Operating instructions with spare parts list ESG Plus
Contents
1. age Sound pressure level measurement was carried out under normal operating conditions according to EN 23741 04 07 MT_ESG Plus BA_04_790052774_07 doc 5 Commissioning 10 Scope of delivery subject to alterations DANGER Operating instructions with spare parts list ESG Plus 5 Commissioning 5 1 Scope of supply gt Check the delivery for completeness and any transportation damage gt Report any missing parts or transportation damage to your supplier immediately 1 Tungsten Grinder ESG Plus 1 Powder coated carrying steel case e 1 Diamond grinding wheel 790 052 487 e 1 Tool to replace the grinding wheel e 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 gt Cut off the power supply before transportation 04 07 MT_ESG Plus_BA_04_ 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 6 Operation DANGER Note Important C orbitalum tools gmbh 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 suitable2. orbitalum na power tools for piping systems simplicity Operating instructions with spare parts list Tungsten Grinder ESG Plus Code 790 052774 _ Machine no ehemals formerly known as Georg Fischer Rohrverbindungstechnik 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 Table of contents U Q D O About these instructions 0 1 Warning messages 0 2 Further symbols and displays 0 3 Abbreviations 1 Safety notes Proper use Safety regulations Work safely Waste disposal environmental protection 1 1 1 1 1 Further safety regulations O AOUN 2 Construction of the product 2 1 Standard 2 2 Accessories optional 2 2 1 Diamond grinding wheels 2 2 2 Cutting device 2 2 3 Electrode holder 2 2 4 Clamping collets 2 2 9 Wall table vice mounting plate 2 2 6 Protective cover 2 2 7 Double Decker Kit ESG 3 Characteristics and range of applications 3 1 Characteristics 3 2 Range of applications oo CO 00 NNNN09099 9 9 O1 oOo gt RW ww NNa 4 Technical data 9 5 Commissioning 10 5 1 Scope of supply 10 5 2 Transportation 10 6 Operation 11 6 1 Switching on the ESG Plus 11 6 2 Grinding the electrodes 11 6 2 1 Combina
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 gt Press the ON OFF switch 1 The ESG Plus stops 04 07 MT_ESG Plus_BA_04_790052774_07 doc 13 6 Operation WARNING Disassembly of the ESG Plus head 14 Operating instructions with spare parts list ESG Plus 6 4 Replacing grinding wheels Danger to injury to hands though unintentional activation of the ESG Plus a ner u Do not switch on the ESG Plus while changing the grinding wheel Pull out the power plug Dismantle and remove the cylinder head screw with collar M4x15 at the ESG Plus head Do not remove the arrest nut 1 Remove the ESG Plus head Slide a 2 4 mm pin through cross hole and motor shaft rotation of the grinding wheel is prevented Loosen and remove the grinding wheel screw cylinder head screw with washer M4x6 Turn the diamond grinding wheel or insert a new grinding wheel Insert the grinding wheel on the shaft gt The hole of the diamond grinding wheel has to be inserted centrally
4. cE Ej j W Fa Attach the second grinding head Attach the cylinder head screw with collar M4x34 to the arrest nut 1 04 07 MT_ESG Plus BA_04_790052774_07 doc C orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 8 Maintenance 8 Maintenance Danger of death by electric shock Non observance could result in death or critical injury gt Before maintenance work remove the mains plug DANGER Time Activity Before starting work gt The connection of the ESG Plus head to the motor has to be firm gt The device may not be moist and may not be used in a humid environment gt No unbalance in the grinding wheel may occur when the machine is switched on gt Check whether ESG Plus head and or the Torx screw sit firm if necessary tighten gt Check the power supply cable for damage gt The tapped holes at the ESG Plus must always be free of dust clean if necessary Weekly daily gt Remove dust from the inside of the housing clean C orbitalum tools gmbh 04 07 MT_ESG Plus_BA_04_790052774_07 doc 17 9 What to do if Operating instructions with spare parts list ESG Plus 9 Whatto do if 9 1 Fault elimination Fault Possible cause Remedy Motor of the ESG Plus does not Power cable defective gt Replace the power cable run Motor defective gt Replace the motor The ESG Plus head does not ESG Plus head is not correctly gt Tighten the Torx sc
5. on the motor shaft T Tighten the Torx screw and assemble the ESG Plus grinding head to the motor 04 07 MT_ESG Plus_BA_04_790052774_07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 7 Assembly of the Double decker Kit ESG2 7 Assembly of the Double decker Kit ESG The Double Decker Kit ESG is not included in the standard scope of supply but is obtainable as extra accessory see chapter 2 2 7 p 7 Disassembly ofthe 1 Dismantle and remove the cylinder head screw with collar M4x15 at the ESG Plus head 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 C orbitalum tools gmbh 04 07 MT_ESG Plus_BA_04_790052774_07 doc 15 7 Assembly of the Double decker Kit ESG2 Operating instructions with spare parts list ESG Plus 5 Attach the shaft elongation and fasten Note For easier fastening of the shaft elongation we recommend to slide a screw driver through the cross hole of the shaft elongation g rS le are 4 f x i er Fastening the 6 Double Decker Kit Attach the first grinding head Attach the rough grinding wheel Code 790 052 488 and fasten with the cylinder head screw with washer M4x6
6. suction devices or a suitable breathing mask gt Only work with safety goggles gt Always 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 04 07 MT_ESG Plus_BA_04_790052774_07 doc 11 6 Operation 12 Note Operating instructions with spare parts list ESG Plus 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 04 07 MT_ESG Plus_BA_04 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 6 Operation C orbitalum tools gmbh 6 2 3 Surface grinding the electrode tip Precision ground point Although able to grind flat land on tip gt Insert the electrode 1 0 1 6 2 0 2 4 3
7. SG Plus_BA_04_790052774_07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 2 Construction of the product C orbitalum tools gmbh 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 ESG 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 e 1 Grinding head e 1 Diamond grinding wheel rough e 1 Cylinder head screw with collar M4x34 e 1 Shaft elongation Code 790 052 490 04 07 MT_ESG Plus_BA_04_790052774_07 doc T 3 Characteristics and range of applications Operating instructions with spare parts list ESG Plus 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 instructio
8. Therefore e Always ensure that the device is in good working condition and always comply with these notes on safety e Keep the complete documentation close by the device e 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 e Only use the dimensions and materials quoted in these instructions Other materials should only be used after consulting Orbitalum Tools customer service department e Only use authentic Orbitalum Tools spare parts and materials e Check the ESG Plus daily for any externally visible damage or defects Have any damage or defects repaired immediately e Work on the electrical equipment should only be carried out by a qualified electrician e Only operate the ESG Plus if the electrical protective devices function e The tapped holes at the ESG Plus must always be free of dust clean if necessary e Pull out the power plug before carrying out repair and maintenance work 1 3 Work safely Play your part in ensuring safety at work e Report any changes in operating performance to the responsible person immediately e Carry out all work with an awareness of safety 04 07 MT_ESG Plus_BA_04_790052774_07 doc 3 1 Safety notes a 4 9 A WARNING Co o RL 2002 96 EC we Operating instructions with spare parts list ESG Plu
9. ctric motor item no 1 790 052 534 Cylinder head screw M4x15 with nut M4 DIN 934 N 0 gt N co Without illustration Spare parts to the Double Decker Kit ESG Item No Part Number Quan Description 790052530 1 Grinding head 790052488 1 Diamond grinding wheel rough 790052536 1 Cylinder head screw with collar M4x34 790052537 1 Shaft elongation _ _ C orbitalum tools gmbh 04 07 MT_ESG Plus_BA_04_790052774_07 doc 19 Orbitalum Tools GmbH Freib hlstra e 19 78224 Singen Deutschland Tel 49 0 77 31 792 0 Fax 49 0 77 31 792 500 tools orbitalum com www orbitalum com An ITW Company 790 052 774_07 04 04 07 Orbitalum Tools GmbH D 78224 Singen 2007 Printed in Germany hemal ly k gt orbitalum ee en tools for piping systems
10. ld result in death or critical injury Restrictions if applicable gt Measures to prevent danger Possible danger Non observance could result in serious injury Restrictions if applicable gt Measures to prevent danger Dangerous situation Non observance could result in minor injuries Dangerous situation Non observance could result in material damage 04 07 MT_ESG Plus BA_04_790052774_07 doc 1 0 About these instructions Operating instructions with spare parts list ESG Plus 0 2 Further symbols and displays Symbol Meaning Important Notes Contain particularly important information for Note comprehension Instruction You must take notice of this symbol 1 Request for action in a sequence of actions You have to do something here Vv Single request for action You have to do something here gt Conditional request for action You have to do something here if the specified condition is met 0 3 Abbreviations Abbr Meaning ESG Plus Tungsten Grinder 2 04 07 MT_ESG Plus_BA_04_ 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 1 Safety notes C orbitalum tools gmbh 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
11. n 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 Working range Electrode diameter ESG Plus 1 0 mm 1 6 mm 2 0 mm 2 4 mm 3 2 mm 4 0mm 0 04 0 06 0 08 0 09 0 13 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 Electrode material Tungsten electrodes alloyed with zirconium lanthanium and cerium Important Not to be used without suction for tungsten electrodes with thorium 04 07 MT_ESG Plus_BA_04_ 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus C orbitalum tools gmbh 4 Technical data Dimensions Weight complete with grinding wheel Power consumption Voltage Main supply cable Rotary speed Power on time Noise level in the workplace Vibration level according to EN 28662 Part 1 Idle running of temperature development 4 Technical data 65 x 350 mm 2 560 x 13 780 inch approx 1 4 kg 500 W 230 V 50 60 Hz 110 V 50 60 Hz 3m 118 inch 30 000 U min r p m 100 Idle running approx 83 dB A 2 5 m s 10 min running time 30 C over running temperatur
12. rew Stick fastened to the motor flange The diamond wheel does not No tension gt Examine tension rotate Engine defectively gt Replace the motor Unbalance of the grinding wheel Grinding wheel mounted gt Tighten or replace the when started up incorrectly grinding wheel immediately 9 2 Servicing customer service For ordering spare parts see the spare parts list chapter 10 p 19 For the resolution of faults please contact your branch office directly You can also contact directly our customer service address in Singen Orbitalum Tools GmbH Freib hlstra e 19 D 78224 Singen Phone 49 0 77 31 792 764 Fax 49 0 77 31 792 500 Please give the following details e Machine type ESG Plus e Machine number see identification plate 18 04 07 MT_ESG Plus BA_04_790052774_07 doc C orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 10 Spare parts list 10 Spare parts list Item No Part Number Quan Description Electric motor 230 V 50 60 Hz Cae only available together with motor flange item no 7 Electric motor 120 V 50 60 Hz AORE OR only available together with motor flange item no 7 790 052 528 2 Carbon brush 790 052 533 Cylinder pin 2 790 052 487 Diamond grinding wheel standard 790 052 488 Diamond grinding wheel rough 790 052 531 Cylinder head screw with washer M4x6 790 052 530 Grinding head Motor flange 790 052 535 only available together with ele
13. ring use may be refused e 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 04 07 MT_ESG Plus_BA_04_ 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 2 Construction of the product 2 Construction of the product 2 1 Standard Motor ON OFF switch Identification plate ESG Plus grinding head Fastening bolt head to motor OAR ODMH m orbitalum tools gmbh 04 07 MT_ESG Plus_BA_04_790052774_07 doc 5 2 Construction of the product Operating instructions with spare parts list ESG Plus 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 0 Electrode holder Without clamping collet Code 790 052 457 2 2 4 Clamping collet i For clamping the electrode into the holder Range mm Range inch Code 1 0 3 2 0 039 0 126 790 052 481 6 04 07 MT_E
14. s e When working with the ESG Plus wear protective goggles safety gloves and breathing mask e Turn the device off at the end of each operating cycle e 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 gt Wear safety gloves 1 4 Waste disposal environmental protection e 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 e 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 e By actively using the offered return and collection systems you actively contribute to the reuse recycling and utilization of electrical electronic devices e 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 e 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 e The return of used devices which pose a health or safety risk for human beings due to soiling du
15. tion 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 7 Assembly of the Double decker Kit ESG 15 8 Maintenance 17 9 What to do if 18 9 1 Fault elimination 18 9 2 Servicing customer service 18 C orbitalum tools gmbh 04 07 MT_ESG Plus_BA_04_790052774_07 doc Table of contents Operating instructions with spare parts list ESG Plus 10 Spare parts list 19 04 07 MT_ESG Plus_BA_04_ 790052774 _07 doc orbitalum tools gmbh Operating instructions with spare parts list ESG Plus 0 About these instructions C orbitalum tools gmbh O0 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 Warning symbol DANGER WARNING ATTENTION ATTENTION 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 Meaning Direct danger Non observance cou
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