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"
2
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"
3
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"
4
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

Operation Manual
"Open Frame Welding Head OSW Series"
5
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