ORBITALSERVICE CompactDual - Two in One User manual

Operation Manual
CompactDual – Two in One
© 08/2019 Rev 0 / Subject to change without notice! Page 1/53
Orbital Welding System
CompactDual – Two in One
Operation Manual

Operation Manual
CompactDual – Two in One
© 08/2019 Rev 0 / Subject to change without notice! Page 2/53
Table of Contents
1. General Instructions..........................................................................................................3
2. Safety Instructions ............................................................................................................4
3. The Power Supply (Front and Rear Panels)....................................................................5
4. The buttons........................................................................................................................7
5. The Home Screen..............................................................................................................8
6. The Main Menu...................................................................................................................9
7. Creating a new welding program...................................................................................10
7.1. The help function (automatic program creation)..........................................................10
8. Program library (Database).............................................................................................19
8.1 Deleting welding programs (from the library) .............................................................21
8.2 Change of program name (new entry) .......................................................................23
8.3 Saving power and wire parameters (percentage changes)........................................24
8.4 The printing menu......................................................................................................25
9. The main parameters.......................................................................................................28
9.1. Other parameters........................................................................................................32
10. Changing the welding parameters (Sectors)...............................................................38
11. Menu MAX/MIN...............................................................................................................44
12. Weld Setup.....................................................................................................................46
13. Administrator.................................................................................................................49
14. Test Menu.......................................................................................................................51
15. Customer Service 53

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1. General Instructions
This Quick Start Guide introduces you to the first steps in how to operate the
CompactDual.
Manufacturer of the CompactDual:
ORBITALSERVICE GmbH
Kreuzdelle 13
63872 Heimbuchenthal
Germany
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.orbitalservice.de
Internet: www.orbitalservice-group.com

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2. Safety Instructions
Arc welding may harm you and others. For this reason, when working with arc welding, you shall always
observe the existing Safety and Accident Prevention guidelines.
Warning of dangerous electrical current
Install and ground welding equipment in accordance to local standards.
Do not touch live parts or electrodes with bare hands or wet protective
equipment.
The workplace must be safe.
Warning of fire hazard
Welding beads can ignite a fire.
Do not store any flammable objects in the workplace.
Also any soiling is often flammable.
Before welding, remove all combustible cleaning materials.
Warning of optical radiation
Protect eyes and body parts. Use suitable protective helmet with filter insert
and wear protective clothing.
Adjacent personnel must be protected by protective curtains or walls.
Warning of harmful smoke and gases
Face must be turned away from the welding smoke.
If necessary, exhaust systems should be used.
Warning of explosion risk with hydrogen containing gases
When using forming gases or gases with hydrogen content, utmost caution
must be observed. These gases are flammable.
Please observe the instructions of the relevant safety data sheets.
Before switching on the system, make sure that no solvents are in the
atmosphere, e.g. in painting plants.
Warning of high temperature
During welding, some weld head parts may get hot
(e.g.: side walls)
General Information!
Observe the safety regulations for welding works in tight areas as well in
closed containers.

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3. The Power Supply (Front and Rear Panels)
Information „Orbital Welding ON“
The switching of hand / orbital is carried out with the right button (orbital -
manual). If the field shows Orbital Service's orbital button (like our logo),
orbital mode is enabled. You cannot set gas times, welding currents, etc.
with the red knob. Only the mode "pulsed current, constant and high
frequency" can be changed by pressing the button below.
We do not recommend the additional pulsed current (up to a maximum of
2.5 kHz). This only makes sense in isolated cases and special
applications!
Display
Switching Orbital - Manual
Information „Orbital Welding
ON“
Constant current

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Main Switch (ON/OFF)
Gas connection ¼“
Connection orbital rotating
motion (Rotation Weld Head,
Wire, AVC, OSC)
Primary Connection
(110-230 VAC)
Remote Control-Foot Switch Power
Supply, Connection Robot,
Connection Update Software
Power Supply
RS 232 (Bluetooth printer,
Update box Orbital Software)
Orbital Remote Control
(wired)

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4. The buttons
Start-Button:With this butto
n you can start the welding process and confirm the
menus.
Stop Button:With this button you can stop the welding process or undo a menu
selection.
Program Button: With this button we reach the Main Menu. Here you can,
among other, create welding programs.
With the "arrow key left" you can "scroll" through the menus. You can also scroll
through the steps of program creation or browse through already existing
welding Programs in the library. Outside the Programming functions, this key
also serves to rotate the weld head, direction of rotation left. Furthermore,
parameters can be changed.
With the "arrow key up" you can "scroll" through the menus. You can also scroll
through the steps of program creation or browse through already existing
welding Programs in the library. Outside the Programming functions, this key
also serves to rotate the weld head, direction of rotation right. Furthermore,
parameters can be changed.
Confirmation key:
This key is mainly used to confirm the individual menus and
settings. In the main screen, this button can be used to adjust the welding
current as a percentage. Furthermore, the key is also an ENTER confirmation
key.
3. Erklärung der Tasten

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5. The Home Screen
This screen is the "main screen". Only from this screen you can start the welding process by
means of the remote control or the button.
With the Button you arrive always at the main screen. Furthermore you can start the
welding process when you are not using the remote control.
With the Button you also arrive at the main screen, but no changes are accepted.
High and Base current
times (Info Sector 1
External diameter (42 mm)
Weld Head 83 (99
possible weld heads)
Internal Information
(Status messages OS)
Changing current through %-Button
Wall thickness tube
(2.0 mm)
Program number 07 (out of 99
possible programs)
Display sectors and angle degrees
High and Base current
(Info Sector 1)
Welding speed (Info
Sector 1)

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6. The Main Menu
The „Programming Key“ and the main menu
By pressing the Programming key you reach the main menu.
All menu items/signs are easily understandable.
They do not need to be translated into different languages.
The icon with the thick, black frame is activated by pressing the button and you reach
the programming screen.
Program key
Main parameters (here you find all
important features about welding
parameters)
Welding parameters in the
individual sectors
( 6 S kt )
Monitoring limits
MAX/MIN
Tool box (Sense of rotation of
the weld head, automatic
return, etc.
Administrator
Tests for gas flow, water
flow and welding without
arc - weld test

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7. Creating a new welding program
7.1. The help function (automatic program creation)
The control allows operators, even if they are not well versed, to easily reach first welding
programs. For this purpose there are basic calculations included in the software, which have
been tested for years and that are recommended and practiced by other manufacturers.
The start screen:
We would now like to create a demonstration program with a certain weld head. A pipe, with
an outside diameter 42.0 mm and a wall thickness of 2.0 mm is to be welded. We would like
to weld this pipe-pipe connection in 4 sectors.
Press button

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Press button
Program library
Create new program
Delete program
Assign new program name

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Press button
Outside diameter of pipe
Press button

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With buttons and the Setting-Enter Button the different data for diameter
Wall thickness, Number (model) of the weld head, etc. can now be entered.
The procedure is always the same.
The number or value with black background can be changed with the arrow keys and then
the setting-enter-key. You can also scroll through the values using the arrow keys.
Press button

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Press button
Wall thickness of pipe
Press button 2 x

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Press button
Number (model) of the weld head/welding device
Press button
In this menu item you can specify the number of sectors. The pipe can be divided into up to 6
different segments.
These are calculated automatically, according to the pipe outside diameter, the wall
thickness, the input continuous or step mode (step mode - to be explained later)
Changing the degrees at which the various sectors are active will also be described in
greater detail.
Desired number of sectors

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Press button
Desired number of sectors-segments-levels (1-6 possible)
Press button
Different Symbol for
Step-Mode
Rotation
In these menu items (see hereunder, New 2) you can define the rotation motion (for now
continuous motion).
Pressing , the motion changes to step mode. The symbol changes as shown above left.

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Press button
Press button
With buttons and you can call up different symbols, numbers, uppercase and
lowercase letters, in order to assign a name or a description to the program. This is important
in order to find it later in the program library and activate it.

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Press button
If you press the button and the water symbol does not change to a dark background, then
we are in presence of a gas cooled weld head. In this case, we have weld head No. 83 (an
open weld head OWH 76-Type LB). If the symbol has a dark background, then we have the
possibility to use a cooler and a water cooled hose. In this case, water flow and temperature
are monitored and shown accordingly.
Welding program No. P 07 is calculated and ready.
You can see important information about the weld head, the program slot and the pipe on the
left side as well as the welding parameters of sector 01 on the right side.
Below we see the current changes, currently at 100% (default setting).

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8. Program library (Database)
It is possible to save in the database (library) 99 welding programs with max. 6 sectors each
(save).
Initial screen:
Press menu button

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Press button
Press button