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Summary of Contents for Orbitalum MOBILE HEAD
- Page 1 MOBILE HEAD Open orbital weld heads Translation of original operating instructions and spare parts list...
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Page 2: Table Of Contents
..Transporting the weld head ..2.7.3 Danger of crushing Commissioning ........ through being caught in by moving parts..Scope of delivery ..... 2.7.4 Injury through rotating Preparing initial operation ..rotor ......ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 3 10.1 Instructions for care ....10.2 Maintenance and care ..... 10.2.1 Standard cleaning process ...... 10.3 Replacing the gas nozzle and/ or lens ........10.4 Troubleshooting ....... 10.5 Grinding electrodes....10.6 Servicing/Customer service ..ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 4: About These Instructions
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. Abbreviations ABBREVIATION MEANING ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 5: Further Applicable Documents
MOBILE HEAD Orbital weld head, type “Mobile Head” Further applicable documents The following documents apply together with these operating instructions: • Instructions for orbital welding power supply ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 6: Information And Safety Instructions For The Owner
Using the machine 2.2.1 Proper use The orbital weld head is intended solely for the following utilization: • Utilization in combination with an Orbital welding power source of the ORBIMAT and Mobile Welder series. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 7: Machine Constraints
• 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. • Smoke, steam, oil vapors and grinding dust must be avoided. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 8: Environmental Protection And Disposal
The regulation (EC) 1907/2006 of the European Parliaments and of the Council concerning the registra- tion, evaluation, authorization and restriction of chemicals (REACh) regulates the production, placing on the market and use of chemical substances and the mixtures produced from these. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 9: Electric Tools And Accessories
Separate collection and selective treatment are the basis for environmentally responsible disposal and protection of human health. • 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. -
Page 10: Fundamental Information On Operational Safety
Safety shoes to EN ISO 20345, Class SB. ► For overhead work safety helmet according to EN 397. Remaining risks 2.7.1 Injury through high weight A significant health hazard exists during lifting. Observe machine weights, chap. Gross weight. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 11: Prick Injury Through Pointed Electrode
The rotation movement of the rotor can cause hair, jewelry or clothes to be caught and pulled into the enclosure. CAUTION! Risk of crushing of hands and fingers! The rotor can start up unexpectedly during the setup of the electrode. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 12: Danger Of Cuts At Sharp Edges
► Ensure that under no circumstances can people trip over lines and/or cables. ► Do not put lines or cables under tension. ► Place the welding tongs in the transport case after dismantling. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 13: Tripping Over Wires And Cables
From the start of the welding process avoid contact with the tube and the housing of the weld head. WARNING! There is a risk of of unintentionally operating the ignition function when connect- ing or disconnecting a weld head/manual welding torch to or from the power supply. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 14: 2.7.10 Damage To Eyes Through Radiation
During the welding process infrared, glaring and ultraviolet rays arise that can seriously damage the eyes. ► Keep clamping cassette or unit and flip cover closed during the welding process. ► Do not look into electric arc ► Wear eye protection to EN 170. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 15: 2.7.11 Dangers Through Electromagnetic Fields
Injuries can occur during dismantling for the proper disposal of the weld head through uncertainties in handling tools. ► In case of uncertainties send the weld head to Orbitalum Tools – proper disposal is carried out here. ► Allow only a professional electrician to access the electrical system and open the weld head. - Page 16 MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 17: Description
MOBILE HEAD Description Basic machine ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 18 For setting the pipe diameter. Ø) Clamping lever For clamping and releasing the weld head to the workpiece. Clamping unit For clamping the weld head to the workpiece. See also 2 Torch unit [ 19] ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 19: Torch Unit
Torch arm locking Fixing and releasing of the torch arm. Electrodes Transfer of welding current. Torch position adjusting Linear torch rough adjustment to pipe axis and side torch tilt adjust- screw ment. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 20: Control Panel/Control Elements
• Pressing and holding: Rotor rotates continuously (counterclockwise) in the welding direction. ROTATION (CLOCK- • Pressing briefly: Rotor rotates step-by-step (clockwise) in the WISE) welding direction. • Pressing and holding: Rotor rotates continuously (clockwise) in the welding direction. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 21: Scope Of Application
- max. Electrode lengths [mm] 30 - 55 [inch] 0.181 - 2.165 min. - max. Welding process Tungsten inert gas process (TIG) Materials All materials that are fundamentally suitable for the TIG welding process. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 22: Technical Specifications
Weld current, max. Ignition voltage, max. [kV] Motor voltage, max. [VDC] Motor current, max. Rotor speed, max. [rpm] Torch pivot range [°] 0 – 90 Sound level, max. (1 m gap) [dB (A)] 70 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 23: Electrodes
(see sketch) 30° (0.094 in) (0.004 - 0.008 in) See chap. Grinding electrodes [} 49] Preparing the tip Solely by grinding Grinding direction Solely lengthwise Recommended tool ORBITALUM TOOLS electrode grinder ESG Plus/ ESG Plus ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 24: Dimensions
Dimension "D": [mm] 223.50 [inch] 8,800 Dimension "E": [mm] 87.00 [inch] 3,425 Dimension "F": [mm] 296.70 [inch] 11,681 Dimension "G": [mm] 88.90 [inch] 3,500 Dimension "H": [mm] 69.90 – 73.90 [inch] 2,752 – 2,909 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 25: Transport
Transport weld head and wound up power/gas cable, either • By the handle (1) of the transport box (2) • Directly by the handle (3) of the unpacked weld head and by the power/gas cable (4). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 26: Commissioning
Prerequisite: Welding power supply connected and ready to operate. ► Check the weld head, power/gas hose, ground cable and lines for damage. ► Check the working environment for possible sources of danger and, if applicable, eliminate these. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 27: Set-Up And Mounting
4. Set up the electrode 5. Set up the torch 6. Connecting the weld head to the power source 7. Wind up power/gas hose 8. Carry out gas function test 9. Configure the welding procedure. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 28: Fit Drop Guard
Before start of work the weld head must be se- cured against falling. To this end the MOBILE HEAD weld heads have a mounting lug (1) for fastening of a suitable drop guard, such as a screw snap hook (2) to a wire ca- ble (3). -
Page 29: Fit Clamping Jaws
ü Pipe ends are tacked together light-/gap-free. ü Rotor is in home position. ü Before placing the weld head on the workpiece, ensure that the torch articulated arm (1) is locked in the home position. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 30: Set Up The Electrode
2. Insert the electrode (1) into the clamping sleeve (2). 3. Insert the clamping sleeve with electrode into the torch body (5). 4. Screw torch cap (4) on again. If required, adjust the electrode projection out of the gas nozzle. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 31: Set Up The Torch
► Wait until the surfaces have cooled down to below 50 °C before working on the orbital weld head or before packing into the transport case. ► Position the weld head correctly. ► Use only permissible materials in the welding area. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 32 3. Slowly and carefully lower torch articulated arm until the scanning wheel (2) touches down on the workpiece. ► Adjust desired electrode gap with the adjusting screw (1) and a feeler gage (7). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 33 If required, open the clamping screw (8) at the torch articulated arm using a key, adjust to 90°, and tighten again. 90° ► If required, carry out torch angle adjustment by means of the fixating screw (9). ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 34: Connecting The Weld Head To The Power Source
► 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 flammable substances. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 35: Connection Scheme
MOBILE HEAD 8.7.1 Connection scheme ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 36: Connection Sequence
3. Connect the Amphenol plug "Control line" to power source" (4b) to the "Control line" socket (1f) at the power source. 4. Connect the "Control line to weld head" plug (4a) to the "Control line" socket (3a) at the weld head and screw tight. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 37: Wind Up Power/Gas Hose
9 o'clock position). ► If required, the electrode/torch position has to be readjusted. ► Hold rotation key (1 or 2) until the torch reaches the desired start position and the power/gas hose is wound up. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 38 Release “ROTATION” key (1 or 2) as soon as the torch reaches the desired position and suffi- cient hose is wound up. Fig.: Torch and start position welding procedure in 9 o’clock position ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 39: Carry Out Gas Function Test
► OR: See operating instructions of the welding power source. 8.10 Configure the welding procedure ► Configure the welding procedure in accordance with the operating instructions of the welding power supply. ► The weld head is ready to use. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 40: Operation
In the worst case a fire will be started. ► Observe the local general fire protection measures. NOTICE Various risks ► Permanently observe welding process! ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 41: Returning The Weld Head To Home Position
Procedure via control panel of weld head: ► Press and hold “ROTATION COUNTERCLOCKWISE” (4) or “ROTATION CLOCKWISE” (5) key. OR via welding power supply: ► See operating instructions of the welding power source. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 42: Removing The Weld Head From The Workpiece
By pressing the “START/STOP” key again during the gas post purge time this is also stopped. OR via welding power supply: INFO To demonstrate power sources in these operating instructions the MOBILE WELDER is used as an example. ► Press hardware softkey 1 (7) ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 43 MOBILE HEAD ► Press touchscreen softkey button “STOP” (8) ► Press the ON-OFF switch (6) ► See operating instructions of the power source ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 44: Preparing Storage
• Do not store near materials that may cause corrosion. • Temperature range -20 to +55 °C • Relative humidity up to 90 % at 40 °C Further care and maintenance advice, see chap. Maintenance and troubleshooting [} 45]. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 45: Maintenance And Troubleshooting
CASTROL LONGTIME PD 2). Annually ► Grease all further moving parts with suitable lubricants. Every 2 years ► Have the power/gas cable replaced by the Service of Orbitalum Tools GmbH. 10.2.1 Standard cleaning process NOTICE Cleaning work on the welding tongs may only be carried after it has... -
Page 46: Replacing The Gas Nozzle And/Or Lens
2. Unscrew gas lens (4) and remove Teflon seal (3). 3. Place Teflon seal onto the new gas lens (4). 4. Screw all the components back together and, if applicable, mount the electrode again. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 47 MOBILE HEAD IMAGE DESIGNATION Torch cap Clamping sleeve Teflon seal Gas lens Gas nozzle Codes, see Ersatzteilliste / Spare parts list [} 51] ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 48: Troubleshooting
Arc tends to one side. Electrode worn. ► Regrind the electrode. Electrode ground incorrectly. ► Regrind the electrode. Poor electrode quality. ► Use Orbitalum electrodes. Incorrect workpiece material ► Change workpiece material. Bad workpiece quality ► Use different material batch. Rotation movement Foreign matter in the transmission. -
Page 49: Grinding Electrodes
• Machine model: (example: MH 4.5) • Machine No.: See type plate ► For ordering spare parts, see the spare part list. ► Contact your local branch directly in order to eliminate problematic situations. ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... -
Page 50: Accessories (Optional)
Danger presented by using accessories 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. ► See product catalog "Orbital Welding" for a comprehensive overview of suitable accessories. Download links PDF: https://www.orbitalum.com/de/download.html... -
Page 51: Ersatzteilliste / Spare Parts List
MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 52 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 53 MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 54 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 55: Grundkörper Mh 4.5 | Base
MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 56 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 57: Drehteller Mh 4.5 | Turntable
MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com... - Page 58 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 59 MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 60 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 61 MOBILE HEAD SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 62 SPARE PARTS MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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Page 63: Konformitätserklärungen
(including optionally available accessories from Orbitalum): / Machine et type (y compris accessoires (*inkl. Orbitalschweißstromquelle): Orbitalum disponibles en option): / Macchina e tipo (inclusi gli articoli accessori acquistabili opzionalmente MOBILE HEAD 3.0 da Orbitalum): / Máquina y tipo (incluidos los artículos de accesorios de Orbitalum disponibles MOBILE HEAD 4.5... - Page 64 Josef-Schüttler-Straße 17 78224 Singen, Deutschland Tel. +49 (0) 77 31 792-0 Offene Orbitalschweißköpfe Maschine und Typ (inklusive optional erhältlichen Zubehörartikeln von Orbitalum): / (*inkl. Orbitalschweißstromquelle / Machinery and type (including optionally available accessories from Orbitalum): incl. Orbital welding power source): MOBILE HEAD 3.0...
- Page 65 MOBILE HEAD Notizen ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 66 MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
- Page 67 MOBILE HEAD ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
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