Orbitalum ESG Plus Guide

precision.
power.
simplicity.
Operating instructions
with spare parts list
Tungsten Grinde
r
ESG Plus
Code 790 052 774
│Machine-no:
________________________________

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 with spare parts list ESG Plus Table of contents
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Table of contents
Page
0About these instructions 1
0.1 Warning messages 1
0.2 Further symbols and displays 2
0.3 Abbreviations 2
1Safety notes 3
1.1 Proper use 3
1.2 Safety regulations 3
1.3 Work safely 3
1.4 Waste disposal / environmental protection 4
1.5 Further safety regulations 4
2Construction of the product 5
2.1 Standard 5
2.2 Accessories (optional) 6
2.2.1 Diamond grinding wheels 6
2.2.2 Cutting device 6
2.2.3 Electrode holder 6
2.2.4 Clamping collet 6
2.2.5 Wall/table/vice-mounting plate 7
2.2.6 Protective cover 7
2.2.7 Double-Decker Kit ESG27
3Characteristics and range of applications 8
3.1 Characteristics 8
3.2 Range of applications 8
4Technical data 9
5Commissioning 10
5.1 Scope of supply 10
5.2 Transportation 10
6Operation 11
6.1 Switching on the ESG Plus 11
6.2 Grinding the electrodes 11
6.2.1 Combination of grinding angle and electrode
diameter 12
6.2.2 Sharpening electrodes 12
6.2.3 Surface-grinding the electrode tip 13
6.2.4 Cutting the electrodes to length 13
6.3 Switching off the ESG Plus 13
6.4 Replacing grinding wheels 14
7Assembly of the Double-decker Kit ESG215
8Maintenance 17
9What to do if...? 18
9.1 Fault elimination 18
9.2 Servicing/customer service 18

Table of contents Operating instructions with spare parts list ESG Plus
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10 Spare parts list 19

Operating instructions with spare parts list ESG Plus 0 About these instructions
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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
symbol Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
:Restrictions (if applicable).
XMeasures to prevent danger.
WARNING
Possible danger!
Non-observance could result in serious injury.
:Restrictions (if applicable).
XMeasures to prevent danger.
ATTENTION
Dangerous situation!
Non-observance could result in minor injuries.
ATTENTION
Dangerous situation!
Non-observance could result in material damage.

0 About these instructions Operating instructions with spare parts list ESG Plus
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0.2 Further symbols and displays
Symbol Meaning
Important
Note
Notes: Contain particularly important information for
comprehension.
Instruction: You must take notice of this symbol.
1.
Request for action in a sequence of actions: You have to do
something here.
X
Single request for action: You have to do something here.
ZConditional request for action: You have to do something here
if the specified condition is met.
0.3 Abbreviations
Abbr. Meaning
ESG Plus Tungsten Grinder

Operating instructions with spare parts list ESG Plus 1 Safety notes
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1 Safety notes
The Tungsten Grinder (called ESG Plus in this document) is state of the art.
Any other use than that described in these instructions can lead to injury to the
user or other persons. In addition the device or other objects can be damaged.
Therefore:
•Always ensure that the device is in good working condition, and always
comply with these notes on safety.
•Keep the complete documentation close by the device.
•All regulations generally valid for the prevention of accidents must be
observed.
1.1 Proper use
The ESG Plus is intended only to be used to process welding electrodes.
1.2 Safety regulations
•Only use the dimensions and materials quoted in these instructions. Other
materials should only be used after consulting Orbitalum Tools customer
service department.
•Only use authentic Orbitalum Tools spare parts and materials.
•Check the ESG Plus daily for any externally visible damage or defects.
Have any damage or defects repaired immediately.
•Work on the electrical equipment should only be carried out by a qualified
electrician.
•Only operate the ESG Plus if the electrical protective devices function.
•The tapped holes at the ESG Plus must always be free of dust, clean if
necessary.
•Pull out the power plug before carrying out repair and maintenance work.
1.3 Work safely
"Play your part in ensuring safety at work."
•Report any changes in operating performance to the responsible person
immediately.
•Carry out all work with an awareness of safety.

1 Safety notes Operating instructions with spare parts list ESG Plus
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•When working with the ESG Plus, wear protective goggles, safety gloves
and breathing mask.
•Turn the device off at the end of each operating cycle.
•Before cleaning pull out the ESG Plus power plug and let the device coast.
Danger of being injured!
:Keep hands away from the tool during processing.
XWear safety gloves.
1.4 Waste disposal / environmental protection
•Use a suction unit or an industrial-type vacuum cleaner to collect the
grinding dust.
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.
•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.
1.5 Further safety regulations
Observe country-specific regulations, norms and guidelines.
WARNING
(RL 2002/96/EC)

Operating instructions with spare parts list ESG Plus 2 Construction of the product
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2 Construction of the product
2.1 Standard
1 Motor
2 ON/OFF switch
3 Identification plate
4 ESG Plus grinding head
5 Fastening bolt head to motor
3
2
1
4
5

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2.2 Accessories (optional)
2.2.1 Diamond grinding wheels
Exchangeable grinding wheel diamond-coated on both sides.
Version Code
Standard 790 052 487
Rough 790 052 488
2.2.2 Cutting device
To cut tungsten electrodes to fixed length.
For electrode diameters 1.0; 1.6 and 2.4 mm (0.040; 0.060 and 0.095 inch).
Fixed cutting lengths: 12; 13; 15 and 17 mm selectable (0.470; 0.500; 0.600
and 0.670 inch). Other cutting lengths possible.
Code
790 052 513
2.2.3 Electrode holder
Without clamping collet.
Code
790 052 457
2.2.4 Clamping collet
For clamping the electrode into the holder.
Range [mm] Range [inch] Code
1.0 – 3.2 0.039 – 0.126 790 052 481

Operating instructions with spare parts list ESG Plus 2 Construction of the product
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2.2.5 Wall/table/vice-mounting plate
Incl. 2 cylinder head screws (790 052 495).
Code
790 052 483
2.2.6 Protective cover
Easy to adapt on the ESG Plus head.
With integrated retainer for suction units.
Code
790 052 496
2.2.7 Double-Decker Kit ESG2
Possibility to use 2 different grinding wheels at the same time on one ESG Plus
(scrubbing and smoothing).
Easy and fast assembly to the ESG Plus (see chapter 7, p. 15).
Including:
•1 Grinding head
•1 Diamond grinding wheel, rough
•1 Cylinder head screw with collar (M4x34)
•1 Shaft elongation
Code
790 052 490

3 Characteristics and range of applications Operating instructions with spare parts list ESG Plus
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3 Characteristics and range of
applications
3.1 Characteristics
The ESG Plus is the perfect hand-held grinder for cutting, grinding and planing
electrodes which are used in WIG or TIG welding machines.*)
The ESG Plus has the following characteristics:
•Electrodes and tips are sharpened to conform to recognized standards
•Replaceable grinding wheel diamond coated on both sides
•ESG Plus head for different electrode angles and electrode diameter
•Machine:
–hand-operated
–optionally wall/table/vice mounting plate possible
•Working instruction:
–the electrode is inserted by hand into the corresponding opening and is
ground round by a manual circular movement
•Drive:
–A/C motor with the R.P.M. controlled electronically
*) Consider country-specific regulations, standards and guidelines when using tungsten
electrodes with thorium.
3.2 Range of applications
Without refitting of the equipment.
Electrode diameter
ESG Plus 1.0 mm
(0.04") 1.6 mm (0.06") 2.0 mm (0.08") 2.4 mm (0.09") 3.2 mm (0.13") 4.0 mm (0.16")
15° x x x x x x
18° x x x x x x
22.5° x x x x x x
30° x x x x x x
Tungsten electrodes alloyed with zirconium, lanthanium and cerium.
Not to be used without suction for tungsten electrodes with thorium.
Working range
Electrode material
Important

Operating instructions with spare parts list ESG Plus 4 Technical data
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4 Technical data
Dimensions Ø 65 x 350 mm
Ø 2.560 x 13.780 inch
Weight complete with grinding wheel approx. 1.4 kg
Power consumption 500 W
Voltage 230 V, 50-60 Hz
110 V, 50-60 Hz
Main supply cable 3 m
118 inch
Rotary speed 30.000 U/min (r.p.m.)
Power-on time 100%
Noise level in the workplace*) Idle running approx. 83 dB (A)
Vibration level according to EN 28662,
Part 1
2.5 m/s²
Idle running of temperature
development
10 min running time
+ 30 °C over running temperatur
*) Sound pressure level measurement was carried out under normal operating conditions
according to EN 23741.

5 Commissioning Operating instructions with spare parts list ESG Plus
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5 Commissioning
5.1 Scope of supply
XCheck the delivery for completeness and any transportation damage.
XReport any missing parts or transportation damage to your supplier
immediately.
•1 Tungsten Grinder ESG Plus
•1 Powder-coated carrying steel case
•1 Diamond grinding wheel (790 052 487)
•1 Tool to replace the grinding wheel
•1 Operating instructions with spare parts list
5.2 Transportation
The ESG Plus is a portable, hand-operated machine. Special transportation
aids are not required.
Danger of death by electric shock!
Non-observance could result in death or critical injury.
XCut off the power supply before transportation.
Scope of delivery
(subject to
alterations)
DANGER

Operating instructions with spare parts list ESG Plus 6 Operation
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6 Operation
6.1 Switching on the ESG Plus
1. Connect the ESG Plus (consider main voltage).
2. Press the ON/OFF switch (1).
The ESG Plus starts.
6.2 Grinding the electrodes
Hot dust!
Danger of injury to eyes!
:Do not use thorium-coated tungsten electrodes without a suitable suction
devices or a suitable breathing mask.
XOnly work with safety goggles.
XAlways wear a breather mask.
Do not exert too much pressure on the grinding wheel, since otherwise the
service life of the diamond wheel is shortened.
The strength of the contact pressure, but even rotation of the electrode around
its own axle and a small contact pressure of the electrode to the grinding
produce a high sharpening achievement.
Use a rough diamond wheel during larger sharpening achievement.
DANGER
Note
Important
1

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6.2.1 Combination of grinding angle and electrode diameter
15° 18°
22,5° 30°
6.2.2 Sharpening electrodes
1. Insert the electrode with the corresponding hole diameter and the desired
angle until the grinding wheel is touched.
2. The electrode tip is sharpened evenly by turning the electrode slowly.
Slow and even rotating motion results in a good and exact sharpening result
(longitudinal grind). If the electrode is not turned, then it is flat ground to the
selected angle.
Note

Operating instructions with spare parts list ESG Plus 6 Operation
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6.2.3 Surface-grinding the electrode tip
Precision ground point. Although able to grind flat land on tip.
XInsert the electrode (1.0 / 1.6 / 2.0 / 2.4 / 3.2 or 4.0 mm) through the
openings at the front end onto the grinding wheel and square the electrode
tip.
6.2.4 Cutting the electrodes to length
In order for the electrode rods to be used for e.g. orbital welding, or for manual
welding, they have to be cut to length.
1. Insert the electrode into the lateral slot.
2. The electrode is cut evenly by turning the electrode slowly (optional cutting
device for 12, 13, 15 and 17 mm, see chapter 2.2.2, p. 6).
6.3 Switching off the ESG Plus
XPress the ON/OFF switch (1).
The ESG Plus stops.
1

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6.4 Replacing grinding wheels
Danger to injury to hands though unintentional activation of the ESG Plus!
:Do not switch on the ESG Plus while changing the grinding wheel.
XPull out the power plug.
1. Dismantle and remove the cylinder head screw with collar (M4x15) at the
ESG Plus head. Do not remove the arrest nut (1).
2. Remove the ESG Plus head.
3. Slide a 2.4 mm pin through cross hole and motor shaft (rotation of the
grinding wheel is prevented).
4. Loosen and remove the grinding wheel screw (cylinder head screw with
washer M4x6).
5. Turn the diamond grinding wheel or insert a new grinding wheel.
6. Insert the grinding wheel on the shaft.
ZThe hole of the diamond grinding wheel has to be inserted centrally on
the motor shaft.
7. Tighten the Torx screw and assemble the ESG Plus grinding head to the
motor.
WARNING
Disassembly of the
ESG Plus head
1

Operating instructions with spare parts list ESG Plus 7 Assembly of the Double-decker Kit ESG2
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7 Assembly of the Double-decker Kit
ESG2
The Double-Decker Kit ESG2is not included in the standard scope of supply
but is obtainable as extra accessory (see chapter 2.2.7, p. 7).
1. Dismantle and remove the cylinder head screw with collar (M4x15) at the
ESG Plus grinding head. Do not remove the arrest nut (1).
2. Remove the ESG Plus grinding head.
3. Slide a 2.4 mm pin through cross hole and motor shaft (rotation of the
grinding wheel is prevented).
4. Loosen and remove the grinding wheel screw (cylinder head screw with
washer, M4x6).
Disassembly of the
ESG Plus head
1

7 Assembly of the Double-decker Kit ESG2 Operating instructions with spare parts list ESG Plus
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5. Attach the shaft elongation and fasten.
For easier fastening of the shaft elongation we recommend to slide a screw
driver through the cross hole of the shaft elongation.
6. Attach the first grinding head.
7. Attach the rough grinding wheel (Code 790 052 488) and fasten with the
cylinder head screw with washer (M4x6).
8. Attach the second grinding head.
9. Attach the cylinder head screw with collar (M4x34) to the arrest nut (1).
Note
Fastening the
Double-Decker Kit
1