Orbitalum RPG 1.5, Operating Instructions Manual

Page 1: ...power simplicity Operating instructions Tube Squaring Machines RPG ONE RPG 1 5 RPG 2 5 Cordless Electric Code 790 036 766 Translation of original operating instructions Machine No ________________________________ ...

Page 2: ...ed in particular the rights of duplication and distribution as well as translation Duplication and reproduction in any form print photocopy microfilm or electronic require the written permission of Orbitalum Tools GmbH ...

Page 3: ...ing plate 10 2 8 Accessories 11 2 8 1 Multifunctional tool MFW 11 2 8 2 Tool holder WH for beveling and squaring 11 2 8 3 Adapter clamping shell 12 2 8 4 Stainless steel clamping shells 12 3 Features and scope of application 13 3 1 Features 13 3 2 Scope of application 14 3 2 1 Application range 14 4 Technical data 14 4 1 Characteristics 14 5 Commissioning 15 5 1 Included with the machine 15 5 2 Co...

Page 4: ... 6 2 Adjusting the speed RPG Cordless 26 6 7 Processing the tube 27 6 7 1 Turn on the RPG Electric 28 6 7 2 Switching on RPG Cordless 28 6 7 3 Facing feeds and Adjustments 29 6 7 4 Switching off RPG Electric 29 6 7 5 Switching off RPG Cordless 30 6 8 Processing in restricted environments 30 6 8 1 Change position of drive 30 6 8 2 Change position of body 31 7 Maintenance 32 8 What to do if 33 8 1 T...

Page 5: ...ies or property damage Please read and observe these warning messages at all times This is a warning symbol It is designed to warn you against risks of injury Please follow all instructions marked 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 X Measures to mi...

Page 6: ...od Instruction You should pay attention to this symbol 1 Request for action in a sequence of actions You need to do something here X Single request for action You need to do something here Z Conditional request for action You need to do something here if the specified condition is met 0 3 Abbreviations Abbr Meaning RPG Tube Squaring Machine with electric drive RPG Cordless Tube Squaring Machine wi...

Page 7: ...ly recognised procedures for the prevention of accidents should be observed 1 1 Intended Use Use RPG ONE RPG 1 5 or RPG 2 5 exclusively as a bench machine for processing thin walled stainless steel or steel tubes and welded micro fittings Use RPG ONE Cordless RPG 1 5 Cordless or RPG 2 5 Cordless exclusively as a mobile machine for processing thin walled stainless steel or steel tubes and welded mi...

Page 8: ...es and safety gloves Tie up long hair hair net do not wear loose fitting clothes Note Jewellery and ties could get caught in the rotating parts Check that the work piece is correctly clamped After the work process have the machine switched off and let it run to a standstill Switch the machine off allow it to run to a standstill or take out the rechargeable battery before any change of tools cleani...

Page 9: ...und Do not touch the running tool while the machine is operating Always wear protective goggles and safety gloves Remove chips only with safety gloves Remove long and bent chips with pincers and or side cutting pliers Danger of death by electric shock If the mains cable is damaged live parts may cause death if touched directly Do not leave the power cord of the electric motor near the processing a...

Page 10: ... that were sold to you after August 13 2005 will be disposed of according to legal standards after they have been delivered free of cost to us by the customer Taking back old appliances which pose a risk to human health or safety due to soiling during their use may be refused The disposal of old appliances that were placed on the market before August 13 2005 is the responsibility of the end user P...

Page 11: ...ixing button 2 Viewing window 6 ON OFF switch 3 Feed with scale divisions 7 Bench stand removable 4 Driving motor Metabo 1010 Plus 8 Release handle for fixing the clamping shells 2 2 RPG ONE Cordless 1 Tool recipient housing 5 Rechargeable battery 2 Viewing window 6 ON OFF switch speed regulator 3 Feed with scale divisions 7 Release handle for fixing the 4 Metabo driving motor clamping shells 1 2 ...

Page 12: ...cipient housing 7 ON OFF switch 3 Viewing window slidable 8 Bench stand removable 4 Feed with scale divisions 9 Small clamp handles 5 Driving motor Metabo 1010 Plus 2 4 RPG 1 5 Cordless 1 Large clamp handle 5 Rechargeable battery 2 Viewing window slidable 6 ON OFF switch speed regulator 3 Feed with scale divisions 7 Small clamp handle 4 Metabo driving motor 8 Tool recipient housing 2 3 4 5 6 7 8 9...

Page 13: ... tool Step 1 2 refer to chap 6 6 1 p 25 for description refer to chap 2 7 p 10 7 Speed thumb wheel for fine tuning 13 Bench stand removable Steps A G refer to chap 6 6 1 p 25 14 Large clamp handle 2 6 RPG 2 5 Cordless 1 Small clamp handles 8 Rechargeable battery 2 Housing 9 ON OFF switch speed regulator 3 Viewing window slidable 10 Large clamp handle 4 Feed with scale divisions 11 Tool recipient w...

Page 14: ...bled in one of the 6 fastening threads 5 as a function of the above listed processing type and tube outer diameter X The bigger the outer diameter of the tube the further apart are the fastening threads selected for the tool holder see arrows X For exact positioning install the tool holder 4 with a multifunctional tool in the groove guide 6 and screw it in as a function of the desired processing t...

Page 15: ...t Possible application Bevel angle Tube OD RPG ONE Cordless Tube OD RPG 1 5 Cordless Tube OD RPG 2 5 Cordless Application range Squaring Beveling mm inch mm inch mm inch Standard tool holder WH12 I x 3 0 25 4 0 118 1 000 3 0 63 5 0 118 2 500 3 0 63 5 0 118 2 500 Optional tool holder WH12 I x 12 7 25 4 0 500 1 000 12 7 63 5 0 500 2 500 12 7 63 5 0 500 2 500 Optional tool holder WH12 I for micro fit...

Page 16: ...e processing range to min 6 35 mm 0 250 inch Comes with 1 Adapter clamping shell 1 long clamping screw Article Code Adapter clamping shell 790 030 094 2 8 4 Stainless steel clamping shells Not supplied as standard For deformation free clamping of tubes Extremely durable Ensures precise mounting of tubes micro fittings and quick change of clamping shells without tools For use on all materials with ...

Page 17: ...only if necessary a screw for fastening and fixing the tools tool cover TiN Cordless drive rotating removable Motor with high performance and small size No memory effect Single cell monitoring in the cordless pack Electronic overload protection with integrated temperature monitor Robust cordless packs with capacity display Minimal self discharge Environmentally friendly AIR COOLED technology for s...

Page 18: ... 5 Cordless mm 390x200x70 261x255x80 400x350x160 275x255x90 500x300x170 260x300x320 Dimensions lxhxd inch 15 35x7 87x2 76 10 28x10 04x3 15 15 75x13 78x6 30 10 83x10 04x3 54 19 69x11 81x6 69 10 24x11 81x12 60 kg 4 14 2 88 4 7 3 44 6 6 5 23 Weight without accessories lbs 9 13 6 35 10 36 7 58 14 6 11 8 Versions 230 V 50 60 Hz EU 110 V 50 60 Hz EU 120 V 50 60 Hz US 230 V 50 60 Hz EU 115 V 60 Hz US 230...

Page 19: ...90 037 118 1 Adapter clamping shell Code 790 030 094 for RPG 2 5 versions only 1 Tool holder WH Code 790 037 152 with 1 Multifunctional tool MFW Code 790 038 314 1 Tool set 1 Set of operating instructions and spare parts list Subject to change 5 2 Connection requirements The mains supply must meet the following requirements 1 phase alternating current protection class II 230 V 50 60 Hz 110 V 50 60...

Page 20: ...e check the machine is switched off before operating X Allow the machine to run to a standstill and remove the power plug from the power supply unit or take out the replaceable battery before transportation and or change of operating environment The RPG is a portable machine Special resources are not required for transportation carry the machines as shown in the diagrams to ensure safe transportat...

Page 21: ...power supply unit or take out the replaceable battery before repair maintenance job set ups change of tools as well as after the end of an operation Risk of injury due to rotating tool Do not touch the tool holder or tool mounting plate whilst processing keep loose clothes away from the processing area X Run the machine only with a clamped tube and a closed viewing window 1 Note the RPG ONE is not...

Page 22: ...se check the outer diameter of the tubes before ordering the clamping shells The different standards sometimes involve a special size particularly for tubes in accordance with DIN 2430 6 2 Assembly of multifunctional tool MFW and tool holder WH Danger of being injured by sharp cutting edges Do not touch the cutting edges while mounting the multifunctional tool X Wear protective gloves 6 2 1 Mount ...

Page 23: ...uide frontal from the front and place the processing type and outer diameter of tube accordingly RPG 2 5 Cordless according to the type of application beveling squaring install the tool holder in one of the 6 fastening threads as per description in chap 2 7 p 10 2 Tighten screw 2 of the tool holder with the spanner RPG ONE and RPG 1 5 Cordless RPG 2 5 Cordless The tool holder with the multifunctio...

Page 24: ... be flush with the inside of the housing Unscrew the clamp handle large handle 2 the end of the clamp handle must be flush with the inside of the housing Screw out clamping shell retainers small handles 3 till free play is achieved the end of the handles must be flush with the inside of the housing RPG ONE Cordless RPG 1 5 Cordless RPG 2 5 Cordless 6 3 1 Remove a clamping shell X If a clamping she...

Page 25: ...ws below The clamp shell has been installed correctly if it is locked in place If the clamping shell is not locked this fact can be rectified by a gentle turn of the clamping shell 2 Setting up clamping shells Screw in the clamping shell with the release handle 1 Screw in the clamping shell with the clamping shell retainers small handles 2 RPG ONE Cordless RPG 1 5 Cordless RPG 2 5 Cordless The cla...

Page 26: ...ocessed For further details refer to chap 2 8 3 p 12 1 Select correct clamping shell according to the tube dimension refer to chap 2 8 4 p 12 2 Unscrew the clamp handle large handle 1 flush with the body on the inside see arrows 3 Unscrew out the clamping shell retainers small handles 2 till free play is achieved flush with the body on the inside see arrows RPG 2 5 Cordless 6 4 2 Removing clamping...

Page 27: ...mping shell with the clamping shell retainers small handles 2 3 Press on the clamping shell slightly and install it into the adapter clamping shell The Orbitalum logo should cover the clamping shell with the point marked in red on the body see arrows below 4 Screw in the clamping shell with the clamp handle large handle 3 The clamping shell has been correctly installed if it is locked in place If ...

Page 28: ... multifunctional tool can be damaged by incorrectly setting up the tube X Before clamping the tube take care that there is enough space between the MFW and the tube X Clamp the tube squarely ensuring that the tube and machine axes are aligned If care is not taken the tube end may not be processed at right angles 1 Set up the tube in the clamping shell of RPG or with the use of a RPG Cordless guide...

Page 29: ...2 5 Cordless 0 24 0 83 6 6 1 Adjusting the speed RPG Electric The chip removal characteristic may be influenced by the speed The speed level can be pre installed using the speed regulator 1 in the RPG Electric The outer diameter of the tube can be adjusted precisely using the thumb wheel 2 Speed regulator 1 level codes Tortoise Level 1 9 52 min 1 Hare Level 2 27 153 min 1 Fine tuning of the thumb ...

Page 30: ...r to chap 6 6 p 25 and fine tuned via the speed regulator 2 The harder the speed regulator 2 is depressed the higher is the speed Chip removal can be influenced by the speed The processing of tubes can slow down and or influence the speed and it can be controlled with the speed regulator 2 X Regulate the speed with the speed regulator and or the ON OFF switch 2 X Press the speed regulator 2 furthe...

Page 31: ...oggles X Remove chips only with safety gloves Remove long and bent chips with pincers and or side cutting pliers Tool breakage Excessive feed can damage the cutting tool during the processing X Refer to Troubleshooting chap 8 1 p 33 X Only drive the rotating tool with limited feed to the tube A tube that is not sawn off at right angles can damage the tool MFW if the distance between the cutting ed...

Page 32: ...y 2 Set the desired speed via the speed regulator 1 3 Activate the ON OFF switch 2 The machine starts If the tool vibrates after starting the cutting speed is too high X Reduce the speed refer to chap 6 6 1 p 25 6 7 2 Switching on RPG Cordless 1 Check whether the viewing window is closed and close it if necessary 2 Connect battery 1 to RPG Cordless 3 Activate the ON OFF switch and or speed regulat...

Page 33: ... stop the machine refer to Troubleshooting chap 8 1 p 33 1 Introduce the tool with feed 1 to the tube until the tool is in contact Feed RPG Electric Feed RPG Cordless 2 When the tool is cutting at the complete face of the tube Z continue the tool with the same pressure further until the desired processing result is achieved Z To achieve the optimum squareness and finish the tool should be allowed ...

Page 34: ...s 3 Remove machine from tube refer to chap 6 5 p 24 6 8 Processing in restricted environments To make operation easier the position of the machine with respect to the tube can be changed as follows 6 8 1 Change position of drive 1 Release screw 1 on the reverse of the body Screw position of RPG ONE Cordless RPG 1 5 Cordless RPG 2 5 Cordless Screw position of RPG ONE Electric RPG 1 5 Electric RPG 2...

Page 35: ... 2 5_BA_04_790036766_00 doc 31 6 8 2 Change position of body Body position changeable only at the RPG 2 5 Cordless 1 Fully unscrew headless screw 2 on the reverse of the body 2 Rotate body to desired position only possible in 4 x 90 steps Pay attention to countersinks in the body 3 Assemble headless screw 2 2 ...

Page 36: ...ly be operated using a fault current FI protect switch X Allow the machine to run to a standstill and take out the plug from the power supply unit or take out the rechargeable battery before any change of tools cleaning maintenance setup and repair operations Interval Activity Every time the machine is cleaned X Clean clamping shell and body tool recipient Every time the tool is changed X Clean to...

Page 37: ...erating instructions of the charger X Use spare battery Rechargeable battery power system of the RPG Cordless does not work Battery not connected to RPG Cordless X Connect battery to RPG Cordless Tool tends to vibrate Speed too high X Reduce speed see chap 6 6 p 25 Strong tendency to vibrate Axial or radial play in the components MFW loose X Check machine for freedom from play X Check MFW on fixed...

Page 38: ...ist entwickelt konstruiert und gefertigt in Übereinstimmung mit folgenden EG Richtlinien was designed constructed and manufactured in accordance with the following EC guidelines è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive a été dessiné produit et commercialisé selon les Directives suivantes ha sido proyectado construido y comercializado bajo observación d...

Page 39: ...mero de serie Baujahr Year Anno Année Año ist entwickelt konstruiert und gefertigt in Übereinstimmung mit folgenden EG Richtlinien was designed constructed and manufactured in accordance with the following EC guidelines è stata progettato costruito e commercializzato in osservanza delle seguenti Direttive a été dessiné produit et commercialisé selon les Directives suivantes ha sido proyectado cons...

Page 40: ... 77 31 792 0 Fax 49 0 77 31 792 524 tools orbitalum com www orbitalum com An ITW Company Plant Division Orbitalum Josef Schüttler Straße 17 78224 Singen Germany 790 036 766_00 01 02 10 Orbitalum Tools GmbH D 78224 Singen 2010 Printed in Germany ...