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Orbitalum ORBIMAT 180 SW User Manual

Orbitalum ORBIMAT 180 SW
80 pages
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Operating instructions
For responsible bodies and persons using the machine
Orbital Welding Power Supply
ORBIMAT 180 SW
Machine No.:
Code 850 060 202 | EN | Translation of original operating instructions
To ensure safe working read the operating
instructions before commissioning.
Retain the operating instructions
for future reference.

Table of Contents

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Orbitalum ORBIMAT 180 SW Specifications

General IconGeneral
BrandOrbitalum
ModelORBIMAT 180 SW
CategoryPower Supply
LanguageEnglish

Summary

Operating instructions

Orbital Welding Power Supply ORBIMAT 180 SW

Identifies the specific Orbital Welding Power Supply model.

About these instructions

Warning messages

Explains warning symbols and their significance.

Further symbols and displays

Details other symbols used for comprehension and action.

Abbreviations

Lists abbreviations used in the manual.

Further applicable documents

Lists related documents to be used with these instructions.

Information and safety instructions

Requirements for the responsible body

Outlines responsibilities for safety and personnel qualifications.

Using the machine

Details proper use and operational constraints of the machine.

Proper use

Defines the intended use and operational guidelines for the power supply.

Machine constraints

Lists the operational constraints and workplace requirements for the machine.

Environmental protection/disposal

Covers disposal of coolant and electronic accessories.

Personnel qualification

Specifies the required qualifications for machine operators.

Fundamental information on operational safety

Provides essential safety principles for machine operation.

Personal protective equipment

Details personal protective equipment requirements during operation.

Remaining risks

Lists potential hazards and risks associated with the machine's use.

Injury through high weight

Addresses risks related to the machine's weight and lifting.

Burns and danger of fire through high temperatures

Warns about burns and fire hazards from high temperatures.

Tripping over the hose package

Highlights the risk of tripping over the hose package.

Long-lasting physical damage through wrong posture

Discusses risks of physical damage from improper posture.

Electric shock

Details dangers and precautions related to electric shock.

Danger through incorrect handling of pressure tanks

Warns about dangers from improper handling of pressure tanks.

Damage to eyes through radiation

Explains risks of eye damage from welding radiation.

Dangers through electromagnetic fields

Covers hazards associated with electromagnetic fields.

Risk of suffocation through an excessive argon share in the air

Addresses suffocation risks from excessive argon.

Health problems

Warns about health issues from welding fumes and substances.

Danger of system tipping over

Highlights the risk of the system tipping over.

Danger of explosion and fire

Details risks of explosion and fire.

General injuries through tools

Warns about general injuries when using tools.

DESCRIPTION

ORBIMAT 180 SW

Provides a detailed description and illustration of the ORBIMAT 180 SW unit.

Operating concept

Operation via push switches (softkeys)

Explains operation using push switches (softkeys) on the unit.

Operation via touch screen

Describes operation using the touch screen interface.

Operation via rotary knob

Details operation using the rotary knob control.

Operation via an external keyboard

Explains how to operate the machine using an external keyboard.

Warning signs

Lists and explains warning and safety signs on the machine.

SCOPE OF APPLICATION

Accessories

Lists optional accessories available for the ORBIMAT 180 SW.

ORBICAR W trolley

Describes the ORBICAR W trolley accessory.

ORBICOOL Active

Details the ORBICOOL Active cooling device.

ORBITWIN switching unit

Explains the ORBITWIN switching unit.

ORBmax oxygen meter

Describes the ORBmax oxygen meter accessory.

Remote control with cable

Details the remote control with cable accessory.

OCL-30 coolant

Describes the OCL-30 coolant.

ORBIPURGE forming set

Details the ORBIPURGE forming set accessory.

Paper rolls and ribbon cartridges

Mentions paper rolls and ribbon cartridges for the printer.

TECHNICAL SPECIFICATIONS

STORAGE AND TRANSPORT

Gross weight

States the gross weight of the machine.

Preparing storage

Details steps required before storing the machine.

Removing the weld head from the orbital welding power supply

Instructs on removing the weld head before storage.

Pumping out coolant

Explains how to pump out the coolant before storage.

COMMISSIONING

Scope of delivery

Lists the items included in the scope of delivery.

Checking the scope of delivery

Provides steps for checking the delivery for completeness and damage.

Accessories (optionally available)

Lists optional accessories available for the ORBIMAT 180 SW.

Connecting the welding power supply

Details how to connect the welding power supply safely and correctly.

Setting up machine

Explains how to set up the machine for connection.

Connecting a gas bottle

Guides on safely connecting a gas bottle.

Connecting weld heads

Provides instructions for connecting weld heads.

Detaching coolant hoses

Explains how to detach coolant hoses.

Pumping out coolant

Details the process of pumping out coolant.

Closing off gas hose

Explains how to close off the gas hose.

Commissioning

Covers the final steps of commissioning the machine.

Topping up coolant

Details how to top up the coolant level.

Connecting Remote control/dummy plug

Explains how to connect the remote control or dummy plug.

Switching on the power source

Guides on switching on the power source and initial checks.

Setting the language

Describes how to change the system language.

Setting the measuring units

Explains how to set the measuring units (Metric/Imperial).

OPERATION

Auto programming

Guides on using the auto programming feature.

Setting parameters

Explains how to set parameters for auto programming.

Configuring weld head

Guides on configuring the connected weld head.

Configuring material

Details how to configure the material type for welding.

Configuring protective gas

Explains how to configure the protective gas settings.

Configuring pipe diameter

Guides on setting the pipe diameter.

Configuring wall thickness

Explains how to configure the wall thickness.

Configuring wire feed

Details how to configure wire feed settings.

Calculating procedure

Guides on calculating the welding procedure.

Testing the procedure

Explains how to test the configured welding procedure.

Preparing weld head

Details preparatory steps for the weld head.

Preparing electrode

Guides on preparing the welding electrode.

Turning weld head

Explains how to turn the weld head for electrode insertion.

Adjusting the procedure

Covers how to adjust welding procedures after initial setup.

Reasons and steps for adjusting procedure

Explains why and how to adjust welding procedures.

Making percental changes

Details how to make percentage-based adjustments to current.

Adjusting individual parameters

Explains how to adjust individual parameters within sectors.

Digital gas management

Covers programming gas quantities individually.

Adjusting gas times

Details how to adjust gas pre and post purge times.

Adjusting ignition current, final current and current slope-off

Guides on adjusting ignition, final current, and slope-off.

Adjusting the pool formation time

Explains how to adjust pool formation time.

Adjusting welding current and transition times ("Slope")

Details adjusting weld current and transition times (slope).

Adjusting pulse times

Explains how to adjust pulse times for seam appearance.

Adjusting weld speed and transition time ("Slope")

Guides on adjusting weld speed and transition time.

Changing the sector

Explains how to adjust sector borders manually.

Saving and calling up a procedure

Covers saving and recalling welding procedures.

Saving a procedure

Details how to save welding procedures.

Calling up a procedure

Explains how to retrieve saved welding procedures.

Locking machine with a login

Describes how to lock the machine using a login system.

Tacking function

Explains how to use the tacking function for temporary fixing.

Using the second gas pressure level ("Flow Force")

Details how to use the second gas pressure level for faster pre-purge.

Connecting supplementary devices

Guides on connecting external devices to the machine.

ORB Residual Oxygen Meter

Explains connection and use of the ORB Residual Oxygen Meter.

Connecting and configuring the BUP control unit

Details connecting and configuring the BUP control unit.

TIG manual welding torch

Describes connecting a TIG manual welding torch.

External remote control

Explains connecting an external remote control.

External printer (A4)

Details connecting an external printer.

External monitor /HDMI

Describes connecting an external monitor via HDMI.

Monitoring functions

Covers system monitoring functions.

General information

Provides general information on monitored parameters.

Adjusting limit values

Guides on adjusting monitoring limit values for alarms and aborts.

Data documentation and data management

Covers managing and documenting welding data.

Managing data

Details how to manage (delete, rename) data.

Entering comments and application data ("Process details")

Explains how to enter comments and application data for procedures.

Working using USB

Details how to use USB devices for data transfer.

Viewing and printing data

Guides on viewing and printing procedures and log files.

Editing data on a PC with the "OrbiProgCA" supplementary software

Explains editing data using the OrbiProgCA software.

Updating and backup functions for the software

Covers software updates and backup functions.

Updating software components

Details how to update software components.

Saving software components

Explains how to save software components to a USB stick.

Restoring software components

Guides on restoring software components.

Working in other languages

Covers changing the system language.

Changing the language

Explains the process of changing the display language.

Printing data in another language

Details printing procedures and logs in different languages.

Creating a new operating language

Mentions the possibility of creating new language files.

Importing programs from other Orbitalum power sources

Covers importing welding programs from other Orbitalum units.

Importing procedures

Guides on importing procedures via USB stick.

Special keyboard commands

Lists special keyboard commands for the virtual/external keyboard.

Operation of the system with other mains voltages

Explains system operation with different mains voltages.

SERVICE AND TROUBLESHOOTING

Performing service work

Details general service tasks that can be performed.

Pumping out coolant

Explains how to pump out coolant for maintenance.

Performing motor calibration

Guides on calibrating the machine's motors.

Adjusting an external printer

Details adjusting settings for an external printer.

Switching on an internal printer

Explains how to insert a new paper roll for the internal printer.

Printing a test page

Guides on printing a test page for printer verification.

Service screen

Explains how to access and use the service screen for diagnostics.

Info

Provides information on software version and serial number.

Possible application/operating errors

Lists common errors and their possible causes and remedies.

Uneven weld seam ("current fluctuations")

Addresses issues with uneven weld seams due to current fluctuations.

Annealing colors inside/outside

Explains causes and remedies for annealing colors.

Wide seam and no weld penetration

Covers issues of wide seams without proper weld penetration.

Uneven seam/hole formation at the end of welding

Discusses uneven seam or hole formation at the end of welding.

Ignition problems

Details causes and remedies for ignition problems.

Machine does not start

Provides troubleshooting steps if the machine does not start.

List of error messages

Provides a comprehensive list of error messages and their explanations.

Status LED indicators

Explains the status of the LEDs on the rear of the machine.

Temporarily deactivating sensors and monitoring functions

Covers temporarily disabling sensors and monitoring functions.

Sensors

Details how to temporarily deactivate sensors.

Monitoring limits

Explains deactivating monitoring limits.

External input for aborting

Covers activating/deactivating external abort inputs.

Setting the date and time

Guides on setting the system date and time.

MAINTENANCE AND TROUBLESHOOTING

Instructions for care

Gives general instructions for cleaning and care.

Maintenance and care

Details regular maintenance tasks and intervals.

Storage

Provides instructions for storing the machine during long periods of non-use.

Servicing/Customer service

Guides on contacting customer service and ordering spare parts.

EC DECLARATION OF CONFORMITY