Orbitalum MOBILE WELDER OC PLUS User manual

en Orbital Welding Power Supply
Translation of original operating instructions and spa-
re parts list
854 060 201
MOBILE WELDER
OC PLUS
00 | 2022REV

ENGLISH MOBILE WELDER OC PLUS
2ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
Table of Contents
1 About these instructions................. 5
1.1 Warning messages .................. 5
1.2 Further icons and displays....... 5
1.3 Legend..................................... 6
1.4 Further applicable documents.. 6
2 Information and safety instructions
for the owner ....................................
7
2.1 Requirements for the owner-
operator....................................
7
2.2 Using the machine ................... 9
2.2.1 Intended use .............. 9
2.2.2 Machine constraints... 10
2.2.3 Welding in environ-
ments with increased
electrical hazards.......
10
2.2.4 Device cooling ........... 10
2.3 Environmental protection and
disposal....................................
11
2.3.1 Information regarding
the Ecodesign Direc-
tive 2009/125/EG .......
11
2.3.2 REach (Registration,
Evaluation, Authoriza-
tion and Restriction of
Chemicals).................
12
2.3.3 Coolant ...................... 12
2.3.4 Electric tools and ac-
cessories....................
13
2.4 Personnel qualification............. 13
2.5 Fundamental information on
operational safety.....................
13
2.6 Personal protective equipment 14
2.7 Remaining risks ....................... 15
2.7.1 Injury through high
weight ........................
15
2.7.2 Burns and danger of
fire through high tem-
peratures....................
16
2.7.3 Tripping over wires
and cables .................
16
2.7.4 Long-lasting physical
damage through
wrong posture ............
17
2.7.5 Electric shock............. 17
2.7.6 Danger from incorrect
handling of shielding
gas bottles .................
18
2.7.7 Damage to eyes
through radiation........
18
2.7.8 Dangers through elec-
tromagnetic fields.......
18
2.7.9 Risk of suffocation
from an excessive
amount of argon in the
air...............................
18
2.7.10 Health problems......... 18
2.7.11 Danger of system tip-
ping over ....................
19
2.7.12 Danger of explosion
and fire.......................
19
2.7.13 General injuries
through tools ..............
19
3 Description ....................................... 21
3.1 Basic machine.......................... 21
3.1.1 Warning signs ............ 23
3.2 Cooling unit .............................. 23
4 Scope of application........................ 24
5 Technical specifications.................. 25
6 Transport and shipping................... 27
6.1 Gross weight ............................ 27
6.2 Shipping ................................... 28
6.3 Transport.................................. 28

MOBILE WELDER OC PLUS ENGLISH
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 3
6.3.1 Adjusting the length of
the shoulder strap ......
30
7 Setup and commissioning .............. 31
7.1 Unpacking the power supply.... 31
7.2 Scope of delivery ..................... 32
7.3 Setting up the power supply..... 32
7.4 Attaching the cooling unit......... 33
7.5 Connecting the weld head/
manual welding torch...............
33
7.6 Setting up the welding gas sup-
ply ............................................
34
7.7 Mains connection..................... 35
7.8 Operation of the power supply
with other mains voltages ........
36
7.9 Connecting the power cable .... 36
7.10 Switching on the power supply 37
7.11 Activation ................................. 38
7.12 Login screen ............................ 39
7.12.1 Login .......................... 40
7.12.2 Changing a password 41
7.12.2.1 Changing the Admin
Password ...................
42
7.12.2.2 Changing the user
password ...................
43
7.12.3 Resetting a password 44
7.13 User levels ............................... 44
7.13.1 Administration level.... 44
7.13.2 User level................... 44
7.14 Operating concept.................... 46
7.14.1 Software control ele-
ments and fields.........
46
7.14.2 Input devices and con-
trol elements ..............
50
7.14.2.1 Softkey buttons .......... 50
7.14.2.2 Touchscreen .............. 50
7.14.2.3 Rotary actuator .......... 53
7.14.2.4 USB keyboard............ 56
7.14.2.5 USB code scanner..... 59
7.15 Setting the system language
and language of the documen-
tation ........................................
60
7.16 Setting the units of measure .... 61
8 Operation .......................................... 62
8.1 Main menu ............................... 64
8.1.1 Program Manager...... 70
8.1.1.1 Loading the welding
procedure...................
73
8.1.1.2 Saving the welding
procedure...................
73
8.1.1.3 Creating a folder ........ 74
8.1.1.4 Managing welding
procedures.................
74
8.1.1.5 Removing share......... 81
8.1.2 Protocol Manager ...... 83
8.1.3 Auto programming ..... 86
8.1.3.1 Using auto program-
ming ...........................
86
8.1.4 Adjusting the program 89
8.1.4.1 Adjusting level seg-
ments .........................
89
8.1.4.2 Adjusting parameters. 91
8.1.5 TIG manual welding
mode..........................
110
8.1.5.1 Welding ramp process
graphic .......................
112
8.1.5.2 Adjust Program - Man-
ual_Welding_Mode ....
114
8.1.5.3 Welding in the manual
welding mode.............
116
8.1.5.4 Functions Man-
ual_Weld-
ing_Torch_Con-
trol_Panel...................
118
8.1.5.5 Logout........................ 122
8.1.6 Settings...................... 123
8.1.6.1 System adjustments... 123
8.1.6.2 Program settings........ 130
8.1.6.3 System data............... 136
8.1.6.4 Network environment. 137
8.1.6.5 Service....................... 144

ENGLISH MOBILE WELDER OC PLUS
4ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
8.1.6.6 Setting the language
and keyboard .............
152
8.2 Weld mode............................... 153
8.2.1 "Gas" softkey ............. 156
8.2.1.1 Gas overview ............. 156
8.2.1.2 "Gas On" softkey........ 160
8.2.1.3 "Permanent Gas" soft-
key .............................
160
8.2.1.4 "Back" softkey ............ 160
8.2.2 Motor control.............. 160
8.2.2.1 "Motor" softkey........... 160
8.2.2.2 "Wire" softkey............. 160
8.2.2.3 "Global Change" soft-
key .............................
161
8.2.2.4 "Menu" softkey ........... 161
8.3 Test mode................................ 162
8.4 Welding process ...................... 164
9 Special commands........................... 166
9.1 Keyboard entry of special com-
mands ......................................
166
9.2 "Special Commands" softkey... 166
10 Service and maintenance................ 167
10.1 Service screen ......................... 167
10.2 Software information................ 167
10.3 Motor calibration ...................... 167
10.4 Printer ...................................... 169
10.4.1 Replacing the roll of
paper..........................
169
10.5 Maintenance schedule............. 169
10.6 Service and customer support . 170
10.6.1 Customer support ...... 170
10.6.2 Technical support &
application engineer-
ing ..............................
170
10.6.3 Operator and service
training .......................
171
11 Storage and decommissioning....... 172
12 Upgrade options............................... 173
13 Accessories...................................... 174
14 Consumables.................................... 176
15 SPARE PARTS LIST......................... 178
15.1 Grundaufbau MW (Frontan-
sicht) | Basic structure MW
(front view) ...............................
178
15.2 Grundaufbau MW (Rückan-
sicht) | Basic structure MW
(rear view) ................................
180
15.3 Bodenblech MW | Base plate
MW...........................................
182
15.4 Frontabdeckung MW | Front
cover MW.................................
184
15.5 Rückwand MW | Rear panel
MW...........................................
186
15.6 Gaskomponenten MW | Gas
components MW ......................
188
15.7 Vertikalblech MW | Vertical
plate MW..................................
190
15.8 Horizontalblech MW | Horizon-
tal plate MW .............................
192
15.9 Handgriff-Abdeckung MW |
Handle-display cover MW ........
194
15.10 Schweißstrominverter MW |
Welding current inverter MW ...
196
15.11 Verbindungskabel | Connection
cables.......................................
198
15.12 Service, Kundendienst | Servic-
ing, customer service ...............
201
16 DECLARATION OF CONFORMITY.. 202

MOBILE WELDER OC PLUS ENGLISH
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 5
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.

ENGLISH MOBILE WELDER OC PLUS
6ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
1.3 Legend
Term/SYMBOL MEANING
MW Mobile Welder
OC ORBICOOL
Orbital weld head Open orbital weld head / orbital welding tongs
Closed orbital weld head
This function is only available with the UPGRADE
• ORBICOOL MW
• Software MW Plus
• Connectivity LAN/IoT/VNC
option
1.4 Further applicable documents
The following documents apply together with these operating instructions:
• Declaration of Conformity
• Calibration certificate
• Operating instructions for weld head/manual welding torch
• Operating instructions for ORBICOOL MW

MOBILE WELDER OC PLUS ENGLISH
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 7
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

ENGLISH MOBILE WELDER OC PLUS
8ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com

MOBILE WELDER OC PLUS ENGLISH
ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 9
2.2 Using the machine
2.2.1 Intended use
WARNING Dangers result from improper use!
The device has been manufactured according to the state of the art and
the recognized safety regulations and standards for use in industry and
trade. It is intended only for the welding processes specified in these
operating instructions. If the device is not used as intended, it may pose
a risk to persons, animals and property. No liability is assumed for any
resulting damage.
► Only use the unit for TIG DC welding with Liftarc (contact ignition) or
HF ignition (non-contact). Accessory components can extend the
range of functions if necessary (see the chapter Accessories
[}174]).
The orbital welding power supply is intended solely for the following utilization:
• Utilization in combination with an orbital weld head or manual welding torch 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 suitable for the TIG welding process.
• Empty unpressurized tubes that are free of contaminations, explosive atmospheres or liquids.
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.
• 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.

ENGLISH MOBILE WELDER OC PLUS
10 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
• 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.
• Cooling is only ensured with a full coolant tank.
• Smoke, steam, oil vapors and grinding dust must be avoided.
• Avoid salty ambient air (sea air).
2.2.3 Welding in environments with increased electrical hazards
The power supply can be used in environments with increased electrical hazards.
It complies with the regulations and standards IEC/DIN EN 60974 and VDE0544.
2.2.4 Device cooling
Insufficient ventilation leads to reduced performance and equipment damage.
► Observe the limits of the machine.
► Keep inlet and outlet openings of the cooling air unobstructed.
► Keep a minimum distance of 0.5 m from obstacles.