ORBIMAT 165 CA 9 1 2 3 4 5 6 7 8 10 11 1 Display housing 2 Printer cover 3 Intregrated Printer 4 Rotary knob 5 Multicard reader 6 Flowmeter 7 Front panel 8 Main switch 9 Hood 10 Softkeys 11 10 5 color display Fig 1 Layout of Orbimat 165 CA ...

Page 11: ...4 6 7 8 9 10 11 5 2 3 1 1 Display housing 2 Printer cover 3 Integrated Printer 4 Rotary knob 5 Multicard reader 6 Flowmeter 7 Front panel 8 Main switch 9 Hood 10 Softkeys 11 10 5 display Fig 2 Layout of ORBIMAT 300 CA 3 3 Integrated compact cooling 1 1 Integrated compact cooling Fig 3 Compact Cooling In ORBIMAT 300 CA Compact and 300 CA AC DC Compact already in its basic configuration ...

Page 12: ...de kg ORBICAR W trolley with integrated water coolant 300 CB 300 CA 300 CA AC DC 884 000 002 58 200 3 4 2 ORBICOOL W Article Suitable for ORBIMAT Code kg ORBICOOL W 300 CB 300 CA 300 CA AC DC 885 000 002 26 000 3 4 3 ORBICOOL Active Article Code kg ORBICOOL Active for OM 165 889 000 001 40 000 ORBICOOL Active for OM 300 889 000 002 40 000 3 4 4 ORBITWIN switching device Article Suitable for ORBIMA...

Page 13: ... 002 17 500 Carrying case 300 CB 300 CA 300 CA AC DC 874 050 001 20 800 3 4 8 BUP Control Box Article Suitable for ORBIMAT Code kg BUP Control Box 165 CA 300 CA 886 000 001 2 700 3 4 9 Oxygen meter ORB 1001 Article Version Code kg Oxygen meter ORB 1001 230 115 V 50 60 Hz single phase 882 000 001 3 100 3 4 10 ORBIPURGE forming set Article Tube ID mm Tube ID inch Code kg ORBIPURGE forming set 12 0 1...

Page 14: ...icle Cable length m Cable length ft Code kg Remote control with cablel 7 5 24 6 875 050 001 1 350 3 4 14 Paper roll for integrated printer Article Code kg Paper roll for integrated printer contains 3 paper rolls 875 050 017 0 150 3 4 15 Ribbon cartridge for integrated printer Article Code kg Ribbon cartridge for integrated printer CA 875 030 004 0 010 Ribbon cartridge for integrated printer CB 875...

Page 15: ...al Operation by multifunctional rotary knob DC direct current welding Control option for cold wire supply 10 5 swiveling monitor Storage capacity for over 5 000 procedures Procedure management through the creation of folder structures Welding data logging and printing of actual values Multicard reader for data transfer to external PC Memory expansion and data exchange possible via CompactFlash car...

Page 16: ...The center of the seam can be accessed manually and be determined using an automatic scanner The electrode accesses each of side of the seam and then calculates the center of the path automatically For asymmetric weld seam configurations this is compensated by an OFFSET function These functions are also shown graphically on the display for easier understanding Remote control cable length 7 5 m All...

Page 17: ...er Unit OM 165 CA OM 300 CA Remarks Input mains Mains system 1 phase PE 3 phase PE Mains input voltage V AV 90 260 400 Permissible voltage tolerance See mains voltage 15 OM165CA Wide Range Mains frequency Hz 50 60 50 60 Continuous input current A AC 14 on 230V 13 Continuous input kVA 3 2 on 230V 9 Current consumption max A AC 19 on 230V 20 Connection value max kVA 4 4 13 5 Mains fuse A 16 20 Slow ...

Page 18: ...A DC 1 5 1 5 Max wire feeding motor current 1 5 1 5 Rotation tacho voltage V DC 0 10 0 10 Rotation speed actual value Other Protection type IP 23 IP 23 Cooling type AF AF Insulation class F F Dimensions WxDxH mm 510x360x220 530x400x400 300 CA without cooling unit Weight kg 26 34 Gas input pressure bar 3 10 3 10 Via pressure reducer Recommended gas input pressure bar 4 4 Via pressure reducer Coolin...

Page 19: ...mage to the location of purchase immediately 6 2 Scope of delivery 1 orbital welding power source of the ORBIMAT CA series 1 ORBIMAT hose connection set 875 030 018 1 dummy plug for insertion into the connection of the remote control if no external remote control will be used 875 050 006 1 liter of anti freeze 875 030 011 1 filling funnel 875 030 014 1 external operating keyboard 875 012 075 2 key...

Page 20: ...included standard PS2 keyboard can be set up before the softkeys The individual menu items are selected using the rotary knob Item 6 and confirmed by pressing the rotary knob Detailed descriptions are provided with the explanation of the respective operating steps 6 5 4 3 2 1 1 Push switch softkey 1 2 Push switch softkey 2 3 Push switch softkey 3 4 Push switch softkey 4 5 Push switch softkey 5 6 R...

Page 21: ...1001 connection Connection of a residual oxygen meter type ORB 1001 optional For continuous monitoring of the forming gas The portion of residual oxygen remains below a percental portion which can be set at the device e g 70 ppm Connection of BUP Control Box For supplementary devices for control of the forming gas pressure BUP BackUp Pressure Control optional These supplementary devices record the...

Page 22: ...hlight a field The field appears in red X Change value within the specified limit values Turn rotary knob X Save value and exit field Briefly press the rotary knob 7 1 5 Operation via push switches softkeys The five push switches are assigned with standard functions as softkeys Examples The push switch Item 5 is usually assigned the Menu function i e pressing it brings you directly to the main men...

Page 23: ...machine against being switched on accidentally Connecting a gas bottle X Check stability of the gas bottle Secure gas bottle against falling over X Ensure that the union nut on the pressure reducer fits the thread on the valve of the gas bottle X Mount pressure reducer on the gas bottle X Connect gas sparger There is no gas sparger if a double pressure reducer is used X Screw both included gas hos...

Page 24: ... and pull off water hose Pumping out water The connections of the machine close automatically when the cooling water is removed X When connecting the water hoses pay attention to the flow and return X Connect drain hose to the water connection blue Fig 5 Item 3 X Close off the water hoses with the included plugs to prevent the cooling water from running out of the weld head Closing off gas hose X ...

Page 25: ...re that the machine is not connected to the mains network during filling X XXSecure machine against being switched on accidentally ORBIMAT 165 CA 1 Open tank closure on the top of the device 2 Add all the included anti freeze to the tank with a suitable funnel 3 Fill tank up to the MAX mark visible behind the left side panel with tap water Carefully wipe off any spilled water from the machine 4 Cl...

Page 26: ...el is lit up Is the STOP indicator on the front panel lit up With external remote control connected EMERGENCY STOP switch is pressed 1 Unlock EMERGENCY STOP switch by turning it counterclockwise 2 Switch off machine 3 Wait at least 5 seconds and then switch machine on again Is an external remote control not connected The dummy plug is missing from the remote control connection EMERGENCY STOP is ac...

Page 27: ...ns SETUP AND ASSEMBLY Fig 9 Sub menu System Adjustments 3 Navigate to the Service menu item 4 Briefly press rotary knob The desired selection appears Fig 10 Sub menu Service 5 Select the Pump water out menu item 6 Briefly press rotary knob The Pumping water out message appears The Cancel button is highlighted in blue Fig 11 Pumping out water ...

Page 28: ...ure 8 Confirm Cancel by briefly pressing the rotary knob The water pump is switched off The water pump is now filled with water and is ready for operation If the water does not exit the hose within a maximum of 10 seconds 1 Cancel drainage as prolonged dry running can damage the pump 2 Check water level 3 Check whether the pump is running and if a pumping sound can be heard Additional help see Sec...

Page 29: ...eed Welding with without filler wire Calculate procedure Calculation of the procedure with the entered parameters Fig 12 Sub menu Auto programming Configuring weld head 1 Select Weld head field and briefly press the rotary knob The following display appears A list of the weld heads which can be used with this system appears This system automatically detects the type of connected head and offers it...

Page 30: ...y briefly pressing the rotary knob Configuring protective gas 1 Select Gas type field and briefly press the rotary knob 2 Select protective gas 3 Confirm by briefly pressing the rotary knob Configuring pipe diameter 1 Select Diameter field The following display appears Fig 15 Pipe diameter setting 2 Select value by pressing the rotary knob 3 Enter values via the external keyboard or the rotary kno...

Page 31: ...he procedure is calculated The main menu appears in the display 8 2 Testing the procedure 8 2 1 Preparing weld head Naturally these operating instructions can only provide basic information on the most commonly used weld heads due to the variety of tools which can be connected In the following the important actions for so called open weld tongs and cassette heads are listed X Refer to detailed inf...

Page 32: ...gray Motor button until the desired position is reached Only one rotation direction is possible here With an additional remote control optional available as accessory X Press MOTOR or MOTOR button The rotor turns in the selected direction as long as a button is being pressed With the push switches of the machine X Call up main menu if necessary X Press softkey 2 Test The main menu in test mode app...

Page 33: ...rammed D Weld heads prepared for welding Properly connected and positioned D Gas bottle secured and opened D Machine switched on D The main menu appears in the display X Press softkey 1 Weld The machine is ready to start The Start button in the display is red X Press softkey 1 Start or X Press START button on an external remote control if connected or X Press red START STOP button on weld head The...

Page 34: ...ent sector number and current position in angular degrees appear in the bottom section of the graphic Info field The following information appears in the info field below the graphic Name of the folder in which the proce dure is saved name of the running procedure current measurement values for water flow in L min water temperature and inverter temperature in C current mains voltage in V Warning m...

Page 35: ...g the procedure 8 3 1 Reasons and steps for adjusting procedure The auto programming of the machine cannot take all influencing factors into account during welding Procedures can be adjusted after the test run for this reason Possible reasons Batch dependent fluctuations in the material composition Different dissipation pipe on solid parts etc X Improve procedure step by step When adjusting change...

Page 36: ... gas pre and post purge times of 30 seconds for cassette weld heads The adjustment of the gas times gas pre purge time and gas post purge time may be necessary to optimize the results of the welding process The space to be filled with gas also depends on the weld head size and pipe diameter It may therefore be necessary to shorten the gas pre purge time for smaller weld heads If the seam with clos...

Page 37: ...on The ignition current is active only very briefly and affects the ignition behavior itself If the ignited arc is detected the machine switches to the current programmed on level 1 within a few tenths of a second Final current Current level reached by the final slope off immediately before switch off of the arc at the end of the wel ding process The value must be greater than 0 Otherwise the arc ...

Page 38: ... the rotation should begin immediately after a visible formation of the melt pool inside the pipe Increasing the weld current in the 1st sector affects the energy introduced to the melt pool during pool formation X Ensure that the weld current of the 1st sector is used during pool formation 1 Using the go further to gas pre purge time go further to start delay time buttons select adjust and save p...

Page 39: ...th proper weld penetration adjust the current setting in the individual sectors For minor adjustments X Change only the high pulse current or X Change both currents in the same direction to obtain the desired pulse effect 1 In the main menu select Manual Adjust programming Adjust parameters 2 Select desired sector The respective selected sector is highlighted in color to the right in the display T...

Page 40: ...of this sector is specified An image of the seam scale appears below the process graphic 3 Select highlight adjust and save the HP time and LP time parameters 4 Press softkey 1 Weld or softkey 2 Test The machine is ready to start Recommendation Do not set the high and low pulse times with different values Experienced users can adjust the pulse times with different values This is recommended for ce...

Page 41: ...e static friction when starting up This protects the motor and leads to higher precision while complying with the angle of rotation while welding Auto programming automatically generates the value 1 for the weld speed in the high pulse time during operation in sync with the pulse Adjusting wire feed parameters X Only adjust wire feed parameters if a weld head is connected or was selected with cold...

Page 42: ...he main menu select Manual Adjust programming Adjust parameters Pool formation 2 Select highlight adjust and save the Wire start delay Wire final delay time and Wire retract parameters 3 Select go forward to sector 1 or select the desired sector The respective selected sector is highlighted in color to the right in the display The angular degree of this sector is specified An image of the seam sca...

Page 43: ...ocess sequence ap pears on the right 2 Move pointer to the 45 position with the rotary knob 3 Briefly press the rotary knob The new sector border is set and the sector list is updated The new sector appears in the list The parameters of the new sector are copied from the previous sector 4 Adjust parameters of the new sector Example Delete sector 1 1 In the main menu select Manual Adjust programmin...

Page 44: ...justed procedure under new name 1 Press the Save button in the main menu 2 Press New folder button or select an existing folder If New folder was pressed Z Select input field and briefly press the rotary knob Z The input field is activated red Z Enter folder name with the keyboard Z Press OK button The new folder is created Z Select new folder 3 Highlight and activate input field for procedure nam...

Page 45: ...at regular intervals Fig 25 Main menu short form Limitation of the percental current change In the disabled position the operator can not adjust or delete existing procedure sequences If it is necessary however to make small adjustments for a welding task e g due to batch based fluctuations of the material composition or minor changes in the wall thickness a percental limit can be set in the weldi...

Page 46: ... respective tack point with rotor not moving is reached If the time specified under Tack time has past the system switches to a low current the pilot current and moves to the next tack point at the maximum possible speed X In case of weak tacking Lengthen tacking time or increase tack current Pilot current Current upon arriving at tack points The pilot current should on the one hand be high enough...

Page 47: ...increased pressure the measuring tube on the front of the machine does not indicate the correct value Gas monitoring by the sensor does not occur until the end of the time of the second gas duct i e at the start of the pressure compensation Using this function together with open type weld tongs has no advantage and is of no use Activating a gas pressure level 1 Switch to Welding mode with go forwa...

Page 48: ...ted The torch should have a torch button for starting the process For cassette weld heads Ground wire required For LP heads The included ground wire can also be used in conjunction with the manual welding torch Procedures can be adjusted and saved for manual operation Functions in manual operation Torch button on manual torch The torch button functions in four cycle operation Start process by pres...

Page 49: ...key 1 Weld The machine is ready to start 8 8 4 External remote control Connecting a remote control 1 Removing the dummy plug in remote control connection of the machine 2 Connect remote control 1 1 Emergency stop switch 2 Function keys Fig 29 Remote control 8 8 5 External printer A4 CENTRONICS connection On back of machine labeled Printer Internal printer driver character set HPGL 8 8 6 External m...

Page 50: ...procedure abortion the running process is interrupted During the process the following parameters are displayed for informational purposes Mains voltage Water temperature 8 9 2 Adjusting limit values X In the main menu select System settings Program settings Limit adjustments The parameters with the limit values appear in the display 8 9 3 Grenzwerte anpassen X Im Hauptmenü Einstellungen Programm ...

Page 51: ...rrent in a sector During the process a value of 70 A 10 A is measured The process is aborted The gas post purge time is still complied with This method of functioning applies for the following parameters in the same way Minimum maximum LP current Minimum maximum HP speed Minimum maximum LP speed Minimum maximum voltage The minimum and maximum deviations are not specified for the arc The absolute v...

Page 52: ...isplay appears Fig 32 Copy functions 2 Press button for desired copy direction 3 Press button for data to be copied e g A procedure from a folder 4 Select and copy element e g procedure 8 10 2 Entering comments and application data Process details Useful information on individual parameters material gas type electrode etc and comments e g a description of the seam preparation an angle setting of t...

Page 53: ...ailable weld heads the auto programming database and the various operating languages of the software Inserting external memory card X Push card into the appropriate slot of the card reader A diskette symbol appears in the bottom right hand corner of the display Is there no diskette symbol 1 Remove memory card from the slot 2 Disengage card reader using the ejector remove it from the housing and in...

Page 54: ...t values weld speed and arc voltage as a table in the display 8 10 4 Viewing and printing data Configuring printer D External printer connected if applicable X Select the desired printer in the main menu System settings Printer selection Select internal for internal printer In addition select the Yes option for Small font for internal printer or Select LPT for external printer In addition select t...

Page 55: ...og after viewing it select it The machine will print a corresponding log with the respective active printer internal or external Printing a log directly after welding If the direct printing function is used the data is not saved The data is deleted after printing The function for saving can also be activated To print a log without using a memory card or saving the data proceed as follows X Select ...

Page 56: ...be read using the Update function if necessary Recommendation X Save all software components system auto programming header list and language files 1 Insert memory card into the card reader 2 In the main menu select System files Save 3 Select software component 4 Follow the instructions on the display 8 14 Restoring software components In case of problems with new program versions or a faulty upda...

Page 57: ...ny CA machine is possible from the following units ORBIMAT 160 C 250 C 300 C ORBIMAT 165 CB 300 CB When importing the procedures are transferred in the format OM 165 300CA and can then be used in the machine Conversion in the other direction procedure from the CA for use in the machines mentioned above is not possible Importing procedures 1 Save the procedures to be transferred to the initial mach...

Page 58: ...oltage input voltage The machine can be set in the voltage range from 90 260 V at a frequency of 50 60 Hz For operation on e g 115 V or any other voltage in the range stated above the operator does not need to switch anything or make any settings or adjustments In 115 V operation higher input currents arise with otherwise even loading of the machine The weld current is automatically limited to 100...

Page 59: ...be found in Commissioning water pump see Sec 7 3 2 Page 25 9 1 2 Performing motor calibration Use in checking and correcting the motor speed If several weld heads of the same type are used a motor calibration should always be carried out before use If using different weld head models this is not required as the machine saves a separate deviation for each head model Continuously large and constantl...

Page 60: ...he weld head starts running The calibration can be aborted at any time by pressing the rotary knob Motor calibration is only possible with heads which have a limit switch 9 1 3 Adjusting an external printer Adjust printing of data when using an external A4 printer Example Printing data on letter paper 1 Press External printer setup button The following display appears Fig 38 Printer Settings exter...

Page 61: ...site side 2 Remove ink ribbon from above 3 Using the rotary knob see arrow for rotation direction which protrudes on one side tighten the external part of the new ink ribbon and insert cartridge into the printer 4 Insert free end of the ink ribbon into the slot through which the paper is also led out The paper is guided between the ink ribbon cartridge and the free end of the ink ribbon 5 Tighten ...

Page 62: ...n undefined quantity and affects the welding result randomly as an energy carrier Remedy X Always use the same gas inside the pipe as in the weld head 9 2 2 Annealing colors inside outside Possible causes Annealing colors arise only as a result of a reaction between the base material and another substance under the effect of a high temperature introduced into the material by the arc This other sub...

Page 63: ... pipe joint If the seam regularly wanders off to the side only in one or two places when welding the corresponding different material composition in the base material and in the seam is responsible for the effect with a longitudinal pipe seam X Shorten arc gap somewhat Gas quantity set too high weld gas or forming gas If an excessive gas quantity is set for small cassette heads especially OW12 tur...

Page 64: ... button of the remote control 9 3 List of error messages No Error message Explanation Elimination 01 Warning A warning appears in the info area of the display directly below the mains voltage information during the process The message can be combined with the parameters of voltage current or speed and the high or low specification The message shows that the limit value specified in the monitoring ...

Page 65: ...ds Worn current water cable 09 Voltage abort The limit values for aborting with regard to arc voltage specified in the monitoring limits are overshot or undershot X Check limit values and heed information in Monitoring functions see Sec 8 9 Page 50 Cause for excessive arc voltage High transition resistances in weld circuit plug ground contact etc For cassette heads Worn current water cables 10 Spe...

Page 66: ...lay Possible excessively low input pressure from bottle manometer X Ensure that there are no excessively large gaps pipe joint X Ensure that the plugs are sealing tightly so that pressure can build up X Set the pressure regulator on the BUP box to max 10 bar if applicable X Correct input pressure from bottle manometer if applicable See also Operating instructions of the BUP unit itself 17 Error co...

Page 67: ... ineffective X For applications which provide data monitoring and actual value recording stop working with the machine X Contact ORBIMATIC to restore the calibration data 37 Auto programming failed The auto programming file may be missing or corrupt Auto programming error Causes The combination of pipe diameter and wall thickness lie outside the value range of auto programming e g wall thicknesses...

Page 68: ...nged in procedure Weld head does not match the one in the parameters The weld head list of the machine contains the parameters of the weld heads which can be connected to the machine e g the maximum rotation of the rotor the maximum pipe diameter to be welded and the maximum permissible current X Adjust parameters of the program to the selected weld head 9 4 Status LED indicators The back of the m...

Page 69: ...the status of the output voltages of the internal power supply units With a tripped fuse row A a LED of row B will not light up because a power supply unit which is disconnected from the mains by a fuse is no longer supplying output voltage If a green LED except for B2 is off and no red LEDs are lit up the power supply unit in question is overloaded on the output side or is defective B1 Weld head ...

Page 70: ...lies 60 W each are operated in series for the power required by the water pump 80 W at 24 V DC These power supply units are only connected if needed on primary side Both LEDs light up when the water pump should be running If only one LED lights up a power supply unit is defective The pump supplies water but an error message appears due to the low current level C5 Water pump ON ON signal for the wa...

Page 71: ... incorrectly or not at all E8 Encoder interface LED signals the presence of a supplementary PCB which permits the operation of weld heads with digital encoder feedback The LED only lights up if a corresponding weld head is connected On standard machines the LED is off 9 5 Temporarily deactivating sensors and monitoring functions Sensors Certain sensors can be deactivated temporarily This can make ...

Page 72: ...tivation of the warning messages and process aborting 4 Select the Yes option for External input for abort and connected external unit 5 Press softkey 3 Save 9 6 Setting date and time 1 In the main menu select System settings System adjustments The following display appears Fig 42 System adjustments 2 Highlight activate and enter values for the Year Month Day Hour Minute and Second fields one afte...

Page 73: ...assen Taste GAS Wasser 2 Check cooling water level and refill if necessary The use of distilled water is not absolutely necessary X If anti freeze is used Supplement with water appropriately X Wipe off display with a slightly damp cloth Do not use cleaning agents Monthly X Clean machine fully from the outside X Check power cable power plug and machine for mechanical damage X Clean weld heads and c...

Page 74: ...rew side panels back on 9 Close hood again and screw it tight 10 1 2 Storage X If the machine will go unused for a longer period of time dismantle the machine and store it in a suitable place X Recommendation Carry out the following activities before storage 1 Clean machine 2 Remove cooling agent For this purpose loosen cooling water return of the weld head on the back of the unit and pump out coo...

Page 75: ...nic devices contain parts which must be handled specially as per EU guidelines We will properly dispose of devices and machines from orbitalum tools GmbH purchased after August 13th 2005 if they are sent to us postage paid In the case of used devices which may represent a risk to human health or safety due to contamination during use we have the option of refusing return Devices and machines from ...

Page 76: ...italum tools GmbH D 78224 Singen www orbitalum com Tel 49 0 77 31 792 0 01 2012 OM_BA_ORBIMAT_CA_01_EN OVERVIEW WIRING DIAGRAM ORBIMAT CA Operating instructions 12 OVERVIEW WIRING DIAGRAM Abb 1 Übersichtsplan ...

Page 77: ...N BUP Control ORB 1001 ORBICOOL etc Seriennummer Series number Numero di serie Nombre de série Número de serie Baujahr Year Anno Année Año ist entwickelt konstruiert und gefertigt in Übereinstimmung mit folgenden EG Richtlinien was designed constructed and manufactured in accordance with the following EC guidelines è stata progettato costruito e commercializzato in osservanza delle seguenti Dirett...

Page 78: ...orbitalum tools gmbh Notizen Notes ...

Page 79: ......

Page 80: ...Singen Germany Sales contact Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 524 tools orbitalum com www orbitalum com Orbitalum Tools GmbH D 78224 Singen 2011 Printed in Germany Your opinion is important to us We look forward to your comments and suggestions ...

Page 81: ...Ersatzteilliste Spare parts list Orbitalschweißen Orbitalschweißstromquelle Orbital Welding Orbital welding power supply ORBIMAT 165 CA Maschinen Nr Machine no Code 871 060 101_03 DE EN ...

Page 82: ... jeglicher Form Druck Fotokopie Mikrofilm oder Datenerfassung bedürfen der schriftlichen Genehmigung durch die Orbitalum Tools GmbH All rights reserved in particular the rights regarding reproduction distribution and translation Reproduction in any form print photocopy microfilm or data storage requires written permission from Orbitalum Tools GmbH ...

Page 83: ...CKANSICHT HOUSING SIDE REAR VIEW 6 165 CA HAUBE DISPLAY MAIN COVER DISPLAY 8 165 CA PLATINE NETZTEILE BOARDS POWER SUPPLIES 10 165 CA VERBINDUNGSLEITUNGEN CONNECTION PLUGS 12 165 CA FLUSSWÄCHTER WASSERPUMPE FLOW METER WATER PUMP 14 165 CA WÄRMETAUSCHER HEAT EXCHANGER 16 165 CA INNENANSICHT RÜCKSEITE INSIDE REAR VIEW 18 165 CA WASSERTANK WATER TANK 20 165 CA ZUBEHÖR ACCESSORIES 22 SERVICE KUNDENDIE...

Page 84: ...Front View ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA GEHÄUSE FRONTANSICHT HOUSING FRONT VIEW 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 6 7 5 3 4 Kartenlesegerät mit herausnehmbaren Einsatz nicht mehr verfügbar Als Ersatz bitte Pos 11 und 12 verwenden Cardreader with removable reader not longer available For replacement use pos 11 and 12 ...

Page 85: ...üssel für OM Key switch with key for ORBIMAT 11 872 001 032 1 Einbauadapter Card Reader CA Adapter for Card Reader CA 12 875 012 005 1 Multicard Reader ORBIMAT 13 861 050 005 1 BUP Buchse mit Anschlussleitungen X132 BUP Connector with connecting leads X132 14 875 012 046 1 Buchse Formiergasüberwachung Socket connector for backup gas control 15 875 012 048 1 Gasanschlussbuchse Gasausgang Gas connec...

Page 86: ...49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Gehäuse Seiten Rückansicht Housing Side Rear View ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA GEHÄUSE SEITEN RÜCKANSICHT HOUSING SIDE REAR VIEW 1 2 3 4 5 6 8 7 9 10 11 14 15 11 13 12 ...

Page 87: ... Rear panel OM 165 CA large 6 875 012 054 1 Zugentlastung Netzkabel 165A Geräte Strain relief power cord 165A units 7 875 012 047 1 Netzanschlussbuchse ORBITWIN Main connector for ORBITWIN 8 875 012 024 1 Gaseingangsbuchse ORBIMAT Socket quick connector gas in ORBIMAT 9 872 020 012 1 Typenschild ORBIMAT SN Name plate ORBIMAT SN 10 875 050 008 1 Blende LED Platine Cover status LED board 11 874 020 ...

Page 88: ...com Tel 49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Haube Display Main Cover Display ORBIMAT 165 CA Ersatzteilliste Spare par ts list 7 1 2 3 16 6 4 5 165 CA HAUBE DISPLAY MAIN COVER DISPLAY 9 10 11 8 12 13 15 14 17 18 19 13 12 14 ...

Page 89: ...ter CPU OM CA X63 Cable backlight inv CPU OM CA X63 9 875 012 010 1 Backlight Inverter für Farbdisplay Backlight inverter for display 10 875 012 009 1 Display 10 4 ORBIMAT 165 Display 10 4 ORBIMAT 165 11 871 012 016 1 Anschlusskabel Display für ORBIMAT CA Display cable for ORBIMAT CA 12 871 012 006 1 Drehsteller für ORBIMAT CA Haptic rotary switch for ORBIMAT CA 13 861 050 002 1 Kabel Drehsteller ...

Page 90: ...talum com Tel 49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Platine Netzteile Boards Power Supplies ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA PLATINE NETZTEILE BOARDS POWER SUPPLIES 4 2 3 5 9 6 7 1 9 10 10 5 6 8 8 ...

Page 91: ...T CA Interface board ORBIMAT CA 4 871 012 010 1 Drucker Spannungsversorgungsplatine CA Printer power control board CA 5 875 050 005 1 Not Aus Platine 165 CA CB Emergency stop board 165 CA CB 6 875 012 025 1 Hauptschütz ORBIMAT 165 Main contactor ORBIMAT 165 7 875 012 002 1 Rechnerboard CPU für ORBIMAT Main board CPU for ORBIMAT 8 875 012 031 2 Netzteil CPU Motor 24VDC 60W Power supply CPU Motor 24...

Page 92: ... OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Verbindungsleitungen Connection Plugs ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA VERBINDUNGSLEITUNGEN CONNECTION PLUGS 1 2 4 4 6 7 9 10 11 12 13 14 16 15 5 8 14 11 17 18 7 20 21 22 23 24 25 13 16 28 29 2 32 30 33 34 ...

Page 93: ...3 Cable LED pcb CPU X83 14 861 050 012 1 Kabel CA Platine CPUX80 Cable CA pcb CPU X80 15 875 012 012 1 Verbindungskabel Filterkarte PC 50 polig Connection Cable Filter Board PC 50 PIN 16 860 050 029 1 Kabel IF Platine CPU X82 Cable LED pcb CPU X82 17 860 050 020 1 Kabel Ausgang PSMOT X112 IF Platine Cable PSMOT output X112 IF PCB 18 860 050 017 1 Kabel Ausgang PSPU2 X114 IF Platine Cable PSPU2 out...

Page 94: ...ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA fLUSSWÄCHTER wASSERPUMPE Flow Meter Water Pump ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA FLUSSWÄCHTER WASSERPUMPE FLOW METER WATER PUMP 14 15 16 17 18 21 22 23 25 18 18 18 18 24 20 26 27 19 1 2 3 4 4 4 4 12 5 6 7 8 9 27 10 11 13 8 ...

Page 95: ...60 020 013 1 Steckverschraubung QSYL G1 8 6 Connector QSYL G1 8 6 12 823 020 016 1 M Teflon Gasschlauch Teflon gas hose 13 875 012 018 1 Magnet Halteplatte IF Platine Magnet IF board holder plate 14 875 001 017 1 Haltewinkel Wasserpumpe Durchflusssensor Holder for water pump water flow sensor 15 860 020 089 1 Gummi Metallpuffer Typ B M5 Ø 20x10 mm Silent buffer type B M5 Ø 20x10 mm 16 871 050 033 ...

Page 96: ... www orbitalum com Tel 49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Wärmetauscher Heat E xchanger ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA WÄRMETAUSCHER HEAT EXCHANGER 1 4 3 2 6 5 5 7 7 8 9 8 10 10 11 11 ...

Page 97: ...chalter Zündgerät Service switch arc starter 4 875 012 035 1 Überlastsicherung 20A Overload protection fuse 5 871 050 034 2 Lüfter für Wärmetauscher ORBIMAT 165 Fan for heat exchanger ORBIMAT 165 6 875 001 016 1 Haltewinkel Kühler Lüfter Holder Heat Exchanger Fan 7 875 020 028 1 M Wasserschlauch schwarz Water hose black 8 860 020 004 2 1 Ohr Klemme mit Einlagering 9 8 11 8mm Clip 9 8 11 8 mm 9 875...

Page 98: ... 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Innenansicht Rückseite Inside Rear View ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA INNENANSICHT RÜCKSEITE INSIDE REAR VIEW 20 21 22 23 19 24 16 16 17 19 15 15 10 1 2 3 4 5 6 18 11 12 14 14 8 9 7 19 ...

Page 99: ...e OM 165 CA 10 875 012 012 1 Verbindungskabel Filterkarte PC 50 polig Connection Cable Filter Board PC 50 PIN 11 875 012 015 1 Filterplatine Filter board 12 874 001 008 1 Halteblech Filterplatine Filter board holder 14 860 020 004 2 1 Ohr Klemme mit Einlagering 9 8 11 8mm Clip 9 8 11 8 mm 15 871 020 002 2 Stecknippel für Wassertank an Schlauch Quick Conn For Water Tank male hose 16 875 020 028 1 M...

Page 100: ... 78224 Singen www orbitalum com Tel 49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Wasser tank Water Tank ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA WASSERTANK WATER TANK 2 3 1 1 7 6 8 4 5 5 1 1 ...

Page 101: ...tank OM165 Filler inlet water tank OM165 3 860 020 097 1 Dichtring für Tankstutzen OM165 Seal ring for filler inlet water tank OM165 4 871 020 006 0 08 M Wasserschlauch 1 2 für Wassertank Hose 1 2 for water tank 5 860 020 023 2 Schlauchschelle 18 28 mm Hose clamp 18 28 mm 6 860 020 096 1 Dichtring Sichtfenster Wassertank Sealing ring for water level window 7 871 050 004 1 Sichtfenster für Wasserta...

Page 102: ... GmbH D 78224 Singen www orbitalum com Tel 49 0 77 31 792 0 OW_ETL_ORBIMAT_165 CA_871 060 101_DE_EN_03 165 CA Zubehör Accessories ORBIMAT 165 CA Ersatzteilliste Spare par ts list 165 CA ZUBEHÖR ACCESSORIES 2 6 5 3 4 1 7 ...

Page 103: ...assette Einbaudrucker CA Ribbon Cartridge for Internal Printer CA 6 875 030 003 1 Papierrolle für ORBIMAT Drucker Paper roll for ORBIMAT printer 875 050 017 3 Papierrolle für ORBIMAT Drucker 3er Pack Paper roll for ORBIMAT printer 3 pack 7 872 020 009 1 Tastatur Adapter USB PS 2 Keyboard adapter USB PS 2 Pos Item No Code Part No Stück Quant Bezeichnung Description SERVICE KUNDENDIENST Für das Best...

Page 104: ...SA Tel 1 847 537 8800 Fax 1 847 520 1147 Toll Free 800 323 8185 CHINA Orbitalum Tools Representative China New Caohejing International Business Center B 1501 No 391 Guiping Road Shanghai China 200052 Tel 86 21 52 30 37 51 Fax 86 21 52 30 37 58 UNITED ARAB EMIRATES WACHS Middle East Africa PO Box 262543 FZS 5 AC 06 Jebel Ali Free Zone South 5 Dubai United Arab Emirates Tel 971 4 88 65 211 Fax 971 4...

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