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Orbitalum Tools GmbH An ITW Company

Josef-Schüttler-Str. 17, 78224 Singen
Germany
Telephone +49 7731 792-0
Fax +49 7731 792-524
tools@orbitalum.com

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Hall map

Tube 2022 hall map (Hall 6): stand F19

Fairground map

Tube 2022 fairground map: Hall 6

Our range of products

Product categories

  • 02  Processing machinery for metallic tubes and pipes
  • 02.01  Machinery for mechanical processing
  • 02.01.02  Tube cutting machines
  • 02.01.02.01  Tube sawing machines
  • 03  Tools, auxiliary materials and agents for the manufacturing and processing of metallic tubes and pipes
  • 03.01  Tools
  • 03.01.05  Saw blades

Saw blades

Our products

Product category: Inert gas welding equipment (TIG, ERW, MIG)

Mobile Welder OC Plus

Do you want to produce consistently high-quality welds regardless of your location? With the Mobile Welder OC Plus, you can master any challenge in modern pipeline construction.

The Mobile Welder OC Plus is the first portable orbital welding power source designed specifically for use on the construction site. The Mobile Welder OC Plus brings the usual high and consistent quality of orbital welding to even the most remote locations.

The lightweight and robust design is equipped with state-of-the-art information and communication technology and builds on the strengths of the Orbimat 180SW - our established Smart Welder.

In addition, the Mobile Welder OC Plus impresses with its ease of use and minimal setup and training requirements.

The Mobile Welder OC Plus relies on the same software platform as our OM180SW. This allows for immediate changeover by trained personnel and seamless program exchange between machines.

The Mobile Welder OC Plus is supplied together with the ORBICOOL MW cooling unit, which is connected in just a few steps and can then be used anywhere on a mobile or stationary basis in production.

This flexibility is extended by the integration of a "Manual Welding Mode" in combination with the possibility to operate a hand torch - a power source for all challenges in modern pipeline construction.

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

ORBIMAT 180 SW orbital welding power source

More quality, safety and flexibility in orbital welding thanks to Industry 4.0 technology: This intelligent power source combines the orbital welding process with state-of-the-art information and communication technology and ensures the best welding results, high efficiency and sustainable quality management.

  • Future-oriented connectivity through IoT/Industry 4.0 technology
  • More sustainable quality management through web-based productivity control
  • 100% data storage - seamlessly available at any time and any place
  • Cost-saving through digital and precise "PERMANENT-GAS" welding gas control
  • Shorter welding cycles through unique gas "FLOW-FORCE" function
  • More safety and longer product life due to rotor stop function
  • Intuitive and easy operation via 12.4" color touch display or rotary dial
  • Auto-programming via input of pipe diameter, wall thickness, material and welding gas
  • Integrated liquid cooling for constant low welding head temperatures

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

ORBIWELD closed orbital weld heads

More handy, more economical, more effective - closed TIG orbital welding heads with outstanding features
The ORBIWELD "S" series from Orbitalum impresses with its extremely slim design and high load capacity due to efficient liquid cooling. With its small dimensions, the ORBIWELD "S" series is ideal for applications in confined spaces, such as those often found in the pharmaceutical, chemical, semiconductor, food and aerospace industries

ADDITIONAL FEATURES:

  • Due to the extremely narrow design, parts with short weld-on lengths can also be processed
  • High-quality, robust housing and handle parts
  • High load capacity due to completely liquid-cooled welding head housing
  • Highly flexible hose package (length: 7.5 m/24.6 ft) with strain relief to power source
  • A control panel integrated into the robust and stable aluminum handle of the welding head allows all commands important for welding to be transmitted to the power source, so that no additional remote control is required
  • Quick-change system for clamping inserts enables easy engagement and disengagement without tools
  • Cost effective clamping inserts

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Open orbital welding guns ORBIWELD TP

The ORBIWELD TP series is unique in terms of design and functionality
Tong housing integrated drive motor, an extremely compact design is realized. The drive concept also eliminates the need for the large and complex gearboxes familiar from conventional welding guns. This compact design offers great advantages for mobile construction site applications.

TP Series Features:

  • Compact design without disturbing protrusions
  • Can be used with and without cold wire additive
  • Cold wire unit can be retrofitted to all TP guns
  • Wire reel for holding the filler wire during TIG cold wire welding is mounted on the gun housing in the KD3 variants. This avoids disturbing twisting of the wire during welding
  • Wire feed nozzle can be precisely adjusted vertically and horizontally
  • Open arc system
  • Infinitely adjustable clamping mechanism
  • Liquid-cooled, steplessly swiveling TIG torch head enables welding of fillet welds or short pipe necks
  • TIG torch head is mounted on an adjustment slide, which allows precise fine adjustment of the electrode position even during the welding process
  • Simple, tool-free adjustment of the clamping unit to the pipe diameter
  • TP 1000 guns are equipped as standard with tool steel clamping plates that ensure optimum grip on the pipe surface. Pipe clamping on the ORBIWELD TP 250, TP 400 and TP 600 is done by clamping jaws made of stainless steel (1.4305). In addition to more clamping force, this new clamping system offers even easier and more precise alignment of the welding gun on the pipe. Clamping jaws to extend the clamping range (TP 400) are optionally available. The new clamping unit can be retrofitted to older TP 250, TP 400 and TP 600 models
  • TP collets are easy to center on the pipe and are clamped by means of clamping levers
  • No additional remote control is required due to the operating buttons integrated directly into the clamp housing

Additional TP AVC/OSC features:

  • With oscillation (OSC) and arc distance control (AVC) - only in conjunction with the ORBIMAT 300 CA AVC/OSC welding power source
  • Arc length is mechanically maintained at a constant distance; with AVC/OSC-
  • Versions, the constant distance is maintained automatically
  • Can be used for thick-walled pipes (multilayer welding)
  • Motor-driven movement of the TIG torch over the entire nominal diameter range, so that no additional basic mechanical pre-setting is required when the pipe diameter changes
  • Max. Torch pendulum travel: 20 mm (0.787")
  • Complete with cold wire feeder unit mounted directly on the welding head with holder for a D 100 mm/1 kg (3.937"/2.2 lbs) standard coil

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Product category: Tube sawing machines

Pipe Cutting and Beveling Machines GF/RA

The pipe saw for precise cutting in seconds. For over 40 years, plant builders have relied on the standard in industrial pipe end preparation shaped by Orbitalum: from the chemical, biotechnology, pharmaceutical, food and beverage industries to energy plant construction and shipbuilding.

The basic prerequisites for productive, high-quality welding of pipes with automated orbital joining technology are precise, right-angled and burr-free cutting and perfect chamfering of the pipe end. Easy to handle and cutting in seconds, the GF series processes pipe materials made of high-alloy steel (stainless steel), low-alloy and unalloyed steel, cast materials, plastics and non-ferrous metals using the "planetary cutting" method. The powerful clamping takes place without any deformation of the workpiece. Optionally, in addition to pure manual operation, the user can choose between manual (MVM) and automatic (AVM) feed modules. The latter optimizes the cutting result, increases the service life of the tool, and reduces the physical strain on the operator. The result: maximum safety and productivity.

  • Right-angled, burr-free and cold machining process
  • Deformation-free clamping system for thin- and thick-walled tubes
  • Optimal preparation for the automated welding process
  • Robust design with powerful drive
  • Unique, automatically guided plunging process
  • Chamfering of tube ends parallel or separately to the cutting process
  • High efficiency, increased productivity
  • Long tool life
  • Anthracite-colored, coated components offer better sliding properties and corrosion protection

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Product category: Tube sawing machines

Pipe Cutting and Beveling Machines GFX

Innovative saws from Orbitalum Tools for cutting and chamfering pipes and for cutting out pipe bends (also from thin-walled stainless steel) in seconds. The optimal preparation for the automated welding process! The GFX is an easy-to-operate, powerful and compact saw with low weight - convince yourself of the many outstanding features of this machine.

Our GFX series is ideal for cutting thin-walled tubes. The saws are particularly economical due to their robust design for a long service life; high tool life also increases productivity.
The GFX is very low-maintenance and service-friendly and offers a wide range of applications. Machinable materials include non-alloy, low-alloy and high-alloy steel, stainless steel, non-ferrous metal, aluminum alloys and titanium alloys.

Now characteristic of ORBITALUM pipe saws, the cutting point on the pipe can be conveniently marked by line laser. A second saw blade clamping point enables the cutting of pipe bends.

The powerful motor is equipped with overload protection and ergonomic handles and is available in 230 V, 50/60 Hz or 120 V, 50/60 Hz. The cable plug connection with quick-connect coupling makes it easy and convenient to replace the flexible rotating cable

Applications are mainly in the food, beverage, pharmaceutical, and chemical industries.

  • Right-angled, burr-free and cold machining process
  • Deformation-free clamping, even with thin-walled tubes
  • Good handling due to low weight
  • Chamfering of tube ends parallel or separately to the cutting process
  • Increased productivity
  • Low maintenance and easy to service
  • Environmentally friendly and long service life
  • Additional saw blade holder for cutting out pipe bends
  • Ideal for pressfitting applications

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Product category: Tube sawing machines

Portable Pipe Saw PS 4.5 Plus

The "Plus" in the name says it all! With the PS 4.5 Plus, Orbitalum Tools presents the redesign of the already conceptually flexible, lightweight pipe saw for burr-free cutting of pipes and pipe bends, focusing on even higher quality and even longer service life thanks to more robust sliding elements. At the same time, especially the hassle-free and simple operability, in addition to the unbeatable price, continue to be in the foreground among users

The most important advantages:

  • Sophisticated technology with new design
  • The lightest machine on the market in this application area
  • Integrated line laser for marking cut-off points
  • Infeed and sawing in one operation
  • Aluminum equipment stand (optionally available) - now space-saving storage in the PS transport box possible
  • Deformation-free clamping of thin-walled tubes
  • For cutting thin-walled tubes and for cutting off tube bends
  • Rework-free due to burr-free and right-angled cut
  • Corrosion prevention due to cold machining process

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Closed orbital weld heads HX

Weld stainless steel tubes economically and to a high quality using the TIG process
The worldwide unique HX orbital welding heads with their automated welding technology are THE solution for efficient as well as high-quality production. Pre-assembled pipe bends, such as those used in heat exchanger construction, even in tight tube bundles, can be joined reliably, quickly and safely with stainless steel tubes

The series includes the HX 12P and HX 25P as well as the HX 16P

All commercially available closed orbital welding heads or open welding guns are unsuitable for positioning between the individual tubes of finned heat exchangers due to their size

The HX series scores several points in terms of economy and efficiency compared with conventional machines: The tube ends of the heat exchanger can be completely fitted with bends before welding and welded in any sequence. For conventional orbital tongs, the principle of bend insertion - welding - bend insertion -... applies, always starting from the tube sheet center outward. If the quality inspection subsequently detects a faulty weld, all elbows must be cut off and new ones welded because of the accessibility in the worst case (fault in the middle of the bundle). With the HX head, it is sufficient to replace the affected arc. This design-related advantage also makes the Orbitalum system the ideal tool for unbeatably cost-effective repairs

In contrast to open guns, which also have an unwieldy hose package, all connections for power, gas and cooling water are permanently integrated in the HX.

All orbital welding power sources from Orbitalum automatically recognize the head with its characteristics, so that the operator only has to call up his predefined welding program and start the process before welding begins.

Traditionally, the complex heat exchangers for cooling systems were made of copper - and soldered to the pipe bends. The high price of copper prompted manufacturers to switch their production to stainless steel. Stainless steel can only be welded economically, reliably and to a high quality using the tungsten inert gas (TIG) process in conjunction with mechanized orbital welding.

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Pipe welding heads P16, P16 AVC, P20

Easy handling with high efficiency and functionality characterize the Orbitalum P series: With maximum precision, these TIG pipe-in-bottom welding heads produce several thousand weld seams with consistent seam quality.

With these TIG tube-in-bottom welding heads, welding tubes into tube sheets with maximum precision and consistent quality is no problem

P-Series liquid cooling leads right up to the TIG torch head, ensuring precise operation and consistent quality of the welding process, as well as extending the duty cycle. The torch head can be continuously tilted up to 30 degrees - this feature is valuable, for example, on pipes entering tube sheets at an angle and in confined spaces



ADDITIONAL FEATURES:

  • Completely liquid-cooled welding head housing (P16/P16 AVC only)
  • Torch head continuously tiltable up to 30° (reduced diameter range)
  • Weld geometries: Recessed, flush and protruding tubes
  • Power transmission: Lamella coupling
  • Gas-water transmission: Rotary coupling
  • Stainless steel three-point support
  • Manual electrode position adjustment:
  • Stroke +/- 5 mm
  • Special torches adaptable, e.g. boxheader (only P16, P16 AVC), internal torch (with/without cold wire)
  • Positioning in the pipe to be welded by centering cartridge, which is plugged onto a locating mandrel (optionally available)
  • Welding heads with cold wire unit are additionally equipped with a cold wire feeder mounted directly on the welding head including a fixture for a D 100 mm/1 kg (3.937"/2.2 lbs) standard wire spool
  • Wire feeder running on the rotary axis of the TIG torch to prevent spin of the filler wire as it exits the wire nozzle (P16/P16 AVC only)
  • Three-point support included
  • Includes 7.5 m (24.6 ft) hose package and tool set

Additional features P16 AVC:

  • With electric arc distance control (AVC) - can only be used in combination with ORBIMAT 300 CA AVC/OSC welding power source

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

ORBmax residual oxygen meter

The ORBmax residual oxygen meter sets a milestone for the fast and exact detection of residual oxygen and thus for the complete documentation of this parameter; at the same time, the new measuring method leads to more economic efficiency and higher quality.

The "optical oxygen measurement via fluorescence quenching" method is superior to conventional methods with zirconium sensors in several ways: it requires no warm-up time; it detects the oxygen content in the gas reliably, quickly and accurately during the entire welding process; uncontrolled supposed increases in the measured value due to ozone formation are ruled out; measurement is possible in all gas mixtures without manual switching (even with forming gas with variable hydrogen content)

The exact and fast detection of the oxygen content reduces the otherwise usual long flooding time of the forming gas. The operator can start the safe welding process much earlier: this saves valuable working time and reduces gas consumption. Moreover, ORBmax does not require any maintenance: annual calibration once a year in accordance with the ISO 9001 standard is perfectly sufficient.
For the welding of pipes in plant and equipment construction for the food, beverage, cosmetics and pharmaceutical industries, medical and biotechnology, and fine chemicals, seamless quality assurance is required, which often stipulates a procedure qualification test for weld seams: As proof of quality, residual oxygen values can be documented with the ORBmax in addition to the values from the current source

Used as a stand-alone solution, ORBmax writes a digital log with time stamp. Used in conjunction with the ORBIMAT welding power source, the welding process can be monitored in real time and automatically shut down in the event of increased oxygen levels.

  • No warm-up time required
  • Fast response times
  • High measuring accuracy
  • Measurement of the residual oxygen value during the welding process
  • No uncontrolled increase in measured value during the welding process
  • Measurement of forming gas with variable hydrogen content without changeover
  • Measurement of the residual oxygen value in all gas mixtures
  • SD card storage of the measured value
  • User-friendly touch screen
  • Moisture resistant sensor
  • Alarm mode with signal tone (beeper) as well as color change of the display (green/red)
  • Protection class IP32
  • Adjustable alarm or limit value and storage interval
  • Multirange power supply
  • Software for data evaluation
  • Possibility of connection to ORBIMAT orbital welding power sources
  • Maintenance-free sensor
  • Attractive and compact design

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Orbital welding power supply ORBIMAT 180 SW

More quality, safety and flexibility in orbital welding by Industry 4.0 technology: This intelligent power supply connects the orbital welding process with state-of-the-art information and communication technology, and makes for the best welding results, high efficiency and sustainable quality management.

  • Future-oriented connectivity by IoT/Industry 4.0 technology
  • Sustainable quality management through web-based productivity monitoring
  • 100% data recording – data available anywhere at anytime
  • Cost saving by precise and digital "PERMANENT GAS" control
  • Short welding cycles through unique gas "FLOW FORCE" function
  • Increased safety and extended product lifetime through rotor torque control
  • Intuitive and simple operation via 12.4" color touch display or rotary actuator
  • Automatic programming by entering the tube diameter, wall thickness, material and welding gas
  • Integrated liquid cooling system for constant low weld head temperatures

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Enclosed orbital weld heads ORBIWELD

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 durability by its efficient integrated liquid cooling system.

  • 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 liquid-­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
  • Quick change system for clamping inserts that engages and relelases smoothly without any tools
  • Cost-effective clamping inserts

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Open orbital weld heads ORBIWELD TP

The ORBIWELD TP series offers outstanding features in terms of design and functionality:
An extremely compact design has been achieved thanks to the drive motor that is fully integrated into the housing. The drive concept has made the well-known large and costly drives associated with conventional weld heads unnecessary. For field applications the compact wire feeder on the weld head is more comfortable than a separate, heavy wire feeder.

Features of the TP series:

  • Compact design without any protrusions that would be disturbing in practice
  • Applicable with and without cold wire unit
  • Cold wire unit retrofittable for all TP weld heads
  • With the KD3 versions, the reel for holding the additional wire during TIG cold wire welding is also mounted on the weld head housing. This prevents an irritating twisting of the wire during the joining process
  • The cold wire feed nozzle can be adjusted exactly in both a vertical and horizontal direction
  • Open arc system
  • Infinitely variable clamping mechanism
  • Liquid-cooled, continuously adjustable TIG torch head allows fillet welds or short hollowed out tubes to be welded
  • The TIG torch head is secured to a slide unit that allows the position of the electrodes to be finely adjusted with great accuracy even during welding
  • Simple adjustment of the clamping unit to the pipe diameter without the need for any tools
  • The standard equipment of the TP 1000 heads include clamping plates made from tool steel which ensures optimum retention to the pipe surface. The ORBIWELD TP 250, TP 400 and TP 600 are equipped with clamping jaws made of stainless steel (1.4305). Besides increased clamping force, this new clamping system offers improved handling and easier and more precise alignment of the weld head on the pipe. Clamping jaws to extend the clamping range (TP 400) are optionally availabe. The new clamping unit can be upgraded for older TP 250, TP 400 and TP 600 models.
  • TP weld heads are easily centered to the tube and clamped in place with the help of a clamping lever
  • No additional remote control is required thanks to the keys integrated directly into the weld head housing

Additional Features of the TP AVC/OSC:

  • With oscillation (OSC) and arc voltage control (AVC) – only applicable in combination with the orbital welding power supply ORBIMAT 300 CA AVC/OSC
  • The arc length is kept at a constant gap mechanically; with AVC/OSC versions the constant gap is kept automatically
  • Can be used for thick wall pipes (multiple layer welds)
  • Including a motorized travel option for the TIG torch across the nominal diameter, so that no additional mechanical basic presetting is required for any change in the tube diameter
  • Max. oscillation of the torch: 20 mm (0.787")
  • Directly on the weld head mounted cold wire feed unit with retainer for Ø 100 mm/1 kg (3.937"/2.2 lbs) wire coil

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Product category: Tube sawing machines

Pipe cutting and beveling machines GF/RA

This saw has been designed for precise cutting of tubes and pipes in just seconds.
For more than 40 years construction companies rely 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.

  • 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 seperate cutting and beveling
  • Cost-effective, increasing productivity
  • Long tool life
The basic requirement for the productive and high-quality welding of pipes with automated welding technology is a precise, right-angled and burrfree cut as well as a perfectly beveled pipe end. The GF series cuts and bevels high-alloy steel (stainless steel), low- and unalloyed steel, plastics, casting materials and non-ferrous metals easily and in just seconds, using the "Planetary Cutting" method. The powerful clamping is effected without any deformation of the workpiece.

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.

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Product category: Tube sawing machines

Pipe cutting and beveling machines GFX

Innovative saws from Orbitalum Tools for cutting and beveling of tubes and for cutting off 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.

Our GFX series is the ideal solution for cutting of thin-walled tubes. The rugged design for a long product life makes the saws especially economical. Furthermore, the long tool lives thereby increase the productivity.

The GFX series is extremely low-maintenance and service-friendly and offers a large range of applications. Materials which can be processed are unalloyed, low-alloy and high-alloy steels, stainless steels, non-ferrous metals, aluminum alloys, titanium alloys, composite materials and plastics.

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 line laser. A second saw blade clamping point enables tube elbows to be cut off.
The cable connection with a quick-release screw coupler enables simple, convenient replacement of the flexible swivel cable.

The applications lie mainly in the food processing, beverage, pharmaceutical and chemical industries.

  • Square, burr-free and cold machining process
  • Deformation-free clamping system especially applicable for thin-walled tubes
  • Easy handling through light weight
  • Simultaneous or seperate cutting and beveling
  • Increased productivity
  • Low-maintenance and service friendly
  • Environmental friendly; long tool life
  • Second saw blade position to cut off elbows
  • Ideal for pressfitting applications

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Product category: Tube sawing machines

Portable tube saws PS 4.5 Plus

A mobile, powerful and flexible tube cutting machine for use on construction sites, that’s what the PS saw from Orbitalum Tools stands for. This tube saw convinces not only with it's burr-free, right-angled and deformation-free cutting results, but also with its low weight.  At the same time its problem-free and simple usage as well as its unbeatable price are the prime factors among it users.

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) is 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 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 handlesand is available for the voltages 230 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.

  • Refined technology — simple and convenient to use
  • The lightest machine in this field of application on the market
  • Integrated line laser to determine the cut off point
  • Feeding and sawing in a single pass
  • High quality and long service life through rugged sliding elements
  • 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

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Enclosed orbital weld heads HX

Welding stainless-steel pipes economically and with high quality using the TIG welding procedure:
Unique in the entire world, HX orbital weld heads are the best solution for efficient, high-quality production thanks to their automated welding technology. Pre-mounted pipe elbows (for example in heat exchanger construction), even those in tight pipe bundles, can be joined to to small stainless-steel pipes reliably, quickly and safely.

Due to their compact size, all fully closed or open orbital weld heads commonly available on the market are not suitable for being positioned between the individual pipes of finned heat exchangers.

The HX series scores points in the areas of economy and efficiency when compared to conventional weld heads: The pipe ends of a heat exchanger can be fully fitted with elbows before joining and then welded in any order. For conventional orbital weld heads, the principle of fit elbow, weld, fit elbow, weld etc. applies, always starting from the center of the pipe sheet and working outward. If quality testing reveals a faulty weld later on, all elbows must be disconnected and new ones must be welded on in the worst case scenario (fault in the middle of the bundle) due to the accessibility factor. With the HX head, only the affected elbow would have to be replaced. This design-based advantage also makes the Orbitalum system the ideal tool for unbeatably cost-effective repairs.

In contrast to open weld heads with a cumbersome hose assembly, all connections for power, gas and cooling liquid are permanently integrated in the HX.

All orbital welding power sources 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 prompted manufacturers to switch over to stainless steel for production. Stainless steel can only be joined economically, reliably and in high quality with tungsten inert gas (TIG) welding in conjunction with mechanized orbital welding.

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Tube-to-tube-sheet orbital weld heads P16, P16 AVC, P20

Our P series is characterized by special design features intended to ensure easy handling combined with a high level of economy and functionality. With extreme precision, these tube-to-tube-sheet orbital weld heads will produce several thousand weld seams at constant quality.

With this TIG weld heads, it is no longer a problem to weld tubes to tubesheets with the highest of accuracy and consistent quality. Its liquid 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.

FEATURES:

  • Completely liquid-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/liquid transmission via rotating cloupling
  • Three-point mounting made of stainless steel
  • Manually electrode positioning
  • Stroke +/- 5 mm
  • Special burner heads adaptable, e.g. for box­header 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"/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

Additional 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

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Product category: Inert gas welding equipment (TIG, ERW, MIG)

Residual oxygen meter ORBmax

This ORBmax residual oxygen meter sets a milestone for fast, exact detection of residual oxygen, and with it complete documentation of these parameters. At the same time, the new measuring method results in greater efficiency and higher quality.

The "Optical oxygen measurement via fluorescence extinction" method for welding technology is far superior to the conventional methods, using zirconium sensors: It requires no warm-up time whatsoever; reliably, quickly and precisely detects the oxygen share in the gas; unchecked alleged increasing of the measured value due to the formation of ozone 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 otherwise long flooding time of the forming gas. The operator can start the safe welding process considerably earlier. As a result, precious working 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 bio-technology 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. When used as a stand-alone solution, ORBmax records a digital log with a time stamp. In conjunction with the ORBIMAT welding power source, the welding process can be monitored in real-time and automatically switched off when increased oxygen content occurs.

  • No warm-up time required
  • Quick response
  • High measurement accuracy
  • Measurement of residual oxygen level during the welding process
  • No uncontrolled increase of the measurement during the welding process
  • Measurement of forming gas with variable hydrogen content without mode change
  • Measurement of the residual oxygen value in all gas mixtures
  • Measured value recording on SD card
  • User-friendly touchscreen
  • Liquid-resistant sensor
  • Alarm mode with beeper and changing colour of the display (green/red)
  • Protection class IP32
  • Setable alarm value and saving interval
  • Multirange power supply
  • Software to evaluate data
  • Can be connected with an ORBIMAT Orbital Welding Power Source
  • Maintenance-free sensor
  • Pleasant and handy design
  • Transportation case with IP67 protection

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Company news

Date

Topic

01 Jun 2022

The new Mobile Welder OC Plus

May we introduce the new Mobile Welder OC Plus!

Do you want to produce consistently high-quality weld seams regardless of where you are working? Then the Mobile Welder OC Plus is just right for you. Our product manager Christoph Dämmig will answer all your important questions about the new power source.

  • How did you come up with the idea of developing the Mobile Welder OC Plus?
    The idea for the Mobile Welder OC Plus came about during our visits to customers. Our customers' welding jobs are varied and range from prefabrication at a fixed workstation to installation work in plants and on construction sites. The orbital power source has to meet different requirements here. With our proven orbital welding power source Orbimat 180 SW and the newly developed Mobile Welder OC Plus, we offer our customers an optimal choice. The Orbimat 180 SW convinces with its clarity and user-friendliness and covers all requirements in prefabrication. The Mobile Welder OC Plus, on the other hand, is perfect for mobile use and thus suitable for installation work.
  • What is the Mobile Welder OC Plus?
    The Mobile Welder OC Plus is our first portable orbital welding power source designed specifically for tube installations. With the new power source, it is now possible to bring the consistently high quality of orbital welding to hard-to-reach work areas. The Mobile Welder OC Plus is based on the strengths of the Orbimat 180 SW and is therefore perfectly suited to any challenge in modern tube construction.
  • What are the advantages of the new power source?
    A major advantage of the Mobile Welder OC Plus is its compact and lightweight design. We have succeeded in keeping the use of materials as low as possible while at the same time equipping the power source with the latest information and communication technology. The Mobile Welder OC Plus can be transported with just one hand and is thus equipped for any task and any location. In addition, it impresses with its simple and intuitive operation as well as low familiarisation and training requirements. So that our customers can also connect a TIG manual torch to the power source, we have integrated a manual welding mode into the software. This allows the customer to switch between manual and orbital welding mode depending on their requirements. Ultimately, with the Mobile Welder OC Plus, the customer gets an all-rounder that is flexible and versatile in use.
  • Where can the Mobile Welder OC Plus be used?
    The power source can be used anywhere in tube construction where tubes are welded. This applies above all to process plant construction in the semiconductor, food and pharmaceutical industries.
  • What are the main differences between the Mobile Welder OC Plus and the Smart Welder OM 180 SW?
    The Orbimat 180 SW is a machine that is mainly used for stationary prefabrication work in production. The power source has a large, clear display and enables simple and intuitive operation. The Mobile Welder OC Plus, on the other hand, has a robust, compact and, above all, lightweight design. As a portable power source, the Mobile Welder OC Plus can be used both stationary and mobile. In addition, it is possible to connect a TIG manual torch to the Mobile Welder OC Plus, allowing even greater flexibility in use. 
  • Why is there a manual welding mode?
    The manual welding mode is a software user interface specifically designed to meet the needs of manual welding. Here, the customer can enter his manual welding parameters and monitor the welding process on the basis of the displayed welding ramp. The integration of the manual welding mode offers customers the possibility to carry out tacking work at any time for a good preparation of the pipes. Likewise, manual pipe joints can be welded in places that are inaccessible with the orbital welding head. It is possible to switch flexibly between orbital and manual welding modes. At the same time, the amount of equipment required on site is significantly reduced. Manual and orbital welding with one device - only the Mobile Welder combines this.
  • Which welding heads can be connected? All welding heads from Orbitalum can be connected to the Mobile Welder OC Plus - regardless of whether they are gas-cooled or liquid-cooled.
  • How is the interface operated?
    The Mobile Welder OC Plus is operated intuitively and can be used in three different ways. There is a touch display, a rotary control with several softkeys and the option of connecting an external keyboard. The graphical user interface is designed in the same way as our tried-and-tested Orbimat 180 SW, and all welding programmes are also interchangeable between power sources.
  • Is the Mobile Welder OC Plus really portable?
    Yes, the Mobile Welder OC Plus is truly portable and can even be carried with one hand. We have attached a carrying handle and a shoulder strap for this purpose. The Mobile Welder OC Plus weighs approximately 21 kg including the cooling unit.
  • What is included in the delivery?
    The delivery includes a Mobile Welder, the ORBICOOL MW cooling unit, a hose set and coolant.
  • What services can customers expect from Orbitalum Tools?
    We offer our customers a comprehensive service - starting with advice, through the commissioning of our products, to our technical support. For us, the needs of our customers are the focus and it is important to us to provide reliable and quick support when questions arise.
Have we aroused your interest? Would you like more information about the Mobile Welder OC Plus? Please feel free to contact us!

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About us

Company portrait

For the finest in pipe & tube cutting, beveling and orbital welding products.

For more than 50 years construction companies rely on the standard in the ­industrial prefabrication of pipeline systems set by the market leader Orbitalum.

Orbitalum Tools based in Singen, Germany and E.H. Wachs based in Lincolnshire, ­Illinois, USA are operating jointly as ITW Orbital Cutting & Welding, a division of the US industrial group ITW.

Orbitalum Tools is a global leader in providing complete solutions for the industrial prefabrication, installation and maintenance of pipeline systems – for everything from cutting pipes and preparing weld seams to orbital welding for process and plant engineering.

With its high-quality, nearly indestructible, portable and user-friendly pipe processing machines for cutting and beveling, E.H. Wachs has established itself in many industries. For example, in the oil and gas industry, the chemical industry and in pipeline and ship construction – in the preproduction, maintenance, repair and dismantling of installations.

ITW (Illinois Tool Works, www.itw.com) is a US Fortune 200 global industrial manufacturer of consumables, specialty equipment and related service businesses headquartered in Glenview, Illinois. ITW Orbital Cutting & Welding is part of the ITW Welding Group, which is world market leader in welding products (e.g. MILLER ELECTRIC, HOBART BROTHERS).

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.


The ITW Orbital Cutting & Welding group stands for the best, most efficient technology for all aspects of orbital cutting and welding around the globe.

As ITW OCW we provide an almost unique product availability, a worldwide ­customer service and technical support as well as a sales network at local level.
A partnership with ITW OCW involves:

  • Acclaimed state-of-the-art technology, competent contact partners
  • Fast, comprehensive delivery service
  • Reliable product support
  • Large stocks at local level
  • Comprehensive OEM spare parts and consumables
  • Strategically ideal located sales locations, service and rental centers
  • Excellently factory-trained and certified technicians
  • Practical trainings – at our site or at your location
  • Certified company

ITW Orbital Cutting & Welding continues the Orbitalum and E.H. WACHS tradition of offering world class products, combined with exceptional service and support, to keep ITW-OCW the supplier of choice for tools used to cut - prep - weld - all from one source.