Orbitalum RPG 3.0 Wiring diagram

An ITW Company
en-
US
Tube squaring machines
Translation of original operating instructions and spa-
re parts list
790 038 761
RPG 3.0 (Akku) / 4.5 (S) /
8.6
02 | 2308REV

RPG 3.0 (Akku) / 4.5 (S) / 8.6
2ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
Table of Contents
1 About these instructions................. 4
1.1 Warning messages .................. 4
1.2 Further icons and displays....... 4
1.3 Abbreviations ........................... 5
2 Information and safety instructions
for the owner ....................................
6
2.1 Requirements for the owner-
operator....................................
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 ma-
chine ..........................
7
2.3 Environmental protection and
disposal....................................
7
2.3.1 REACh (Registration,
Evaluation, Authoriza-
tion and Restriction of
Chemicals).................
7
2.3.2 Chips and gear lubri-
cant ............................
8
2.3.3 Electric tools and ac-
cessories....................
8
2.3.4 Return of accumula-
tors and batteries .......
9
2.4 Basic safety precautions.......... 9
2.5 Warning signs .......................... 14
3 Description ....................................... 16
3.1 RPG 3.0 Electric ...................... 16
3.2 RPG 3.0 battery ....................... 18
3.3 RPG 4.5, RPG 8.6 Electric....... 20
3.4 RPG 4.5 S................................ 22
3.5 Accessories.............................. 23
3.5.1 Multifunctional tool
(MFW)........................
23
3.5.2 Tool holder (WH) for
beveling and squaring
24
3.5.3 Clamping shells (op-
tional) .........................
24
3.5.4 Warning signs ............ 24
4 Characteristics and range of appli-
cations...............................................
25
4.1 Characteristics ......................... 25
4.2 Scope of application................. 26
5 Technical specifications.................. 27
6 Commissioning ................................ 29
6.1 Scope of delivery ..................... 29
6.2 Requirements for connection ... 30
7 Storage and transport...................... 32
7.1 Transporting the machine ........ 32
8 Set-up and mounting ....................... 34
8.1 Mounting the multifunctional
tool (MFW) and tool holder
(WH).........................................
36
8.2 Inserting/replacing the clamp-
ing shells RPG 3.0 ...................
37
8.3 Inserting/replacing the clamp-
ing shells RPG 4.5 and RPG
8.6 ............................................
37
8.3.1 Inserting the lower
clamping shell ............
37
8.3.2 Inserting the upper
clamping shell ............
38
8.3.2.1 Replacing clamping
shells..........................
38
8.4 Clamping pipe .......................... 39
8.4.1 RPG 3.0 ..................... 39

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 3
8.4.2 RPG 4.5 and RPG 8.6 40
8.4.3 RPG 4.5 S.................. 40
8.4.4 Adjustment options
with the clamping
lever and adjusting
bolt for offsetting tube
tolerances (RPG 4.5
and RPG 8.6).............
41
8.4.4.1 Shifting the adjusting
bolt .............................
42
9 Operation .......................................... 43
9.1 Shutdown (including in case of
emergency)..............................
46
9.2 Setting the speed..................... 46
9.3 Switching on the machine........ 48
9.4 Machining the pipe................... 48
9.5 Switching off machine.............. 49
10 Maintenance, service and trou-
bleshooting.......................................
50
10.1 Maintenance ............................ 50
10.2 What to do if...? – General
troubleshooting ........................
51
10.3 Servicing/Customer service ..... 51
11 ERSATZTEILLISTE / SPARE
PARTS LIST ......................................
53
11.1 RPG 3.0: Vorschub | RPG 3.0:
Feed.........................................
54
11.2 RPG 3.0: Spanneinheit | RPG
3.0: Clamping unit....................
58
11.3 RPG 3.0: Gehäuse mit Antrieb
| RPG 3.0: Main housing with
drive .........................................
60
11.4 RPG 4.5 (S): Vorschub | RPG
4.5 (S): Feed............................
64
11.5 RPG 4.5: Spanneinheit | RPG
4.5: Clamping unit....................
68
11.6 RPG 4.5 (S): Gehäuse mit
Antrieb | RPG 4.5 (S): Main
housing with drive ....................
72
11.7 RPG 4.5 S: Schraubstock kom-
plett | RPG 4.5 S: Vice com-
plete .........................................
76
11.8 RPG 8.6: Vorschub | RPG 8.6:
Feed.........................................
78
11.9 RPG 8.6: Spanneinheit | RPG
8.6: Clamping unit ....................
82
11.10 RPG 8.6: Gehäuse mit Antrieb
| RPG 8.6: Main housing with
drive .........................................
86
11.11 Ohne Abbildung | Not shown ... 88
12 Declaration of Conformity............... 89

RPG 3.0 (Akku) / 4.5 (S) / 8.6
4ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
1 About these instructions
1.1 Warning messages
The warnings used in these instructions warn you of injuries or damage to property.
Always read and observe these warnings!
This is a warning icon. It warns against dangers of injury. In order to avoid injuries or
death observe the measures marked with a safety sign.
WARNING LEVEL MEANING
DANGER Imminently hazardous situation that results in death or serious in-
juries if the safety measures are not observed.
WARNING Potentially hazardous situation that may result in death or serious
injuries if the safety measures are not observed.
CAUTION Potentially hazardous situation that may result in slight injuries if
the safety measures are not observed.
NOTE! Potentially hazardous situation that may result in material damage
if the safety measures are not observed.
1.2 Further icons and displays
SYMBOL MEANING
Important information for comprehension.
1.
2.
3.
…
Request for action in a sequence of actions: Action is required here.
► Single request for action: Action is required here.

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1.3 Abbreviations
ABBREVIATION MEANING
RPG 3.0 (battery), RPG
4.5 or RPG 8.6
Tube squaring machine up to 3.0 inch, 4.5 inch or 8.6 inch outer diameter
of the tube
RPG 4.5 S Tube squaring machine up to 4.5 inch outer diameter of the tube with vice
clamping system
MFW Multifunctional tool
WH Tool holder
QTC® Quick Tool Change

RPG 3.0 (Akku) / 4.5 (S) / 8.6
6ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
2 Information and safety instructions for the
owner
2.1 Requirements for the owner-operator
Workshop/outdoor/field use: The owner is responsible for safety in the danger zone around the ma-
chine, and should allow only qualified personnel to enter the zone or operate the machine in the danger
zone.
Employee safety: The safety instructions described in the chapter Information and safety instructions
of the operating instructions and the general safety instructions described in the safety regulations as
well as safety-conscious work with all required safety equipment must be maintained.
2.2 Using the machine
2.2.1 Proper use
• The machine must only be used for squaring or beveling of pipes made of materials and pipe
dimensions, as listed in chapter Scope of application of the operating instructions.
• Only use dimension-specific clamping shells by Orbitalum Tools GmbH to fixate the pipes.
• Only operate the machine within the voltages specified on the type plate of the drive (see chapter
Technical specifications of the operating instructions).
• Only use the RPG motors code 790 038 190 to 790 038 192 as a drive for the electric variants.
• The drive motor may only be used in connection with the machine.
• The machine may only be used on empty, unpressurized pipes and tanks in a non-explosive
atmosphere.
Intended use also includes:
• Observing all safety and warning information of these operating instructions and the general tube
squaring machine safety information
• Complying with all inspection and maintenance work
• Using it only in its original condition with genuine accessories, spare parts and operating materials
• Processing only those materials named in the operating instructions.
2.2.2 Improper use
• Any use that differs from or goes beyond the use and stated limits specified under "Intended use" is
improper due to the danger involved.

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• The owner shall be responsible for any damage which results from improper use. The
manufacturer accepts no liability.
• No tools should be used that have not been authorized by the manufacturer of this machine.
• Tubes of non-metal material should not be processed.
• The removal of safety devices is not permissible.
• Do not misuse the machine.
• The machine is not intended for use by private consumers.
• The machine is intended solely for commercial and industrial use.
• It is impermissible to exceed the technical values specified for normal operation.
• Do not use the machine as a drive for any applications other than that named as the intended use
(see chapter Intended use).
• Do not clamp machine between legs.
2.2.3 Machine constraints
• Keep your working area clean. Disorder or unlit working areas can lead to accidents.
• The workplace can be in the tube preparation, in plant construction or the plant itself.
• Work lighting: min. 300Lux.
• Operation by one person.
• Climate conditions: Temperature range for machine operation: –15° to 40°C.
• Only operate the machine in dry surroundings (not in misty, rainy or stormy conditions... (< 80% rel.
humidity)).
2.2.4 Shutting down the machine
EMERGENCY STOP or shutdown function descriptions, see chapter Shutdown (including in case of
emergency).
2.3 Environmental protection and disposal
2.3.1 REACh (Registration, Evaluation, Authorization and
Restriction of Chemicals)
The regulation (EC) 1907/2006 of the European Parliaments and of the Council concerning the registra-
tion, evaluation, authorization and restriction of chemicals (REACh) regulates the production, placing on
the market and use of chemical substances and the mixtures produced from these.

RPG 3.0 (Akku) / 4.5 (S) / 8.6
8ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
Our products are "products" in the sense of the REACh regulation. In accordance with Article33 of the
REACh regulation, suppliers of products must inform their customers if the supplied product contains a
substance specified in the REACh SVHC candidate list exceeding 0.1percent by mass of the object. On
June 27, 2018, lead (CAS: 7439-92-1 / EINECS: 231-100-4) was included in the SVHC candidate list.
This inclusion activates an obligation to inform along the chain of delivery.
We herewith inform you that individual partial components of our products contain lead in quantities ex-
ceeding 0.1% by mass of the object as an alloy component in steel, aluminum and copper alloys as
well as in solders and capacitors of electronic components. The lead content lies within the exceptions
specified in the RoHS Directive.
Since lead as an alloy component is firmly bound and therefore no exposure is to be expected in the
case of proper use, no additional specification of its safe use are required.
2.3.2 Chips and gear lubricant
Dispose of chips and replaced gear lubricant as prescribed.
2.3.3 Electric tools and accessories
Used-up power tools and accessories contain a large amount of valuable raw materi-
als and plastics which can be recycled. For this reason:
• Electrical and electronic devices marked with the symbol at the right may not be
disposed of with household garbage as per EU directive.
• By actively using the offered return and collection systems, you are doing
your part to reuse and recycle used electrical and electronic devices.
• Used electric and electronic devices contain parts which must be handled
specially as per EU directives. Separate collection and selective treatment are
the basis for environmentally responsible disposal and protection of human
health.
• We will properly dispose of devices and machines from us purchased after
August 13, 2005, if they are sent to us postage-paid.
• In the case of used devices which may represent a risk to human health or safety
due to contamination during use, we have the option of refusing return.
• The user is responsible for disposing of used devices purchased before August
13, 2005. For this purpose, please contact a professional disposal company in
your area.
•Important note for Germany: Our devices and machines may not be disposed
of at communal dumps, as they are only used in the commercial sector.
(as per RL
2012/19/EU)

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2.3.4 Return of accumulators and batteries
• Accumulators and batteries that are marked with the adjacent symbol may not be
disposed of with household garbage as per EU Directive 2006/66/EC.
• In the case of accumulators and batteries containing hazardous materials the
chemical sign for the heavy metal contained is specified below the refuse bin: Cd
= cadmium Hg = mercury Pb = lead
•Applies for Germany: The end consumer is obliged to return defective or used
accumulators and batteries to the distributor or to the returning facilities set up to
this purpose.
Cd
2.4 Basic safety precautions
The machine is a state-of-the-art accessory designed for safe use. Remaining risks are described in the
following operating instructions. Use other than that described in these instructions can lead to severe
personal injury and damage to property. For this reason:
• Warning information must be observed.
• Along with these operating instructions, the general warning information for electric tools (see
supplement) also apply, which must always be kept.
• Store all documentation near the machine.
• Generally valid regulations for the prevention of accidents must be observed.
• Observe country-specific regulations, standards and guidelines.
• Use the machine only in perfect technical condition, otherwise have it repaired at a service point.
Observe the maintenance specifications (chapter Maintenance, service and troubleshooting of the
operating instructions).
• Only operate the machine if all the safety equipment such as the restart inhibitor protection and
overload protection are in good working order, the viewing window is closed. The machine must
have a solid footing. Check whether the substrate is able to take sufficient loads. A radial space
requirement/freedom of movement of approx. 1 m around the machine is required for people.
• Report deviations in operating behavior of the machine to the person in charge immediately.
• Use only the dimensions and materials listed in these instructions. Other materials may only be
used after consulting with Orbitalum Tools customer service.
• Use only genuine tools, spare parts, operating 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, wait until the machine/tool
stops running and pull the mains plug or remove the battery.

RPG 3.0 (Akku) / 4.5 (S) / 8.6
10 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
• Do not carry the machine by its cable and do not use the cable to pull the power plug out of the
socket outlet (except in case of an emergency). Protect the cable against heat, oil and sharp edges
(chips).
• Do not reach into the tools while machining is being carried out.
• Ensure that the workpiece is clamped properly.
• Only switch on the machine if a pipe is clamped.
• Do not use the machine in wet surroundings. Only work in surroundings having a roof or canopy.
• 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).
• Operator age: The respectively valid country-specific laws/standards/guidelines/directives have to
be followed.
• 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, see chapter Shutdown (including in
case of emergency) of the operating instructions.
• Do not use angled power plugs.
NOTICE The suggestions for "personal safety equipment" apply exclu-
sively and specifically for the product described. Other require-
ments arising from ambient conditions at the location of use, other
products or the link with other products are not taken into ac-
count. These suggestions do not relieve the owner (employer) of
his/her legal duties regarding work-safety and health protection of
employees in any way.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 11
DANGER If the power cable is damaged, exposed parts can be energized
with lethal voltage!
Fatal electric shock.
► Do not allow the power cable of the motor to be near the machine,
especially the cutting tool (MFW).
► Do not operate machine unattended.
► Keep an eye on the power cable at all times when processing is be-
ing carried out.
► Keep machine clean and thoroughly remove lubricant residue on the
machine.
DANGER Damaged insulation!
Fatal electric shock.
► Do not screw signs to the drive motor.
► Use adhesive signs.
DANGER Loss of insulation due to collection of metal dust in the motor
housing!
Fatal electric shock.
► Clean the machine at least once daily with the brush supplied ac-
cording to its level of soiling.
DANGER Damaged plug.
Fatal electric shock.
► Do not use adapter plugs together with protectively grounded power
tools.
► Connecting plugs of the machine must fit into the outlet
DANGER Risk of danger through the use of the machine outdoors!
Fatal electric shock.
► Do not use the machine in wet surroundings.
WARNING The electrical motor can overheat with operation in a 110V net-
work!
Severe injury or death.
► Only use the machine in the specified temperature range.

RPG 3.0 (Akku) / 4.5 (S) / 8.6
12 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
DANGER Grounded body!
Fatal electric shock.
► Avoid contact with grounded surfaces such as tubes, heating, cook-
ers or refrigerators.
DANGER Danger of fire from charging the battery with a wrong charger!
Severe injury or death.
► Only charge the batteries with chargers recommended by the manu-
facturer.
DANGER Danger of fire from short-circuiting between the battery contacts!
Severe injury or death.
► Keep the unused battery away from paper clips, coins, keys, nails,
screws or other small metal objects that may cause a bypassing of
the contacts.
DANGER Defective safety parts due to soiling and wear!
Bodily injury due to failure of safety parts.
► Do not misuse the cable, for example by suspending or carrying the
machine by the cable.
► Replace defective safety parts immediately and check daily for
proper functioning.
► Have an expert replace defective power cables immediately.
► Clean and maintain machine after every use.
► Keep cable away from heat, oil, sharp edges and moving device
parts.
► Check machine daily for externally visible damage and defects and
have them remedied by a professional if necessary.

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 13
WARNING Parts thrown off/tool breakage and rotating pipe!
Various injuries and damage to property.
►No damaged or deformed cutting tools (MFW) should be used.
► Firmly clamp the tube to be processed into the clamping unit.
► Change worn tool immediately.
► Ensure proper mounting of the cutting tools.
► Keep the clamping surface of the clamping shells free of chips and
dirt.
► The inner diameter of the clamping shells must be identical to the
outer diameter of the tube to be machined. The specific inner diame-
ter is specified on the clamping shells. The outer diameter of the
tube must be determined.
► Avoid tool breakage by ensuring low (measured) infeed (max.
clamping thickness: 0.2 mm) and correct speed setting (see operat-
ing instructions chap. Setting the speed).
► Check that the tool holder (WH) and multifunctional tool (MFW) are
seated firmly, and tighten if required.
► After adjusting the tool, remove the hexagon key from the working
area.
WARNING Falling objects or tilting and bending tubes!
Irreversible crushing.
► Wear safety shoes (in accordance with EN ISO 20345, at least S1).
► Place sufficient supports under the tube.
► Transport the machine as shown in chapter Transporting the ma-
chine of the operating instructions.
WARNING Danger from vibration and unergonomic, monotonous work!
Discomfort, fatigue and malfunctioning of the moving apparatus!
Limited response capability and cramps.
► Perform "loosening-up" exercises.
► Ensure a varied range of activities.
► Assume an upright, fatigue-free and comfortable body position dur-
ing operation

RPG 3.0 (Akku) / 4.5 (S) / 8.6
14 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
WARNING Inadvertent actuation of the ON/OFF switch!
Various injuries and damage to property.
► At the end of each working cycle, before transportation, changing
tools, cleaning and performing any maintenance, adjustment or re-
pair work, switch off the machine, wait until the machine/tool stops
running and pull the mains plug or remove the battery.
WARNING Liquid leaking from the battery due to wrong use!
Various injuries and damage to property.
► Wash with water if touched accidentally.
► If liquid enters the eyes, contact a doctor.
2.5 Warning signs
The warning signs and safety signs located on the machine must be observed.
The warning signs are part of the machine. They must not be removed or modified. Missing or illegible
warning signs must be replaced immediately.
IMAGE POSITION ON MACHINE MEANING CODE
Housing, top Warning:
Danger of injury due to
rotating tool.
790 046 196
Housing, top Rule:
Wear safety goggles accord-
ing to DINEN166, hearing
protection according to
DINEN352
and snug-fitting safety gloves
according to DINEN388 and
EN407.
Read operating instructions.
790 086 200

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 15
IMAGE POSITION ON MACHINE MEANING CODE
Motor
(only with US Ver-
sion120 V)
Warning:
Pull power plug before tool
change or maintenance.
Wear protective clothing.
Keep hands away from mov-
ing parts.
790 086 199

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16 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
3 Description
3.1 RPG 3.0 Electric
1
2
3
4
6
12
8
7
3
9
11
105 9
NO. DESIGNATION
1 Infeed handle with adjustable scale
2 Enclosure
3 Protection
4 Tensioning screw

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 17
NO. DESIGNATION
5 Clamping screw
6 ON/OFF switch
7 Tool holder retainer
8 Tool holder with multifunctional tool
9 Base plate
10 Adjusting wheel for speed selection
11 Drive motor
12 Cable with power plug

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18 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
3.2 RPG 3.0 battery
1
2
3
4
6
8
7
5
9
10
11
8

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ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com 19
NO. DESIGNATION
1 Tensioning screw
2 Protection
3 Infeed handle with adjustable scale
4 Battery motor
5 Exchangeable battery
6 ON/OFF switch/RPM regulator
7 Enclosure
8 Base plate
9 Clamping screw
10 Tool holder retainer
11 Tool holder with multifunctional tool

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20 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com
3.3 RPG 4.5, RPG 8.6 Electric
1
2
3
4
6
8
7
5
11
9
10
13
12
15
14
14