ITW Orbitalum ORBICOOL MW Wiring diagram
ORBICOOL MW
2ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
Table of Contents
1 About these instructions................. 4
1.1 Warning messages .................. 4
1.2 Further icons and displays....... 4
1.3 Abbreviations ........................... 5
1.4 Further applicable documents.. 5
2 Information and safety instructions
for the owner ....................................
6
2.1 Using the machine ................... 6
2.1.1 Intended use .............. 6
2.1.2 Machine constraints... 7
2.1.3 Device cooling ........... 7
2.2 Environmental protection and
disposal....................................
8
2.2.1 REACh (Registration,
Evaluation, Authoriza-
tion and Restriction of
Chemicals).................
8
2.2.2 Coolant ...................... 8
2.2.3 Electric tools and ac-
cessories....................
9
3 Technical specifications.................. 10
4 Description ....................................... 12
4.1 Cooling unit.............................. 12
4.1.1 Warning signs ............ 13
4.2 Power supply ........................... 13
5 Transport and shipping ................... 14
5.1 Gross weight............................ 14
5.2 Shipping................................... 14
5.3 Transport.................................. 14
6 Setup and commissioning .............. 16
6.1 Unpack cooling unit.................. 16
6.2 Scope of delivery ..................... 16
6.3 Set up cooling unit ................... 17
6.4 Activate cooling unit in soft-
ware .........................................
17
6.5 Mounting .................................. 18
6.5.1 Power supply prepara-
tion .............................
18
6.5.2 Connect cooling unit
to power supply..........
19
6.6 Disassembly............................. 20
6.7 Coolant..................................... 20
6.8 Fill coolant tank ........................ 20
7 Maintenance and care...................... 22
7.1 Cleaning................................... 22
7.2 Maintenance schedule............. 22
7.3 Pumping out coolant ................ 23
7.4 Troubleshooting ....................... 25
8 Storage and decommissioning....... 26
9 Service and customer support ....... 27
9.1 Customer support .................... 27
9.2 Technical support & application
engineering ..............................
27
9.3 Operator and service training... 28
10 Ersatzteilliste / Spare parts list ....... 30
10.1 Grundaufbau OCMW | basic
structure OCMW ......................
30
10.2 Bodenplatte OCMW | Base
plate OCMW ............................
32
10.3 Rückwand OCMW | Rear panel
OCMW .....................................
34
10.4 Kühlmitteltank OCMW |
Coolant tank OCMW OCMW ...
36
10.5 Wärmetauscher OCMW | Heat
exchanger OCMW ...................
38
ORBICOOL MW
4ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
1 About these instructions
1.1 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.
WARNING LEVEL MEANING
DANGER Imminently hazardous situation that results in death or serious in-
juries if the safety measures are not observed.
WARNING! Potentially hazardous situation that may result in death or serious
injuries if the safety measures are not observed.
CAUTION Potentially hazardous situation that may result in slight injuries if
the safety measures are not observed.
NOTE! Potentially hazardous situation that may result in material damage
if the safety measures are not observed.
1.2 Further icons and displays
SYMBOL MEANING
Request for action in a sequence of actions: Action is required
here.
1.
2.
3.
…
Request for action in a sequence of actions: Action is required
here.
► Single request for action: Action is required here.
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 5
1.3 Abbreviations
ABBREVIATION MEANING
OC ORBICOOL
MW MOBILE WELDER
1.4 Further applicable documents
The following documents apply together with these operating instructions:
• MOBILE WELDER Instruction Manual with Parts List
ORBICOOL MW
6ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
2 Information and safety instructions for the owner
2.1 Using the machine
2.1.1 Intended use
WARNING Dangers result from improper use!
The device has been manufactured according to the state of the art and
the recognized safety regulations and standards for use in industry and
trade. It is intended only for the welding processes specified in these
operating instructions. If the device is not used as intended, it may pose
a risk to persons, animals and property. No liability is assumed for any
resulting damage.
► Device should only be operated as intended and by instructed, com-
petent personnel.
► Operate the device only with the MOBILE WELDER welding power
supply by Orbitalum Tools GmbH.
► Use the device only to cool orbital weld heads and welding torches.
► Operate the device only with the OCL-30 coolant by Orbitalum Tools
GmbH.
The cooling unit is intended solely for the following utilization:
Utilization in combination with an orbital welding power supply of type MOBILE WELDER and orbital
weld heads and manual and machine welding torches by Orbitalum Tools GmbH or with a compatible
third-party device in combination with a weld head adapter by Orbitalum Tools GmbH.
Proper use also includes the following points:
• Permanent supervision of the machine during operation. The operator must always be able to stop
the process.
• Observing all safety and warning information in these operating instructions.
• Observing of the further applicable documents.
• Complying with all inspection and maintenance work.
• Use of the machine solely in its original state.
• Usage solely of original accessories as well as original spare parts and operating materials.
• Usage solely of coolant OCL-30 of the company Orbitalum Tools GmbH.
• Checking of all the safety-relevant items and functions before commissioning.
• Solely commercial usage.
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 7
2.1.2 Machine constraints
• The device may only be set up and operated on a stable, level and non-slip surface.
• A radial freedom of movement for people of approx. 2 m around the device must be ensured.
• Work lighting: min. 300Lux.
• Climate conditions:
- Ambient temperature in operation: –10°C to 40°C (14°F to 104°F)
- Ambient temperature during storage and transportation: -20°C to 5°C (-4°F to 131°F)
• Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
• 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.
• Cooling is only ensured with a full coolant tank.
• High quantities of smoke, steam, oil vapors and grinding dust must be avoided.
• Avoid salty ambient air (sea air).
2.1.3 Device cooling
Insufficient ventilation leads to reduced performance and equipment damage.
► Observe the limits of the machine.
► Keep inlet and outlet openings of the cooling air unobstructed.
► Keep a minimum distance of 0.5 m from obstacles.
ORBICOOL MW
8ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
2.2 Environmental protection and disposal
2.2.1 REACh (Registration, Evaluation, Authorization and Restriction of
Chemicals)
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.
Our products are "products" in the sense of the REACh regulation. In accordance with Article33 of the
REACh regulation, suppliers of products must inform their customers if the supplied product contains a
substance specified in the REACh SVHC candidate list exceeding 0.1percent by mass of the object. On
June 27, 2018 lead (CAS: 7439-92-1 / EINECS: 231-100-4) was included in the SVHC candidate list.
This inclusion activates an obligation to inform along the chain of delivery.
We herewith inform you that individual partial components of our products contain lead in quantities ex-
ceeding 0.1% by mass of the object as an alloy component in steel, aluminum and copper alloys as
well as in solders and capacitors of electronic components. The lead content lies within the exceptions
specified in the RoHS Directive.
Since lead as an alloy component is firmly bound and therefore no exposure is to be expected in the
case of proper use, no additional specification of its safe use are required.
2.2.2 Coolant
Dispose of coolant in accordance with the local statutory regulations.
(as per RL 2012/19/EU)
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 9
2.2.3 Electric tools and accessories
Used-up power tools and accessories contain a large amount of valuable raw materials and plastics
which can be recycled:
• Used electronic devices marked with the adjacent icon may not be disposed of with household
waste in accordance with EU directives.
• By actively using the offered return and collection systems, you are doing your part to reuse and
recycle used electronic devices.
• Used electronic devices contain parts that must be handled selectively according to the EU
directive. 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.
• In the case of used electronic devices which may represent a risk to human health or safety due to
contamination during use, we have the option of refusing return.
•Important note for Germany: Devices and machines of Orbitalum Tools GmbH may not be
disposed of at communal dumps, as they are only used in the commercial sector.
ORBICOOL MW
10 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
3 Technical specifications
COOLING UNIT ORBICOOL MW UNIT VALUE
Code 854 030 100
Supply voltage (via power supply) [V (DC)] 24
Weight (without filled tank) [kg]
[lbs]
5.5
12.13
Dimensions L x W x H [mm]
[inch]
539 x 273 x 149
21.2 x 10.8 x 5.9
Power supplies compatibility ORBITALUM Mobile Welder
Cooling type Recirculation cooler
Cooling [W @ 0.9 l/min] 400
Max. feed rate [l/min] 0.9
Max. pressure [bar] 7.5
Max. tank capacity [l] 2.1
Degree of protection IP23S
Max. noise emission [dB(A)] 68
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 11
ORBICOOL MW
12 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
4 Description
4.1 Cooling unit
123
4
5
5
6
67
811
19
10
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 13
POS. DESIGNATION FUNCTION
1 Mounting base, rear Cooling unit power supply connecting element
2 Mounting base, front Cooling unit power supply connecting element
3 Coolant connection, red Connection for coolant return line
4 Coolant connection, blue Connection for coolant flow line
5 Air inlet Inlet opening for cooling air
6 Device foot Secure stand for cooling unit
7 Air outlet Outlet opening for cooling air
8 Coolant level display Indicates the fill level of the coolant in the tank.
9 Tank opening with lid Filling opening for coolant, coolant tank closure.
10 “Signals” connection socket Connection for cooling unit power supply connecting cable
11 Oval-head screws M4x10 Cooling unit power supply connecting element
4.1.1 Warning signs
The warning signs and safety signs located on the machine must be observed.
The warning signs are part of the machine. They must not be removed or modified. Missing or illegible
warning signs must be replaced immediately.
IMAGE POSITION ON MACHINE MEANING CODE
Rear panel Use original OR-
BITALUM cooling liquid
only!
854 060 052
4.2 Power supply
1
3 (4x)3 (4x) 2
Illustration: Mobile Welder mounting plate underside
POS. DESIGNATION FUNCTION
1 Mounting plate Cooling unit power supply connecting element
2 Countersunk screw M4x8 Cooling unit power supply connecting element
ORBICOOL MW
14 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
5 Transport and shipping
WARNING Improper transport
Permanent damage to the cooling unit.
► Transport the cooling unit only in a suitable, all-round protective and
shockproof outer packaging.
CAUTION Risk of accidents from falling and tripping hazards
During transport, supply lines that are not disconnected can cause haz-
ards, such as connected devices tipping over and causing injury to peo-
ple.
► Climate conditions during storage and transportation, see the chapter Machine constraints [}7]
5.1 Gross weight
ITEM WEIGHT* UNIT
ORBICOOL MW, incl. scope of delivery 14.00 kg
30.86 lbs
* incl. original ORBITALUM shipping cartons
5.2 Shipping
Transport the cooling unit only in a suitable, all-round protective and shockproof outer packaging, e.g.
the original ORBITALUM shipping cartons.
For some types of transport, liquid-free shipping of equipment is required.
In this case, completely empty the coolant tank before transportation. See the chapter Pumping out
coolant [}23]
5.3 Transport
WARNING Danger of accident from loose fastening screws
The cooling unit can detach from the power supply and cause serious
injury.
► Before installing, remove any dirt from the feet of the power supply
and the connecting elements.
► Before transporting, check the fastening screws between the power
supply and the cooling unit for secure fit; tighten if necessary.
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 15
WARNING Risk of accident from impermissible transport by crane
The device may drop and injure people.
► Do not transport the device by crane.
► Use handles, straps or holders for hand transport only.
ORBICOOL MW
16 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
6 Setup and commissioning
6.1 Unpack cooling unit
1. Take accessories and coolant from the cardboard packaging.
2. Take cardboard cover from the cardboard packaging.
3. Lift cooling unit out of the cardboard packaging and place upright on a stable, non-slip surface.
4. Check the cooling unit and accessories for transport damage.
NOTICE ► Report any damage to your power supply immediately.
6.2 Scope of delivery
ITEM CODE QUA
NTITY
UNIT
Cooling unit ORBICOOL MW 1 PCS.
Cooling liquid OCL-30 3.5l/118.3floz 850 030 010 1 PCS.
Hose bridge 875 030 016 1 PCS.
Hexagon screwdriver 2.5x60 823 020 031 1 PCS.
Connection line MW-OCMW 854 040 100 1 PCS.
Mounting plate, cooling unit 854 020 019 2 PCS.
Countersunk screw M4x8 ISO10642-A2 302 303 118 10 PCS.
Oval-head screw ISO7380-M4x10-A2 307 001 112 3 PCS.
Instruction Manual with OR-
BICOOL MW Parts List
Download link PDF:
https://www.orbitalum.com/
de/download.html
854 060 250 Unlim-
ited
(PDF)
PCS.
MOBILE WELDER QuickStart Guide 854 060 102 1 PCS.
General safety instructions welding power sources 854 060 101 1 PCS.
“UPGRADE LICENSE” activation documentation Depending on MOBILE
WELDER starting equip-
ment
1 PCS.
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 17
We reserve the right to make changes.
► Check the delivery for completeness and damage caused by transport.
► Report any missing parts or damage caused by transport to your supplier immediately.
6.3 Set up cooling unit
► Place cooling unit upright on a stable, level, non-slip and non-combustible surface.
► Operate the cooling unit only in an upright position!
Operation in non-approved positions may cause damage.
► Set up only in a dry environment.
►Climate conditions, see the chapter Machine constraints [}7]
► Work lighting: min. 300Lux.
6.4 Activate cooling unit in software
üIn order to be able to use the cooling unit, it must first be activated in the power supply software.
► For detailed information on software navigation, see the user manual of the power supply.
NOTICE ► The activation keys are coupled with a power supply serial number.
Activation can therefore only take place on the associated power
supply! You can find the activation key and the matching power sup-
ply serial number on the purchased activation document (“UP-
GRADE LICENSE”).
Procedure:
► From the main menu of the power supply, navigate to "System Settings" > "Activation”.
ORBICOOL MW
18 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
4
3
2
1
5
1. Enter the activation key (2) in the text input field (3).
2. Confirm the entry by pressing the "Activation" menu button (4).
ðSuccessful activation is indicated by a teardrop icon (5) in the menu header.
NOTICE If an error message is displayed:
► Check whether the activation key entered matches the activation
key provided in the documentation.
► Check whether the serial number specified in the activation docu-
mentation matches the serial number of the power supply.
6.5 Mounting
6.5.1 Power supply preparation
1. Disconnect power supply from mains/pull power plug.
2. Place power supply on its side on a clean, non-abrasive base.
1
3 (4x)3 (4x) 2
Illustration: MOBILE WELDER underside
3. Mount front (1) and rear (2) mounting plate to power supply underside, each with four M4x8 (3)
countersunk bolts. Use bolt and hexagon screwdriver included in the scope of delivery.
ORBICOOL MW
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 19
6.5.2 Connect cooling unit to power supply
WARNING Danger of accident from loose fastening screws
The cooling unit can detach from the power supply and cause serious
injury.
► Before installing, remove any dirt from the feet of the power supply
and the connecting elements.
► Before transporting, check the fastening screws between the power
supply and the cooling unit for secure fit; tighten if necessary.
1. Place cooling unit upright on a stable, non-slip surface.
2. Carefully place power supply on the cooling unit diagonally from above, thereby leading the metal
lip of the front mounting base (4) of the cooling unit into the slot of the front mounting plate (1) of
the power supply.
1
4
► Bolt power supply and cooling unit to the rear of the device with two M4x10 oval-head screws (5).
Use bolt and hexagon screwdriver included in the scope of delivery.
5
6
► Mount connecting cable (6) between power supply and cooling unit.
ORBICOOL MW
20 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
6.6 Disassembly
For disassembly follow the steps of the chapter Connect cooling unit to power supply [}19] in reverse
order.
6.7 Coolant
NOTICE ► Operate the device only with the OCL-30 coolant by Orbitalum Tools
GmbH.
► Mixing with other liquids or use of other coolants can lead to dam-
age.
► Regularly check coolant level.
► Always completely replace coolant.
► Do not allow coolant to escape into the sewage system or waters.
► The coolant must be disposed according to local regulations and
taking into account the coolant safety data sheet.
► Immediately clear up any spilled coolant and dispose correctly.
6.8 Fill coolant tank
NOTICE Check and, if necessary, refill the coolant level before welding.
► Ensure that the power supply is not connected to the mains network
during refilling.
NOTICE Cooling is only ensured with a full coolant tank.
► Please adhere to the following steps, otherwise the pump could be
damaged by running dry.
2
3
4
1
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