Orbitalum PS 4.5 User manual

precision.
power.
simplicity.
ehemals / formerly known as
Georg Fischer Rohrverbindungstechnik
Operating
instructions
Portable Tube Saws
PS 4.5, PS 6.6
Code 790 048 762
│Machine-no.:
________________________________

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Duplication and reproduction in any form (print, photocopy, microfilm or electronic) require the written
permission of Orbitalum Tools GmbH.

Operating instructions PS 4.5, PS 6.6 Table of contents
orbitalum tools gmbh
(12.06) MT_PS 4.5, PS 6.6_BA_04_790048762_03.doc I
Table of contents
Page
0About these instructions 1
0.1 Warning messages 1
0.2 Further symbols and displays 2
0.3 Abbreviations 2
1Notes on safety 3
1.1 Proper use 3
1.2 Safety regulations 3
1.3 Working with safety in mind 4
1.4 Waste disposal / environmental protection 5
1.5 Further safety regulations 5
2Design of the product 6
2.1 Standard 6
2.2 Accessories 7
2.2.1 Quick mounting plate with screw clamps 7
2.2.2 Saw blades 7
2.2.3 Tripod 7
2.2.4 Clamping jaws for PS 6.6 7
3Features and scope of application 8
3.1 Features 8
3.2 Scope of application 9
4Technical specifications 10
5Commissioning 11
5.1.1 Scope of delivery* 11
6Transport and assembly 12
6.1 Transport 12
6.1.1 Positioning the PS in the durable storage and
shipping case 12
6.2 Mounting the on the work bench 13
6.2.1 Mounting the PS on the work bench without quick
mounting plate 13
6.2.2 Mounting the PS on the work bench with quick
mounting plate 14
6.2.3 Mounting the PS on the Tripod 14
7Operation 15
7.1 Mounting the clamping jaws to the vice 16
7.1.1 Disassembling clamping jaws from PS 4.5 16
7.1.2 Disassembling clamping jaws from PS 6.6 17
7.2 Mounting the saw blade on saw position 1 18
7.3 Mounting the saw blade on saw position 2 21
7.4 Adjusting the tube dimension 23
7.5 Selecting speed stages 25
7.6 Cutting the tube (saw position 1) 26
7.7 Cutting elbows (saw position 2) 27

Table of contents Operating instructions PS 4.5, PS 6.6
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7.8 Cutting tubes or elbows in a cramped workplace 28
7.8.1 Altering the swivel radius 28
8Maintenance 29
9What to do if ...? 30
9.1 General trouble shooting 30
9.2 Servicing/after-sales service 31

Operating instructions PS 4.5, PS 6.6 0 About these instructions
orbitalum tools gmbh
(12.06) MT_PS 4.5, PS 6.6_BA_04_790048762_03.doc 1
0 About these instructions
To allow quick understanding of these instructions and safe handling of the
machine, all the warning messages, notes and symbols used in these
instructions are presented here along with their meaning.
0.1 Warning messages
In these instructions, warning messages are used to warn you against the
dangers of injury or material damage. Always read and observe these warning
messages!
This is a warning symbol. It should warn you against dangers
of injury.
Follow all instructions which are identified with this safety
symbol in order to avoid injuries or death.
Warning
symbol
Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
!Restrictions (if applicable).
!Measures to prevent danger.
WARNING
Possible danger!
Non-observance could result in serious injury.
!Restrictions (if applicable).
!Measures to prevent danger.
ATTENTION
Dangerous situation!
Non-observance could result in minor injuries.
ATTENTION
Dangerous situation!
Non-observance could result in material damage.

0 About these instructions Operating instructions PS 4.5, PS 6.6
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0.2 Further symbols and displays
Symbol Meaning
Important
Note
Notes: Contain particularly important information for
comprehension.
Instruction: You must take notice of this symbol.
1.
Request for action in a sequence of actions: You have to do
something here.
!
Single request for action: You have to do something here.
"Conditional request for action: You have to do something here
if the specified condition is met.
0.3 Abbreviations
Abbr. Meaning
PS 4.5 Portable Tube Saw for cutting tubes with an outer diameter
of up to 4.5 inches
PS 6.6 Portable Tube Saw for cutting tubes with an outer diameter
of up to 6.6 inches

Operating instructions PS 4.5, PS 6.6 1 Notes on safety
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1 Notes on safety
The Portable Tube Saw (in the following referred to as PS) is a state-of-the-art
machine. Using it for purposes other than those described in this manual may
cause injury to the user or to others. The machine or other equipment may also
be damaged.
Therefore:
•Always ensure that the machine is in good working condition, and always
comply with these notes on safety.
•Keep the complete documentation close by the machine.
•Generally valid regulations for the prevention of accidents must be
observed.
1.1 Proper use
•Use the PS only for cutting tubes and elbows (see “Scope of application”,
chapter 3.2, p. 9).
•The user will be the only person liable for damages caused by improper
use.
1.2 Safety regulations
•Only use the dimensions and materials specified in this manual. Always
consult Orbitalum Tools after-sales service personnel before using other
materials.
•Read the enclosed safety notes completely and carefully before working
with the electric tool Metabo SBE 1010 Plus.
•Only use original Orbitalum Tools spare parts and auxiliaries.
•Inspect the PS every day for visible signs of damage or defects.
Any damage or defect must be repaired immediately.
•Work on the electrical equipment may only be performed by a qualified
electrician.
•Disconnect the PS from power supply before changing the tools or carrying
out maintenance and repair work and allow the machine to come to a stop.
•Do not use the PS unless all safety devices (restart inhibitor, saw blade
guard) are working properly and the fixtures are fitted securely on the work
bench.

1 Notes on safety Operating instructions PS 4.5, PS 6.6
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1.3 Working with safety in mind
"Make your contribution to safety in the workplace."
•Report any unusual behavior of the machine to the person in charge
immediately.
•Always work with safety in mind.
•Wear safety goggles, safety gloves and ear protection when working with
the PS.
•Tie up long hair (snood-type cap); do not wear any wide clothing.
Attention: jewelry and ties can get caught by rotating parts.
•Switch off the PS after each working cycle and allow the machine to come
to a stop.
•Disconnect the PS from power supply before performing any cleaning,
maintenance or repair work and allow the machine to come to a stop.
•Keep hands away from the tools during processing.
•Keep the PS dry, do not use it in the rain.
•Do not use the PS in areas subject to explosion hazards.
•Do not carry the electric tool holding it at the cable and do not use it to pull
the plug out of the socket. Protect the cable against heat, oil and sharp
edges (chips).
•Read the enclosed safety notes on the driving motor Metabo 1010 Plus
carefully.
Danger of death by electric shock
If the mains cable is damaged, live parts may cause death when being touched
directly.
!Keep the mains cable of the tube saw motor away from the saw blade.
!Secure the falling tube piece.
!Do not let the cut-off tube piece drop in an uncontrolled way.
!Do not run the machine unattended.
!While processing the tube, always keep an eye on the position of the mains
cable.
Danger of being injured by sharp cutting edges
!Keep hands away from the tools during cutting.
!Never equip both sawing positions with saw blades at the same time.
!Wear safety gloves.
DANGER
WARNING

Operating instructions PS 4.5, PS 6.6 1 Notes on safety
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Danger of being injured by the rotating slide housing
!Make sure that the slide housing starts from its home position.
!Clamp the tube to be processed into the vice.
1.4 Waste disposal / environmental protection
•Dispose of chips and used gear lubricant oil according to the regulations.
Discarded electric tools and accessories contain a large share of
valuable raw and synthetic materials which can be recycled.
Therefore:
•Electrical (electronic) devices which are marked with the symbol to the left,
may not be disposed of with household waste in accordance to the EU
directive 2002/96/EC.
•By actively using the offered return and collection systems, you actively
contribute to the reuse, recycling and utilization of electrical (electronic)
devices.
•Electrical (electronic) used devices contain parts which must be handled
selectively according to the EU directive. Separate collection and selective
treatment is the basis for environment-friendly disposal and the protection
of human health.
•Our products that were sold to you after August 13th, 2005 are taken back
and treated according to legal standards. These products have to be send
free of charge.
•The return of used devices which pose a health or safety risk for human
beings due to soiling during use may be refused.
•The legally compliant disposal of electrical (electronic) devices that were
placed on the market before August 13th, 2005 are in the responsibility of
the end-user.
1.5 Further safety regulations
Observe the regulations, standards and guidelines applicable in your country.
WARNING
(RL 2002/96/EC)

2 Design of the product Operating instructions PS 4.5, PS 6.6
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2 Design of the product
2.1 Standard
1 Turning handle for clamping jaws 11 Allen wrench
2 Saw blade position 1 (to loosen the clamping
3 Saw blade position 2 screw of the motor)
4 Saw blade guard 12 Electric motor
5 Hand wheel 13 Speed setting
6 Type plate 14 Slide
7 ON/OFF switch 15 Slide housing
8 Arrest button 16 Vice
9 Motor grip 17 Swivel ring
10 Connecting cable with rotary contact 18 Aluminum clamping jaws
19 Slide jaws
15
1
16
14
13
12
7
8
9
10
11
5
3
6
4
2
18
19
17

Operating instructions PS 4.5, PS 6.6 2 Design of the product
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2.2 Accessories
Not included in the standard scope of supply.
2.2.1 Quick mounting plate with screw clamps
Easy and fast assembly. Including 4 hexagon socket screws for mounting the
PS on the quick mounting plate.
Article Code-no.
Quick mounting plate with screw clamps 790 048 334
2.2.2 Saw blades
Orbitalum Tools Performance Range.
Tube wall
thickness
[mm]
Tube wall
thickness
[inch]
Saw blade Ø
[mm]
Saw blade Ø
[inch]
Code-no.
1.0 - 3.0 0.039 - 0.118 63 2.480 790 048 072
1.2 - 2.5 0.047 - 0.098 63 2.480 790 041 035
0.6 - 1.2 0.024 - 0.047 63 2.480 790 041 036
2.2.3 Tripod
Made of stainless steel. Easy assembly of the PS saw on the Tripod.
•Space saving
•Fast application
•Easy handling
Article Code-no.
Tripod for PS 790 048 335
2.2.4 Clamping jaws for PS 6.6
It is possible to cut tubes with a outer diameter min. 30 mm (1.181 inch) by
using additional clamping jaws (accessory, Code 790 048 380).These
clamping jaws are delivered as a standard with the PS 4.5.
Made from coated aluminum-cast.
Article Code-no.
Clamping jaw set PS 4.5 790 048 380

3 Features and scope of application Operating instructions PS 4.5, PS 6.6
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3 Features and scope of application
3.1 Features
The Portable Tube Saws PS are distinguished by the following main features:
•Increased safety due to stationary tube and rotating tool
•Self-centering vice with all-purpose aluminum-coated clamping jaws
•Low-maintenance gearing
•Variable-speed electric motor with restart inhibitor
•Right-angled, burr-free and deformation-free cut
•Cold machining process
•Quick cutting process
•Easy and space-saving assembly
•Quick tool change
•Saw blade position 1: Cutting of tubes
Saw blade and clamping jaws are close to one another to absorb vibrations
when sawing
•Saw blade position 2: Cutting of elbows

Operating instructions PS 4.5, PS 6.6 3 Features and scope of application
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3.2 Scope of application
Machine Material Saw
position
Tube OD
[mm]
Tube OD
[inch]
Wall
thickness
[mm]
Wall
thickness
[inch]
Tube 1 6 - 120 0.236 - 4.724
PS 4.5 Elbow 2 30 - 120 1.181 - 4.724
Tube 1 50* - 170 1.969* - 6.693
PS 6.6 Elbow 2 50* - 170 1.969* - 6.693
< 3 < 0.118
*) It is possible to cut tubes with a outer diameter min. 30 mm (1.181 inch) by using additional
clamping jaws. These clamping jaws are delivered as a standard with the PS 4.5
(see „Accessories“, chapter 2.2.4, p. 7).
•Stainless steel with the following mass fractions:
–Cr ≤12%; Mo < 2%; Ni < 26%
–Cr ≤20%; Mo = 0%; Ni < 13%
–Cr ≤28%; Mo < 8%; Ni < 30%
•High-alloy steel (stainless steel, material no. 1.40... – 1.45... in accordance
with DIN 17455 and 17456)
•Unalloyed and low-alloy steel
•High-temperature steels
•Aluminum
•Copper
•CuNi-materials
Consult Orbitalum Tools before using for other applications or materials.
Working range
Tube materials

4 Technical specifications Operating instructions PS 4.5, PS 6.6
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4 Technical specifications
Characteristics PS 4.5 PS 6.6
Dimensions (l x b x h) 480 x 230 x 600 mm
20.9 x 9.1 x 23.6 inches
480 x 230 x 660 mm
20.9 x 9.1 x 26 inches
Weight 19 kg / 41.9 lbs 22 kg / 48.5 lbs
Power 1010 W 1010 W
Protection class Totally insulated in
accordance with
class II, DIN VDE 0740
Totally insulated in
accordance with
class II, DIN VDE 0740
Speed 30 – 160 rpm 30 – 160 rpm
Versions 110 V, 50/60 Hz
120 V, 50/60 Hz
230 V, 50/60 Hz
110 V, 50/60 Hz
120 V, 50/60 Hz
230 V, 50/60 Hz
Vibration level in
accordance with
EN 28662, part 1
< 2.5 m/s² < 2.5 m/s²
Sound pressure level at
workplace*)
approx. 78 dB (A) approx. 78 dB (A)
*) The sound pressure level was measured under normal operating conditions in accordance
with EN 50144-1. As the noise level may also exceed 85 dB (A) under unfavorable operating
conditions, we recommend the use of a suitable ear protection when the machine is used for
extended periods.

Operating instructions PS 4.5, PS 6.6 5 Commissioning
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5 Commissioning
!Check all parts of the delivery for completeness and transportation
damage.
!Report any missing parts or transportation damage to your supplier
immediately.
5.1.1 Scope of delivery*
•1 Portable Tube Saw PS 4.5 or PS 6.6
•1 Set of clamping jaws made from coated aluminum-cast
•1 Durable storage and shipping case
•1 Saw blade (already mounted to the tube saw)
•1 Ring spanner (SW22)
•4 Allen screws (M8 x 80) for mounting the machine on the work bench
•3 Allen keys (SW5, SW6, SW8)
•1 Brush
•1 Tube of GF TOP saw blade lubricating compound
•1 Tool bag
•1 Set of operating instructions and spare parts list
*)Subject to modifications
Checking the scope
of delivery

6 Transport and assembly Operating instructions PS 4.5, PS 6.6
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6 Transport and assembly
6.1 Transport
Danger of death caused by electric shock and restart of the machine
During transportation, the ON/OFF switch could be actuated inadvertently so
that the machine is started.
!Cut off the power supply before carrying out the transportation or a
workplace change and allow the machine to come to a stop.
The PS is a portable machine. Special transportation aids are not required.
For a safe transport, hold the machine as shown in the illustration on the left.
6.1.1 Positioning the PS in the durable storage and shipping case
For a safe transport, the PS 4.5 of PS 6.6 should be positioned in the durable
storage and shipping case as shown in the two pictures below:
!The vice (with or without quick mounting plate) should lie parallel to the
length side of the case in the wooden enclosure.
!The slide housing with motor then should be rotated approx. 70° sidewards,
so that it fits into the case enclosure.
PS with quick mounting plate PS without quick mounting plate
DANGER
70° 70°

Operating instructions PS 4.5, PS 6.6 6 Transport and assembly
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6.2 Mounting the on the work bench
6.2.1 Mounting the PS on the work bench without quick mounting
plate
Fit the Portable Tube Saw together with the vice on the work bench:
1. Use the PS as a template to punch holes in the work bench.
2. Drill 4 holes of 9 mm Ø.
3. Fasten the PS 4.5 to the work bench using 4 hexagon socket screws (1).
1

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6.2.2 Mounting the PS on the work bench with quick mounting plate
The quick mounting plate with screw clamps is not included in the scope of
supply but is obtainable as extra accessory (see chapter 2.2.1, p. 7).
Fit the Portable Tube Saw together with the vice to the quick mounting plate:
1. Screw the quick mounting plate to the work bench by means of the 2 screw
clamps.
2. Mount the PS to the quick mounting plate with 4 Allen screws.
6.2.3 Mounting the PS on the Tripod
The Tripod is not included in the scope of supply but also obtainable as extra
accessory (see chapter 2.2.3, p. 7).
To mount the Portable Tube Saw on the Tripod:
!Mount the PS to the Tripod with 4 Allen screws.

Operating instructions PS 4.5, PS 6.6 7 Operation
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7 Operation
Use the Portable Tube Saw PS for cutting tubes and elbows only.
The user will be the only person liable for damages caused by improper use.
Saw position 1 Saw position 2
Cutting tubes Cutting elbows
Note
Which saw position
for which application?
Saw position 1
Saw position 2

7 Operation Operating instructions PS 4.5, PS 6.6
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7.1 Mounting the clamping jaws to the vice
The PS 4.5 is equipped with rotatable clamping jaws made from coated
aluminum cast. By rotating of the clamping jaws it is possible to process
small (<45 mm/1.772 inch) or large (> 45 mm/1.772 inch) tube diameters
(see „Scope of application“, chapter 3.2, p. 9).
When delivery of the PS 4.5 the clamping jaws are already mounted on the
PS 4.5, so that it can be started with processing of tubes > 45 mm/1.772 inch.
With the standard clamping jaws of the PS 6.6 made from coated aluminum cast
it is possible to process tubes with a outer diameter of > 50 mm/1.969 inch.
They are included in the standard scope of supply and are on delivery already
mounted on the PS 6.6. To cut tubes with a smaller outer diameter (min. 30 mm /
1.181 inch), special clamping jaws are necessary (see “Accessories”,
chapter 2.2.4, p. 7).
7.1.1 Disassembling clamping jaws from PS 4.5
1. Detach 2 wing screws (1) sidewards of the vice.
2. Remove the clamping jaws and turn by 180°.
3. Fasten the clamping jaws with 2 wing screws.
Note
1
1
180°