ORBIWELD 12 / 19 (HD) Table of Contents About these instructions....2.7.7 Long-lasting physical damage through Warnhinweise ......wrong posture .... Weitere Symbole und Ausze- 2.7.8 Injury through high ichnungen ........ weight......2.7.9 Burns and risk of fire .. Mitgeltende Dokumente ... 2.7.10 Prick injury through Legend ........
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ORBIWELD 12 / 19 (HD) Clamping inserts for OW 12, Mounting clamping inserts ..clamping cassette Type "B" 8.5.1 Mounting clamping in- (wide) ........sert on clamping cas- sette type "B" (wide) Clamping inserts for OW 19..OW 12......Clamping inserts for OW 19 8.5.2 Installing clamping in- HD..........
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ORBIWELD 12 / 19 (HD) 10.2 Operating and cooling phases . 10.3 Wartung und Pflege ....10.3.1 Standard cleaning process ...... 10.3.1.1 OW 12......10.3.1.2 OW 19......10.3.1.3 OW 19 HD ....10.4 Troubleshooting ....... 10.5 Grinding electrode....10.6 Service/Kundendienst ....11 _Registration a Rum a / suspend Eelworm ropes_ .......
ORBIWELD 12 / 19 (HD) About these instructions Warnhinweise Die in dieser Anleitung verwendeten Warnhinweise warnen vor Verletzungen oder vor Sachschäden. Warnhinweise immer lesen und beachten! Dies ist das Warnsymbol. Es warnt vor Verletzungsgefahren. Um Verletzungen oder Tod zu vermeiden, die mit dem Sicherheitszeichen gekennzeichneten Maßnahmen befolgen.
ORBIWELD 12 / 19 (HD) Information and safety instructions for the owner 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.
ORBIWELD 12 / 19 (HD) 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. • TIG welding of materials that are specified in these operating instructions (see chap. applications). •...
ORBIWELD 12 / 19 (HD) 2.2.2 Machine constraints • The workplace can be in the tube preparation, in plant construction or in the plant itself. • The machine is operated by one person. • A space of about 2 m for people to move around the machine must be provided. •...
ORBIWELD 12 / 19 (HD) Environmental protection and disposal 2.3.1 Information regarding the Ecodesign Directive 2009/125/ • Do not dispose of product (if applicable) with general waste. • Reuse or recycle waste electrical and electronic equipment (WEEE) by disposing of it at a designated collection point. •...
ORBIWELD 12 / 19 (HD) Personnel qualification CAUTION! The weld head/manual welding torch may only be used by instructed personnel. • Only employ personnel who satisfy the job- and age-specific regulations that apply to the operation site. • No physical and mental impairments. •...
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ORBIWELD 12 / 19 (HD) • Perform "loosening-up" exercises. • Ensure a varied range of activities. • Assume an upright, fatigue-free and comfortable body position during operation. ORBITALUM TOOLS GmbH, D-78224 Singen www.orbitalum.com...
ORBIWELD 12 / 19 (HD) Personal protective equipment The following personal protective equipment must be worn while working at the system: Safety gloves according to EN 407 for welding operation and DIN 388 for installing the elec- ► trode. ► Safety shoes according to EN ISO 20345, Class SB.
ORBIWELD 12 / 19 (HD) Wear dry safety shoes, dry metal-free (grommet-free) leather gloves and dry safety suits to mini- ► mize the electrical hazard. ► Work on a dry surface. Electric shock along with injuries and damage to property on other devices due DANGER! to erroneous ignition with unmounted or incorrectly positioned weld head.
ORBIWELD 12 / 19 (HD) 2.7.3 Damage to eyes through radiation During the welding process infrared, glaring and ultraviolet rays arise that can WARNING! seriously damage the eyes. ► Do not look into the electric arc. ► Wear eye protection to EN 170. 2.7.4 Risk of suffocation from an excessive amount of argon in the air...
ORBIWELD 12 / 19 (HD) 2.7.7 Long-lasting physical damage through wrong posture Use the machine so that an upright and comfortable body position can be achieved during operation. 2.7.8 Injury through high weight A significant health hazard exists during lifting. Observe machine weights, chapt. Gross weight! Danger of impact and crushing exists in the following situations: Falling of the orbital weld head during transportation, mounting/dismantling or CAUTION!
ORBIWELD 12 / 19 (HD) ► Safety gloves in accordance with EN 407. Wait until the surfaces have cooled down to below 50 °C (122 °F) before working on the weld ► head or before packing into the transport case. ► Position the weld head correctly. ►...
ORBIWELD 12 / 19 (HD) Before connecting the weld head and before mounting the electrode: Switch off orbital welding ► system. Before moving the rotor with closed weld heads, fit clamping cassette or clamping unit and close ► flip cover. ►...
ORBIWELD 12 / 19 (HD) 2.7.16 General injuries through tools Injuries can occur during dismantling for the proper disposal of the weld head CAUTION! through uncertainties in handling tools. In case of uncertainties send the weld head to Orbitalum Tools – proper disposal is carried out ►...
ORBIWELD 12 / 19 (HD) Description OW 12 OW 12 mit schmaler Spannkassette (Typ A) OW 12 mit breiter Spannkassette (Typ B) OW 12 Rotor ITEM DESCRIPTION FUNCTION Hose package Connect weld head with welding power supply. Control panel Operate weld head. Handle Hold weld head.
ORBIWELD 12 / 19 (HD) ITEM DESCRIPTION FUNCTION Clamping cassette*, Type "A" Align and clamp workpieces (hoses). (narrow) Clamping cassette*, Type "B" Mounting of clamping inserts Type "B". (wide) Clamping inserts*, Type "B" Align and clamp workpieces (hoses). (wide) Rotor Guide the electrode radially around the workpiece.
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ORBIWELD 12 / 19 (HD) OW 19 OW 19 ohne Spanneinsatz OW 19 mit OW 19 mit Spanneinsatz S Spanneinsatz W ("small") ("wide") OW 19 Rotor ITEM DESCRIPTION FUNCTION Hose package Connect weld head with welding power supply. Control panel Operate weld head.
ORBIWELD 12 / 19 (HD) ITEM DESCRIPTION FUNCTION Rotor Guide the electrode radially around the workpiece. Electrode tensioning Fasten the electrodes. screws Electrode holder Ø 1.0 mm Inserting electrodes (see chapt. Set up the electrode [} 48]). (0.039") Electrode holder Ø 1.6 mm Inserting electrodes (see chapt.
ORBIWELD 12 / 19 (HD) OW 19 HD OW 19 HD mit Spannkassette 13b 12b OW 19 HD Spannkassette OW 19 (HD) Rotor ITEM DESCRIPTION FUNCTION Hose package Connect weld head with welding power supply. Control panel Operate weld head. Handle Hold weld head.
ORBIWELD 12 / 19 (HD) ITEM DESCRIPTION FUNCTION Rotor Guide the electrode radially around the workpiece. Electrode tensioning screw Fasten the electrodes. Ø 1.0 mm (0.039") Electrode tensioning screw Fasten the electrodes. Ø 1.6 mm (0.063") Electrode holder Inserting electrodes (see chapt. Set up the electrode [} 48]). Ø 1.0 mm (0.039") Electrode holder Inserting electrodes (see chapt.
ORBIWELD 12 / 19 (HD) Accessories (optional) WARNING 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. Clamping cassettes and clamping inserts are not included in the scope of deliv- INFO ery of the weld head.
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ORBIWELD 12 / 19 (HD) Clamping inserts for OW 12, clamping cassette Type "B" (wide) Made of aluminum. Can only be used if the Type "B" clamping cartridge is used. A clamping insert consists of 4 diameter-specific individual parts (2 inserts per side).
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ORBIWELD 12 / 19 (HD) LENGTH LENGTH ITEM [FT] Hose package extension 5 m (16 ft) Hose package extension 10 m (32 ft) Hose package extension 15 m (49 ft) Hose package extension 20 m (64 ft) Further lengths on request. Special hose package OW 19 HD Using the special hose package the OW 19 HD can be expended to 23 m (75 ft). Suitable for all Orbitalum weld heads, with the exception of the AVC/OSC versions of the ORBIWELD TP series.
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ORBIWELD 12 / 19 (HD) DIMENSIONS DIMENSION ELECKTRODE GAP Dimension "K" 60.00 2,362 Dimension "L" 26.50 1,043 5.2.2 OW 19 * Elektrodenposition A1 mit Spanneinsatz Typ S A2 mit Spanneinsatz Typ W DIMENSION ELECTRODE GAP DIMENSIONS Clamping insert Type Clamping insert Type “S“...
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ORBIWELD 12 / 19 (HD) Transport and shipping Gross weight OW 12 OW 19 OW 19 HD ITEM [kg] 11.0 14.8 15.0 Weight* [lbs] 24.2 32.6 33.1 * incl. scope of delivery and transport case Transport WARNING Danger of injury through high weight of the weld head! Depending on the model, the transport case with orbital weld head and delivery contents weighs max.
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ORBIWELD 12 / 19 (HD) Inbetriebnahme Lieferumfang We reserve the right to make changes. CODE QUANTITY UNIT ITEM ORBIWELD 12* 821 000 010 PCS. Tool set 821 030 002 PCS. transport case 821 030 001 PCS. General safety information for enclosed weld heads 836 060 101 PCS.
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ORBIWELD 12 / 19 (HD) CODE QUANTITY UNIT ITEM ORBIWELD 19 HD*** 822 000 011 PCS. Tool set 822 030 001 PCS. transport case 811 030 006 PCS. General safety information for enclosed weld heads 836 060 101 PCS. Operating instructions & ETL, OW 12/19 Unlimited Download link PDF: 821 060 203...
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ORBIWELD 12 / 19 (HD) Inbetriebnahme vorbereiten Prerequisite: Welding power supply connected and ready to operate. WARNING Risk of explosion when using incorrect (explosive) gases during welding process. Severe injuries and death may be the result. ► Observe safety instructions in the operating instructions of the power source.
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ORBIWELD 12 / 19 (HD) Setup and mounting Vorgehensweise INFO Follow the operating instructions for the welding power source! Carry out setting up and mounting in the following order: 1. Mounting the safety clamp [} 39] 2. Connecting the weld head to the power source [} 40] 3.
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ORBIWELD 12 / 19 (HD) Mounting the safety clamp WARNING Falling of unsecured weld head. The device may drop and injure people. ► Before start of work, fit drop guard with sufficient load capacity (e.g. wire cable with snap hook) to weld head. ►...
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ORBIWELD 12 / 19 (HD) Connecting the weld head to the power source WARNING Danger of burns and fire from arcs! Tripping over the hose package can cause the welding current plugs to be pulled out of the welding power source which may result in an arc. ►...
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ORBIWELD 12 / 19 (HD) 8.3.1 Connection sequence (See also chapt. Anschlussschema [} 42]). 1. Attach the strain relief. 2. Connect the Amphenol plug. 3. Connect the welding current plug and welding current socket. 4. Connect the blue and red cooling liquid connection. 5.
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ORBIWELD 12 / 19 (HD) ITEM DESCRIPTION TO BE CONNECTED WITH ITEM Power source, e.g. Smart Welder type Socket "Gas" Plug "Gas", hose package "Coolant supply line" plug, blue, hose pack- "Coolant supply line" socket, blue "Coolant return line" socket, red "Coolant return line"...
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ORBIWELD 12 / 19 (HD) Mounting the clamping cassette 8.4.1 Mounting the clamping cassette for OW 12 WARNING The orbital weld head falling down while setting up. Risk of injury and damage to the weld head. ► To set up the orbital weld head place it flat on a level, non-slip sur- face and ensure that it cannot fall down.
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ORBIWELD 12 / 19 (HD) 1. Position the weld head (3) flat on the supporting area. 2. Unscrew the screws (1) using a hexagon screwdriver. 3. Pull the old clamping cassette (2) off the weld head (3). 4. Push the clamping cassette (4) onto the weld head (3) as far as the stop. 5.
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ORBIWELD 12 / 19 (HD) 1. Position the weld head flat on the supporting area. 2. Open the cylinder head screws ISO 4762- M2.5x6-A2 (1) using a hexagon screwdriver. 3. If a clamping insert (2) is already mounted, it can now be removed. 4.
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ORBIWELD 12 / 19 (HD) 1. Position the weld head flat on the supporting area. 2. Open the clamping locks (1). 3. Loosen and remove the screws (2) using a Phillips recessed head or Phillips screwdriver. OW 19, Type "S": Countersunk screw ISO 7046-1-M2.5x4-A2 OW 19, Type "W": Cylinder head screw ISO 4762-M2.5x4-A2...
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ORBIWELD 12 / 19 (HD) Set up the electrode DANGER The rotation movement of the rotor can cause hair, jewelry or clothes to be caught and pulled into the enclosure. ► Wear tight-fitting clothes. ► Do not wear open hair, jewelery or other accessories that can be easily drawn in.
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ORBIWELD 12 / 19 (HD) 8.6.1 Setting up electrode OW 12 The OW 12 has 2 x 2 electrode holes for electrode diameters 1.0 mm (0.039") INFO and 1.6 mm (0.063") (see chapt. Electrode holders OW 12 [} 21]). 1. Ensure that the Orbital welding power source is switched on. 2.
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ORBIWELD 12 / 19 (HD) 8.6.2 Setting up electrode OW 19 (HD) The OW 19 has 2 x 2 electrode holes for electrode diameters 1.0 mm (0.039") INFO and 1.6 mm (0.063") (see chapt. Electrode holders OW 19 [} 23]). 1. Ensure that the Orbital welding power source is switched on. 2.
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ORBIWELD 12 / 19 (HD) Clamping the workpieces CAUTION The orbital weld head or pipe falls down during mounting/disman- tling/setup or during unsecured usage in overhead position. ► Attach the orbital weld head securely to the workpiece and ensure that it cannot fall down. ►...
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ORBIWELD 12 / 19 (HD) 8.7.1 Clamping workpieces OW 12 1. Ensure that the Orbital welding power source is switched on. 2. Move the rotor to the home setting (0 position) (e.g. by pressing the "END.-0-POS" button on the control panel on the weld head). 3.
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ORBIWELD 12 / 19 (HD) 8.7.2 Clamping workpieces OW 19 1. Ensure that the Orbital welding power source is switched on. 2. Move the rotor to the home setting (0 position) (e.g. by pressing the "END.-0-POS" button on the control panel on the weld head). 3.
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ORBIWELD 12 / 19 (HD) 8.7.3 Clamping workpieces OW 19 HD 1. Open the flip cover (7). 2. Open and turn down both clamping levers (1) and swivel bracket locks (2) to unlock the clamping cassette. 3. Open both swivel brackets (3). 4.
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ORBIWELD 12 / 19 (HD) Carry out the gas and cooling liquid function test 1. Press the “GAS“ button to start the function test of the gas and cooling liquid supply. 2. At the initial operation or if the weld head is not filled, wait 1 minute until the weld head is filled with cooling liquid.
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ORBIWELD 12 / 19 (HD) ► Calibrate motors in accordance with the operating instructions for the welding power supply. ð The weld head is ready to use. 8.12 Dismantling clamping inserts and clamping cassettes Perform the work steps described in chapt. Mounting clamping inserts [} 45] and in chapt. Mounting the clamping cassette [} 44] in the reverse order.
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ORBIWELD 12 / 19 (HD) Operation Operator button panel ITEM CONTROL ELEMENT FUNCTION • Flashes red in the ready-to-weld state. • Lights up continuously red during the welding process. • Pressing once: Starts the welding process. • Press during the welding process: Welding process is stopped START/ and gas post purge time is started.
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ORBIWELD 12 / 19 (HD) Schweißen DANGER Electromagnetic fields arise during the welding process. ► The plant operator must realize the workplaces in accordance with the EMF Directive 2013/35/EU in such a manner that no danger whatsoever exists for the operator or persons in the vicinity of the welding system.
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ORBIWELD 12 / 19 (HD) Preparing storage Carry out the following steps before storage: 1. Remove the electrode. 2. If appropriate, remove the clamping inserts. 3. Disconnect the weld head from the welding power supply. 4. Put closure caps on the cooling liquid connections. 5.
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ORBIWELD 12 / 19 (HD) Maintenance and troubleshooting 10.1 Instructions for care CAUTION The use of cleaning agents may cause sensitization. ► Wear protective clothing to prevent contact with cleaning agents. ► Do not use lubricants or sliding agents. Ensure that dirt particles or small items do not get into the transmission (head inside) (the trans- ►...
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ORBIWELD 12 / 19 (HD) MACHINE TYPE HOSE-Ø OPERATING PHASE COOLING PHASE Up to 1/4" Max. 15 weld seams in sequence 15 minutes OW 12 1/ 4” - 1/2" Max. 5 weld seams in sequence 15 minutes OW 19 (HD) Continuous work possible, no cooling phase required.
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ORBIWELD 12 / 19 (HD) 10.3 Wartung und Pflege The following instructions for care depend, if not stated otherwise, strongly on the usage of the weld head. Shorter cleaning intervals influence the equipment service life positively. INTERVAL RESPECTIVE COMPONENT ACTIVITY ►...
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ORBIWELD 12 / 19 (HD) INTERVAL RESPECTIVE COMPONENT ACTIVITY ► Only use protective gases that are classified for the TIG welding process according to DIN EN ISO 14175 (e.g. argon 4.6 or purer protective gas for welding). Protective gas for welding ►...
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ORBIWELD 12 / 19 (HD) INTERVAL RESPECTIVE COMPONENT ACTIVITY OW 12: Min. every 15,000 weldings or every 12 ► Send in weld head to Orbitalum service for ba- months. Weld head sic cleaning or have cleaning performed by an OW 19 (HD): authorized expert trained by Orbitalum.
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ORBIWELD 12 / 19 (HD) 10.3.1.1 OW 12 Preparation: 1. Ensure that the orbital welding power source is switched on. 2. Remove electrode if necessary (see chapt. Set up the electrode [} 48]). 3. Move the rotor to the home setting (0 position) (e.g. by pressing the "END.-0-POS" button on the control panel on the weld head).
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ORBIWELD 12 / 19 (HD) 6. Remount the clamping cassette and clamping inserts. 10.3.1.2 OW 19 Preparation: 1. Ensure that the Orbital welding power source is switched on. 2. Remove electrode if necessary (see chapt. ). 3. Move the rotor to the home setting (0 position) (e.g. by pressing the "END.-0-POS" button on the control panel on the weld head).
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ORBIWELD 12 / 19 (HD) 1. Spray the rotor (2), weld head interior (1) (both front surfaces of the rotor in particular), clamping in- serts (3) and the entire clamping cassette (4) again with contact cleaner. Let the rotor rotate by 360°...
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ORBIWELD 12 / 19 (HD) Fine cleaning procedure: CAUTION The use of lubricants can severely influence the function and cause damage. ► Never spray lubricant into the welding tongs! WARNING Danger of burning and fire due to the ignition of cleaning agent residues on the weld head during welding! Danger of burning and fire.
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ORBIWELD 12 / 19 (HD) 10.4 Troubleshooting PROBLEM POSSIBLE CAUSE REMEDY ► Check the connections at the weld- ing power supply. Welding process does ► Check the coolant level at the No gas and cooling liquid supply. not start. power source. ►...
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ORBIWELD 12 / 19 (HD) PROBLEM POSSIBLE CAUSE REMEDY ► Regrind the electrode. Electrode worn. (See chapt. Grinding electrode [} 71]) ► Regrind the electrode. Electrode ground incorrectly. (See chapt. Grinding electrode Arc tends to one side. [} 71]) Poor electrode quality. ►...
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ORBIWELD 12 / 19 (HD) 10.5 Grinding electrode 1. Grind the electrode only in the longitudinal direction. 2. After the electrode has been ground, break the tip in accordance with the following sketch. Ø 22,5° Ø 0,1 - 0,2 mm (0.004 - 0.008 in) 10.6 Service/Kundendienst The following data are required to order spare parts:...
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ORBIWELD 12 / 19 (HD) Konformitätserklärungen ORIGINAL EG-Konformitätserklärung EC Declaration of conformity CE Déclaration de conformité CE Dichiarazione di conformità CE Declaración de conformidad EG-conformiteitsverklaring ES Prohlášení o shodě EÚ Prehlásenie o zhode Deklaracja zgodności WE Orbitalum Tools GmbH Josef-Schüttler-Straße 17 78224 Singen, Deutschland Tel.
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ORBIWELD 12 / 19 (HD) ORIGINAL UKCA-Konformitätserklärung UKCA Declaration of conformity Orbitalum Tools GmbH Josef-Schüttler-Straße 17 78224 Singen, Deutschland Tel. +49 (0) 77 31 792-0 Orbitalschweißköpfe Maschine und Typ (inklusive optional erhältlichen Zubehörartikeln von Orbitalum): / (*inkl. Orbitalschweißstromquelle) Machinery and type (including optionally available accessories from Orbitalum): Orbital weld heads (*incl.
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Pasadena, Texas 77505 Units 4 & 5 Navigation Park Blackwood, New Jersey 08012 Road One, Winsford Industrial Estate ITW India Pvt. Ltd Tel. +1 713 983 0784 Winsford, Cheshire CW7 3 RL Sr.no. 234/235 & 245 Tel. +1 856 579 8747...
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