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Contact your local ITW Orbital Cutting & Welding representative for additional information or to request a product demonstration.

Corporate Locations

Sales Locations

UNITED STATESITW-OCW US Headquarters E.H. Wachs® 600 Knightsbridge Parkway Lincolnshire, IL 60069 USA T: +1.847.537.8800 F: +1.847.520.1147 Toll Free: 800.323.8185

Northeast Sales, Service & Rental Center E.H. Wachs 1001 Lower Landing Road, Suite 208 Blackwood, New Jersey 08012 USA T: +1.856.579.8747 F: +1.856.579.8748

Southeast Sales, Service & Rental Center E.H. Wachs 171 Johns Road, Unit A Greer, South Carolina 29560 USA T: +1.910.228.3454 F: +1.847.520.1147

West Coast Sales, Service & Rental Center E.H. Wachs 5130 Fulton Drive, Unit J Fairfield, California 94534 USA T: +1.707.439.3763 F: +1.707.439.3766

Gulf Coast Sales, Service & Rental Center E.H. Wachs 2220 South Philippe Avenue Gonzales, LA 70737 USA T: +1.225.644.7780 F: +1.225.644.7785

Houston South Sales, Service & Rental Center E.H. Wachs 3414 Lilac Unit E Pasadena, Texas 77505 USA T: +1.713.983.0784 F: +1.713.983.0703

UNITED KINGDOMWachs UK® UK Sales, Service & Rental Centre Units 4 & 5 Navigation Park Road One, Winsford Industrial Estate Winsford, Cheshire CW7 3RL United Kingdom T: +44 (0) 1606 861 423 F: +44 (0) 1606 556 364

UNITED ARAB EMIRATESWachs Middle East & Africa Operations® E.H. Wachs PO Box 262543 Jebel Ali Free Zone South Dubai FZS 5, ACO6 United Arab Emirates T: +00 971 4 88 65 211 F: +00 971 4 88 65 212

INDIAWachs India® E.H. Wachs / ITW India Private Limited Orbital Cutting & Welding Division 4A/19, IDA Phase-1 Medak District Telangana 502 319 India T: +91 40 3026 1812 F: +91 40 3048 0815

CHINAWachs China® E.H. Wachs / ITW Welding China New Caohejing International Business Centre B-1501 No. 391 Guiping Road Shanghai 200052 China T: +86 (21) 52303751 F: +86 (21) 52303758

Houston North Sales & Technical Center E.H. Wachs 15331 Vantage Parkway East Houston, Texas 77032 USA T: +1.920.831.4720 F: +1.847.520.1147

GERMANYITW-OCW Europe Headquarters Orbitalum Tools GmbH® E.H. Wachs Sales & Service Center Josef-Schüttler-Straße 17 Singen D78224 Germany T: +49 (0) 77 31 - 792 0 F: +49 (0) 77 31 - 792 500

CANADAWachs Canada Ltd® Eastern Canada Sales, Service & Rental Center 1250 Journey’s End Circle, Unit 5 Newmarket, Ontario L3Y 0B9 Canada T: +1.905.830.8888 F: +1.905.830.6050 Toll Free: 888.785.2000

Wachs Canada Ltd® Western Canada Sales, Service & Rental Center 5411 82 Ave NW Edmonton, Alberta T6B 2J6 Canada T: +1.780.469.6402 F: +1.780.463.0654 Toll Free: 800.661.4235

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ORBITAL TUBE CUTTING & WELDING SYSTEMSehwachs.com

ORB20161011-Orbitalum-Cat-Cover-v4.indd 1 10/11/16 7:01 PM

Our ITW Partners

When you partner with us you’re not only partnering with the industry leader in portable weld preparation machine tools and orbital welding systems, you’re partnering with ITW, the industry leader in advanced welding technologies.

ITW has a market leading portfolio of best in class brands offering reliable and responsible products for the markets we serve.

When reliability matters... We’re there.

Forging the Tools for Excellence

About Orbitalum

Founded in 1960 as a subsidiary of Georg Fischer (GF) and renamed Orbitalum in 2006, we are the world’s premier manufacturer of high purity tube cutting and pipe preparation machine tools and orbital welding systems.

At Orbitalum we understand the needs of process piping professionals in the aerospace, food, dairy and beverage, pharmaceutical and semiconductor industries. Every machine features robust design and ease of operation, and is constructed with high quality materials and extreme precision. German engineered and built, Orbitalum products exceed the rigorous standards of ISO 9001:2008.

Orbital Cutting

Orbitalum cutting products are the perfect complement to our orbital welding equipment. For over 55 years, first as GF and now as Orbitalum, we’ve remained the industry leader in high quality tube cutting and facing equipment. We manufacture the world’s leading series of tube and pipe saws, the GF and GFX, that utilize an orbital cutting motion around a stationary workpiece.

Extending the GF series, RPG tube squaring machines from Orbitalum are designed to produce perfectly square, burr free preps required for critical, defect free orbital welding applications. Featuring precise micrometer feed, deformation-free quick-clamping systems, and electronic speed regulation and stabilization on electric powered models, these machines produce a perfect weld prep. Also available with convenient cordless drive on select models.

Orbital Welding

The Orbitalum orbital welding system includes Orbimat power supplies, Orbiweld weld heads, the Orbitwin switching unit, and the advanced ORBmax digital oxygen analyzer. At Orbitalum we surpass the best features of other systems, while delivering a unique user experience with our easy to use software and one touch control.

Engineered and built to satisfy today’s welding professional who is looking for the best combination of power, features and convenience, these machines deliver precision welds and are easily transported, programmed, operated, and maintained.

WeldingThe ITW Welding group serves the global welding industry with superior products, and unparalleled service. The group includes leading manufacturers of weld prep machine tools, filler metals, welding machines, induction heating equipment, and welding consumables, components and accessories for a wide variety of applications. ITWWelding.com

Orbitalum Tools and E.H. Wachs are organized together as ITW Orbital Cutting & Welding, to provide our global customers One Source for the finest in pipe & tube cutting, beveling and orbital tube welding products. E.H. Wachs manufactures portable machine tools used in pipe weld preparation, including OD mounted split frames and ID mounted end preps. Orbitalum manufactures high purity cutting products including GF saws, RPG facers and Orbimat power supply and weld heads. ITW-OCW.com

ITW Welding offers a full line of industrial quality welders from Miller Electric Mfg. Co., headquartered in Appleton, Wisconsin. Miller is a leading worldwide manufacturer of Miller arc welding and cutting equipment, delivering ruggedly reliable equipment of the highest quality. The Welding Components group includes Bernard MIG-Guns, Weldcraft TIG-Torches, Tempil temperature markers, and Smith Equipment, combining four well known suppliers for welding accessories. MillerWelds.com

Hobart Brothers based in Troy, Ohio features a full line of filler metals for applications ranging from mild steel and low alloy steel to stainless steel. Available products include stick electrodes, solid wires and flux cored wires in a variety of diameters and packaging. All Hobart brand filler metals feature superior arc performance and selections are available for fast-freezing or self-peeling slag, low hydrogen weld deposits, high deposition rates and efficiencies, and x-ray quality welds. HobartBrothers.com

ITW Welding Cut. Prep. Weld.

E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com

ITW Orbital Cutting & Welding Europe Headquarters

Orbitalum Tube & Pipe Saw

Orbitalum Orbital Weld Head

ITW Orbital Cutting & Welding U.S. Headquarters


E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com |

1

One Source.

ITW Welding

Orbitalum Tools and E.H. Wachs are organized together as ITW Orbital Cutting & Welding, to provide our global customers One Source for the finest in pipe & tube cutting, beveling and orbital welding products. When you partner with us you’re not only partnering with the industry leader in portable weld preparation machine tools and orbital welding systems, you’re partnering with ITW, the industry leader in advanced welding technologies.

Orbitalum equipment is sold, serviced and rented in North and South America by E.H. Wachs, through our dealer network and conveniently located Sales, Service and Rental Centers in the US and Canada. With a large selection of Orbitalum cutting and welding equipment in stock and ready for immediate shipment, plus a nationwide fleet of rental machines, Orbitalum is the industry’s best built and best supported line of high purity cutting and welding machines.

Best Warranty

The best built orbital welding system should be backed up by the industry’s best warranty, and with Orbitalum it is. Every Orbimat welding power supply unit sold in the Americas includes a 2 Year Limited Warranty, making it the best orbital welding system value on the market today. We double the warranty so you can enjoy Orbitalum’s unrivaled productivity for years to come.

Local Availability

Orbitalum rental machines, consumables and replacement parts are also available at most ITW Orbital Cutting & Welding Sales, Service and Rental Centers. Many offer full repair and calibration services by factory trained certified service technicians. We stock a large inventory of OEM parts and consumables that are designed to keep your Orbitalum cutting and welding machines operating at peak efficiency.

Factory Training

The most advanced machines in the world require skilled operators to operate them. As part of our ongoing commitment to customer support, we've developed new training programs and built dedicated classroom and lab facilities to train our users to get the full potential from their state-of-the-art cutting and welding machines.

GF 4 Tube & Pipe Saw

Orbimat 165CA Power Supply

Orbiweld 76S Orbital Weld Head

RPG 4.5 Tube Facer

| E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com

Applications

2

Applications

ITW Orbital Cutting & Welding manufactures the world’s most complete line of portable, powered tube and pipe cutting, facing and beveling weld preparation machine tools. In addition we build a complete line of advanced orbital welding systems used in high purity, process piping and specialized heat exchanger applications. ITW Orbital Cutting & Welding products are widely used in the following industries:

INDUSTRY APPLICATIONS ORBITALUM PRODUCTSHeat Exchanger • Shell & tube

• Box header• HVAC• Seal weld (autogenous)• Strength weld (wire)• Gas cabinets• Component manufacturing

• RPG Tube squaring machines• ORBIMAT Orbital welding power supplies• ORBIWELD Orbital weld heads• P16 & TX38P Tube-to-tube-sheet orbital weld heads• HX16 Orbital weld heads• ORBmax Digital oxygen analyzer

Pharmaceutical & Chemistry

• UHP water lines• Process lines• Mixing valves• CIP clean in place lines

• GF, PS, RA & GFX Pipe cutting & beveling machines• RPG Tube squaring machines• ORBIMAT Orbital welding power supplies• ORBIWELD Orbital weld heads• ORBmax Digital oxygen analyzer

Semicon • UHP water lines• Vacuum lines• Wafer processing lines• CFOS lines• Jacketed product• Gas cabinets• Component manufacturing

• RPG Tube squaring machines• ORBIMAT Orbital welding power supplies• ORBIWELD Orbital weld heads• ORBmax Digital oxygen analyzer

Aerospace • Airframe hydraulic lines• Engine fuel lines• Engine specific components• Onboard HVAC


Food & Dairy • Product water lines• Jacketed product• Mixing valves• CIP clean in place lines


INDUSTRY APPLICATIONS E.H. WACHS PRODUCTSOil & Gas • Piping & delivery systems

• Heat exchangers• Flange maintenance• Casing cutting• Wellhead maintenance• Valve operation

• SDSF Small Diam. Split Frames (Pipe cutting & beveling machines)• DynaPrep MDSF Split Frames (Pipe cutting, beveling, & facing)• EP424 Bevelers• Guillotine Portable pipe saws• ECC & EICC Casing cutters• RS-2 Rising stem valve operators

Power Generation • Storage tanks & drain systems• Safety & coolant injection systems• Hydrogen off gas systems• Instrument lines & nozzles• Reactor, feed water, & steam piping systems• Steam generator (SGRP) & turbines

• SDSF Small Diam. Split Frames (Pipe cutting & beveling machines)• DynaPrep MDSF Split Frames (Pipe cutting, beveling, & facing)• EP424, SDB, & FF Bevelers• Valve operators

Pipelines • New construction & expansion• Pipeline repair & decommissioning• Pipeline tie ins• Flange, trap door, & valve replacement• Casing cutting• Wellhead maintenance

• DynaPrep MDSF Split Frames (Pipe cutting, beveling, & facing)• LDSF Large Diameter Split Frame (Pipe cutting & beveling machines)• Trav-L-Cutter (Portable Milling Machines)• Goliath Guillotine Portable pipe saws• ECC & EICC Casing cutters


Table of Contents

3

Table of Contents

Pipe Cutting Machines 4GF 4, GF 6 (AVM/MVM) 6

RA 8, RA 12 (AVM/MVM) 9

GFX 3.0, GFX 6.6 12

Accessories for GF & RA machines 15

Saw blades & bevel cutters 19

PS 4.5 Plus, PS 6.6 22

MRA 25

Tube Squaring Machines 27RPG XS, RPG ONE, RPG 1.5, & RPG 2.5 28

RPG 4.5, RPG 4.5 S, & RPG 8.6 34

Accessories for Workshop and Site 40

Orbital Welding Power Supplies and Accessories 42ORBIMAT CA 43

Enclosed Orbital Weld Heads 48ORBIWELD 12, ORBIWELD 19 51

ORBIWELD 38S, 76S, 115S 56

ORBIWELD 170 58

HX 16P 67

Tube-to-Tubesheet Orbital Weld Heads 70TX38P 71

P16, P16 AVC 73

Orbital Welding Accessories and Consumables 78ESG MAX, ESG Plus, & ESG Plus2 79

ORBmax 83

Orbitalum Rentals 87

Orbitalum Training 88


Pipe Cutting

5

Quick overview pipe cutting technologyOur products cover a wide range of applications. Regardless of whether you want to prepare large or small, thin-walled or thick-walled, high-alloyed or low-alloyed tube and pipe, Orbitalum has a suitable solution. This quick overview shows you the various application possibilities of our pipe cutting and beveling machines. Would you like a personal consultation?

Then simply contact us by phone +1.847.537.8800 or by e-mail to [email protected]

Our team will gladly help you find the suitable solution for your individual application.

Tube outer diameter OD

PS 6.6

PS 4.5 Plus

GFX 6.6

GFX 3.0

RA 12

RA 8

GF 6

GF 4

0 100 mm3.937 in

200 mm7.874 in

300 mm11.811 in

400 mm15.748 in

500 mm19.685 in

see page 22

see page 22

see page 12

see page 12

see page 9

see page 9

see page 6

see page 6

PS series: Lightweight, portable tube saws

GFX series with eccentric cutting principle

GF/RA series

Tube wall thicknesses

PS 6.6

PS 4.5 Plus

GFX 6.6

GFX 3.0

RA 12

RA 8

GF 6

GF 4

0 2 mm0.079 in

4 mm0.157 in

6 mm0.236 in

8 mm0.315 in

10 mm0.394 in

12 mm0.472 in

14 mm0.551 in

16 mm0.630 in

see page 22

see page 22

see page 12

see page 12

see page 9

see page 9

see page 6

see page 6

PS series for thin-walled applications

GFX series for thin-walled applications

GF/RA series for thick-walled applications


Pipe Cutting

6

GF 4, GF 6 (AVM/MVM)

Designed to complement orbital welding systems, the GF series cuts and bevels high-alloy steel, stainless steel, low-alloy and unalloyed steel, plastics, casting materials and non-ferrous metals easily and in seconds. The pipe end will now have a precise, right-angle, burr-free cut and perfect bevel. The powerful integrated clamp secures the workpiece without any deformation.

Besides the completely manual operation, users also have the possibility to choose between manual operation with manual feed module (MVM) or automatic feed module (AVM) – both optional. The latter option optimizes the cutting result, increases the tool life and reduces the operator impact. The result: Maximum safety and productivity.

• Square, burr-free and cold machining process• Deformation-free clamping

system for tubes and pipes• Optimum preparation for the

automated welding process• Sturdy design with powerful drive• Unique and automated orbital cutting process• Simultaneous or separate cutting and beveling• Cost-effective, increasing productivity• Long tool life• Anthracite-colored coated components

for improved sliding properties and protection against corrosion

• Stainless steel clamping attachments for protection against contact corrosion included

• Reduced operator impact by optional feed module AVM or MVM for an automated or manual cutting process

• Locking mechanism prevents unauthorized usage and theft

• An ergonomically-designed motor handle for a safe and comfortable operating position, which also enables easy cutting of elbows

• Integrated line laser to determine the cut off point

• 2 position clamping jaws to reduce chatter and enable smaller length of pipe to be machined

• Multifunctional tool for all adjustments on the machine

• Optimized speed range (40-215 rpm), ideal for cutting high-performance materials (Hastelloy®, P91, etc.)

• Swivel cable with a quick-disconnect coupler: for easy and comfortable replacement of the power cable

• Optimized saw blade guard protects the user against flying chips and comes with a measuring port (for GF 4 only)

This saw has been designed for precise cutting of tube and pipe in just seconds.

For more than 40 years, construction companies have relied on the standard set by Orbitalum in the industrial prefabrication of pipeline systems: From the chemical, biotechnology, pharmaceutical, food and beverage industry to the energy plant construction and shipbuilding.

PIPE CUTTING MACHINES

Multifunctional tool for all adjustments on the machine

The GF series sets new standards in orbital pipe machining. Numerous innovative functions combined with an ergonomic design create significant advantages for you in the industrial prefabrication of pipeline systems

Integrated line laser to determine the cut off point

Available with automatic or manual feed modules AVM/MVM

Reversible clamping jaws for preparing thin- or thick-walled pipes


Pipe Cutting

7

APPLICATION RANGE GF 4 GF 4 AVM* GF 4 MVM* GF 6 GF 6 AVM* GF 6 MVM*

Tube OD [mm][inch]

12 - 1200.472 - 4.724

12 - 1200.472 - 4.724

12 - 1200.472 - 4.724

21.3 - 168.30.839 - 6.626

21.3 - 168.30.839 - 6.626

21.3 - 168.30.839 - 6.626

Wall thickness (depends on material)** [mm][inch]

1 - 90.039 - 0.354

1 - 90.039 - 0.354

1 - 90.039 - 0.354

1.5 - 150.059 - 0.591

1.5 - 150.059 - 0.591

1.5 - 150.059 - 0.591

Tube ID min. (saw blade Ø 63 mm)Tube ID min. (saw blade Ø 2.480 in)

[mm][inch]

210.827

210.827

210.827

301.181

301.181

301.181


[mm][inch]

160.630

160.630

160.630

250.984

250.984

250.984


[mm][inch]

40.157

40.157

40.157

130.512

130.512

130.512


[mm][inch]

––

––

––

00

00

00

Tube materials: High-quality steel (any Cr and Mo content); high-quality stainless steel (any Cr and Mo content); high-quality steel (Cr < 12% and Mo < 2.5%; Cr < 20% and Mo = 0%): case hardened steels, high-speed steels, tempering steels, bearing steels, tool steels; black and galvanized steel pipe; general structural steel; annealed cast iron pipe (GGG); aluminum; brass; copper; plastics (PE, PP, PVDE, PVC)

TECHNICAL DATA GF 4 GF 4 AVM* GF 4 MVM* GF 6 GF 6 AVM* GF 6 MVM*

Power [kW][hp]

1.82.41

1.92.54

1.82.41

1.82.41

1.92.54

1.82.41

Power AVM [kW][hp]

– 0.050.07

– – 0.050.07

–

Built-in electronic variable cutting speed with restart inhibitor

[rpm] 40 - 215 40 - 215 40 - 215 40 - 215 40 - 215 40 - 215

Slide housing speed with AVM [rpm] – 0.1 - 3.9 – – 0.3 - 3.5 –

Slide housing torque max. with AVM [Nm] – 101 – – 353 –

Protection class [class] II (DIN EN 60745-1) I (DIN EN 60204-1) II (DIN EN 60745-1) II (DIN EN 60745-1) I (DIN EN 60204-1) II (DIN EN 60745-1)

Noise level at the workplace approx. [dB (A)] 79 79 79 79 79 79

Vibration level (according to DIN EN 28662, part 1) [m/s2] < 2.5 < 2.5 < 2.5 < 2.5 < 2.5 < 2.5

Mains fuse by customer [A] 16 16 16 16 16 16

Dimensions (L x W x H) [mm][inch]

480 x 325 x 68018.9 x 12.8 x 26.8

480 x 325 x 81018.9 x 12.8 x 31.9

480 x 325 x 78018.9 x 12.8 x 30.7

574 x 352.7 x 92022.6 x 13.9 x 36.2

574 x 352.7 x 97222.6 x 13.9 x 38.3

574 x 352.7 x 92022.6 x 13.9 x 36.2

Machine Weight approx.*** [kg][lbs]

55.0121.2

64.5142.2

60.0132.2

92.7204.4

101.7224.2

97.8215.6

Versions (single-phase AC) [V, Hz] 230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

SCOPE OF DELIVERY GF 4 GF 4 AVM* GF 4 MVM* GF 6 GF 6 AVM* GF 6 MVM*

Pipe cutting and beveling machine Pc. 1 1 1 1 1 1

Transportation case Pc. 1 1 1 1 1 1

Set of stainless steel clamping attachments Pc. 1 1 1 1 1 1

Saw blade (Code 790 ...) Pc. 1 (...042 064) 1 (...042 064) 1 (...042 064) 1 (...043 018) 1 (...043 018) 1 (...043 018)

Mounting plate Pc. 1 1 1 1 1 1

Line laser with fastening screw**** Pc. 1 1 1 1 1 1

Tool set Set 1 1 1 1 1 1

Saw blade lubricant GF TOP (Code 790 060 228) Tube 1 1 1 1 1 1

Special gear oil (Code 790 041 030) Bottle 1 1 1 1 1 1

Operating instructions and spare parts list Set 1 1 1 1 1 1

The technical data are not binding. They are not warranted characteristics and are subject to change. Please consult our general conditions of supply.* The automatic/manual feed module AVM/MVM is already fitted to the pipe cutter upon delivery. **With automatic cutting process. Increased wall thickness possible with manual feed or by adding an additional cut (depending on the saw blade diameter). *** Weight without packaging and accessories. **** The line laser is already mounted at the GF 4 (AVM/MVM) on delivery. At the GF 6 (AVM/MVM) the line laser is supplied separately and has to be mounted on the machine before commissioning

Standard Feed:User manual controlled, default configuration option.

Automatic Feed Module AVM*: Continuously controls cutting speed using torque and parameter settings, improving handling of GF and RA machines. Stops automatically after the cutting process.

Manual Feed Module MVM*: Manual option, includes a hand wheel, enabling the machine head to rotate easily and with little effort around the pipe with a constant speed.

GF 4 GF 4 AVM GF 4 MVMGF 6 GF 6 AVM GF 6 MVM

FEED OPTIONS:


Pipe Cutting

8

Pipe cutting machines

GF 4, GF 6 (AVM/MVM)

Features, application range, technical data and scope of delivery, see page 6.

MODEL VERSION CODE MACHINE WEIGHT SHIPPING WEIGHT

GF 4 230 V, 50/60 Hz EU 790 142 001 135.1 lb (61.3 kg) 194 lb (88 kg)

GF 4 120 V, 50/60 Hz EU/US 790 142 002 135.1 lb (61.3 kg) 194 lb (88 kg)

GF 4 AVM 230 V, 50/60 Hz EU 790 142 011 155.4 lb (70.5 kg) 216.1 lb (98 kg)

GF 4 AVM 120 V, 50/60 Hz EU/US 790 142 012 155.4 lb (70.5 kg) 216.1 lb (98 kg)

GF 4 MVM 230 V, 50/60 Hz EU 790 142 021 146.8 lb (66.6 kg) 216.1 lb (98 kg)

GF 4 MVM 120 V, 50/60 Hz EU/US 790 142 022 146.8 lb (66.6 kg) 216.1 lb (98 kg)

GF 6 230 V, 50/60 Hz EU 790 143 001 204.4 lb (92.7 kg) 308.6 lb (140 kg)

GF 6 120 V, 50/60 Hz EU/US 790 143 002 204.4 lb (92.7 kg) 308.6 lb (140 kg)

GF 6 AVM 230 V, 50/60 Hz EU 790 143 011 224.2 lb (101.7 kg) 337.3 lb (153 kg)

GF 6 AVM 120 V, 50/60 Hz EU/US 790 143 012 224.2 lb (101.7 kg) 337.3 lb (153 kg)

GF 6 MVM 230 V, 50/60 Hz EU 790 143 021 215.6 lb (97.8 kg) 324.1 lb (147 kg)

GF 6 MVM 120 V, 50/60 Hz EU/US 790 143 022 215.6 lb (97.8 kg) 324.1 lb (147 kg)

Accessories

• Saw blades and bevel cutters, see page 19• High-performance lubricants for cutting and beveling, see page 16• Special gear oil, see page 16• Swivel cable, see page 17• Quick-mounting base plates with integrated screw clamps, see page 17• Pipe feeder base unit and extension unit, see page 17• Mobile workstation, see page 18• Work benches and tool box, see page 28• Pipe vices, see page 28

GF 4, GF 6

GF 4 AVM, GF 6 AVM

GF 4 MVM, GF 6 MVM


Pipe Cutting

9

RA 8, RA 12 (AVM/MVM)

Perform economical cutting and beveling with technology made by Orbitalum Tools!

Cutting and beveling high-alloy steel (stainless steel), low- and unalloyed steel, plastics, casting materials and non-ferrous metals in just seconds, using the "Planetary Cutting" method.


The perfect preparation for orbital welding

Available with automatic or manual feed modules AVM/MVM

Optimized speed range

Planetary cutting technology

"Enhanced safety due to stationary tube – rotating tool". The tested process of planetary cutting is another important feature, which characterizes all ORBITALUM pipe cutting machines. The saw blade rises into the cutting area and is driven orbitally around the tube. The advantage is that a small saw blade can cut a large tube diameter, without heating the tube.

An innovative clamping principle which clamps the tube at several points: Thanks to the deformation-free clamping system, pipes with a wall-thickness of 2 up to 10 mm (0.079 in - 0.394 in) can be prepared easily an quickly. It is possible to cut all high-alloyed, un- and low-alloyed steels, black and galvanized steel pipes, general structural steels, annealed cast iron pipes (GGG), aluminum, brass, copper and plastics.

Besides the completely manual operation, users also have the possibility to choose between manual operation with manual feed module (MVM) or automatic feed module (AVM) = both optional. The latter option optimizes the cutting result, increases the tool life and reduces the operator impact. The result: Maximum safety and productivity.

• Square, burr-free and cold machining process• Deformation-free clamping system for tubes

and pipes• Optimum preparation for the automated

welding process• Sturdy design with powerful drive• Unique and automated orbital cutting process • Multiple point clamping• Reduced operator impact by optional feed

module AVM or MVM for an automated or manual cutting process

• Fast adjustment of dimensions• Regulated cutting speed• Optimal tool contact

• Fast tool replacement• Optimized speed range (40-215 rpm), ideal for

cutting high-performance materials (Hastelloy®, P91, etc.)

• An ergonomically-designed motor handle for a safe and comfortable operating position

• Cutting in seconds• Simultaneous or separate cutting and beveling• Increased productivity• Increased service life of tools• More corrosion protection through clamping

jaw attachments (included)


Pipe Cutting

10

APPLICATION RANGE RA 8 RA 8 AVM* RA 8 MVM* RA 12 RA 12 AVM* RA 12 MVM*

Tube OD [mm][inch]

114 - 2304.488 - 9.055

114 - 2304.488 - 9.055

114 - 2304.488 - 9.055

154 - 3256.063 - 12.795

154 - 3256.063 - 12.795

154 - 3256.063 - 12.795

Wall thickness (depends on material)** [mm][inch]

2 - 100.079 - 0.394

2 - 100.079 - 0.394

2 - 100.079 - 0.394

2 - 100.079 - 0.394

2 - 100.079 - 0.394

2 - 100.079 - 0.394


[mm][inch]

1375.394

1375.394

1375.394

1907.480

1907.480

1907.480


[mm][inch]

1325.197

1325.197

1325.197

1857.283

1857.283

1857.283


[mm][inch]

1204.724

1204.724

1204.724

1736.811

1736.811

1736.811


[mm][inch]

1003.937

1003.937

1003.937

1536.024

1536.024

1536.024

Tube materials High-quality steel (any Cr and Mo content); high-quality stainless steel (any Cr and Mo content); high-quality steel (Cr < 12% and Mo < 2.5%; Cr < 20% and Mo = 0%): case hardened steels, high-speed steels, tempering steels, bearing steels, tool steels; black and galvanized steel pipe; general structural steel; annealed cast iron pipe (GGG); aluminum; brass; copper; plastics (PE, PP, PVDE, PVC)

TECHNICAL DATA RA 8 RA 8 AVM* RA 8 MVM* RA 12 RA 12 AVM* RA 12 MVM*

Power [kW][hp]

1.82.41

1.92.54

1.82.41

1.82.41

1.92.54

1.82.41

Power AVM [kW][hp]

– 0.050.07

– – 0.050.07

–


[rpm] 40 - 215 40 - 215 40 - 215 40 - 215 40 - 215 40 - 215

Slide housing speed with AVM [rpm] – 0.1 - 2.3 – – 0.1 - 1.8 –

Slide housing torque max. with AVM [Nm] – 165 – – 210 –

Protection class [class] II (DIN EN 60745-1) I (DIN EN 60204-1) II (DIN EN 60745-1) II (DIN EN 60745-1) I (DIN EN 60204-1) II (DIN EN 60745-1)

Noise level at the workplace approx. [dB (A)] 79 79 79 79 79 79

Vibration level (according to DIN EN 28662, part 1) [m/s2] < 2.5 < 2.5 < 2.5 < 2.5 < 2.5 < 2.5

Mains fuse by customer [A] 16 16 16 16 16 16


778 x 430 x 48530.6 x 16.9 x 19.1

918 x 430 x 48536.1 x 16.9 x 19.1

788 x 430 x 48531.0 x 16.1 x 19.1

940 x 374 x 59237.0 x 14.7 x 23.3

1.070 x 374 x 59242.1 x 14.7 x 23.3

1.090 x 374 x 59242.9 x 14.7 x 23.3

Machine Weight approx.*** [kg][lbs]

102.5225.9

110.0242.5

104.6230.6

138.6305.6

146.1322.1

140.7310.2

Versions (single-phase AC) [V, Hz] 230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

230 V, 50/60 Hz120 V, 50/60 Hz

SCOPE OF DELIVERY RA 8 RA 8 AVM* RA 8 MVM* RA 12 RA 12 AVM* RA 12 MVM*

Pipe cutting and beveling machine Pc. 1 1 1 1 1 1

Transportation case Pc. 1 1 1 1 1 1

Saw blade (Code 790 043 018) Pc. 1 1 1 1 1 1

Mounting plate Pc. 1 1 1 1 1 1

Tool set Set 1 1 1 1 1 1

Saw blade lubricant GF TOP (Code 790 060 228) Tube 1 1 1 1 1 1

Special gear oil (Code 790 041 030) Bottle 1 1 1 1 1 1

Operating instructions and spare parts list Set 1 1 1 1 1 1

The technical data are not binding and are subject to change. Please consult our general conditions of supply. * The automatic/manual feed module AVM/MVM is already fitted to the pipe cutter upon delivery. ** With automatic cutting process. Increased wall thickness possible with manual feed or by adding an additional cut (depending on the saw blade diameter). *** Weight without packaging and accessories.

RA 8 RA 8 AVM RA 8 MVMRA 12 RA 12 AVM RA 12 MVM

All RA‘s are fitted with the swivel cable with a quick-disconnect coupler.

Standard Feed:User manual controlled, default configuration option.

Automatic Feed Module AVM*: Continuously controls cutting speed using torque and parameter settings, improving handling of GF and RA machines. Stops automatically after the cutting process.

Manual Feed Module MVM*: Manual option, includes a hand wheel, enabling the machine head to rotate easily and with little effort around the pipe with a constant speed.

FEED OPTIONS:


Pipe Cutting

11


RA 8, RA 12 (AVM/MVM)



RA 8 230 V, 50/60 Hz EU 790 045 095 226 lb (102.5 kg) 328.5 lb (149 kg)

RA 8 120 V, 50/60 Hz EU/US 790 045 096 226 lb (102.5 kg) 328.5 lb (149 kg)

RA 8 AVM 230 V, 50/60 Hz EU 790 045 001 242.5 lb (110 kg) 363.8 lb (165 kg)

RA 8 AVM 120 V, 50/60 Hz EU/US 790 045 007 242.5 lb (110 kg) 363.8 lb (165 kg)

RA 8 MVM 230 V, 50/60 Hz EU 790 045 069 227.1 lb (103 kg) 337.3 lb (153 kg)

RA 8 MVM 120 V, 50/60 Hz EU/US 790 045 082 227.1 lb (103 kg) 337.3 lb (153 kg)

RA 12 230 V, 50/60 Hz EU 790 047 095 305.6 lb (138.6 kg) 390.2 lb (177 kg)

RA 12 120 V, 50/60 Hz EU/US 790 047 096 305.6 lb (138.6 kg) 390.2 lb (177 kg)

RA 12 AVM 230 V, 50/60 Hz EU 790 047 001 321.9 lb (146 kg) 451.9 lb (205 kg)

RA 12 AVM 120 V, 50/60 Hz EU/US 790 047 007 321.9 lb (146 kg) 451.9 lb (205 kg)

RA 12 MVM 230 V, 50/60 Hz EU 790 047 069 310.2 lb (140.7 kg) 440.9 lb (200 kg)

RA 12 MVM 120 V, 50/60 Hz EU/US 790 047 082 310.2 lb (140.7 kg) 440.9 lb (200 kg)

Accessories

• Aluminum clamping shells and clamping jaws, see page 45• Saw blades and bevel cutters, see page 19• High-performance lubricants for cutting and beveling, see page 16• Special gear oil, see page 16• Swivel cable, see page 17• Quick-mounting base plates with integrated screw clamps, see page 17• Pipe feeder base unit and extension unit, see page 17• Mobile workstation, see page 18• Work benches and tool box, see page 28• Pipe vices, see page 28

RA 8, RA 12

RA 8 AVM, RA 12 AVM

RA 8 MVM, RA 12 MVM


Pipe Cutting

12

GFX 3.0, GFX 6.6

Our GFX series is the ideal solution for cutting of thin-walled tubes. The rugged design ensures a long product life, making the saws highly economical.

The ergonomic GFX series is extremely low-maintenance and ideal for a large range of applications. Materials the GFX can cut include unalloyed, low and high-alloy steels, stainless steels, non-ferrous metals, aluminum and titanium alloys, composites and plastics.

State-of-the-art, ORBITALUM pipe saws include a laser alignment cut-off guide. When cutting elbows, a second clamping point enables tube elbow severing. The powerful motor is equipped with overload protection and ergonomic handles and is available for the voltages 230 V, 50/60 Hz or 120 V, 50/60 Hz.

The GFX series saw is designed for applications in the food processing, beverage, pharmaceutical, and chemical industries.

• Square, burr-free and cold machining process• Deformation-free clamping system engineered

for thin-walled tubes• Easy handling through light weight• Simultaneous or separate cutting and beveling• Increased productivity• Low-maintenance and service friendly• Ideal for pressfitting applications• Second saw blade position to cut off elbows• Ideal for pressfitting applications• Optimized chip flow due to a new vice design• Cast iron clamping jaws• Integrated laser alignment guide to determine

the cut off point• Ergonomically designed motor handle

• Powerful drive with 1.2 kW and adjustable speed control for cutting several materials and extended tool life

• Electronic overload protection with integrated temperature monitor and electronic speed regulation

• Increased durability of tools due to the new drive GF10

• Ergonomically positioned speed control adjusting wheel

• Swivel cable with a quick-disconnect coupler: For easy and quick replacement of power cables

• Direct mounting on workbench possible with GFX 3.0

Innovative saws from Orbitalum Tools for cutting and beveling of tubes and elbows (also for thin-walled stainless steel) in just seconds. The perfect preparation for orbital welding!

Easy to use, powerful and compact saw with low weight – our new GFX provides even more outstanding features.


The GFX series: Easy to handle, powerful and compact

Square, burr-free and deformation-free pipe end – ideal for press-fitting applications


Pipe Cutting

13

APPLICATION RANGE GFX 3.0 GFX 6.6

Tube OD [mm][inch]

6.0 - 78.00.236 - 3.07

21.3 - 168.30.838 - 6.659

Wall thickness [mm][inch]

0.8 - 7.00.031 - 0.275

0.8 - 7.00.031 - 0.275

Tube ID min. (saw blade Ø 63/2.248 in) [mm][inch]

00

23.00.905

OD range (saw blade Ø 63/2.248 in) [mm][inch]

6.0 - 78.00.236 - 3.07

24.6 - 168.31.008 - 6.659


00

180.708


6.0 - 73.00.236 - 3.07

21.3 - 168.30.838 - 6.659


––

6.00.236


––

21.3 - 156.00.838 - 2.205

Tube materials Unalloyed, low-alloy and high-alloy steel, stainless steel, non-ferrous metal, aluminum alloy, titanium alloy, composite material and plastic

TECHNICAL DATA GFX 3.0 GFX 6.6


570 x 330 x 28022.44 x 12.99 x 11.02

575 x 350 x 67122.64 x 13.78 x 26.42

Weight includes vice [kg][lbs]

28.562.83

74.4164.02

Power [W] 1200 1200

Protection class [class] II II


[rpm] 30 - 200 30 - 200

Versions (single-phase AC) [V, Hz][V, Hz]

230 V, 50/60 Hz EU120 V, 50/60 Hz US

230 V, 50/60 Hz EU120 V, 50/60 Hz US

Vibration level (EN 50144) [m/s2] < 2.5 < 2.5

Noise level at the workplace (EN 23741) [dB (A)] 79.7 79.7

SCOPE OF DELIVERY GFX 3.0 GFX 6.6

Pipe cutting and beveling machine Pc. 1 1

Wooden transportation case Pc. 1 1

Saw blade (Code 790 ...) Pc. 1 (...041 035) 1 (...042 064)

Quick-mounting plate without screw clamps* Pc. – 1

Stainless steel caps** Set 1 1

Line laser with holder and fastening screws*** Pc. 1 1

Tool set Set 1 1

Saw blade lubricant GF TOP (Code 790 060 228) Tube 1 1

Operating instructions and spare parts list Set 1 1

The technical data are not binding. They are not warranted characteristics and are subject to change. Please consult our general conditions of supply.

* The GFX 3.0 can be mounted directly on the workbench without a quick-mounting plate. Quick-mounting plates with screw clamps for GFX 3.0 and GFX 6.6 are available optionally.

** Already mounted on the sliding clamping jaws of the GFX at delivery.*** The line laser has to be mounted on the GFX before commissioning.

Cast iron clamping jaws with stainless steel caps

Powerful drive with electronic overload protection and ergonomically designed motor handle

Second saw blade position to cut off elbows


GFX 3.0

GFX 6.6

Saw blade lubricant GF TOP included

OEM blades offer low cost per cut


Pipe Cutting

14


GFX 3.0, GFX 6.6



GFX 3.0 230 V, 50/60 Hz EU 790 144 001 61.7 lb (28 kg) 97 lb (44 kg)

GFX 3.0 120 V, 50/60 Hz US 790 144 002 61.7 lb (28 kg) 97 lb (44 kg)

GFX 6.6 230 V, 50/60 Hz EU 790 146 001 164 lb (74.4 kg) 229.3 lb (104 kg)

GFX 6.6 120 V, 50/60 Hz US 790 146 002 164 lb (74.4 kg) 229.3 lb (104 kg)

Stainless steel caps

Already included on delivery of the GFX series.

Ideal for preparing stainless steel tubes. Prevents contact corrosion between tube and clamping parts.

Clamping shells for thin-walled tubes are available on request.

Set comes with:

• Stainless steel caps (Qty.): 6 (GFX 3.0) / 4 (GFX 6.6)• Countersunk screws (Qty.): 12 (GFX 3.0) / 16 (GFX 6.6)• Allen key (Qty.): 1

MODEL CODE WEIGHT

Stainless steel caps for GFX 3.0 complete 790 144 200 5.3 oz (150 g)

Stainless steel caps for GFX 6.6 complete 790 146 200 27.9 oz (792 g)

Durable storage and shipping case

High-quality shipping case.

MODEL CODE WEIGHT

Durable storage and shipping case for GFX 3.0 CALL CALL

Other accessories

• Saw blades and bevel cutters, see page 19• High-performance lubricants for cutting, see page 16• Special gear oil, see page 16• Swivel cable, see page 17• Quick-mounting base plates with integrated screw clamps, see page 17• Pipe feeder base unit and extension unit, see page 17• Mobile workstation, see page 18• Work benches and tool box, see page 28• Pipe vices, see page 28

GFX 3.0, GFX 6.6

Stainless steel caps



Pipe Cutting

16

Accessories for GF and RA machines

Clamping jaws

In pairs. Retrofit. While stock last.

MODEL CODE WEIGHT

Special clamping jaws for RA 2 and RA 21 S 790 041 323 2.3 lb (1 kg)

Aluminum clamping jaws for RA 4 and RA 41 Plus 790 046 250 5.7 lb (2.6 kg)

Set of stainless steel clamping attachments

For GF 4 and GF 6 (AVM/MVM). For protection against contact corrosion.Standard part of the GF 4 and the GF 6 (AVM/MVM).

MODEL VERSION CODE WEIGHT

Set of stainless steel clamping attachments for GF 4 right + left 790 142 241 10.9 oz (310 g)

Set of stainless steel clamping attachments for GF 6 right + left 790 143 200 18 oz (510 g)

Saw blade lubricant GF TOP

Synthetic high-performance lubricant for cutting and beveling machines.Increases the tool life of the saw blade. Compliant with the food approval NSF H2. The screwable brush guarantees an easy and uniform application of lubricant on the saw blade.


Saw blade lubricant GF TOP Tube, 180 g 790 060 228 7.2 oz (205 g)

Saw blade lubricant GF LUB

The NEW chlorine-free high-performance lubricant for cutting and beveling.Increases the tool life of the saw blade. This ecologically cutting compound is the environmentally friendly replacement for ROCOL: just with a new name and improved quality. GF LUB meets the latest environmental directives and ecological standards.


Saw blade lubricant GF LUB Tube, 160 ml 790 041 016 5.6 oz (160 g)

Special gear oil

For all GF and RA machines.


Special gear oil Bottle, 250 ml 790 041 030 8.3 oz (235 g)

Special clamping jaws for RA 2 and RA 21 S

Set of stainless steel clamping attachments

GF TOP

GF LUB

Special gear oil


Pipe Cutting

17

Swivel cableTo prevent twisting of the cable. For all GF, RA and PS machines with protection class II (double insulated).

MODEL VERSION CABLE LENGTH CODE WEIGHT

[M] [FT]

Swivel cable complete 230 V, 50/60 Hz EU 4 13.12 790 142 081 24 oz (680 g)

Swivel cable complete 120 V, 50/60 Hz US/CA 4 13.12 790 142 082 23.1 oz (654 g)

Swivel cable complete 230 V, 50/60 Hz CH 4 13.12 790 142 083 21 oz (595 g)

Swivel cable complete 230 V, 50/60 Hz AU 4 13.12 790 142 084 23.1 oz (655 g)

Swivel cable complete 120 V, 50/60 Hz GB 4 13.12 790 142 087 26.1 oz (740 g)

Swivel cable 230 V, 50/60 Hz EU 4 13.12 790 142 076 19.8 oz (560 g)

Swivel cable 120 V, 50/60 Hz US/CA 4 13.12 790 142 077 26.1 oz (740 g)

Swivel cable 230 V, 50/60 Hz CH 4 13.12 790 142 078 18.3 oz (520 g)

Swivel cable 120 V, 50/60 Hz GB 4 13.12 790 142 079 22.2 oz (630 g)

Swivel cable 230 V, 50/60 Hz AU 4 13.12 790 142 080 19.8 oz (560 g)

Quick-mounting base plates with integrated screw clampsFor quickly mounting machine to work benches. Ideal for frequent changes of location.

MODEL CODE WEIGHT

Quick-mounting base plate for GFX 3.0, RA 2, RA 21 S 790 041 027 9.3 lb (4.2 kg)

Quick-mounting base plate for GF 4, GF 6, GFX 6.6, RA 4, RA 6, RA 8, RA 41 Plus 790 042 027 13.6 lb (6.2 kg)

Quick-mounting base plate for PS 4.5 Plus and PS 6.6 790 048 334 5.7 lb (2.6 kg)

Pipe feeder base unit and extension unit

The pipe feeder accurately feeds long and heavy pipes into GF and RA machines. Sturdy, stable design with powder-coated frames and stainless steel rollers.

Advantages:• Extremely stable and sturdy• Fast adjustment of dimensions• Centerline of tubes and pipes adjust easily in seconds• Steel frame coated for maintenance-free finish• Rollers made of stainless steel• Extension of the pipe feeder possible with extension unit• Saves time and money• Perfect for all kinds of steel

Base unit: Fits all pipe cutting and beveling machines from Orbitalum Tools (except the RA 21 S and GF 20 AVM. RA 2, GFX 3.0, PS 4.5 Plus and PS 6.6 on request). The machines can be directly mounted onto the base plate of the pipe feeder base unit, without further parts. The machines can be easily adjusted to the required cutting dimension using the handwheel-operated mechanical height adjustment. The machine is securely fastened to the base plate.

1600 mm 460 mm

1050 mm

542 mm

508 mm

250 mm

x =

68 m

m

x = Slideway

Extension unit: Extend the base unit with multiple extension units, which easily bolt together.

Swivel cable

Swivel cable complete

Quick-mounting base plates with integrated screw clamps

Pipe feeder base unit

Pipe feeder extension unit


Pipe Cutting

18

Floor bracket accessory: To fasten the base unit or the extension unit to the floor.The assembly consists of 4 brackets and 8 bolts with washers.

APPLICATION RANGE/TECHNICAL DATA

PIPE FEEDER BASE UNIT

PIPE FEEDER EXTENSION UNIT

Tube OD 16 - 325 mm0.63 in - 12.8 in

16 - 325 mm0.63 in - 12.8 in

Dimensions approx. 185 x 105 x 50 cm72.8 in x 41.3 in x 19.7 in

approx. 160 x 105 x 5062.9 in x 41.3 in x 19.7 in

Load capacity max. 400 kg881.8 lbs

400 kg881.8 lbs

Height-adjustable mounting plate(adjusting range)

68 mm2.68 in

––

MODEL CODE WEIGHT

Pipe feeder base unit 790 068 051 255.7 lb (116 kg)

Pipe feeder extension unit 790 068 061 158.7 lb (72 kg)

Floor bracket accessory 790 068 053 4.2 lb (1.9 kg)

Mobile workstation

For the mobile site and/or workshop. The ideal addition for all Orbitalum pipe cutters (with exception of GF 20 AVM. RA 2, PS 4.5 Plus, PS 6.6 on request).

Advantages:

• Safe and easy transportation of machines and equipment on site• Flexible operation at each working station• Elimination of material handling and setting up of the machines e.g. no

requirement to mount the machines to benches• Height-adjustable pipe support with stainless steel roller• The tool box comes with 4 drawers for tools and equipment and is lockable• Lifting table with height adjustment of the GF- and RA-machines to the required

pipe dimension• Accurate and clean work by swarf collection tray

TECHNICAL DATA MOBILE WORKSTATION

Dimensions (L x W x H) 115 x 43 x 91 cm45.3 in x 16.9 in x 35.8 in

Load capacity max. 675 kg1488.1 lbs

MODEL CODE WEIGHT

Mobile workstation 790 068 071 302 lb (137 kg)

Other accessories

• Saw blades and bevel cutters, see page 19• Work benches and tool box, see page 28• Pipe vices, see page 28

Mobile workstation


Pipe Cutting

19

BLADES & BEVEL TOOLING

Whether it's beveling or performing a square, burr-free cut, Orbitalum offers quality blades and cutting tools that are designed to work directly with Orbitalum machines. Engineered to increase the life of the tool and the machine, these saw blades and bevel cutters are tested under the highest tolerances, and like Orbitalum machines, are built for the most demanding jobs and environments. 4 different ranges of saw blades are available.

FOR GF AND RA MACHINES

• Economy range for low and non-alloy steels and cast iron pipes• Performance range for high-alloy steels (stainless steel)• High-Performance range for high-performance materials and high-alloy steels• Premium range specifically made for stainless steel applications with extra long durability

WORKABLEPIPE MATERIALS

AL MILD STEEL, CU, CUNI,CUZN, CUSN

INOX, V2A, V4A, 304, 316 (L)

TI, DUPLEX, INCONEL

Economy * *

Performance * *

High-Performance * * *

Premium *


Innovative manufacturing methods and special cutting geometry ensure a precise, square and burr-free cut

Square

Burr-free and deformation-free

Cutting and beveling


Pipe Cutting

20

Saw blades and bevel cutters for GF and RA machines

Saw blades

Features and application ranges, see page 19.Minimum purchase: 5 blades.

MODEL VERSION WALL THICKNESS SAW BLADE Ø CODE WEIGHT

[MM] [INCH] [MM] [INCH]

Saw blade Economy 1.2 - 2.5 .047 - .098 63 2.480 790 041 135 1.2 oz (35 g)

Saw blade Economy* 1.5 - 6.0 .059 - .236 68 2.677 790 042 063 1.3 oz (36 g)





Saw blade Performance 0.6 - 1.2 .024 - .047 63 2.480 790 041 036 1 oz (27 g)

Saw blade Performance 1.0 - 1.6 .039 - .063 68 2.677 790 042 049 1.8 oz (50 g)




Saw blade Performance** 1.2 - 2.5 .047 - .098 100 3.937 790 043 036 3.7 oz (104 g)









Saw blade High-Performance 1.2 - 2.5 .047 - .098 80 3.150 790 046 021 2.3 oz (64 g)



Saw blade Premium 1.2 - 2.5 .047 - .098 63 2.480 790 041 049 1.2 oz (33 g)

* applicable only for aluminum tubes ** only for RA 6, RA 8, RA 12 and GF 20 AVM

Saw blade/bevel cutter combinations

Features and application ranges, see page 19.Simultaneous cutting and beveling of pipes in just seconds.

Weld-prep saw blade/bevel cutter combinations (V-prep)

Consisting of one saw blade and one bevel cutter. It is possible to order the individual parts separately.

VERSION WALL THICKNESS BEVELINGANGLE

[°]

HEIGHT OF BEVEL MAX.

SAW BLADE Ø CODE WEIGHT

[MM] [INCH] [MM] [INCH] [MM] [INCH]

Performance 1.2 - 3.0 .047 - .118 30 3 .118 63 2.480 790 044 050 3.5 oz (100 g)

Performance 2.5 - 7.0 .098 - .276 30 7 .276 68 2.677 790 042 161 3.8 oz (108 g)

High-Performance 2.5 - 5.0 .098 - .197 35 5 .197 68 2.677 790 042 015 4.2 oz (120 g)



Saw blade Economy

Saw blade Premium

Saw blade High-Performance

Saw blade Performance

Weld-prep saw blade/bevel cutter combination (V-prep)


Pipe Cutting

21

Replacement parts for weld-prep saw blade/bevel cutter combinations (V-prep)


Saw blade for 790 044 050 Performance 790 044 040 1 oz (27 g)

Bevel cutter 30° for 790 044 050 Performance 790 044 049 2.3 oz (65 g)

Saw blade for 790 042 155, 790 042 157 and 790 042 161 Performance 790 042 153 1.4 oz (40 g)

Bevel cutter 30° for 790 042 161 Performance 790 042 160 2.1 oz (60 g)

Saw blade for 790 042 018, 790 042 015, 790 042 023, 790 042 013 High-Performance 790 042 016 1.4 oz (40 g)

Bevel cutter 30° for 790 042 013 High-Performance 790 042 021 2.7 oz (77 g)

Support disc for saw blade/bevel cutter combinations

We recommend the use of 1 support disc for the saw blade/bevel cutter combination.

MODEL CODE WEIGHT

Support disc 790 046 188 2.4 oz (68 g)

Bevel cutters

Features and application ranges, see page 19.

For V-prep profiles on pipe ends.The bevel cutter is mounted on the RA pipe cutter instead of a saw blade. Reproducible weld seam preparation in just seconds.

Bevel cutters V-prep

MODEL BEVELINGANGLE [°]

HEIGHT OF BEVEL MAX.

BEVEL CUTTER Ø CODE WEIGHT


Economy 30.0 9.5 .374 72 2.835 790 042 045 5.8 oz (165 g)

Economy 35.0 8.9 .350 70 2.756 790 042 037 6 oz (170 g)

Economy 37.5 8.4 .331 70 2.756 790 042 036 5.7 oz (162 g)

Economy 45.0 7.5 .295 70 2.756 790 042 038 5.7 oz (162 g)

Performance 30.0 9.5 .374 72 2.835 790 042 071 5.4 oz (153 g)

Performance 30.0 13.0 .512 76 2.992 790 043 023 6.6 oz (187 g)

Performance 37.5 8.4 .331 70 2.756 790 042 070 5.7 oz (163 g)

High-Performance 30.0 9.5 .374 72 2.835 790 042 073 5.5 oz (157 g)

Saw blade lubricant GF TOP

Synthetic high-performance lubricant for cutting and beveling machines.Increases the tool life of the saw blade. Compliant with the food approval NSF H2. The screwable brush guarantees an easy and uniform application of lubricant on the saw blade.


Saw blade lubricant GF TOP Tube, 180 g 790 060 228 7.2 oz (205 g)

Saw blade lubricant GF LUB

The NEW chlorine-free high-performance lubricant for cutting and beveling.Increases the tool life of the saw blade. This ecologically cutting compound is the environmentally friendly replacement for ROCOL: just with a new name and improved quality. GF LUB meets the latest environmental directives and ecological standards.


Saw blade lubricant GF LUB Tube, 160 ml 790 041 016 5.6 oz (160 g)

Bevel cutter V-prep

GF TOP

GF LUB


Pipe Cutting

22

PS 4.5 PLUS, PS 6.6

Tube cutting made easy! Cutting thin-walled stainless-steel tubes and elbows using the superior "Planetary cutting technology". For its field of applications, the PS 4.5 Plus (23 kg) as well as the PS 6.6 (26 kg) are amongst the lightest in their class available machines on the market today.

"Enhanced safety due to stationary tube – rotating tool." The tested process of planetary cutting is another important feature, which characterizes all ORBITALUM pipe cutting machines. The saw blade rises into the cutting area and is driven orbitally around the pipe. The advantage is that a small saw blade can cut a large tube diameter, without heating the tube.

As is characteristic for the ORBITALUM pipe saws, the saw allows convenient marking of the cut-off point on the tube with the help of a

A mobile, powerful and flexible tube cutting machine for use on construction sites, that’s what the PS series from Orbitalum Tools stands for. This new generation of tube saws convinces not only with its burr-free, right-angled and deformation-free cutting results, but also with its low weight.

PORTABLE TUBE SAWS

line laser. A second saw blade clamping point enables tube elbows to be cut off.The powerful motor is equipped with overload protection and ergonomic handles and is available for the voltages230 V, 110 V or 120 V, 50/60 Hz.

The slide housing as well as the self-centering clamping jaws were produced from high-quality aluminum alloys, which measure up to the highest requirements for construction sites.

• Lightweight and easily transportable machine to provide flexibility for on-site applications

• Deformation-free clamping of thin-walled tubes

• For cutting of thin-walled tubes and elbows• No rework necessary because of a burr-free

and square cut• Cold cutting process prevents corrosion

• Integrated line laser to determine the cut off point

• Orbital cutting process saves time• Multiple point clamping• Fast adjustment of the pipe dimension• Long saw blade service life• Press fitting saw blade combinations can be

used*• Speed controlled single-phase AC motor with

restart inhibitor

* Only with saw blade/bevel cutter combinations of Orbitalum Tools: Code 790 044 046 or 790 044 047. Engineered for stainless steel press fitting systems. Consisting of one saw blade and one bevel cutter. Individual parts available separately. Workable wall thickness: 1 - 2 mm (0.039 in - 0.079 in), beveling angle: 45°/70°, height of bevel: max. 0.4/1 mm (0.016 in/.0.039 in).

Simple and convenient to use: The PS saws can be mounted quickly with minimum space requirements and transported and operated by a single person


Pipe Cutting

23

APPLICATION RANGE PS 4.5 PLUS PS 6.6

Tube OD [mm] 6 - 120 50* - 170

[inch] 0.236 - 4.724 1.969* - 6.693

Elbow OD [mm] 30 - 120 50* - 170

[inch] 1.181 - 4.724 1.969* - 6.693

Wall thickness max. [mm] 3 3

[inch] 0.118 0.118

TECHNICAL DATA PS 4.5 PLUS PS 6.6

Dimensions [mm] 480 x 230 x 600 480 x 230 x 660

[inch] 20.9 x 9.1 x 23.6 20.9 x 9.1 x 26

Power [W] 1100 1100

[hp] 1.5 1.5

Protection class (DIN VDE 0740, isolated) [class] II II

Speed [rpm] 30 - 165 30 - 165

Vibration level (DIN EN 28662, part 1) [m/s2] < 2.5 < 2.5

Noise level at the workplace approx. [dB (A)] 78 78

SCOPE OF DELIVERY PS 4.5 PLUS PS 6.6

Portable tube saw Pc. 1 1

Cast aluminum clamping jaws Set 1 1

Durable storage and shipping case Pc. 1 1

Saw blade (Code 790 048 072) Pc. 1 1

Tool bag equipped with tools Pc. 1 1

Saw blade lubricant GF TOP (Code 790 060 228) Tube 1 1

Operating instructions and spare parts list Set 1 1


* It is possible to cut tubes with an outer diameter min. 30 mm (1.181 in) with the PS 6.6 by using additional clamping jaws (accessory, Code 790 048 380). These clamping jaws are delivered as a standard with the PS 4.5 Plus.

Deformation-free clamping of thin-walled tubes

Second saw blade position to cut off elbows

GF TOP saw blade lubricant included with saw

Includes Performance saw blade (790 048 072)


PS 4.5 Plus

PS 6.6

Delivery with durable storage and shipping case


Pipe Cutting

24

Portable tube saws

PS 4.5 Plus, PS 6.6



PS 4.5 Plus 230 V, 50/60 Hz EU 790 048 001 52 lb (23.6 kg) 81.6 lb (37 kg)

PS 4.5 Plus 110 V, 50/60 Hz EU 790 048 002 52 lb (23.6 kg) 81.6 lb (37 kg)

PS 4.5 Plus 120 V, 50/60 Hz US 790 048 003 52 lb (23.6 kg) 81.6 lb (37 kg)

PS 6.6 230 V, 50/60 Hz EU 790 049 001 58 lb (26.3 kg) 90.4 lb (41 kg)

PS 6.6 110 V, 50/60 Hz EU 790 049 002 58 lb (26.3 kg) 90.4 lb (41 kg)

PS 6.6 120 V, 50/60 Hz US 790 049 003 58 lb (26.3 kg) 90.4 lb (41 kg)


Quick and easy mounting of the machine to the bench with no drilling. Including 4 socket head screws to fix the PS to the quick-mounting base plate.

MODEL CODE WEIGHT

Quick-mounting base plates with integrated screw clamps 790 048 334 5.7 lb (2.6 kg)

Saw blades

Performance range for high-alloy steels (stainless steel). Recommended saw blades (only Ø 63 mm/2.480 in) for PS 4.5 Plus and PS 6.6.

MODEL VERSION WALL THICKNESS SAW BLADE Ø CODE WEIGHT


Saw blade Performance 1.0 - 3.0 0.039 - 0.118 63 2.480 790 048 072 1.2 oz (35 g)

Saw blade Performance 0.6 - 1.2 0.024 - 0.047 63 2.480 790 041 036 1 oz (27 g)

Clamping jaws replacement set

Made from coated cast aluminum. Extends the dimension range of the PS 6.6 to OD min. 30 mm (1.181 in).

MODEL CODE WEIGHT

Clamping jaws replacement set for PS 4.5 Plus and extension jaws for PS 6.6 790 048 380 4.5 lb (2 kg)

Laser retrofitting kit

Line laser to identify the cutting point on the tube.Easy mounting on the swivel on the PS machines. Kit contains 1 line laser, 1 laser holder with 2 fixing screws, replacement batteries, 1 set of assembly instructions.

MODEL CODE WEIGHT

Laser retrofitting kit for PS 4.5 Plus and PS 6.6 790 048 060 3.9 oz (110 g)

Other accessories

• High-performance lubricants for cutting and beveling, see page 16• Swivel cable, see page 17• Quick-mounting base plates with integrated screw clamps, see page 17• Pipe feeder base unit and extension unit, see page 17• Mobile workstation, see page 18• Work benches and tool box, see page 28• Pipe vices, see page 28

PS 4.5 Plus, PS 6.6


Saw blade Performance

Clamping jaws replacement set

Laser retrofitting kit


Pipe Cutting

25

MRA

For manual cutting of metal tubes in any position. Easy to use – first-rate cutting technology.

The patented cutting technique used in designing the MRA is based on the diameter-specific clamping shells and the flexible multi-roller cutting chain. Both these components are made of hardened, wear resistant steel and provide the following advantages:

• Long service life of the components• The cutting chain is at a right-

angle around the tube• The MRA runs on track rollers

on the clamping shells• Minimum hand movements• Tubes made of stainless steel can be cut

The clever solution for cutting metal tubes manually in any position.

The MRA metal tube cutter is specially designed for tight clearance where chipless cutting processes are needed.

METAL TUBE CUTTER

APPLICATION RANGE MRA

Tube OD [mm][inch]

25.0 - 254.00.984 - 10.000

Wall thickness* [mm][inch]

0.8 - 3.00.031 - 0.118

TECHNICAL DATA MRA

Dimensions [mm][inch]

450 x 10517.7 x 4.1

SCOPE OF DELIVERY MRA

Metal tube cutter MRA Pc. 1

Durable storage & shipping case Pc. 1

Socket head key Pc. 1

Connection clamp Pc. 1

Working gloves Pair 1

Operating instructions and spare parts list

Set 1


* Depends on material. For high-alloy steels, the max. wall thickness which can be processed is 2.0 - 2.5 mm (0.079 - 0.098 in)

ADVANTAGES:• Deformation-free and square cut• No electricity required• Requires little space, for use in limited access

areas

FOR TUBE MATERIALS:• High-alloy steel (stainless steel material e.g.

no. 1.40... to 1.45... or 304/316 materials)• Low-alloy and unalloyed steel• Cast materials• Non-ferrous metals

Diameter-specific clamping shells

Multi-roller cutting chains:The cutting wheels are made from hardened steel

Guiding of the multi-roller cutting chain and the MRA through the clamping shells

Durable storage and shipping case included


Pipe Cutting

26

Metal tube cutter

MRAFeatures, application range, technical data and scope of delivery, see page 25.Multi-roller cutting chains and clamping shells must be ordered separately.

MODEL CODE MACHINE WEIGHT SHIPPING WEIGHT

Metal tube cutter MRA 790 008 001 6.8 lb (3.1 kg) 17.6 lb (8 kg)

Multi-roller cutting chainsCutting wheels made from hardened steel.

MODEL TUBE OD CUTTING WHEELS[QTY]

CODE WEIGHT

[MM] [INCH]

Multi-roller cutting chain MRA 25.0 - 114.3 0.984 - 4.500 15 790 008 018 1.1 lb (0.5 kg)

Multi-roller cutting chain MRA 114.3 - 254.0 4.500 - 10.000 16 790 008 041 2 lb (0.9 kg)

Clamping shells for MRAHardened steel, two-piece sets. One pair of clamping shells needed per tube size. Other sizes available on request.MRA

Multi-roller cutting chain

Clamping shells

TUBE OD CODE WEIGHT

0.984 in (25 mm) 790 008 102 1.4 lb (0.7 kg)

1 in (25 mm) 790 008 104 1.4 lb (0.7 kg)

1.142 in (29 mm) 790 008 103 1.6 lb (0.7 kg)

1.327 in (34 mm) 790 008 105 2 lb (0.9 kg)

1.5 in (38 mm) 790 008 130 2.1 lb (1 kg)

1.575 in (40 mm) 790 008 135 2.1 lb (1 kg)

1.669 in (42 mm) 790 008 140 2.2 lb (1 kg)

1.752 in (45 mm) 790 008 150 2.3 lb (1.1 kg)

1.902 in (48 mm) 790 008 155 2.4 lb (1.1 kg)

1.969 in (50 mm) 790 008 160 2.5 lb (1.1 kg)

2 in (51 mm) 790 008 165 2.5 lb (1.1 kg)

2.047 in (52 mm) 790 008 175 2.6 lb (1.2 kg)

2.087 in (53 mm) 790 008 180 2.5 lb (1.2 kg)

2.126 in (54 mm) 790 008 185 2.4 lb (1.1 kg)

2.244 in (57 mm) 790 008 190 2.7 lb (1.2 kg)

2.374 in (60 mm) 790 008 195 2.9 lb (1.3 kg)

2.5 in (64 mm) 790 008 200 3 lb (1.4 kg)

2.559 in (65 mm) 790 008 203 3 lb (1.4 kg)

2.756 in (70 mm) 790 008 215 3.2 lb (1.4 kg)

2.874 in (73 mm) 790 008 220 3.3 lb (1.5 kg)

2.953 in (75 mm) 790 008 225 3.5 lb (1.6 kg)

2.996 in (76 mm) 790 008 230 3.4 lb (1.6 kg)

TUBE OD CODE WEIGHT

3.15 in (80 mm) 790 008 233 3 lb (1.4 kg)

3.307 in (84 mm) 790 008 240 3.7 lb (1.7 kg)

3.346 in (85 mm) 790 008 245 3.9 lb (1.8 kg)

3.5 in (89 mm) 790 008 250 3.9 lb (1.8 kg)

3.937 in (100 mm) 790 008 255 4.3 lb (2 kg)

4 in (102 mm) 790 008 260 4.5 lb (2 kg)

4.094 in (104 mm) 790 008 270 4.2 lb (1.9 kg)

4.252 in (108 mm) 790 008 280 4.6 lb (2.1 kg)

4.331 in (110 mm) 790 008 285 4.7 lb (2.2 kg)

4.5 in (114 mm) 790 008 290 5.1 lb (2.3 kg)

5.079 in (129 mm) 790 008 315 6.2 lb (2.8 kg)

5.5 in (140 mm) 790 008 325 6.6 lb (3 kg)

5.906 in (150 mm) 790 008 333 7.4 lb (3.4 kg)

6 in (152 mm) 790 008 335 7.1 lb (3.2 kg)

6.063 in (154 mm) 790 008 340 7.4 lb (3.4 kg)

6.299 in (160 mm) 790 008 355 7.8 lb (3.5 kg)

6.496 in (165 mm) 790 008 360 9.1 lb (4.1 kg)

6.626 in (168 mm) 790 008 365 7.9 lb (3.6 kg)

8.032 in (204 mm) 790 008 380 9.6 lb (4.4 kg)

8.626 in (219 mm) 790 008 385 10.3 lb (4.7 kg)

9 in (229 mm) 790 008 387 10.8 lb (4.9 kg)

10 in (254 mm) 790 008 390 11.9 lb (5.4 kg)

Other accessories• Work benches and tool box, see page 28• Pipe vices, see page 28


Accessories for Workshop & Site


Pipe Cutting

28

Work benches, tool box, pipe vices, deburring tool

Work benches

DIMENSIONS WORK BENCH, SMALL WORK BENCH, LARGE COLLAPSIBLE WORK BENCH

Dimension (L x W x H) 120 x 75 x 85 cm47.24 in x 29.53 in x 33.46 in

150 x 100 x 85 cm59.06 in x 39.37 in x 33.46 in

100 x 70 x 85 cm39.37 in x 27.56 in x 33.46 in

MODEL CODE WEIGHT

Work bench, small, collapsible, with 1 tool box support 790 052 001 141.1 lb (64 kg)

Work bench, large*, collapsible, with 2 tool box supports 790 052 004 209.4 lb (95 kg)

Collapsible work bench, load capacity: 650 kg 790 052 030 66.1 lb (30 kg)

* while stock last

Tool box

For mounting under the work benches Code 790 052 001 and 790 052 004.

DIMENSIONS TOOL BOX

Outside dimensions (L x W x H) 100 x 44 x 45 cm39.37 in x 17.32 in x 17.72 in

Outside dimensions with handles (L x W x H) 100 x 46 x 45 cm39.37 in x 18.11 in x 17.72 in

MODEL CODE WEIGHT

Tool box 790 052 101 110.2 lb (50 kg)

Pipe vices

APPLICATION RANGE CHAIN PIPE VICE CHAIN PIPE VICE WITH EXTENSION ROLLER CHAIN

COLLAPSIBLE WORK BENCH

Tube OD Up to 165 mmUp to 6.496 in

Up to 230 mmUp to 9.055 in

20 - 250 mm0.8 in - 9.8 in

MODEL CODE WEIGHT

Chain pipe vice, complete with pipe support 790 052 201 12.1 lb (5.5 kg)

Extension roller chain 790 052 859 1.9 lb (870 g)

Bench vice for plastic and stainless steel pipes 790 052 231 12.1 lb (5.5 kg)

Spare belt (930 x 28 mm / 36.6 x 1.1 inch) for bench vice 790 052 247 3.5 oz (100 g)

Deburring tool

APPLICATION RANGE DEBURRING TOOL

Tube OD max. 54 mm2.126 in

Tube ID max. 10 mm0.394 in

MODEL CODE WEIGHT

Deburring tool 790 052 052 1 lb (455 g)

Work bench small

Collapsible work bench

Tool box

Chain pipe vice

Bench vice for plastic and stainless steelpipes

Deburring tool


Tube Squaring Machines


Tube Squaring

30

RPG XS, RPG ONE, RPG 1.5, RPG 2.5

Pipe and installation manufacturers from the high-purity gas, electronics, pharmaceuticals, food processing, beverages, solar and chemical industries benefit from the mobile, high-quality and burr-free processing of pipe ends.

The quick tool change system allows clamping shells and tubes to be easily changed without additional equipment. All multi-functional tools (MFW) are two-sided tool bits with protective coating against tool wear. This enables the preparation of tubes made of high-alloy, unalloyed and low-alloy steels and aluminum with high precision very quickly and efficiently.

The cordless versions of the RPG machines are ideal in situations where access to a power service are limited.

The machines and accessories are supplied in a handy, durable storage and shipping case – the cordless versions additionally with a 230 V charger for the European market or a 120 V charger for the American market.

• High-quality, burr-free and square finishing• Beveling possible with a special tool holder• Integrated quick clamping system for tooling,

clamping shells, and tube• Preparation of thin-walled stainless steel

tubes (V4A) and micro fittings• High-performance coated tool bit with two

cutting edges• Micrometer feed for optimum results• No additional tools required for operation• Compact, light weight and portable machine• The special adaptor clamping shell allows the

RPG 2.5 to be used with the clamping shells for the RPG 1.5 machines.

FEATURES OF THE ELECTRIC VERSIONS:• Machine with rotating/removable drive• Built-in electronic speed regulation with

speed stabilization: Vario-Tachometer-Constamatic (VTC) full wave electronics

• Restart protection to prevent the machine from starting in an uncontrolled way after it has been re-connected to the electric mains or after the voltage supply has been reestablished after a power failure

• RPM regulator• Sturdy marathon motor• Overload protection• Shut-off carbon brushes• Carbon wear indicator

The RPG series provide ease of use through clamping. The capabilities of our RPG range include squaring (I-seam) thin-walled stainless steel tubes and micro-fittings, as well as unalloyed and low-alloyed steels, aluminum and titanium. The machines are lightweight and handheld. Users can select the appropriate clamping shells from the range of accessories for each diameter.

TUBE SQUARING MACHINES (ELECTRIC/CORDLESS)

Designed for burr-free squaring and beveling of thin-walled stainless steel tubes and micro fittings. For the required, high quality tube end preparation for orbital welding!

Built-in electronic speed regulation with speed stabilization

Precise clamping of tubes and micro fittings

Environmentally friendly cordless versions thanks to lithium-ion technology


Tube Squaring

31

APPLICATION RANGE RPG XS RPG ONE RPG ONE CORDLESS

RPG 1.5 RPG 1.5 CORDLESS


Tube OD min.-max. [mm] 3.0* - 19.05 3.0* - 25.4 3.0* - 25.4 3.0* - 38.1 3.0* - 38.1 3.0* - 63.5 3.0* - 63.5

[inch] 0.118* - 0.75 0.118* - 1.0 0.118* - 1.0 0.118* - 1.5 0.118* - 1.5 0.118* - 2.5 0.118* - 2.5

Wall thickness max. [mm] 2.0 3.0 3.0 3.0 3.0 3.0 3.0

[inch] 0.079 0.118 0.118 0.118 0.118 0.118 0.118

Tube materials High-alloy steels (stainless steel material no. 1.40... to 1.45... as per DIN 17455 and DIN 17456), unalloyed and low-alloy steels, aluminum.

TECHNICAL DATA RPG XS RPG ONE RPG ONE CORDLESS



Dimensions (L x W x H) [mm] 217 x 53 x 187 390 x 70 x 200 261 x 80 x 255 400 x 160 x 350 275 x 90 x 255 500 x 170 x 300 260 x 320 x 300

[inch] 8.5 x 2.1 x 7.4 15.4 x 2.8 x 7.9 10.3 x 3.2 x 10 15.8 x 6.3 x 13.8 10.8 x 3.5 x 10 19.7 x 6.7 x 11.8 10.2 x 12.6 x 11.8

Built-in electronic variable cutting speed [rpm] 0 - 350 145 - 380 0 - 400 145 - 380 0 - 400 1. speed: 9 - 22. speed: 27 - 153

1. speed: 0 - 242. speed: 0 - 83

Power [W] – 1100 – 1100 – 1100 –

Voltage of rechargeable battery [V] 10.8 – 18 – 18 – 18

Capacity [Ah] 1.5 – 2.6 – 2.6 – 2.6

Noise level at the workplace (EN 23741) [dB (A)] approx. 78 approx. 78 approx. 78 approx. 78 approx. 78 approx. 78.2 approx. 78.2

Vibration level (EN 50144) [m/s2] < 2.5 < 2.5 < 2.5 < 2.5 < 2.5 < 2.5 < 2.5

SCOPE OF DELIVERY RPG XS RPG ONE RPG ONE CORDLESS



Tube squaring machine Pc. 1 1 1 1 1 1 1

Durable storage and shipping case Pc. 1 1 1 1 1 1 1

Rechargeable batteries Pc. 2 – 2 – 2 – 2

Battery charger Pc. 1 – 1 – 1 – 1

Overload protection (square nut) Pc. – – – 1 1 1 1

Tool holder WH (Code 790 ...) Pc. 1 (... 033 150) 1 (... 037 152) 1 (... 037 152) 1 (... 037 152) 1 (... 037 152) 1 (... 037 152) 1 (... 037 152)

Multifunctional tool MFW (Code 790 038 314) Pc. 1 1 1 1 1 1 1

Adapter clamping shell (Code 790 030 094) Pc. – – – – – 1 1

Tool set Set 1 1 1 1 1 1 1

Operating instructions and spare parts list Set 1 1 1 1 1 1 1

Bench stand for cordless machines optional available (Code 790 037 169)


* Application range with standard tool holder (Code 790 037 152) is from 6.0 mm/0.236 in OD. With special tool holder (Code 790 037 161) 3.0 mm/0.118 in OD is possible. For the RPG 2.5 (battery) only with a special adapter clamping shell (included in the standard scope of delivery of the RPG 2.5).

RPG XS Cordless RPG ONE RPG 1.5 RPG 2.5

RPG XS Cordless angle drive RPG ONE Cordless RPG 1.5 Cordless RPG 2.5 Cordless

FEATURES OF THE CORDLESS VERSIONS:

• Very short design • Lithium-ion technology• Motor with high performance and small size• No memory effect• Single cell monitoring in the cordless pack

• Electronic overload protection with integrated temperature monitor• Robust cordless packs with capacity display• Minimal self-discharge• Environmentally friendly• AIR-COOLED technology for short charging times and a long service life


Tube Squaring

32

Tube squaring machines

RPG XS, RPG ONE, RPG 1.5, RPG 2.5 (Cordless)


Stainless steel clamping shells must be ordered separately.


RPG XS Cordless (10.8 V) 230 V, 50/60 Hz EU 790 033 001 2.9 lb (1.3 kg) 9.5 lb (4.3 kg)

RPG XS Cordless (10.8 V) 115 V, 60 Hz US 790 033 002 2.9 lb (1.3 kg) 9.5 lb (4.3 kg)

RPG XS Cordless angle drive (10.8 V) 230 V, 50/60 Hz EU 790 033 011 3.4 lb (1.5 kg) 13.9 lb (6.3 kg)

RPG XS Cordless angle drive (10.8 V) 115 V, 60 Hz US 790 033 012 3.4 lb (1.5 kg) 13.9 lb (6.3 kg)

RPG ONE 230 V, 50/60 Hz EU 790 036 031 9.1 lb (4.1 kg) 21.2 lb (9.6 kg)

RPG ONE 120 V, 50/60 Hz US 790 036 032 9.1 lb (4.1 kg) 21.2 lb (9.6 kg)

RPG ONE 110 V, 50/60 Hz EU 790 036 033 9.1 lb (4.1 kg) 21.2 lb (9.6 kg)

RPG ONE Cordless (18 V) 230 V, 50/60 Hz EU 790 036 021 6.3 lb (2.9 kg) 18.1 lb (8.2 kg)

RPG ONE Cordless (18 V) 115 V, 60 Hz US 790 036 022 6.3 lb (2.9 kg) 18.1 lb (8.2 kg)

RPG 1.5 230 V, 50/60 Hz EU 790 037 001 10.4 lb (4.7 kg) 20.9 lb (9.5 kg)

RPG 1.5 120 V, 50/60 Hz US 790 037 002 10.4 lb (4.7 kg) 20.9 lb (9.5 kg)


RPG 1.5 Cordless (18 V) 230 V, 50/60 Hz EU 790 037 011 7.6 lb (3.4 kg) 22.3 lb (10.1 kg)

RPG 1.5 Cordless (18 V) 115 V, 60 Hz US 790 037 012 7.6 lb (3.4 kg) 22.3 lb (10.1 kg)




RPG 2.5 Cordless (18 V) 230 V, 50/60 Hz EU 790 030 011 11.8 lb (5.3 kg) 25 lb (11.3 kg)

RPG 2.5 Cordless (18 V) 110 V, 60 Hz US 790 030 012 11.8 lb (5.3 kg) 25 lb (11.3 kg)

Stainless steel clamping shells

Extremely durable. Assures accurate centering and quick clamping shell change without any tools with its unique design and positive clamping shell mechanism. Other dimensions of clamping shells are available.

Please check the outer diameter of the tubes before ordering the clamping shells.

WORKS WITH APPLICABLEFOR

TUBE OD TUBE CLAMPING LENGTH CODE WEIGHT


RPG XS Tubes 6.35 0.250 10.00 0.394 790 033 202 3 oz (83 g)

RPG XS Tubes 8.00 0.315 10.00 0.394 790 033 203 3 oz (82 g)

RPG XS Tubes 9.53 0.375 10.00 0.394 790 033 204 3 oz (80 g)

RPG XS Tubes 10.00 0.394 10.00 0.394 790 033 205 3 oz (80 g)

RPG XS Tubes 12.70 0.500 10.00 0.394 790 033 206 3 oz (76 g)

RPG XS Tubes 13.50 0.531 10.00 0.394 790 033 207 3 oz (75 g)

RPG XS Tubes 19.05 0.750 10.00 0.394 790 033 209 2 oz (65 g)

RPG XS Micro fittings 6.35 0.250 10.00 0.394 790 033 301 2 oz (49 g)

RPG ONE Tubes 3.00 0.118 10.00 0.394 790 036 232 4 oz (118 g)

RPG ONE Tubes 3.18 0.125 10.00 0.394 790 036 201 4 oz (119 g)

RPG ONE Tubes 6.00 0.236 10.00 0.394 790 036 213 4 oz (117 g)

RPG ONE Tubes 6.35 0.250 10.00 0.394 790 036 202 4 oz (118 g)

RPG ONE Tubes 7.00 0.276 10.00 0.394 790 036 214 4 oz (118 g)

RPG ONE Tubes 8.00 0.315 10.00 0.394 790 036 215 4 oz (116 g)

RPG ONE Tubes 9.53 0.375 10.00 0.394 790 036 203 4 oz (115 g)

RPG ONE Tubes 10.00 0.394 10.00 0.394 790 036 204 4 oz (115 g)

RPG ONE Tubes 10.10 0.398 10.00 0.394 790 036 222 4 oz (114 g)

RPG ONE Tubes 11.00 0.433 10.00 0.394 790 036 226 4 oz (112 g)

RPG ONE Tubes 12.00 0.472 10.00 0.394 790 036 205 4 oz (112 g)

RPG ONE Tubes 12.10 0.476 10.00 0.394 790 036 223 4 oz (111 g)

RPG ONE Tubes 12.70 0.500 10.00 0.394 790 036 206 4 oz (111 g)

RPG ONE Tubes 13.50 0.531 10.00 0.394 790 036 227 4 oz (110 g)

RPG ONE Tubes 14.00 0.551 10.00 0.394 790 036 228 4 oz (108 g)

RPG ONE Tubes 14.10 0.555 10.00 0.394 790 036 224 4 oz (107 g)

RPG ONE Tubes 15.00 0.590 10.00 0.394 790 036 216 4 oz (107 g)

RPG XS Cordless / RPG XS Cordless angle drive


Stainless steel clamping shell for micro fittings

RPG ONE / RPG ONE Cordless


Tube Squaring

33




RPG ONE Tubes 15.60 0.614 10.00 0.394 790 036 225 4 oz (105 g)

RPG ONE Tubes 15.88 0.625 10.00 0.394 790 036 211 4 oz (105 g)

RPG ONE Tubes 16.00 0.630 10.00 0.394 790 036 212 4 oz (104 g)

RPG ONE Tubes 17.00 0.670 10.00 0.394 790 036 221 4 oz (103 g)

RPG ONE Tubes 17.20 0.677 10.00 0.394 790 036 207 4 oz (104 g)

RPG ONE Tubes 18.00 0.709 10.00 0.394 790 036 217 4 oz (102 g)

RPG ONE Tubes 19.05 0.750 10.00 0.394 790 036 208 4 oz (100 g)

RPG ONE Tubes 20.00 0.787 10.00 0.394 790 036 230 3 oz (96 g)

RPG ONE Tubes 21.30 0.839 10.00 0.394 790 036 209 3 oz (94 g)

RPG ONE Tubes 21.70 0.854 10.00 0.394 790 036 220 3 oz (93 g)

RPG ONE Tubes 22.00 0.866 10.00 0.394 790 036 218 3 oz (93 g)

RPG ONE Tubes 23.00 0.906 10.00 0.394 790 036 219 3 oz (85 g)

RPG ONE Tubes 25.00 0.984 10.00 0.394 790 036 231 3 oz (81 g)

RPG ONE Tubes 25.40 1.000 10.00 0.394 790 036 210 3 oz (83 g)

RPG ONE Micro fittings 6.00 0.236 4.00 0.157 790 036 304 2 oz (66 g)







RPG 1.5 Tubes 3.00 0.118 15.00 0.591 790 037 220 11 oz (300 g)

RPG 1.5 Tubes 3.18 0.125 15.00 0.591 790 037 221 11 oz (308 g)

RPG 1.5 Tubes 4.00 0.157 15.00 0.591 790 037 222 11 oz (310 g)

RPG 1.5 Tubes 4.78 0.188 15.00 0.591 790 037 223 11 oz (310 g)

RPG 1.5 Tubes 5.00 0.197 15.00 0.591 790 037 224 11 oz (308 g)

RPG 1.5 Tubes 6.00 0.236 15.00 0.591 790 037 225 11 oz (310 g)

RPG 1.5, RPG 2.5 Tubes 6.35 0.250 15.00 0.591 790 037 226 11 oz (306 g)

RPG 1.5, RPG 2.5 Tubes 7.00 0.276 15.00 0.591 790 037 257 11 oz (306 g)

RPG 1.5, RPG 2.5 Tubes 8.00 0.314 15.00 0.591 790 037 227 11 oz (299 g)

RPG 1.5, RPG 2.5 Tubes 9.00 0.354 15.00 0.591 790 037 254 10 oz (280 g)

RPG 1.5, RPG 2.5 Tubes 9.53 0.375 15.00 0.591 790 037 228 10 oz (297 g)

RPG 1.5, RPG 2.5 Tubes 10.00 0.394 15.00 0.591 790 037 229 11 oz (298 g)

RPG 1.5, RPG 2.5 Tubes 11.00 0.433 15.00 0.591 790 037 293 9 oz (252 g)

RPG 1.5, RPG 2.5 Tubes 11.11 0.437 15.00 0.591 790 037 255 10 oz (295 g)

RPG 1.5, RPG 2.5 Tubes 12.00 0.472 15.00 0.591 790 037 230 10 oz (293 g)

RPG 1.5, RPG 2.5 Tubes 12.70 0.500 15.00 0.591 790 037 231 10 oz (292 g)

RPG 1.5, RPG 2.5 Tubes 13.00 0.512 15.00 0.591 790 037 232 10 oz (295 g)

RPG 1.5, RPG 2.5 Tubes 13.20 0.520 15.00 0.591 790 037 263 10 oz (290 g)

RPG 1.5, RPG 2.5 Tubes 13.50 0.531 15.00 0.591 790 037 233 10 oz (290 g)

RPG 1.5, RPG 2.5 Tubes 14.00 0.551 15.00 0.591 790 037 234 10 oz (288 g)

RPG 1.5, RPG 2.5 Tubes 14.30 0.563 15.00 0.591 790 037 253 10 oz (289 g)

RPG 1.5, RPG 2.5 Tubes 14.70 0.579 15.00 0.591 790 037 290 10 oz (287 g)

RPG 1.5, RPG 2.5 Tubes 15.00 0.591 15.00 0.591 790 037 235 10 oz (287 g)

RPG 1.5, RPG 2.5 Tubes 15.30 0.602 15.00 0.591 790 037 259 10 oz (287 g)

RPG 1.5, RPG 2.5 Tubes 15.70 0.618 15.00 0.591 790 037 291 10 oz (284 g)

RPG 1.5, RPG 2.5 Tubes 15.88 0.625 15.00 0.591 790 037 236 10 oz (285 g)

RPG 1.5, RPG 2.5 Tubes 16.00 0.630 15.00 0.591 790 037 237 10 oz (285 g)

RPG 1.5, RPG 2.5 Tubes 17.00 0.669 15.00 0.591 790 037 256 10 oz (280 g)

RPG 1.5, RPG 2.5 Tubes 17.08 0.672 15.00 0.591 790 037 260 10 oz (281 g)

RPG 1.5, RPG 2.5 Tubes 17.20 0.677 15.00 0.591 790 037 238 11 oz (300 g)

RPG 1.5, RPG 2.5 Tubes 18.00 0.709 15.00 0.591 790 037 239 10 oz (280 g)

RPG 1.5, RPG 2.5 Tubes 19.00 0.748 15.00 0.591 790 037 240 10 oz (275 g)

RPG 1.5, RPG 2.5 Tubes 19.05 0.750 15.00 0.591 790 037 241 10 oz (274 g)

RPG 1.5, RPG 2.5 Tubes 20.00 0.787 15.00 0.591 790 037 242 10 oz (272 g)

RPG 1.5, RPG 2.5 Tubes 21.00 0.827 15.00 0.591 790 037 294 10 oz (270 g)

RPG 1.5, RPG 2.5 Tubes 21.30 0.839 15.00 0.591 790 037 243 10 oz (270 g)

RPG 1.5, RPG 2.5 Tubes 21.70 0.854 15.00 0.591 790 037 261 10 oz (270 g)

RPG 1.5, RPG 2.5 Tubes 22.00 0.866 15.00 0.591 790 037 244 9 oz (264 g)

RPG 1.5, RPG 2.5 Tubes 22.22 0.875 15.00 0.591 790 037 292 10 oz (270 g)

RPG 1.5, RPG 2.5 Tubes 23.00 0.906 15.00 0.591 790 037 245 9 oz (255 g)

RPG 1.5, RPG 2.5 Tubes 24.00 0.945 15.00 0.591 790 037 246 9 oz (256 g)

RPG 1.5, RPG 2.5 Tubes 25.00 0.984 15.00 0.591 790 037 247 9 oz (252 g)

RPG 1.5, RPG 2.5 Tubes 25.40 1.000 15.00 0.591 790 037 248 8 oz (240 g)

RPG 1.5, RPG 2.5 Tubes 26.90 1.059 15.00 0.591 790 037 249 9 oz (260 g)

RPG 1.5, RPG 2.5 Tubes 27.00 1.063 15.00 0.591 790 037 264 9 oz (260 g)

RPG 1.5, RPG 2.5 Tubes 27.20 1.071 15.00 0.591 790 037 262 9 oz (260 g)

RPG 1.5

RPG 1.5 Cordless

RPG 2.5 Cordless

RPG 2.5


Tube Squaring

34




RPG 1.5, RPG 2.5 Tubes 28.00 1.102 15.00 0.591 790 037 250 8 oz (240 g)

RPG 1.5, RPG 2.5 Tubes 29.00 1.142 15.00 0.591 790 037 251 8 oz (232 g)

RPG 1.5, RPG 2.5 Tubes 30.00 1.181 15.00 0.591 790 037 252 8 oz (228 g)

RPG 1.5, RPG 2.5 Tubes 31.80 1.250 15.00 0.591 790 037 280 8 oz (230 g)

RPG 1.5, RPG 2.5 Tubes 32.00 1.260 15.00 0.591 790 037 258 8 oz (226 g)

RPG 1.5, RPG 2.5 Tubes 33.40 1.315 15.00 0.591 790 037 281 8 oz (220 g)

RPG 1.5, RPG 2.5 Tubes 33.70 1.327 15.00 0.591 790 037 282 8 oz (218 g)

RPG 1.5, RPG 2.5 Tubes 34.00 1.339 15.00 0.591 790 037 283 8 oz (215 g)

RPG 1.5, RPG 2.5 Tubes 35.00 1.377 15.00 0.591 790 037 284 7 oz (210 g)

RPG 1.5, RPG 2.5 Tubes 36.00 1.417 15.00 0.591 790 037 285 7 oz (204 g)

RPG 1.5, RPG 2.5 Tubes 38.00 1.496 15.00 0.591 790 037 286 7 oz (199 g)

RPG 1.5, RPG 2.5 Tubes 38.10 1.500 15.00 0.591 790 037 287 7 oz (194 g)

RPG 2.5 Tubes 40.00 1.575 15.00 0.591 790 030 234 1.25 lb (565 g)

RPG 2.5 Tubes 41.00 1.614 15.00 0.591 790 030 230 1.23 lb (560 g)

RPG 2.5 Tubes 42.00 1.654 15.00 0.591 790 030 117 1.06 lb (483 g)

RPG 2.5 Tubes 42.40 1.669 15.00 0.591 790 030 227 1.06 lb (483 g)

RPG 2.5 Tubes 42.70 1.681 15.00 0.591 790 030 224 1.06 lb (483 g)

RPG 2.5 Tubes 43.00 1.693 15.00 0.591 790 030 231 1.2 lb (544 g)

RPG 2.5 Tubes 44.50 1.752 15.00 0.591 790 030 228 1.06 lb (483 g)

RPG 2.5 Tubes 48.30 1.902 15.00 0.591 790 030 226 11 lb (5 kg)

RPG 2.5 Tubes 50.80 2.000 15.00 0.591 790 030 220 1.06 lb (483 g)

RPG 2.5 Tubes 51.00 2.008 15.00 0.591 790 030 233 1.06 lb (482 g)

RPG 2.5 Tubes 52.00 2.047 15.00 0.591 790 030 225 1.06 lb (483 g)

RPG 2.5 Tubes 53.00 2.087 15.00 0.591 790 030 232 1.01 lb (457 g)

RPG 2.5 Tubes 54.00 2.126 15.00 0.591 790 030 221 16 oz (452 g)

RPG 2.5 Tubes 55.00 2.165 15.00 0.591 790 030 235 16 oz (440 g)

RPG 2.5 Tubes 57.00 2.244 15.00 0.591 790 030 229 15 oz (419 g)

RPG 2.5 Tubes 60.30 2.374 15.00 0.591 790 030 222 14 oz (386 g)

RPG 2.5 Tubes 63.50 2.500 15.00 0.591 790 030 223 12 oz (350 g)

RPG 2.5 Tubes 65.00 2.559 15.00 0.591 790 030 236 12 oz (330 g)

RPG 1.5 Micro fittings 3.00 0.118 4.00 0.157 790 037 300 8 oz (225 g)






RPG 1.5, RPG 2.5 Micro fittings 6.35 0.250 4.00 0.157 790 037 306 1.01 lb (460 g)

RPG 1.5, RPG 2.5 Micro fittings 8.00 0.314 4.00 0.157 790 037 307 8 oz (223 g)











Stainless steel clamping shell for micro fittings



Tube Squaring

35

Tool holder WH

Fits multifunctional tool 790 038 314. Incl. Torx fixing screw. For max. wall thickness 3 mm (0.118 in).

Application rangeTool holder

Possible application

Bevelingangle

[°]

Recommended application range

Tube OD

Squaring Beveling RPG XSCordless

RPG ONE(Cordless)

RPG 1.5(Cordless)

RPG 2.5(Cordless)

WH12-I/Standard*Code 790 037 152 x – –

[mm] 6.0 - 12.7 – 6.0 - 25.4 6.0 - 38.1 6.0 - 63.5

[inch] 0.236 - 0.5 – 0.236 - 1.0 0.236 - 1.5 0.236 - 2.5

WH12-ICode 790 037 161 x – –

[mm] 3.0 - 6.0 – 3.0 - 6.0 3.0 - 6.0 3.0 - 6.0

[inch] 0.118 - 0.236 – 0.118 - 0.236 0.118 - 0.236 0.118 - 0.236

WH12-I/Micro fittings**Code 790 037 156 x – –

[mm] – – 3.0 - 21.2 6.35 - 21.2

[inch] – – 0.118 - 0.84 0.25 - 0.84

WH3-V-30Code 790 037 158 – x 30°

[mm] – – max. 35.0 max. 60.3

[inch] – – max. 1.378 max. 2.374

WH3-V-35Code 790 037 159 – x 35°

[mm] – – max. 33.7 max. 59.3

[inch] – – max. 1.327 max. 2.335

WH3-V-45***Code 790 037 157 – x 45°

[mm] – – max. 33.7 max. 59.0

[inch] – – max. 1.327 max. 2.3

WH-ICode 790 033 150 x – –

[mm] 3.0 - 12.0 3.0 - 19.05 – – –

[inch] 0.118 - 0.472 0.118 - 0.75 – – –

WH-ICode 790 033 151 x – –

[mm] 12.0 - 19.05 12.0 - 19.05 – – –

[inch] 0.472 - 0.75 0.472 - 0.75 – – –

MODEL CODE WEIGHT

Standard tool holder WH12-I* 790 037 152 1 oz (40 g)

Special tool holder WH12-I 790 037 161 1 oz (26 g)

Special tool holder micro fittings WH12-I** 790 037 156 4 oz (100 g)

Tool holder WH3-V-30 790 037 158 1 oz (24 g)

Tool holder WH3-V-35 790 037 159 1 oz (24 g)

Tool holder WH3-V-45*** 790 037 157 1 oz (22 g)

Tool holder WH-I 790 033 150 1 oz (20 g)

Tool holder WH-I 790 033 151 1 oz (20 g)

* Supplied as standard with the RPG. ** Only to be used with stainless steel clamping shells for micro fittings.*** Not applicable with the RPG XS and the RPG ONE.

Multifunctional tool MFW

Two-sided tool bit with protective coating against tool wear.Usable for all machines of the RPG series.

MODEL QTY CODE WEIGHT

Multifunctional tool MFW-P-2 1 790 038 314 0.1 oz (3 g)


Torx screw (RPG ONE, RPG 1.5, RPG 2.5) 1 790 086 220 0.1 oz (2 g)

Torx screw (RPG XS) 1 790 086 217 0.1 oz (2 g)

Other accessories

• Work benches and tool box, see page 28• Pipe vices, see page 28

Tool holder WH



Tube Squaring

36

RPG 4.5, RPG 4.5 S, RPG 8.6

With high-precision, the user is able to prepare tubes with the RPG 4.5 up to 114.4 mm (4.5 in) and with the RPG 8.6 up to 219.1 mm (8.6 in) tube outer diameters quickly, burr-free and absolutely square.

Low operating costs for processing tubes are a big advantage. Our symmetric, exchangeable stainless steel and aluminum clamping shells (not for RPG 4.5 S) allow for a quick and easy tool change without any tool. A dimension change no longer requires a lot of time. The operator can work comfortably thanks to the ergonomic design of the machine, and can also save time.

All multifunctional tools (MFW) are two-sided tool bits with protective coating against tool wear. This enables the preparation of tubes made of high-alloy, unalloyed and low-alloy

steels and aluminum with high precision very quickly and efficiently. Clean and secure working area with a clear view of the cutting head.

The RPG 4.5 (S) and RPG 8.6 are equipped with a high-quality, powerful drive with 230 Volt and/or 120 Volt.

The machines and accessories are supplied in a handy, durable storage and shipping case.

• Squaring tube ends with a high-quality finish• Burr-free and square• Beveling possible with a special tool holder

(not with RPG 4.5 S)• Quick clamping system for tools, clamping

shells and tubes• Preparation of thin-walled stainless steel

tubes (V4A)

• High-performance coated tool bit with two cutting edges

• Built-in electronic speed regulation• Micrometer feed for optimum results• Space saving, light weight and portable

machine for a mobile and secure application• Machine with rotating/removable bench stand

FEATURES OF THE RPG 4.5 S:The tube squaring machine RPG 4.5 S is characterized by its universal vice-clamping system. With this particularly economical alternative to other conventional dimension-specific clamping shells, tubes can be centered, clamped and processed in the easiest way possible.

High quality, pipe-end machining is a necessity in automated orbital welding. Orbitalum has developed the squaring tube machines RPG 4.5, RPG 4.5 S and RPG 8.6: the perfect solution for the demanding, quality preparation of pipe ends for orbital welding.

TUBE SQUARING MACHINES

Designed for burr-free squaring of thin-walled stainless steel tubes


Tube Squaring

37

Quick clamping system for tools, clamping shells and tubes

APPLICATION RANGE RPG 4.5 RPG 4.5 S RPG 8.6

Tube OD [mm] 12.7 - 114.3 12.7 - 114.3 50.8 - 219.1

[inch] 0.5 - 4.5 0.5 - 4.5 2 - 8.6

Wall thickness max. [mm] 3.0 3.0 3.6

[inch] 0.118 0.118 0.142

Tube materials High-alloy steels. unalloyed and low-alloy steels and aluminum. Others on request.

TECHNICAL DATA RPG 4.5 RPG 4.5 S RPG 8.6

Dimensions (including motor) [mm] 460 x 260 x 230 610 x 380 x 270 500 x 350 x 350

[inch] 18.1 x 10.2 x 9.1 24 x 15 x 10.6 19.7 x 13.8 x 13.8

Power [W] 1100 1100 1100

Protection class [class] II II II

Speed (max. idling speed) [min-1] 8 - 52 8 - 52 7 - 18

Vibration level (EN 60745) [m/s2] < 2.5 < 2.5 < 2.5

Noise level at the workplace (EN 23741) [dB (A)] Idle running approx. 83 Idle running approx. 83 Idle running approx. 83

SCOPE OF DELIVERY RPG 4.5 RPG 4.5 S RPG 8.6

Tube squaring machine Pc. 1 1 1

Durable storage and shipping case Pc. 1 1 1

Tool holder WH (Code 790 038 320) Pc. 1 1 1

Multifunctional tool MFW (Code 790 038 314) Pc. 1 1 1

Tool set Set 1 1 1

Operating instructions and spare parts list Set 1 1 1


RPG 4.5 SRPG 4.5 RPG 8.6

Including tool holder WH and multifunctional tool MFW

Widely specified in high purity process piping applications

Wide range of stainless steel clamping shells

Including durable storage and shipping case


Tube Squaring

38

Tube squaring machines

RPG 4.5, RPG 4.5 S, RPG 8.6


Clamping shells must be ordered separately.





RPG 4.5 S 230 V, 50/60 Hz EU 790 038 011 50.7 lb (23 kg) 75 lb (34 kg)

RPG 4.5 S 120 V, 50/60 Hz US 790 038 012 50.7 lb (23 kg) 75 lb (34 kg)

RPG 8.6 230 V, 50/60 Hz EU 790 039 001 45.2 lb (20.5 kg) 70.5 lb (32 kg)

RPG 8.6 110 V, 50/60 Hz EU 790 039 003 45.2 lb (20.5 kg) 70.5 lb (32 kg)

RPG 8.6 120 V, 50/60 Hz US 790 039 002 45.2 lb (20.5 kg) 70.5 lb (32 kg)

Clamping shells

Extremely durable. The two-piece-design with click mechanism ensures accurate centering and quick clamping shell change without any tools. Other dimensions of clamping shells are available.

Please check the outer diameter of the tubes before ordering the clamping shells.

WORKS WITH VERSION TUBE OD CODE WEIGHT

[MM] [INCH]

RPG 4.5 Stainless steel 12.00 0.472 790 038 454 4.78 lb (2.17 kg)

































RPG 4.5

RPG 4.5 S

RPG 8.6

Stainless steel clamping shell for RPG 4.5

Aluminum clamping shells for RPG 8.6


Tube Squaring

39


[MM] [INCH]



RPG 4.5 Stainless steel 40.00 1.575 790 038 411 4.41 lb (2 kg)








































RPG 4.5 Stainless steel 101.60 4.000 790 038 058 1.76 lb (800 g)



RPG 4.5 Stainless steel 114.30 4.500 790 038 059 15.3 oz (435 g)

RPG 8.6 Aluminum 50.80 2.000 790 039 260 9.92 lb (4.5 kg)

RPG 8.6 Aluminum 57.00 2.244 790 039 265 8.82 lb (4 kg)


RPG 8.6 Aluminum 88.90 3.500 790 039 264 8.82 lb (4 kg)














RPG 8.6 Aluminum 219.10 8.625 790 039 255 1.32 lb (600 g)




Stainless steel clamping shell for RPG 4.5

Aluminum clamping shells for RPG 8.6


Tube Squaring

40


[MM] [INCH]





Tool holder WH

Fits multifunctional tool 790 038 314. Incl. Torx fixing screw.

Beveling with the RPG 4.5 S is not recommended.

Application rangeTool holder

Possible application Beveling angle[°]Squaring Beveling

Tool holder WH12-I x – –

Tool holder WH12-V-30° – x 30



Tool holder WH12-U-20° – x 20

MODEL CODE WEIGHT

Tool holder WH12-I 790 038 320 0.9 oz (25 g)

Tool holder WH12-V-30° 790 038 329 1.2 oz (34 g)



Tool holder WH12-U-20° 790 038 326 1.1 oz (31 g)


Two-sided tool bit with protective coating against tool wear.Usable for all machines of the RPG series.

MODEL QTY. CODE WEIGHT



Other accessories

• Work benches and tool box, see page 28• Pipe vices, see page 28

Tool holder WH



Pipe Cutting

41

The correct tooling for your individual applicationWe will gladly help you find the suitable tools for your specific application.

To offer you the relevant tool holders and multifunctional tools for our machines we need some information

from you.

Please use the following form and let us know your needs (if known):

Your contact details:

Company name:

Customer no.: Date: Contact person:

Phone: Fax:

Address: Signature and stamp

Remarks:

Please return the completed form by fax to +1.847.520.1147 or e-mail to [email protected]

V-prep Y-prep

U-prep (1) U-prep (2)

DS

d

DS

d h

DS

d

R1

h

x1

x2

D1

DS

d

h

x1 D1

R2

D:

d:

S:

:

D:

d:

S:

h:

:

D:

d:

S:

h:

R1:

R2:

x1:

x2:

:

:

D1:

D:

d:

S:

h:

R1:

R2:

x1:

:

:

:

D1:

R2

R1


Orbital Welding Power Supplies & Accessories

Orbital Welding


ORBIMAT CA

In addition to default welding parameters using the tube diameter, wall thickness, material, and welding gas, all ORBIMAT CA models also include a FLOW FORCE function to reduce the pre-flow gas time when the weld heads are closed. Optionally the BUP control function with controllable, position-dependent tube internal pressure control is also available.

The operating concept for the power supply is quite different from the standard operating variants available on the market: The operator guidance with a display and single-knob operation originates from the automotive manufacturing sector and has become tried and tested worldwide in the "information entertainment systems" in modern luxury vehicles. The main advantage of this is that the gaze of the operator remains focused on the screen.

Other technical refinements of the ORBIMAT CA include softkeys for essential, high-level and quick-action commands such as "Start/Stop". The integrated RTOS (Real Time Operating System) has the advantage that not even a direct, abrupt shutdown of the system will lead to any problems. This is particularly important in areas where power consistency is problematic. The RTOS always focuses on the steering and control of the welding process, which is ultimately crucial for the quality of the weld.

The optional, innovative BUP (Backup Pressure Control) control upgrade regulates the pressure of the forming gas in the tube on a sector basis, depending on the torch setting. This unit counteracts the gravity of the welding gas pool, guaranteeing an even weld seam.

Moreover, the Flow Force function, which decisively shortens the work process through the

use of closed weld heads, is also unique on the market. Before the start of the welding process, inert gas is fed from the pressure reducer through a second duct for inert gas into the chamber of the weld head – and the undesired oxygen is rinsed out abruptly; the ORBIMAT power supply automatically detects and takes into account for the course of the process any connected system components, from the sealed or open weld head with automatic control of the arc clearance* (AVC = Arc Voltage Control) and/or the integrated oscillation of the torch* (OSC = Oscillation) through to the oxygen analysis unit. In contrast to conventional orbital welding power controllers, the setting and controlling of the torch clearance with regard to the weld seam is carried out directly via the arc clearance, without the need for any further manual corrections. *ORBIMAT 300 AVC/OSC only

Compact power supplies for automated TIG orbital welding with a currently unique operating concept and a whole series of other special technical features.

When paired with an ORBITALUM orbital weld head, the user has the most extremely innovative and economical orbital welding system on the market.

ORBITAL WELDING POWER SUPPLIES

Intuitive operator interface

Automatic programming and multilingual menu navigation via color display

ORBIMAT 165 CA

ORBIMAT 300 CA

Integrated, folding 10.5 in display and printer

Simple and convenient operation with intuitive, ergonomic user interface.

Orbital Welding


Orbital welding power supplies

ORBIMAT CA

Features, application range, technical data, see page 43.

Scope of delivery:

• 1 Orbital welding power supply of the ORBIMAT CA series• 1 Hose connection set ORBIMAT (Code 875 030 018)• 1 Dummy plug for remote control socket (Code 875 050 006))• 1 Bottle of OCL-15 coolant, 2 liters (Code 875 030 015) (165 CA only)• 1 External keyboard (Code 875 012 075)• 2 Keys for the key switch (for reordering of 1 key: Code 875 012 058)• 1 Operating instructions with calibration certificate • 1 QuickStart guide


ORBIMAT 165 CA Wide-Range 90 - 260 V, 50/60 Hz, 1 phase 871 000 001 57.32 lb (26 kg) 90.39 lb (41 kg)

ORBIMAT 300 CA 400 V +/– 15%, 50/60 Hz, 3 phase 872 000 010 72.75 lb (33 kg) 105.82 lb (48 kg)

ORBIMAT 300 CA AVC/OSC 400 V +/– 15%, 50/60 Hz, 3 phase 872 000 020 82.23 lb (37.3 kg) 116.84 lb (53 kg)

Accessories (available option):

• ORBICAR W trolley with integrated water cooling, see page 45• ORBICAR S trolley, see page 45• ORBITWIN switching device, see page 45• Remote control with cable, see page 46• Soft-/Hardware package, see page 46• BUP control box (purging gas pressure regulator), see page 45• ORBmax digital oxygen analyzer, see page 83• TIG manual welding torch, see page 14• Pressure regulator, see page 86

ORBIMAT 165 CA

ORBIMAT 300 CA

ORBIMAT 300 CA AVC/OSC

ACCESSORIES (available option): TECHNICAL DATA 165 CA 300 CA 300 CA AC/DC 300 CA AVC/OSC

• ORBICAR W trolley with integrated water cooling

• ORBICOOL ACTIVE compressor cooling device• ORBICAR S trolley• Durable storage and shipping case• ORBITWIN switching device• Remote control with cable• Soft-/Hardware package• BUP control box (purging gas pressure

regulator)• ORBmax digital oxygen analyzer• Pressure regulator• TIG manual welding torch for ORBIMAT

Code 871 000 001 872 000 010 877 000 001 872 000 020

Connection voltage Wide-Range 90 - 260 V, 50/60 Hz, 1 phase

480 V +/– 15%,50/60 Hz, 3 phase

480 V +/– 15%,50/60 Hz, 3 phase

480 V +/– 15%,50/60 Hz, 3 phase

Control range (Connection voltage > 160 V)

2 - 165 A2 - 110 A

5 - 300 A 5 - 300 A 5 - 300 A

Power-on time 30% at 165 A100% at 120 A

40% at 300 A60% at 260 A100% at 220 A

40% at 300 A60% at 260 A100% at 220 A

40% at 300 A60% at 260 A100% at 220 A

Dimensions 510 x 360 x 220 mm20.1 in x 14.2 in x 8.7 in

530 x 400 x 400 mm20.9 in x 15.7 in x 15.7 in

540 x 420 x 440 mm21.3 in x 16.5 in x 17.3 in

540 x 420 x 440 mm21.3 in x 16.5 in x 17.3 in

Orbital Welding


Accessories for ORBIMAT

ORBICAR W trolley with integrated water cooling

The ORBICAR W trolley is the perfect accessory for the Orbitalum 300 A power supplies due to the integrated water cooling. Beside the water coolant, the trolley is equipped with a practical holder for gas bottles.

The tank already contains 8 liters (2.11 gal) of the OCL-15 coolant at delivery (see page 47).

TECHNICAL DATA ORBICAR W TROLLEY

Water tank contents 8 l / 2.11 gal

Cooling type Convection cooling

Dimensions (L x W x H) 107 x 52.5 x 113 cm42.1 in x 20.7 in x 44.5 in

MODEL WORKS WITH ORBIMAT CODE WEIGHT

ORBICAR W trolley with integrated water cooling 300 CA, 300 CA AC/DC, 300 CA AVC/OSC 884 000 002 128.31 lb (58.2 kg)

ORBICAR W trolley with integrated water cooling* 165 CA* 884 000 004 128.31 lb (58.2 kg)

* ORBIMAT 165 power sources must be retrofitted at the factory

ORBITWIN switching devices

To increase productivity, the switching unit ORBITWIN is available which allows the alternately operation with 2 weld heads on the ORBIMAT.The previously assigned program is recalled automatically when the start key of the weld head is actuated. The weld head that is not being used is locked and can be prepared for the next welding operation

Including all connecting cables and hoses.


ORBITWIN 165 CA switching device 165 CA 861 000 001 19.4 lb (8.8 kg)

ORBITWIN 300 switching device 300 CA, 300 CA AC/DC, 300 CB 876 000 001 19.4 lb (8.8 kg)

ORBICAR S trolley

The ORBICAR S is a practical trolley with storage shelf and an option of securing a gas cylinder. The ORBICAR S trolley can be combined with all power supplies of the ORBIMAT series. This trolley is often used in combination with the ORBITALUM 165 A orbital welding power supplies.

TECHNICAL DATA ORBICAR S TROLLEY

Dimensions (L x W x H) 107 x 52.5 x 113 cm42.1 in x 20.7 in x 44.5 in

MODEL CODE WEIGHT

ORBICAR S trolley 884 000 001 42.11 lb (19.1 kg)

BUP control box

The power supplies of the ORBIMAT CA series offer the option in conjunction with the BUP control attachment (BUP = Backup Pressure Control) to adjust the forming gas pressure in the inner tube via a pressure sensor, which compensates almost entirely the often undesirably occurring of the seam weld into the sump position. At the same time, the gas pressure is modified automatically during welding by the system between a programmable minimum and maximum value depending on the position of the electrodes.

Including ORBIPURGE forming set for tube ID 12 - 110 mm (0.472 in - 4.331 in), see page 85.


BUP control box 165 CA, 300 CA 886 000 001 5.95 lb (2.7 kg)

ORBICAR W trolley with integrated water cooling

ORBITWIN 300CA switching device

ORBICAR S trolley

+

BUP control box (incl. ORBIPURGE forming set)

ORBITWIN 165CA switching device

Orbital Welding


Software/Hardware package

Compatible with all ORBIMAT orbital welding power supplies.

For external programming and data documentation, consisting of:

• 1 CompactFlash card for transferring data between the machine and PC. For storing weld data protocols or for extending the program memory. Capacity to store over 5.000 welding programs.

• 1 USB card reader for exporting the CompactFlash card on the PC.• Software ORBIPROG_CA. ORBIPROG_CA software allows programs and protocols

to be stored on the PC. The parameters of the CA programs can be edited using the software and can be transferred back to CA models and used there after processing. Additionally, programs from C-series machines (e.g. OM 160 C) can be converted to CA format with the help of software. The parameters of the CA programs can be edited using the software and can be transferred back to CA models and used there after processing.

MODEL CODE WEIGHT

Soft-/Hardware package 875 050 003 1.08 lb (488 g)

CompactFlash Card

For storing weld data protocols or for extending the program memory.1 CompactFlash Card is already included in the scope of delivery of the Soft-/Hardware package.

Capacity to store over 5.000 welding programs.

MODEL CODE WEIGHT

CompactFlash Card 875 012 056 0.4 oz (10 g)

Remote control with cable

Compatible with all ORBIMAT orbital welding power supplies.1 remote control with cable is already included in the scope of delivery of the ORBIMAT 300 CA AVC/OSC.

The remote control is not required when working with enclosed orbital weld heads.

MODEL CABLE LENGTH [M]

CABLE LENGTH [INCH]

CODE WEIGHT

Remote control with cable 7.5 24.6 875 050 001 2.98 lb (1.35 kg)


High-quality shipping case.

MODEL CODE WEIGHT

Durable storage and shipping case for Orbimat 165CA OT871 001 30.42 lb (13.8 kg)

Soft-/Hardware package

CompactFlash Card

Remote control with cable


Orbital Welding


Consumables for ORBIMAT

Paper rolls and ribbon cartridges

For integrated system printer. Compatible with all ORBIMAT orbital welding power supplies.

1 paper roll and 1 ribbon cartridge are already included in the scope of delivery of the ORBIMAT orbital welding power supplies.

MODEL CODE WEIGHT

Paper rolls for integrated printer, pack of 3 875 050 017 5.3 oz (150 g)

Ribbon cartridge for integrated printer CA 875 030 004 0.4 oz (10 g)

Ribbon cartridge for integrated printer CB 875 030 002 0.7 oz (20 g)

Antifreeze/Coolant

Antifreeze pre-mix for ORBIMAT power supplies and cooling units to avoid freezing of the cooling water. Applicable up to –15 °C (5 F) outside temperature. Increased service life of components of the cooling system through very high corrosion protection and high pH-value. For even better ignition characteristics due to low conductivity. Clear coolant liquid.

Works with ORBICAR W, ORBICOOL ACTIVE, and ORBIMAT 165 CA.

1 container is already included in the scope of delivery of the ORBIMAT 165 CA orbital welding power supply.


Antifreeze/Coolant Container with 1 US Gallon (3.79l) 875 030 015 9.3 lb (4.22 kg)

Hose connection set ORBIMAT

1 hose connection set is already included in the scope of delivery of the ORBIMAT orbital welding power supplies.

Set, consisting of:• Teflon gas hose• Ear clamps with insert• Hose clips 3/8 in• Water hose for tank ventilation• Gas input connector• Swivel nuts 3/8 in• Hose clips 1/4 in• Swivel nuts 1/4 in• Funnel

MODEL CODE WEIGHT

Hose connection set ORBIMAT 875 030 018 15.7 oz (445 g)

Other accessories for orbital welding

• ESG tungsten grinders, see page 79• ORBmax digital oxygen analyzer, see page 83• ORBIPURGE forming set, see page 85• Pressure regulator, see page 86• Inspection set, see page 86• WS2 tungsten electrodes, see page 86• TIG manual welding torch for ORBIMAT, see page 14

Paper rolls and ribbon cartridges for integrated printer

Antifreeze/Coolant

Hose connection set ORBIMAT


Enclosed Orbital Weld Heads

Orbital Welding


Overview enclosed orbital weld heads

3-12.7 mm

3-19mm

.118-1.5in (3-38.10mm)

.24-3in (6-76.1mm)

.787-4.53in (20-115mm)

1.97-6.69in (50-170mm)

Tube OD [mm] 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

Tube OD [in] 0 .118in .5in .75in 1.5in 3in 4.53in 6.69in

OW170

OW115S

OW76S

OW38S

OW19

OW12

WEL

DH

EAD

MO

DEL

S

Enclosed weld heads ORBIWELD / ORBIWELD SModel OW 12 OW 19 OW 38S OW 76S OW 115S OW 170Code 821 000 001 822 000 001 826 000 001 827 000 001 828 000 001 825 000 001Tube Ø [mm] 3 - 12.7 3 - 19.05 3 - 39 6 - 76 20 - 115 50 - 170

[inch] 1/8 - 5 1/8 - 7.5 1/8 - 1.5 ¼ - 3 ¾ - 4.5 2 - 6Rotor Ø [mm] 40 58 82 122 191 252

[inch] 15.75 22.83 32.28 48.03 75.2 99.21

3822.1

3471.2

382.6

78.5

145.8135R45

R70146

67.3

Elektrode 19.0

75.966.4

32.729.7

-R36.5

34

34

19

55

102.5

357.2

102.5

95

47.5

71.2

R26R50

Electrode 17.0

436

15°

585

331

70

3529.6436

11.75Electrode- Position

172

140.5

ORBIWELD 12

ORBIWELD 76S

ORBIWELD 19

ORBIWELD 115S

ORBIWELD 38S

ORBIWELD 170

28

8

46

478376

235

117

4.934.024.519.614.5

7.2

Orbital Welding


FORMULA: Electrode length =Rotor Ø – Tube Ø

– Electrode interval (generally 1.5 mm) – 32

ORBIWELD replacement tungsten electrode chart

ORBIWELD 12 TungstenTUBE OD (IN) TUBE OD (MM) PART NUMBER

.125 in 3.175 mm TC 04-0500-010

.250 in 6.35 mm TC 04-0450-010

.375 in 9.525 mm TC 04-0400-010

.500 in 12.7 mm TC 04-0350-010


.125 in 3.175 mm TC 06-0900-020

.250 in 6.35 mm TC 06-0800-020

.375 in 9.525 mm TC 06-0750-020

.500 in 12.7 mm TC 06-0700-020

.625 in 15.875 mm TC 06-0650-020

.750 in 19.05 mm TC 06-0550-020

ORBIWELD 38S TungstenTUBE OD (IN) TUBE OD (MM) PART NUMBER

.125 in 3.175 mm TC 06-1350-020

.250 in 6.35 mm TC 06-1300-020

.375 in 9.525 mm TC 06-1200-020

.500 in 12.7 mm TC 06-1150-020

.625 in 15.875 mm TC 06-1100-020

.750 in 19.05 mm TC 06-1050-020

1.0 in 25.4 mm TC 06-0900-020

1.5 in 38.1 mm TC 06-0650-020


.250 in 6.35 mm TC 06-2050-020

.375 in 9.525 mm TC 06-2000-020

.500 in 12.7 mm TC 06-1950-020

.625 in 15.875 mm TC 06-1900-020

.750 in 19.05 mm TC 06-1800-020

1.0 in 25.4 mm TC 06-1700-020

1.5 in 38.1 mm TC 06-1450-020

2.0 in 50.8 mm TC 06-1200-020

2.5 in 63.5 mm TC 06-0950-020

3.0 in 76.2 mm TC 06-0700-020


1.0 in 25.4 mm TC 06-3050-020

1.5 in 38.1 mm TC 06-2800-020

2.0 in 50.8 mm TC 06-2550-020

2.5 in 63.5 mm TC 06-2300-020

3.0 in 76.2 mm TC 06-2050-020

4.0 in 101.6 mm TC 06-1550-020

4.5 in 114.3 mm TC 06-1300-020


2.0 in 50.8 mm TC 06-3750-020

2.5 in 63.5 mm TC 06-3500-020

3.0 in 76.2 mm TC 06-3250-020

4.0 in 101.6 mm TC 06-2750-020

4.5 in 114.3 mm TC 06-2500-020

6.0 in 152.4 mm TC 06-1750-020

6.625 in 168.275 mm TC 06-1450-020

Orbital Welding


The 3-part clamping mechanism ensures that the head can be clamped even in the most confined spaces

OW 12

ORBIWELD 12, ORBIWELD 19

Extremely narrow design and yet highly durable thanks to intensive water cooling system:

The small dimensions of the OW 12 and OW 19 weld heads make it ideal for applications where space is very restricted, such as the semiconductor industry, aerospace, pharmaceutical industry as well as the ultra pure water supply sectors. Particularly suitable for welding all common microfittings.

MICRO WELD HEADS

OW 12 and OW 19: Optimal for applications where space is very restricted OW 19

Possible applications OW 12: Microfitting-to-microfitting Microfitting-to-tube Tube-to-tube AdvantagesClamping cartridges, Type "A" (narrow)

x x xHigh flexibility thanks tonarrow design

Clamping cartridges, Type "B" (wide)

xLow cost due to exchangeable clamping inserts

Clamping cartridges, Type "C" (microfittings)

x x xForm-closed fastening of microfittings for precise alignment

ORBIWELD 12:

• With its extremely compact design and different clamping cartridges, the OW 12 microweld head offers a unique versatility and a quick power-on time new for weld heads of this size due to the water coolant system

• Quick change system for clamping shells• All the important commands for welding

can be transmitted to the power supply via a control panel built into the robust and durable aluminum handle, so that no additional remote control is required

• Extremely narrow clamping cartridges (Type "A") for welding microfittings and for other applications with very limited clamping lengths

• Wide clamping cartridge (Type "B") with exchangeable clamping shells for standard applications

• The removable clamping cartridge enables accurate alignment with the parts to be welded, even where there is very little space

ORBIWELD 19:

• The 3-part clamping mechanism ensures that the head can be clamped in the most confined spaces, as even when open no parts protrude beyond the contour of the head. Equally, an exact alignment, with no misalignment is guaranteed with the parts to be welded

• All the important commands for welding can be transmitted to the power supply via a control panel built into the robust and durable aluminum handle, so that no additional remote control is required

Orbital Welding


Micro weld heads OW

ORBIWELD 12, ORBIWELD 19

Features and technical data, see page 51.

Scope of delivery:• 1 Micro weld head ORBIWELD 12 or ORBIWELD 19• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list

Clamping cartridges and clamping inserts are not included in the scope of delivery (see page 53).

MODEL CODE MACHINE WEIGHT KG SHIPPING WEIGHT KG

Micro weld head OW 12 821 000 001 5.700 11.000

Micro weld head OW 19 822 000 001 7.500 14.800

APPLICATION RANGE ORBIWELD 12 ORBIWELD 19Code 821 000 001 822 000 001

Tube OD, min. - max. 3.0 - 12.7 mm (0.118 in - 0.500 in) 3.0 - 19.05 mm (0.118 in - 0.750 in)

Electrode Ø 1.0 mm (0.039 in) 1.0 / 1.6 mm (0.039 in / 0.063 in)

Weight 5.7 kg (12.6 lbs) 7.5 kg (16.5 lbs)

Shipping Weight 11.0 kg 14.8 kg

Hose package length 7.5 m (24.6 ft) 7.5 m (24.6 ft)

SCOPE OF DELIVERYIncluding:• 1 Micro weld head ORBIWELD 12 or ORBIWELD 19• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list

Accessories (available option):• Clamping cartridges for OW 12, Type "A" (narrow)• Clamping cartridge for OW 12, Type "B" (wide)• Clamping inserts for OW 12, Type "B" (wide)• Clamping cartridges for OW 12, Type "C"• Clamping inserts for OW 19• ESG tungsten grinders• ORBmax digital oxygen analyzer• ORBIPURGE forming set• Hose package extensions• Inspection set• WS2 tungsten electrodes

ORBIWELD 12 DIMENSION

A1 A2 B C D E F G H I J K

OverallDimension

mm 4.25 3.75 7.62 73.00 36.50 27.50 49.00 253.00 59.00 26.00 30.00 59.00

in 0.17 0.15 0.30 2.87 1.44 1.08 1.93 9.96 2.32 1.02 1.18 2.32

Car

trid

ge T

ype

Amm 6.35 5.85 12.20

in 0.25 0.23 0.48

Bmm 15.60 15.10 30.70

in 0.61 0.59 1.21

Cmm 22.79 21.91 44.70

in 0.90 0.86 1.76

ORBIWELD 19 DIMENSION

A1 A2 B C D E F G H I J K

OverallDimension

mm 12.00 12.00 34.00 66.00 33.00 35.20 45.00 312.00 76.00 34.00 35.00 71.00

in 0.47 0.47 1.34 2.60 1.30 1.39 1.77 12.28 2.99 1.34 1.38 2.80

Clam

ping

Ins

ert

Type

S

mm 12.80 11.70 24.50

in 0.50 0.46 0.97

W

mm 16.50 17.50 34.00

in 0.65 0.69 1.34

OW 12 with wide clamping cartridge (Type "B")and exchangeable clamping inserts

OW 12 with narrow clamping cartridge (Type "A")

ORBIWELD 19

Orbital Welding


Clamping cartridges for OW 12, Type "A" (narrow)

Clamping cartridges with a total width of only 12.2 mm (0.48 in) can be supplied for welding of microfittings and other applications with very limited clamping lengths (Type "A").

For type "A" a separate clamping cartridge is required for each tube diameter.

MODEL TUBE ODMM

TUBE ODINCH

CODE WEIGHT

Clamping cartridge for OW 12, Type "A" (narrow) 3.00 0.118 821 050 301

Clamping cartridge for OW 12, Type "A" (narrow) 3.18 0.125 821 050 302 1.8 oz (50 g)
























Clamping cartridge for OW 12, Type "B" (wide)

When using the exchangeable clamping cartridges, Type "B", one set of clamping inserts is required in addition for each tube diameter.

MODEL CODE WEIGHT

Clamping cartridge for OW 12, Type "B" (wide) 821 050 002 3.4 oz (95 g)

Clamping cartridges for OW 12, Type "A" (narrow)

Clamping cartridge for OW 12, Type "B" (wide)

Orbital Welding


Clamping inserts for OW 12, Type "B" (wide)

Made of aluminum. Can only be used in connection with the clamping cartridges, Type "B".

One set of clamping inserts consists of 4 individual parts (2 inserts each side).

MODEL TUBE ODMM

TUBE ODINCH

CODE WEIGHT

Clamping insert for OW 12, Type "B" (wide), 4 pcs. 3.00 0.118 821 002 220



Clamping insert for OW 12, Type "B" (wide), 4 pcs. 4.00 0.157 821 002 224 1.9 oz (54 g)






















Clamping cartridges for OW 12, Type "C" (microfittings)

Form-closed fastening of microfittings for precise alignment.When using the clamping cartridges, Type "C" for microfittings, one set of clamping inserts is required in addition for each tube diameter.

Possible welding applications:

• Microfitting-to-microfitting• Microfitting-to-tube• Tube-to-tube

MODEL TUBE ODMM

TUBE ODINCH

CODE WEIGHT

Clamping cartridges for OW 12, Type "C" (microfittings) 3.18 0.125 821 050 029


Clamping cartridges for OW 12, Type "C" (microfittings) 6.35 0.250 821 050 030 2.5 oz (70 g)


Clamping cartridges for OW 12, Type "C" (microfittings) 9.53 0.375 821 050 050 3 oz (84 g)



Clamping cartridges for OW 12, Type "C" (microfittings) 12.70 0.500 821 050 060 3.5 oz (99 g)

Clamping inserts for OW 12, Type "B" (wide), 4 pcs.

Clamping cartridges for OW 12, Type "C" (microfittings)

Orbital Welding


Clamping inserts for OW 19

Made of stainless steel.One set of clamping inserts consists of 6 individual parts (3 inserts each side).

Type "W" (wide) for standard applications.Type "S" (small) for applications in extremely conditions with low clearances.

MODEL TUBE ODMM

TUBE ODINCH

TYPE "W" (WIDE) TYPE "S" (SMALL)

CODE WEIGHT CODE WEIGHT

Clamping insert for OW 19, 6 pcs. 3.00 0.118 822 002 120 822 002 320



Clamping insert for OW 19, 6 pcs. 4.00 0.157 822 002 124 822 002 324 1.6 oz (44 g)




Clamping insert for OW 19, 6 pcs. 6.00 0.236 822 002 128 3.2 oz (90 g) 822 002 328 1.5 oz (43 g)







Clamping insert for OW 19, 6 pcs. 9.53 0.375 822 002 135 3.1 oz (89 g) 822 002 335 1 oz (29 g)






















Clamping insert for OW 19, 6 pcs. 15.88 0.625 822 002 157 2.5 oz (71 g) 822 002 357







Clamping insert for OW 19, 6 pcs. 18.00 0.709 822 002 164 2 oz (58 g) 822 002 364 0.9 oz (26 g)


Clamping insert for OW 19, 6 pcs. 19.05 0.750 822 002 166 2 oz (58 g) 822 002 366 0.9 oz (25 g)


• ESG tungsten grinders, see page 79• ORBmax digital oxygen analyzer, see page 83• ORBIPURGE forming set, see page 85• Hose package extensions, see page 85• Inspection set, see page 86• WS2 tungsten electrodes, see page 86

Clamping insert for OW 19 "W" (wide) 6 pcs.

Clamping insert for OW 19 "S" (small) 6 pcs.

Orbital Welding


ORBIWELD 38S, 76S, 115S

The small dimensions of the ORBIWELD "S" series make it ideal for applications where space is very restricted, such as the pharmaceutical and chemical industry, the semiconductor, food and beverage industry as well as aerospace.

All enclosed orbital weld heads of the ORBIWELD series are made from strong, durable materials of the finest quality and are characterized by their unique water cooling system.

The appropriate high-grade, functional and long-lasting clamping inserts are lasting longer than the inserts of many competitors.The inserts are available in small and wide design and easily and quickly insert-able into the weld heads.

FEATURES:• Thanks to the extremely narrow design, parts

with short straight welding lengths can also be processed

• High-quality, rugged housing and handle parts• High durability due to completely water-

cooled weld head housing• Highly flexible hose package (Length: 7.5 m/

24.6 ft) with strain relief to the power supply• All the important commands for welding can

be transmitted to the power supply via a control panel built into the robust and durable aluminum handle, so that no additional remote control is required

• Tool-Free Quick change system for clamping inserts that engages and releases smoothly

Easier to handle, more economical , more effective – enclosed TIG orbital welding heads with outstanding characteristics : The ORBIWELD "S" series from Orbitalum convinces by its extremely narrow design and high durabi l i ty by its eff icient integrated water cool ing system.

ENCLOSED ORBITAL WELD HEADS

OW 38S

Secure clamping of the parts to be welded without misalignment

Combined with a power source of the ORBIMAT CA series this welding system offers maximum precision

OW 76S OW 115S

• Cost-effective clamping inserts• Durable clamping connections in combination

with clamping inserts available for all tube dimensions guarantee that the parts to be welded are clamped securely without misalignment

• Comprehensive and customer-specific range of accessories

• NEW: A folding cover at the weld head enables to test and/or to readjust the electrode position before the welding procedure

Orbital Welding


Enclosed orbital weld heads OW S

ORBIWELD 38S, ORBIWELD 76S, ORBIWELD 115S

Features and application ranges, see page 56.Clamping inserts are not included in the scope of delivery (see page 60).

APPLICATION RANGE ORBIWELD 38S ORBIWELD 76S ORBIWELD 115SCode 826 000 001 827 000 001 828 000 001

Tube OD, min. - max. 3 - 38.1 mm1/8 in - 1.5 in

6 - 77 mm1/4 in - 3.0 in

20 - 115 mm3/4 in - 4.5 in

Electrode Ø 1.6/2.4 mm.063 in/.094 in

1.6/2.4 mm.063 in/.094 in

1.6/2.4 mm.063 in/.094 in

Weight 9 kg19.8 lbs

9.4 kg20.7 lbs

13 kg28.7 lbs

Shipping Weight 16.5 kg 16.9 kg 18.6 kg

Hose package length 7.5 m24.6 ft

7.5 m24.6 ft

7.5 m24.6 ft

SCOPE OF DELIVERYIncluding:• 1 Enclosed orbital weld head

OW 38S, OW 76S or OW 115S• 1 Durable storage and

shipping case• 1 Tool set• 1 Operating instructions

and spare parts list

Accessories (available option)s:

• Clamping inserts, small and wide• Spare pressure pieces• Plastic case for clamping inserts• Cavity inserts for moldings• Inserts for elbow welding• T-piece clamping shells• Electrode adapters

• Table mounts• ESG tungsten grinders• ORBmax digital oxygen analyzer• ORBIPURGE forming set• Hose package extensions• Inspection set• WS2 tungsten electrodes

ORBIWELD 38S DIMENSIONS

A1 A2 B C D E F G H I J K L

OverallDimension

mm 17 17 34 112 47.5 47 144 357 95 34 55 71 110

in 0.67 0.67 1.34 4.41 1.87 1.85 5.67 14.06 3.74 1.34 2.17 2.80 4.33

Clam

ping

Ins

ert

Type

[2 P

air]

mm 17.50 17.50 35.00

in 0.69 0.69 1.38



OverallDimension

mm 19.00 19.00 38.00 159.00 67.50 66.00 187.00 400.00 135.00 34.00 55.00 71.00 153.00

in 0.75 0.75 1.50 6.26 2.66 2.60 7.36 15.75 5.32 1.34 2.17 2.80 6.02

Clam

ping

In

sert

Ty

pe[2

Pai

r] mm 21.00 21.00 42.00

in 0.83 0.83 1.65



OverallDimension

mm 22.75 21.25 44.00 220.00 104.00 102.00 244.00 480.00 208.00 44.00 55.00 102.00 216.00

in 0.90 0.84 1.73 8.66 4.09 4.02 9.61 18.90 8.19 1.73 2.17 4.02 8.50

Clam

ping

Ins

ert

Type

[2 P

air]

Type

"S" mm 25.75 24.25 50.00

in 1.01 0.96 1.97

Type

"W

" mm 45.75 44.25 90.00

in 1.80 1.74 3.54

ORBIWELD 38S

ORBIWELD 76S

ORBIWELD 115S

C

D

E

F

G

KH

J

L

I

A1A2

B

Orbital Welding


ORBIWELD 170

Coolant channels running through the entire weld head body ensure an excellent heat dissipation that enable the ORBIWELD weld heads to work continuously even at high welding currents and intensive load.

The closed design of the ORBIWELD series and the gas management system of the head ensure a permanent infiltration of the weld seam during welding with inert gas, guaranteeing seams that are very low in welding colors.

FEATURES:

• Quick change system for clamping inserts that engages and releases smoothly without any tools

• High durability due to completely water- cooled weld head housing

• Durable clamping connections in combination with clamping inserts available for all tube dimensions guarantee that the parts to be welded are clamped securely without misalignment

The ORBIWELD series is characterized by very high thermal resistance. It is therefore particularly suitable for applications in the chemical, pharmaceutical, food and beverage industry, where ever greater demands are made on the closed weld heads by ever greater tube diameters and wall thicknesses.

ENCLOSED ORBITAL WELD HEADS

ORBIWELD weld heads are working continuously even at high welding currents and intensive loads

OW 170

• All the important commands for welding can be transmitted to the power supply via a control panel built into the robust and durable aluminum handle, so that no additional remote control is required

• High-quality, rugged housing and handle parts

• Highly flexible hose package (Length: 7.5 m/ 24.6 ft) with strain relief to the power supply

• Cost-effective clamping inserts• Comprehensive and customer-specific range

of accessories

Orbital Welding


ORBIWELD 170

APPLICATION RANGE ORBIWELD 170Code 825 000 001

Tube OD, min. - max. 50 - 170 mm1.969 in - 6.693 in

Electrode Ø 1.6/2.4 mm.063 in/.094 in

Weight 20.7 kg45.63 lbs


SCOPE OF DELIVERYIncluding: • 1 Enclosed orbital weld head

• 1 Durable storage and shipping case (Code 821 030 001)• 1 Tool set• 1 Operating instructions and spare parts list


• Clamping inserts, small and wide• Plastic case for clamping inserts• Cavity inserts for moldings• Inserts for elbow welding• T-piece clamping shells• Electrode adapters• Table mounts• ESG tungsten grinders• ORBmax digital oxygen analyzer• ORBIPURGE forming set• Hose package extensions• Pressure regulator• Inspection set• WS2 tungsten electrodes

C

D

E

F

G

KH

J

L

I

A1A2

BORBIWELD 170 DIMENSION CLAMPING INSERT TYPE "S"[2 PAIRS]

CLAMPING INSERT TYPE "W"[2 PAIRS]

[MM] [INCH] [MM] [INCH] [MM] [INCH]

Dimension "A1" 30.00 1.181 32.00 1.260 50.00 1.969

Dimension "A2" 41.00 1.614 43.00 1.693 61.00 2.402

Dimension "B" 70.00 2.756 72.00 2.835 110.00 4.331

Dimension "C" 345.00 13.583

Dimension "D" 160.00 6.299

Dimension "E" 140.00 5.512

Dimension "F" 365.00 14.370

Dimension "G" 585.00 23.031

Dimension "H" 285.00 11.220

Dimension "I" 50.00 1.969

Dimension "J" 67.00 2.638

Dimension "K" 88.00 3.465

Dimension "L" 332.00 13.071

Orbital Welding


Enclosed orbital weld heads OW

ORBIWELD 170


Scope of delivery:

• 1 Enclosed orbital weld head• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list

Clamping inserts are not included in the scope of delivery (see page 60).

MODEL CODE MACHINE WEIGHT SHIPPING WEIGHT

Enclosed orbital weld head OW 170 825 000 001 45.64 lb (20.7 kg) 79.81 lb (36.2 kg)


• Clamping inserts for ORBIWELD S and ORBIWELD, see page 60• Plastic case for clamping inserts, see page 63• Cavity inserts for moldings, see page 64• Inserts for elbow welding, see page 65• T-piece clamping shells, see page 64• Electrode adapters, see page 65• Table mounts, see page 66

Accessories for ORBIWELD S & ORBIWELD

Clamping inserts for ORBIWELD S and ORBIWELD

Made of aluminum. 1 set of clamping inserts consists of 2 parts for 1 clamping side.

2 clamping inserts (= 4 parts) are required for each tube dimension.For the ORBIWELD 115, 115S and 170 you can choose between wide "W" and small "S" clamping inserts which can be combined with one another as desired.

For clamping insert blanks which can be drilled by customer to specific diameters, see page 63.

Clamping insert for OW 38S, 2 pcs.

for one clamping side

Clamping insert for OW 76S, 2 pcs.


Clamping insert "S" (small) for OW 115/115S, 2 pcs.for one clamping side

Clamping insert "W" (wide) for OW 115/115S, 2 pcs. for one clamping side

Clamping insert "S" (small) for OW 170, 2 pcs.


Clamping insert "W" (wide) for OW 170, 2 pcs.


ORBIWELD 170

Orbital Welding


Clamping inserts for ORBIWELD S and ORBIWELDTUBE OD OW 38S OW 76S OW 65 OW 115/115S "S"

(SMALL)OW 115/115S "W"(WIDE)

OW 170 "S"(SMALL)

OW 170 "W"(WIDE)

[MM] [INCH] CODE CODE CODE CODE CODE CODE CODE

3.00 0.118 826 002 120 – – – – – –

3.18 0.125 826 002 122 – – – – – –

3.95 0.156 826 002 123 – – – – – –

4.00 0.157 826 002 124 – – – – – –

4.76 0.187 826 002 125 – – – – – –

4.78 0.188 826 002 126 – – – – – –

5.95 0.234 826 002 127 – – – – – –

6.00 0.236 826 002 128 827 002 120 823 002 120 – – – –

6.35 0.250 826 002 129 827 002 121 823 002 121 – – – –

7.00 0.276 826 002 130 827 002 122 823 002 122 – – – –

7.50 0.295 826 002 131 827 002 123 823 002 123 – – – –

7.94 0.313 826 002 132 827 002 124 823 002 124 – – – –

8.00 0.315 826 002 133 827 002 125 823 002 125 – – – –

9.00 0.354 826 002 134 827 002 126 823 002 126 – – – –

9.53 0.375 826 002 135 827 002 127 823 002 127 – – – –

9.95 0.392 826 002 136 827 002 128 823 002 128 – – – –

10.00 0.394 826 002 137 827 002 129 823 002 129 – – – –

10.10 0.398 826 002 138 827 002 130 823 002 130 – – – –

10.20 0.402 826 002 139 827 002 131 823 002 131 – – – –

11.00 0.433 826 002 140 827 002 132 823 002 132 – – – –

11.11 0.437 826 002 141 827 002 133 823 002 133 – – – –

11.95 0.470 826 002 142 827 002 134 823 002 134 – – – –

12.00 0.472 826 002 143 827 002 135 823 002 135 – – – –

12.10 0.476 826 002 144 827 002 136 823 002 136 – – – –

12.70 0.500 826 002 145 827 002 137 823 002 137 – – – –

13.00 0.512 826 002 146 827 002 138 823 002 138 – – – –

13.20 0.520 826 002 147 827 002 139 823 002 139 – – – –

13.50 0.531 826 002 148 827 002 140 823 002 140 – – – –

13.70 0.539 826 002 149 827 002 141 823 002 141 – – – –

14.00 0.551 826 002 150 827 002 142 823 002 142 – – – –

14.30 0.563 826 002 151 827 002 143 823 002 143 – – – –

14.70 0.579 826 002 152 827 002 144 823 002 144 – – – –

15.00 0.591 826 002 153 827 002 145 823 002 145 – – – –

15.30 0.602 826 002 154 827 002 146 823 002 146 – – – –

15.60 0.614 826 002 155 827 002 147 823 002 147 – – – –

15.70 0.618 826 002 156 827 002 148 823 002 148 – – – –

15.88 0.625 826 002 157 827 002 149 823 002 149 – – – –

16.00 0.630 826 002 158 827 002 150 823 002 150 – – – –

16.70 0.657 826 002 159 827 002 151 823 002 151 – – – –

17.00 0.669 826 002 160 827 002 152 823 002 152 – – – –

17.08 0.672 826 002 161 827 002 153 823 002 153 – – – –

17.20 0.677 826 002 162 827 002 154 823 002 154 – – – –

17.30 0.681 826 002 163 827 002 155 823 002 155 – – – –

18.00 0.709 826 002 164 827 002 156 823 002 156 – – – –

19.00 0.748 826 002 165 827 002 157 823 002 157 – – – –

19.05 0.750 826 002 166 827 002 158 823 002 158 – – – –

19.50 0.768 826 002 167 827 002 159 823 002 159 – – – –

20.00 0.787 826 002 168 827 002 160 823 002 160 824 002 120 824 002 320 – –

21.00 0.827 826 002 169 827 002 161 823 002 161 824 002 121 824 002 321 – –

21.30 0.839 826 002 170 827 002 162 823 002 162 824 002 122 824 002 322 – –

21.70 0.854 826 002 171 827 002 163 823 002 163 824 002 123 824 002 323 – –

22.00 0.866 826 002 172 827 002 164 823 002 164 824 002 124 824 002 324 – –

22.22 0.875 826 002 173 827 002 165 823 002 165 824 002 125 824 002 325 – –

22.23 0.875 826 002 174 827 002 166 823 002 166 824 002 126 824 002 326 – –

22.55 0.888 826 002 175 827 002 167 823 002 167 824 002 127 824 002 327 – –

23.00 0.906 826 002 176 827 002 168 823 002 168 824 002 128 824 002 328 – –

24.00 0.945 826 002 177 827 002 169 823 002 169 824 002 129 824 002 329 – –

24.13 0.950 826 002 178 827 002 170 823 002 170 824 002 130 824 002 330 – –

25.00 0.984 826 002 179 827 002 171 823 002 171 824 002 131 824 002 331 – –

25.25 0.994 826 002 180 827 002 172 823 002 172 824 002 132 824 002 332 – –

25.40 1.000 826 002 181 827 002 173 823 002 173 824 002 133 824 002 333 – –

26.00 1.024 826 002 182 827 002 174 823 002 174 824 002 134 824 002 334 – –

26.70 1.051 826 002 183 827 002 175 823 002 175 824 002 135 824 002 335 – –

26.90 1.059 826 002 184 827 002 176 823 002 176 824 002 136 824 002 336 – –

Orbital Welding




OW 170 "S"(SMALL)

OW 170 "W"(WIDE)


27.00 1.063 826 002 185 827 002 177 823 002 177 824 002 137 824 002 337 – –

27.20 1.071 826 002 186 827 002 178 823 002 178 824 002 138 824 002 338 – –

28.00 1.102 826 002 187 827 002 179 823 002 179 824 002 139 824 002 339 – –

29.00 1.142 826 002 188 827 002 180 823 002 180 824 002 140 824 002 340 – –

30.00 1.181 826 002 189 827 002 181 823 002 181 824 002 141 824 002 341 – –

30.53 1.202 826 002 190 827 002 182 823 002 182 824 002 142 824 002 342 – –

31.75 1.250 826 002 191 827 002 183 823 002 183 824 002 143 824 002 343 – –

31.80 1.252 826 002 192 827 002 184 823 002 184 824 002 144 824 002 344 – –

32.00 1.260 826 002 193 827 002 185 823 002 185 824 002 145 824 002 345 – –

33.00 1.299 826 002 194 827 002 186 823 002 186 824 002 146 824 002 346 – –

33.40 1.315 826 002 195 827 002 187 823 002 187 824 002 147 824 002 347 – –

33.70 1.327 826 002 196 827 002 188 823 002 188 824 002 148 824 002 348 – –

34.00 1.339 826 002 197 827 002 189 823 002 189 824 002 149 824 002 349 – –

35.00 1.378 826 002 198 827 002 190 823 002 190 824 002 150 824 002 350 – –

36.00 1.417 826 002 199 827 002 191 823 002 191 824 002 151 824 002 351 – –

38.00 1.496 826 002 200 827 002 192 823 002 192 824 002 152 824 002 352 – –

38.10 1.500 826 002 201 827 002 193 823 002 193 824 002 153 824 002 353 – –

40.00 1.575 – 827 002 194 823 002 194 824 002 154 824 002 354 – –

41.00 1.614 – 827 002 195 823 002 195 824 002 155 824 002 355 – –

42.00 1.654 – 827 002 196 823 002 196 824 002 156 824 002 356 – –

42.16 1.660 – 827 002 197 823 002 197 824 002 157 824 002 357 – –

42.30 1.665 – 827 002 198 823 002 198 824 002 158 824 002 358 – –

42.40 1.669 – 827 002 199 823 002 199 824 002 159 824 002 359 – –

42.70 1.681 – 827 002 200 823 002 200 824 002 160 824 002 360 – –

43.00 1.693 – 827 002 201 823 002 201 824 002 161 824 002 361 – –

43.20 1.701 – 827 002 202 823 002 202 824 002 162 824 002 362 – –

44.00 1.732 – 827 002 203 823 002 203 824 002 163 824 002 363 – –

44.45 1.750 – 827 002 204 823 002 204 824 002 164 824 002 364 – –

44.50 1.752 – 827 002 205 823 002 205 824 002 165 824 002 365 – –

45.00 1.772 – 827 002 206 823 002 206 824 002 166 824 002 366 – –

45.80 1.803 – 827 002 207 823 002 207 824 002 167 824 002 367 – –

48.00 1.890 – 827 002 208 823 002 208 824 002 168 824 002 368 – –

48.26 1.900 – 827 002 209 823 002 209 824 002 169 824 002 369 – –

48.30 1.902 – 827 002 210 823 002 210 824 002 170 824 002 370 – –

48.60 1.913 – 827 002 211 823 002 211 824 002 171 824 002 371 – –

50.00 1.969 – 827 002 212 823 002 212 824 002 172 824 002 372 825 002 120 825 002 320

50.80 2.000 – 827 002 213 823 002 213 824 002 173 824 002 373 825 002 121 825 002 321

51.00 2.008 – 827 002 214 823 002 214 824 002 174 824 002 374 825 002 122 825 002 322

52.00 2.047 – 827 002 215 823 002 215 824 002 175 824 002 375 825 002 123 825 002 323

53.00 2.087 – 827 002 216 823 002 216 824 002 176 824 002 376 825 002 124 825 002 324

54.00 2.126 – 827 002 217 823 002 217 824 002 177 824 002 377 825 002 125 825 002 325

57.00 2.244 – 827 002 218 823 002 218 824 002 178 824 002 378 825 002 126 825 002 326

60.00 2.363 – 827 002 219 823 002 219 824 002 179 824 002 379 825 002 127 825 002 327

60.10 2.366 – 827 002 220 823 002 220 824 002 180 824 002 380 825 002 128 825 002 328

60.30 2.374 – 827 002 221 823 002 221 824 002 181 824 002 381 825 002 129 825 002 329

60.45 2.380 – 827 002 222 823 002 222 824 002 182 824 002 382 825 002 130 825 002 330

60.50 2.382 – 827 002 223 823 002 223 824 002 183 824 002 383 825 002 131 825 002 331

63.00 2.480 – 827 002 224 823 002 224 824 002 184 824 002 384 825 002 132 825 002 332

63.20 2.488 – 827 002 225 823 002 225 824 002 185 824 002 385 825 002 133 825 002 333

63.50 2.500 – 827 002 226 823 002 226 824 002 186 824 002 386 825 002 134 825 002 334

65.00 2.559 – 827 002 227 823 002 227 824 002 187 824 002 387 825 002 135 825 002 335

70.00 2.756 – 827 002 228 823 002 228 824 002 188 824 002 388 825 002 136 825 002 336

70.20 2.764 – 827 002 229 823 002 229 824 002 189 824 002 389 825 002 137 825 002 337

73.00 2.874 – 827 002 230 – 824 002 190 824 002 390 825 002 138 825 002 338

73.03 2.875 – 827 002 231 – 824 002 191 824 002 391 825 002 139 825 002 339

73.15 2.880 – 827 002 232 – 824 002 192 824 002 392 825 002 140 825 002 340

75.00 2.953 – 827 002 233 – 824 002 193 824 002 393 825 002 141 825 002 341

76.00 2.992 – 827 002 234 – 824 002 194 824 002 394 825 002 142 825 002 342

76.10 2.996 – 827 002 235 – 824 002 195 824 002 395 825 002 143 825 002 343

76.20 3.000 – 827 002 236 – 824 002 196 824 002 396 825 002 144 825 002 344

76.30 3.004 – 827 002 237 – 824 002 197 824 002 397 825 002 145 825 002 345

80.00 3.150 – – – 824 002 198 824 002 398 825 002 146 825 002 346

82.00 3.228 – – – 824 002 199 824 002 399 825 002 147 825 002 347

82.30 3.240 – – – 824 002 200 824 002 400 825 002 148 825 002 348

Orbital Welding




OW 170 "S"(SMALL)

OW 170 "W"(WIDE)


85.00 3.346 – – – 824 002 201 824 002 401 825 002 149 825 002 349

85.90 3.382 – – – 824 002 202 824 002 402 825 002 150 825 002 350

88.90 3.500 – – – 824 002 203 824 002 403 825 002 151 825 002 351

89.00 3.504 – – – 824 002 204 824 002 404 825 002 152 825 002 352

89.10 3.508 – – – 824 002 205 824 002 405 825 002 153 825 002 353

90.00 3.543 – – – 824 002 206 824 002 406 825 002 154 825 002 354

93.00 3.661 – – – 824 002 207 824 002 407 825 002 155 825 002 355

95.00 3.740 – – – 824 002 208 824 002 408 825 002 156 825 002 356

100.00 3.937 – – – 824 002 209 824 002 409 825 002 157 825 002 357

101.60 4.000 – – – 824 002 210 824 002 410 825 002 158 825 002 358

104.00 4.094 – – – 824 002 211 824 002 411 825 002 159 825 002 359

108.00 4.252 – – – 824 002 212 824 002 412 825 002 160 825 002 360

110.00 4.331 – – – 824 002 213 824 002 413 825 002 161 825 002 361

113.50 4.468 – – – 824 002 214 824 002 414 825 002 162 825 002 362

114.00 4.488 – – – 824 002 215 824 002 415 825 002 163 825 002 363

114.30 4.500 – – – 824 002 216 824 002 416 825 002 164 825 002 364

115.00 4.528 – – – 824 002 217 824 002 417 825 002 165 825 002 365

125.00 4.921 – – – – – 825 002 166 825 002 366

127.00 5.000 – – – – – 825 002 167 825 002 367

127.05 5.002 – – – – – 825 002 168 825 002 368

129.00 5.079 – – – – – 825 002 169 825 002 369

133.00 5.236 – – – – – 825 002 170 825 002 370

139.70 5.500 – – – – – 825 002 171 825 002 371

141.30 5.563 – – – – – 825 002 172 825 002 372

152.40 6.000 – – – – – 825 002 173 825 002 373

154.00 5.063 – – – – – 825 002 174 825 002 374

159.00 6.260 – – – – – 825 002 175 825 002 375

165.10 6.500 – – – – – 825 002 176 825 002 376

165.20 6.504 – – – – – 825 002 177 825 002 377

168.30 6.626 – – – – – 825 002 178 825 002 378

170.00 6.693 – – – – – 825 002 179 825 002 379

Clamping insert blanksIdeal for special applications. Completely enclosed clamping inserts which can be drilled by customer to specific diameters.

MODEL CODE KG

Clamping insert blank for OW 38S, 2 pcs. 826 002 210

Clamping insert blank for OW 76S, 2 pcs. 827 002 241 9.9 oz (280 g)

Clamping insert blank for OW 115/115S "S" (small), 2 pcs. 824 002 220 1.3 lb (590 g)

Clamping insert blank for OW 115/115S "W" (wide), 2 pcs. 824 002 420 3.19 lb (1.45 kg)

Clamping insert blank for OW 170 "S" (small), 2 pcs. 825 002 185 2.23 lb (1.01 kg)

Clamping insert blank for OW 170 "W" (wide), 2 pcs. 825 002 385

Plastic covers for clamping insertsAll clamping inserts are packaged in pairs, in a plastic sleeve. Replacement sleeves can be ordered.

MODEL CODE KG

Plastic cover for clamping inserts OW 38S 826 002 010 0.7 oz (19 g)

Plastic cover for clamping inserts OW 76S/OW 65 827 002 010 2.3 oz (65 g)

Plastic cover for clamping inserts OW 115 "S" (small) 824 002 010 3.6 oz (101 g)

Plastic cover for clamping inserts OW 115 "W" (wide) 824 002 011 4.6 oz (129 g)

Plastic case for clamping insertsWith compartments. For storing up to 40 pairs of standard clamping inserts.

MODEL STORAGE CAPACITY CLAMPING INSERTS[PAIRS]

CODE KG

Plastic case for clamping inserts for OW 38S 20 826 020 001 12.3 oz (350 g)

Plastic case for clamping inserts for OW 65 and OW 76S 40 827 020 006 3.06 lb (1.39 kg)

Plastic case for clamping inserts for OW 115 and OW 115S 20 824 020 002 3.18 lb (1.44 kg)

Clamping insert blanks

Plastic covers for clamping inserts

Plastic case for clamping inserts for OW 115 (without clamping inserts)

Orbital Welding


Cavity inserts for moldings

Clamping inserts for welding of shaped pieces (e.g. flanges, flanged wheels and screw fittings in the food industry).

1 cavity insert consists of 2 half shells.

Dimensions of the different cavity inserts:

ORBIWELD DIMENSION "A"(Ø) DIMENSION "B"

38S [mm] 85.0 30.0

[inch] 3.346 1.181

65 [mm] 125.0 30.0

[inch] 4.921 1.181

76S [mm] 130.0 35.0

[inch] 5.118 1.378

115/115S [mm] 179.0 39.0

[inch] 7.047 1.535

170 [mm] 214.0 44.0

[inch] 8.425 1.732

A

B

MODEL CODE WEIGHT

Cavity insert for moldings for OW 38S 826 050 010 5.2 oz (146 g)

Cavity insert for moldings for OW 76S 827 050 007 9.4 oz (266 g)

Cavity insert for moldings for OW 65 823 050 010 1.35 lb (612 g)

Cavity insert for moldings for OW 115 and OW 115S 824 050 003 1.46 lb (660 g)

Cavity insert for moldings for OW 170 825 050 002 1.88 lb (852 g)

T-piece clamping shells

Clamping shell with the ability to clamp the hollowed tube and the tube to be welded.

For each task and dimension, 1 complete T-piece clamping shell set, 1 electrode adapter set (page 65) as well as 1 standard clamping insert set (from page 60) is required (to be ordered separately).

When ordering, please request from us the respective questionnaire and then submit the completed form together with a drawing.

Special clamping inserts for other orbital weld heads are available on request.Inner centering with simultaneous forming system available on request.

MODEL TUBE OD MAX.[MM]

TUBE OD MAX.[INCH]

CODE WEIGHT

T-piece clamping shells for OW 38S 16.00 0.630 826 050 038

T-piece clamping shells for OW 76S 48.30 1.902 827 050 005 1.76 lb (800 g)

T-piece clamping shells for OW 115/115S 85.00 3.346 824 050 004 2.87 lb (1.3 kg)

T-piece clamping shells for OW 170 154.00 6.063 825 050 003 8.16 lb (3.7 kg)

Cavity insert for moldings

T-piece clamping shells

Orbital Welding


Inserts for elbow welding

For welding of standard elbows to tubes without straight side attachment. When using this inserts on a weld head side (left or right) only the gas protection around the elbow is guaranteed; there is no clamping so that the elbow has to be tacked in place before welding.

Inserts, consisting of:• 2 basic retainers, independent of the tube diameter • 2 covers, depending on the tube diameter*

Retainer/CoverThe covers are placed into the retainer and can be turned so that the side of the elbow can exit at any angle from the weld head. The tube to be welded on the other side of the weld head must be straight and be clamped with inserts from the particular standard clamping insert set (standard clamping inserts are not included in the scope of delivery).

Elbow cover plate for OW 38SFor the OW 38S the covers (2 halves) are made to customer specifications* and have to be placed without retainers directly into the head. A basic retainer is therefore not required.

When ordering, please indicate and/or submit:• The required tube OD and the inside radius of the elbow.• Drawing of the elbow or sample part — an appropriate drawing template

is available in advance on request. We will then check whether or not an additional electrode adapter is required.

MODEL CODE WEIGHT

Elbow cover plate OW 38S complete* 826 050 031 0.1 oz (2 g)

Basic retainer for elbow insert for OW 76S 827 002 018 3.2 oz (90 g)

Cover for elbow insert for OW 76S 827 050 021 1.1 oz (30 g)

Basic retainer for elbow insert for OW 65 823 050 029 3.2 oz (90 g)

Cover for elbow insert for OW 65* 823 050 030 1.1 oz (30 g)

Basic retainer for elbow insert for OW 115 and OW 115S 824 050 006 5.3 oz (150 g)

Cover for elbow insert for OW 115S* 828 050 016 1.4 oz (40 g)


Basic retainer for elbow insert for OW 170 825 050 005 9.2 oz (260 g)


* When ordering, please submit a drawing of the elbow or the sample part.

Electrode adapters

Robust brass adapter for transverse alignment of the tungsten electrode.Can be ordered as a set or individually.

Please note that the maximum tube diameter that can be welded is reduced by using an electrode adapter.

The complete electrode adapter set consists of:

• Base part for extension arms• Extension arms 15°, 30°, 45° and 90°

ELECTRODE ADAPTERS ARE APPLICABLE UP TO MAX. TUBE DIAMETER [MM] [INCH]

OW 38S 16.0 0.630

OW 76S 48.0 1.890

OW 65 48.0 1.890

OW 115 / OW 115S 82.0 3.228

OW 170 146.0 5.748

Inserts for elbow welding(Basic retainer/Cover)

Electrode adapters for OW 38S, OW 76S

Adapter for inside welding (without rotor)

Orbital Welding


ELECTRODE ADAPTER SETS CODE WEIGHT

Electrode adapter for OW 38S, Set 826 050 034 0.5 oz (15 g)

Electrode adapter for OW 76S, Set 827 050 027 0.5 oz (15 g)

Electrode adapter for OW 65, Set 823 050 028 1.6 oz (45 g)

Electrode adapter for OW 115 and OW 115S, Set 824 050 021 2.3 oz (64 g)

Electrode adapter for OW 170, Set 825 050 022 3.3 oz (94 g)

INDIVIDUAL PARTS FOR OW 38S

Base part for extension arms OW 38S 826 004 003 0.8 oz (24 g)

10 mm/0.394 in, 15° extension arm for electrode adapters OW 38S 823 004 008 0.1 oz (3 g)



INDIVIDUAL PARTS FOR OW 76S

Base part for extension arms OW 76S 827 004 003 0.8 oz (24 g)

15 mm/0.591 in, 15°/90° extension arm for electrode adapters OW 76S 823 004 002 0.1 oz (3 g)



INDIVIDUAL PARTS FOR OW 65

Base part for extension arms OW 65 823 004 011 0.6 oz (18 g)

15 mm/0.591 in, 15°/90° extension arm for electrode adapters OW 65 823 004 002 0.1 oz (3 g)



INDIVIDUAL PARTS FOR OW 115 AND OW 115S

Base part for extension arms OW 115 and OW 115S 824 004 004 1.3 oz (37 g)

25 mm/0.984 in, 15°/90° extension arm for electrode adapters OW 115/115S 823 004 006 0.3 oz (9 g)



INDIVIDUAL PARTS FOR OW 170

Base part for extension arms OW 170 825 004 001 2.4 oz (67 g)




ELECTRODE ADAPTERS FOR HEAD SEAM WELDING*

Electrode adapters OW 38S for head seam welding, Set 826 050 036

Electrode adapters OW 76S for head seam welding, Set 827 050 038 1.6 oz (45 g)

Electrode adapters OW 65 for head seam welding, Set 823 050 034 1.3 oz (38 g)

Electrode adapters OW 115 for head seam welding, Set 824 050 022 2.5 oz (70 g)

ELECTRODE ADAPTER FOR INSIDE WELDING*

Electrode adapters OW 38S for inside welding, Set 826 050 037

Electrode adapters OW 76S for inside welding, Set 827 050 039 2.5 oz (71 g)

Electrode adapters OW 115 for inside welding, Set 824 050 023 6.8 oz (193 g)

* Other electrode adapters for other weld heads upon request.

Table mounts

Practical and sturdy (anodized) aluminum table mounts. For comfortable and secure storage of the ORBIWELD weld heads.

The mount is quickly and easily clamped to the table top using the integrated screw clamp. Thus, the weld head is firmly fixed in the holder for stationary applications – also ideal for storage or temporary placement of the weld head between individual welding jobs.

TECHNICAL DATA TABLE MOUNTS

Dimensions (L x W x H) 180 x 140 x 185 mm7.1 in x 5.5 in x 7.3 in

Clamping range (bottom surface of table to maximum extended screw clamp) max. 65 mm / 2.56 in

MODEL CODE KG

Table mount for OW 38S, OW 76S 826 030 006 2.76 lb (1.25 kg)

Table mount for OW 65, OW 115, OW 115S, OW 170 823 030 006 2.36 lb (1.07 kg)

Other accessories for orbital welding• ESG tungsten grinders, see page 79• ORBmax digital oxygen analyzer, see page 83• ORBIPURGE forming set, see page 85• Hose package extensions, see page 85• Inspection set, see page 86• WS2 tungsten electrodes, see page 86

Table mounts

Electrode adapter for OW 170

Head seam adapter (without rotor)

Orbital Welding


HX 16P

The HX 16P is engineered for positioning between the individual pipes of finned heat exchangers.

Economic and efficient when compared to conventional weld heads, the HX 16P allows the pipe outlets of a heat exchanger to be fully fitted with elbows before joining and then welded in any order. For conventional orbital weld heads, always starting from the center of the pipe sheet and working outward, the process of fit elbow, weld, repeat applies. If quality testing reveals a faulty weld later on, all elbows must be replaced and rewelded, with the worst case scenario being a fault in the middle of the sheet, which is costly. Using the HX head however, only the affected elbow needs replacement. This design-based advantage also makes the Orbitalum system the ideal tool for unbeatably cost-effective repairs.

The HX 16P only weighs 1.5 kg (3.3 lbs), in contrast to open weld heads and their unwieldy hose assembly. All connections for power, gas, and cooling water are permanently integrated into the HX.

All orbital welding power supplies from Orbitalum automatically detect the head and its properties so that the operator only has to call up his or her specified jointing program and start the joining process before beginning to weld.

Traditionally, complex heat exchangers for cooling systems were made of copper and soldered with the pipe elbows. The high price of copper required manufacturers to switch to stainless steel, which requires high quality tungsten inert gas (TIG) in conjunction with automatic orbital welding systems.

FEATURES:

• Highly durable thanks to water-cooled earth plate and rotor housing

• Horizontal, vertical and tilted welding positions are possible

• Very robust and ergonomic design• Fast and easy mounting at the tube • Self-retaining weld head, patented

fixation mechanism via pistons saves up to 80% of the preparation time

• Pneumatic clamping system for easy mounting on the pipe elbow

• External stop for adjusting the electrode position

The orbital weld head HX 16P for compact cooling systems sets new standards!

HX stands for heat exchanger and for the welding of pre-mounted elbows in tight pipe bundles of heat exchangers into a pipe coil. At present, there is no other solution as effective as this one in the world!

ENCLOSED ORBITAL WELD HEAD

Orbital Welding


APPLICATION RANGE HX 16PCode 848 000 001

Tube OD, min. - max.* 15 - 16.8 mm0.591 in - 0.661 in

TECHNICAL DATA HX 16PElectrode Ø 1.6 mm

0.063 in

Weight 1.5 kg3.3 lbs


TECHNICAL DATA PNEUMATIC BOXInput Argon

Recommended input pressure 8 bar/116PSI

SCOPE OF DELIVERY HX 16PIncluding: • 1 Enclosed orbital weld head HX 16P

• 1 Durable storage and shipping case• 1 Pneumatic box• 1 Supply hose (3 m/9.84 ft) for pneumatic box• 1 Pivoting arm (set) for pipes up to OD 16.80 mm (0.661 in)• 1 Elbow stop• 1 Tool set• 1 Operating instructions and spare parts list


• Clamping inserts• Bar pressure regulator Argon for HX 16P• Earth cable• WS2 tungsten electrodes• ESG tungsten grinders

DIMENSIONS HX 16PDimension "A" 292.50 mm / 11.516 in

Dimension "B" 243.50 mm / 9.587 in

Dimension "C" 190.00 mm / 7.480 in

Dimension "D" 223.50 mm / 8.799 in

Dimension "E" 280.50 mm / 11.043 in

Dimension "F" 72.00 mm / 2.835 in

Dimension "G" 91.20 mm / 3.591 in

Dimension "H" 60.00 mm / 2.362 in

Dimension "I" 12.50 mm / 0.492 in

Dimension "J" 239.50 mm / 9.429 in

Dimension "K" 30.00 mm / 1.181 in

Dimension "L" 82.92 mm / 3.265 in

Dimension "M" 71.00 mm / 2.795 in

* Other dimensions on request

AB

GF

D

E

C

H

IJ

L

K

M

Orbital Welding


Enclosed orbital weld head

HX 16P


Scope of delivery:• 1 Enclosed orbital weld head HX 16P• 1 Durable storage and shipping case• 1 Pneumatic box• 1 Supply hose (3 m/9.84 ft) for pneumatic box• 1 Pivoting arm (set) for pipes up to OD 16.80 mm (0.661 in)• 1 Elbow stop• 1 Tool set• 1 Operating instructions and spare parts list

The following accessories are essentially required for operating the HX enclosed orbital weld heads and must be ordered separately:• Clamping inserts, see page 69• Earth cable, see page 85

MODEL CODE MACHINE WEIGHT

SHIPPING WEIGHT

Enclosed orbital weld head HX 16P 848 000 001 34.39 lb (15.6 kg)

Accessories for HX

Clamping inserts for HX 16P

Made of stainless steel. 2 clamping inserts for each dimension are required.

MODEL PIPE OD[MM]

PIPE OD[INCH]

CODE KG

Clamping insert for HX 16P 15.80 0.622 848 002 313









• ESG tungsten grinders, see page 79• ORBmax digital oxygen analyzer, see page 83• Earth cable, see page 85• WS2 tungsten electrodes, see page 86

HX 16P

Pneumatic box

Clamping inserts for HX 16P


Tube-to-Tubesheet Orbital Weld Heads

Orbital Welding


TX38P

Welding heat exchanger tubes particular effectively and easily: With our new TX38P for automated TIG orbital welding you can now accurately and precisely weld tube sheets with heat exchanger tubes, such as thousands of welded joints on cooling tubes.

In connection with an ORBITALUM orbital welding power supply, the user is being offered an extremely innovative and economical welding system. All ORBITALUM orbital welding power sources automatically detect the head and its properties so that the operator only has to call up his or her specified joining program and start the joining process before beginning to weld. To increase productivity, the operator can work with up to two weld heads on one machine in an alternating fashion, which reduces welding times and downtimes considerably.

THE MAIN ADVANTAGES AT A GLANCE:• Lightweight, hand-held TIG orbital weld head

designed for welding of tubes-to-tube-sheets in fusion welding process

• Precise working conditions in any position to achieve high-quality results on horizontal or vertical tube sheets

• A pneumatically operated clamping mandrel with one-hand operation enables a fast assembly and dismantling on tube sheets

• Applicable for flush tubes, slightly recessed tubes and protruding tubes

• Also compatible with AMI clamping mandrels, model 96

• Service friendly design of the clamping and drive system within the housing

• One-hand operation through integrated remote control and pneumatic control via handle

• Self-supporting weld head at the tube sheet via stable clamping mandrels (eyelet for spring balancer available)

• Closed water circuit from the welding power supply via cable to the slide contact; thereby higher durability at a low thermal load

• Closed cover for inert gas – ideal for oxidation sensitive materials, e.g. titanium materials

• Limit switch for the electrode position; thus, the start position is freely selectable

• Integrated rapid adjustment of the electrode position to the tube diameter

• Constant or pulsating rotor movement possible (CONT-STEP-Mode)

• Sturdy, speed-regulated 24-volt driving motor with a reduction gear

• Water-cooled slide contact for transmission of welding current prevents rotary transmission and leakages

TUBE-TO-TUBE-SHEET ORBITAL WELD HEAD

Ideal for repairing and maintainingof large-scaled heatexchanger plants

Precise centering of the weld headin the tube via dimensionally stableclamping mandrels which areavailable for tube inner diametersfrom 10 to 36 mm (0.394" - 1.417")

The new ORBITALUM orbital TIG weld head for producing tube-to-tube-sheet connections guarantees extremely short production times whi le consistently maintaining a high and a reproducible qual ity. This weld head is the perfect solution for the repair, maintenance and servicing of industr ia l heat exchanger systems.

Applicable for flush, slightly recessed, and protruding tubes

NEW

Orbital Welding


The perfect complement: Orbital weldingpower supplies of the ORBIMAT CA series

APPLICATION RANGE TX38P

Code 830 000 005

From tube ID to tube OD [mm] 10 - 38

[inch] 0.394" - 1.500"

TECHNICAL DATA

Welding current, max., pulsed, with water cooling of the rotor and of the connection cables

[Amp DC ] 150

Rotation speed, max. [rpm] 10

Drive motor with tachometer [VDC ] 24

Electrode Ø [mm] 1.6 (available option: 2.4)

[inch] 0.063 (available option: 0.094)

Gas flow [l/min] 5 - 20

Gas type Argon/Argon-Helium/Argon-Hydrogen

Water pressure, max. [bar] 2.5

Air pressure [bar] 5 - 7

Hose package length [m] 7.5

[ft] 25

Weight, approx. (without hose package) [kg] 3

[lbs] 6.6

Type of connection Fully compatible with all Orbitalum power supplies

DIMENSIONS

Dimension "A" [mm/inch] 65 / 2.559

Dimension "B" [mm/inch] 241 / 9.488

Dimension "C" [mm/inch] 207 / 8.150

Dimension "D" [mm/inch] 36 / 1.417

Dimension "E" [mm/inch] 68 / 2.677

Dimension "F" [mm/inch] 185 / 7.283


SCOPE OF DELIVERY

Includes • 1 Tube-to-tube-sheet orbital weld head TX38P (Code 830 000 005)• 1 Hose package, length 7.5 m (25 ft)• 1 Integrated remote control• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list

THE FOLLOWING ACCESSORIES ARE ESSENTIALLY REQUIRED FOR OPERATING THE TX38P:

To be ordered separately: • Clamping mandrels• Earth cable

FURTHER ACCESSORIES

Available option: • Various shielded gas covers• Various centering plates• Various sizes of clamping mandrel• Spring balancers• ESG Tungsten Grinders• Earth cable• Hose package extensions 5 m / 10 m / 15 m• Pressure regulator• Inspection set• WS2 tungsten electrodes

EQUIPMENT

Integrated remote control,with control keys:

• START/STOP welding process• ON/OFF gas• Motor (rotor movement)• Approaching the end position (home position)• Activating the clamping mandrel pneumatic

Self-supporting weld head at the tube sheet via stable clamping mandrels

One-hand operation through integrated remote control and pneumatic control via handle

Powerful and sturdy design – despite compact size and low weight

Orbital Welding


P16, P16 AVC

With these TIG weld heads, it is no longer a problem to weld tubes to tubesheets with the highest of accuracy and consistent quality

Its water cooling is fed right to the TIG burner head, which ensures more precise working and consistent quality of the welding process, as well as extending the power-on time. The burner head can be pivoted freely by up to 30° – this function is valuable, for instance, on tubes that are entering tubesheets at an angle or in restricted spaces.

ADDITIONAL FEATURES:• Completely water-cooled weld head housing

(P16/P16 AVC only)• Burner head can be pivoted freely by up to

30° (reduced diameter range) • Weld seam geometries: Recessed, flush and

protruded tubes • Current transmission via multi-plate clutch • Gas/water transmission via rotating cloupling • Three-point mounting made of stainless steel• Manually electrode positioning

Stroke +/- 5 mm• Special burner heads adaptable, e.g. for box-

header welding (P16, P16 AVC only) or for IBW/internal bore welding (with/ without cold wire)

• Positioning on the tube to be welded is by means of a centering tool that is placed on a retaining arbor (available option)

• The weld heads with integrated cold wire unit additionally include a retaining mechanism for Ø 100 mm/1 kg (3.937 in/2.2 lbs) standard wire reels

• Revolving wire feed on the rotational axis of the TIG burner prevents the additional wire from twisting when it exits the wire nozzle (only P16/P16 AVC)

• Three-point mounting included• 7.5 m (24.6 ft) hose package and tool set

included

FEATURES P16 AVC:• Equipped with an electric arc voltage control

(AVC) – only applicable in combination with the orbital welding power supply ORBIMAT 300 CA AVC/OSC

• Cold wire unit included

TUBE-TO-TUBE-SHEET ORBITAL WELD HEADS

Easy handling and a maximum of functionality

Tube-to-tube-welding on large-scale heat exchanger with highest precision and efficiency

Water-cooled weld head up to 30° freely pivotable

Our P series is characterized by special design features intended to ensure easy handl ing combined with a high level of economy and functional ity.

With extreme precision , these tube-to-tube-sheet orbital weld heads wi l l produce several thousand weld seams with consistent qual ity.

Orbital Welding


APPLICATION RANGE P16 P16 AVCCode with cold wire unit 831 000 001 831 000 002

without cold wire unit 831 000 003 831 000 004

From tube ID to tube OD 10 - 78 mm*0.394 in - 3.071 in*

12 - 100 mm*0.470 in - 3.937 in*

TECHNICAL DATA P16 P16 AVCMachine Weight with cold wire unit 17.5 kg

38.6 lbs18.3 kg40.3 lbs

without cold wire unit 16.2 kg35.7 lbs

–

Weight of cold wire unit 1.0 kg2.2 lbs

1.0 kg2.2 lbs

Cold wire unit Ø 1.0 kg2.2 lbs

1.0 kg2.2 lbs


7.5 m24.6 ft

SCOPE OF DELIVERYIncluding: • 1 Tube-to-tube-sheet orbital weld head P16 or P16 AVC

• 1 Three-point mount• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list


• Centering tools and retaining arbors• Special torches (e.g. for boxheader or internal bore welding (IBW))• Cold wire feed units (retrofit kits)• Spring balancers• Closed gas covers• Front cages• Pneumatic centering devices• Pneumatic centering tools• ESG tungsten grinders• Earth cable• Hose package extensions• Pressure regulator• Inspection set• WS2 tungsten electrodes

DIMENSIONS P16 P16 AVCDimension "A" 182.97 mm

7.204 in187.05 mm7.364 in

Dimension "B" 427.25 mm16.821 in

427.25 mm16.821 in

Dimension "C" 344.00 mm13.543 in

344.00 mm13.543 in

Dimension "D" 80.00 mm3.150 in

80.00 mm3.150 in

Dimension "E" 95.50 mm3.760 in

95.50 mm3.760 in

Dimension "F" 466.00 mm18.346 in

582.00 mm22.913 in

* Smaller and larger dimensions on request.

A

B

C

D

E

F

P16

Orbital Welding


P16

Tube-to-tube-sheet orbital weld heads

P16, P16 AVCScope of delivery:• 1 Tube-to-tube-sheet orbital weld head P16, P16 AVC• 1 Three-point mount• 1 Durable storage and shipping case• 1 Tool set• 1 Operating instructions and spare parts list

The following accessories are essentially required for operating the tube-to-tube-sheet orbital weld heads and must be ordered separately: • Retaining arbors and centering tools (see page 77) • Earth cable (see page 85)

MODEL CODE MACHINE WEIGHT (KG) SHIPPING WEIGHT (KG)

Orbital weld head P16 with cold wire unit 831 000 001 38.58 lb (17.5 kg) 58.42 lb (26.5 kg)

Orbital weld head P16 AVC with cold wire unit 831 000 002 40.34 lb (18.3 kg) 60.19 lb (27.3 kg)

Accessories (available option):• Centering tools and retaining arbors, see page 77• Special torches (e.g. for boxheader or internal bore welding (IBW)), see page 75• Spring balancers, see page 76• Closed gas covers, see page 76• Front cages, see page 76• Pneumatic centering devices, see page 76• Remote control, see page 46

Tube-to-tube-sheet weld head accessories

Custom torchesSpecial torches for the following welding positions are available on request:

Boxheader welding torch

Internal bore welding torch (IBW):For welding of recessed tubes and back sheet applications

MODEL CODE KG

Boxheader welding torch on request

Internal bore welding torch (IBW) on request

P16 custom torch for box header

P16 custom torch for box header

Orbital Welding


Spring balancerFor load-free suspension of tube-to-tube-sheet orbital weld heads.

MODEL TENSILE LOAD MAX.[KG]

CODE WEIGHT

Spring balancer for P16 10 – 14 832 030 002 8.38 lb (3.8 kg)

Closed gas coversFor welding titanium tubes under a full gas cover.

MODEL CODE WEIGHT

Closed gas cover for P16 831 001 101 2.87 lb (1.3 kg)

Front cagesWith bearing ring. Ideal for welding of flush and recessed tubes.

MODEL CODE WEIGHT

Front cage for P16 831 050 001 10.9 oz (310 g)

Front cage for P16 AVC 831 050 003

Pneumatic centering devicesFor highly precise alignment of the weld head by friction-locked clamping. Perfect for welding of thin-walled tubes and protruding tubes.

The suitable pneumatic centering tool must be ordered separately (please see below).

MODEL CODE WEIGHT

Pneumatic centering device for P16 831 020 030 7.72 lb (3.5 kg)

Pneumatic centering device for P16 AVC 831 020 029

Pneumatic centering tools

Compatible with pneumatic centering devices.

MODEL PIPE ID[MM]

PIPE ID[INCH]

CODE WEIGHT

Pneumatic centering tool 14.5 - 16.0 0.570 - 0.630 831 020 031


Pneumatic centering tool 18.0 - 22.0 0.708 - 0.866 831 020 033 6.3 oz (180 g)




Pneumatic centering tool 30.0 - 34.0 1.181 - 1.338 831 020 037 1.32 lb (600 g)



Spring balancer

Closed gas cover

Front cage

Pneumatic centering device

Pneumatic centering tool

Orbital Welding


Centering tools and retaining arbors

The tube diameter is required to select the correct centering tool. Smaller and larger dimensions on request.

When ordering, please consider the correct centering tool/retaining arbor combination.

MODEL GROUP CARTRIDGESIZE/NO.

PIPE ID*[MM]

PIPE ID*[INCH]

CODE KG

Retaining arbor for centering tools for group A 832 020 003 2.1 oz (60 g)

Centering tool A 1 10.0 - 10.5 0.394 - 0.413 832 020 004 1.4 oz (40 g)







Retaining arbor for centering tools for group B 832 020 010 2.5 oz (70 g)

Centering tool B 8 13.8 - 15.0 0.543 - 0.591 832 020 012 4.2 oz (120 g)

Centering tool B 9 14.8 - 16.0 0.583 - 0.630

832 020 013 4.9 oz (140 g)





Centering tool B 14 19.8 - 22.5 0.780 - 0.886

832 020 018 8.8 oz (250 g)

Retaining arbor for centering tools for group C 832 020 019 4.1 oz (115 g)

Centering tool C 15 22.3 - 25.0 0.878 - 0.984 832 020 020 12 oz (340 g)

Centering tool C 16 24.5 - 27.0 0.965 - 1.063 832 020 021 12.3 oz (350 g)



Centering tool C 19 30.5 - 33.0 1.201 - 1.299 832 020 024 1.1 lb (500 g)





Centering tool C 24 44.5 - 48.0 1.752 - 1.890 832 020 029 2.2 lb (1 kg)

Centering tool C 25 47.5 - 51.0 1.870 - 2.008 832 020 030 2.65 lb (1.2 kg)

Retaining arbor for centering tools for group D 832 020 031 7.6 oz (215 g)

Centering tool D 26 50.5 - 54.0 1.988 - 2.126 832 020 032 3.31 lb (1.5 kg)









Centering tool D 35 87.0 - 91.0 3.425 - 3.582 832 020 046

Centering tool D 36 91.0 - 95.0 3.582 - 3.740 832 020 047


Centering tool D 38 99.0 - 103.0 3.897 - 4.055 832 020 049

Centering tool D 39 103.0 - 107.0 4.055 - 4.212 832 020 050

Centering tool D 40 107.0 - 111.0 4.212 - 4.370 832 020 051

Centering tool D 41 111.0 - 115.0 4.370 - 4.527 832 020 052

Centering tool D 42 115.0 - 120.0 4.527 - 4.724 832 020 053

* Smaller pipe dimensions on request.


• Earth cable, see page 85• ESG tungsten grinders, see page 76• WS2 tungsten electrodes, see page 86

Centering tools

Retaining arbor


Orbital Welding Accessories and Consumables

Orbital Welding


ESG MAX, ESG Plus, ESG Plus2

The powerful Hand-Tungsten-Grinder for grinding, facing and cutting.One machine – complete electrode preparation:• Grinding electrodes:

– 4 different angles – 6 different electrode sizes

• Facing electrodes• Cutting electrodes

The machines are available with a high-quality and powerful drive with 230 Volt and/or 110 Volt.Machines and accessories are delivered in a durable storage and shipping case.

• Repeatable points every time due to preset grinding angles

• Easy and fast to use• Optimum preparation for orbital and manual

welding

• Longitudinal grinding for optimum arc ignition and excellent arc stability

• Guarantees longer tool life and ease of ignition of the tungsten electrode

• Specially designed for one-off jobs on site• Compact design, optimum resilience and

perfect reproducibility• Solid, functional design• Precise orbital grinding• Facility for easy trimming of the electrodes

(optional)• External dust extractor can be easily adapted• Short preparation times with high grinding

performance• No adjustment needs to be done before operation

FEATURES ESG MAX:• Lateral adjustment of the head for increased

service life of the grinding wheel• Grinding head with 72 holes: 36 holes for the

grinding wheel with coarse grain, 36 holes for the grinding wheel with fine grain and cutting edge

• Variable cutting device from 9.0 to 34.5 mm / 0.354 in to 1.358 in (available option)

• Includes dust protection to isolate sensitive components from grinding dust

• Adapter for extraction device for up to 96% less grinding dust particles (available option)

• Table mount included

FEATURES ESG PLUS2 AND ESG MAX:• Portable tungsten grinder with two different

grinding wheels. This allows the electrode to be pre-ground with the coarse diamond wheel then finished with the fine diamond wheel.

The best solution for a precise and fast preparation of tungsten electrodes.

The perfect hand-held grinder for cutting, grinding and planing electrodes which are used in WIG/TIG welding machines. Consider country-specific regulations, standards and guidelines when using tungsten electrodes with thorium.

TUNGSTEN GRINDERS

Repeatable points every time due to preset grinding angles

Cutting electrodes (e.g. with ESG MAX)

Grinding electrodes: 4 different angles and 6 different electrode sizes

ESG MAX: Laterally adjustable grinding head with 72 holes

Facing electrodes

Orbital Welding


Tungsten Grinders ESG

ESG MAX, ESG Plus, ESG Plus2


MODEL VERSION GRINDING ANGLES [°]

CODE MACHINE WEIGHT SHIPPING WEIGHT

ESG MAX 230 V, 50/60 Hz EU 15 / 18 / 22.5 / 30 / 45 / 60 790 052 591 3.44 lb (1.56 kg) 8.11 lb (3.68 kg)

ESG MAX 110 V, 50/60 Hz EU/US 15 / 18 / 22.5 / 30 / 45 / 60 790 052 592 3.44 lb (1.56 kg) 8.11 lb (3.68 kg)

ESG Plus 230 V, 50/60 Hz EU 15 / 18 / 22.5 / 30 790 052 485 3.15 lb (1.43 kg) 7.85 lb (3.56 kg)

ESG Plus 110 V, 50/60 Hz EU/US 15 / 18 / 22.5 / 30 790 052 486 3.15 lb (1.43 kg) 7.85 lb (3.56 kg)

ESG Plus 230 V, 50/60 Hz EU 15 / 30 / 45 / 60 790 052 545 3.15 lb (1.43 kg) 7.85 lb (3.56 kg)

ESG Plus 110 V, 50/60 Hz EU/US 15 / 30 / 45 / 60 790 052 645 3.15 lb (1.43 kg) 7.85 lb (3.56 kg)

ESG Plus2 230 V, 50/60 Hz EU 15 / 18 / 22.5 / 30 790 052 585 3.35 lb (1.52 kg) 8.43 lb (3.83 kg)

ESG Plus2 110 V, 50/60 Hz EU/US 15 / 18 / 22.5 / 30 790 052 586 3.35 lb (1.52 kg) 8.43 lb (3.83 kg)

ESG Plus2 230 V, 50/60 Hz EU 15 / 30 / 45 / 60 790 052 546 3.35 lb (1.52 kg) 8.43 lb (3.83 kg)

ESG Plus2 110 V, 50/60 Hz EU/US 15 / 30 / 45 / 60 790 052 646 3.35 lb (1.52 kg) 8.43 lb (3.83 kg)

ESG MAX

ESG Plus

ESG Plus2

SCOPE OF DELIVERY / APPLICATION RANGE ESG MAX ESG PLUS ESG PLUS2

Tungsten Grinder Pc. 1 1 1

Durable storage and shipping case Pc. 1 1 1

Grinding head for electrodes Ø 1.0 - 1.6 - 2.0 - 2.4 - 3.2 - 4.0 mm* (0.04 in - 1/16 in - 0.08 in - 3/32 in - 1/8 in - 5/32 in)*

Pc. 1 1 1

Grinding head for grinding angle 15° - 18° - 22.5° - 30° - 45° - 60°

Pc. 1 – –

Grinding head for grinding angle 15° - 18° - 22.5° - 30° or 15° - 30° - 45° - 60°

Pc. – 1 1

Diamond grinding wheel Fine (790 052 517) Pc. 1 – –

Diamond grinding wheel Coarse (790 052 518) Pc. 1 – –

Diamond grinding wheel Fine (790 052 487) Pc. – – 1

Diamond grinding wheel Medium (790 052 488) Pc. – 1 –

Diamond grinding wheel Coarse (790 052 550) Pc. – – 1

Table mounting plate Pc. 1 – –

Tool to replace the grinding wheel Pc. 1 1 1

Operating instructions and spare parts list Set 1 1 1

TECHNICAL DATA ESG MAX ESG PLUS ESG PLUS2

Dimensions (including motor) [mm] Ø 65 x 350 Ø 65 x 350 Ø 65 x 350

[inch] Ø 2.56 x 13.78 Ø 2.56 x 13.78 Ø 2.56 x 13.78

Power [W] 500 500 500

Power-on time [%] 100 100 100

Speed (Rotary speed) [rpm] 30.000 30.000 30.000

Main supply cable (length) [m] 3 3 3

[inch] 118.1 118.1 118.1

Vibration level (EN 28662, part 1) [m/s2] < 2.5 < 2.5 < 2.5

Noise level at the workplace (Idle running), approx. [dB (A)] 83 83 83


* An electrode holder is required to grind electrodes with 4.0 mm (5/32 in) diameter (available option).

Orbital Welding


Diamond grinding wheels

Replaceable grinding wheel diamond-coated on both sides for optimal performance.

For 1.0 and 1.6 mm (0.039 in/0.063 in) electrodes we recommend the standard grinding wheel. For 2.0 and 2.4 mm (0.078 in/0.094 in) electrodes a medium grained grinding wheel and for 3.2 and 4.0 mm (0.126 in/0.157 in) a coarse grained grinding wheel is advisable.

MODEL WORKS WITH GRAIN WHEEL Ø S CODE WEIGHT


Diamond grinding wheel ESG MAX Fine 40.00 1.574 2.1 0.083 790 052 517 0.6 oz (17 g)

Diamond grinding wheel ESG MAX Coarse 37.00 1.574 2.2 0.087 790 052 518 0.6 oz (16 g)

Diamond grinding wheel ESG 4 Standard 32.00 1.290 1.2 0.047 790 052 460 0.2 oz (5 g)

Diamond grinding wheel ESG Plus, ESG Plus2 Fine 33.50 1.319 2.2 0.087 790 052 487 0.4 oz (10 g)

Diamond grinding wheel ESG Plus, ESG Plus2 Medium 33.50 1.319 2.2 0.087 790 052 488 0.4 oz (11 g)

Diamond grinding wheel ESG Plus, ESG Plus2 Coarse 33.50 1.319 2.2 0.087 790 052 550 0.4 oz (11 g)

Cutting devices

For simple separating of the electrodes.

Electrode minimum length for grinding with ESG MAX:15° = 24.8 mm (0.976 in)18° = 22.3 mm (0.878 in)22.5° = 20.6 mm (0.811 in)30° = 19.1 mm (0.752 in)45° = 18.6 mm (0.339 in)60° = 19.5 mm (0.768 in)

MODEL WORKS WITH SETTING CUTTING LENGTHS CODE WEIGHT

[MM] [INCH]

Cutting device ESG MAX continuous 9.0 - 34.5 0.354 - 1.358 790 052 613 1.2 oz (33 g)

Cutting device ESG Plus, ESG Plus2 fixed* 12.013.015.017.0

0.4720.5120.5910.669

790 052 513 1.1 oz (30 g)

* Other cutting lengths possible on request.

Diamond grinding wheels

Cutting device for ESG MAX

Orbital Welding


Electrode holderFor machining smaller electrodes.

The electrode holder for the ESG MAX is available in a set including collets for 6 different electrode diameters.

The electrode holder for the ESG Plus or ESG Plus2 includes (1) flexible collet.

MODEL WORKS WITH SETTING ELECTRODE Ø CODE WEIGHT

[MM] [INCH]

Electrode holderwith 6 collets

ESG MAX fixed 1.01.62.02.43.24.0

0.0391/16

0.0803/32

1/85/32

790 052 614 1 oz (27 g)

Electrode holderwith collet

ESG Plus, ESG Plus2 continuous 1.0 - 3.2 0.039 - 0.126 790 052 457 0.8 oz (23 g)

Spare collet ESG Plus, ESG Plus2 continuous 1.0 - 3.2 0.039 - 0.126 790 052 481 0.1 oz (2 g)

Wall-/table-/vice-mounting plate

For stationary use of the ESG Plus and ESG Plus2.Simple and rapid mounting to a wall, a table or a vice.

MODEL WORKS WITH CODE WEIGHT

Wall-/table-/vice-mounting plate ESG Plus, ESG Plus2 790 052 483 3.6 oz (102 g)

Adapter for extraction device

This adapter for an extraction device can be placed rapidly and simply on the ESG MAX grinding head and reduces grinding dust by up to 96% less particles. For use on electrodes with thorium. Consider country-specific regulations, standards and guidelines.


Adapter for extraction device ESG MAX ESG MAX 790 052 612 2.7 oz (77 g)

Protective cover

Easy to adapt on the ESG Plus head. With integrated retainer for suction units. For use on electrodes with thorium. Consider country-specific regulations, standards and guidelines.


Protective cover ESG Plus ESG Plus 790 052 496 6 oz (170 g)

Protective cover ESG Plus2 ESG Plus2 790 052 596 7.8 oz (220 g)

Double-Decker Kit

Easy to mount to the ESG Plus.

This attachment makes it possible to use 2 different grinding wheels at the same time.

Including:

• 1 Grinding head• 1 Diamond grinding wheel (Coarse)• 1 Cylinder-head screw with collar (M4x34)• 1 Shaft extension

MODEL WORKS WITH GRINDING ANGLES [°] CODE WEIGHT

Double-Decker Kit ESG Plus 15 / 18 / 22.5 / 30 790 052 490 5.6 oz (160 g)

Double-Decker Kit ESG Plus 15 / 30 / 45 / 60 790 052 390 3.5 oz (100 g)

Electrode holder with 6 collets (for ESG MAX)

Electrode holder with collet (for ESG Plus, ESG Plus2)

Spare collet (for ESG Plus, ESG Plus2)

Wall-/table-/vice-mounting plate

Adapter for extraction device

Protective cover

Double-Decker Kit

Orbital Welding


ORBmax

The "Optical oxygen measurement via fluorescence extinction" method for welding technology (patent pending) is far superior to conventional methods, using zirconium sensors: requiring no warm-up wait time, it reliably, quickly and precisely detects the amount of oxygen share in the gas; ozone formation is eliminated; the measurement is possible in all gas mixtures without manual switch-over (even with forming gas with a variable percentage of hydrogen).

The exact, fast detection of the oxygen content reduces the long flooding time of the forming gas. The operator can start the safe welding process more quickly. As a result, precious work time is saved and the gas consumption reduced. In addition, ORBmax requires no maintenance of any kind. Calibration once a year in accordance with the standard ISO 9001 is sufficient.

For welding pipes in plant and equipment construction for the food processing, beverage, cosmetics and pharmaceuticals industries, medical and biotechnology as well as fine chemicals, comprehensive quality assurance is required and a procedure qualification is specified for the welded seams. For quality certification, not only the values from the power source, but also the residual oxygen values can be documented with the ORBmax, thereby eliminating a more in-depth inspection (eg. x-rays). When used as a stand-alone solution, ORBmax records a digital log with a time stamp. In conjunction with the ORBIMAT welding power supply, the weld is monitored in real-time and automatically adjusted when increased oxygen content occurs.

• No warm-up time required• Quick response• High measurement accuracy• Measurement of residual oxygen level during

the welding process in all gas mixtures• No uncontrolled increase of the measurement

during the welding process• Measurement of forming gas with variable

hydrogen content without mode change• Measured value recording on SD card• User-friendly touchscreen• Water-resistant sensor

DIGITAL OXYGEN ANALYZER

In combination with the ORBIMAT welding power source, the joining process can be monitored in real-time and automatically switched off when increased oxygen content occurs

Comprehensive range of accessories, including durable storage and shipping case

In Tungsten Inert Gas (TIG)-welding oxygen is generally undesirable as it is detrimental to the welded joint. The ORBmax digital oxygen analyzer sets a milestone for fast, exact detection of residual oxygen, allowing greater efficiency and higher quality welds. The compact unit can perform complete documentation of the results.

The NEW ORBmax

ORBIMAT 165 CA

ORBIWELD 76S

O2 Log Analyzer Software Included

• Alarm mode with beeper and changing color display (green/red)

• Protection class IP32• Programmable alarm and saving interval• Multi-range power supply• Software to evaluate data• Can be connected with an ORBIMAT Orbital

Welding Power Source• Maintenance-free sensor (yearly calibration

recommended)• Compact design• Transportation case with IP67 protection

Orbital Welding


Digital oxygen analyzer

ORBmax

Features, see page 83.

TECHNICAL DATA ORBMAX

Dimensions (L x W x H) 215 x 200 x 74 mm

8.46 in x 7.87 in x 2.91 in

Weight, approx. 2 kg

4.4 lbs

Protection class device IP32

Protection class transport case IP67

Power connection AC 100 - 240 V, 50 - 60 Hz

Measuring range 1 - 999 ppm

SCOPE OF DELIVERY • 1 ORBmax digital oxygen analyzer• 1 Durable storage and shipping case• 1 power unit supply set 100 - 240 VAC / 12 VDC• 1 measuring hose (with test tip and filter)• 1 SD card including evaluation software "O2_log"• 1 interface cable• 2 reserve filter inserts• 1 operating instructions

MODEL VERSION CODE MACHINE WEIGHT

SHIPPINGWEIGHT

ORBmax 100 - 240 V, 50/60 Hz 882 000 002 4.41 lb (2 kg) 10.53 lb (4.78 kg)

Consumables for ORBmax

All individual parts are already included in the scope of delivery of the ORBmax.

MODEL CODE WEIGHT

Measuring hose set, including: • 1 hose*• 1 filter for protecting the oxygen sensor against soiling• 2 filter inserts• 1 test tip• 1 hose connector

882 050 006 2.9 oz (81 g)

Hose* 882 012 010 1.8 oz (50 g)

Filter 882 020 003 0.7 oz (21 g)

Filter inserts (5 pieces per packing unit) 882 030 002 0.1 oz (3 g)

Test tip 882 012 011 0.1 oz (4 g)

Hose connector 882 012 012 0 oz (1 g)

* Please specify the hose length in meters when ordering.

ORBmax

Practical protective cover included

Measuring hose set (Individual parts)

Orbital Welding



ORBIPURGE forming set

Complete with Teflon gas hose and rapid-action couplings.The ORBIPURGE forming set for tube internal diameters 12 - 110 mm (0.472 in - 4.331 in) includes all accessories for fast and efficient internal forming during orbital welding.

Forming plugs for larger diameters are separately available.

• The various stoppers match the internal diameter of the tube exactly and therefore from a continuous sealing

• The complete set is supplied in a durable plastic carrying case• The scope of delivery includes 2 forming plugs in each size, a Teflon gas hose,

and a set of rapid-action couplings• Particularly suitable where there are very high demands for purity in the forming

atmosphere and is an ideal addition to our digital oxygen analyzer ORBmax (see page 83)

• The included rapid-action couplings allow a simple connection and separation of the gas hose

Inert gas outlets for ORBIPURGE forming plugs:Compatible with all ORBIPURGE forming plugs.

MODEL CODE WEIGHT

ORBIPURGE forming set 881 000 001 6.94 lb (3.15 kg)

Inert gas outlet for ORBIPURGE 3/8 in 881 020 014 1.1 oz (30 g)

Inert gas outlet for ORBIPURGE M5 881 020 015 0.2 oz (5 g)

Forming plugs, set for ID 114 - 130 mm (4.488 in - 5.118 in), 3/8 in 881 050 030



Earth cable

For use in combination with an orbital welding power supply of the ORBIMAT CB- other CA series.

MODEL LENGTH[M]

LENGTH[FT]

CODE WEIGHT

Earth cable for 165 Ampere welding power supplies 5.0 16.4 811 050 004 5.18 lb (2.35 kg)

Earth cable for 300 Ampere welding power supplies 5.0 16.4 811 050 005 5.29 lb (2.4 kg)

Earth cable for 300 CA AVC/OSC welding power supplies 5.0 16.4 812 050 046 6.28 lb (2.85 kg)

OM 165CA Extension and Adapter Cables

Compatible with all Orbitalum orbital weld heads, with the exception of the ORBIWELD TP AVC/OSC heads.

Other lengths on request.

MODEL LENGTH[M]

LENGTH[FT]

CODE WEIGHT

Hose package extension 5 m (16 ft) 5 16 871 050 011 16.76 lb (7.6 kg)




AMI Adapter - Water Cooled Heads 871 030 020

AMI Adapter – Air Cooled Heads 871 030 021

AMI Remote for adapter cable 871 050 036

ORBIPURGE forming set

Inert gas outlets

Earth cable

Hose package extensions

Orbital Welding


Flow regulator

With 2 adjustable flow displays and option to connect welding and forming gas.

Technical data Argonmax. inlet pressure 230 bar / 3.000 psigflow indicator up to 30 L/min /60/160 scfgcylinder connection W21.8x1/14 in /CGA 580hose connection 9 1/4 / 5/8-18

Item Version Code WeightDual flow regulator argon 888 000 001 4.08 lb (1.85 kg)

Inspection set

Optimal tool for visually checking the welding seam, including lighting.Minimum sensor (Length: 110 mm/4.331 in) complete with handle and attachable mirrors Ø 16 mm (0.630 in) and 20 mm (0.630 in).

MODEL CODE Weight

Inspection set 875 030 020 6.7 oz (190 g)

Spare bulb for inspection set 875 030 028 0.1 oz (2 g)

Spare mirror 16 mm (0.63 in) for inspection set 875 030 029 0.4 oz (10 g)

Spare mirror 25 mm (0.98 in) for inspection set 875 030 031 0.4 oz (10 g)

WS2 tungsten electrodes

WS electrodes are used for DC and AC welding and are a completely satisfactoryreplacement for the WT electrodes.

Benefits:• High ignition safety• Low combustion• Long service life• High arc quality

Content: 10 piecesLength: 175 mm (6.890 in)Composition: WS2 = Rare earths (mixed oxides)Color code: Turquoise

MODEL ELECTRODE Ø[MM]

ELECTRODE Ø[INCH]

CODE Weight

WS2 tungsten electrodes 1.0 0.039 826 004 018 6.3 oz (180 g)



Inspection set

WS2 tungsten electrodes

Dual flow regulator


Orbitalum Rentals

87

Orbitalum Rentals

Virtually the entire range of Orbitalum welding system components including the latest Orbimat power supply units, Orbiweld welding heads, Orbitwin switching units and genuine Orbitalum accessories are available as rentals. We supply equipment for both short and long term rentals, a highly cost effective alternative to purchasing in some circumstances.

Factory rentals offer multiple benefits to our users. No more waiting for machines or systems - most of our equipment is available for same day shipping, eliminating the long lead times and vague shipping dates. We have the youngest Orbitalum cutting and welding system rental fleet in the industry. And every machine or welding system we rent is individually checked and configured for your exact application – tell us what you need and we’ll even preprogram your power supply unit. Orbitalum rental equipment ships in durable storage cases to protect them in transit offering you extra peace of mind.

RENTAL BENEFITS

Reduced Storage RequirementsMinimize Repair Expenses

Minimize Down Time No Large Capital Expenditure

Latest Technology

RENTAL SERVICES

Fast Service/ Delivery

Monthly Rental Terms

Rental Buy-Out Options

Renting an Orbitalum welding system gives you complete access to the expert service and technical advice our customers have relied on for over 130 years. It's also an excellent way to “test drive” the system you’re considering prior to purchase. Call us today and we’ll help match the right Orbitalum equipment to your applications and materials for specific projects big or small.


Orbitalum Training

88

Orbitalum Training

Technology Center

Advanced cutting machines and orbital welding systems require skilled operators to operate them. As part of our ongoing commitment to customer support Orbitalum has recently completed a new state of the art Technology Center at E.H. Wachs Lincolnshire, Illinois headquarters. The Technology Center was purpose-built for specialized training on Orbitalum's pipe cutting, weld preparation machine tools and advanced orbital welding systems.

From software to hardware to maintenance, our instructors demonstrate the proper setup, operation and typical applications encountered in the field. Including both welding theory in the classroom and hands-on cutting and welding procedures in the lab, these courses are designed to jump start productivity and realize the full potential of each machine.

Field Training

Orbitalum also offers field training at your location that can be tailored to your specific workforce and projects. Our instructors and field technicians have years of experience in orbital cutting technology and orbital welding systems, with each having received advanced training in operation and maintenance from the factory in Singen, Germany. Training can also be conducted at our Sales, Service & Rental Centers if that is a better alternative.

We'll teach operational techniques and detailed maintenance procedures that ensure a long life from your new Orbitalum equipment. Our goal is for every Orbitalum operator to have a comprehensive understanding of the technology, a detailed knowledge of their machine's capability, and a valuable skill set.

Typical Topics

• GF Saw Tube Cutting; RPG Facing, Intro and Safe Operation • Orbimat 165CA Introduction, Setup and Operating Procedure • Orbital Welding Theory, Software Navigation • Simplified Position-based Weld Program Development • ID Purge Pressure Control through the OM 165CA • Oxygen Monitoring and Datalogging with the ORBmax • Orbitwin Switching Device, Alternate Operation of Two Heads• Testing and Certification by Orbitalum

Classroom training on standard welding procedure

Courses are offered at our Sales, Service, & Rental Centers

Orbitalum Technology Center in Lincolnshire, IL

TRAINING BENEFITS

Orbitalum Factory Instructors

Learn Safe, Proper Operation

Instruction at our Location or Yours

Jump Start Your Productivity

Courses for New Grads & Seasoned Professionals

Factory Certification

Our ITW Partners

When you partner with us you’re not only partnering with the industry leader in portable weld preparation machine tools and orbital welding systems, you’re partnering with ITW, the industry leader in advanced welding technologies.

ITW has a market leading portfolio of best in class brands offering reliable and responsible products for the markets we serve.

When reliability matters... We’re there.

Forging the Tools for Excellence

About Orbitalum

Founded in 1960 as a subsidiary of Georg Fischer (GF) and renamed Orbitalum in 2006, we are the world’s premier manufacturer of high purity tube cutting and pipe preparation machine tools and orbital welding systems.

At Orbitalum we understand the needs of process piping professionals in the aerospace, food, dairy and beverage, pharmaceutical and semiconductor industries. Every machine features robust design and ease of operation, and is constructed with high quality materials and extreme precision. German engineered and built, Orbitalum products exceed the rigorous standards of ISO 9001:2008.

Orbital Cutting

Orbitalum cutting products are the perfect complement to our orbital welding equipment. For over 55 years, first as GF and now as Orbitalum, we’ve remained the industry leader in high quality tube cutting and facing equipment. We manufacture the world’s leading series of tube and pipe saws, the GF and GFX, that utilize an orbital cutting motion around a stationary workpiece.

Extending the GF series, RPG tube squaring machines from Orbitalum are designed to produce perfectly square, burr free preps required for critical, defect free orbital welding applications. Featuring precise micrometer feed, deformation-free quick-clamping systems, and electronic speed regulation and stabilization on electric powered models, these machines produce a perfect weld prep. Also available with convenient cordless drive on select models.

Orbital Welding

The Orbitalum orbital welding system includes Orbimat power supplies, Orbiweld weld heads, the Orbitwin switching unit, and the advanced ORBmax digital oxygen analyzer. At Orbitalum we surpass the best features of other systems, while delivering a unique user experience with our easy to use software and one touch control.

Engineered and built to satisfy today’s welding professional who is looking for the best combination of power, features and convenience, these machines deliver precision welds and are easily transported, programmed, operated, and maintained.

WeldingThe ITW Welding group serves the global welding industry with superior products, and unparalleled service. The group includes leading manufacturers of weld prep machine tools, filler metals, welding machines, induction heating equipment, and welding consumables, components and accessories for a wide variety of applications. ITWWelding.com

Orbitalum Tools and E.H. Wachs are organized together as ITW Orbital Cutting & Welding, to provide our global customers One Source for the finest in pipe & tube cutting, beveling and orbital tube welding products. E.H. Wachs manufactures portable machine tools used in pipe weld preparation, including OD mounted split frames and ID mounted end preps. Orbitalum manufactures high purity cutting products including GF saws, RPG facers and Orbimat power supply and weld heads. ITW-OCW.com

ITW Welding offers a full line of industrial quality welders from Miller Electric Mfg. Co., headquartered in Appleton, Wisconsin. Miller is a leading worldwide manufacturer of Miller arc welding and cutting equipment, delivering ruggedly reliable equipment of the highest quality. The Welding Components group includes Bernard MIG-Guns, Weldcraft TIG-Torches, Tempil temperature markers, and Smith Equipment, combining four well known suppliers for welding accessories. MillerWelds.com

Hobart Brothers based in Troy, Ohio features a full line of filler metals for applications ranging from mild steel and low alloy steel to stainless steel. Available products include stick electrodes, solid wires and flux cored wires in a variety of diameters and packaging. All Hobart brand filler metals feature superior arc performance and selections are available for fast-freezing or self-peeling slag, low hydrogen weld deposits, high deposition rates and efficiencies, and x-ray quality welds. HobartBrothers.com

ITW Welding Cut. Prep. Weld.

E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com E.H. Wachs | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069 | T:+1.847.537.8800 | F:+1.847.520.1147 | [email protected] | ehwachs.com

ITW Orbital Cutting & Welding Europe Headquarters

Orbitalum Tube & Pipe Saw

Orbitalum Orbital Weld Head

ITW Orbital Cutting & Welding U.S. Headquarters


©2016 ORB-001 1016

YouTube.com/ehwachs

TMYou

Contact your local ITW Orbital Cutting & Welding representative for additional information or to request a product demonstration.

Corporate Locations

Sales Locations

UNITED STATESITW-OCW US Headquarters E.H. Wachs® 600 Knightsbridge Parkway Lincolnshire, IL 60069 USA T: +1.847.537.8800 F: +1.847.520.1147 Toll Free: 800.323.8185

Northeast Sales, Service & Rental Center E.H. Wachs 1001 Lower Landing Road, Suite 208 Blackwood, New Jersey 08012 USA T: +1.856.579.8747 F: +1.856.579.8748

Southeast Sales, Service & Rental Center E.H. Wachs 171 Johns Road, Unit A Greer, South Carolina 29560 USA T: +1.910.228.3454 F: +1.847.520.1147

West Coast Sales, Service & Rental Center E.H. Wachs 5130 Fulton Drive, Unit J Fairfield, California 94534 USA T: +1.707.439.3763 F: +1.707.439.3766

Gulf Coast Sales, Service & Rental Center E.H. Wachs 2220 South Philippe Avenue Gonzales, LA 70737 USA T: +1.225.644.7780 F: +1.225.644.7785

Houston South Sales, Service & Rental Center E.H. Wachs 3414 Lilac Unit E Pasadena, Texas 77505 USA T: +1.713.983.0784 F: +1.713.983.0703

UNITED KINGDOMWachs UK® UK Sales, Service & Rental Centre Units 4 & 5 Navigation Park Road One, Winsford Industrial Estate Winsford, Cheshire CW7 3RL United Kingdom T: +44 (0) 1606 861 423 F: +44 (0) 1606 556 364

UNITED ARAB EMIRATESWachs Middle East & Africa Operations® E.H. Wachs PO Box 262543 Jebel Ali Free Zone South Dubai FZS 5, ACO6 United Arab Emirates T: +00 971 4 88 65 211 F: +00 971 4 88 65 212

INDIAWachs India® E.H. Wachs / ITW India Private Limited Orbital Cutting & Welding Division 4A/19, IDA Phase-1 Medak District Telangana 502 319 India T: +91 40 3026 1812 F: +91 40 3048 0815

CHINAWachs China® E.H. Wachs / ITW Welding China New Caohejing International Business Centre B-1501 No. 391 Guiping Road Shanghai 200052 China T: +86 (21) 52303751 F: +86 (21) 52303758

Houston North Sales & Technical Center E.H. Wachs 15331 Vantage Parkway East Houston, Texas 77032 USA T: +1.920.831.4720 F: +1.847.520.1147

GERMANYITW-OCW Europe Headquarters Orbitalum Tools GmbH® E.H. Wachs Sales & Service Center Josef-Schüttler-Straße 17 Singen D78224 Germany T: +49 (0) 77 31 - 792 0 F: +49 (0) 77 31 - 792 500

CANADAWachs Canada Ltd® Eastern Canada Sales, Service & Rental Center 1250 Journey’s End Circle, Unit 5 Newmarket, Ontario L3Y 0B9 Canada T: +1.905.830.8888 F: +1.905.830.6050 Toll Free: 888.785.2000

Wachs Canada Ltd® Western Canada Sales, Service & Rental Center 5411 82 Ave NW Edmonton, Alberta T6B 2J6 Canada T: +1.780.469.6402 F: +1.780.463.0654 Toll Free: 800.661.4235

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