ORBIWELD 17 / 17 GC Table of Contents About these instructions....2.7.7 Long-lasting physical damage through Warning messages ....wrong posture .... Further icons and displays ..2.7.8 Injury through high weight......Legend ........2.7.9 Burns and risk of fire .. Further applicable documents..
Page 3
ORBIWELD 17 / 17 GC 5.2.2 Clamping cassette for 8.11 Calibrating the motor....OW17......8.12 Dismantling clamping inserts and clamping cassettes ... Transport and shipping ....Gross weight ......Operation .......... Transport........Operator button panel ....Setting the welding parameters Commissioning ........
ORBIWELD 17 / 17 GC About these instructions 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.
ORBIWELD 17 / 17 GC Legend ABBREVIATION MEANING Orbital weld head (micro weld head), water cooled, OW17 Type "ORBIWELD 17" Orbital weld head (micro weld head), water cooled, OW17 GC Type "ORBIWELD 17 GC" Orbital welding power source of the Smart Welder series Orbital welding power source of the Mobile Welder series Further applicable documents Folgende Dokumente gelten mit dieser Betriebsanleitung:...
ORBIWELD 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC 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. •...
Page 12
ORBIWELD 17 / 17 GC • 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC ► 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 17 / 17 GC 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 17 / 17 GC 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 17 / 17 GC POS. DESIGNATION FUNCTION Enclosure Containing interior components and enclosing protectively. Handle/motor Hold weld head. Hose package Connect weld head with welding power supply. Rotating clamping handle Fix, contact and lock the clamping cassette on the weld head. Control panel Operate weld head.
ORBIWELD 17 / 17 GC Electrode setting gage OW17 The supplied, adjustable electrode setting gage makes it easier to set up the electrode. POS. DESIGNATION Knurl Limit stop Holder For information on setting up the electrodes, see chapt. Set up the electrode [} 37].
ORBIWELD 17 / 17 GC Clamping cassette and clamping insert OW17 Clamping cassettes and clamping inserts are not included in the scope of deliv- INFO ery of the weld head. POS. DESIGNATION FUNCTION Clamping cassette, side plate Holding clamping inserts and workpieces. Spacer, center Holding side plates at a precise distance.
ORBIWELD 17 / 17 GC Scope of application NOTICE! The weld head can be used for hose-to-hose and COAX connec- tions. Two hoses with the same diameter are welded together for Rhose-to- hose connections (standard). For COAX connections, also called double hose connections, usually 2 hoses with different hose diameters are welded together, e.g.
Page 28
ORBIWELD 17 / 17 GC Transport and shipping The following illustrations for the individual work steps show the weld head INFO model OW17 as an example. Procedures or work steps that deviate are, if re- quired, described separately and represented in a separate figure. Gross weight ITEM OW17...
Page 30
ORBIWELD 17 / 17 GC 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. ► Lay the lines and cables so that they are not under tension. ►...
Page 31
ORBIWELD 17 / 17 GC Setup and mounting Procedure Observe operating instructions of the ORBIMAT welding power supply or MO- INFO BILE WELDER! Carry out setting up and mounting in the following order: 1. Mounting the safety clamp [} 32] 2. Connecting the weld head to the power source [} 33] 3.
Page 32
ORBIWELD 17 / 17 GC 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. ►...
Page 33
ORBIWELD 17 / 17 GC 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. ►...
Page 34
ORBIWELD 17 / 17 GC 8.3.1 Connection sequence See also chapt. Wiring diagram [} 35]). 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 connections (does not apply to OW17 GC). 5.
Page 36
ORBIWELD 17 / 17 GC POS. DESIGNATION TO BE CONNECTED WITH POS. Power source, e.g. Smart Welder type Socket "Gas" Plug "Gas", hose package "Coolant supply line" plug, blue, hose pack- 1b * "Coolant supply line" socket, blue age (only OW17) "Coolant return line"...
Page 37
ORBIWELD 17 / 17 GC Set up the electrode The weld head contains 2 electrode holes for different electrode diameters that are identified by elec- trode markings in the rotor. The following steps apply for both electrode diameters. DANGER Electrical hazards due to touching as well as incorrect or damp protective equipment.
Page 38
ORBIWELD 17 / 17 GC NOTICE! Damage to property through electrode in the toothed space! If the electrode projects into the toothed space, jamming can occur in the transmission. ► Shorten the electrode. The OW17 weld heads have 2 electrode holes for thee electrode diameters INFO 1.0 mm (0.039 in) and 1.6 mm (0.063 in) which are marked by electrode markings in the rotor (see chapt.
Page 39
ORBIWELD 17 / 17 GC Electrodes Ø 1.0 mm (0.039") Setting dimension Electrode OD hose OD rotor ID rotor Electrode gap length (Z)* Electrode setting gage [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] 0,118 15.6 0,614 16.70 0,657...
Page 40
ORBIWELD 17 / 17 GC Electrodes Ø 1.6 mm (0.063") Setting dimension Electrode OD hose OD rotor ID rotor Electrode gap length (Z)* Electrode setting gage [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] [mm] [inch] 0,118 – – 17.20 0,677 3.175...
Page 41
ORBIWELD 17 / 17 GC 1. Ensure that the Orbital welding power source is switched on. 2. In the control panel, press the MOTOR button and keep it pressed until the desired electrode hole has reached the 12 o'clock position. Ob- serve the markings in the rotor.
Page 42
ORBIWELD 17 / 17 GC Mounting clamping inserts NOTICE! A clamping insert consists of 2 half shells for 1 clamping side. Fur- ther information on the use of clamping sets, see chapt. Clamping inserts for OW17 [} 65] NOTICE! For COAX connections 2 hoses with different hose diameters are usually welded together (see chapt.
Page 43
ORBIWELD 17 / 17 GC 2. Insert the clamping insert (5) with the writing facing outwards. 3. Tighten the hexagon screws (4) hand-tight with the hexagon key. 4. Close both swivel brackets (3) again. 5. Close both swivel bracket locks (2) and clamping levers (1) again. 6.
Page 44
ORBIWELD 17 / 17 GC 8.6.1 Aligning the side plates of the clamping cassette NOTICE! Before both workpieces are clamped you have to check whether both side plates of the clamping cassette are exactly aligned to each other. Only of this is so, can the central hose joint be exactly on a straight line, when the workpieces are clamped, and the weld- ing can be performed according to the highest standards of qual- ity.
Page 46
ORBIWELD 17 / 17 GC 8.6.2 Hose-to-hose connections (standard) NOTICE! Ensure that the hose centering gage "Standard" is used and not "COAX". Otherwise the hoses cannot be centrally aligned. The electrode has to be positioned centrally over the gap-free workpiece joint INFO (7).
Page 47
ORBIWELD 17 / 17 GC 1. Open and turn down both clamping levers (1) and swivel brackets (2) to unlock the clamping cas- sette. 2. Open both swivel brackets (3). 3. Insert the hose centering gage "Standard" (4) (see note above). 4.
Page 48
ORBIWELD 17 / 17 GC 8.6.3 COAX connections (double hose applications) NOTICE! For COAX connections 2 hoses with different hose diameters are usually welded together (see chapt. Scope of application [} 24]). ► Ensure that for each clamping cassette side different clamping in- serts are used that correspond to the respective hose diameters that are to be welded.
Page 49
ORBIWELD 17 / 17 GC Mounting the weld head in the clamping cassette 1. Position the clamping cassette (1) flat on the supporting area. 2. Bring the rotating tension handle (2) at the weld head (3) into the open position. 3.
Page 50
ORBIWELD 17 / 17 GC 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.
Page 51
ORBIWELD 17 / 17 GC ► 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 [} 42] and chapt. Mounting the weld head in the clamping cassette [} 49] in the reverse order.
Page 52
ORBIWELD 17 / 17 GC Operation Operator button panel POS. 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.
Page 53
ORBIWELD 17 / 17 GC Setting the welding parameters ► See operating instructions for the welding power source. Welding Prerequisite: Welding power supply connected and ready to operate. DANGER Electromagnetic fields arise during the welding process. ► The plant operator must configure the workplaces in accordance with the EMF Directive 2013/35/EU in such a way that there is no danger whatsoever for the operator or persons in the vicinity of the welding system.
Page 54
ORBIWELD 17 / 17 GC 3. Observe the welding process. ð The welding process ends automatically after the gas post purge time has expired. ð The electrode returns automatically to the 0-position. ORBITALUM TOOLS GmbH, D-78224 Singen www.orbitalum.com...
Page 55
ORBIWELD 17 / 17 GC 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- ►...
Page 56
ORBIWELD 17 / 17 GC 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. RESPECTIVE COMPO- INTERVAL ACTIVITY NENT ►...
Page 57
ORBIWELD 17 / 17 GC RESPECTIVE COMPO- INTERVAL ACTIVITY NENT ► Only use protective gases that are classified for the TIG welding process according to EN ISO 14175 (e.g. Ar- gon 4.6 or purer protective gas for welding). Protective gas for ►...
Page 58
ORBIWELD 17 / 17 GC 10.3.1 Standard cleaning process 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.
Page 59
ORBIWELD 17 / 17 GC Fine cleaning procedure: CAUTION The use of lubricants can severely influence the function and cause damage. ► Never spray lubricant into the welding tongs! 1. Spray the rotor (1), weld head interior (5) as well as the complete clamping cassette and the clamp- ing insert again thoroughly using the contact cleaner (in particular the 2 front surfaces of the rotor).
Page 60
ORBIWELD 17 / 17 GC PROBLEM POSSIBLE CAUSE REMEDY Continuously large and Defect at the power source or weld constantly different ► Contact Service. head. speed deviations. 1. Clean the workpiece and clamping insert. Excess electrical resistance arising 2. Clean the contact surfaces be- from soiling between the weld head tween the weld head and clamp- and the clamping inserts/clamping...
Page 61
ORBIWELD 17 / 17 GC PROBLEM POSSIBLE CAUSE REMEDY Electrode worn. ► Replace the electrode. Electrode ground incorrectly. ► Set the electrode distance. Arc ignites against parts Poor electrode quality. ► Clean the weld head. of the weld head. Gas pre purge time too short. ►...
Page 62
ORBIWELD 17 / 17 GC 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:...
Page 63
ORBIWELD 17 / 17 GC Storage and decommissioning 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. Pull the end caps for cooling liquid over the cooling liquid connections*. 5.
Page 64
ORBIWELD 17 / 17 GC 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.
Page 65
ORBIWELD 17 / 17 GC 12.2 Clamping inserts for OW17 • Made of stainless steel. Can only be used when clamping cassette OW17 and other common or compatible clamping cassettes are used. • 1 clamping insert consists of 2 half shells. ►...
Page 66
ORBIWELD 17 / 17 GC Fitting for all weld heads of Orbitalum, with exception of the AVC/OSC versions of the ORBIWELD TP series. The weld current connection adapter set may be required for use with older Orbitalum welding power supplies and heads with green Superior connections. Newer machine models are already equipped with DINSE-compatible connections.
Page 84
ORBIWELD 17 / 17 GC Declarations of conformity 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.
Page 85
ORBIWELD 17 / 17 GC 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.
Need help?
Do you have a question about the orbitalum ORBIWELD 17 and is the answer not in the manual?
Questions and answers