Orbitalum MOBILE WELDER OC PLUS Bedienungsanleitung

en Orbital Welding Power Supply

Translation of original operating instructions and spa-

re parts list

854 060 201

MOBILE WELDER

OC PLUS

00 | 2022REV

ENGLISH MOBILE WELDER OC PLUS

2ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

Table of Contents

1 About these instructions................. 5

1.1 Warning messages .................. 5

1.2 Further icons and displays....... 5

1.3 Legend..................................... 6

1.4 Further applicable documents.. 6

2 Information and safety instructions

for the owner ....................................

2.1 Requirements for the owner-

operator....................................

2.2 Using the machine ................... 9

2.2.1 Intended use .............. 9

2.2.2 Machine constraints... 10

2.2.3 Welding in environ-

ments with increased

electrical hazards.......

2.2.4 Device cooling ........... 10

2.3 Environmental protection and

disposal....................................

2.3.1 Information regarding

the Ecodesign Direc-

tive 2009/125/EG .......

2.3.2 REach (Registration,

Evaluation, Authoriza-

tion and Restriction of

Chemicals).................

2.3.3 Coolant ...................... 12

2.3.4 Electric tools and ac-

cessories....................

2.4 Personnel qualification............. 13

2.5 Fundamental information on

operational safety.....................

2.6 Personal protective equipment 14

2.7 Remaining risks ....................... 15

2.7.1 Injury through high

weight ........................

2.7.2 Burns and danger of

fire through high tem-

peratures....................

2.7.3 Tripping over wires

and cables .................

2.7.4 Long-lasting physical

damage through

wrong posture ............

2.7.5 Electric shock............. 17

2.7.6 Danger from incorrect

handling of shielding

gas bottles .................

2.7.7 Damage to eyes

through radiation........

2.7.8 Dangers through elec-

tromagnetic fields.......

2.7.9 Risk of suffocation

from an excessive

amount of argon in the

air...............................

2.7.10 Health problems......... 18

2.7.11 Danger of system tip-

ping over ....................

2.7.12 Danger of explosion

and fire.......................

2.7.13 General injuries

through tools ..............

3 Description ....................................... 21

3.1 Basic machine.......................... 21

3.1.1 Warning signs ............ 23

3.2 Cooling unit .............................. 23

4 Scope of application........................ 24

5 Technical specifications.................. 25

6 Transport and shipping................... 27

6.1 Gross weight ............................ 27

6.2 Shipping ................................... 28

6.3 Transport.................................. 28

MOBILE WELDER OC PLUS ENGLISH

ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 3

6.3.1 Adjusting the length of

the shoulder strap ......

7 Setup and commissioning .............. 31

7.1 Unpacking the power supply.... 31

7.2 Scope of delivery ..................... 32

7.3 Setting up the power supply..... 32

7.4 Attaching the cooling unit......... 33

7.5 Connecting the weld head/

manual welding torch...............

7.6 Setting up the welding gas sup-

ply ............................................

7.7 Mains connection..................... 35

7.8 Operation of the power supply

with other mains voltages ........

7.9 Connecting the power cable .... 36

7.10 Switching on the power supply 37

7.11 Activation ................................. 38

7.12 Login screen ............................ 39

7.12.1 Login .......................... 40

7.12.2 Changing a password 41

7.12.2.1 Changing the Admin

Password ...................

7.12.2.2 Changing the user

password ...................

7.12.3 Resetting a password 44

7.13 User levels ............................... 44

7.13.1 Administration level.... 44

7.13.2 User level................... 44

7.14 Operating concept.................... 46

7.14.1 Software control ele-

ments and fields.........

7.14.2 Input devices and con-

trol elements ..............

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 ........................................

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...................

8.1.1.2 Saving the welding

procedure...................

8.1.1.3 Creating a folder ........ 74

8.1.1.4 Managing welding

procedures.................

8.1.1.5 Removing share......... 81

8.1.2 Protocol Manager ...... 83

8.1.3 Auto programming ..... 86

8.1.3.1 Using auto program-

ming ...........................

8.1.4 Adjusting the program 89

8.1.4.1 Adjusting level seg-

ments .........................

8.1.4.2 Adjusting parameters. 91

8.1.5 TIG manual welding

mode..........................

110

8.1.5.1 Welding ramp process

graphic .......................

112

8.1.5.2 Adjust Program - Man-

ual_Welding_Mode ....

114

8.1.5.3 Welding in the manual

welding mode.............

116

8.1.5.4 Functions Man-

ual_Weld-

ing_Torch_Con-

trol_Panel...................

118

8.1.5.5 Logout........................ 122

8.1.6 Settings...................... 123

8.1.6.1 System adjustments... 123

8.1.6.2 Program settings........ 130

8.1.6.3 System data............... 136

8.1.6.4 Network environment. 137

8.1.6.5 Service....................... 144

ENGLISH MOBILE WELDER OC PLUS

4ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

8.1.6.6 Setting the language

and keyboard .............

152

8.2 Weld mode............................... 153

8.2.1 "Gas" softkey ............. 156

8.2.1.1 Gas overview ............. 156

8.2.1.2 "Gas On" softkey........ 160

8.2.1.3 "Permanent Gas" soft-

key .............................

160

8.2.1.4 "Back" softkey ............ 160

8.2.2 Motor control.............. 160

8.2.2.1 "Motor" softkey........... 160

8.2.2.2 "Wire" softkey............. 160

8.2.2.3 "Global Change" soft-

key .............................

161

8.2.2.4 "Menu" softkey ........... 161

8.3 Test mode................................ 162

8.4 Welding process ...................... 164

9 Special commands........................... 166

9.1 Keyboard entry of special com-

mands ......................................

166

9.2 "Special Commands" softkey... 166

10 Service and maintenance................ 167

10.1 Service screen ......................... 167

10.2 Software information................ 167

10.3 Motor calibration ...................... 167

10.4 Printer ...................................... 169

10.4.1 Replacing the roll of

paper..........................

169

10.5 Maintenance 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-

sicht) | Basic structure MW

(rear view) ................................

180

15.3 Bodenblech MW | Base plate

MW...........................................

182

15.4 Frontabdeckung MW | Front

cover MW.................................

184

15.5 Rückwand MW | Rear panel

MW...........................................

186

15.6 Gaskomponenten MW | Gas

components MW ......................

188

15.7 Vertikalblech MW | Vertical

plate MW..................................

190

15.8 Horizontalblech MW | Horizon-

tal plate MW .............................

192

15.9 Handgriff-Abdeckung MW |

Handle-display cover MW ........

194

15.10 Schweißstrominverter MW |

Welding current inverter MW ...

196

15.11 Verbindungskabel | Connection

cables.......................................

198

15.12 Service, Kundendienst | Servic-

ing, customer service ...............

201

16 DECLARATION OF CONFORMITY.. 202

MOBILE WELDER OC PLUS ENGLISH

ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 5

1 About these instructions

1.1 Warning messages

The warnings used in these instructions warn you of injuries or damage to property.

Always read and observe these warnings!

This is a warning icon. It warns against dangers of injury. In order to avoid injuries or

death observe the measures marked with a safety sign.

WARNING LEVEL MEANING

DANGER Imminently hazardous situation that results in death or serious 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 safety measures are not observed.

1.2 Further icons and displays

SYMBOL MEANING

Request for action in a sequence of actions: Action is required here.

…

Request for action in a sequence of actions: Action is required here.

► Single request for action: Action is required here.

ENGLISH MOBILE WELDER OC PLUS

6ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

1.3 Legend

Term/SYMBOL MEANING

MW Mobile Welder

OC ORBICOOL

Orbital weld head Open orbital weld head / orbital welding 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

MOBILE WELDER OC PLUS ENGLISH

ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 7

2 Information and safety instructions for the owner

2.1 Requirements for the owner-operator

Workshop/outdoor/field use: The owner is responsible for safety in the danger zone around the ma-

chine, and should allow only qualified personnel to enter the zone or operate the machine in the danger

zone.

Employee safety: The operator has to observe the safety regulations described in this chapter as well

as has to work safety-consciously and with all prescribed safety equipment.

The employer undertakes to give the employees clear notice of the dangers arising that are specified in

the EMF directives and to evaluate the workplace correspondingly.

Requirements for special EMF evaluations with regard to general activities, working materials

and workplaces*:

TYPE OF WORKPLACE

OR WORK EQUIP-

MENT

EVALUATION REQUIRED FOR:

Employees without

particular risk

Employees at particu-

lar risk

(with the exception of

those

with active implants)

Employees with active

implants

(1) (2) (3)

Arc welding, manual (in-

cluding MIG (Metal Inert

Gas), MAG (Metal Active

Gas), TIG (Tungsten In-

ert Gas)) under obser-

vance of tried-and-tested

procedures and without

physical contact to the

line

No No Yes

* To Directive 2013/35/EU

ENGLISH MOBILE WELDER OC PLUS

8ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

MOBILE WELDER OC PLUS ENGLISH

ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 9

2.2 Using the machine

2.2.1 Intended use

WARNING Dangers result from improper use!

The device has been manufactured according to the state of the art and

the recognized safety regulations and standards for use in industry and

trade. It is intended only for the welding processes specified in these

operating instructions. If the device is not used as intended, it may pose

a risk to persons, animals and property. No liability is assumed for any

resulting damage.

► Only use the unit for TIG DC welding with Liftarc (contact ignition) or

HF ignition (non-contact). Accessory components can extend the

range of functions if necessary (see the chapter Accessories

[}174]).

The orbital welding power supply is intended solely for the following utilization:

• Utilization in combination with an orbital weld head or manual welding torch of the company

Orbitalum Tools GmbH or with a compatible third-part device in combination with a weld head

adapter of the company Orbitalum Tools GmbH.

• TIG welding of materials that are 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 during operation. The operator must always be able to stop

the process.

• Observing all safety and warning information in these operating instructions.

• Observing of the further applicable documents.

• Complying with all inspection and maintenance work.

• Use of the machine solely in its original state.

• Usage solely of original accessories as well as original spare parts and operating materials.

• Usage solely of protective gases that are classified for TIG welding process in accordance with EN

ISO 14175.

• Usage solely of coolant OCL-30 of the company Orbitalum Tools GmbH

• Checking of all the safety-relevant items and functions before commissioning.

• Processing of those materials named in the operating instructions.

ENGLISH MOBILE WELDER OC PLUS

10 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

• Proper usage of all components involved in the welding processes as well as of all further factors

that have an influence on the welding process.

• Solely commercial usage.

2.2.2 Machine constraints

• The workplace can be in the tube preparation, in plant construction or in the plant itself.

• The device is operated by one person.

• The device may only be set up and operated on a stable, level and non-slip surface.

• A space of about 2 m for people to move around the unit must be provided.

• Work lighting: min. 300Lux.

• Ambient conditions during operation:

Ambient temperature: –10°C to +40°C

Relative humidity: < 90% at +20°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 salty ambient air (sea air).

2.2.3 Welding in environments with increased electrical hazards

The power supply can be used in environments with increased electrical hazards.

It complies with the regulations and standards IEC/DIN EN 60974 and VDE0544.

2.2.4 Device cooling

Insufficient ventilation leads to reduced performance and equipment damage.

► Observe the limits of the machine.

► Keep inlet and outlet openings of the cooling air unobstructed.

► Keep a minimum distance of 0.5 m from obstacles.

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