Orbitalum ORBmax User manual

Operating instructions
For responsible bodies and persons using the machine
Residual Oxygen Meter
ORBmax
Device No.:
To work safely with this device, please
read through the operating instructions
in full before initial operation.
Retain the operating instructions for
future reference.
Code 882 060 202 | 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.

(17.07.14) OW_ORBmax_BA_882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
ORBmax | Operating instructions
1. About these instructions ......................................4
1.1 Warning messages.....................................4
1.2 Further symbols and displays.....................4
1.3 Abbreviations ............................................4
2. Information and safety instructions for the
responsible body .................................................5
2.1 Requirements for the responsible body.......5
2.2 Using the device.........................................5
2.2.1 Proper use .......................................5
2.2.2 Improper use ...................................5
2.2.3 Limits of the device ..........................5
2.3 Environmental protection/disposal.............6
2.3.1 Electric tools and accessories ..........6
2.4 Basic safety instructions............................6
3. Product design.....................................................8
3.1 ORBmax ....................................................8
3.2 Accessories and consumables ....................8
3.2.1 Measuring hose set..........................8
3.2.2 Individual parts for measuring
hose set...........................................9
3.2.3 Power supply unit set.......................9
3.2.4 Interface cable.................................9
3.2.5 SD card............................................9
3.2.6 Protective cover .............................10
3.2.7 Transport case ...............................10
4. Features ............................................................11
4.1 Properties of the sensor ...........................11
4.2 Further properties of the ORBmax.............11
5. Technical data....................................................12
6. Included in delivery, storage and transport.........13
6.1 Included in delivery .................................13
6.1.1 Checking the parts of delivery .......13
6.1.2 Included in delivery .......................13
6.2 Storage and transport ..............................13
7. Initial operation .................................................14
7.1 Setting up the device ...............................14
7.2 Connecting the ORBmax...........................14
8. Operation ..........................................................15
8.1 Touch screen (main display elements).......15
8.2 Control or setting keys .............................15
8.2.1 "Start logging" key ........................15
8.2.2 "Start pump" key ...........................16
8.2.3 "Menu" key....................................16
8.3 Carrying out a measurement ....................17
8.4 Evaluating a measurement .......................17
8.4.1 Evaluating a measurement with
Microsoft Excel ..............................17
8.4.2 Evaluating a measurement with
a text editor ...................................18
8.4.3 Evaluating the measurement with
the "O2_Log" evaluation software .... 19
8.5 Connecting the ORBmax to the
power source ...........................................21
9. Servicing, maintenance, troubleshooting............22
9.1 Maintenance............................................22
9.2 What to do if? –
General trouble-shooting .........................22
9.3 Service, customer service &
spare parts ..............................................23
10. EU declaration of conformity...............................24
TABLE OF CONTENTS

4orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_BA_882.060.202_00_EN
About these instructions ORBmax | Operating instructions
1. ABOUT THESE INSTRUCTIONS
To allow quick understanding of these instructions and safe handling of the device, 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.
1.3 Abbreviations
Abbr. Meaning
ORBmax Residual Oxygen Meter

(17.07.14) OW_ORBmax_BA_882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
ORBmax | Operating instructions Information and safety instructions for the responsible body
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
device, and should allow only qualified personnel to enter the zone or operate the device 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 device
2.2.1 Proper use
• The device should be exclusively used for measuring the residual oxygen in forming vessels.
• Operate the device only at the voltages specified on the rating plate (Technical data, see chap. 5,
p. 12).
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
2.2.2 Improper use
• A use other than that defined under "proper use" or a use that goes beyond this or the speci-
fied 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.
• Tools or accessories that have not been approved by the manufacturer for this device may not
be used.
• The removal of safety equipment is not permitted.
• Do not misuse the device.
• The device is not intended for use by private consumers.
• The technical values defined for normal operation must not be exceeded.
2.2.3 Limits of the device
• Keep your working area clean. Disorder or unlit working areas can lead to accidents.
• The workplace can be in pipe preparation, in plant construction or in the plant itself.
• A radial space requirement/freedom of movement of approx. 2 m around the device is required for people.
• Work lighting: min. 300 Lux.
• Operator age: at least 14 years old and without physical impairments.
• Operated by one person.
• Climate conditions: Temperature range for device operation: 0 °C to 40 °C

6orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_BA_882.060.202_00_EN
Information and safety instructions for the responsible body ORBmax | Operating instructions
2.3 Environmental protection/disposal
2.3.1 Electric tools and accessories
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 at the side may not be dis-
posed 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 be-
fore 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 Residual Oxygen Meter (hereinafter referred to as ORBmax) is designed using state-of-the-art technology 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.
• In addition to these operating instructions the general safety precautions of the welding machines together with
which ORBmax is used apply. Store all documentation near the device.
• Generally valid regulations for the prevention of accidents must be observed.
• Observe country-specific regulations, standards and guidlines.
• Use the device only in proper operating order. Observe the maintenance information (chap. 9, p. 22).
• Use the device only when it has a solid footing. Check whether the substrate is able to take sufficient loads.
• Report deviations in operating behavior of the device to the person in charge immediately.
• 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.
• Switch the device off and unplug the power plug before carrying out transportation, cleaning, maintenance and
repairs.
• Do not carry the device by the cable and do not use the cable to pull the power plug out of the socket outlet (except
in case of an emergency). Protect the cable against heat, oil and sharp edges (shavings).

(17.07.14) OW_ORBmax_BA_882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
ORBmax | Operating instructions Information and safety instructions for the responsible body
DANGER
If the mains cable is damaged, live parts may cause death if touched directly!
Fatal electric shock.
[Do not operate the device unattended.
XKeep the power cable away from heat, oil, sharp edges or moving device parts.
XDuring processing, always keep an eye on the position of the mains cable.
XKeep the device clean, always remove lubricant or other residues from the device.
DANGER
Damaged insulation!
Fatal electric shock.
[Do not screw signs to the device.
XUse stickers.
DANGER
Damaged plug!
Fatal electric shock.
[Do not use adapter plugs with ground protected electrical tools.
XConnecting plugs of the device must fit into the outlet.
DANGER
Grounded body!
Fatal electric shock.
XAvoid contact with grounded surfaces such as tubes, heating, cookers or refrigerators.
DANGER
Safety components that are contaminated, worn or broken are defective!
The failure of safety components can cause physical injury.
[Do not misuse the cable, for example by suspending or carrying the device by the cable.
XReplace defective safety components immediately and check them daily to ensure proper operation.
XReplace defective mains cable immediately by a specialist.
XClean and maintain the device after every use.
XKeep cables away from heat, oil, sharp edges and moving equipment parts.
XCheck the device daily for externally visible damage and defects and have them remedied by a
professional if necessary.
WARNING
Danger caused by vibration and unergonomic, monotonous work!
Discomfort, tiredness and disruptions to the locomotor system.
Limited ability to react, and cramps.
XDo relaxation exercises.
XEnsure activity is varied.
XAssume an upright and relaxed posture when working.

8orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_BA_882.060.202_00_EN
Product design ORBmax | Operating instructions
3. PRODUCT DESIGN
3.1 ORBmax
For accessories and consumables (e.g. power supply unit, measuring hose, filter, etc.), see as of chap. 3.2.
1
6
27 3 4 5
8
1. Touch screen (description, see chap. 8.1)
2. Gas inlet / Connection measuring hose
3. Gas outlet
4. Connection of interface cable
5. Connection of power supply unit
6. ON/OFF toggle switch
7. Protective cover
8. SD card port
3.2 Accessories and consumables
WARNING
Danger presented by using poor-quality accessories and tools not approved by Orbitalum Tools!
Diverse physical injuries and material damage.
XUse only original tools, spare parts, materials, and accessories from Orbitalum Tools.
3.2.1 Measuring hose set
Including:
• 1 hose (please specify the hose length in meters when ordering)
• 1 filter for protecting the oxygen sensor against soiling
• 2 filter inserts
• 1 test tip
• 1 hose connector
All individual parts are already included in the scope of delivery of the ORBmax.
Article Code
Measuring hose set 882 050 006

(17.07.14) OW_ORBmax_BA_882.060.202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone]
ORBmax | Operating instructions Product design
3.2.2 Individual parts for measuring hose set
All individual parts are already included in the scope of delivery of the ORBmax.
Article Code
Hose* 882 012 010
Filter 882 020 003
Filter inserts (5 piece per packing unit) 882 030 002
Test tip 882 012 011
Hose connector 882 012 012
* Please specify the hose length in meters when ordering.
3.2.3 Power supply unit set
100 - 240 VAC / 12 VDC. For connecting the ORBmax to the mains network.
Including diverse country-specific AC adapters.
Article Code
Power supply unit set 882 012 023
3.2.4 Interface cable
For connecting the ORBmax to the ORBIMAT orbital welding power sources of Orbitalum Tools.
Can be set at ORBIMAT so that welding can only be started after the oxygen value has been
underpassed.
1 interface cable is already included in the scope of delivery of the ORBmax.
Article Code
Interface cable 882 012 028
3.2.5 SD card
1 Gbyte. For measured data storage.
Evaluation software "O2_log" included.
1 SD card including evaluation software is already included in the scope of delivery of the ORBmax.
Article Code
SD card (1 GB) 882 050 007

10 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Tel. [phone] (17.07.14) OW_ORBmax_BA_882.060.202_00_EN
Product design ORBmax | Operating instructions
3.2.6 Protective cover
Practical protective cover that can be converted into a stand when rolled together on the device rear.
1 protective cover is already included in the scope of delivery of the ORBmax.
Article Code
Protective cover 882 001 013
3.2.7 Transport case
Robust transport case with degree of protection IP67.
1 transport case is already included in the scope of delivery of the ORBmax.
Article Code
Transport case 882 050 008