Orbitalum ORBIMAT 180 SW User manual

Operating instructions
For responsible bodies and persons using the machine
Orbital Welding Power Supply
ORBIMAT 180 SW
Machine No.:
Code 850 060 202 | EN | Translation of original operating instructions
To ensure safe working read the operating
instructions before commissioning.
Retain the operating instructions
for future reference.

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 180 SW | Operating instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
1. About these instructions ......................................5
1.1 Warning messages.....................................5
1.2 Further symbols and displays.....................5
1.3 Abbreviations ............................................5
1.4 Further applicable documents ....................5
2. Information and safety instructions ......................6
2.1 Requirements for the responsible body.......6
2.2 Using the machine .....................................6
2.2.1 Proper use .......................................6
2.2.2 Machine constraints.........................7
2.3 Environmental protection/disposal .............7
2.3.1 Coolant............................................7
2.3.2 Electric tools and accessories...........7
2.4 Personnel qualification ..............................7
2.5 Fundamental information on operational
safety ........................................................8
2.6 Personal protective equipment ...................8
2.7 Remaining risks .........................................8
2.7.1 Injury through high weight ...............8
2.7.2 Burns and danger of fire through
high temperatures ...........................9
2.7.3 Tripping over the hose package ........9
2.7.4 Long-lasting physical damage
through wrong posture.....................9
2.7.5 Electric shock ..................................9
2.7.6 Danger through incorrect handling
of pressure tanks ...........................10
2.7.7 Damage to eyes through radiation ..10
2.7.8 Dangers through electromagnetic
fields.............................................10
2.7.9 Risk of suffocation through an
excessive argon share in the air......11
2.7.10 Health problems ............................11
2.7.11 Danger of system tipping over ........11
2.7.12 Danger of explosion and fire...........11
2.7.13 General injuries through tools ........11
3. Description ........................................................12
3.1 ORBIMAT 180 SW.....................................12
3.2 Operating concept....................................14
3.2.1 Operation via push switches
(softkeys) ......................................14
3.2.2 Operation via touch screen.............14
3.2.3 Operation via rotary knob...............14
3.2.4 Operation via an external
keyboard .......................................15
3.3 Warning signs..........................................16
4. Scope of application...........................................17
4.1 Accessories .............................................17
4.1.1 ORBICAR W trolley..........................17
4.1.2 ORBICOOL Active ...........................17
4.1.3 ORBITWIN switching unit................18
4.1.4 ORBmax oxygen meter ...................18
4.1.5 Remote control with cable ..............18
4.1.6 OCL-30 coolant...............................18
4.1.7 ORBIPURGE forming set..................18
4.1.8 Paper rolls and ribbon cartridges ...18
5. Technical specifications .....................................19
6. Storage and transport........................................20
6.1 Gross weight............................................20
6.2 Preparing storage ....................................20
6.2.1 Removing the weld head from the
orbital welding power supply..........20
6.2.2 Pumping out coolant ......................20
7. Commissioning ..................................................23
7.1 Scope of delivery .....................................23
7.2 Checking the scope of delivery .................23
7.3 Accessories (optionally available).............23
7.4 Connecting the welding power supply.......24
7.4.1 Setting up machine........................24
7.4.2 Connecting a gas bottle .................24
7.4.3 Connecting weld heads ..................25
7.4.4 Detaching coolant hoses ................25
7.4.5 Pumping out coolant ......................25
7.4.6 Closing off gas hose.......................25
7.5 Commissioning ........................................25
7.5.1 Topping up coolant.........................26
7.5.2 Connecting Remote control/dummy
plug...............................................26
7.5.3 Switching on the power source.......27
7.5.4 Setting the language......................28
7.5.5 Setting the measuring units ...........28
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 .................34
8.2.5 Welding .........................................34
8.2.6 Interrupting the welding process ....36
8.3 Adjusting the procedure ...........................37
8.3.1 Reasons and steps for adjusting
procedure ......................................37
8.3.2 Making percental changes..............37
TABLE OF CONTENTS

ORBIMAT 180 SW | Operating instructions
4orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
8.3.3 Adjusting individual parameters.....38
8.3.4 Digital gas management.................38
8.3.5 Adjusting gas times .......................38
8.3.6 Adjusting ignition current, final
current and current slope-off..........39
8.3.7 Adjusting the pool formation time ..39
8.3.8 Adjusting welding current and
transition times ("Slope").............. 40
8.3.9 Adjusting pulse times ....................41
8.3.10Adjusting weld speed and
transition time ("Slope") ................42
8.3.11 Changing the sector ...................... 44
8.4 Saving and calling up a procedure ........... 46
8.4.1 Saving a procedure ....................... 46
8.4.2 Calling up a procedure .................. 46
8.5 Locking machine with a login....................47
8.6 Tacking function...................................... 48
8.7 Using the second gas pressure level
("Flow Force") ..........................................49
8.8 Connecting supplementary devices ..........51
8.8.1 ORB Residual Oxygen Meter ...........51
8.8.2 Connecting and configuring the
BUP control unit.............................51
8.8.3 TIG manual welding torch ...............51
8.8.4 External remote control..................53
8.8.5 External printer (A4).......................53
8.8.6 External monitor /HDMI.................53
8.9 Monitoring functions................................53
8.9.1 General information .......................53
8.9.2 Adjusting limit values.....................54
8.10 Data documentation and data
management............................................55
8.10.1 Managing data...............................55
8.10.2Entering comments and application
data ("Process details") .................57
8.10.3Working using USB ........................58
8.10.4Viewing and printing data ..............59
8.10.5Editing data on a PC with the
"OrbiProgCA" supplementary
software....................................... 60
8.11 Updating and backup functions for the
software................................................. 60
8.12 Updating software components................61
8.13 Saving software components ...................61
8.14 Restoring software components ...............61
8.15 Working in other languages......................61
8.15.1 Changing the language ..................61
8.15.2Printing data in another language...62
8.15.3Creating a new operating
language .......................................62
8.16 Importing programs from other
Orbitalum power sources .........................62
8.16.1 Importing procedures.....................63
8.17 Special keyboard commands ....................63
8.18 Operation of the system with other mains
voltages...................................................63
9. Service and troubleshooting.............................. 64
9.1 Performing service work.......................... 64
9.1.1 Pumping out coolant ..................... 64
9.1.2 Performing motor calibration......... 64
9.1.3 Adjusting an external printer ......... 66
9.1.4 Switching on an internal printer..... 66
9.1.5 Printing a test page........................67
9.1.6 Service screen ...............................67
9.1.7 Info............................................... 68
9.2 Possible application/operating errors...... 68
9.2.1 Uneven weld seam ("current
fluctuations") ............................... 68
9.2.2 Annealing colors inside/outside .... 68
9.2.3 Wide seam and no weld
penetration....................................69
9.2.4 Uneven seam/hole formation at
the end of welding .........................69
9.2.5 Ignition problems...........................70
9.2.6 Machine does not start ..................70
9.3 List of error messages ..............................71
9.4 Status LED indicators ...............................75
9.5 Temporarily deactivating sensors and
monitoring functions................................75
9.5.1 Sensors.........................................75
9.5.2 Monitoring limits ...........................75
9.5.3 External input for aborting .............75
9.6 Setting the date and time .........................76
10. Maintenance and troubleshooting ......................77
10.1 Instructions for care .................................77
10.2 Maintenance and care ..............................77
10.2.1 Storage..........................................78
10.3 Servicing/Customer service......................78
11. EC Declaration of Conformity ....................79

ORBIMAT 180 SW | Operating instructions About these instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
1. ABOUT THESE INSTRUCTIONS
1.1 Warning messages
The warning messages used in these instructions warn you of injuries or damage to property.
Always read and observe these warning messages!
This is the warning symbol. It should warn you 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 injuries 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 symbols and displays
SYMBOL MEANING
Important information for comprehension.
1.
2.
3.
...
Request for action in a sequence of actions: Action is required here.
Single request for action: Action is required here.
1.3 Abbreviations
ABBREVIATION MEANING
OM, SW ORBIMAT, Type "SmartWelder"
1.4 Further applicable documents
The following documents apply together with these operating instructions:
• Operating instructions of the orbital weld head

Information and safety instructions ORBIMAT 180 SW | Operating instructions
6orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
2. INFORMATION AND SAFETY INSTRUCTIONS
2.1 Requirements for the responsible body
Workshop/outdoor/field use: 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 operator has to observe the safety regulations described in this chapter as well as has to work
safety-consciously and with all prescribed safety equipment.
The employer undertakes to give the employees clear notice of the dangers arising that are specified in the EMF direc-
tives and to evaluate the workplace correspondingly.
Requirements for special EMF evaluations with regard to general activities, working materials and workplaces*:
TYPE OF WORKING MATERIALS OR
WORKPLACE
EVALUATION REQUIRED FOR:
Employees without
particular risk
Employees at particular
risk (with the exception
of those with active im-
plants)
Employees with active
implants
(1) (2) (3)
Arc welding, manual (including MIG (Metal
Inert Gas), MAG (Metal Active Gas), TIG (Tung-
sten Inert Gas)) under observance of tried-
and-tested procedures and without physical
contact to the line
No No Yes
* According to Directive 2013/35/EU
2.2 Using the machine
2.2.1 Proper use
The orbital welding power supply is intended solely for the following utilization:
• Utilization in combination with an orbital weld head of the company Orbitalum Tools GmbH or with
a compatible third-part device in combination with a weld head adapter of the company Orbitalum
Tools GmbH.
• TIG welding of materials that are specified in these operating instructions (see chap. 4, p. 17).
• Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.
Intended 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 instructions and warning messages 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 protective gases that are classified for TIG welding process in accordance with EN ISO 14175.
• Usage solely of coolant OCL-30 of the company Orbitalum Tools GmbH.
• Checking of all the safety-relevant items and functions before commissioning.
• Processing of those materials named in the operating instructions.

ORBIMAT 180 SW | Operating instructions Information and safety instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
• Purpose usage of all components involved in the welding processes as well as of all further factors that have an
influence on the welding process.
• Solely commercial usage.
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.
• Erect the machine solely on a solid surface.
• A radial space requirement/freedom of movement of approx. 2 m around the machine is required for people.
• Work lighting: min. 300 Lux.
• Climate conditions: –10 °C to 40 °C; < 80% rel. humidity.
• Only work with the machine in dry surroundings (not in misty, rainy or stormy conditions). If appropriate use a weld-
ing tent.
• Cooling is only ensured with a full coolant tank.
2.3 Environmental protection/disposal
2.3.1 Coolant
Dispose of coolant in accordance with the local statutory regulations.
2.3.2 Electric tools and accessories
Used-up power tools and accessories contain a large amount of valuable raw materials and plas-
tics which can be recycled.
(as per RL 2002/96/EC)
• Used electronic devices marked with the adjacent symbol may not be disposed of with household waste in accor-
dance with EU directives.
• By actively using the offered return and collection systems, you are doing your part to reuse and recycle used elec-
tronic 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.
• The user is responsible for disposing of used electronic devices purchased before August 13th, 2005. Bitte wenden
Sie sich hierfür an einen Entsorgungsfachbetrieb in Ihrer Nähe.
• Important 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.
2.4 Personnel qualification
CAUTION! The orbital welding power supply may only be used by instructed personnel.
• Minimum age: 18 years old.
• No physical impairments.
• Operation of the machine by underage persons only under supervision by a person authorized to issue instructions.
• A basic knowledge of TIG welding process is advisable.

Information and safety instructions ORBIMAT 180 SW | Operating instructions
8orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
2.5 Fundamental information on operational safety
CAUTION! Observe valid safety and accident prevention regulations.
Improper usage can impair safety. This can result in life-threatening injuries.
XNever leave an welding power supply unattended when it is switched on.
XThe operator has to ensure that no 2nd person is inside the danger zone.
XDo not modify or convert the orbital welding power supply.
XUse the orbital welding power supply only in proper operating order.
XUse only genuine tools, spare parts and accessories as well as specified operating materials.
XIn case of changes in the operating behavior stop operation immediately and have the fault eliminated.
XDo not remove safety devices.
XIn order to increase safety a customer-provided SPE-PRCD or a universal-current residual-current circuit-breaker 30
mA or an isolating transformer between the mains network and the welding power supply is required.
XDo not pull the machine at the hose package or the cable.
XRepair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
XDo 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 against heat, oil and sharp edges (chips).
2.6 Personal protective equipment
The sole act of operating the welding power supply does not require personal protective equipment:
XWhen connecting and using a weld head observe the respective safety instructions and warning messages of the
weld head.
XObserve the remaining risks.
2.7 Remaining risks
2.7.1 Injury through high weight
The orbital welding power supply has a weight of 28 kg (61.73 lbs). A significant health hazard exists during lifting.
Danger of impact and crushing exists in the following situations:
CAUTION! Falling of the orbital welding power supply during transportation or setting up.
CAUTION! Falling of the orbital welding power supply caused by it being put down improperly.
XUse a suitable transport medium to transport the orbital welding power supply.
XAlways use 2 persons to lift and remove the orbital welding power supply from the packaging.
XWhen lifting the machine do not exceed the permissible total weight of 25 kg for men and 15 kg for women.
XPlace the orbital welding power supply on a stable base.
XWear safety shoes.

ORBIMAT 180 SW | Operating instructions Information and safety instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
2.7.2 Burns and danger of fire through high temperatures
CAUTION! The orbital weld head is hot after welding. Very high temperatures arise in particular after several
consecutive welding processes. There is a danger of burns or damage to the points of contact when
working on the orbital weld head (for example when changing clamps or mounting/removing the elec-
trodes). Materials without thermal resistance (for example foam inlay of the transport packages) can
be damaged when coming into contact with the hot orbital weld head.
XWear safety gloves.
XWait until the surfaces have cooled down to below 50 °C before working on the orbital weld head or before packing
into the transport packaging.
WARNING! Thermal problems can arise in the case of incorrect positioning of the forming 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.
XPosition the forming system correctly.
XUse only permissible materials in the welding area.
WARNING! Danger of scalding through hot emitted liquids as well as hot plug connections during heavy opera-
tion.
XHeed the safety precautions of the technical supervisor/person in charge of safety.
2.7.3 Tripping over the hose package
CAUTION! If a hose package is connected, there is the danger that persons may trip over it and be injured.
WARNING!
Tripping over could cause the plug to be pulled out so that in the worst case an arc may arise between
the plug and the orbital weld system. Burns and glaring light may be the result.
XEnsure that under no circumstances can people trip over the hose package.
XDo not place the hose package under tension.
XEnsure that the hose package is connected properly and that the strain relief is attached.
2.7.4 Long-lasting physical damage through wrong posture
XUse the machine so that an upright and comfortable body position can be achieved during operation.
2.7.5 Electric shock
WARNING!
The danger exists of unintentionally operating the ignition function when connecting or disconnect-
ing a weld head from the welding power supply.
XSwitch off the orbital welding power supply when connecting or disconnecting a weld head.
XDo not play with weld head.
XIf the weld head is not ready for operation, switch it to the "Test" function.
WARNING! Electrical hazards through contact.

Information and safety instructions ORBIMAT 180 SW | Operating instructions
10 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
XDo not touch energized parts (workpieces), especially when igniting the arc.
XFrom the start of the welding process avoid contact with the tube and the housing of the orbital weld head.
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! Risk of death for people with heart problems or cardiac pacemakers.
XDo not allow persons with increased sensitivity to electrical hazards (e.g. weakness of the heart) to work with the
machine.
DANGER! Danger of an electric shock in the case of improper reaching in into and opening of the machine.
XAllow only a professional electrician to access the electrical system.
DANGER! The danger of an electric shock exists through non-compatible or damaged connectors.
XDo not use adapter plugs together with protectively grounded power tools.
XEnsure that the connecting plugs of the machine fit into the outlet.
XWhen connecting use a residual-current circuit breaker 30 mA.
2.7.6 Danger through incorrect handling of pressure tanks
WARNING! Various injuries and damage to property.
XHeed safety regulations for pressure tanks.
XHeed safety data sheets for pressure tanks.
2.7.7 Damage to eyes through radiation
WARNING!
During the welding process infrared, glaring and ultraviolet rays arise that can seriously damage
the eyes.
XKeep the flip cover and swivel clamp closed during the welding process.
XDuring operation, wear eye protection to EN 170 and skin-covering safety clothing.
XAt closed weld heads ensure proper working order of the eye protection.
2.7.8 Dangers through electromagnetic fields
DANGER! Depending on the form of the workplace life-threatening electromagnetic fields can arise in the direct
vicinity.
XPeople with heart problems or cardiac pacemakers may not operate the welding system.
XThe operator has to ensure safe design of the workplace in accordance with the EMF Directive 2013/35/EU.
XUse only electrical devices with protective insulation in the working area of the welding system.
XObserve electromagnetically-sensitive devices when igniting the system.

ORBIMAT 180 SW | Operating instructions Information and safety instructions
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
2.7.9 Risk of suffocation through an excessive argon share in the air
DANGER! If the argon share in the air rises above 50%, lasting damage or risk of death can arise suffocation.
XEnsure sufficient ventilation in rooms.
XIf necessary, monitor the oxygen level in the air.
2.7.10 Health problems
WARNING! Poisonous vapors and substances during the welding process and handling of the electrodes!
XUse extraction devices in accordance with the professional association regulations (e.g. BGI: 7006-1).
XExtra caution is required with chrome, nickel and manganese.
XDo not use electrodes containing thorium.
2.7.11 Danger of system tipping over
WARNING! Manifold injuries and damage to property through system (for example ORBICAR welding carriage,
gas bottle, welding power supply, cooling unit) tipping over from the application of force from outside!
XSet up the machine so that it stands securely against external influences.
XKeep moving masses at least 1 meter away from the machine.
2.7.12 Danger of explosion and fire
DANGER! Danger of explosion and fire through flammable materials near the welding zone or solvent in the
room air.
XDo not weld near solvents (for example where painting is being carried out) or explosive substances.
XDo not use flammable substances as a base in the welding area.
XEnsure that no flammable materials or soiling is located near the machine.
2.7.13 General injuries through tools
CAUTION! Injuries can occur during dismantling for the proper disposal of the orbital welding power supply
through uncertainties in handling tools.
XIn case of uncertainties send the orbital welding power supply to Orbitalum Tools – proper disposal is carried out
here.

Description ORBIMAT 180 SW | Operating instructions
12 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
3. DESCRIPTION
3.1 ORBIMAT 180 SW
1
4
2
5
6
7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
26
27
31 32
2524
28 29 30
21 2322
33
34

ORBIMAT 180 SW | Operating instructions Description
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
ITEM DESIGNATION FUNCTION
1 Color touch display Operating the welding power supply, see chap. 3.2, p. 14
2Push switches (softkeys) Operating the welding power supply, see chap. 3.2, p. 14
3Cover, hinged Protects the operating elements
4 Connection socket, "USB", front Connection possibility for USB devices (2x) (optional)
5Integrated system printer For printing actual values and welding data reports
6Rotary knob Operating the welding power supply, see chap. 3.2, p. 14
7Carry handles Transporting the welding power supply
8 Main switch (green) Switch on the welding power supply; lights up green during operation
9 Off button (red) Switch off the welding power supply; lights up red during operation and
in "Stand-by" mode
10 Connection socket "BUP" Connection possibility for "BUP Control Box", forming gas pressure con-
troller (optional)
11 Connection socket "ORBmax" Connection possibility for "ORBmax", residual oxygen meter (optional)
12 Connection socket "Remote" Connection for remote external control (optional) or dummy plug
13 Connection socket "Weld head" Connection for weld head signal line
14 Connection socket "Gas" Connection for gas hose to the weld head
15 Coolant connection, blue Connection for coolant supply line
16 Eye, strain relief Strain relief weld head to the power source
17 Coolant connection, red Connection for coolant return line
18 Weld current socket Connection weld head
19 Weld current connection Connection weld head
20 Ventilation slot Venting the welding power supply
21 Connection socket "LAN", rear Connection possibility for LAN cable
22 Connection socket "USB", rear Connection possibility for USB devices (2x) – see Item 4
23 Connection socket "HDMI", rear Connection possibility for HDMI cable
24 Coolant level indication Indicates the fill level of the coolant in the tank
25 Tank opening with lid Holding of up to 2.2 liter coolant for cooling the connected weld tongs
and heads
26 Rating plate Indication of the machine data
27 Gas connection Weld gas input
28 Connection socket "External cooling" Connection of external cooling unit signal line
29 Connection socket "ORBITWIN" Connection for ORBITWIN Switching Unit
30 Power input socket Connection for power line
31 Connection socket Connection possibility superordinate control system
32 Connection socket Connection possibility CAN-compatible components
33 Surface for keyboard The optionally available keyboard can be placed before the softkeys.
34 LED display Display of operating states and coolant flow

Description ORBIMAT 180 SW | Operating instructions
14 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
3.2 Operating concept
The main control elements are the 6 push switches, whose current function assignment is displayed at the bottom mar-
gin of the display, the touch screen and the rotary knob. Direct access to standard functions (e.g. "Start" and "STOP")
is always possible. The entry of text is optionally possible using a keyboard that can be connected externally. If faults
occur (e.g. failure of the rotary knob or softkeys), the machine can be operated completely using the external keyboard.
3.2.1 Operation via push switches (softkeys)
The five push switches (Items 1 - 6) are assigned with
standard functions as softkeys.
Examples:
The push switch (Item 6) is usually assigned the "Menu"
function, meaning pressing it brings you directly to the
main menu, regardless of which sub-menu currently ap-
pears in the display. The push switch
(Item 3) is assigned the "Save" function. This allows a pro-
cedure change to be saved rapidly.
123456
3.2.2 Operation via touch screen
Rapid and efficient operation via touch screen. Directly
touch the values to be changed. A virtual keyboard is
displayed. Operation while wearing protective gloves only
possible to a limited extent and not recommended.
7
3.2.3 Operation via rotary knob
The rotary knob (Item 8) has either a fine or rough detent
when being turned, depending on whether you are
navigating between menu items/fields (rough detent) or
setting parameter values (for example weld current) (fine
detent).
Navigating to a menu item/field in the display:
XTurn the rotary knob.
The menu item/field appears in blue.
8

ORBIMAT 180 SW | Operating instructions Description
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
Select the menu item/field:
XBriefly press the rotary knob. The menu item is selected.
Exiting the menu and navigating to the next-higher menu level:
XPress the rotary knob long (> 2 seconds). The menu of the next-higher level appears in the display.
Setting a parameter/Entering a value:
XHighlight a field. The field appears in red.
XChange the value within the specified limit values: Turn the rotary knob.
XSaving the value and exiting the field: Briefly press the rotary knob.
3.2.4 Operation via an external keyboard
Navigating to a menu item/field in the display:
XPress the UP and DOWN arrow buttons.
Selecting the menu item/field:
XPress the ENTER key.
Setting a parameter/Entering a value:
XHighlight a field. The field appears in red.
XEntering a value: Change with the arrow buttons or enter directly with the number keys.
XSaving the value and exiting the field: Press the ENTER key.
Entering comments on procedures:
XSelect a comment field.
XEnter the text using the keyboard.
Using push switches (softkeys) on the keyboard:
Function keys F1 through F6 on the external keyboard correspond to push switches 1 through 6.

Description ORBIMAT 180 SW | Operating instructions
16 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
3.3 Warning signs
The warning signs and safety signs located on the machine must be observed.
Image Position on machine Meaning Code
Hood inside Read the safety instructions! 871 001 057
Rear panel Before opening the unit disconnect the
mains plug.
850 060 025
Side, left Caution: Only use Orbitalum coolant! 884 001 001

ORBIMAT 180 SW | Operating instructions Scope of application
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
4. SCOPE OF APPLICATION
The ORBIMAT 180 SW is characterized by the following scope of application and functions:
• For welding using the Tungsten Inert Gas (TIG) process
• Can be used for all materials that are fundamentally suitable for the TIG welding process.
• Simple and convenient operation thanks to multifunctional rotary knob or touch screen
• DC current welding source
• WIDE RANGE input voltages for safe operation of power sets or voltage networks with extreme fluctuations in voltage
• "Flow Force" function to reduce the gas pre-flow and post-flow time
• "Permanent gas" function
• Digital regulation of the weld gas quantity
• Monitoring of coolant and weld gas
• Control option for cold wire feed
• Possibility of connecting an external remote control
• Constant or pulsed wire feed motion and rotation
• Optimal visibility and operating conditions thanks to clearly laid-out 12.4" swivel monitor
• Graphically-supported operating interface and multilingual menu navigation via color display
• Metric and imperial measuring units
• Process-oriented, stable and real-time operating system without power-down sequence
• Automatic weld head recognition and resulting parameter modification
• Motor current monitoring of the drive motors
• Capacity to store over 5.000 welding procedures, providing systematic and clear procedure management thanks to
the creation of folder structures
• Welding data logging and printout of actual values
• Integrated system printer
• Possibility of connecting a monitor or printer (through HMDI/USB/LAN)
• Optional PC software (OrbiProg CA) for welding procedure management and logging
• Integrated, folding carrying grips
• Option to program up to 99 sectors
• Power and motor slope adjustment between the individual sectors
• Integrated liquid cooling system for cooling the connected weld heads
• Can only be used in combination with separately available liquid cooling system
4.1 Accessories
Optionally available:
WARNING! Danger presented by using accessories that have not been approved.
Various injuries and damage to property.
XUse only original tools, spare parts, materials, and accessories from Orbitalum Tools.
4.1.1 ORBICAR W trolley
Thanks to its integrated liquid cooling function the ORBICAR W trolley
is the perfect supplement to the ORBIMAT 180 SW power source.
Beside the liquid cooling, the trolley is equipped with a practical holder for gas
bottles.
4.1.2 ORBICOOL Active
Very efficient compressor cooling device.
Particularly suitable for welding units in series production.

Scope of application ORBIMAT 180 SW | Operating instructions
18 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
4.1.3 ORBITWIN switching unit
To increase productivity, the ORBITWIN switching unit is available which allows the
alternately operation with 2 weld heads on the ORBIMAT.
4.1.4 ORBmax oxygen meter
For optical oxygen measurement using fluorescence extinction.
The ORBmax does not require any heating-up time. It recognizes the oxygen percent-
age reliably, rapidly and precisely during the entire welding process.
4.1.5 Remote control with cable
For transferring all the commands important for welding to the power source.
It is not required when working with enclosed orbital weld heads.
4.1.6 OCL-30 coolant
1 canister already included in the scope of delivery of the ORBIMAT 180 SW power
source.
Anti-freeze pre-mix for ORBIMAT power sources and cooling units to avoid freezing of
the cooling water. Protects up to –30 °C (-22°F) outside temperature. Increased ser-
vice life of components of the cooling system through very high corrosion protection
and high pH-value. Excellent ignition characteristics due to low conductivity. Clear
cooling liquid.
4.1.7 ORBIPURGE forming set
For rapid and efficient internal forming during pipe and molded part weld connections
while at the same time reducing gas consumptions.
4.1.8 Paper rolls and ribbon cartridges
For internal system printer.
Suitable for all ORBIMAT orbital welding power supplies.

ORBIMAT 180 SW | Operating instructions Technical specifications
(17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone]
5. TECHNICAL SPECIFICATIONS
PARAMETER UNIT ORBIMAT 180 SW REMARKS
Code 850 000 001
Weld system type Welding rectifier (inverter)
Input (mains)
Mains system 1 phase + PE
Mains input voltage [V (AV)] 110 - 230
Permissible voltage tolerance [%] +/–10
Mains frequency [Hz] 50/60 –
Continuous input current [A (AC)] 15.3
Continuous input [kVA] 3.6
Current consumption, max. [A (AC)] 19.5
Connection value, max. [kVA] 13.5
Power factor [cos ϕ] 1.0 (with 180 A)
Output (welding circuit)
Setting range weld current [A (DC)] 3 - 180 In 0.1 A increments
Weld current reproducibility [%] +/– 0.5
Rated current at 100% duty cycle [A (DC)] 160
Rated current at 60% duty cycle [A (DC)] 180
Weld voltage, min. [V (DC)] 10
Weld voltage, max. [V (DC)] 20
Open-circuit voltage, max. [V (DC)] 85
Ignition power, max. [Joule] 0.9
Ignition voltage, max. [kV] 10
Output (control)
Rotation motor voltage, max. [V (DC)] 24 PWM signal
Wire feeding motor voltage, max. [V (DC)] 24 PWM signal
Rotation motor current, max. [A (DC)] 1.5
Wire feeding motor current, max. [A (DC)] 1.5
Rotation tacho voltage [V (DC)] 0 - 10 Rotation speed, actual value
Other
Degree of protection IP 23 S
Cooling type AF
Insulation class F
Dimensions (wxdxh) [mm]
[inch]
600 x 400 x 310
23.6 x 15.7 x 12.2
300 CA without cooling unit
Weight [kg]
[lbs]
24.6
54.23
Gas input pressure [bar] 3 - 10 Via pressure reducer
Recommended gas input pressure [bar] 4 Via pressure reducer
Coolant volume [l] 2.2
Coolant pressure, max. [bar] 4
Sound level, max. [dB (A)] 70

Storage and transport ORBIMAT 180 SW | Operating instructions
20 orbitalum tools GmbH, D-78224 Singen, www.orbitalum.com, Phone [phone] (17.09.18) OW_ORBIMAT_180SW_BA_850060202_00_EN
6. STORAGE AND TRANSPORT
6.1 Gross weight
ARTICLE WEIGHT*
ORBIMAT 180 SW [kg] 28.0
[lbs] 61.73
* incl. transport packaging
WARNING! Damage of electronic components with personal harm and damage to property.
If coolant is still located in the machine during transportation, coolant can enter from the tank into
the machine interior if tilted strongly.
XPump out coolant before transporting.
WARNING! Danger of injury through high weight of the orbital welding power supply!
The orbital welding power supply has a weight of 28.0 kg (61.73 lbs).
XAlways lift the orbital weld head with two persons or use a suitable means of transport.
XWhen lifting the machine do not exceed the permissible total weight of 25 kg for men and 15 kg
for women.
6.2 Preparing storage
Carry out the following steps before storage:
6.2.1 Removing the weld head from the orbital welding power supply
For procedure see operating instructions of weld head.
6.2.2 Pumping out coolant
1. Connect the drain hose to the coolant connection,
blue.
2. Hold the end of the drain hose into a collecting vessel
(min. 3 liter). 1