Operating instructions with spare parts list RPG
Contents
1. OD mm inch min 3 18 0 125 max 25 40 1 000 The maximum machinable wall thickness is 2 mm 0 079 inches High alloy steels high grade steel material no 1 40 1 45 in accordance with DIN 17 455 and DIN 17 456 unalloyed and low alloy steels aluminum others on request 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 4 Technical specifications 4 Technical specifications 4 1 Rating Dimensions RPG 1 0 Cordless RPG 1 0 Cordless right angled drive 145 x 380 x 75 mm 235 x 380 x 75 mm 9 25 x 15x 3 inch 5 7 x 15x 3 inch Total weight with accumulator without clamping shells 2 1 kg 4 63 Ibs 2 2 kg 4 85 Ibs Voltage of rechargeable accumulator 12 V 12V Power supply of battery charger 220 240 V 50 60 Hz 220 240 V 50 60 Hz Speed max idling speed 0 400 min rpm 0 350 min rpm Noise level at the workplace Idle running approx 70 dB A With load approx 85 dB A Idle running approx 70 dB A With load approx 85 dB A Vibration level according to EN 50144 lt 2 5 m s lt 2 5 m s G orbitalum tools gmbh 09 07 MT_RPG 1 0 BA_04 790036762_02 doc 11 5 Commissioning Operating instructions RPG 1 0 Cordless right angled drive 5 Commissioning Checking the scope Check all parts of the deli2. gt orbitalum u tools for piping systems simplicity Operating instructions with spare parts list Tube Squaring Machines RPG 1 0 Cordless right angled drive Code 790 036762 _ Maschine no ehemals formerly All rights reserved 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 Operating instructions RPG 1 0 Cordless right angled drive Table of contents Table of contents Page 0 About these instructions 1 0 1 Warning messages 1 0 2 Further symbols and displays 2 0 3 Abbreviations 2 1 Notes 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 4 1 5 Further safety regulations 5 2 Design ofthe product 6 2 1 RPG 1 0 Cordless 6 2 2 RPG 1 0 Cordless right angled drive 7 2 3 Accessories 8 2 3 1 Multifunctional tool MFW 8 2 3 2 One piece clamping shells 8 2 3 3 Durable storage and shipping case 9 3 Features and scope of application 10 3 1 Features 10 3 2 Scope of application 10 4 Technical specifications 11 4 1 Rating 11 5 Commissioning 12 5 1 Scope of delivery 12 5 2 Transport 13 6 Operation 14 6 1 Preparation 14 6 2 Mounting the multifunctional tool MFW to the tool support 15 6 3 Inserting and replacing clamping shells 16 6 4 Mountin
3. tubes the number of revolutions may decrease or be influenced and can be readjusted with the speed controller 7 G orbitalum tools gmbh 09 07 MT_RPG 1 0 BA_04 790036762_02 doc 19 6 Operation Switching the RPG 1 0 on Increasing the speed Reducing the speed Stopping the RPG 1 0 WARNING ATTENTION 20 Operating instructions RPG 1 0 Cordless right angled drive gt Press the speed controller down stronger gt Release the speed controller 6 7 Machining the tube Hot and sharp edged chips Danger of injuries to eyes and hands gt Always wear protective goggles while working gt Only remove chips when wearing safety gloves Tool damage The tool could get stuck in the tube during processing gt See Trouble shooting chapter 8 p 24 gt Move the rotating tool towards the tube end setting the automatic advance to a very low level If the tool gets stuck in the tube during processing and the ON OFF switch remains pressed the drive could get damaged due to overheating gt Release the ON OFF switch immediately and remove the machine from the tube If the speed is reduced too quickly during processing the tool could get stuck in the tube and come to a stop gt Always reduce the advance evenly A tube which has not been cut off square could damage the tool MFW if the distance between the cutting edge and the tube end is too short Before switching on the RPG 1 0 make sure t
4. 3 To detach the machine from the tube turn the release handle 5 machine from the counterclockwise tube G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 17 6 Operation 18 Operating instructions RPG 1 0 Cordless right angled drive 6 5 Machining tubes in a cramped working area 6 5 1 Adjusting the feed unit The feed unit with release handle is adjustable in 3 positions 1 Detach the feed with scale ring 2 by turning clockwise 2 Unplug the feed unit 1 and turn into the desired position Position 1 Standard Position 2 Position 3 3 Attach the feed with scale ring 2 by turning counterclockwise 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 6 Operation 6 5 2 Adjusting the release handle It is possible to adjust the release handle of the RPG 1 0 in any position Slightly unplug the release handle 5 and turn to the desired position 6 6 Determining the speed Speed range Speed range RPG 1 0 Cordless RPG 1 0 Cordless right angled drive 0 400 rpm 0 350 rpm gt Set the speed by means of ON OFF switch speed controller 7 RPG 1 0 Cordless RPG 1 0 Cordless right angled drive Notes e The more the speed controller 7 is pressed the higher is the number of revolutions e The machining behavior can be influenced by altering the speed e During the processing of
5. T_RPG 1 0 BA _04 _790036762_02 doc 15 6 Operation Operating instructions RPG 1 0 Cordless right angled drive 6 3 Inserting and replacing clamping shells 1 Select the appropriate set of clamping shells according to the tube dimension see chapter 2 3 2 p 8 2 Turn out the release handle 5 the end of the release handle must be flush with the inside of the housing Removing If an already mounted set of clamping shells is to be replaced it can now be clamping shells removed by compressing it Inserting 3 Compress the set of clamping shells 6 slightly and insert it into the clamping shells housing Note The clamping shell is correctly inserted if it has engaged If the clamping shell does not engage readjustment is possible by slightly turning the clamping shell The set of clamping shells has now been inserted correctly 16 09 07 MT_RPG 1 0 BA_04 790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 6 Operation 6 4 Mounting the tube ATTENTION Tool damage The multifunctional tool could get damaged by an incorrect inserted tube gt Before clamping the tube make sure that there is sufficient distance between the MFW and the tube Fixing the machine 1 Fix the machine with sufficient distance to the tube to the tube 2 Toclamp the tube turn the large release handle 5 clockwise to the limit AU The tube may now be processed Detaching the
6. Work on the electrical equipment may only be performed by a qualified electrician Disconnect the RPG 1 0 from power supply before changing the tools transport or carrying out maintenance and repair work and allow the machine to come to a stop 09 07 MT_RPG 1 0 BA_04 790036762_02 doc 3 1 Notes on safety RL 2002 96 EC Operating instructions RPG 1 0 Cordless right angled drive 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 and safety gloves when working with the RPG 1 0 Tie up long hair snood type cap do not wear any wide clothing Attention jewelry and ties can get caught by rotating parts Make sure that the work piece has been clamped correctly Switch off the RPG 1 0 after each working cycle and allow the machine to come to a stop Disconnect the RPG 1 0 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 Pay attention to the surroundings Do not use any electric tools or rechargeable batteries in a damp or wet area Make sure to have good illumination Do not work near combustible liquids or gases 1 4 Waste disposal environmental protection Dispose of chips and used gear lubricant oil according to the regulati
7. com An ITW Company 790 036 762_02 04 09 07 Orbitalum Tools GmbH D 78224 Singen 2007 Printed in Germany Jo Or b t a um ehemals formerly tools for piping systems
8. cumulator is Recharge the accumulator almost run down The multifunctional tool loose Tighten the multifunctional tool The driving motor of the RPG 1 0 The rechargeable accumulator is Recharge the accumulator is not running completely run down see the enclosed operating instructions of the battery charger gt Use the stand by accumulator The rechargeable accumulator has not been connected to the RPG 1 0 gt Connect the rechargeable accumulator to the RPG 1 0 The tool tends to vibrate The cutting speed is too high gt Reduce the number of revolutions cutting speed see chapter 6 6 p 19 High level of vibration Axial or radial play in the components The multifunctional tool is loose gt Check the machine for zero backlash gt Check the multifunctional tool for tightness The machined tube is rough or shows too much burr The multifunctional tool is blunt gt Replace the multifunctional tool 8 2 Servicing customer service For ordering spare parts see the spare parts list from chapter 9 p 25 For problem solving please contact your competent branch office directly Please give the following details e Machine type RPG 1 0 Cordless RPG 1 0 Cordless right angled drive e Machine number see the identification plate 24 09 07 MT_RPG 1 0 BA _04 790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless
9. es Multifunctional tool MFW Contained in the standard scope of delivery Multifunctional tool with 2 cutting edges and high performance coating Futura Balinit Usable for all tool holders of the RPG series Article For tube OD mm For tube OD inch Code no MFW P 2 3 18 25 4 0 125 1 790 038 314 Torx screw 790 086 220 2 3 2 One piece clamping shells Extreme durable Ensures accurate centering and quick clamping shell change without any tools Not contained in the standard scope of delivery Other dimensions are available upon request Article For tube OD mm For tube OD inch Code no One piece clamping 3 18 0 125 790 036 201 shell 6 35 0 250 790 036 202 9 53 0 375 790 036 203 10 00 0 394 790 036 204 12 00 0 472 790 036 205 12 70 0 500 790 036 206 17 20 0 677 790 036 207 19 05 0 750 790 036 208 21 30 0 839 790 036 209 25 40 1 000 790 036 210 One piece clamping 6 00 0 236 790 036 304 shell for micro fittings 6 35 0 250 790 036 301 9 53 0 375 790 036 302 10 00 0 394 790 036 305 12 00 0 472 790 036 306 12 70 0 500 790 036 303 Please check the outer diameter of the pipe before ordering the clamping shells The various standards sometimes mean a special outline dimension in particular for pipes in accordance with DIN2430 8 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 C
10. g the tube 17 6 5 Machining tubes in a cramped working area 18 6 5 1 Adjusting the feed unit 18 6 5 2 Adjusting the release handle 19 6 6 Determining the speed 19 6 7 Machining the tube 20 6 7 1 Switching the machine on 21 6 7 2 Advancing the tool 21 7 Maintenance 23 8 What to do if 24 8 1 Trouble shooting 24 8 2 Servicing customer service 24 9 Spare parts list 25 G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc Table of contents Operating instructions RPG 1 0 Cordless right angled drive 9 1 RPG 1 0 Cordless 25 9 2 RPG 1 0 Cordless right angled drive 26 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 0 About these instructions 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 Meaning symbol Direct danger Non observance could result in death or critical i
11. h versions of the tube facing machine is identical the pictures shown in this chapter solely represent the essential working steps using the RPG 1 0 cordless version Danger of injury by unintended restart of the machine gt Remove the rechargeable accumulator before performing any repair maintenance or adjustment work or tool change Danger of injury Rotating tool support Do not reach into the tool support while machining keep wide clothing away from the working area gt Operate the machine only after the tube has been clamped 6 1 Preparation 1 Specify the tube dimension to be processed 2 Select the multifunctional tool and the clamping shells for tool accessories see chapter 2 3 p 8 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 6 Operation 6 2 Mounting the multifunctional tool MFW to the tool support Danger of injury Sharp cutting edges Do not touch the cutting edges when mounting the multifunctional tool WARNING gt Wear safety gloves 1 To detach the feed unit 1 turn the feed with scale ring 2 clockwise 2 Screw the multifunctional tool 3 to the tool support 4 using the Torx screwdriver 3 Mount the feed unit 1 by means of turning the feed with scale ring 2 counterclockwise The assembly of the multifunctional tool is now completed G orbitalum tools gmbh 09 07 M
12. hat there is sufficient distance between the cutting edge MFW and the tube end 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 6 Operation 6 7 1 Switching the machine on 1 Connect the rechargeable accumulator 8 to the RPG 1 0 RPG 1 0 Cordless RPG 1 0 Cordless right angled drive 2 Press the ON OFF switch or speed controller 7 RPG 1 0 Cordless RPG 1 0 Cordless right angled drive The machine starts to run Note Ifthe tool chatters after starting the facing speed is too high gt Reduce the speed see chapter 6 6 p 19 6 7 2 Advancing the tool Feed with scale ring e Each pitch line corresponds to an advance of 0 05 mm 0 002 in one revolution corresponds to an advance of 1 5 mm 0 059 in e When facing make sure not to exceed a chip thickness of 0 05 mm 0 002 in If this thickness is exceeded the speed can be reduced or it can cause a stop of the machine see Trouble shooting chapter 8 p 24 orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 21 6 Operation Operating instructions RPG 1 0 Cordless right angled drive e There are 3 marks 9 on the feed unit to metering the feed 1 Move the tool towards the tube by means of the feed with scale ring 2 until the tool contacts the tube 2 When the cutting edge of the tool is facing along the entire circumference of the tube gt G
13. njury Restrictions if applicable gt DANGER Measures to prevent danger Possible danger Non observance could result in serious injury Restrictions if applicable gt WARNING Measures to prevent danger Dangerous situation Non observance could result in minor injuries gt ATTENTION ATTENTION Dangerous situation Non observance could result in material damage G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 1 0 About these instructions Operating instructions RPG 1 0 Cordless right angled drive 0 2 Further symbols and displays Symbol Meaning Important Note Notes Contain particularly important information for comprehension i _ Instruction You must take notice of this symbol 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 RPG 1 0 Cordless RPG 1 0 Cordless right angled drive Tube Squaring Machine for tubes with an outer diameter of up to 1 0 inches equipped with a rechargeable accumulator Tube Squaring Machine for tubes with an outer diameter of up to 1 0 inches equipped with rechargeable accumulator and with a right angled drive MFW Multifunctional To
14. o on advancing the tool with constant pressure until the desired machining result is achieved Switching the 3 Release the ON OFF switch or speed controller respectively RPG 1 0 off The machine comes to a stop 4 Detach the machine from the tube 22 09 07 MT_RPG 1 0 BA_04 790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 7 Maintenance 7 Maintenance Danger of being injured when pressing the ON OFF switch inadvertently gt Remove the rechargeable accumulator from the machine before performing DANGER any maintenance work Time Interval Activity Whenever the machine gt Clean the clamping shells and the housing tool support is cleaned Whenever the tool is Clean the tool support and the multifunctional tool changed G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 23 8 What to do if Operating instructions RPG 1 0 Cordless right angled drive 8 Whatto do if 8 1 Trouble shooting In the following table you will find possible causes for faults and the appropriate remedies Fault Possible cause Remedy The tool multifunctional tool is catching during machining Too much forward feed gt Reduce the feed gt Remove the tube from the machine gt Remove the chip using side cutting pliers and file off the shoulder Feed carefully for further machining The rechargeable ac
15. ol 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 1 Notes on safety G orbitalum tools gmbh 1 Notes on safety The Tube Squaring Machine Cordless and or with right angled drive in the following referred to as RPG 1 0 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 RPG 1 0 exclusively for machining thin walled tubes see Scope of application chapter 3 2 p 10 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 handling the rechargeable accumulator and the battery charger Only use original Orbitalum Tools spare parts and auxiliaries Inspect the RPG 1 0 every day for visible signs of damage or defects Any damage or defect must be repaired immediately
16. ons 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 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 1 Notes on safety e 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 e Batteries which are marked with the symbol on the left may not be disposed of together with household waste according to the applicable EU di
17. ordless right angled drive 2 Design of the product G orbitalum tools gmbh 2 3 3 Durable storage and shipping case High quality blue transportation case with insert Very sturdy design Already included in the standard scope of delivery of the RPG 1 0 Cordless right angled drive Article Code no Durable storage and shipping case 790 036 080 09 07 MT_RPG 1 0 BA_04 790036762_02 doc 9 3 Features and scope of application 10 Working range Tube materials Operating instructions RPG 1 0 Cordless right angled drive 3 Features and scope of application 3 1 Features The RPG 1 0 is suitable for squaring tube ends made of metallic materials It has the following features Tube end preparation for welds conforming to standards Only one multifunctional tool is needed for different tube wall thicknesses up to 2 mm 0 079 inches different tube materials exclusively ferritic materials Multifunctional tool cutting geometry adapted to application multi cutting tool only one screw is needed to fix and secure the tools tool coating TiN Machine hand operated Drive with rechargeable accumulator Quick clamping system for tubes Quick change system for clamping shells Feed with scale ring total 10 mm 0 393 inches per revolution 1 5 mm 0 059 inches per pitch line 0 05 mm 0 002 inches Feed unit twistable detachable Release handle adjustable 3 2 Scope of application
18. rective 91 157 EEC e With batteries containing hazardous substances the chemical symbol for the heavy metal content is indicated below the waste bin 1 5 Further safety regulations Observe the regulations norms and guidelines specific to your country G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 5 2 Design of the product Operating instructions RPG 1 0 Cordless right angled drive 2 Design of the product 2 1 RPG 1 0 Cordless 1 Rechargeable accumulator Housing with driving motor Switch for right handed left handed rotation 10 Feed with scale ring Release handle for fixing the clamping shells ON D 09 07 MT_RPG 1 0 BA_04 790036762_02 doc Feed Unit ON OFF switch Speed controller Tool support Multifunctional tool MFW G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive G orbitalum tools gmbh 2 2 2 Design of the product RPG 1 0 Cordless right angled drive Rechargeable accumulator 6 ON OFF switch Speed controller 7 Switch for right handed left handed 8 rotation Hoop guard Carrying handle 9 Housing with driving motor 10 09 07 MT_RPG 1 0 BA_04 790036762_02 doc Feed with scale ring Feed Unit Release handle for fixing the clamping shells Multifunctional tool MFW Tool support 2 Design of the product Operating instructions RPG 1 0 Cordless right angled drive 2 3 2 3 1 Accessori
19. right angled drive 9 Spare parts list 9 Spare parts list 9 1 RPG 1 0 Cordless Item Code Description No 1 790 036 170 Feed unit complete 2 790 036 132 Tool support Cordless 790 038 314 Multifunctional tool MFW P 2 en 790 038 315 Multifunctional tool MFW P 2 10 pieces 790 086 220 Torx screw to multifunctional tool 3 610 810 017 Grooved ball bearing 4 790 036 160 Driving unit complete 5 790 036 180 Release handle complete G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 25 9 Spare parts list 9 2 Operating instructions RPG 1 0 Cordless right angled drive RPG 1 0 Cordless right angled drive Item Code Description No 1 790 036 170 Feed unit complete 2 790 036 134 Tool support Cordless right angled drive 790 038 314 Multifunctional tool MFW P 2 rie 790 038 315 Multifunctional tool MFW P 2 10 pieces 790 086 220 Torx screw to multifunctional tool 3 610 810 017 Grooved ball bearing 4 790 036 160 Driving unit complete 5 790 036 180 Release handle complete 26 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 9 Spare parts list G orbitalum tools gmbh 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 1 Orbitalum Tools GmbH Freib hlstra e 19 78224 Singen Deutschland Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 500 tools orbitalum com www orbitalum
20. very for completeness and transportation of delivery damage gt Report any missing parts or transportation damage to your supplier immediately 5 1 Scope of delivery e 1 Tube Squaring Machine RPG 1 0 Cordless Cordless right angled drive e 1 Durable storage and shipping case e 2 Rechargeable accumulators e 1 Battery charger e 1 Multifunctional tool e 1 Torx T spanner for securing the multifunctional tools T 15 e 1 Operating instructions with Spare parts list e Operating instructions and safety notes for the battery charger Subject to modifications 12 09 07 MT_RPG 1 0_BA_04_790036762_02 doc G orbitalum tools gmbh Operating instructions RPG 1 0 Cordless right angled drive 5 Commissioning DANGER G orbitalum tools gmbh 5 2 Transport The RPG 1 0 is a portable machine Special transportation aids are not required For safe transportation hold the machine as shown in the illustrations below Transport RPG 1 0 Cordless Transport RPG 1 0 Cordless right angled drive Danger of injury by unintended restart of the machine During transport the ON OFF switch could be actuated inadvertently so that the machine is started gt Remove the rechargeable accumulator before transportation or workplace change 09 07 MT_RPG 1 0_BA_04_790036762_02 doc 13 6 Operation 14 Note DANGER Specifying dimensions Operating instructions RPG 1 0 Cordless right angled drive 6 Operation As the usage of bot
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