ORBITEC OSW Series User manual

Operation Manual
"Open Frame Welding Head OSW Series"
1
OSW Weld Heads
Rev 00/092014
Subject to revision and change without notice!
ORBITEC GmbH
Willi-Brehm-Straße 8
D-63500 Seligenstadt
Tel.: [phone] / 78693-0
Fax: [phone]
E-Mail: [email protected]
Internet: www.orbitec-group.com

Operation Manual
"Open Frame Welding Head OSW Series"
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Table of contents
Page
Table of contents 2
1. General 3
2. Safety information 4
3. Application ranges - dimensions - views 5
4. Functional principles of the open frame weld head 9
5. Connecting the weld head to the power supply 10
6. Operation of the open frame weld head 12
7. Spare parts and consumables 15
7.1. Torch parts list 15
7.2. Torch arm parts list 15
8. Predetermined breaking point in drive 16
8.1. Maintenance 16
9. Addendum 17
9.1. Water-cooled torch 17
9.2. Fillet welds 18
9.3. Torch variants 18
10. Addendum OSW new version Bj 19

Operation Manual
"Open Frame Welding Head OSW Series"
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1. General
The OSW Series welding tongs are welding tongs of the open construction type. The OSW Series welding
tongs are driven by 24 V DC motors. Excellent speed control is achieved through the absolutely maintenance-
free and indestructible encoder².
ORBITEC offers a wide range of open frame weld heads. The concept behind the OSW Series is for use in
mobile applications in the food industry, in general mechanical engineering and in the chemical, cleaning and
pharmaceutical industries.
OSW Series welding tongs offer:
Compensation for tube quality by sensing
Robust design
User-friendly operation through quick-action clamping devices
3D adjustable torch head
Coverage of large diameter ranges with each individual head
No need for separate collets for each outside diameter
The possibility of a wire feed
TIG hose package can be used for several weld heads

Operation Manual
"Open Frame Welding Head OSW Series"
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2. Safety information
Serious injury can occur to you and others when arc welding. You should therefore
observe the relevant safety and accident prevention regulations also during orbital
welding work.
Electric shock can lead to death!
Welding equipment must be installed and earthed in accordance with local
standards.
Do not touch live parts or electrodes with bare hands or wet protective
equipment.
Welding personnel must themselves be insulated from ground and the
workpiece.
The workplace must be safe.
Welding pearls can ignite a fire.
Do not store combustible items at the workplace.
UV and IR radiation can cause burns to the eyes and skin.
Protect the eyes and the body. Wear a suitable protective helmet with filter
and protective clothing.
Protect adjacent personnel with safety curtains or screens.
Smoke and gas can be harmful to health!
Turn your face away from the welding smoke.
Extraction equipment should be used where appropriate.
Exercise care when using gases containing hydrogen ((danger of explo-
sion)!
Greatest care is necessary when using forming gases or gases containing
hydrogen. These gases are flammable.
Please observe the instructions provided in the relevant safety data sheets.
General information!
Before switching on the welding unit, make sure that there are no solvents
in the surrounding air, e.g. with paint-spraying equipment.
Even dirt can sometimes be combustible.
Remove all combustible cleaning agents before commencing to weld.
Do not touch any live parts while welding.
Observe the safety regulations relating to welding in confined spaces and
closed containers.
smoke
exhaust

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"Open Frame Welding Head OSW Series"
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3. Application ranges - dimensions
Weld head type
Application range (OD)
Application range for screw-
on jaws (OD)
Weight
(without hose pack-
age)
OSW - 40
6.0 mm - 40.0 mm
------------
2.0 kg
OSW - 80
6.0 mm - 40.0 mm
6.0 mm - 40.0 mm
3.0 kg
OSW - 115
20.0 mm - 115.0 mm
20.0 mm - 85.0 mm
4.5 kg
OSW - 170
40.0 mm - 170.0 mm
40.0 mm - 85.0 mm
6.5 kg
Guide values
Wall thickness / electrode separation
0.5 mm - 1.0 mm
0.8 mm
1.25 mm - 2.0 mm
1.3 mm
2.25 mm - 3.9 mm
1.8 mm
with cold wire feed
2.5 mm - 3.5 mm
Type
A
B
C
D
F
G max.
Ê
OSW - 40
90
40
81
7
66
120
96
OSW - 80
142
64
81
10
90
230
96
OSW - 115
200
90
81
10
130
260
96
OSW - 170
300
134
81
10
185
400
96

Operation Manual
"Open Frame Welding Head OSW Series"
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Front view with explanation of terms:
Holding ring
Body
Tool carrier
Clamping
lever
TIG torch
Torch holder
Angle lock for
torch holder
Torch arm
Knurled screw for
sideways adjustment
Lock for torch arm
Hose package
holder
Reduction jaws
Connector for gas-
cooled hose package
Clamping system

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"Open Frame Welding Head OSW Series"
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Rear view:
Handle with
drive unit
Connector for
motor control
cable
Quick-action clamp-
ing lever
Adjustment screw for
clamping system
Closed
Open

Operation Manual
"Open Frame Welding Head OSW Series"
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Side view:
Hose package holder
Knurled screw for
sideways adjustment
Torch height adjust-
ment and sensing
Retaining screws for
reduction jaws

Operation Manual
"Open Frame Welding Head OSW Series"
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4. Functional principles of the open frame weld head
In the OSW welding tongs, the torch ring onto which the TIG torch is mounted, as well as the body of the
tongs, are open. The tool carrier is driven by several gear wheels. This ensures a continuous turning move-
ment in all welding positions.
The head is adjusted to the diameter of the pipe using the adjustment screws of the quick-action clamping
lever.
It can be fastened immediately onto the tube over the weld joint.
The torch arm is loaded with a pressure spring at its point of rotation. After releasing the torch arm lock, the
torch is pressed onto the pipe. The torch arm with the TIG torch can be adjusted over the weld joint in three
dimensions.
The arc distance is set via the torch height adjustment using a hexagon key and kept constant. The surface of
the pipe is continuously sensed.
The knurled screw provides fine adjustment to alter the side distance of the torch to the weld joint. The angle
of the torch head to the weld joint is continuously adjustable via the locking screws of the insulator and the
torch body Adjustment of the head for welding fillet welds is thus accomplished with little effort. For fillet welds,
torch holder which can be turned inwards and possibly also a "ceramic fillet weld nozzle" is required.
Welding with cold wire is possible by fitting the wire guide and the feed nozzle. The feed nozzle is attached to
the torch boy with two knurled screws It is adjustable. The wire guide hose is placed on the hose package
holder together with the hose package of the TIG torch before welding.
For further information see the Orbifeed operation manual.

Operation Manual
"Open Frame Welding Head OSW Series"
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5. Connecting the weld head to the power supply
The power connector marked in blue is the negative pole. –Hose package connector
The power connector marked in red is the positive pole - ground connection clamp.
Gas connector,
hose 6x1, ¼“
screw thread
Power connector
Electrode (minus
pole) colour: blue
Power connector
Ground (plus pole)
colour: red
Fix the ground
clamp onto the
tube.

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"Open Frame Welding Head OSW Series"
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On the power supply there is a C 016 socket (plastic, Amphenol) marked in green. The short green control unit
connection cable is connected to this.
The yellow motor control cable is connected directly to the control unit. The socket (yellow) is labelled with an
arrow for the turning direction and also with two rollers and an arrow for the wire feed direction.
(With open tools such as open frame weld heads, turntable welding and tube to tubesheet weld heads, wire is
often used. When using closed weld heads (enclosed chamber weld head), no wire is used.)
C 016 –connector for
control unit cable
Five-pole connector for the
Manual TIG hose package
Power supply connector
Connector for motor control cable with
and without wire feed
Connector for wired re-
mote control

Operation Manual
"Open Frame Welding Head OSW Series"
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6. Operation of the open frame weld head
1
Connect the control cable for the drive motor.
2
Close the quick-action clamping lever and place onto the tube.
3
Preadjust the clamping jaws to the required tube out-
side diameter.
Then open the clamping lever and close it ¼ to ½ a
turn using the adjustment screws.
Close the clamping lever.
4
Pull out the lock for the torch arm.
The torch arm is pressed onto the workpiece using a torsion
spring.
A constant distance to the tube is maintained via the spring
and the torch height adjustment.
5
CAUTION! Hold the torch arm firmly and let it down slowly,
otherwise possible damage to the torch height adjustment
cannot be ruled out.

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"Open Frame Welding Head OSW Series"
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6
Sideways adjustment to the centre of the tube via the knurled
screw on the torch arm.
7
Adjustment of the torch head angle to the tube axis with a hex-
agon key
8
Adjustment of the arc distance via the torch height adjustment
with the hexagon key.
Guide values
Wall thickness / electrode separation
0.5 mm - 1.0 mm
0.8 mm
1.25 mm - 2.0 mm
1.3 mm
2.25 mm - 3.9 mm
1.8 mm
with cold wire feed
2.5 mm - 3.5 mm
9
The hose package is coiled automatically via the welding pro-
gram in the control unit. CAUTION: pay attention to the rout-
ing of the hose package.

Operation Manual
"Open Frame Welding Head OSW Series"
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10
CAUTION! Check before starting:
Ground cable connected
Power connected
Welding gas
Forming gas
Water cooling
Start the welding process
11
Pull back the torch arm until the lock latches. Keep an eye on
the hose package while doing this.
12
Open the head with the quick-action clamping lever and re-
move it.

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"Open Frame Welding Head OSW Series"
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7. Spare parts and consumables
7.1. Torch parts list
Item
Components
Article number
Explosion view
1
Torch body
2
Ceramic nozzle
Size 8
3
Teflon shim
4
Torch cap
5
Clamping sleeve
1.6 mm
or
2.4 mm
6
Gas lens
1.6 mm
or
2.4 mm
7
Tungsten elec-
trode
1.6mm
or
2.4 mm;
L=35mm
to
55mm
7.2. Torch arm parts list
Item
Components
Article number
Explosion view
1
Torch arm
2
Torsion spring
3
Knurled screw
4
Spherical washer
(pressure bear-
ing)
5
Screw

Operation Manual
"Open Frame Welding Head OSW Series"
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8. Predetermined breaking point in the drive
The predetermined breaking point in the plastic intermediate clutch can break on overloading, e.g. seizing of
the torch ring. This can have the result that the rotor no longer runs true and exhibits too much play.
8.1. Maintenance
- The recommended maintenance interval by Orbitec personnel is 1 year.
If the plastic intermediate clutch
breaks, it must be replaced
Remove the screw

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"Open Frame Welding Head OSW Series"
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9. Addendum
9.1. Water-cooled torch
- Cooling unit needed.
It is possible to adapt a water-cooled torch, including the associated hose package, which permits welding with
an amperage of up to 300 A. Recommended with wall thicknesses upwards of 3 mm or for series production
with a high heat load.
Cooling unit connection
Power connector
Electrode (minus
pole) colour: blue
Gas connector,
hose 6x1, ¼“
screw thread
Water connections
Return
Supply
Water-cooled hose
package capable of up
to 300 A load.

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"Open Frame Welding Head OSW Series"
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9.2. Fillet welds
It is possible to attach a torch holder for fillet welds which is wider and therefore allows the torch to be turned
inwards.
In this case, a longer fillet weld nozzle is recommended.
9.3. Torch variants
OSW Mini Art. No. 1.3.1617
OSW Mini 45° Art. No. 1.3.1609
OSW StandardArt. No. 1.3.1607
OSW StandardArt. No. 1.3.1608

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"Open Frame Welding Head OSW Series"
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10. Addendum OSW new version Bj
From the following serial number of technical modifications to the Welding Head OSW were made:
OSW 80 -> from serial number 06-12-XX
OSW 115 -> from serial number 08-12-XX
OSW 170 -> from serial number 10-12-XX
Torch and torch holder were revised.
The torch holder is now adjustable via an Allen key 3mm

Operation Manual
"Open Frame Welding Head OSW Series"
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Necked formation weld with torch holder multiposition and long nozzle size 6