ORBIWELD 25 GC Table of Contents About these instructions....................Warning messages ....................Further icons and displays ..................Legend ........................Further applicable documents................... Information and safety instructions for the owner ............Requirements for the owner-operator ............... Using the machine ....................2.2.1 Proper use....................
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ORBIWELD 25 GC 5.1.2 Clamping cassette for OW 25 GC ............Transport and shipping ....................Gross weight ......................Transport........................Commissioning ......................... Scope of delivery ...................... Prepare commissioning .................... Setup and mounting ......................Procedure ......................... Mounting the safety clamp ..................Connecting the weld head to the power source............8.3.1 Connection sequence................
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ORBIWELD 25 GC 10.1 Instructions for care ....................10.2 Operating and cooling phases .................. 10.3 Wartung und Pflege ....................10.3.1 Standard cleaning process............... 10.4 Troubleshooting ......................10.5 Grinding electrode..................... 10.6 Service/Kundendienst ....................11 Accessories (optional)...................... 11.1 Clamping cassette ....................11.2 Clamping inserts ....................... 11.3 Hose package extensions..................
ORBIWELD 25 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 25 GC Legend ABBREVIATION MEANING OW 25 GC Orbital weld head (micro weld head), gas cooled, Type "ORBIWELD 25 GC" Orbital welding power supply of the Smart Welder series Orbital welding power supply of the Mobile Welder series Further applicable documents The following documents apply together with these operating instructions: •...
ORBIWELD 25 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 25 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 supply of the ORBIMAT, Mobile Welder and Smart Welder series. • TIG welding of materials that are specified in these operating instructions (see chap. applications). •...
ORBIWELD 25 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 25 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 25 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. •...
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ORBIWELD 25 GC CAUTION! Risk of injury due to monotonous work and exhausting work in places that are difficult to access and performing overhead work! Discomfort, tiredness and malfunctions in the motor system, restricted ability to react and cramping. ► Increase break times.
ORBIWELD 25 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. ►...
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ORBIWELD 25 GC ► Always carry out orbital weld head OW 170 mounting/dismantling work on the pipe employing 2 persons. CAUTION! Falling of the transport case caused by it being put down improperly! ► Place the transport case on a stable base near (approx. 1.5 m) the welding power supply. CAUTION! Danger of being pricked by the electrode or, where applicable, by the cold wire both for the operator and for third parties while grasping the weld head.
ORBIWELD 25 GC ► Wear safety gloves according to DIN 388. CAUTION! Danger of cut injuries caused by sharp pipe edges when clamping the weld head onto the pipe. ► Wear safety gloves according to DIN 388. CAUTION! Injuries can occur during dismantling for the proper disposal of the weld head through uncertainties in handling tools.
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ORBIWELD 25 GC DANGER! Risk of death for people with heart problems or cardiac pacemakers. DANGER! Depending on the form of the workplace, life-threatening electromagnetic fields can arise in the direct vicinity. ► People with heart problems or cardiac pacemakers must not operate the welding system. ►...
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ORBIWELD 25 GC WARNING! Various injuries and damage to property due to electromagnetic incompatibility of surrounding devices during high-frequency ignition and devices in operation without a protective ground. ► Use only electrical devices with protective insulation in the working area of the welding system. ►...
ORBIWELD 25 GC 2.7.3 Thermal hazards DANGER! Safety parts can fail due to impurity, breakage and wear, causing many risks of injury and risk of fire and burning due to the arc. ► Do not misuse the cable, for example by suspending or carrying the machine by the cable. ►...
ORBIWELD 25 GC WARNING! Thermal problems can arise in the event of incorrect positioning of the weld head, purging system or the use of impermissible materials in the welding area. In the worst case a fire will be started. Observe the local general fire protection measures.
ORBIWELD 25 GC ► Observe safety instructions in the operating instructions of the power source. ► Usage solely of protective gases that are classified for TIG welding process in accordance with EN ISO 14175. CAUTION! Risk of slipping due to coolant leaking when connecting and disconnecting the hose package and power supply.
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ORBIWELD 25 GC ► In case of danger, unplug the mains plug! ► Accessibility to the mains plug must always be assured in order to permit disconnecting the power supply from the mains. ORBITALUM TOOLS GmbH, D-78224 Singen www.orbitalum.com...
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ORBIWELD 25 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 25 GC Electrode holders OW 25 GC The OW 25 GC has 2 electrode holes for electrode diameters of 1.6 mm (0.063 in) and 2.4 mm (0.094 in). Ø 2,4 mm / 0.094 in Ø 1,6 mm / 0.063 in Illustration: Rotor electrode holes Electrode hole Ø...
ORBIWELD 25 GC Clamping cassette and clamping insert INFO Clamping cassettes and clamping inserts are not included in the scope of deliv- ery but are absolutely necessary for the insert and have to be ordered sepa- rately. POS. DESIGNATION FUNCTION Clamping cassette, side plate Holding clamping inserts and workpieces.
ORBIWELD 25 GC Transport and shipping Gross weight ITEM OW 25 GC Weight* [kg] 13,20 [lbs] 29.101 * incl. scope of delivery and transport case Transport ► Transport the weld head in the transport case using the handle. CAUTION Danger of injury through pointed electrode! If the weld head is removed incorrectly from the transport case, there is the risk that you may touch the pointed electrode in the process.
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ORBIWELD 25 GC WARNING Risk of burns, blindness and fire due to arcs! An arc may develop by releasing the welding contacts during operation. This can result in burns and blindness, in the worst case a fire can be started. ►...
ORBIWELD 25 GC Setup and mounting CAUTION Risk of injury due to monotonous work and exhausting work in places that are difficult to access and performing overhead work. Risk of discomfort, tiredness and malfunctions in the motor system, re- stricted ability to react and cramping. ►...
ORBIWELD 25 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. ►...
ORBIWELD 25 GC Connecting the weld head to the power source WARNING Risk of burns, blindness and fire due to arcs! An arc may develop by releasing the welding contacts during operation. This can result in burns and blindness, in the worst case a fire can be started.
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ORBIWELD 25 GC CAUTION If the power cable, gas line or control cable are under tension, there is the danger that persons may trip over them and be injured. Fall injuries ► Ensure that under no circumstances can people trip over lines and/ or cables.
ORBIWELD 25 GC 8.3.1 Connection sequence See also chapt. Connection diagram). 1. Attach the strain relief. 2. Connect the Amphenol plug. 3. Connect the welding current plug and welding current socket. 4. Connect the gas hose. 5. Switch on the welding power supply. 6.
ORBIWELD 25 GC Set up the electrode The weld head contains 2 electrode holes for different electrode diameters that are identified by elec- trode markings on the rotor. The following steps apply for both electrode diameters. DANGER Electrical hazards due to touching as well as incorrect or damp protective equipment.
ORBIWELD 25 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. INFO The OW 25 GC weld head has 2 electrode holes for the electrode diame- ters 1.6 mm (0.063 in) and 2.4 mm (0.094 in) which are marked by electrode markings on the rotor (see chapt.
ORBIWELD 25 GC 8.4.2 Inserting an electrode INFO The OW 25 GC weld head has 2 electrode holes for the electrode diameters 1.6 mm (0.063 in) and 2.4 mm (0.094 in) which are marked by electrode mark- ings on the rotor (see chapt. Electrode holders [} 26]). CAUTION Material damage through protruding electrode clamping screw in the guide area of the rotor!
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ORBIWELD 25 GC 1. Make sure that the orbital welding power supply 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.
ORBIWELD 25 GC 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.
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ORBIWELD 25 GC 10. The side plates are now exactly aligned to each other. ORBITALUM TOOLS GmbH, D-78224 Singen www.orbitalum.com...
ORBIWELD 25 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 OW 25 GC NOTICE! The ORBIWELD 25 GC is often used in areas of application where by default you work with tools in inch sizes.
ORBIWELD 25 GC 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 25 GC CAUTION Risk of falling due to being startled following electric shock when working at heights. In addition to fall injuries, the weld head and, where applicable, the clamping cassette can fall off and cause injuries. ► Before clamping the weld head on the workpieces switch the power supply to test mode.
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ORBIWELD 25 GC INFO The electrode has to be positioned centrally over the gap-free workpiece joint (7). Illustration: Gap-free hose joint 1. Open and turn down both clamping levers (1) and swivel brackets (2) to unlock the clamping cas- sette. 2.
ORBIWELD 25 GC Mounting the weld head in the clamping cassette ü The clamping cassette side plates are aligned. ü Clamping cassette (1) is clamped on the workpieces. ü Clamping levers (4) of the clamping cassette are locked. 1. Release rotating clamping handle (2) on the weld head (3). 2.
ORBIWELD 25 GC Attach drop guard to clamping cassette CAUTION Risk of falling due to being startled following electric shock when working at heights. In addition to fall injuries, the weld head and, where applicable, the clamping cassette can fall off and cause injuries. ►...
ORBIWELD 25 GC 8.10 Carry out gas 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.
ORBIWELD 25 GC 8.14 Dismantling clamping inserts and clamping cassettes Perform the work steps described in chapt. Mounting clamping inserts [} 48] and chapt. Mounting the weld head in the clamping cassette [} 52] in the reverse order. ORBITALUM TOOLS GmbH, D-78224 Singen www.orbitalum.com...
ORBIWELD 25 GC Operation Operator button panel ITEM CONTROL ELEMENT FUNCTION • Flashes red in the ready-to-weld state. • Lights up continuously red during the welding process. START/ • Pressing once: Starts the welding process. • Press during the welding process: Welding process is stopped STOP and gas post purge time is started.
ORBIWELD 25 GC Setting the welding parameters ► See operating instructions for the welding power source. Welding 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 supply.
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ORBIWELD 25 GC 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.
ORBIWELD 25 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. Preparing storage Carry out the following steps before storage: 1. Remove the electrode. 2.
ORBIWELD 25 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- mission is open at the head end for design reasons).
ORBIWELD 25 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. INTERVAL RESPECTIVE COMPO- ACTIVITY NENT Before every use Weld head, hose ►...
ORBIWELD 25 GC INTERVAL RESPECTIVE COMPO- ACTIVITY NENT Every 100 weld- Welding chamber ► Clean and remove residues. Depending on the soiling, ings or daily (clamping cassette), by using, for example, a wipe/alcohol/isopropyl, clean- rotor, basic body ing fleece or vacuum cleaner (do not use aggressive cleaning agents, as the surfaces might be damaged).
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ORBIWELD 25 GC NOTICE! Cleaning of the welding tongs should be carried out at least every 500 welding processes. Shorter cleaning intervals influence the equipment service life positively. Required cleaning materials: • Compressed-air vacuum unit or vacuum cleaner • Nylon brush •...
ORBIWELD 25 GC 6. Remount the clamping cassette and clamping inserts. 10.4 Troubleshooting PROBLEM POSSIBLE CAUSE REMEDY Welding process does No gas supply. ► Check the connections at the weld- not start. ing power supply. ► Check the forming gas supply and forming gas quantity.
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ORBIWELD 25 GC PROBLEM POSSIBLE CAUSE REMEDY Arc does not ignite. Excess electrical resistance arising 1. Clean the workpiece and clamping from soiling between the weld head insert. and the clamping inserts/clamping 2. Clean the contact surfaces be- cassette and workpiece. tween the weld head and clamp- ing inserts/clamping cassette and workpiece to clamping jaw/clamp-...
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ORBIWELD 25 GC PROBLEM POSSIBLE CAUSE REMEDY Arc ignites against parts Electrode worn. ► Replace the electrode. of the weld head. Electrode ground incorrectly. ► Regrind the electrode. (See chapt. Grinding electrode [} 67]) Poor electrode quality. ► Clean the weld head. Gas pre purge time too short.
ORBIWELD 25 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 0,01 - 0,2 mm (0.0004 - 0.008 in) 10.6 Service/Kundendienst The following data are required to order spare parts: •...
ORBIWELD 25 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. ► See product catalog "Orbital Welding" for a comprehensive overview of suitable accessories. Download links PDF: https://www.orbitalum.com/de/download.html ►...
ORBIWELD 25 GC 11.2 Clamping inserts Clamping inserts for OW 25 GC Made of stainless steel. Can only be used when clamping cassette OW 25 GC and other common or compatible clamping cassettes are used. 1 clamping insert consists of 2 half shells. Per clamping side of the clamping cassette you require 1 clamping insert (= 2 half shells).
ORBIWELD 25 GC 11.3 Hose package extensions Hose package extensions Fitting for all weld heads of Orbitalum, with exception of the AVC/ OSC versions of the ORBIWELD TP series. The Schweißstro- manschluss-Adapter-Set may be required for usage with older Or- bital welding power sources and heads with green Superior con- nections.
ORBIWELD 25 GC 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 25 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.
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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 Plot No.28/22, D-2 Block Tel. +1 856 579 8747...
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