Contec ORBITER 800 User manual

ORBITER 800
Manual
www.contecgmbh.com

Manual ORBITER 800
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Important Information!
Dear Customer!
Thank you for choosing CONTEC as your supplier.
We wish you all the best with your new ORBITER 800 and hope that it
meets all your expectations.
This Manual only concerns the floor grinding machines “ORBITER 800”.
ORBITER 800 may only be used for grinding horizontal surfaces approved
by CONTEC GmbH.
If ORBITER 800 is used for other purposes or handled in ways other than
that described in this Manual, CONTEC GmbH disclaims all responsibility.
Especially note the section “2Safety Regulations”. Read the Manual
before using the floor grinding machine ORBITER 800. The spare
parts, grinding discs used on ORBITER 800 must be approved by CONTEC
GmbH.

Manual ORBITER 800
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Table of Contents
1 Specifications ...................................................................................................................................... 2
1.1 Electrical specifications ............................................................................................................... 2
1.2 Mechanical specifications ............................................................................................................ 3
1.3 Water tank .................................................................................................................................... 4
1.4 Tools ............................................................................................................................................. 5
1.5 Range of application .................................................................................................................... 6
1.6 Scope of supply ............................................................................................................................ 6
1.7 Overview ...................................................................................................................................... 7
2 Safety Regulations .............................................................................................................................. 8
2.1 Legend .......................................................................................................................................... 8
2.2 Safety precautions ........................................................................................................................ 8
2.3 Organizational measures .............................................................................................................. 9
2.4 Personnel qualification ............................................................................................................... 10
2.5 Safety regarding operation of machine ...................................................................................... 10
2.6 Electrical safety .......................................................................................................................... 11
2.6.1 Cables .................................................................................................................................. 12
2.6.2 Using a generator ................................................................................................................ 12
2.7 Definition of the “Safety off position” ....................................................................................... 12
2.8 Safety regarding maintenance .................................................................................................... 13
2.9 Safety regarding transport .......................................................................................................... 13
2.9.1 Manual transport ................................................................................................................. 13
2.9.2 Lifting ................................................................................................................................. 14
2.9.3 Inside vehicles ..................................................................................................................... 14
3 Transport ........................................................................................................................................... 15
3.1 Precautions ................................................................................................................................. 15
3.2 Manual transport ........................................................................................................................ 15
3.3 Lifting ......................................................................................................................................... 15
3.4 Inside vehicles ............................................................................................................................ 15
4 Operation .......................................................................................................................................... 16
4.1 Precautions ................................................................................................................................. 16
4.2 Operation of machine ................................................................................................................. 16
4.3 Control panel .............................................................................................................................. 17
4.3.1 Standard Control Panel ....................................................................................................... 17
4.3.2 RC Control Panel ................................................................................................................ 17
4.4 Start up ....................................................................................................................................... 18
4.5 Stop ............................................................................................................................................ 18
4.6 Adjusting grinding speed ........................................................................................................... 19
4.7 Change grinding direction on a standard machine ..................................................................... 19
4.8 Changing grinding direction on a RC machine .......................................................................... 19
4.9 Safety off position ...................................................................................................................... 19
4.10 Grinding .................................................................................................................................. 19
4.11 Navigate the “HMI” on a RC model ...................................................................................... 19
4.12 Adjusting the grinding pressure .............................................................................................. 21
4.13 Wheel system release.............................................................................................................. 22
4.14 Changing tools ........................................................................................................................ 23
4.15 Using with generator .............................................................................................................. 23
5 Maintenance ...................................................................................................................................... 24
5.1 Precautions ................................................................................................................................. 24

Manual ORBITER 800
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5.2 Daily inspection prior to operation ............................................................................................ 24
5.3 Maintenance and inspection list ................................................................................................. 25
5.4 Grinding head replacement / assembly ...................................................................................... 27
5.5 Cleaning the machine ................................................................................................................. 27
5.6 Trouble shooting ........................................................................................................................ 27
5.6.1 Common faults .................................................................................................................... 27
5.6.2 Error codes .......................................................................................................................... 28
5.6.3 Fault history ........................................................................................................................ 29
6 Spare Parts ........................................................................................................................................ 30
6.1 General parts .............................................................................................................................. 30
6.2 Front Wheel ................................................................................................................................ 33
6.3 Floating Cover ............................................................................................................................ 34
6.4 Upper Machine House Connections ........................................................................................... 35
6.5 Upper Machine House ................................................................................................................ 36
6.6 Machine house lower end ........................................................................................................... 37
6.7 Machine House Belt System ...................................................................................................... 38
6.8 Center Shaft Assembly ............................................................................................................... 39
6.9 Machine House Lower ............................................................................................................... 41
6.10 Grinding Shaft with bushed gear wheel (2 per machine) ....................................................... 42
6.11 Grinding Shaft with locked gear wheel (1 per machine) ........................................................ 43
6.12 Grinding Head ........................................................................................................................ 44
6.13 Wheel System Standard .......................................................................................................... 45
6.14 Wheel System RC ................................................................................................................... 46
6.15 Kick Stand .............................................................................................................................. 47
6.16 Handle ..................................................................................................................................... 48
6.17 Chassis hose system ............................................................................................................... 49
6.18 Control Panel Standard ........................................................................................................... 50
6.19 Control Panel RC .................................................................................................................... 51
6.20 Wiring Schematics Std ........................................................................................................... 52
6.21 Wiring schematics RC ............................................................................................................ 53
7 Warranty ........................................................................................................................................... 60
8 EU Declaration ................................................................................................................................. 61
9 Contact information .......................................................................................................................... 62

Manual ORBITER 800
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1 Specifications
The ORBITER 800 is available with different power inputs and some options regarding wet
grinding. This is described in the different sections later on in this chapter.
1.1 Electrical specifications
To find the specifications that apply to your machine, check the information plate on the electrical
cabinet door.
Never connect the ORBITER 800 to any other voltage or number of phases than described in
this specification.
The power source must be fused according to “External fuse” in this specification; also, the
cables used must be marked and rated in accordance with the fuse used. Failure to comply
with the correct fuses may cause fire or injuries.
Power choice1
400 V 3~2
230 V 3~
Power
15 kW (20 hp)
11 kW (15 hp)
Current
32 A
50 A
Voltage
380 – 400 V 3~
200 – 240 V 3~
Frequency
50/60 Hz ± 5%
50/60 Hz ± 5%
External fuse3
32 A
50 A
Power inlet4
IEC 60309
3P+N+E 400V
32A
IEC 60309 3P+E
250V 32A
Partnumber Inlet
Eu 570057
US 910911
US 910912
Table 1-1 Electrical specifications
All models are CE-marked.
If using a generator see “2.6.2Using a generator”
1 This refers to different power choices. Note that an ORBITER 800 made for one choice of power must be used with that
particular choice.
2 Standard
3 Maximum current for the fuses used in the power source (i.e. the distribution box).
4 This is the standard inlet used. Machines sold outside of EU will be shipped either with a local standard inlet or an adapter.

Manual ORBITER 800
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1.2 Mechanical specifications
Model
ORBITER 800
Grinding width
785 mm (31”)
Grinding head diameter
280 mm (11”)
Grinding head speed
350 – 850 Rpm
Mass
610 kg (1345 lbs) / RC 640 kg (1410 lbs)
Water tank
20 liter / 5.2 gal
Gear barrel
Synchronized
Table 1-2 Mechanical specifications
Measurements of ORBITER 800
Width 800 mm (32”)
Height 1250 mm (49.2”)
Length 1550 mm (61”)
Measurements of shipping box
Width 850 mm (33.5”)
Height 1500 mm (59”)
Length 1600 mm (63”)
Ambient temperature range during operation -10°C to +50°C (14°F to 122°F)
Ambient temperature range during storage -40°C to +70°C (-40°F to 158°F)
When using water, the ambient temperature must never fall below 0°C (32°F).

Manual ORBITER 800
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1.3 Water tank
ORBITER 800 has a built-in water tank (1.) that can be used to keep the grinding tools at the
lower temperature and in those occasions where it´s not possible to use a dust collector together
with the machine.
The water tank has a built-in system that prevents the water from getting out while the machine is
tilted back for grinding tool exchange. It also has a filter that prevents larger debris to get into the
tank.
System in general:
Inside the floating cover over the machine house there is a sprinkler system connected to the water
tank. To engage the water flow after filling he water tank set the control on the operation panel
Water to “1”. To stop the flow, turn the control nub to “0”
At the backs lower end of the machine chassis underneath the electrical cabinet there is a valve to
adjust the flow of water.
Figure 1-1 Standard ORBITER 800
1.
2.

Manual ORBITER 800
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1.4 Tools
The machine must be equipped with tools approved by CONTEC GmbH before operation.
Failure to follow the directions in this Manual will void the warranty
See “Grinding guide” for information about available tools and “4.14 Changing tools” for
information about how to change the tools.
The tools are fitted using the Scan-On system for easy fitting.
Figure 1-2 Scan-On plate with tools fitted.

Manual ORBITER 800
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1.5 Range of application
ORBITER 800 is exclusively designed to process horizontal surfaces. ORBITER 800 must not
be used for other purposes than stated in this Manual. The manufacturer will not be liable
for damage or injury resulting from incorrect usage of ORBITER 800. Failure to follow the
directions in this Manual will void the warranty.
Typical applications
•Removal of old coatings, carpets, putty from hard surfaces
•Removal of undulated concrete surfaces
•Preparation of the surface for coatings
•Polishing of the surface
•Removal of coating defects
•Removal of glue residues
1.6 Scope of supply
The following parts are included with the standard ORBITER 800 grinding machine:
•Key to electrical cabinet
•Manual
Machines sold outside of Europe will be either equipped with a local standard connector for the
power inlet or the mating connector will be included and fitted at the main power inlet.
Read “2.6 Electrical safety” before connecting any included connectors.

Manual ORBITER 800
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1.7 Overview
Figure 1-3 Overview of ORBITER 800
Item
Description
Reference
1
Control panel
4.3Control panel
2
Handle
3
Power inlet
1.1Electrical specifications
4
Dust collector connection
6 Spare Parts
5
Wheel
6 Spare Parts
6
Floating Cover
6 Spare Parts
7
Air inlet Electrical cabinet
8
Water inlet
9
Motor
1.1Electrical specifications
10
Lifting points
3.3 Lifting
11
Front wheel
12
Cover
15
Electrical cabinet
1.1Electrical specifications
Table 1-3 Machine parts overview
1.
2.
3.
4.
5.
8.
6.
9.
7.
11.
10.