Orbitalum MOBILE HEAD User manual

en-
US
Open orbital weld heads
Translation of original operating instructions and
spare parts list
803 060 201
MOBILE HEAD
00REV

MOBILE HEAD
2ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
Table of Contents
1 ABOUT THESE INSTRUCTIONS ..... 4
1.1 Warning messages .................. 4
1.2 Further icons and displays....... 4
1.3 Abbreviations ........................... 4
1.4 Further applicable documents.. 5
2 Information and safety instructions
for the owner ....................................
6
2.1 Requirements for the owner-
operator....................................
6
2.2 Using the machine ................... 6
2.2.1 Proper use ................. 6
2.2.2 Machine constraints... 7
2.3 Environmental protection and
disposal....................................
8
2.3.1 Information regarding
the Ecodesign Direc-
tive 2009/125/EG .......
8
2.3.2 REACh (Registration,
Evaluation, Authoriza-
tion and Restriction of
Chemicals).................
8
2.3.3 Electric tools and ac-
cessories....................
9
2.4 Personnel qualification............. 9
2.5 Fundamental information on
operational safety.....................
10
2.6 Personal protective equipment 10
2.7 Remaining risks ....................... 10
2.7.1 Injury through high
weight ........................
10
2.7.2 Prick injury through
pointed electrode .......
11
2.7.3 Danger of crushing
through being caught
in by moving parts......
11
2.7.4 Injury through rotating
rotor ...........................
11
2.7.5 Danger of cuts at
sharp edges ...............
12
2.7.6 Burns and risk of fire.. 12
2.7.7 Tripping over wires
and cables .................
13
2.7.8 Long-lasting physical
damage through
wrong posture ............
13
2.7.9 Electric shock............. 13
2.7.10 Damage to eyes
through radiation........
14
2.7.11 Dangers through elec-
tromagnetic fields.......
15
2.7.12 Risk of suffocation
from an excessive
amount of argon in the
air...............................
15
2.7.13 General injuries
through tools ..............
15
3 Description ....................................... 17
3.1 Basic machine.......................... 17
3.2 Torch unit ................................. 19
3.3 Control panel/control elements 20
4 Scope of application........................ 21
5 Technical specifications.................. 22
5.1 Weld head................................ 22
5.2 Electrodes ................................ 23
5.3 Dimensions .............................. 24
6 Transport .......................................... 25
6.1 Transport weight ...................... 25
6.2 Transporting the weld head ..... 25
7 Commissioning ................................ 26
7.1 Scope of delivery ..................... 26
7.2 Preparing initial operation ........ 26

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 3
8 Set-up and mounting ....................... 27
8.1 Procedure ................................ 27
8.2 Fit drop guard........................... 28
8.3 Fit clamping jaws ..................... 29
8.4 Clamp the weld head onto the
workpiece.................................
29
8.5 Set up the electrode................. 30
8.6 Set up the torch........................ 31
8.7 Connecting the weld head to
the power source .....................
34
8.7.1 Connection scheme ... 35
8.7.1.1 Connection sequence 36
8.8 Wind up power/gas hose ......... 37
8.9 Carry out gas function test....... 39
8.10 Configure the welding proce-
dure..........................................
39
9 Operation .......................................... 40
9.1 Weld mode............................... 40
9.2 Returning the weld head to
home position...........................
41
9.3 Removing the weld head from
the workpiece...........................
42
9.4 Aborting welding ...................... 42
9.5 Preparing storage .................... 44
10 Maintenance and troubleshooting.. 45
10.1 Instructions for care ................. 45
10.2 Maintenance and care ............. 45
10.2.1 Standard cleaning
process ......................
45
10.3 Replacing the gas nozzle and/
or lens ......................................
46
10.4 Troubleshooting ....................... 48
10.5 Grinding electrodes.................. 49
10.6 Servicing/Customer service ..... 49
11 Accessories (optional)..................... 50
Ersatzteilliste / Spare parts list....... 51
Gesamtmaschine MH
3.0/4.5/6.6 | Total machine MH
3.0/4.5/6.6................................
51
Motorhülse MH 6.6-4.5-3.0 |
Motor sleeve MH 6.6-4.5-3.0 ...
53
Grundkörper MH 4.5 | Base
body MH 4.5.............................
55
Drehteller MH 4.5 | Turntable
MH 4.5 .....................................
57
Spanneinheit MH 4.5 | Clamp-
ing unit MH 4.5.........................
61
Konformitätserklärungen ................ 63

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4ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
1 ABOUT THESE INSTRUCTIONS
1.1 Warning messages
The warnings used in these instructions warn you of injuries or damage to property.
Always read and observe these warnings!
This is a warning icon. It warns against dangers of injury. In order to avoid injuries or
death observe the measures marked with a safety sign.
WARNING LEVEL MEANING
DANGER Imminently hazardous situation that results in death or serious in-
juries if the safety measures are not observed.
WARNING Potentially hazardous situation that may result in death or serious
injuries if the safety measures are not observed.
CAUTION Potentially hazardous situation that may result in slight injuries if
the safety measures are not observed.
NOTE! Potentially hazardous situation that may result in material damage
if the safety measures are not observed.
1.2 Further icons and displays
SYMBOL MEANING
Request for action in a sequence of actions: Action is required
here.
1.
2.
3.
…
Request for action in a sequence of actions: Action is required
here.
► Single request for action: Action is required here.
1.3 Abbreviations
ABBREVIATION MEANING

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 5
MH Orbital weld head, type “Mobile Head”
1.4 Further applicable documents
The following documents apply together with these operating instructions:
• Instructions for orbital welding power supply

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6ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
2 Information and safety instructions for the owner
2.1 Requirements for the owner-operator
Workshop/outdoor/field use: The owner is responsible for safety in the danger zone around the ma-
chine, 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 directives and to evaluate the workplace correspondingly.
Requirements for special EMF evaluations with regard to general activities, working materials
and workplaces*:
TYPE OF WORKPLACE
OR WORK EQUIP-
MENT
EVALUATION REQUIRED FOR:
Employees without
particular risk
Employees at particu-
lar risk
(with the exception of
those
with active implants)
Employees with active
implants
(1) (2) (3)
Arc welding, manual (in-
cluding MIG (Metal Inert
Gas), MAG (Metal Active
Gas), TIG (Tungsten In-
ert Gas) under obser-
vance of tried-and-tested
procedures and without
physical contact to the
line
No No Yes
* To Directive 2013/35/EU
2.2 Using the machine
2.2.1 Proper use
The orbital weld head is intended solely for the following utilization:
• Utilization in combination with an Orbital welding power source of the ORBIMAT and Mobile Welder
series.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 7
• TIG welding of materials that are specified in these operating instructions (see chap. applications).
• Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.
Only protective gases that are classified for TIG welding in accordance with EN ISO 14175 may be
used.
Proper use also includes the following points:
• Permanent supervision of the machine during operation. The operator must always be able to stop
the process.
• Observing all safety and warning information in these operating instructions.
• Observing of the further applicable documents.
• Complying with all inspection and maintenance work.
• Use of the machine solely in its original state.
• Usage solely of original accessories as well as original spare parts and operating materials.
• Checking of all the safety-relevant items and functions before commissioning.
• Processing of those materials named in the operating instructions.
• Proper 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 device is operated by one person.
• The device may only be set up and operated on a stable, level and non-slip surface.
• A space of about 2 m for people to move around the unit must be provided.
• Work lighting: min. 300Lux.
• Ambient conditions during operation:
Ambient temperature: –10°C to +40°C
Relative humidity: < 90% at +20°C, < 50% at +40°C
• Ambient conditions during storage and transport:
Ambient temperature: –20°C to +55°C
Relative humidity: < 90% at +20°C, < 50% at +40°C
• The device may only be installed and operated in a dry environment according to IP 23 (not in fog,
rain, thunderstorms, etc.). If appropriate, use a welding tent.
• Smoke, steam, oil vapors and grinding dust must be avoided.

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8ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
• Avoid salty ambient air (sea air).
2.3 Environmental protection and disposal
2.3.1 Information regarding the Ecodesign Directive 2009/125/EG
(as per RL 2012/19/EU)
• Do not dispose of product (if applicable) with general waste.
• Reuse or recycle waste electrical and electronic equipment (WEEE)
by disposing of it at a designated collection point.
• Contact your local recycling office or dealer for more information.
Critical raw materials potentially present in indicative quantities
greater than 1 gram at the component level.
Critical raw materials potentially present in indicative quantities greater than 1 gram at the com-
ponent
COMPONENT CRITICAL RAW MATERIAL
Printed circuit boards Barite, bismuth, cobalt, gallium, germanium, hafnium, indium, heavy rare
earths, light rare earths,
Niobium, platinum group metals, scandium, silicon metal, tantalum, vana-
dium
Plastic components Antimony, Barite
Electrical and electronic
components
Antimony, beryllium, magnesium
Metal components Beryllium, cobalt, magnesium, tungsten, vanadium
Cable and cable assem-
blies
Borate, antimony, barite, beryllium, magnesium
Displays Gallium, indium, heavy rare earths, light rare earths, niobium, platinum
group metals, scandium
Batteries Fluorspar, heavy rare earths, light rare earths, magnesium
2.3.2 REACh (Registration, Evaluation, Authorization and Restriction of
Chemicals)
The regulation (EC) 1907/2006 of the European Parliaments and of the Council concerning the registra-
tion, evaluation, authorization and restriction of chemicals (REACh) regulates the production, placing on
the market and use of chemical substances and the mixtures produced from these.

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Our products are "products" in the sense of the REACh regulation. In accordance with Article33 of the
REACh regulation, suppliers of products must inform their customers if the supplied product contains a
substance specified in the REACh SVHC candidate list exceeding 0.1percent by mass of the object. On
June 27, 2018 lead (CAS: 7439-92-1 / EINECS: 231-100-4) was included in the SVHC candidate list.
This inclusion activates an obligation to inform along the chain of delivery.
We herewith inform you that individual partial components of our products contain lead in quantities ex-
ceeding 0.1% by mass of the object as an alloy component in steel, aluminum and copper alloys as
well as in solders and capacitors of electronic components. The lead content lies within the exceptions
specified in the RoHS Directive.
Since lead as an alloy component is firmly bound and therefore no exposure is to be expected in the
case of proper use, no additional specification of its safe use are required.
2.3.3 Electric tools and accessories
Used-up power tools and accessories contain a large amount of valuable raw materials and plastics
which can be recycled:
• Used electronic devices marked with the adjacent icon may not be disposed of with household
waste in accordance with EU directives.
• By actively using the offered return and collection systems, you are doing your part to reuse and
recycle used electronic devices.
• Used electronic devices contain parts that must be handled selectively according to the EU
directive. Separate collection and selective treatment are the basis for environmentally responsible
disposal and protection of human health.
• We will properly dispose of devices and machines from Orbitalum Tools GmbH purchased after
August 13th, 2005 if they are sent to us postage-paid.
• In the case of used electronic devices which may represent a risk to human health or safety due to
contamination during use, we have the option of refusing return.
•Important note for Germany: Devices and machines of Orbitalum Tools GmbH may not be
disposed of at communal dumps, as they are only used in the commercial sector.
2.4 Personnel qualification
CAUTION! The weld head may only be used by instructed personnel.
• Minimum age: 18 years old.
•No physical and mental impairments.
• Operation of the machine by underage persons only under supervision by a person authorized to
issue instructions.
• A basic knowledge of the TIG welding process is advisable.

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10 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
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.
• Never leave the weld head unattended when the power supply is switched on.
• The operator must ensure that no 2nd person is located within the danger zone.
• Do not modify or convert the weld head.
• Use the weld head only in proper operating order.
• Use only genuine tools, spare parts and accessories as well as specified operating materials.
• In case of changes in the operating behavior, stop operation immediately and have the fault
eliminated.
• Do not remove safety devices.
• Do not pull the machine by the hose assembly or the cable.
• Repair and maintenance work on the electrical equipment may only be carried out by a qualified
expert.
CAUTION! Risk of injury through monotonous work!
Discomfort, tiredness and malfunctions in the motor system, restricted ability to
react and cramping.
• Perform "loosening-up" exercises.
• Ensure a varied range of activities.
• Assume an upright, fatigue-free and comfortable body position during operation.
2.6 Personal protective equipment
The following personal protective equipment must be worn while working at the system:
► Safety gloves 1/1/1/1 in accordance with EN 388 or 1/2/1/1 EN 407.
► Safety gloves DIN 12477, Type A for welding operation and DIN 388, Class 4 for mounting the
electrode.
► Safety shoes to ENISO20345, Class SB.
► For overhead work safety helmet according to EN397.
2.7 Remaining risks
2.7.1 Injury through high weight
A significant health hazard exists during lifting. Observe machine weights, chap. Gross weight.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 11
Danger of impact and crushing exists in the following situations:
CAUTION! Falling of the orbital weld head during transportation, mounting/dismantling or
setting up.
CAUTION! Falling of the transport case caused by it being put down improperly.
CAUTION! Falling of the weld head in case of impermissible usage in overhead position.
► Wear safety shoes to ENISO20345, Class SB.
► Place the transport case on a stable base near (approx. 1.5m/ 4.9 ft) the welding power supply.
► Do not carry the transport case on a ladder.
► To set up the weld head place it flat and ensure that it cannot fall down.
► Fit drop guard to weld head.
► Weld head may only be used with drop guard in overhead positions.
► Do not transport the device by crane. Use handles, straps or holders for hand transport only.
2.7.2 Prick injury through pointed electrode
CAUTION! Danger of being pricked by the electrode for the operator as well as for third par-
ties while taking hold of the weld head.
► Do not grasp the weld head at the position of the electrode.
► Remove electrode before storing the weld head.
2.7.3 Danger of crushing through being caught in by moving parts
CAUTION! Hands and fingers can be caught in and crushed while setting up the weld head.
► Before setting up or before electrode replacement lay the weld head flat on the base.
► Switch off the welding power supply before setting up or before an electrode replacement.
2.7.4 Injury through rotating rotor
DANGER! The rotation movement of the rotor can cause hair, jewelry or clothes to be
caught and pulled into the enclosure.
CAUTION! Risk of crushing of hands and fingers!
The rotor can start up unexpectedly during the setup of the electrode.

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12 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
► Before connecting the weld head and before mounting the electrode: Switch off orbital welding
system.
► Before moving the rotor with closed weld heads, fit clamping cassette or clamping unit and close
flip cover.
► Wear tight-fitting clothes.
►Do not wear open hair, jewelry or other accessories that can be easily drawn in.
► Before connecting the weld head and before mounting the electrode. Switch off the welding
power supply.
2.7.5 Danger of cuts at sharp edges
CAUTION! Danger of cut injuries caused by sharp tube edges when clamping the weld
head at the tube.
► Wear safety gloves 1/1/1/1 in accordance with EN 388 or 1/2/1/1 EN 407.
2.7.6 Burns and risk of fire
CAUTION! After welding the weld head and the workpiece are hot. Very high temperatures
arise in particular after several consecutive welding processes. There is a dan-
ger of burns or damage to the points of contact when working on the weld head
(for example when changing clamps or mounting/removing the electrodes). Ma-
terials without thermal resistance can be damaged when coming into contact
with the hot weld head.
WARNING! Thermal problems can arise in the case of incorrect positioning of the weld head
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.
WARNING! Tripping over the above could cause the weld current connection to be pulled
out so that an arc may arise between the weld current connection and the orbital
weld system. This can result in burns and blindness, in the worst case a fire can
be started.
► Wear safety gloves 1/1/1/1 in accordance with EN 388 or 1/2/1/1 EN 407.
► Wait until the surfaces have cooled down to below 50°C (122°F) before working on the weld
head or before packing into the transport case.
► Position the weld head correctly.
► Use only permissible materials in the welding area.
► Ensure that under no circumstances can people trip over lines and/or cables.
► Do not put lines or cables under tension.
► Place the welding tongs in the transport case after dismantling.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 13
► Ensure that the hose assembly is connected properly and that the strain relief is attached.
2.7.7 Tripping over wires and cables
CAUTION! If the power cable, gas line or control cable are under tension, there is the dan-
ger that persons may trip over them and be injured.
WARNING! Tripping over the above could cause the weld current connection to be pulled
out so that in the worst case an arc may arise between the weld current connec-
tion and the orbital weld system. Burns and glaring light may be the result.
► Ensure that under no circumstances can people trip over lines and/or cables.
► Do not put lines or cables under tension.
► Place the welding tongs in the transport case after dismantling.
► Ensure that the hose assembly is connected properly and that the strain relief is attached.
2.7.8 Long-lasting physical damage through wrong posture
Use the machine so that an upright and comfortable body position can be achieved during operation.
2.7.9 Electric shock
Two electrical potentials are applied during the welding process:
• Potential 1: Electrode/torch body (-)
• Potential 2: Remaining components of the weld head incl. pipe (+)
CAUTION! Danger of an electric shock at simultaneous contact with both potentials during
the high-frequency ignition.
► From the start of the welding process avoid contact with the tube and the housing of the orbital
weld head.
► Wear safety gloves DIN12477, Type A for welding operation and DIN 388, Class 4 for mounting
the electrode.
DANGER! Risk of death for people with heart problems or cardiac pacemakers.
► From the start of the welding process avoid contact with the tube and the housing of the weld
head.
WARNING! There is a risk of of unintentionally operating the ignition function when connect-
ing or disconnecting a weld head/manual welding torch to or from the power
supply.

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14 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
► Switch off the power supply when connecting or disconnecting a weld head or manual welding
torch.
► If the weld head or manual welding torch is not ready for operation, switch it to the "Test" func-
tion.
DANGER! Electrical hazards through touching as well as incorrect or damp protective
equipment.
► Wear dry safety shoes, dry metal-free (grommet-free) leather gloves and dry safety suits to mini-
mize the electrical hazard.
► Work on a dry surface.
DANGER! Electric shock along with injuries and damage to property on other devices due
to erroneous ignition with unmounted or incorrectly positioned weld head.
► Do not play with weld head.
DANGER! Electric shock and risk of crushing due to improper action and opening of the
weld head.
► Unplug the weld head from the power source.
► Allow machine to cool down sufficiently before opening.
► Allow only a professional electrician to access the electrical system.
►Never connect open weld head to the power source.
WARNING! Various injuries and damage to property due to electromagnetic incompatibility
of surrounding devices during high-frequency ignition and devices in operation
without a protective ground.
► Use only electrical devices with protective insulation in the working area of the welding system.
► Observe electromagnetically-sensitive devices when igniting the system.
2.7.10 Damage to eyes through radiation
WARNING! During the welding process infrared, glaring and ultraviolet rays arise that can
seriously damage the eyes.
► Keep clamping cassette or unit and flip cover closed during the welding process.
►Do not look into electric arc
► Wear eye protection to EN 170.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 15
2.7.11 Dangers through electromagnetic fields
DANGER! Depending on the form of the workplace, life-threatening electromagnetic fields
can arise in the direct vicinity.
► People with heart problems or cardiac pacemakers must not operate the welding system.
► The owner has to ensure safe design of the workplace in accordance with the EMF Directive
2013/35/EU.
► Use only electrical devices with protective insulation in the working area of the welding system.
► Observe electromagnetically-sensitive devices when igniting the system.
2.7.12 Risk of suffocation from an excessive amount of argon in the air
DANGER! If the level of shielding gas in the ambient air rises, lasting damage or risk of
death can arise as the result of suffocation.
► Ensure sufficient ventilation in rooms.
► If necessary, monitor the oxygen level in the air.
2.7.13 General injuries through tools
CAUTION! Injuries can occur during dismantling for the proper disposal of the weld head
through uncertainties in handling tools.
► In case of uncertainties send the weld head to Orbitalum Tools – proper disposal is carried out
here.
► Allow only a professional electrician to access the electrical system and open the weld head.

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3 Description
3.1 Basic machine
1
12
3
45
9
2
7
13
10
11
11
6
5
8

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18 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
NO. DESIGNATION FUNCTION
1 Torch articulated arm Holder and movement of torch assembly.
2 Mounting lug Fastening of a drop guard.
3 Control panel Control of weld head functions.
4 Motor/handle Drive of rotation movement and handle.
5 Connection control line For connection to the control cable.
6 Rotor plate Carrier part for torch arm and hose holder.
7 Power/gas cable Transfer of welding current and shielding gas.
8 Hose holder For the secure winding of the hose package during rotation
of the weld head.
9 Clamp arms For clamping the weld head to the workpiece to be welded.
Installation option of reduction jaws.
10 Type plate Lists data for the weld head.
11 Setting of the clamping range (pipe
Ø)
For setting the pipe diameter.
12 Clamping lever For clamping and releasing the weld head to the workpiece.
13 Clamping unit For clamping the weld head to the workpiece.
See also
2 Torch unit [ } 19]

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3.2 Torch unit
1
7
3
4
2
6
5
8
9
10
11
NO. DESIGNATION FUNCTION
1 Holder for torch body Fastening of torch body
2 Torch body Supply of the weld current to the electrode.
3 Insulation ring Sealing of torch and gas nozzle against air intake.
4 Gas nozzle Bundling of the gas flow.
5 Electrode gap adjusting
screw
Setting of the distance between electrode and workpiece.
Depending on the application, the arc gap must amount to between
approx. 1mm and 3mm (0.039" and 0.118") and be effected by
means of a feeler gage.
6 Torch cap Clamping of electrode.
7 Electrode angle adjusting
screw
Adjusting of electrode angle to pipe axis.
8 Axial torch adjustment
knurled nut
Linear torch adjustment parallel to the pipe axis.
9 Torch arm locking Fixing and releasing of the torch arm.
10 Electrodes Transfer of welding current.
11 Torch position adjusting
screw
Linear torch rough adjustment to pipe axis and side torch tilt adjust-
ment.

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3.3 Control panel/control elements
1 2 3 4 5
POS. CONTROL ELEMENT FUNCTION
1LED • LED blinks in ready-to-weld state.
• LED lights up constantly during the welding process.
2START/
STOP
• Pressing once: Starts the welding process.
• Press during the welding process: Welding process is stopped
and gas post purge time is started.
• Press during the gas post purge time: Gas post purge is
interrupted.
3GAS • Pressing once: Function test of the gas supply is started.
• Pressing again: Function test is terminated.
• Pressing and holding the key in welding mode or in test mode of
welding power supply: Mode is switched.
4ROTATION (COUN-
TERCLOCKWISE)
• Pressing briefly: Rotor rotates step-by-step (counterclockwise) in
the welding direction.
• Pressing and holding: Rotor rotates continuously
(counterclockwise) in the welding direction.
5ROTATION (CLOCK-
WISE)
• Pressing briefly: Rotor rotates step-by-step (clockwise) in the
welding direction.
• Pressing and holding: Rotor rotates continuously (clockwise) in
the welding direction.