ITW Orbitalum ORBIMAT 165 CA User manual

Operating instructions
For responsible bodies and persons using the machine
Orbital Welding Power Supplies
ORBIMAT 165 CA
ORBIMAT 300 CA
Machine no.:
To work safely with this machine, please
read through the operating instructions in
full before initial operation.
Retain the operating instructions for future
reference.
Code 871 060 202 | EN | Translation of original operating instructions

All rights reserved, in particular the rights of duplication and distribution as well as translation. Duplication and reproduction in any form (print, photo-
copy, microfilm or electronic) require the written permission of Orbitalum Tools GmbH.

ORBIMAT CA | Operating instructions
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
1. About these instructions ......................................5
1.1 Warning messages.....................................5
1.2 Further symbols and displays.....................5
1.3 Abbreviations ............................................6
1.4 Warning symbols .......................................6
2. Information and safety instructions for the
responsible body .................................................7
2.1 Requirements for the responsible body.......7
2.2 Using the machine .....................................7
2.2.1 Proper use .......................................7
2.2.2 Improper use ...................................7
2.2.3 Machine constraints.........................7
2.3 Environmental protection/disposal.............8
2.3.1 Electric tools and accessories...........8
2.4 Basic safety instructions............................8
3. Product design...................................................12
3.1 ORBIMAT 165 CA......................................12
3.2 ORBIMAT 300 CA......................................12
3.3 Accessories .............................................13
4. Features and scope of application.......................16
4.1 Features ..................................................16
4.2 Additional characteristics.........................16
4.2.1 ORBIMAT 165 CA............................16
4.2.2 ORBIMAT 300 CA AC/DC.................16
4.2.3 ORBIMAT 300 CA AVC/OSC.............17
4.3 Functional description..............................17
5. Technical specifications .....................................18
6. Initial operation .................................................19
6.1 Checking the parts of delivery ..................19
6.2 Included with the machine........................19
7. Set-up and assembly..........................................20
7.1 Control elements......................................20
7.1.1 Overview of the main control
elements .......................................20
7.1.2 Connections and control elements
on the front panel ..........................20
7.2 Operating concept....................................22
7.2.1 Operation via rotary knob...............22
7.2.2 Operation via push switches
(softkeys) ......................................22
7.2.3 Operation via an external keyboard .. 22
7.3 Connection of the power source................23
7.3.1 Setting up machine........................23
7.3.2 Connecting a gas bottle .................23
7.3.3 Connecting weld head....................23
7.3.4 Detaching water hoses...................24
7.3.5 Pumping out coolant ......................24
7.3.6 Closing off gas hose.......................24
7.4 Initial operation .......................................25
7.4.1 Adding coolant...............................25
7.4.2 Commissioning the power source ...26
8. Operation ..........................................................29
8.1 Auto programming ...................................29
8.1.1 Setting parameters ........................29
8.1.2 Configuring weld head ...................29
8.1.3 Configuring material ......................30
8.1.4 Configuring protective gas .............30
8.1.5 Configuring pipe diameter..............31
8.1.6 Configuring wall thickness .............31
8.1.7 Configuring wire feed.....................31
8.1.8 Calculating procedure ....................31
8.2 Testing the procedure...............................32
8.2.1 Preparing weld head ......................32
8.2.2 Preparing electrode .......................32
8.2.3 Turning weld head..........................32
8.2.4 Connecting forming gas .................33
8.2.5 Welding .........................................34
8.2.6 Interrupting the welding process ....36
8.3 Adjusting the procedure ...........................36
8.3.1 Reasons and steps for adjusting
procedure ......................................36
8.3.2 Making percental changes..............37
8.3.3 Adjusting individual parameters.....37
8.3.4 Adjusting gas times .......................37
8.3.5 Adjusting ignition current, end
current and current slope-off..........38
8.3.6 Adjusting the pool formation time ..39
8.3.7 Adjusting welding current and
transition times ("Slope")...............39
8.3.8 Adjusting pulse times ....................41
8.3.9 Adjusting weld speed and transition
time ("Slope")................................41
8.3.10 Changing the sector .......................43
8.4 Saving and calling up a procedure ............45
8.4.1 Saving a procedure ........................45
8.4.2 Calling up a procedure .................. 46
8.5 Locking machine with key switch............. 46
8.6 Tacking function.......................................47
8.7 Using the second gas pressure level
("flow force") .......................................... 48
8.8 Connecting supplementary devic..............49
8.8.1 ORB Residual Oxygen Meter ...........49
8.8.2 Connecting and configuring the
BUP control unit.............................49
8.8.3 TIG manual welding torch ...............50
8.8.4 External remote control..................51
8.8.5 External printer (A4).......................51
8.8.6 External monitor/LCD (VGA)............52
8.9 Monitoring functions................................52
8.9.1 General information .......................52
8.9.2 Adjusting limit values.....................52
TABLE OF CONTENTS

ORBIMAT CA | Operating instructions
4orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
8.10 Data documentation and data
management............................................54
8.10.1 Managing data...............................54
8.10.2Entering comments and application
data ("Process details") .................55
8.10.3Working with external memory
cards .............................................56
8.10.4Viewing and printing data ..............57
8.10.5 Editing data on a PC with the
"OrbiProgCA" supplemental
software........................................59
8.11 Updating and backup functions for the
software..................................................59
8.12 Updating software components................59
8.13 Saving software components .................. 60
8.14 Restoring software components .............. 60
8.15 Working in other languages..................... 60
8.15.1 Changing the languag ................... 60
8.15.2 Printing data in another language..... 61
8.15.3 Creating a new operating language... 61
8.16 Importing programs from other Orbitalum
power sources .........................................61
8.16.1 Importing procedures.....................61
8.17 Special keyboard commands....................62
8.18 Operation of the system with other mains
voltages (OM 165 CA only)........................62
9. Service and troubleshooting...............................63
9.1 Performing service work...........................63
9.1.1 Pumping out coolant ......................63
9.1.2 Performing motor calibration..........63
9.1.3 Adjusting an external printer ......... 64
9.1.4 Switching on an internal printer......65
9.1.5 Printing a test page....................... 66
9.1.6 Service Screen.............................. 66
9.1.7 Info............................................... 66
9.2 Possible application/operating errors.......67
9.2.1 Uneven weld seam ("current
fluctuations") ................................67
9.2.2 Annealing colors inside/outside .....67
9.2.3 Wide seam and no weld
penetration....................................67
9.2.4 Uneven seam/hole formation at the
end of welding .............................. 68
9.2.5 Ignition problems.......................... 68
9.2.6 Machine does not start ..................69
9.3 List of error messages ..............................69
9.4 Status LED indicators ...............................73
9.4.1 Meaning of the LEDs.......................74
9.5 Temporarily deactivating sensors and
monitoring functions................................76
9.5.1 Sensors .........................................76
9.5.2 Monitoring limits ...........................76
9.5.3 External input for aborting .............76
9.6 Setting date and time...............................77
10. Servicing, maintenance, troubleshooting............78
10.1 Maintenance............................................78
10.1.1 Maintenance intervals....................78
10.1.2 Storage..........................................79
10.2 Servicing/customer service ......................79
11. Overview wiring diagram................................... 80
12. EC Declaration of conformity...............................81
12.1 ORBIMAT 165 CA, ORBIMAT 300 CA ..........81

ORBIMAT CA | Operating instructions About these instructions
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
1. ABOUT THESE INSTRUCTIONS
To allow quick understanding of these instructions and safe handling of the machine, all the warning messages, notes
and symbols used in these instructions are presented here along with their meaning.
1.1 Warning messages
In these instructions, warning messages are used to warn you against the dangers of injury or material damage.
Always read and observe these warning messages!
This is a warning symbol. It should warn you against dangers of injury.
Follow all instructions which are identified with this safety symbol in order to avoid injuries or death.
Warning symbol Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
[Restrictions (if applicable).
XMeasures to prevent danger.
WARNING
Possible danger!
Non-observance could result in serious injury.
[Restrictions (if applicable).
XMeasures to prevent danger.
ATTENTION
Dangerous situation!
XNon-observance could result in minor injuries.
ATTENTION Dangerous situation!
XNon-observance could result in material damage.
1.2 Further symbols and displays
Symbol Meaning
IMPORTANT
NOTE
Notes: Contain particularly important information for comprehension.
Instruction: You must take notice of this symbol.
1. Request for action in a sequence of actions: You have to do something here.
Single request for action: You have to do something here.
Conditional request for action: You have to do something here if the specified condition is met.

About these instructions ORBIMAT CA | Operating instructions
6orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
1.3 Abbreviations
Abbr. Meaning
OM, CA ORBIMAT, CAdvanced
1.4 Warning symbols
Observe all of the warnings and safety instructions affixed to the machines.
The following labels also appear on the machine:
Image Machine model Position on machine Meaning Code
ORBIMAT 165 CA
ORBIMAT 300 CA
Rear DANGER:
Danger of injury from
electric shock.
–
ORBIMAT 165 CA
ORBIMAT 300 CA
Rear DANGER:
Danger of injury from
electric shock.
–

ORBIMAT CA | Operating instructions Information and safety instructions for the responsible body
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
2. INFORMATION AND SAFETY INSTRUCTIONS FOR THE
RESPONSIBLE BODY
2.1 Requirements for the responsible body
Workshop/outdoor/field application: The responsible body is responsible for safety in the danger zone around the
machine, and should allow only qualified personnel to enter the zone or operate the machine in the danger zone.
Employee safety: The safety regulations described in chap. 2 must be observed and work must be carried out with
safety in mind using the prescribed protective equipment.
2.2 Using the machine
2.2.1 Proper use
• The machines (Power Sources CA/CB 165/300 and Orbitwin in conjunction with the orbital weld
heads of the OW/OWS/TP/P/OP/HX series and the accessories recommended by the manufac-
turer) are used for the welding of ferritic, uncoated pipes up to the pipe circumferences speci-
fied by the heads and maximum possible pipe walls using the Tungsten Inert Gas process (TIG)
with a direct current arc, and if specified, with an alternating current arc.
• The machine may only be used on tubes and containers that are empty, unpressurized, do not
have explosive atmospheres and are not contaminated.
Proper use also includes the following:
• observing all safety instructions and warning messages included in these operating instructions
• carrying out all inspection and maintenance work
• sole use in the original condition with original accessories, spare parts and materials
• processing only materials set out in the operating instructions
2.2.2 Improper use
• A use other than that defined under "proper use" or a use that goes beyond this or the specified
constraints shall be considered improper use due to the potential risks involved.
• The responsible body shall be solely responsible for damages that arise through improper use
and the manufacturer shall assume no liability whatsoever.
• No tools should be used that have not been authorized by the manufacturer for this machine.
• The removal of safety equipment is not permitted.
• Do not misuse the machine.
• The machine is not intended for use by private consumers.
• The technical values defined for normal operation must not be exceeded.
2.2.3 Machine constraints
• Keep your working area clean. Disorder or unlit working areas can lead to accidents.
• The workplace can be in tube preparation, in plant construction or in the plant itself.
• A radial space requirement/freedom of movement of approx. 2 m around the machine is required for people.
• Work lighting: min. 300 lux.
• Operator age: at least 14 years old and without physical impairments.
• Qualification of operating personnel: Instructed person with professional training in welding technology.
• Operation by one person.

Information and safety instructions for the responsible body ORBIMAT CA | Operating instructions
8orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
• Climate conditions: Temperature range for machine operation: –10 °C to 40 °C (< 70% rel. humidity).
Temperature range for machine storage: –20 °C to 40 °C, (< 70% rel. humidity)
• Only work with the machine in dry surroundings (not in misty, rainy or stormy conditions).
Cooling is only ensured with a full water tank.
2.3 Environmental protection/disposal
2.3.1 Electric tools and accessories
XClean machine properly before disposal.
Discarded electric tools and accessories contain large quantities of valuable raw and synthetic
materials that can be recycled. Therefore:
• Electrical (electronic) devices that are marked with the symbol to the left may not be
disposed of with household waste in accordance with EU regulations.
• By actively using the available return and collection systems, you actively contribute to the
reuse, recycling and utilization of electrical (electronic) devices.
• Used electrical (electronic) devices contain parts that must be handled selectively according
to EU regulations. Separate collection and selective treatment is the basis for environment-
friendly disposal and the protection of human health.
• Appliances and products that you bought from us after August 13, 2005 will be disposed of
in accordance with legal standards after they have been supplied to us at no cost.
• We may refuse to accept old appliances that pose a risk to human health or safety due to
contamination produced during use.
• The end user is responsible for disposing of used appliances introduced to the market
before August 13, 2005. Please contact a disposal center near you for this purpose.
• Important for Germany: our products may not be disposed of in municipal disposal sites as
they are only used for industrial purposes.
(as per RL 2002/96/EC)
2.4 Basic safety instructions
The machine (hereinafter referred to as the ORBIMAT 165 CA or ORBIMAT 300 CA) is a state-of-the-art machine designed
for safe use. The risks involved in using the machine are described in the operating instructions below. Using this machine
in a way other than that described in these instructions can lead to serious physical injury and material damage.
Therefore:
• Observe warning messages at all times.
• Keep complete documentation close by the machine.
• Generally valid regulations for the prevention of accidents must be observed.
• Observe country-specific regulations, standards and guidelines.
• Always ensure that the machine is in good working order. Observe the maintenance information (see chap. 10, p. 78).
• Only operate the machine if all the safety equipment are in good working order and the machine is firmly positioned.
Check whether the substrate is able to take sufficient loads.
• Report any unusual machine behavior to the person responsible immediately.
• Only use the dimensions and materials specified in these instructions. Other materials should be used only after
consulting with Orbitalum Tools customer service.
• Use only original tools, spare parts, materials and accessories from Orbitalum Tools.
• Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
• At the end of each working cycle, before transportation, changing tools, cleaning and performing any maintenance,
adjustment or repair work, switch off the machine, allow it to run to a stop and pull the mains plug.
• Do not carry the machine by the hose package or the cable and do not use the machine to pull out the plug except
in an emergency. Protect the cable from heat, oil and sharp edges (chips).

ORBIMAT CA | Operating instructions Information and safety instructions for the responsible body
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
• During operation, keep hands away from the tools.
• Check that the tube is correctly clamped.
• Switch on the machine only when the tube has been clamped.
• Do not use the machine in wet surroundings. Only work in canopied surroundings.
• In extreme conditions of use, conductive dust can settle inside the machine. For this reason and for better safety,
an on-site SPE-PRCD or a sensitive to all types of current ground-fault circuit or a isolating transformer is required
between the mains network and the machine, to be checked and installed if necessary by a professional electrician.
• When working with the machine, wear safety shoes (in accordance with EN ISO 20345, at least S1).
NOTE The recommendations concerning "Personal protective equipment" only apply
to the product being described. Other requirements resulting from the ambient
conditions on-site or of other products, or from combining with other products,
are not taken into account. These recommendations do not in any way release
the responsible body (employer) from its statutory health and safety at work
obligations towards its employees.
DANGER
Dangers of operation by multiple persons!
Various injuries and damage to property.
XHave one person operate the machine and weld head.
DANGER
Dangers of improper maintenance of the system!
Various injuries and damage to property.
XCarry out maintenance as described in the "Maintenance" chapter, see chap. 10, p. 78.
DANGER
Electrical hazards through touching and incorrect or damp safety equipment!
Electric shock.
[Do not touch energized parts (pipe), especially when igniting the arc.
[Do not allow persons with increased sensitivity to electrical hazards (e.g. weakness of the
heart) to work with the machine.
XWear dry safety shoes, dry metal-free (grommet-free) leather gloves and dry safety suits to
minimize the electrical hazard.
XWork on a dry surface.
DANGER
Accidental ignition!
Electric shock.
XSwitch off the orbital welding power source when connecting or disconnecting a weld head.
DANGER
Incorrect handling of pressure tanks and other parts of the system (e.g. forming gas bottle)!
Various injuries and damage to property.
XHeed safety regulations, especially those for pressure tanks.
XComply with safety data sheets.
XIf the system and its components exceed 25 kg in weight, lift using several people or lifting
equipment.
DANGER
Flammable material near the welding zone or solvent in the room air!
Danger of explosion and fire.
[Do not weld near solvents (e.g. where painting is being carried out).
[Do not weld near explosive substances.
[Do not use flammable materials as a base in the welding area.
XEnsure that no flammable materials or soiling is located near the machine.
DANGER
Faulty ignition in case of non-connected or incorrectly positioned weld head!
Electric shock, bodily injury and damage to property at other devices as well.
[Do not play with weld head.
XIf the weld head is not ready for operation, switch it to the "Test" function.

Information and safety instructions for the responsible body ORBIMAT CA | Operating instructions
10 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
DANGER
Improper access to and opening of the machine!
Electric shock.
XDisconnect system from mains.
XDisconnect all external devices connected to the machine (weld heads etc.).
XAllow machine to cool down sufficiently before opening.
XAllow only a professional electrician to access the electrical system.
[Never connect an opened system to the mains network.
DANGER
Liquid in the housing due to improper use and transport!
Electric shock.
[Do not place liquids (e.g. drinks) on the system.
XDo not block ventilation slots.
XCheck housing interior for moisture after transporting the machine and leave it open to air it
out if necessary.
DANGER
Risk of danger through the use of the machine outdoors!
Fatal electric shock.
[Do not use the machine outdoors.
DANGER
Damaged plugs!
Electric shock.
[Do not use adapter plugs together with protectively grounded power tools.
XEnsure that the connecting plugs of the machine fit into the outlet.
DANGER
Loose/baggy clothing, long hair or jewelry can get caught in rotating machine parts!
Serious injury or death.
XWear tight-fitting clothing when using the machine.
XTie up long hair to prevent it from being caught.
DANGER
Defective safety components due to soiling, breakage and wear!
The failure of safety components can cause physical injury.
[Do not misuse the cable, e.g. such as using it to suspend or carry the machine.
XReplace defective safety components immediately and check them daily to ensure proper
operation.
XHave an expert replace defective power cables immediately.
XClean and perform maintenance on the machine after each use.
XKeep cables away from heat, oil, sharp edges and moving equipment parts.
XInspect the machine daily for visible signs of damage or defects, and have them repaired by a
specialist if necessary.
WARNING
Danger of system (e.g. ORBICAR welding carriage, gas bottle, welding power source, cooling
unit) tipping over from the application of force from outside!
Various injuries and damage to property.
XSet up machine so that it stands securely against external influences.
XKeep moving masses at least 1 meter away from the machine.
WARNING
Electromagnetic incompatibility of surrounding devices during high-frequency ignition and de-
vices in operation without a protective ground!
Various injuries and damage to property.
XUse only electrical devices with protective insulation in the working area of the welding system.
XObserve electromagnetically-sensitive devices when igniting the system.
WARNING
Ultraviolet radiation from the arc while welding!
Damage to eyes and burning of skin.
XDuring operation, wear eye protection as per EN 170 and skin-covering safety clothing.
XWith closed weld heads, ensure proper working order of the eye protection.
WARNING
Hot, leaking liquids and hot plug connections during heavy operation!
Danger of scalding.
XHeed the safety precautions of the technical supervisor/person in charge of safety.

ORBIMAT CA | Operating instructions Information and safety instructions for the responsible body
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
WARNING
Poisonous vapors and substances during the welding process and handling of the electrodes!
Health problems, including cancer.
XUse extraction devices as per the professional association regulations (e.g. BGI: 7006-1).
XExtra caution is required with chrome, nickel and manganese.
[Do not use electrodes containing thorium.
ATTENTION
Hot surfaces of the weld head and weld points, including for a period of time after welding!
Danger of burns.
XWear safety gloves.

Product design ORBIMAT CA | Operating instructions
12 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
3. PRODUCT DESIGN
3.1 ORBIMAT 165 CA
11
10
9
8
7
4
3
2
5
6
1
1. Display housing
2. Printer cover
3. Intregrated printer
4. Rotary knob
5. Multicard reader
6. Flowmeter
7. Front panel
8. Main switch
9. Hood
10. Softkeys
11. Display 10.5"
For a detailed description
of the different operating
elements (buttons, switches
and connectors), see chap.
7.1, p. 20.
3.2 ORBIMAT 300 CA
11
1
10
9
8
2
3
4
5
6
7
1. Display housing
2. Printer cover
3. Integrated printer
4. Rotary knob
5. Multicard reader
6. Flowmeter
7. Front panel
8. Main switch
9. Hood
10. Softkeys
11. Display 10.5"
For a detailed description
of the different operating
elements (buttons, switches
and connectors), see chap.
7.1, p. 20.

ORBIMAT CA | Operating instructions Product design
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
3.3 Accessories
Not included as standard.
WARNING
Danger presented by using poor-quality accessories and tools not approved by Orbitalum Tools!
Various injuries and damage to property.
XUse only original tools, spare parts, materials, and accessories from Orbitalum Tools.
Article Description Version Code Figure
ORBICAR W trolley with
integrated water coolant
The perfect accessory for the Orbitalum 300 A
power supplies.
In addition to the water cooling the trolley has
a gas bottle holder.
For ORBIMAT 300 CB, 300 CA,
300 CA AC/DC, 300 CA AVC/
OSC
884 000 002
For ORBIMAT 165 CA*, 165 CB
* The ORBIMAT 165 CA has to be
modified in our plant.
884 000 004
ORBICAR S trolley A practical trolley with storage shelf and an
option of securing a gas cylinder.
The ORBICAR S trolley can be combined with
all power supplies of the ORBIMAT series.
This trolley is most commonly used an orbital
welding power supply of the ORBIMAT 165 A
series.
884 000 001
ORBICOOL Active Very efficient compressor cooling device with
constant and adjustable water temperature.
Including water flow sensor. Significantly
increases cooling performance for the weld
heads. Particularly suitable for welding units in
series production.
Suitable for all* ORBIMAT orbital welding
power supplies.
For ORBIMAT 165 CA*/CB
* The ORBIMAT 165 CA has to be
modified in our plant.
889 000 001
For ORBIMAT 300 CA/CB 889 000 002
ORBITWIN switching
device
To increase productivity, the switching unit
ORBITWIN is available, with which 2 welding
heads can be operated alternately on the OR-
BIMAT. The previously assigned program is
recalled automatically when the start key of
the weld head is actuated. The welding
head that is not being used is locked and can
be prepared for the next welding operation.
Including connection cables and hoses.
For ORBIMAT 165 CA 861 000 001
For all ORBIMAT 300*
* not suitable for AVC/OSC machines.
876 000 001
Oxygen meter ORBmax NEW optical oxygen measurement method by
fluorescence quenching.
The ideal complement for orbital welding!
• No warm-up time required
• Quick response
• High measurement accuracy
• Measurement of residual oxygen level during
the welding process
• No uncontrolled increase of the measure-
ment during the welding process
• Measurement of forming gas with variable
hydrogen content without mode change
• Measurement of the residual oxygen value in
all gas mixtures
• Measured value recording on SD card
• User-friedly touchscreen
100 - 240 V, 50/60 Hz 882 000 002

Product design ORBIMAT CA | Operating instructions
14 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
Article Description Version Code Figure
Oxygen Meter
ORB 1001
• To determine the residual oxygen in the
forming gases.
• Maintenance-free.
• Complete in a dust-and water-proof trans-
port container.
• User-definable settings of the switching
value for alarm and process control.
• Display in PPM.
• Acoustic signal if the set value has been
exceeded.
• RS-232 interface to the PC link.
• Integrated suction pump.
• Simple control of the forming gas in the
residual gas content.
• Can be used for ARGON and all common
forming gas mixtures (with the exception
of flammable mixtures)
230/115 V, 50/60 Hz,
1-phasig
882 000 001
Remote control with cable Suitable for all ORBIMAT orbital welding
power supplies (the and ORBIMAT 300
CA AVC/OSC already include the remote
control).
Is required when connecting closed orbital
weld heads.
Cable length: 7.5 m (24.6 ft) 875 050 001
BUP Control Box The power supplies of the ORBIMAT CA-
series offer the option in conjunction with
the BUP control attachment to adjust the
forming gas pressure in the inner tube via
a pressure sensor, which compensates
almost entirely for the often otherwise an-
noying entry of the seam weld into the sump
position. At the same time, the gas pressure
is modified automatically during welding
by the system between a programmable
minimum and maximum value depending on
the position of the electrodes.
Including ORBIPURGE forming set for tube
ID 12 - 110 mm (0.472" - 4.331").
For ORBIMAT 165 CA, 300 CA 886 000 001
Coolant OCL-15 Pre-Mix for ORBIMAT power sources and cool-
ing systems, to avoid freezing of the cooling
water. Protects undilated up to –15 °C (5 F)
degree.
Extended life of cooling system with corro-
sion protection and high pH-value.
Low conductivity. Clear coolant liquid.
Applicable for ORBICAR W, ORBICOOL Active,
ORBIMAT 165 CB and ORBIMAT 165 CA.
Canister with 2000 ml
(67.6 fl oz)
875 030 015
Durable carrying case With castors. Protects the power supply
during transport. Ideal for use on construc-
tion sites.
For ORBIMAT 165 CB, 165 CA 875 050 002
For ORBIMAT 300 CB, 300 CA,
300 CA AC/DC
874 050 001
ORBIPURGE forming set • The forming set for tube ID 12 - 110 mm
(0.472" - 4.331") includes all accessories
for fast and efficient internal forming dur-
ing orbital welding.
• The various stoppers match the internal
diameter of the tube exactly and therefore
from an optimally sealed forming gas
chamber.
• Complete with Teflon gas hose and rapid-
action couplings.
881 000 001
CompactFlash Card For storing weld data protocols or for extend-
ing the program memory (one is already
included in the soft/hardware package.
Capacity to store over 5,000 welding pro-
grams.
875 012 056

ORBIMAT CA | Operating instructions Product design
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
Article Description Version Code Figure
Soft-/Hardware package Suitable for all ORBIMAT orbital welding
power supplies. For external programming
and data documentation, consisting of:
• 1 CompactFlash card 32 MB for transfer-
ring data between the machine and PC.
• 1 USB card reader for exporting the
CompactFlash card on the PC (no further
device required).
• ORBIPROG_CA software allows programs
and protocols to be stored on the PC.
875 050 003
Paper rolls For the integrated ORBIMAT printer.
Suitable for all ORBIMAT orbital welding
power supplies.
Contains 3 paper rolls 875 050 017
Ribbon cartridges For the integrated ORBIMAT printer. For ORBIMAT CA 875 030 004
For ORBIMAT CB 875 030 002
Warning symbols Overview of warning symbols with order
numbers, see chap. 2.

Features and scope of application ORBIMAT CA | Operating instructions
16 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
4. FEATURES AND SCOPE OF APPLICATION
4.1 Features
The ORBIMAT CA-series is distinguished by the following characteristics:
The ORBIMAT CA series of orbital welding power supplies are equipped with an unique operating concept. In addition to
the reliable automatic programming which generates welding parameters by entering the tube diameter, wall thickness,
material, and welding gas all ORBIMAT CA models also have the"FLOW FORCE" function to reduce the pre-flow gas time
when the weld heads are closed as well as the "BUP control" function with controllable, position-dependent tube internal
pressure control as an optional extra.
• Simple and convenient operation thanks to multifunctional rotary actuator.
• Control option for cold wire feed.
• DC welding.
• Optimal visibility and operating conditions thanks to clearly laid-out 10.5" swivel monitor.
• Graphically-supported operating interface and multilingual menu navigation via color display.
• Capacity to store over 5,000 welding programs, providing systematic and clear program management thanks to the
creation of folder structures.
• Welding data logging and printout of actual values.
• A multicard reader enables data to be transferred easily to an external PC.
• It is possible to extend memory and data exchange using CompactFlash card (CF), SD, MMC, Sony memory stick.
• (Optional) PC-offline software with the capability to convert data protocols to PDF.
• Extremely easy to service thanks to PSS (Pro Service System):
– Simple functional test with no need to open the unit.
– Easy to service and components can be replaced quickly thanks to systematic component structure.
• Power and motor slope adjustment between the individual sectors.
• Coolant water and welding gas are monitored.
• Option to program up to 99 sectors.
• Possibility of connecting a monitor or printer (through VGA).
• Integrated printer.
• Metric and imperial units.
4.2 Additional characteristics
4.2.1 ORBIMAT 165 CA
• Integrated water cooling system for cooling the connected weld heads.
• WIDE RANGE input voltages for safe operation of power sets or voltage networks with extreme fluctuations in voltage.
4.2.2 ORBIMAT 300 CA AC/DC
• Option of AC welding.
• Option to set a positive and negative half-cycle in the ratio 20 - 80%.
• Frequency setting 50 - 200 Hz.
• Detection of actual values for the welding reports in the DC regime.

ORBIMAT CA | Operating instructions Features and scope of application
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
4.2.3 ORBIMAT 300 CA AVC/OSC
• The new arc voltage control calculates and programs the length of the arc automatically in "mm" from the current
voltage characteristics. This avoids the usual time spent calculating the necessary arc voltage each time the weld
power changes to maintain the arc at a consistent length in the individual sectors.
• During oscillation each of the edge holding times can be synchronized with the high-pulse settings.
• The center of the seam can be accessed manually and be determined using an automatic scanner. The electrode ac-
cesses each of side of the seam and then calculates the center of the path automatically. For asymmetric weld seam
configurations this is compensated by an OFFSET function.
• Including remote control (cable length: 7,5 m) Code 875 050 001.
• There is the option of an HF-free touch start ignition.
4.3 Functional description
• The machine is supplied with voltage and controlled by the orbital welding power supply.
• The weld head is clamped to the pipe to be welded using clamping inserts or clamping jaws. The weld head is ar-
ranged in such a way that the weld electrode is located radially over the weld joint.
• After ignition of the weld arc, the electrode is guided around the workpiece at the speed specified by the welding
controller and the weld seam is constructed.
• The cassette (closed weld heads only) is fully closed and thus forms a space which keeps the atmospheric air away
from the weld point.
• A procedure is required for welding with the machine. The machine features a procedure library, which enables pro-
cedures to be created and can create a procedure automatically via auto programming. You do not need to carry out
complex calculations, as the software calculates the required parameters automatically depending on the welding
task.
• After entering the pipe diameter, wall thickness, material and gas type, the machine creates a procedure sugges-
tion. This procedure suggestion usually requires only minimal adjustments which can be determined by carrying
out a test run of the procedure, for example.

Technical specifications ORBIMAT CA | Operating instructions
18 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
5. TECHNICAL SPECIFICATIONS
Parameter Unit OM 165 CA OM 300 CA Remarks
Weld system type Welding rectifier (inverter)
Input (mains)
Mains system 1 phase + PE 3 phase + PE
Mains input voltage [V (AV)] 90 - 260 400
Permissible voltage tolerance [%] see mains input voltage +/–15 OM 165 CA Wide Range
Mains frequency [Hz] 50 - 60 50 - 60 –
Continuous input current [A (AC)] 14 (on 230 V) 13
Continuous input [kVA] 3.2 (on 230 V) 9
Current consumption, max. [A (AC)] 19 (on 230 V) 20
Connection value, max. [kVA] 4.4 13.5
Mains fuse [A] 16 20 Slow-blow characteristic
Power factor [cos ϕ] 0.99 (with 100 A) 0.7 (with 200 A) OM 165 CA: PFC
Output (welding circuit)
Setting range Weld current [A (DC)] 2 - 165 5 - 300 In 0.1 A increments
Weld current reproducibility [%] +/– 0.5 +/– 0.5
Rated current at 100 % ED [A (DC)] 120 220
Rated current at 60 % ED [A (DC)] 260
Rated current at 40 % ED [A (DC)] 300
Rated current at 30 % ED [A (DC)] 165
Weld voltage, min. [V (DC)] 10 10
Weld voltage, max. [V (DC)] 16 22
Open-circuit voltage, max. [V (DC)] 85 86
Cable diameter, min. [mm2]16 35
Ignition power, max. [Joule] 0.9 0.9
Ignition voltage, max. [kV] 8 8
Output (control)
Rotation motor voltage, max. [V (DC)] 24 24 PWM signal
Wire feeding motor voltage, max. [V (DC)] 24 24 PWM signal
Rotation motor current, max. [A (DC)] 1.5 1.5
Wire feeding motor current, max. [A (DC)] 1.5 1.5
Rotation tacho voltage [V (DC)] 0 - 10 0 - 10 Rotation speed, actual
value
Other
Protection type IP 21 IP 21
Cooling type AF AF
Insulation class F F
Dimensions (wxdxh) [mm]
[inch]
540 x 420 x 290
21.3 x 16.5 x 11.4
540 x 420 x 440
21.3 x 16.5 x 17.3
300 CA without cooling
unit
Weight [kg]
[lbs]
26
57.3
34
75
Gas input pressure [bar] 3 - 10 3 - 10 Via pressure reducer
Recommended gas input pressure [bar] 4 4 Via pressure reducer
Cooling water volume [l] 2.3 – CA 165 only
Water pressure, max. [bar] 2.5 – CA 165 only
Sound level, max. [dB (A)] 84 84 IP 21

ORBIMAT CA | Operating instructions Initial operation
(09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
6. INITIAL OPERATION
6.1 Checking the parts of delivery
XCheck delivery for completeness and damage caused by transport.
XReport any missing parts or damage caused by transport to your supplier immediately.
6.2 Included with the machine
Subject to modifications.
• 1 Orbital welding power source of the ORBIMAT CA series
• 1 Hose connection set ORBIMAT (Code 875 030 018)
• 1 Dummy plug for insertion into the connection of the remote control if no external remote control will be used
(Code 875 050 006)
• 1 Bottle with 2 litre (67.6 fl oz) of coolant OCL-15 (Code 875 030 015) (only with 165 CA)
• 1 Filling funnel (Code 875 030 014)
• 1 External operating keyboard (Code 875 012 075)
• 2 Keys for key switch (for subsequent ordering of one key: Code 875 012 058)
• 1 Operating instructions
• 1 QuickStart guide

Set-up and assembly ORBIMAT CA | Operating instructions
20 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (09.03.15) OW_ORBIMAT_CA_BA_871060202_04_EN
7. SET-UP AND ASSEMBLY
7.1 Control elements
7.1.1 Overview of the main control elements
The main control elements are five push switches, so-called "softkeys" (Items 1–5) with variable functions located on
the top of the machine. The current function of these softkeys depends on the respective operating status of the system
and is indicated by the display on the bottom line.
The included standard PS2 keyboard can be set up before the softkeys.
The individual menu items are selected using the rotary knob (Item 6) and confirmed by pressing the rotary knob.
Detailed descriptions are provided with the explanation of the respective operating steps.
1
6
2 3 4 5
1. Push switch (softkey) 1
2. Push switch (softkey) 2
3. Push switch (softkey) 3
4. Push switch (softkey) 4
5. Push switch (softkey) 5
6. Rotary knob
Fig. 1: Main control elements
7.1.2 Connections and control elements on the front panel
7 26 5 4 3 1
1. Gas hose
2. Water connection, red (water return)
3. Water connection, blue (water flow)
4. Weld current socket
5. Weld current plug
6. Amphenol socket, control line
7. Strain relief eye
Fig. 2: Front panel: Connections and control elements
The connections at items 1 - 7 are intended for the connection of the various weld heads from the Orbitalum line.
The coding prevents plugs from being mixed up. The cooling water connections (water flow and return) are the same.