Orbitalum RPG 4.5, RPG 4.5 S, RPG 8.6 Operating Instructions Manual
Operating instructions
For responsible bodies and persons using the machine
Tube Squaring Machines
RPG 4.5
RPG 4.5 S
RPG 8.6
To work safely with this machine, please
read through the operating instructions
in full before initial operation.
Retain the operating instructions for
future reference.
Machine no.:
Code 790 038 762 | EN | Translation of original operating instructions
All rights reser ved, 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.
RPG 4.5 (S), RPG 8.6 | Operating instructions
TABLE OF CONTENTS
1. About these instructions ......................................4
1.1 Warning messages .....................................4
1.2 Further symbols and displays .....................4
1.3 Abbreviations ............................................5
2. Information and safety instructions for the
responsible body .................................................6
2.1 Requirements for the responsible body .......6
2.2 Using the machine .....................................6
2.2.1 Proper use .......................................6
2.2.2 Improper use ...................................6
2.2.3 Machine constraints .........................7
2.2.4 Shutting down the machine ..............7
2.3 Environmental protection/disposal .............7
2.3.1 Chips and gear lubricant ..................7
2.3.2 Electric tools and accessories ..........7
2.4 Basic safety instructions ............................8
2.5 Warning symbols .....................................11
3. Product design ...................................................12
3.1 Tube Squaring Machines RPG 4.5,
RPG 8.6 ...................................................12
3.2 Tube Squaring Machine RPG 4.5 S ............12
3.3 Accessories .............................................13
3.3.1 Multifunctional tool (MFW) .............13
3.3.2 Tool holder (WH) for beveling and
squaring ........................................13
3.3.3 Clamping shells .............................13
3.3.4 Warning symbols ...........................13
8.3 Clamping the tube ...................................21
8.3.1 RPG 4.5 and RPG 8.6 ......................21
8.3.2 RPG 4.5 S.......................................22
8.3.3 Adjustment options with the
clamping lever and adjusting bolt
for offsetting tube tolerances
(RPG 4.5 and RPG 8.6) ....................22
8.3.4 Shifting the adjusting bolt ..............23
9. Operation .........................................................24
9.1 Shutting down (even in an emergency) .....25
9.2 Determining and setting the speed ...........26
9.2.1 Determining the cutting speed .......26
9.2.2 Setting the cutting speed ...............26
9.3 Switching the machine on.........................27
9.4 Processing the tube .................................27
9.5 Switching the machine off ........................27
10. Servicing, maintenance, troubleshooting ............28
10.1 Maintenance ............................................28
10.2 What to do if ...?
– General trouble shooting .......................28
10.3 Servicing/customer service ......................29
11. EU Declaration of Conformity ..............................31
4. Features and scope of application .......................14
4.1 Features ..................................................14
4.2 Range of applications ...............................14
5. Technical specifications .....................................15
6. Initial operation .................................................16
6.1 Checking the parts of delivery .................16
6.2 Included with the machine .......................16
6.3 Connection requirements ........................16
7. Storage and Transport ........................................ 17
7.1 Transporting the machine .........................17
8. Setup and assembly .......................................... 18
8.1 Fitting the multifunctional tool (MFW)
and the tool holder (WH) ..........................19
8.2 Inserting/replacing the clamping shells
(not with RPG 4.5 S) .................................20
8.2.1 Inserting the lower clamping
shell ..............................................20
8.2.2 Inserting the upper clamping
shell ..............................................20
8.2.3 Replacing the clamping shells ........20
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About these instructions RPG 4.5 (S), RPG 8.6 | Operating instructions
1. 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.
1.1 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
Direct danger!
Non-observance could result in death or critical injury.
DANGER
WARNING
ATTENTION
ATTENTION Dangerous situation!
[ Restrictions (if applicable).
X Measures to prevent danger.
Possible danger!
Non-observance could result in serious injury.
[ Restrictions (if applicable).
X Measures to prevent danger.
Dangerous situation!
X Non-observance could result in minor injuries.
X Non-observance could result in material damage.
1.2 Further symbols and displays
Symbol Meaning
IMPORTANT
NOTE
1. Request for action in a sequence of actions: You have to do something here.
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Notes: Contain particularly important information for comprehension.
Instruction: You must take notice of this symbol.
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.
RPG 4.5 (S), RPG 8.6 | Operating instructions About these instructions
1.3 Abbreviations
Abbr. Meaning
RPG 4.5 Tube Squaring Machine for tubes with an outer diameter of up to 4.5 inches
RPG 4.5 S Tube Squaring Machine for tubes with an outer diameter of up to 4.5 inches with vice
RPG 8.6 Tube Squaring Machine for tubes with an outer diameter of up to 8.6 inches
MFW Multifunctional Tool
WH Tool Holder
QTC
®
Quick Tool Change
(18.12.17) OC_RPG_L_BA_790038762_01_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. +49 (0) 77 31 792-0 | 5
Information and safety instructions for the responsible body RPG 4.5 (S), RPG 8.6 | Operating instructions
2. INFORMATION AND SAFETY INSTRUCTIONS FOR THE
RESPONSIBLE BODY
2.1 Requirements for the responsible body
Workshop/outdoor/field application: The responsible body is responsible for safety in the danger zone around the
machine, and should allow only qualified personnel to enter the zone or operate the machine in the danger zone.
Employee safety: The safety regulations described in chap. 2 must be observed and work must be carried out with
safety in mind using the prescribed protective equipment.
2.2 Using the machine
2.2.1 Proper use
• The machine should be exclusively used for the squaring and beveling of materials and tube
dimensions as specified in chap. 4.2, p. 14.
• The machines must only be operated using the voltage levels specified on the drive identifica-
tion plate and in the "technical data" (see chap. 5, p. 15).
• Only the RPG17 motor (Code 790 038 190 to 790 038 192) should be used as the drive for the
electrical variant.
• The drive motor may only be used in connection with the machine.
• The machine may only be used on tubes and containers that are empty, unpressurized, do not
have explosive atmospheres and are not contaminated.
Proper use also includes the following:
• observing all safety instructions and warning messages included in these operating instructions
• carrying out all inspection and maintenance work
• sole use in the original condition with original accessories, spare parts and materials
• processing only materials set out in the operating instructions.
2.2.2 Improper use
• A use other than that defined under "proper use" or a use that goes beyond this or the
specified constraints shall be considered improper use due to the potential risks involved.
• The responsible body shall be solely responsible for damages that arise through improper use
and the manufacturer shall assume no liability whatsoever.
• No tools should be used that have not been authorized by the manufacturer for this machine.
• Tubes from non-metallic materials must not be machined.
• The removal of safety equipment is not permitted.
• Do not misuse the machine.
• The machine is not intended for use by private consumers.
• The technical values defined for normal operation must not be exceeded.
• Do not use the machine as a drive for applications other than those listed under proper use
(chap. 2.2.1).
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RPG 4.5 (S), RPG 8.6 | Operating instructions Information and safety instructions for the responsible body
2.2.3 Machine constraints
• Keep your working area clean. Disorder or unlit working areas can lead to accidents.
• The workplace can be in pipe preparation, in plant construction or in the plant itself.
• A radial space requirement/freedom of movement of approx. 1 m around the machine is required for people.
• Work lighting: min. 300 Lux.
• Operator age: at least 14 years old and without physical impairments.
• Operated by one person.
• Climate conditions: temperature range for machine operation: –15 °C to 40 °C (< 80% rel. humidity).
• Only work with the machine in dry surroundings (not in misty, rainy or stormy conditions).
2.2.4 Shutting down the machine
Information on the EMERGENCY STOP or the shutting down function, see chap. 9.1, p. 25.
2.3 Environmental protection/disposal
2.3.1 Chips and gear lubricant
Dispose of chips and used gear lubricant according to the regulations.
2.3.2 Electric tools and accessories
Discarded electric tools and accessories contain large quantities of valuable raw and synthetic
materials that can be recycled. Therefore:
• Electrical (electronic) devices that are marked with the symbol at the side may not be
disposed of with household waste in accordance with EU regulations.
• By actively using the available return and collection systems, you actively contribute to the
reuse, recycling and utilization of electrical (electronic) devices.
• Used electrical (electronic) devices contain parts that must be handled selectively according
to EU regulations. Separate collection and selective treatment is the basis for environmentfriendly disposal and the protection of human health.
• Appliances and products that you bought from us after August 13, 2005 will be disposed of
in accordance with legal standards after they have been supplied to us at no cost.
• We may refuse to accept old appliances that pose a risk to human health or safety due to
contamination produced during use.
• The end user is responsible for disposing of used appliances introduced to the market
before August 13, 2005. Please contact a disposal center near you for this purpose.
• Important for Germany: our products may not be disposed of in municipal disposal sites as
they are only used for industrial purposes.
(as per RL 20 02/96/EC)
(18.12.17) OC_RPG_L_BA_790038762_01_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. +49 (0) 77 31 792-0 | 7
Information and safety instructions for the responsible body RPG 4.5 (S), RPG 8.6 | Operating instructions
2.4 Basic safety instructions
The maschine (hereinafter referred to as the RPG 4.5 (S) or RPG 8.6) is a state-of-the-art machine designed for safe
use. The risks involved in using the machine are described in the operating instructions below. Using this machine in
a way other than that described in these instructions can lead to serious physical injury and material damage.
Therefore:
• Observe warning messages at all times.
• In addition to this operating instructions, the general warning messages for electric tools (see supplement), which
should always be retained.
• Keep complete documentation close by the machine.
• Generally valid regulations for the prevention of accidents must be observed.
• Observe country-specific regulations, standards and guidelines.
• Always ensure that the machine is in good working order. Observe the maintenance information (chap. 10, p. 28).
• The machine may only be operated if all safety equipment such as restarting block and overload protection is in
proper working order, the viewing window is closed and the machine has a solid footing. Check whether the substrate is able to take sufficient loads.
• Report any unusual machine behavior to the person responsible immediately.
• Only use the dimensions and materials specified in these instructions. Other materials should be used only after
consulting with Orbitalum Tools customer service.
• Use only original tools, spare parts, materials and accessories from Orbitalum Tools.
• Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
• At the end of each working cycle, before transportation, changing tools, cleaning and performing any maintenance,
adjustment or repair work, switch off the machine, allow it to run to a stop and pull the mains plug.
• Do not carry the machine by the cable and do not use the machine to pull out the mains plug except in an emergency.
Protect the cable from heat, oil and sharp edges (chips).
• During operation, keep hands away from the tools.
• Check that the tube is correctly clamped.
• Switch on the machine only when the tube has been clamped.
• Do not use the machine in wet surroundings. Only work in canopied surroundings.
• In extreme conditions of use, conductive dust can settle inside the machine. For this reason and for better safety,
an on-site SPE-PRCD or ground-fault circuit is required between the mains network and the machine, to be installed
and tested if necessary by a professional electrician.
• When working with the machine wear safety shoes (as per EN ISO 20345 at least S1), safety goggles (as per DIN EN
166 Class 2, basic strength S), snug-fitting safety gloves (as per DIN EN 388, Class 2 resistance to abrasion, cut
resistance Class 3, tear resistance Class 2, perforation resistance Class 3 and as per EN 407 at least Performance
level 1 against contact heat) and hearing protection (as per DIN EN 352-4 or comparable).
• Do not use click-in socket outlets and click-in power plugs (blue CEE power plugs) for power connection, otherwise
the EMERGENCY STOP does not function. The user must check whether the power plug can be pulled out of the
outlet by the cable (shutdown, see chap. 9.1, p. 25).
• Do not use angled power plugs.
NOTE The recommendations concerning "Personal protective equipment" only apply
DANGER
to the product being described. Other requirements resulting from the ambient
conditions on-site or of other products, or from combining with other products,
are not taken into account. These recommendations do not in any way release
the responsible body (employer) from its statutory health and safety at work
obligations towards its employees.
If the mains cable is damaged, live parts may cause death if touched directly!
Fatal electric shock.
[ Do not allow the power cable of the motor to be near the machine, especially the cutting tool (MFW).
[ Do not run the machine unattended.
X During processing, always keep an eye on the position of the mains cable.
X Keep the machine clean. Always remove lubricant residues from the machine.
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RPG 4.5 (S), RPG 8.6 | Operating instructions Information and safety instructions for the responsible body
Damaged insulation!
Fatal electric shock.
DANGER
[ Do not screw any indicators or signs to the drive motor.
X Use stickers.
Metal dust can collect in the motor housing and cause loss of insulation!
Fatal electric shock.
DANGER
X Depending on the level of contamination, clean the machine at least once a day using the brush
supplied.
Damaged mains plug!
Fatal electric shock.
DANGER
[ Do not use adapter plugs with ground protected electrical tools.
X The machine connector plug must fit the socket.
Risk of danger through the use of the machine outdoors!
Fatal electric shock.
DANGER
[ Do not use the machine outdoors.
Danger! The electrical motor can overheat with operation in a 110 V network.
Serious injury or death.
DANGER
X Only use the machine in the specified temperature range.
Grounded body!
Fatal electric shock.
DANGER
X Avoid contact with grounded surfaces such as tubes, heating, cookers or refrigerators.
Loose/baggy clothing, long hair or jewelry can get caught in rotating machine parts!
Serious injury or death.
DANGER
X Wear tight-fitting clothing during work.
X Tie up long hair to prevent it from being caught.
Safety components that are contaminated or worn are defective!
The failure of safety components can cause physical injury.
DANGER
[ Do not misuse the cable, e.g. such as using it to suspend or carry the machine.
X Replace defective safety components immediately and check them daily to ensure proper operation.
X Clean and perform maintenance on the machine after each use.
X Keep cables away from heat, oil, sharp edges and moving equipment parts.
X Inspect the machine daily for visible signs of damage or defects, and have them repaired by a
specialist if necessary.
Flying parts/breaking tool!
Diverse physical injuries and material damage.
WARNING
[ No damaged or deformed cutting tools (MFW) should be used.
X Firmly clamp the tube to be machined into the clamping unit.
X Immediately replace worn-out tools.
X Ensure that the cutting tools are correctly fitted.
X The inner diameter of the clamping shells must be identical to the outer diameter of the tube to
be machined. The specific inner diameter is specified on the clamping shells. The outer diameter of the tube must be determined.
X Avoid tool breakage by ensuring low (measured) infeed (max. clamping thickness: 0.05 mm)
and correct setting of speed (see chap. 9.2, p. 26).
X Check that the tool holder (WH) and multifunctional tool (MFW) are seated firmly, and tighten if
required.
Falling objects or tilting and bending tubes!
Irreversible crushing.
WARNING
X Wear safety shoes (in accordance with EN ISO 20345, at least S1).
X Place sufficient supports under the tube.
X Transport the machine as shown in chap. 7.1, p. 17.
(18.12.17) OC_RPG_L_BA_790038762_01_EN orbitalum tools GmbH, D-78224 Singen, w ww.orbit alum.com, Tel. +49 (0) 77 31 792-0 | 9
Information and safety instructions for the responsible body RPG 4.5 (S), RPG 8.6 | Operating instructions
Danger caused by vibration and unergonomic, monotonous work!
Discomfort, tiredness and disruptions to the locomotor system.
WARNING
Limited ability to react, and cramps.
X Do relaxation exercises.
X Ensure activity is varied.
X Assume an upright, fatigue-free and comfortable body position during operation.
Pressing the ON-OFF switch unintentionally!
Diverse physical injuries and material damage.
WARNING
X At the end of each working cycle, before transportation, changing tools, cleaning and performing
any maintenance, adjustment or repair work, switch off the machine, allow it to run to a stop and
pull the mains plug.
10 | orbitalum tools GmbH, D-78224 Singen, ww w.orbitalum.com, Tel. + 49 (0) 77 31 792-0 (18.12.17) OC_ RPG_L _BA_79 0038762_01_E N
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