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.

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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

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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).

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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.

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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.

Manual ORBITER 800
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2 Safety Regulations
Read this entire chapter carefully! Failure to comply with safety regulations may result in
serious injuries or damages.
2.1 Legend
Notation regarding safety
Notation regarding electrical safety
Notation regarding safety during transport
Tipping hazard
See reference
2.2 Safety precautions
Any machine, if it is not used according the regulations, may be hazardous for operating,
setting-up and service personnel. The operating authority is responsible for compliance with
the safety regulations during operation and maintenance, and for the use of safety devices
supplied with the machine, as well as the provision of appropriate additional safety devices!
Eye and ear protection must be worn at all times.
Never operate the machine when it’s not in its upright position.
Make sure there is no debris in the work area.
Check the work area for screws or other hard objects in the concrete. Don’t use the machine
if there are any foreign objects stuck into the surface. Such objects must be removed prior to
operation of machine.
Read “2.3Organizational measures” and “2.5Safety regarding operation of machine”
thoroughly before operation!

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2.3 Organizational measures
The Manual is to be kept near the location where the machine is being operated and must be
within reach at all times.
In addition to this Manual general and legal regulations regarding accident prevention and
environmental protection must be complied with as per local regulations.
Such duties may, for example, relate to the handling of hazardous substances, or to the
provision and wearing of personal protection equipment, as well as compliance with traffic
regulations.
The Manual must be supplemented by other instructions, including the duty to supervise and
report incidents relating to particular working practices, for example work organization,
work procedures and personnel safety.
Personnel entrusted with working with the machine must read the Manual before starting
work, in particular the “2Safety Regulations” chapter. To read these instructions after work
is commenced is too late. This particularly applies to incidental activities such as setting up
the equipment, carrying out maintenance work or training staff to work with the machine.
From time to time the working practices of the operators are to be checked by a supervisor
especially to the items regarding awareness of safety and hazards.
Operators must tie back long hair, and not wear loose clothing or jewelry including rings.
There is a risk of injury through items getting caught or being drawn into moving machinery.
Eye and ear protection must be worn at all times!
Use personnel protection equipment if necessary or required by local regulations! Take
notice of all safety and hazard notices on the machine!
All safety and hazard notices at or on the machine must be kept complete and legible!
If safety-critical changes occur to the machine or its working method, the machine must be
shut down immediately! The cause of the fault must be established, and rectified.
Changes, add-ons or conversation to the machine, which might impair safety, must not be
made, without the manufacturer’s permission!
This applies in particular to the fitting and adjustment of safety devices.
Spare parts must comply with the technical requirements specified by the manufacturer. This
is always guaranteed if original spare parts are used.
Intervals for recurring checks and inspections specified in this Manual must be complied
with!
To perform maintenance work correctly it is imperative to be equipped with the proper tools
for the task in question.

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Repairs may only be made by CONTEC GmbH certified service technicians.
Some grinding work may generate sparks under certain circumstances. Personnel working
with the machine must therefore be aware of the risk of fire and how to handle a fire
situation properly.
Do not use the machine in areas with highly flammable and/or explosive materials.
2.4 Personnel qualification
Fundamental duties:
•Work on the machine may only be undertaken by trained personnel.
•Specify clearly the responsibilities of personnel for operation, setting up, servicing and
maintenance work!
•Make sure that only authorized personnel operate or work on the machine!
•Define responsibilities of the machine operator, with regard to traffic safety regulations, and
inform him not to take instructions from third parties who may not be complying with the local
safety requirements.
•Personnel, who are being trained to operate equipment, may only use the machine under
constant supervision of an experienced person!
•Work on electrical equipment may only be undertaken by a skilled electrician or by trained
persons under the supervision of a skilled electrician, as well as in accordance with the local
electrical engineering regulations.
2.5 Safety regarding operation of machine
Do not allow any method of working that impairs safety!
Recognized official procedures have to be used to ensure the machine is operated in safe
and best conditions.
Only operate the machine when all safety devices and related safety equipment are present
and operational!
Check the machine visually for any damage and defects at least once a day.
In the event of operational malfunction, the machine must be shut down immediately and
secured!
Secure the work area around the machine in public areas providing a safety distance of at
least 10 m (3.3 ft) from the machine.

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Faults must be immediately rectified.
Carry out the switch on and switch off operations in accordance with this Manual.
Before switching on the machine make sure that no-one can be endangered when the
machine starts up.
Never operate the machine when not in its upright position.
Do not switch off or remove the exhaust and or the ventilation devices whilst the machine is
running!
All persons in the proximity of the machine must wear ear and eye protection as well as
safety shoes. In addition, the machine operator must wear close-fitting protective clothing.
Only use extension cables that are sized and marked in accordance with the overall power
consumption of the machine and the valid VDE guidelines.
See “2.6Electrical safety” for further information.
Make sure there is no debris in the work area.
Check the work area for screws or other hard objects in the concrete. Don’t use the machine
if there are any foreign objects stuck into the surface. Such objects must be removed prior to
operation of machine
2.6 Electrical safety
The power source must be equipped fuses according to the table in “1.1Electrical
specifications”. All cables used must be marked and rated according to the fuses used.
Never connect the machine to a power source that does not provide protective earth!
Work on electrical equipment may only be undertaken by a skilled electrician or by trained
persons under the supervision of a skilled electrician as well as in accordance with the local
electrical engineering regulations.
Use only extension cables, that are used for extending the main cable, that are sized and
marked in accordance with the overall power consumption of the machine and the valid
VDE guidelines.
The electrical equipment for the plant must be inspected regularly. Defects such as loose
connections or scorched cables must be rectified immediately. Call as skilled electrician or
out customer services.
A second person must be in attendance whilst the electrical engineer is working on the
equipment.

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The work area must be secured against any third party entering the work area. Follow local
electrical engineering regulations while working on the machine. Never leave a machine
unattended. Use only tools that are insulated against electricity.
Only start work after you are familiar with the electrical engineering regulations that apply
to the local area.
Only use voltage seekers that comply with the regulations when troubleshooting. From time
to time check voltage seekers to ensure that they are operationally efficient.
2.6.1 Cables
Only use cables that are marked and rated according to the specifications in “1.1Electrical
specifications”. Don’t use excessive length of the cables. If a very long cable is needed we
recommend that you use a cable rated for more current and connect it to a distribution
central near the machine. Never lay the cable in a loop when operating the machine, this will
cause the cable to heat up and may cause fire. See “Figure 2-1” for explanation.
Figure 2-1 Recommended way to handle excessive cable length.
2.6.2 Using a generator
The generator must be equipped with protective earth and operated in accordance with the
current EN-VDE directives (this applies to the protective earth conductor in particular) in
order to ensure that all safety devices are functioning and eliminate possible damage to
electrical components.
2.7 Definition of the “Safety off position”
The machine is in a safe condition where it cannot be any hazard.
How to set the machine in the Safety off position:
1. Switch off the machine
2. If a dust collector is used, switch it off
3. Wait for all drives to come to a complete stop
4. Disconnect the main power
5. Secure against unintended restart
Always disconnect the main power at the machine end to be able to prevent other persons
from accidentally reconnect the main power while working on the machine.

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2.8 Safety regarding maintenance
Set the machine into the Safety off position before beginning any work on the machine.
See “2.7 Definition of the “Safety off position””.
Never work on the machine while power is still connected!
All parts must have come to a complete stop before beginning any work!
When the machine is lying down on its back it might tilt to its upwards position. Take extra
care to prevent this from happening to ensure that no injuries or damages occur.
When the machine has been operated the segments, Scan-On plates and other parts on the
gear barrel may be hot. Take extra care to prevent burn injuries.
Adjustment, servicing and inspection work on the period of time limits, specified in this Manual as
well as any information on the replacement or parts and equipment must be undertaken and/or
complied with!
These activities may only be undertaken by qualified personnel.
The machine must not be connected to any power source while cleaning.
See “2.7 Definition of the “Safety off position”” for further information.
2.9 Safety regarding transport
Always remove the tools before transport. The tools may fall of or damage the surface the
machine is transported along.
2.9.1 Manual transport
When transporting the machine manually be observant about ramps and/or edges.
Follow local traffic regulations for the work site to prevent accidents. Failure to comply with
these regulations may cause injuries or damages.

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2.9.2 Lifting
The machine must be secured according to local safety regulations before lifted.
No person is allowed beneath a lifted machine! The machine must be lifted according to the
instructions in “3.3Lifting”Observe the machines point of balance before lifting! Failure to
comply with these regulations may cause injuries or damages. Only use straps approved for the
weight and circumstances!
2.9.3 Inside vehicles
Secure the machine according to local transport safety regulations before transporting the
machine inside a vehicle.

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3 Transport
3.1 Precautions
Read “2.9 Safety regarding transport” before attempting to transport the machine.
.
3.2 Manual transport
Detach the tools according to the instructions in “4.14 Changing tools”.
Push the handle downwards to lift the gear barrel about 10 cm (4”) from the ground.
Push the machine in desired direction.
3.3 Lifting
Before attempting to lift the machine, read “2.9.2 Lifting”
Detach the tools according to the instructions in “4.14 Changing tools”.
Fasten the straps used for lifting at the two handles as shown in “Figure 3-1”.
Lift the machine.
Figure 3-1 Lifting points
3.4 Inside vehicles
Detach the tools according to the instruction in “4.14 Changing tools”.
Secure the machine inside the vehicle.

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4 Operation
4.1 Precautions
Any machine, if it is not used according the regulations, may be hazardous for operating,
setting-up and service personnel. The operating authority is responsible for compliance with
the safety regulations during operation and maintenance, and for the use of safety devices
supplied with the machine, as well as the provision of appropriate additional safety devices!
Never operate the machine without proper tools.
Eye and ear protection must be worn at all times.
Never operate the machine when it’s not in its upright position.
Make sure there is no debris in the work area.
Check the work area for screws or other hard objects in the concrete. Don’t use the machine
if there are any foreign objects stuck into the surface. Such objects must be removed prior to
operation of machine.
Read “2 Safety Regulations” before operating the machine.
4.2 Operation of machine
The machine head has three grinding heads that rotates in the opposite direction of the lower
machine body. Each grinding head is equipped with a Scan-on tool plate where the tools used are
attached. See “Figure 4-1”.
Figure 4-1 Illustrates the rotation of the grinding heads versus the lower gear.

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4.3 Control panel
4.3.1 Standard Control Panel
Figure 4-2 Control panel of ORBITER 800 Standard.
4.3.2 RC Control Panel
4. Water Off/ On
6. Start/
Stop
1. Left/Right 2. Hour Meter
5. EMERGENCY STOP
3. Speed
Figure 4
-3 Control panel of ORBITER 800 RC
§
4. Water
Off/ On
5. EMERGENCY STOP
6. Start/
Stop
3. Speed
7.Main
Switch
8. Joystick
9. DSP System ”HMI”