Made in Germany. orbital welding ORBITAL WELDING. DIN EN ISO 9001 certified. 32 Years

Transcription

1 Made in Germany orbital welding ORBITAL WELDING DIN EN ISO 9001 certified 32 Years CATALOGUE APRIL 2016

2 TABLE OF CONTENTS COMPANY INTRODUCTION TO ORBITAL WELDING PRODUCTS ORBITAL WELDING CONTROLLERS INVERTERS 10 WATER COOLING UNIT 11 ACCESSORIES FOR STANDARD EQUIPMENT 12 ENCLOSED WELD HEADS AND ACCESSORIES 14 OPEN-FRAME WELD HEADS AND ACCESSORIES 19 TURN TABLE SYSTEM WIRE FEED UNITS TUBE-TO-TUBE-SHEET WELD HEADS AND ACCESSORIES COMPATIBLE WITH COMPETITOR POWER SUPPLIES 27 TUNGSTENS / CHART FOR TUNGSTEN LENGTHS 28 TORCH CONSUMABLES 29 MOBILE WORKSTATION AND ACCESSORIES 30 ORBITAL CUTTING SAW AND ACCESSORIES 33 TUBE SQUARING SYSTEMS AND AND ACCESSORIES 35 PURGING, OXYGEN ANALYSERS, PURGING ACCESSORIES 39 SERVICES 45 RENTAL SERVICE, REPAIR SERVICE, FINANCING 45 TRAINING 46 SPECIAL OFFER 47 REPLACEMENT 47 ADAPTION AND SERVICE AMI 48 APPENDICES 49 GENERAL WARRANTY TERMS AND GENERAL TERMS AND CONDITIONS OF HIRE GENERAL TERMS AND CONDITIONS CHARTS FOR STANDARD TUBE OUTSIDE DIAMETERS 51 2 Copyright 2016 Orbitec. All rights are reserved.we reserve the right to make technical changes.

3 COMPANY Orbitec was founded in Orbitec designs, develops and manufactures orbital welding equipment for domestic hire and sales worldwide. Orbitec aims to provide high-quality and easy-to-use products at a reasonable price. Orbitec supplies products and services to industries such as: Pharmaceutical, Biotechnology, Semiconductor, Food & Dairy and Aerospace. 32 Years A5 A3 30 KM SELIGENSTADT A5 AIRPORT FRANKFURT GERMANY Headquarter Seligenstadt / Germany APPLICATION COMPETENCE Especially customers new to buying an Orbital welding system will be initially confronted by a wealth of pertinent questions and problems. It s not all simply done by the press of a button! There are a whole host of conditions that need to be in place if orbital welding technology is to be used economically. In this respect, Orbitec can provide you with application competence and customer proximity. The quickest reaction times and high availability of products of course go without saying. 3

4 INTRODUCTION TO ORBITAL WELDING Orbital welding is a mechanised version of the tungsten inert gas arc welding (TIG) process and is used to weld stationary tube or pipe; the tungsten electrode contained in the weld head rotor rotates or orbits around the weld joint circumference. The TIG process can be either a fusion (autogenous) process in which the edges of the weld joint are heated by the arc and fused together without the addition of filler material to the weld pool. Or filler, usually in the form of a solid wire can be added. EXAMPLE: OPEN-FRAME OSW WELD HEAD 4

5 PRODUCTS INNOVATIVE, PRACTICAL AND AFFORDABLE! Orbitec s equipment technology is focused on the particular practical needs of its customers, whether they specialise in tube and pipe fabrication or you have a one-off requirement to join tubular components. Key factors on our list of design considerations are safe and easy to use, modular where possible, with a form and construction that reduces manufacturing costs to a minimum. Because of this philosophy Orbitec has been able to offer practical, robust and easy to use products at price levels not previously available to the Orbital market. To fulfil all customer requests the current controller TIGTRONIC ORBITAL 4 in conjunction with the TETRIX 200 inverter is now also available as a compact system TIGTRONIC COMPACT. In 1996 Orbitec developed its forward-looking operator guidance which uses symbols and has programming aids in all requested national languages: Enter tube outside diameter Enter wall thickness Enter weld head code Start IT COULD NOT BE SIMPLER! Our range of OSK weld heads are unique in design the cable and handle /motor assembly is separate from the weld head itself, so one handle assembly can run a variety of different sized weld heads. This concept provides significant cost savings on multiple weld head systems and unmatched flexibility using the same weld heads on different manufacturers power supplies. Other products such as oxygen analysers, which are often considered peripheral to the orbital process, but nevertheless key to ist successful application, compliment the comprehensive product range available from Orbitec. EXAMPLE: ENCLOSED WELD HEADS WITH HANDLE AND CABLE ASSEMBLY 5

6 //ORBITAL WELDING CONTROLLERS / INVERTERS 6

7 ORBITAL WELDING CONTROLLERS TIGTRONIC BASIC CONTROLLERS B A S I C BASIC 2: OSK OSW TURN RBK (AVC) BASIC 3: OSK OSW TURN ORBIFEED RBK (AVC) TIGTRONIC BASIC 2 CONTROLLER Low-cost, compact microprocessor-based Orbital controller for applications with open- frame weld heads, enclosed weld heads, tube- to-tubesheet weld heads and turn tables. The controller is based on our tried-and-tested and reliable TIGTRONIC ORBITAL controller. Can be used with TETRIX 200 or TETRIX display, fixed Simple, multilingual operator guidance through auto programming of weld schedule parameters: tube outside diameter, wall thickness and weld head code Gas and water cooling monitoring Options for 6 level programming with continuous and step travel modes Simple tuning of auto calculated parameters by individual level or overall percentage Graphic display of the welding progress Real-time monitoring of the welding parameters Integrated weld counter (assignment to isometrics and weld numbers) Storage of up to 99 programmes Weld data recording facility for up to 400 weld records Software updates possible Diagnostic fault detection system Options for connecting a remote control pendant (Note: The controller can also be operated without a remote pendant) Connections for oxygen analysers Data transfer of setpoint /actual parameter, as well as programmes via USB interface Compact and lightweight with outer dimensions (L x W x H) 340 x 295 x 150mm and a weight of only 5.5kg Auto ranging input voltage VAC Optional: COOL 50 water cooling unit Upgrade kit AVC TIGTRONIC BASIC 3 CONTROLLER Specifications as per BASIC 2 Additional servo PCB for wire feed TIGTRONIC BASIC 4 CONTROLLER Specifications as per BASIC 3 With special software only for tube-to-tube-sheet weld heads RBK BASIC 4: RBK (AVC) Package includes for BASIC 2/3/4: Controller Power cable Interface cable for controller / power source USB stick, 1GB 7

8 ORBITAL WELDING CONTROLLERS TIGTRONIC ORBITAL 4, TIGTRONIC COMPACT 4 The Reliable OSK OSW TURN ORBIFEED RBK (AVC) TIGTRONIC ORBITAL 4 CONTROLLER The 4th generation of our tried-and-tested and reliable standard controller. Can be used with TETRIX 200 or TETRIX display, collapsible Simple, multilingual operator guidance through auto programming of weld schedule parameters: tube outside diameter, wall thickness and weld head code Gas and water cooling monitoring Tacking mode can be activated Options for 6 level programming with continuous and step travel modes Simple tuning of auto calculated parameters by individual level or overall percentage The output and wire feed parameters can also be changed during welding Graphic display of the welding progress Real-time monitoring of the welding parameters Integrated weld counter (assignment to isometrics and weld numbers) Storage of up to 99 programmes Storage of up to 400 actual parameters Data transfer of weld parameters and programmes via USB interface Software updates possible Diagnostic fault detection system Options for connecting a remote control pendant (Note: The controller can also be operated without a remote pendant) Connection for oxygen analysers Servo PCB for wire feed Integrated printer Compact and lightweight with outer dimensions (L x W x H) 405 x 325 x 170mm and a weight of only 6.5kg Auto ranging input voltage VAC Optional: COOL 50 water cooling unit AVC upgrade kit Package includes: Controller Power cable Connection cable controller / power source USB stick, 1GB COMPACT SYSTEM TIGTRONIC COMPACT (AUTO RANGE) Portable compact system, based on the inverter TETRIX 200 auto range with integrated Controller TIGTRONIC ORBITAL 4. Dimensions (L x W x H) 624 x 298 x 480mm Weight 24kg Technical date: as inverter TETRIX OSK OSW TURN ORBIFEED RBK (AVC) Package includes: Compact system Power cable USB stick, 1GB Optional: COOL 50 water cooling unit, flange connected Upgrade kit AVC AVC UPGRADE KIT FOR TIGTRONIC CONTROLLERS Additional integrated AVC card incl. software upgrade for welding in conjunction with wire feed and AVC

9 ORBITAL WELDING CONTROLLERS ACCESSORIES DOCUTRONIC 2.1 SOFTWARE FOR DOCUMENTATION For all Tigtronic controllers for back-up, administration and processing of the welding joint documentation (setpoint / actual parameter) at the PC in English and German REMOTE CONTROL ORBICONTROL 3 8m cable remote control for all orbital controllers Start, downslope and termination of weld sequence Travel jog buttons Wire feed jog buttons AVC jog buttons Visual status display SPARE-PAPER ROLL FOR INTEGRATED PRINTER Contains 3 Paper Rolls SPARE-RIBBON CARTRIDGE FOR INTEGRATED PRINTER Ribbon Cartridge for TIGTRONIC ORBITAL 4 + COMPACT

10 INVERTER TETRIX 200, TETRIX 351 INVERTER TETRIX 200, control range 5 200A / 230V Lightweight, compact inverter power source for the TIG manual or orbital welding (automatic detection) in conjunction with all Orbitec controllers Optional: COOL 50 water cooling unit. Technical Data: Output DC Mains voltage AC 1 x 230V Mains frequency 50 / 60Hz Power rating 4.4kVA Generator output 7.5kVA Current range 5A 200A Current duty cycles 25% TIG / MMA 200A 60% TIG / MMA 150A 100% TIG / MMA 120A Weight: 8.9kg Dimensions (L x W x H) 475 x 180 x 295mm Package includes: Inverter Power cable INVERTER TETRIX 200 (AUTO RANGE), control range 5 200A / 110 / 230V Same characteristics as TETRIX 200 inverter but input voltage of 115VAC or 230VAC can be used. No switching required as the unit recognises the input voltage and adjusts automatically. (Note: Maximum output of 150A when used on 115VAC.) INVERTER TETRIX 351, control range 5 350A / 415V Mobile inverter power source for the TIG manual or orbital welding with built-in cooling system and gas sensor. Can be used with all Orbitec controllers, particular in high-demand applications such as tube-to-tube-sheet Technical Data: Output DC Mains voltage AC 3 x 415V Mains frequency 50 / 60Hz Power rating 15kVA Generator output 20.3kVA Current range 5A 350A Current duty cycles 60% TIG / MMA 350A 100% TIG / MMA 300A Cooling efficiency 1500W Water column 35m/5l/min. Tank capacity 12l Weight 131kg Dimensions (L x W x H) 1100 x 455 x 1000mm Package includes: Inverter Power cable 10l colant 10

11 WATER COOLING UNIT COOL 50 COOL 50 WATER COOLING UNIT Water-cooling unit for application with TETRIX 200 inverter and TIGTRONIC COMPACT in conjunction with water-cooled welding tools Technical Data: Input voltage 230V AC Cooling system F / IP 23 Weight 16.5kg Dimensions (L x W x H) 610 x 298 x 330mm Tank capacity approx. 4l Water column 35m/5l/min. Cooling capacity 1000W (1l/min.) Package includes: Water cooling unit Connection cable Inverter / water cooling unit 5l coolant COOL 50 WATER COOLING UNIT, 115V Same charachteristics as COOL 50 water-cooling unit for input voltage of 115VAC

12 ACCESSORIES FOR STANDARD EQUIPMENT PRESSURE REGULATORS, GAS HOSE, GROUND CABLES The pressure regulator can be tightened by hand without the need for a spanner. It reduces the stored bottle pressure for max. 200bar (on request 300bar) to an outlet pressure adjusted at the flowmeters. The flowmeters are used to set the required flow in l/min. Important: The pressure regulator has a constant outlet pressure of 2.5 bar which is necessary to protect the gas flow sensor of the orbital unit. Purging Twin flowmeter outlet Triple flowmeter outlet 1 16l/min, 3 30l/min 1 16l/min, 3 30l/min, 5 55l/min Orbital TIG SPECIAL ARGON PRESSURE REGULATOR twin flowmeters, brass SPECIAL PRESSURE REGULATORS with twin flowmeter for H2 gases, brass SPECIAL ARGON PRESSURE REGULATOR with triple flowmeters, brass Pressure regulators with different connections and for use with other gas types / mixes or nickel-plated available on request Purging Manual TIG Orbital TIG GAS HOSE, 3m GROUND CABLE, 5m, 35mm², up to 300A GROUND CABLE, 5m, 50mm², up to 500A

13 //ORBITAL WELDING TOOLS 13

14 ENCLOSED WELD HEADS OSK 13 S Enclosed weld heads provide complete inert gas protection of the full weld bead circumference (an industry requirement for producing welded joints in electro-polished and hygienic applications). Collets are required for each tube diameter to be welded. Cold wire feed is not possible. Welding will be made after preparation of the tube ends to provide a flat, square face. During welding the weld head remains static, only the rotor carrying the electrode rotates in an orbital motion around the tube (90 saw cut, if necessary square off). Advantage: Compact size for use in restricted space environments. MICROFIT WELD HEAD OSK 13 S Gas-cooled weld head for applications with extreme narrow space requirements as e.g. in the semiconductor industry. Specially designed to weld micro-fittings. Unique construction, including specifically directed gas routing to improve gas coverage and material selection resulting in a high duty cycle even without water cooling Extreme narrow / compact design Simple design allows easy to maintain Handle with control element (start/stop kit with status display) Arc Machines Model cassettes will fit too Weld head type: Tube size Range mm inch Weight OSK 13 S DA mm kg Dimension Sheet Enclosed Weld Heads OSK 13 S Weld head type A B C D E F mm inch mm inch mm inch mm inch mm inch mm inch OSK 13 S OSK 13 S MICROFIT CLAMPING CASSETTE For welding with extreme narrow space requirements Ø Orbitec clamping cassette (Titanium), width 12mm (0.472inch) Clamping cassette compatible with Arc Machines, model Cassette can be mounted in either direction (left or right hand) 14

15 ENCLOSED WELD HEADS OSK C/CW, HANDLE AND CABEL ASSEMBLY ENCLOSED WELD HEADS OSK C (compact version) Our latest series of 2 gas-cooled and compact weld heads. Those weld heads are for smaller outside diameters with a narrow handle for tighter access conditions. Weld head type: Field of application mm inch Weight OSK 21 C OD mm kg OSK 38 C OD mm kg Only one handle and cable assembly is needed for both weld heads OSK C HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with control element (start/stop with status display), weld head interface, motor, gearbox and tacho /encoder unit with 8m long cable Optional: ADAPTERFLANGE OSK C/G Advantage: While using the flange the OSK 21 C and OSK 38 C weld heads can also get used with the OSK G handle and cable assembly WATER-COOLED WELD HEADS OSK GW Our new generation of compact weld heads for high duty cycle requirements have watercooled clamp housings and clamping levers. Both OSK CW weld heads are operated using a sharable handle and cable assembly. Weld head type: Tube size Range mm inch Weight OSK 21 CW DA mm kg OSK 38 CW DA mm kg W W Only one drive unit is needed for all C and CW weld heads. OSK CW HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with control element (start/stop kit status display), weld head interface, motor, gearbox and tacho/encoder unit with 8m long cable Dimension Sheet Enclosed Weld Heads OSK C and CW Weld head type A B C D E F mm inch mm inch mm inch mm inch mm inch mm inch OSK 21 C OSK 38 C OSK 21 CW OSK 38 CW

16 ENCLOSED WELD HEADS OSK G/GW, HANDLE AND CABLE ASSEMBLIES GAS-COOLED WELD HEADS OSK G Our latest series of 2 gas-cooled weld heads covers the tube size ranges from 6mm 114.3mm. Unique construction and material selection allows a high duty cycle even without water cooling. The weld heads are one of the narrowest on the market and have a quick latch system for retaining the collets. Weld head type: Field of application mm inch Weight OSK 53 G OD 6 53mm kg OSK 76 G OD mm kg WATER-COOLED WELD HEADS OSK GW For the highest duty cycle applications we also offer the gas-cooled G series weld heads in a water-cooled GW-version (the overall width remains unchanged). Full water-cooling of the lower clamp housing. Also available as an upgrade for standard OSK G Weld heads. Water-stop-connector (old weld heads and cable assemblies can get retrofitted). OSK G, HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with controle element (start/stop kit status display), weld head interface, motor, gearbox and tacho/ encoder unit with 8m long cable Weld head type: Field of application mm inch Weight OSK 53 GW OD 6 53mm ,2kg OSK 76 GW OD mm ,7kg Only one drive unit is needed for all G and GW weld heads. OSK GW, HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with controle element (start/stop kit status display), weld head interface, motor, gearbox and tacho/ encoder unit with 8m long cable Weld head type A B C D E F mm inch mm inch mm inch mm inch mm inch mm inch OSK 53 G / GW OSK 76 G / GW

17 ENCLOSED WELD HEADS OSK S/SW, HANDLE AND CABLE ASSEMBLY GAS-COOLED WELD HEADS OSK115 S First model of a new enclosed weld head generation, more narrow, technical optimized and in a new design. Weld head type: Field of application mm inch Weight OSK 115 S DA mm kg OSK S, HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with control element (start/stop kit status display), weld head interface, motor, gearbox and tacho/encoder unit with 8m long cable Handle and cable assemblies of the OSK G and S weld heads are interchangeable! WATER-COOLED WELD HEADS OSK 115 SW First model of a new enclosed OSK SW weld head generation, more narrow, technically optimized and in a new design. For the highest duty cycle applications we also offer the gas-cooled S series weld heads in a water-cooled SW-version (the overall width remains unchanged). Full water-cooling of the lower clamp housing. Weld head type: Field of application mm inch Weight OSK 115 SW DA mm kg W OSK SW, HANDLE AND CABLE ASSEMBLY, 8m Consisting of a handle with control element (start/stop kit status display), weld head interface, motor, gearbox and tacho/encoder unit with 8m long cable Handle and cable assemblies of the OSK GW and SW weld heads are interchangeable! Weld head type A B C D E F mm inch mm inch mm inch mm inch mm inch mm inch OSK 115 S /SW

18 ENCLOSED WELD HEADS COLLETS OSK, ACCESSORIES COLLETS OSK Immediate availability We maintain a large stock of collets for all OSK weld heads. 1 set for each outside diameter = 4 collets. COLLETS FOR OSK 21 COLLETS FOR OSK 38 COLLETS FOR OSK 53 COLLETS FOR OSK 76 COLLETS FOR OSK Ø Ø Ø Ø Ø The standard collet sizes available from stock are listed on page 28. Non-standard sizes and specials are available on request. HP-COLLETS (OSK 53/76/117) for specific clean welding seams for the semiconductor industry are available on request. OFFSET ELECTRODE HOLDER from sizes OSK 53 upward The maximum coverage of the weld head size is then reduced. OFFSET ELECTRODE HOLDER for tungsten Ø 1.6mm OFFSET ELECTRODE HOLDER for tungsten Ø 2.4mm MULTI-POSITION ELECTRODE HOLDER from sizes OSK 53 upward The maximum coverage of the weld head size is then reduced MULTI-POSITION ELECTRODE HOLDER for tungsten Ø 1.6mm MULTI-POSITION ELECTRODE HOLDER for tungsten Ø 2.4mm Gasabdeckung Elektrodenhalter GAS-SHIELD COLLETS Gas-shield collets are particularly narrow and have an aluminium base jaw and a gas-shield cover of heat-resistant material for welding fittings, flanges, elbows, etc. In combination with offset or multi-position electrode holders the weld can be completed very close to one side of the weld head. Special wide clamps are available for a more secure fixture on request. Gas-shield collets are available for OSK weld heads size 53 / 76 / 115 (tube size range limited). Gas-shield base collets and covers (1 set 2 collets) GAS-SHIELD BASE COLLETS FOR OSK 53 GAS-SHIELD BASE COLLETS FOR OSK 76 GAS-SHIELD BASE COLLETS FOR OSK 115 GAS-SHIELD COVER COLLETS (GRP) FOR OSK 53 (adaptation by the customer) FOR OSK 76 FOR OSK 115 GAS-SHIELD COVER COLLETS (GRP) FOR OSK 53 (prefabricated with through hole) FOR OSK 76 FOR OSK

19 OPEN-FRAME WELD HEADS OSW The open-frame weld head locates one side of the weld joint. During welding, a gas or water cooled torch and cable assembly rotates around the tube or pipe. Some advantages of open-frame weld heads: Robust construction Ease of handling Option to add wire feed No size specific collets required, each weld head will accommodate its full tube/pipe OD size range as supplied 90 tilting torch bracket OSW WELD HEADS A selection of 4 weld heads to cover the size range from 8mm to 168.3mm OD. Weld Head: Tube Size Range mm inch Weight OSW 40 OD 8 40mm kg OSW 80 OD mm kg OSW 115 OD mm kg OSW 170 OD mm kg Package includes: Weld head Integrated start/stop-button at the handle Clamp shoes Torch bracket Mechanical arc gap adjusting screw Optional: Angular gear complete for OSW Dimension Sheet OSW Open-frame Orbital Weld Heads Ø + A Ø G = 2 Weld head Ø A B C D E F mm inch mm inch mm inch mm inch mm inch mm inch OSW OSW OSW OSW

20 OPEN-FRAME WELD HEADS OSZ The OSZ weld heads were developed for welding larger pipe diameters with a thinner wall thickness, with or without wire feed, with a gas-cooled or water-cooled torch hose. Special design feature: Enclosed gear ring system WELD HEAD OSZ Weld head type: Tube Size Range mm inch Weight OSZ 275 OD mm kg OSZ 325 OD mm kg Package includes: Weld head Clamp shoes Standard OSZ torch bracket Mechanical arc gap adjusting screw Dimension Sheet OSZ 325 Open-frame Orbital Weld Head Weld head type OSZ 275 A B C D E F mm (12) inch (0.472) Weld head type OSZ 325 A B C D E F mm (12) inch (0.472) 20

21 OPEN-FRAME WELD HEADS CABLE ASSEMBLIES INTERCONNECTION CABLE BJ, 8m INTERCONNECTION CABLE, with ORBIFEED plug BJ, 8m TIG TORCH WITH CABLE ASSEMBLY, GAS OR WATER-COOLED FOR OSW AND OSZ TIG TORCH STANDARD with cable assembly BJ, 8.5m, gas-cooled TIG TORCH STANDARD with cable assembly BJ, 8.5m, water-cooled TIG TORCH MINI with cable assembly, 8.5m, gas-cooled TIG TORCH MINI with cable assembly, 8.5m, water-cooled SILICON CABLE, 2.5m, gas-cooled EXTENSION CABLE ASSEMBLIES FOR OSK, OSW AND OSZ EXTENSION CABLE ASSEMBLY, 8m, gas-cooled EXTENSION CABLE ASSEMBLY, 8m, combined gas and water-cooled

22 OPEN-FRAME WELD HEADS TORCH BRACKETS, MANUAL TIG HOSE PACKAGE TIG TORCH BRACKET (isolator) TORCH BRACKET OSW MINI TORCH BRACKET OSW MINI 45, MULTI-POSITION TORCH BRACKET, MULTI-POSITION FOR OSW TORCH BRACKET OSZ STANDARD TORCH BRACKET OSZ 90, MULTI-POSITION Package includes: Torch bracket Arc gap adjusting screw with ceramic ball Torch clamping screw Stainless steel thread insert HIGH-FLEX MANUAL TIG HOSE PACKAGE SR 9, 8m, gas-cooled High-Flex cable assembly Same spare parts as OSW/OSZ Plug, 5 poles 22

23 TURN TABLE SYSTEM TURN 300, UPGRADE KITS TURN 300 TURN TABLE SYSTEM, complete with accessories Turn table system, particularly suitable for non-orbital ready components at higher quantities. Can be connected to all Orbitec controllers Hollow shaft OD 70mm (e. g. for purging components through the centre) Quick-change TIG torch system Bit tilted to any angle 90 High quality three-jaw chuck Technical Data: Max. load 300N Swivel range 0 90, infinitely variable Current transmission Max. 300A Chucking capacity min. mm / max. mm min. inch / max. inch Inner 50mm / 230mm / Outer 10mm / 120mm / Optional also with cold wire feed and AVC in conjunction with the TIGTRONIC controllers and the AVC upgrade kit. Package includes: Turn table incl. console 2 sets of jaw chucks Bed-plate with assorted fixings and positional plate Multi-positional torch arm for infinite adjustment of torch position TIG torch bracket Cable for connection to Tigtronic controller with Orbifeed plug Chuck key Ground cable CABLE ASSEMBLY TURN 300 4m, gas-cooled CABLE ASSEMBLY TURN 300 4m, water-cooled UPGRADE KITS FOR TURN 300 TURN TABLE SYSTEM TORCH HOLDER WITH CROSS-SLIDE FOR FINE ADJUSTMENT (50mm travelling distance) AVC UPGRADE KIT TURN Package includes: AVC motor/ gear unit incl. mounting Cross-slide WIRE CONSOLE TURN

24 EXTERNAL WIRE FEED UNITS ORBIFEED, ACCESSORIES ORBIFEED EXTERNAL WIRE FEED UNITS Compact and lightweight wire feed unit mounted in a Peli case for 5kg (ORBIFEED 5) and 15kg (ORBIFEED 15) standard spools. EXTERNAL WIRE FEED UNIT ORBIFEED 5, for 5kg spools EXTERNAL WIRE FEED UNIT ORBIFEED 15, for 15kg spools Technical Data: Orbifeed 5 Orbifeed 15 Motor voltage and power 24V DC, 6W 24V DC, 6W Weight approx. 7kg approx. 8kg Dimensions (L x W x H) 406 x 330 x 174mm 525 x 436 x 217mm Wire spools Standard spools 5kg Standard spools 5 and 15kg Wire outside diameter 0.8 / 1.0mm 0.8 / 1.0mm Package includes: Water-resistant and dust-proof Peli case Four roller drive mechanism Delivery hose with inlet and outlet nozzles Torch bracket for wire feed on OSW / OSZ / TURN Interconnecting cables wire feed unit / controller SPARE DELIVERY HOSE FOR ORBIFEED, complete SPARE DELIVERY HOSE TEFLON FOR ORBIFEED SPARE WIRE INLET NOZZLE SPARE WIRE OUTLET NOOZLE TORCH BRACKETS FOR WIRE FEED, complete Can be fitted to TIG torch OSW/OSZ TORCH BRACKET FOR WIRE FEED OSW STANDARD, OSZ INTERNAL TORCH BRACKET FOR WIRE FEED OSZ STANDARD, OSW INTERNAL TORCH BRACKET FOR WIRE FEED OSW SPARE TORCH BRACKET GFP OSW STANDARD, OSZ INTERNAL SPARE TORCH BRACKET GFP OSZ STANDARD, OSW INTERNAL SPARE TORCH BRACKET GFP OSW SPARE TORCH BRACKET ALU, OSW SPARE TORCH BRACKET ALU, OSW

25 TUBE-TO-TUBE-SHEET WELD HEADS RBK With tube-to-tube-sheet weld heads the reproducible welding of tubes to tube-sheets is possible at a constantly high quality, with and without an external wire. The tubes to be welded can be flush with the tube-sheet, offset, protrude or in the rear sheet. The RBK 20 is an easy-to-use and lightweight tube-to-tube-sheet weld head with a water-cooled torch. The optional cold wire feed is static at the head, i.e. does not turn. RBK 20 WELD HEAD without wire feed, incl. cable assembly, 8m RBK 20 WELD HEAD with wire feed, incl. cable assembly, 8m RBK 16 is a tube-to-tube-sheet weld head for high demands with a completely water-cooled machine body and torch. The RBK 16 has in comparison to the RBK 20 a modified and very comfortable torch adjustment, at which the tripod or the support ring does not turn. The optional cold wire device rotates dynamically with the head. The RBK 16 is available with AVC upon request or with corresponding lances for rear tube-sheet welding. RBK 16 WELD HEAD without wire feed, incl. cable assembly, 8m RBK 16 WELD HEAD with wire feed, incl. cable assembly, 8m RBK 16 WELD HEAD with wire feed and AVC, incl. cable assembly, 8m Dimension Sheet for RBK Weld Heads A B A B RBK 20 E RBK 16 E D C D C Weld head A B C Ø D Ø E mm inch mm inch mm inch mm inch mm inch RBK RBK TECHNICAL DATA: Field of application Field of application with AVC Max. welding current Wire motor Rotation speed Wire coil Wire diameter Weight (without wire feed) Weight (with wire feed) Weight (with AVC) RBK 20 ID mm 200A 24V DC Tacho Max. 5rpm 1kg, dia. 100mm mm 5kg 6kg RBK 16 ID mm / ID mm / A 24V DC Tacho Max. 5rpm 1kg, dia. 100mm mm 8kg 10kg 11kg Package includes: RBK weld head Water-cooled cable assembly Three-point support (support ring optional) Torch equipment Tool kit 25

26 TUBE-TO-TUBE-SHEET WELD HEADS CENTRING SPINDLES, MANDRELS, ACCESSORIES MANDREL A, Ø 4 mm ID CENTRING SPINDLES mm inch TYP 01 9,8-10, TYP 02 10,3-10, Centring spindles TYP 03 10,8-11, TYP 04 11,3-11, TYP 05 11,8-12, TYP 06 12,3-13, MANDREL B, Ø 6 mm ID CENTRING SPINDLES mm inch Mandrel TYP TYP TYP TYP TYP TYP TYP TYP MANDREL C, Ø 9 mm ID CENTRING SPINDLES mm inch TYP TYP TYP TYP TYP TYP TYP TYP TYP TYP TYP MANDREL D, Ø 12 mm ID CENTRING SPINDLES mm inch TYP TYP TYP TYP TYP TYP TYP THREE-POINT SUPPORT RBK 20 THREE-POINT SUPPORT RBK 16 SUPPORT RING with cage for RBK 20 SUPPORT RING with cage for RBK 16 BALANCER for RBK 20 (4.5 9kg) BALANCER for RBK 16 (9 15kg)

27 COMPATIBLE WITH COMPETITOR POWER SUPPLIES ARC MACHINES, POLYSOUDE, ORBITALUM,... Solutions to operate Orbitec weld heads in combination with other manufacture equipment, e.g. AMI, Polysoude and Orbitalum are available. To some extend other manufacturer weld heads can also get connected to Orbitec welding systems. The matching adaptations are available for purchase and rental. ARC MACHINES OSK G HANDLE AND CABLE ASSEMBLY, Version AMI, 8m OSK GW HANDLE AND CABLE ASSEMBLY, Version AMI, 8m OSK C HANDLE AND CABLE ASSEMBLY, Version AMI, 8m Adaptations for other weld heads are available on request. POLYSOUDE ADAPTOR FOR ORBITEC OSK WELD HEAD, Gas-cooled on Polysoude ADAPTOR FOR ORBITEC OSK WELD HEAD, Water-cooled on Polysoude ADAPTOR FOR ORBITEC OSW WELD HEAD, Gas-cooled on Polysoude ADAPTOR FOR ORBITEC OSW WELD HEAD, Water-cooled on Polysoude ADAPTER POLYSOUDE WELD HEAD ON ORBITEC ORBITALUM ADAPTATION ORBITEC OSK WELD HEAD, Gas-cooled on Orbitalum incl. Remote Control Pendant, 8m ADAPTATION ORBITEC OSK WELD HEAD, Water-cooled on Orbitalum incl. Remote Control Pendant, 8m Adaptations of other weld heads are available on request. Adaptations of other manufacture equipment are available on request. 27

28 TUNGSTENS CHART FOR TUNGSTEN LENGTHS SuperArc: Precision ground tungstens for repeatable high-quality orbital welds. Reduce your costs by using disposable tungstens because manual sharpening costs time and money. Standard quality WC 20 to DIN EN ISO Sizes for all ORBITEC weld heads depending on the tube outer diameter Ø Length Ø Tip Diameter Grinding 1.6mm All lengths available 0.2mm mm All lengths available 0.4mm 30 TUNGSTENS SUPERARC Ø 1.6MM TUNGSTENS SUPERARC Ø 2.4MM Length Length WELD HEAD OSK 13 OSK 21 OSK 38 OSK 53 OSK 76 OSK 115 Tube OD Ø Tungsten length mm inch mm inch mm inch mm inch mm inch mm inch mm inch v102 Tungsten lengths for: open-frame weld heads OSW 40: 20 35mm open-frame weld heads OSW , OSZ 325: 35 50mm tube-to-tube-sheet weld heads RBK 16, RBK 20: 35 46mm Non-Standard length are available on request. 28

29 TORCH CONSUMABLES OSW, RBK, TURN BACK CAPS BACK CAP OSW, OSZ BACK CAP TURN BACK CAP MANUAL TORCH CLAMP SLEEVES CLAMP SLEEVE OSW 40 Ø 1.6mm CLAMP SLEEVE OSW 40 Ø 2.4mm CLAMP SLEEVE OSW , OSZ, RBK, Manual torch Ø 1.6mm CLAMP SLEEVE OSW , OSZ, RBK, Manual torch Ø 2.4mm CLAMP SLEEVE TURN Ø 1.6mm CLAMP SLEEVE TURN Ø 2.4mm TEFLON TORCH INSOLATORS TEFLON TORCH INSOLATOR OSW, OSZ TEFLON TORCH INSOLATOR TURN, RBK, Manual torch GAS LENSES GAS LENS OSW 40 Ø 1.6mm GAS LENS OSW 40 Ø 2.4mm GAS LENS OSW , OSZ, TURN, Manual torch Ø 1.6mm GAS LENS OSW , OSZ, TURN, Manual torch Ø 2.4mm GAS LENS RBK Ø 1.6mm GAS LENS RBK Ø 2.4mm GAS CUPS GAS CUP OSW 40 GAS CUP OSW , OSZ, TURN GAS CUP RBK GAS CUP Manual torch STRIKING AIDS / HF-SPIRALS STRIKING AID / HF-SPIRAL TURN (150mm length, Ø 15mm) STRIKING AID / HF-SPIRAL TURN (150mm length, Ø 19mm) STRIKING AID / HF-SPIRAL RBK (50mm length, Ø 15mm) STRIKING AID / HF-SPIRAL RBK (50mm length, Ø 19mm) TORCH EQUIPMENT OSW / OSZ SPARE PARTS BOX for TIG torch Standard Ø 1.6mm SPARE PARTS BOX for TIG torch Standard Ø 2.4mm SPARE PARTS BOX for TIG torch Mini Ø 1.6mm SPARE PARTS BOX for TIG torch Mini Ø 2.4mm Package includes: 1 back cap 1 clamp sleeve Ø 1.6 or 2.4mm 1 teflon torch isolator 1 gas lens Ø 1.6 or 2.4mm 1 gas cup 29

30 MOBILE WORKSTATION MOBILE WORKSTATION Your business card: The Orbital-Workstation MOBILE ORBITAL WORKSTATION gang accessory power outlet (European plugs) fitted in the workstation. 5 x 230V, 10A (not suitable for the power source) 2 x Ø160mm locking swivel wheels 2 x Ø280mm heavy duty rubber tired wheels Adjustable gas bottle bracket with high level fixing chain High-quality powder-coated finish Formed and welded stainless steel work top Pull-out platform for oxygen analyser Fixings for bench vice with V block Holder for open-frame weld head Holder for enclosed weld head Holder for manual TIG-Torch Continuously adjustable controller holder for TIGTRONIC ORBITAL 4 and BASIC 2/3/4 Footprint for inverter, water cooling unit, etc. Dimensions (excluding brackets): (L x W x H): 1110 x 710 x 850mm Weight: unloaded approx. 70kg Optional: ADAPTER PLATE for TIGTRONIC COMPACT

31 MOBILE WORKSTATION ACCESSORIES BENCH VICE, NICKEL-PLATED Parallel bench vice size 100 suitable for use in cleanroom V BLOCKS For securing tubes when tacking before welding Electro-plated aluminium V BLOCKS FOR MINI FITTINGS V BLOCK for mini fitting OD 6mm OD 6.35mm V BLOCK for mini fitting OD 8mm OD 9.53mm OD 10mm V BLOCK for mini fitting OD 12mm OD 12.7mm OD 13.5mm V BLOCKS FOR LARGER TUBE DIAMETERS V BLOCK OD 5 30mm V BLOCK OD 10 65mm V BLOCK OD mm TOOL KIT Package includes: Nine-piece ball-ended allen key set Feeler gauge (21 blade) Tweezers Slotted screwdriver Carrying case 31

32 //SAWS / TUBE SQUARING DEVICES 32

33 CUTTING SAW ORS, ACCESSORIES CUTTING SAW ORS A precise 90 cut is essential for orbital welding joint preparation. Portable lightweight unit Flash-free square cut 2 cast aluminum clamping jaws Multiple clamping points on the tube OD provides deformation-free clamping For cutting thin-walled tubes and elbows Saw blade located close to the clamps to provide an optimal cut even with small tube diameters Blade position indicator Precise scale to enable correct cutting depth CUTTING SAW ORS 115 (OD 5 120mm) Technical Data: Size range OD 5 120mm Wall thickness 0,5 5mm Electric drive Single-phase AC motor Power 1010W Protection class II Built-in electronic variable cutting speed RPM Weight 30kg Package includes: Orbital saw and drive unit 1 saw blade Tool wallet and tools 1 bottle of lubricant oil Transportation box with inlay (600x800x600mm) Saws for other dimensions are available on request. STAND FOR CUTTING SAWS ORS SAW BLADE for wall thickness 1 3mm Ø 68mm, 72 teeth SAW BLADE for wall thickness 2.5 7mm Ø 68 mm, 44 teeth SAW BLADE AND LUBRICANT OIL 250ml bottle

34 CUTTING SAWS CUTTING BLOCKS CUTTING BLOCKS, quick lock system For locking no tools needed Save and quick clamping at site Angular kerf for a precise cutting of tubes Saw blades up to 1mm applicable Made of high quality hardened tool steel CUTTING BLOCKS DIN 11850/ RANGE 1 DN mm CUTTING BLOCKS DIN 11850/ RANGE 2 CUTTING BLOCKS INCH CUTTING BLOCKS ISO Other sizes on request. DN mm inch 1/4 1/2 3/8 3/ /4 1 1/ / / mm

35 TUBE SQUARING DEVICES PLANFIX 40 Tube squaring systems are available for precise weld preparation, an essential ingredient for producing high-quality welds. TUBE SQUARING SYSTEM PLANFIX 40 (OD 3 40mm) The PLANFIX 40 is a handy, high-performance, battery-powered tube squaring system Technical Data: Tube size range OD 3 40mm Max. wall thickness 3.0mm Weight 3,9kg Feed with scale division Technical Data Drive Unit: Motor and transmission unit Voltage Power (battery) Speed ranges Fein ASCM14 14V DC 4.0Ah / / RPM Technical Data Battery Charger: Battery charger ALG 50 Mains voltage (input) 220/230VAC (50/60Hz) Output voltage 4A 22V Power 75W/ 4A Charging time 70min Package includes: Drive unit, tool hub and tube clamping mechanism 2 rechargeable lithium ion batteries Battery charger Allen key set 1 facing tool bit SPECIAL TRANSPORTATION BOX with inlet for PLANFIX 40 and accessories Dust- and moisture-proof PLANFIX 40 COLLETS 1 set for each outside diameter = 2 collets. Additionally the OSK 38 weld head collets are compatible Ø 35

36 TUBE SQUARING DEVICES PLANFIX 115 TUBE SQUARING SYSTEM PLANFIX 115 (OD mm) The PLANFIX 115 is a high-performance lightweight tube squaring system with a high torque worm gear transmission and electric drive unit Technical Data: Tube size range OD mm Wall thickness max. 3.0mm Electric drive Single-phase AC motor Power 1010W (1.5HP) Protection class II Built-in electronic variable cutting speed 0 144rpm Weight 12.5kg Feed with scale Package includes: Drive unit, tool hub and tube clamping mechanism Allen key set 1 facing tool bit TRANSPORTATION BOX with inlet for PLANFIX 115 and accessories PLANFIX 115 COLLETS 1 set for each outside diameter = 2 collets Ø Additionally the OSK 115 weld head collets are compatible. FACING TOOL BITS (TIC COATED), for squaring for PLANFIX 40 and PLANFIX Facing tool bits for chamfering 30 and 37.5 are available on request. 36

37 TUBE SQUARING DEVICES ADDITIVES DEBURRING TOOLS UNIVERSAL DEBURRING TOOL SET (7 PARTS) OD 3 16mm ID BURR REMOVING TOOL WITH NOZZLE ID BURR REMOVING TOOL WITH THREE-EDGE SUPPORT OD BURR REMOVING TOOL BOXED DEBURRING TOOL KIT (3 PARTS) UNIVERSAL DEBURRING TOOL, Ø 10 54m FOR WELDING SEAM CLEANING: ABRASIVE PAD ROLL, SUPER FINE, role 10m 0.394, 115mm wide POLISHING DISC SC 80 WP, Ø 150mm POLISHING DISC ARBOUR

38 //PURGING 38

39 PURGING PRECISE AND EFFECTIVE PURGING Precise purging is essential for controlling weld quality, particularly when welding high-alloy, corrosion-resistant materials that are highly sensitive to oxygen in the welding process. Our oxygen analysers can be connected to our controllers for monitoring ID purge quality as part of the programmed weld schedule parameters (except Oxy Smart). Values measured during welding will also be recorded as part of the weld data recording facility. The maximum oxygen value (in ppm) is entered in the controller (typically < 20ppm). Welding will not commence until the measured value drops below the programmed threshold. The analysers are calibrated to measure in the for welding relvant range below 30ppm up to + /- 2ppm precise. Since oxidation starts at around 30ppm analysers with values displayed as a percentage are not recommended 0.1% = 1,000ppm! Examples of ppm vs oxidation levels: 7ppm 27ppm 500ppm % % 0.05 % 39

40 OXYGEN ANALYSERS OXY 2 OXY 2 OXYGEN ANALYSER incl. accessories For inert gases For mixed gases containing hydrogen Measuring cell made of zirconium oxide (maintenance-free) Interface for communication with our orbital controllers Technical Data: Measuring range 5 999ppm O 2 Operating temperature 0 45 Celsius Measuring accuracy +/- 0.3mV (EMK Sensor) Stabilisation time 10 15min. Response time approx. 2 seconds for changes Dimensions (H x W x L) 140mm x 210mm x 225mm without handle Mains voltage 230V AC / 110VAC adjustable Heating cycle load approx. 200VA Standard load approx. 40VA Package includes: Oxygen analyser Power cable Hors set, 3m incl. filter and stainless steel probe Calibration certificate Simple plastic case Optional: SPECIAL TRANSPORTATION CASE FOR OXY 2 with inlet for OXY 2 and accessories Dust- and moisture-proof COM-CABLE OXY 2 FOR COMMUNICATION AND DOCUMENTATION COM-CABLE for connection to controllers TIGTRONIC BASIC COM-CABLE OXY 2 for connection to controllers TIGTRONIC ORBITAL 4 and COMPACT

41 OXYGEN ANALYSERS OXY SMART SMART Restsauerstoffmessgerät Oxygen Analyser OXY SMART OXYGEN ANALYSER incl. accessories and box Battery powered device For inert gases For mixed gases with hydrogen (max. 10%) Measuring cell made of zirconium oxide (maintenance free), long lifetime through intelligent software Robust for use at site (protective frame out of rubber) Dust- and moisture-proof, also for use around high humidity Intuitive operator guidance through symbols Coloured enlighten display Battery indicator Fault indication in case of error Technical Data Analyser: Measuring range 5 999ppm O 2 Dimensions (L x W x H) 160mm x 80mm x 35mm Weight 0.35kg Supply voltage 12V Charging cable V with various adapter plugs Battery life 9h using lithium ion technology Package includes: Oxygen analyser Charging cable with various adapter plugs for worldwide use Hose set, 1m, incl. filter and stainless steel probe Calibration certificate Plastic case with inlay 41

42 OXYGEN ANALYSERS OXY 3, ACCESSORIES RESIDUAL OXYGEN ANALYZER OXY 3, incl. accessories Simple menu navigation For inert gases and mixed gases containing hydrogen Measuring cell made of zirconium oxide (maintenance-free) Large high resolution touch screen panel Graphic display of measured values SD card interface for storing documentation Interface for communication with our controllers User adjustable alarm limits and thresholds Audible key tones and alarms Colour display for figures outside setpoint values Interface for communication with our orbital controllers Software updates possible Multi language Bluetooth compatible Multirange V Technical Data: Measuring range 5ppm -21% O 2 Ambient temperature 0 45 Celsius Measuring accuracy +/- 0.3mV (EMK sensor) Stabilisation time 10 14min Response time approx. 2 seconds for changer Dimensions (L x W x H) 190mm x 270mm x 55mm Mains voltage Multirange V AC Heating cycle load approx. 40VA Standard load approx. 20VA Package includes: Oxygen analyser Power cable Hors set, 3m incl. filter and stainless steel probe Calibration certificate Simple plastic case Optional: SPECIAL TRANSPORTATION BOX FOR OXY 3 with inlet for OXY 3 and accessories Dust- and moisture-proof COM-CABLE OXY 3 for communication and documentation COM-CABLE OXY 3 for connection to controllers TIGTRONIC BASIC 2-4 COM-CABLE OXY 3 for connection OXY 3 to controllers TIGTRONIC ORBITAL 4 and COMPACT SPARE PLASTIC HOSE for OXY 2 / OXY 3, 3m, with particle filter and stainless steel probe SPARE PLASTIC HOSE for OXY SMART, 1m, particle filter and stainless steel probe SPARE FILTER

43 PURGE ACCESSORIES PURGE BUNGS PURGE HOSE with ball valve, 8m ALUMINIUM ADHESIVE TAPE ROLL 50 x 0.09mm, roll 55m PURGE BUNGS Conical Hole: Ø 6mm Material: silicon, clear Heat resistant up to 250 C Purge bungs for ID mm inch Purging caps with outside screwing available on request. 43

44 PURGE ACCESSORIES FLEXIBLE PURGE DAM FLEXIBLE PURGE DAM Gas and time saving Heat resistant up to 340 C Applicable in all positions Simple pull through elbows possible SC PROFI SUPPLIED WITH 2 DISCS (340 C), FLEXIBLE CONNECTION WITH RECTUS NIPPLE TYPE 21 Type Connection ID (mm) ID (inch) SC Profi Ø 17mm SC Profi Ø 21mm 80mm spring SC Profi Ø 24mm connection SC Profi Ø 30mm SC Profi Ø 39mm SC Profi Ø 45mm SC Profi Ø 57mm mm flex SC Profi Ø 60mm connection SC Profi Ø 70mm SC Profi Ø 82mm SC Profi Ø 95mm SC Profi Ø 117mm 150mm flex connection SC Profi Ø 145mm SC Profi Ø 176mm SC Profi Ø 182mm SC Profi Ø 220mm 250mm flex SC Profi Ø 231mm connection Other purge dams are available on request. PULL ROPE, 10m, (insulated) with carabiner CONNECTION FOR FLEXIBLE PURGE DAM / PURGE HOSE OD 6mm Measurement connection for purge dam to Oxy (from SC Profi Ø 57mm) available upon request. 44

45 SERVICES RENTAL SERVICE, REPAIR SERVICE, FINANCING RENTAL SERVICE USE INSTEAD OF INVEST All Orbitec orbital welding equipment is available for hire at competetive prices. Some of the advantages of hiring: Multiple systems available as required Fixed prices for end of hire return servicing Reliable basis for cost calculation No investment risk High availability in multiple combinations Your business card on site: The Orbital-Workstation Mobile workstation provided free of charge when hiring a complete system. Complete systems with mobile workstations are sent by us in special containers. RENT MIETE N Purchase option: Your benefit If you decide to purchase the system within 4 weeks of the end of the rental period, we will deduct the rental costs up to 30 calendar days from the purchase price. REPAIR AND MAINTENANCE A quick and reliable repair and maintenance service is a matter of course. Our comprehensive rental service helps to bypass the downtimes of devices. HIRE PURCHASE / LEASING We are happy to provide you with a hire purchase over 3, 6 or 12 months, a leasing offer via our leasing partner. HELP WITH CONTRACTING OUT If you would prefer to contract out the orbital welding of your application, we are happy to recommend one of our many customers who are equipped with appropriate equipment, qualified procedures and personnel, and can provide this service. 45

46 SERVICES APPLICATION TRAINING Excellent welding results are achievable with most orbital equipment available on the market today, good operator training is essential to achieve the most from your equipment and Orbitec offer training courses to suit all equipment and application combinations. Training is delivered by our experienced orbital engineers; we can provide standard and application tailored courses at our facility which is equipped with all the necessary equipment and accessories. All courses include a high degree of practical hands on use. Application of the process with supporting literature and one-to-one instruction included as required. CERTIFICATE OF COMPETENCE Instructed by: Signature: Jane Doe John Doe has successfully completed a course of instruction for: Automatic Welding System Operation J. Doe as provided by Orbitec GmbH Course Dates: Date: 22. / ORBITEC GMBH Gesellschaft für Orbital- und Sonderschweisstechnik Willi-Brehm-Straße 8 D Seligenstadt Telefon +49 (0) 6182 / Fax +49 (0)6182 / info@orbitec.de DIN EN ISO 9001 certified Some topics covered in one of our courses: Explanation of the process Process technology, examples of various manufacturers products Welding gases Weld joint preparation Purging techniques Creating a weld schedule Equipment set-up and operation Welding with various equipment and material combinations Weld schedule development Material related issues Weld acceptance criteria Main focus on costumer preference 46

47 47

48 48

49 GENERAL TERMS AND CONDITIONS OF WARRANTY AND OF HIRE GENERAL TERMS AND CONDITIONS OF WARRANTY A warranty period of 24 months in a one-shift operation is provided with Orbitec equipment. However, batteries, measuring cells, gas level monitors and wearing parts are not covered under warranty. The warranty period commences at the time of transfer (in the case of shipment it commences when the goods leave our factory). During this period Orbitec guarantees all products against material and manufacturing defects: Fault investigation free of charge Replacement of defective parts free of charge (except consumable parts) Professional repair service free of charge Defects caused by inappropriate treatment or use of spare parts not supplied by Orbitec will not be covered by this guarantee All work covered by guarantee will be performed at the Orbitec facility in Seligenstadt / Germany. All costs for transportation of goods to/from Seligenstadt to be covered by the customer. The guarantee is void if the equipment has been subject to interference or where repair has been attempted by unauthorised persons. These terms are additional to the legal guarantee regulations. GENERAL TERMS AND CONDITIONS OF HIRE 1. General These terms and conditions also apply to future business transactions conducted between the contracting parties. These General Terms & Conditions of Hire apply exclusively. The General Terms & Conditions of Business of the customer are only valid if the supplier has expressly approved their validity in writing. 2. Period of rent The period of rent is calculated according to full calendar days. The period of rent commences upon dispatch of the equipment to the place of use and ends when the equipment is returned to the lessor. There is no minimum rental period. 3. Dispatch and transfer of risk The equipment is dispatched at the expense of the lessee using normal shipping methods, unless the lessee has expressly stipulated a certain shipping method. The cost of transport insurance is borne by the lessee. The transfer of risk commences upon pick-up or collection of the equipment from the lessor and ceases upon return of the equipment to the lessor. 4. Use of the rental property The rented equipment remains the property of the lessor. The lessee must use the equipment with care, adhere to all obligations related to the possession, use and preservation of the rental property, and comply with the lessor s recommendations for maintenance, support and use. Any necessary repairs arising from improper use shall be invoiced to the lessee separately. The status and repair report from the lessor forms the basis of the invoice and is made available to the lessee. 5. Liability and guarantee To the exclusion of other claims, the lessor is responsible for the functional operation of the rented equipment at the time of the transfer of risk in the following way: If the rented equipment has a fault at the time of the transfer of risk, which voids its capability for the contractual use or reduces its scope of use amounting to its invalidation, the lessor can at his own discretion eliminate the fault, replace the faulty equipment or rescind the contract. The rental price is reduced accordingly for the duration of the fault. For damage arising from the use of the rental object by the lessee, the lessor is only liable if this is based on a fault existing at the time of transfer of risk. The liability extends to the cost of repairs to the amount of the rental price claim of the lessor, with which any subsequent claim for damages must be invoiced. Furthermore, any resulting claims from the lessee, in particular for damages, are excluded. Cases of fatal or serious personal injury and damage to health are exempt from the limitation of liability clause. 6. Liability of the lessee The lessee is liable to the lessor for all damage arising from the non-intended and improper use of the rental object. Furthermore, the lessee shall bear the costs of any claims for accidental destruction, accidental damage, as well as theft. The lessee is obligated to insure the rental property against loss and/or damage. In the case of complete damage, the lessee must provide the replacement value. 7. Third party rights The lessee must keep the rental property exempt from all charges, demands and liens from third parties. He is obligated to immediately inform the lessor, by making available all necessary documents, if, during the period of the rental agreement, the rental property is subject to a lien or any other such charge by third parties. The lessee shall bear all costs necessary to cancel any such third party intervention. 8. Payment The rental price is due immediately upon receipt of the invoice and payable without deductions. 9. Return of the rental property The lessee must return, at his own risk and expense, the rented equipment immediately upon expiry of the period of rent to the lessor. 10. Deposit The lessor reserves the right to charge a deposit. The deposit is payable before the rental property has been transferred and is returned to the lessor once the rental objects have been returned or is charged against any unpaid invoice. 11. Final provisions Verbal supplementary agreements are null and void. Any amendments made to this contract are required in writing. Should one clause of this contract not be legally effective, the validity of the other clauses remains unaffected. Incidentally, the General Terms & Conditions of Business of the lessor apply, in addition to the terms and conditions stated herein. 49

50 GENERAL TERMS AND CONDITIONS 1. General These terms and conditions also apply to future business transactions conducted between the contracting parties. These General Terms and Conditions of Business apply exclusively. The General Terms and Conditions of Business of the purchaser are only valid if the supplier has expressly approved their validity in writing. 2. Final specification of services The aspects of this specification of services provide a comprehensive and conclusive definition of the delivery item. 3. Correct and punctual deliveries The contract is concluded under the reservation of correct and punctual delivery by the supplier. [The contractor must immediately inform the principal of the non-availability of the delivery item and in the case of rescission the contractor must be reimbursed the equivalent amount immediately.] 4. Payment conditions and supplementary performance Payment is due in full upon delivery or acceptance. The principal is, without additional declarations from the seller, in default 14 days after the due date for payment if he has not paid. In the case of the presence of defects, the principal is not entitled to retain possession of the goods, unless the delivery was evidently faulty or the principal is clearly entitled to the right to decline acceptance of the work; in such cases, the principal is only entitled to retain possession if the retained amount covers to a reasonable extent the defects and any foreseeable costs for subsequent performance (in particular the costs for eliminating the fault). The principal is not entitled to assert claims and rights for defects if he has not made any payments due and the amount due (including any payments made) covers to a reasonable extent the value of the delivery, with faults, or the work. 5. Reservation of proprietary rights (1) The delivery item remains the property of the contractor until fulfilment of all contractual obligations to the principal. (2) During the period of reservation of proprietary rights, the principal is prohibited from taking out a lien or assigning the item as security. Further disposal is only permitted to distributors in the ordinary course of business and subject to the conditions that payment of the equivalent value for the delivery item is made to the principal. The principal must also agree with the purchaser that the purchaser only acquires the proprietary rights upon this payment. (3) The principal is allowed to process the delivery item or combine it with other objects. The processing or combination (hereinafter referred to collectively as processing and with regard to the delivery item: processed ) occurs when an object is designated as a new item following the processing of an existing item. The principal stores the new item for the contractor with the due care and prudence of an ordinary business. In the event of processing with other objects not belonging to the contractor, the contractor is entitled to co-ownership of the new item for the amount of the share, which results from the proportion of the value of the processed or combined delivery item to the value of the other processed goods at the time of processing. If the principal acquires sole ownership of the new item, both the principal and contractor agree that the principal shall grant the contractor co-ownership of the new item for the proportion of the value of the processed delivery item to the other processed goods at the time of processing. (4) In the case of disposal of the delivery item or the new item, the principal hereby assigns his rights for further disposal against the purchaser to the contractor by way of security, without the need for further declarations. The assignation also includes outstanding balance claims. However, the assignation is only applicable for the amount that corresponds to the price of the delivery item invoiced by the contractor. The part of the balance assigned to the contractor is to be satisfied prior-ranking. (5) If the principal combines the delivery item or the new item with moveable objects, he, without the need for further declarations, also assigns his claim, which is due to him as payment for the connection, to the contractor, with all ancillary rights by way of security for the amount in proportion of the value of the delivery item or new item to the other combined goods at the time of the combination. (6) Except for revocation, the principal is authorised to forfeit the assigned debts. The principal shall immediately forward the payments for the assigned debts for the amount of the secured debt to the contractor. In the event of reasonable cause, in particular delay in payment, cessation of payments, initiation of insolvency proceedings, act of protest or reasonable evidence for excess indebtedness or threatened payment incapacity, the contractor is entitled to revoke the forfeiture authorisation of the principal. In addition, the contractor can, after a prior warning of notifying the debtor of the assignment or of utilizing the assigned claims subject to observance of an adequate respite, notify the debtor of the assignment, utilize the assigned claims, and demand that the principal notify the customer of the assignment. (7) In the case of establishing prima facie evidence, the principal must provide the contractor with the necessary information and documents for the assertion of his rights against the customer. (8) For charges, seizures or other dispositions or intervention by third parties, the principal must immediately inform the contractor thereof. (9) Where the realizable value of all security rights, to which the contractor is entitled, exceeds the amount of all secured claims by more than 10%, the contractor at the request of the principal can approve a partial release of the security; the contractor has the choice between the various security rights. (10) In the event of contractual breaches by the principal, in particular late payment, the contractor is entitled to demand without notice the withdrawal of the delivery item or new item and / or rescind the contract; the principal is obliged to surrender the item. The demand for the return of a delivery item or new item does not constitute cancellation of the contract by the contractor unless expressly stated. 6. No liability for damages from distributors The seller is not liable for material damage of the delivery which he procured from third parties and distributed to the customer unchanged; the liability for intent and gross negligence remains unaffected. 7. Minor defects The liability for defects does not apply to insignificant deviations from the agreed conditions or to minor impairments to usability. General Terms & Conditions of Business 11. Liability (without delay of delivery / impossibility) (1) The contractor is liable in cases of intent or gross negligence of the contractor or an agent or agents in accordance with statutory provisions. In addition, the contractor is liable only under the Product Liability Act in cases of loss of life, limb or health or because of culpable violation of essential contractual obligations. The claim for damages for the breach of significant contractual obligations is, however, restricted to the contractual foreseeable damage. The liability of the contractor in cases of gross negligence is also restricted to contractual foreseeable damage, if none of the exceptions mentioned in Clause 2, of Para. 1 are present. (2) The liability for damages caused by the delivery item to legal interests of the principal, e.g. damage to other matters, is, however, fully excluded. This does not apply in cases of intent or gross negligence or injury to life, limb or health. (3)The aforementioned provisions in paragraphs 1 and 2 extend to damages in addition to performance and compensation in place of performance, regardless of the cause of action, in particular because of defects, breach of obligations arising from the debt ratio or tort actions. They also apply to claims to cover expenses. The liability for delay is determined in accordance with paragraph 12. However, the liability for impossibility is covered under paragraph 13. (4) A change in the burden of proof to the detriment of the principal is not connected to the above regulations. 12. Liability in the case of delayed delivery (1) If non-observance of time periods is due to force majeure, for example, mobilisation, war, riot or similar events, e.g. strike or lockout, the time periods shall be extended accordingly. (2) The contractor is liable for delay in performance of services in cases of intent or gross negligence on his part or on the part of an agent or agents in accordance with statutory provisions. The liability of the contractor in cases of gross negligence is restricted, however, to contractual foreseeable damage, if none of the exceptions stated in clause 5 of this provision are present. Furthermore, the liability of the contractor due to delayed performance for damages, in addition to performance, and in place of performance, is restricted to 5% of the value of deliveries / services. Additional claims by the principal, even after expiry of a deadline to the contractor, for performance, are excluded. The aforementioned restrictions do not apply to liability for injury to life, limb or health. A change in the burden of proof to the detriment of the principal is not connected to the above-mentioned regulations. 13. Liability in the case of impossibility The contractor is liable for the impossibility of delivery in cases of intent or gross negligence of the contractor or an agent or agents in accordance with statutory provisions. The liability of the contractor is in cases of gross negligence limited to contractual, foreseeable damage, if no exceptions are present that are stated in clause 5. In addition, the contractor's liability for damages due to impossibility and for compensation for expenses is restricted to 10% of the value of deliveries / services. Additional claims by the principal due to impossibility of delivery are excluded. This limitation shall not apply in cases of intent, gross negligence or injury to life, limb or health. The right of the principal to rescind the contract remains unaffected. A change in the burden of proof to the detriment of the principal is not connected with the above regulations. 14. Right to withdraw from the contract The principal may only, within the framework of the statutory provisions of the contract, withdraw from the contract if the contractor has performed a contractual breach; in the event of defects, however, the statutory conditions remain effective. In the event of contractual breaches, the principal must declare within an appropriate timeframe at the request of the contractor whether he is withdrawing from the contract due to contractual breach or he insists on the delivery. 15. Limitation of actions (1) The limitation of actions for claims and assertion of rights due to defects in deliveries / services, regardless of the cause in law, is one year for new items and barred for used items. This does not apply, however, for the cases specified in 479 S. 1 of the German Civil Code (BGB) (Right of recourse). The time periods stated in clause 2 are subject to a limitation period of three years. (2) Statute-barred or limitation regulations in accordance with S. 1 also apply to all claims for damages against contractors who are connected to the damage regardless of the cause of action of the claim. Insofar as claims for damages of any type arise against contractors who are not connected to the damage, the limitation period stated in 1 S. 1 applies. (3) The limitation period regulations in accordance with S. 1 and S. 2 apply with the following provisions: a) The limitation periods in general do not apply in the case of intent. b) The limitation periods also do not apply if the contractor intentionally misrepresented the defects by silence or if the contractor took out a guarantee for the conditions of the deliveries / services. If the contractor intentionally misrepresents the defects, then in place of the limitation periods listed in S. 1, the statutory limitation applicable to fraudulent intent apply [ 438 S. 1 No. 3 (other deliveries) and 634a S. 1 No. 1 German Civil Code (BGB) (Manufacture / Maintenance / Change of an item or Planning / Monitoring Services) and No. 3 (other services)] to the exclusion of the period extension for fraudulent intent in accordance with 438 S. 3 or 634 a S, 3 German Civil Code (BGB)),if no other exception is present in accordance with this S. 3. c) The limitation periods apply to claims for damages and not to cases of injury to life, limb or health, infringement of freedom, claims for product liability, gross negligence or breach of other significant contractual duties. (4) The period of limitation for all claims commences upon delivery of the items and for services upon acceptance. (5) Insofar as nothing else is expressly agreed, the statutory terms and conditions on the commencement of the limitation period, suspension of the statute of limitations, the suspension and recommencement of periods remain unaffected. (6) A change of the burden of proof to the detriment of the principal is not connected with the aforementioned regulations. 8. Choice of supplementary performance The contractor is entitled to choose between remedial and replacement options in all cases. If the subsequent performance fails, then the principal has the right to reduce or, at his own discretion, rescind the contract. [This does not affect the rights of the principal in accordance with the statutory provisions and conditions of this contract to demand damages in place of performance.] 9. Number of improvement attempts If the principal demands damages in place of performance or even self-remedy of defects, this isonly provided after the second attempt at repairing the item fails. The statutory provisions regarding the dispensability of setting a grace period shall remain unaffected. 10. Expenses for supplementary performance The expenses necessary for the purposes of subsequent performance shall be borne by the principal; if higher expenses are incurred as the deliveries or services in question are to be transported to a location other than that of the subsidiary of the principal, unless this is in the course of correct and proper use. 16. Recourse to contractor in accordance with 478 of the German Civil Code (BGB) Recourse to the purchaser against the seller in accordance with 478 German Civil Code (BGB) (Recourse to the Contractor) only exists if the purchaser has not come to any agreements with the seller resulting from the legal defects claims. 17. Part performance Part performances are permitted insofar as they are considered just and reasonable by the purchaser. 18. Offsetting The purchaser can only offset such claims that are undisputed and final. 19. Place of jurisdiction The sole place of jurisdiction for all disputes arising from this contract is the residence of the contractor, if the contracting partner of the contractor is the purchaser. 20. Applicable law This contract is governed by the law of the Federal Republic of Germany to the exclusion of the United Nations Convention on Contracts for the International Sale of Goods. 50

51 CHART CHART FOR STANDARD TUBE OUTSIDE DIAMETERS DIN ISO inch (DIN 11850) (EN ISO 1127) (ASME BPE 1997) ID (mm) ID (inch) 3, , /4 6, , /8 9, , ,2 10, , /2 12, , ,5 13, , , ,2 17, , , /4 19, , ,3 21, , , , ,9 26, , , , ,7 33, , /2 38, , , ,4 42, ,50 1,752 48,3 48, , , , , , ,3 60, /2 63, , ,1 76, , , ,9 88, , , , ,3 114, , , ,7 139, , , , ,3 168, , , , ,1 219, Standard collets available from stock for enclosed OSK weld heads. Non-Standard length are available on request. 51

52 Made in Germany orbital welding 32 Years ORBITEC GMBH Willi-Brehm-Straße 8 D Seligenstadt Germany Phone: +49 (0) 6182 / Fax: +49 (0) 6182 / info@orbitec-group.com Web: