Orbitalum RPG ONE User manual

precision.
power.
simplicity.
Operating
instructions
Tube Squaring Machines
RPG ONE
RPG 1.5
RPG 2.5
Cordless
Electric
Code 790 036 766
Translation of original operating instructions
│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 RPG ONE, RPG 1.5, RPG 2.5 Table of contents
orbitalum tools gmbh
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Table of contents
Page
0About these instructions 1
0.1 Warning messages 1
0.2 Other symbols and displays 2
0.3 Abbreviations 2
1Safety instructions 3
1.1 Intended Use 3
1.2 Safety Regulations 3
1.3 Working with safety in mind 4
1.4 Environmental Protection/Disposal 6
1.5 Further safety regulations 6
2Design of the product 7
2.1 RPG ONE Electric 7
2.2 RPG ONE Cordless 7
2.3 RPG 1.5 Electric 8
2.4 RPG 1.5 Cordless 8
2.5 RPG 2.5 Electric 9
2.6 RPG 2.5 Cordless 9
2.7 RPG 2.5 (Cordless) tool mounting plate 10
2.8 Accessories 11
2.8.1 Multifunctional tool (MFW) 11
2.8.2 Tool holder (WH) for beveling and squaring 11
2.8.3 Adapter clamping shell 12
2.8.4 Stainless steel clamping shells 12
3Features and scope of application 13
3.1 Features 13
3.2 Scope of application 14
3.2.1 Application range 14
4Technical data 14
4.1 Characteristics 14
5Commissioning 15
5.1 Included with the machine* 15
5.2 Connection requirements 15
5.3 Assembly of the bench stand 15
5.4 Transportation 16
6Operation 17
6.1 Determining tube dimension 18
6.2 Assembly of multifunctional tool (MFW) and tool holder
(WH) 18
6.2.1 Mount multifunctional tool 18
6.2.2 Assemble tool holder 19
6.3 Setting up and/or replacing clamping shell 20
6.3.1 Remove a clamping shell 20
6.3.2 Inserting a clamping shell 21
6.4 RPG 2.5: Setting up and/or replacing adapter clamping shell 22

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6.4.1 When is the adapter clamping shell necessary? 22
6.4.2 Removing clamping shell 22
6.4.3 Inserting adapter clamping shell 23
6.5 Clamping the tube 24
6.6 Selecting the speed range 25
6.6.1 Adjusting the speed: RPG Electric 25
6.6.2 Adjusting the speed: RPG Cordless 26
6.7 Processing the tube 27
6.7.1 Turn on the RPG Electric 28
6.7.2 Switching on RPG Cordless 28
6.7.3 Facing, feeds and Adjustments 29
6.7.4 Switching off RPG Electric 29
6.7.5 Switching off RPG Cordless 30
6.8 Processing in restricted environments 30
6.8.1 Change position of drive 30
6.8.2 Change position of body 31
7Maintenance 32
8What to do if? 33
8.1 Troubleshooting 33
8.2 Servicing/after-sales service 33
9EU declaration of conformity 34
9.1 RPG ONE, RPG 1.5, RPG 2.5 34
9.2 RPG ONE Cordless, RPG 1.5 Cordless, RPG 2.5 Cordless 35

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 0 About these instructions
orbitalum tools gmbh
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0 About these instructions
For a quick understanding of these instructions and safe operation 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 about the risks
of bodily injuries or property damage. Please read and observe these warning
messages at all times!
This is a warning symbol. It is designed to warn you against
risks of injury.
Please follow all instructions marked 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 minimize risks.
WARNING
Possible danger!
Non-observance could result in serious injury.
:Restrictions (if applicable).
XMeasures to prevent risks.
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 RPG ONE, RPG 1.5, RPG 2.5
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0.2 Other symbols and displays
Symbol Meaning
Important
Note Notes: Contain particularly important information to be
understood.
Instruction: You should pay attention to this symbol.
1. Request for action in a sequence of actions: You need to do
something here.
X
Single request for action: You need to do something here.
ZConditional request for action: You need to do something
here if the specified condition is met.
0.3 Abbreviations
Abbr. Meaning
RPG Tube Squaring Machine with electric drive
RPG Cordless Tube Squaring Machine with cordless drive
MFW Multifunctional tool
WH Tool holder
QTC®Quick Tool Change

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 1 Safety instructions
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Warning: While using electrical tools, the following safety measures need
to be observed in order to protect against electrical shock, risk of injury
or fire.
Read all these instructions before using this electrical tool, and preserve
the safety instructions carefully.
1 Safety instructions
The Tube Squaring Machine (later called RPG ONE, RPG 1.5 or RPG 2.5
(Cordless)) is built to state-of-the-art technology. Using this machine in a
manner other than that described in this manual can lead to personal injuries to
the user or of third parties. Furthermore, the machine or other objects may by
damaged.
Therefore:
•Always ensure that the machine is in good working order and comply with
these notes on safety.
•Keep complete documents close by the machine.
•Generally recognised procedures for the prevention of accidents should be
observed.
1.1 Intended Use
•Use RPG ONE, RPG 1.5 or RPG 2.5 exclusively as a bench machine for
processing thin-walled stainless-steel or steel tubes and welded micro
fittings.
•Use RPG ONE Cordless, RPG 1.5 Cordless or RPG 2.5 Cordless
exclusively as a mobile machine for processing thin-walled stainless-steel
or steel tubes and welded micro fittings at fixed tubeline systems.
•The user will be the only person liable for damages caused by
improper use.
1.2 Safety Regulations
•Only use the dimensions and materials specified in these instructions.
Other materials should be used only after consulting the Orbitalum Tools
after-sales service.
•Please read through the operating instructions and safety prescriptions
completely, before using the rechargeable battery and charger of the
RPG ONE Cordless, RPG 1.5 Cordless or RPG 2.5 Cordless.
•Only use original Orbitalum Tools spare parts and resources.
•Inspect the RPG ONE, RPG 1.5 or RPG 2.5 daily for visible signs of
damage or defects. Have any damages or defects repaired immediately.
Important

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•Work on the electrical equipment must only be carried out by a qualified
electrician.
•Only operate the RPG ONE, RPG 1.5 or RPG 2.5 if the electrical restart
prevention is working correctly.
•Switch off the machine, allow it to run to a standstill and take out the plug
from the power supply unit or take out the rechargeable battery before any
change of tools, transport, maintenance and repair operations.
1.3 Working with safety in mind
“Make your contribution to safety in the workplace.”
•Report any unusual response from the machine to the person responsible
immediately.
•Be aware of safety aspects at all times during work.
•When working with the RPG, wear protective goggles and safety gloves.
•Tie up long hair (hair-net); do not wear loose-fitting clothes.
Note: Jewellery and ties could get caught in the rotating parts!
•Check that the work piece is correctly clamped.
•After the work process, have the machine switched off and let it run to a
standstill.
•Switch the machine off, allow it to run to a standstill or take out the
rechargeable battery before any change of tools, cleaning, maintenance,
setup and repair operations.
•During operations, keep hands away from the tools.
•Be aware of environmental influences: Do not use electric tools and
rechargeable batteries in a damp or wet environment. Ensure lighting is
adequate. Do not use in close proximity to flammable liquids or gases.
•Do not carry the electric tool by the cable and do not use the electric tool to
pull out the plug. Protect the cable from heat, oil and sharp edges (chips).
•Before and during the processing of tubes, ensure that the viewing window
is closed.
•In order to reduce vibrations, always work with sharp multifunctional tools
(MFW).

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Danger of being injured by sharp cutting edges
:Do not touch the running tool while the machine is operating.
►Wear safety gloves.
►Tie up long hair (hair-net); do not wear loose-fitting clothes.
►Use the tube squaring machine only when the tube has been clamped.
►No chips or workpiece parts should be removed from the processing area
as long as the machine is running and the tool is not yet at rest.
Danger of eyes and hands being injured by hot and sharp-edged chips
flying around
:Do not touch the running tool while the machine is operating.
►Always wear protective goggles and safety gloves.
►Remove chips only with safety gloves. Remove long and bent chips with
pincers and/or side cutting pliers.
Danger of death by electric shock
If the mains cable is damaged, live parts may cause death if touched directly.
:Do not leave the power cord of the electric motor near the processing area
and/or the tool.
:Do not run the machine unattended.
Danger to life by unintentionally touching the ON/OFF switch
►The machine may only be operated using a fault current (FI) protect switch.
►Allow the machine to run to a standstill and remove the power plug from the
power supply unit or take out the rechargeable battery before any change
of tools, cleaning, maintenance, setup and repair operations.
WARNING
WARNING
DANGER

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1.4 Environmental Protection/Disposal
•Dispose of chips and used gear lubricant oil according to the regulations.
Discarded electric tools and accessories contain a large share of
valuable raw and synthetic materials, which can be recycled. Therefore:
•Electrical (electronic) devices that are marked with the symbol to the left,
may not be disposed of with household waste in accordance with EU
regulations.
•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 EU regulations. Separate collection and selective
treatment is the basis for environment-friendly disposal and the protection
of human health.
•Our appliances and products that were sold to you after August 13, 2005
will be disposed of according to legal standards after they have been
delivered free of cost to us by the customer.
•Taking back old appliances, which pose a risk to human health or safety
due to soiling during their use, may be refused.
•The disposal of old appliances that were placed on the market before
August 13, 2005 is the responsibility of the end user. Please contact a
disposal unit near you for this purpose.
•Important for Germany: our products may not be disposed of in municipal
disposal sites as they are used for industrial purposes only.
•Accumulators and batteries that are marked with the symbol to the left
may not be disposed of with household garbage according to EU directive
91/157/EEA.
•In batteries containing harmful substances, the chemical sign for the heavy
metal contained is indicated below the garbage can: Cd = Cadmium
•For Germany, it holds that: The end user is liable to return defective or
used batteries to the distributor or to a recycling center established for the
purpose.
1.5 Further safety regulations
Observe the regulations, standards and guidelines applicable in your country.
(as per RL 2002/96/EC)
Cd

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 2 Design of the product
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2 Design of the product
2.1 RPG ONE Electric
1 Tool recipient/housing 5 Fixing button
2 Viewing window 6 ON-OFF switch
3 Feed with scale divisions 7 Bench stand (removable)
4 Driving motor Metabo 1010 Plus 8 Release handle for fixing the
clamping shells
2.2 RPG ONE Cordless
1 Tool recipient/housing 5 Rechargeable battery
2 Viewing window 6 ON-OFF switch/speed regulator
3 Feed with scale divisions 7 Release handle for fixing the
4 Metabo driving motor clamping shells
1
2 3
4 5
6
7
8
1
7
2 3
6
5
4

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2.3 RPG 1.5 Electric
1 Large clamp handle 6 Fixing button
2 Tool recipient/housing 7 ON-OFF switch
3 Viewing window (slidable) 8 Bench stand (removable)
4 Feed with scale divisions 9 Small clamp handles
5 Driving motor Metabo 1010 Plus
2.4 RPG 1.5 Cordless
1 Large clamp handle 5 Rechargeable battery
2 Viewing window (slidable) 6 ON-OFF switch/speed regulator
3 Feed with scale divisions 7 Small clamp handle
4 Metabo driving motor 8 Tool recipient/housing
2
3
4
5 6
7
8
9
1
7
3
6
5
4
1
8
2

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 2 Design of the product
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2.5 RPG 2.5 Electric
1 Small clamp handles 8 Driving motor Metabo 1010 Plus
2 Housing 9 ON-OFF switch
3 Viewing window (slidable) 10 Fixing button
4 Feed with scale divisions 11 Clamping shell
5 Gear box unit 12 Tool recipient with tool holder
6 Speed regulator for pre-adjustment and multifunctional tool
(Step 1 + 2, refer to chap. 6.6.1, p. 25) (for description refer to chap. 2.7, p. 10)
7 Speed thumb wheel for fine-tuning 13 Bench stand (removable)
(Steps A – G, refer to chap. 6.6.1, p. 25) 14 Large clamp handle
2.6 RPG 2.5 Cordless
1 Small clamp handles 8 Rechargeable battery
2 Housing 9 ON-OFF switch/speed regulator
3 Viewing window (slidable) 10 Large clamp handle
4 Feed with scale divisions 11 Tool recipient with tool holder
5 Gear box unit and multifunctional tool
6 Speed switch (for description refer to chap. 2.7, p. 10)
(Step 1 + 2, refer to chap. 6.6.2, p. 26) 12 Clamping shell
7 Metabo driving motor
1 2
3 4 5 6 8 9
10
1 11 13 14
7
12
1
3 5
1
12
2 4 6 7
8
9
10
11

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2.7 RPG 2.5 (Cordless) tool mounting plate
The tool mounting plate of the RPG 2.5 (Cordless) offers different tool holder
assembly possibilities, according to type of application:
•Facing (1) of 6.35 - 12.7 mm (¼" - ½")
•Facing (2) of 12.7 - 63.5 mm (½" - 2½")
•Beveling (3), dimension range as per bevel tool
XThe tool holder (4) should be assembled in one of the 6 fastening threads
(5) as a function of the above listed processing type and tube outer
diameter.
XThe bigger the outer diameter of the tube, the further apart are the
fastening threads selected for the tool holder (see arrows).
XFor exact positioning, install the tool holder (4) with a multifunctional tool in
the groove guide (6) and screw it in as a function of the desired processing
type along the groove guide and using the correct fastening thread (5).
XThe groove guide (6) is provided with fine lines, so as to facilitate the
positioning of the tool holder (4).
Tool recipient without tool holder Tool recipient with tool holder
Notes
1
2
3
5
4
6

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 2 Design of the product
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2.8 Accessories
Please check the outer diameter of the tubes before ordering the clamping
shells. The different standards sometimes involve a special size (particularly
for tubes in accordance with DIN 2430).
2.8.1 Multifunctional tool (MFW)
Supplied as standard. Cutting insert with two cutting edges and high-
performance coat of Futura®Balinit.
Can be used with all tool holders of the RPG series.
Article Pieces Code
Multifunctional tool MFW-P-2 1 790 038 314
Multifunctional tool MFW-P-2 10 790 038 315
2.8.2 Tool holder (WH) for beveling and squaring
Adjustable tool holder incl. Torx screw. Further tool holder for different bevel
angels on request.
Possible
application Bevel angle Tube OD RPG ONE (Cordless) Tube OD RPG 1.5 (Cordless) Tube OD RPG 2.5 (Cordless)
Application range
Squaring Beveling [°] [mm] [inch] [mm] [inch] [mm] [inch]
Standard tool holder WH12-I** x – – 3.0 - 25.4 0.118 - 1.000 3.0 - 63.5 0.118 - 2.500 3.0 - 63.5 0.118 - 2.500
Optional tool holder WH12-I x – – 12.7 - 25.4 0.500 - 1.000 12.7 - 63.5 0.500 - 2.500 12.7 - 63.5 0.500 - 2.500
Optional tool holder WH12-I for
micro fittings* x – – – –
3.0 - 21.2 0.118 - 0.835 6.35 - 21.2 0.250 - 0.835
Tool holder WH3-V-30 – x 30° max. 25.4 max. 1.000 max. 35.0 max. 1.378 max. 60.3 max. 2.374
Tool holder WH3-V-35 – x 35° max. 25.4 max. 1.000 max. 34.0 max. 1.339 max. 59.3 max. 2.335
Article Code
Standard tool holder WH12-I** 790 037 152
Optional tool holder WH12-I 790 037 154
Optional tool holder for micro fittings WH12-I* 790 037 156
Tool holder WH3-V-30 790 037 158
Tool holder WH3-V-35 790 037 159
* Only to be used with stainless steel clamping shells for micro fittings.
** Recommended application range with the standard tool holder: 3.0 - 12.7 mm (0.118 - 0.5 inch).

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2.8.3 Adapter clamping shell
Supplied as standard with the RPG 2.5 (Cordless). Using this adapter clamping
shell, the clamping shells for the RPG 1.5 can also be set up on RPG 2.5
machines, extending the processing range to min. 6.35 mm (0.250 inch).
Comes with:
•1 Adapter clamping shell
•1 long clamping screw
Article Code
Adapter clamping shell 790 030 094
2.8.4 Stainless steel clamping shells
Not supplied as standard.
For deformation-free clamping of tubes. Extremely durable. Ensures precise
mounting of tubes/micro fittings and quick change of clamping shells without
tools. For use on all materials with an OD from 6.0 mm up to 63.5 mm (0.236 -
2.500 inch).
You can find a range of clamping shell dimensions with code numbers in our
current product catalogue.

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 3 Features and scope of application
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3 Features and scope of application
3.1 Features
The RPG is designed for facing tube ends/welded micro fittings of metallic
materials and has the following properties:
•Preparation of tube ends for welding conforming to standards
•Tool holding system QTC® (Quick Tool Change):
Fastener for fixing the tool holder to the tool recipient
•Only one multifunctional tool necessary for:
–different tube wall thicknesses (up to 3 mm/0.118 inch)
–different tube materials (exclusively ferrous materials)
•Multifunctional tool:
–non standard tool holders are available on request to the case under
consideration
–tool with multiple cutting edges
–only if necessary, a screw for fastening and fixing the tools
–tool cover TiN
•Cordless drive:
–rotating / removable
–Motor with high performance and small size
–No memory effect
–Single cell monitoring in the cordless pack
–Electronic overload protection with integrated temperature monitor
–Robust cordless packs with capacity display
–Minimal self-discharge
–Environmentally friendly
–AIR COOLED technology for short charging times and a long service
life
•Electric drive:
–twistable/detachable
–speed-controlled electric motor with speed stabilization
–restart protection to prevent the machine from starting in an
uncontrolled
–way after it has been re-connected to the electric mains or after the
–voltage supply has been re-established after a power failure
•Quick change system for clamping shells
•Feed with scale divisions:
–total: 10 mm (0.394 inch)
–per rotation: 9 mm (0.354 inch)
–per graduation mark: 0.1 mm (0.004 inch)
•Simple movable viewing window and/or protection from chips makes clean
work possible

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3.2 Scope of application
3.2.1 Application range
Machine type RPG ONE (Cordless) RPG 1.5 (Cordless) RPG 2.5 (Cordless)
Tube OD min.-max. [mm] 3.00 - 25.40 3.0 - 38.10 6.35* - 63.50
[inch] 0.118 - 1.000 0.118 - 1.500 0.250* - 2.500
Wall thickness max. [mm] 3.0 3.0 3.0
[inch] 0.118 0.118 0.118
* only with special adapter clamping shells (refer to chap. 2.8.3, p. 12).
•High-alloy steels (stainless steel material no. 1.40... to 1.45...)
•Unalloyed and low-alloy steels
•Aluminum
More upon request.
4 Technical data
4.1 Characteristics
Machine type RPG ONE RPG ONE
Cordless RPG 1.5 RPG 1.5 Cordless RPG 2.5 RPG 2.5 Cordless
[mm] 390x200x70 261x255x80 400x350x160 275x255x90 500x300x170 260x300x320 Dimensions (lxhxd)
[inch] 15.35x7.87x2.76 10.28x10.04x3.15 15.75x13.78x6.30 10.83x10.04x3.54 19.69x11.81x6.69 10.24x11.81x12.60
[kg] 4.14 2.88 4.7 3.44 6.6 5.23 Weight (without
accessories) [lbs] 9.13 6.35 10.36 7.58 14.6 11.8
Versions
230 V. 50/60 Hz EU
110 V. 50/60 Hz EU
120 V. 50/60 Hz US
230 V. 50/60 Hz EU
115 V. 60 Hz US 230 V. 50/60 Hz EU 110 V. 50/60 Hz EU
120 V. 50/60 Hz US
230 V. 50/60 Hz EU
115 V. 60 Hz US 230 V. 50/60 Hz EU 110 V. 50/60 Hz EU
120 V. 50/60 Hz US
230 V. 50/60 Hz EU
115 V. 60 Hz US
Power [W]
1010 – 1010 – 1010 –
Voltage rechargeable
battery
[V] – 18 – 18 – 18
Speed of the tool [rpm] 145 - 380 0 - 400 145 - 380 0 - 400 1. speed: 9 - 52
2. speed: 27 - 153
1. speed: 0 - 24
2. speed: 0 - 83
Sound pressure level
(EN 23741)
[dB (A)] approx. 78 approx. 78 approx. 78 approx. 78 approx. 78.2 approx. 78.2
Vibration level (EN 50144) [m/s²] < 2.5 < 2.5 < 2.5 < 2.5 < 2.5 < 2.5
Tube materials

Operating instructions RPG ONE, RPG 1.5, RPG 2.5 5 Commissioning
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5 Commissioning
XCheck all parts of the delivery for completeness and damage in
transportation.
XReport any missing parts or transportation damage to your supplier
immediately.
5.1 Included with the machine*
•1 Tube Squaring Machine RPG ONE, RPG 1.5 or RPG 2.5 (Cordless)
•1 Durable storage and shipping case
•2 Rechargeable batteries, 1 battery charger (for cordless versions only)
•1 Overload protection (square nut 790 037 118)
•1 Adapter clamping shell (Code 790 030 094, for RPG 2.5 versions only)
•1 Tool holder WH (Code 790 037 152) with
1 Multifunctional tool MFW (Code 790 038 314)
•1 Tool set
•1 Set of operating instructions and spare parts list
* Subject to change
5.2 Connection requirements
The mains supply must meet the following requirements:
•1-phase alternating current, protection class II:
230 V, 50/60 Hz
110 V, 50/60 Hz
120 V, 50/60 Hz
230 V, 50/60 Hz EU, Cordless: 18 V
115 V, 60 Hz US, Cordless: 18 V
•Mains fuse at least 10 A
5.3 Assembly of the bench stand
The bench stand for RPG ONE, RPG 1.5 and RPG 2.5 Electric needs to be
assembled for commissioning the machine.
XFasten the bench stand on the machine with a spanner (SW4x150).
Checking the parts
of delivery
Bench stand

5 Commissioning Operating instructions RPG ONE, RPG 1.5, RPG 2.5
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5.4 Transportation
Risk of injury due to unintentional activation of the machine
During transportation, the ON/OFF switch (speed regulator) may
unintentionally be activated, please check the machine is switched off before
operating.
XAllow the machine to run to a standstill and remove the power plug from the
power supply unit or take out the replaceable battery before transportation
and/or change of operating environment.
The RPG is a portable machine. Special resources are not required for
transportation (carry the machines as shown in the diagrams to ensure safe
transportation).
RPG ONE Electric and RPG 1.5 Electric RPG ONE Cordless and RPG 1.5 Cordless
RPG 2.5 Electric RPG 2.5 Cordless
DANGER