TPG 650 Planetary Floor Grinder

Operation and Maintenance Manual

www.trelawnyspt.co.uk

OPERATION

Foreword Thank you for your purchase of the TRELAWNY TPG650 Floor Grinder. This manual contains the necessary maintenance information for you to ensure proper operation and care for this machine. It is essential for you to read t h r o u g h t h e s e m a n u a l s thoroughly. In the unlikely event that you experience problems with your TPG650, please do not hesitate to contact your local Trelawny dealer or agent. We always welcome feedback and comments from our valued customers.

General Information Before operating, performing maintenance or repairing the TPG650 FLOOR GRINDER this manual must be read and understood by the operator, if in any doubt, ask your supervisor before using this equipment. Local safety regulations must be followed at all times. Failure to follow these instructions could result in damage to the TPG650 and/or personal injury. Trelawny SPT Limited disclaims all responsibility for damage to persons or objects arising as a consequence of incorrect handling of the machine, failure to inspect the machine for damage or other faults that may influence the operation prior to starting work, or failure to follow the safety regulations listed or applicable to the job site. This machine is primarily designed for the grinding and polishing concrete, marble and terrazzo surfaces. It can be used both indoors and out. This machine must not be used in a fixture.

Safety WEAR SAFETY BOOTS, FACE M A S K , S H A T T E R P R O O F GLASSES, HELMET, GLOVES and any other personal protective equipment required for the working conditions. Avoid loose clothing; this may become trapped in moving

TO AVOID NUISANCE DUST, connect an industrial vacuum cleaner (minimum 3000 watts or equivalent) to the 50mm (2”) vacuum port situated at the rear of the machine.

BE VERY CAREFUL WITH HOT COMPONENTS.

The diamond tools and tool heads can become very hot in use. Always use gloves when changing or replacing the grinding segments.

DO NOT OPERATE ELECTRIC VERSIONS IN WET CONDITIONS.

CAUTION THIS MACHINE IS HEAVY. It weighs (260kg/573lbs). Do not lift this machine manually, use a hoist or crane with the grinder securely fastened to a pallet.

Risk of Hand-arm Vibration injury These tools may cause Hand-arm Vibration Syndrome injury if their use is not adequately managed. Although the vibration from this machine is low, we advise you to carry out a risk assessment and to implement measures such as; limiting exposure time [i.e. actual operation time, not total time at work]. Use job rotation and ensure machine tools are used correctly, ensuring the machines are maintained according to our recommendations, and ensure that the operators wear personal p ro tec t ive equ ipment [PPE] particularly gloves and clothing to keep them warm and dry. Employers should consider setting up a programme of health surve i l lance to establ ish a benchmark for each operator and to detect early symptoms of vibration injury. We are not aware of any PPE that provides protection against vibration injury by attenuating vibration emissions. See ‘Specifications’ section for vibration emission data.

Further advice is available from our Technical Department. We strongly advise you to visit the Health & Safety Executive website http://www.hse.gov.uk/vibration This site provides excellent advice and information on HAV and currently, includes a Hand-arm Vibration Exposure Calculator that is easy to use to work out the daily vibration exposure for each of your operators.

Media Types & Application Guide Grinding Segments All the diamond range can be used wet or dry. (Resin bound polishing discs) PD400, PD800, PD1500 and PD3000. Universal polishing discs, can be used wet or dry. (See page 6 for more information)

Media Types - Metal Bond Tools

Image Part Number Tool Description

365.5495L

PCD Removal Diamond Anti Clock Wise For removal of coatings, adhesives & toppings

365.5495R

PCD Removal Diamond Clock Wise For removal of coatings, adhesives & toppings

365.5500

16 Grit Single (Quick Release) Soft Bond For very course grinding and thin coating removal

365.5500/2

16 Grit Double (Quick Release) Soft Bond For very course grinding and thin coating removal

365.5501

30 Grit Single (Quick Release) Soft Bond For Hard Concrete

365.5502 30 Grit Single (Quick Release) Medium Bond For Medium Hardness concrete

365.5503 30 Grit Single (Quick Release) Hard Bond For Soft Concrete or for very rough concrete

365.5501/2 30 Grit Double (Quick Release) Soft Bond For Hard Concrete

365.5502/2 30 Grit Double (Quick Release) Medium Bond For Medium Hardness concrete

365.5503/2 30 Grit Double (Quick Release) Hard Bond For Soft Concrete or for very rough concrete

365.5504/2 70 Grit Double (Quick Release) Medium Bond For Light Grinding and Scratch Removal

365.5506/2 120 Grit Double (Quick Release) Medium Bond For Light Grinding and Scratch Removal

365.5725 3 Segment Quick Release Diamond Plate (Set of 3)

For use with only the TPG 650/540 Machine

Media Types - Resin Bond Tools

Image Part Number Tool Description

365.5605

50 Grit Hybrid

365.5610

100 Grit Hybrid

365.5620

200 Grit Hybrid

365.5602A

200 Grit Resin Bond

365.5604A

400 Grit Resin Bond

365.5608A

800 Grit Resin Bond

365.5618A

1500 Grit Resin Bond

365.5635A

3000 Grit Resin Bond

350.5666 Polishing Adapter Plate

Used to attach the “Polishing Tools” to the quick release plate

365.5745

3 Segment Polishing Plate (Set of 3)

Used to attach “Polishing Tools” For use only on the TPG650/540

Maintenance

Machine Start Procedure: Check on the Speed Controller that it is on it‟s lowest speed setting. Press the White „START‟ Button Adjust the speed as required. The machine may oscillate slightly during use, which is normal. Move the machine slowly backwards and forwards and overlap each strip by 10cm (4”), complete a small area noting the performance. Press the Black „STOP‟ Button to stop the machine and inspect the finish produced. If required change the bond of the diamond tools or speed of rotation, recheck performance and surface finish.

: EMERGENCY SHUTDOWN : Press the “Red Emergency Stop

Button”

Pre-Start Check ALL VERSIONS Check all bolts and screws for tightness. Ensure that all fittings are secure. The TPG650 is supplied with a specially commissioned frequency inverter, starter switch and electric motor. Each unit is fully tested and the overload relays have been calibrated and se t accord ing to the manufactures specifications. In the event of malfunction on a new machine, the owner should first check that the power supply on site is suitable and adequate. All cables must be fully uncoiled and never left wrapped around cable reels or tied in loops. 415v Motor Take particular care when using 415v Machines, ensure that the electrical supply is earthed and that breakers and fuses are correct for the loading. The 415v motor requires a minimum of a 16amp, 380v power supply. Always use the shortest possible length of extension cable. To avoid voltage drop the cable must have a minimum core wire size of 2.5mm

2

cross-section area. Maximum length of cable 30 meters. Starting Check over the whole area to be worked. It is important to check the area to ensure that there are no obstacles or protrusions that will damage the machine or the tools. This is a “flat” surface grinder. If the surface is very bumpy or uneven, consider using the Trelawny Floor Planer to level the floor first, before starting to use the TPG650. Ensure that the machine is started on a level surface.

Machine Operation Connect a suitable commercial vacuum which has been designed for the collection of concrete dust and possibly toxic paint particles, Trelawny can supply special HEPA filtered vacuums suitable for these applications. For wet grinding, fill the reservoir with approximately 40 litres of water. When filling, ensure that no water splashes onto any electrical components. On the frame below the tank, there is a valve to regulate the flow of water. Control Box The White „START‟ button operates a soft start circuit and is the only way to start the machine. Use the Black „STOP‟ button or the Red Emergency „Stop‟ Button to stop the machine. When changing the direction of rotation, be sure to let the machine completely stop before changing direction.

Be careful with HOT COMPONENTS.

The discs and diamond segments are hot during and for some time after

operation. Do not touch them until they have

cooled down.

Important: If using the PCD tools ensure that the direction of rotation is set to FORWARD - “FWD”. These tools should only be used in the forward rotation direction. Use the speed regulator to adjust the grinding head speed.

Rotary direction switch, “FWD” - Forward. “OFF”. “REV” - Reverse.

Maintenance

Carefully tilt the machine backwards to rest on its handle bar. Place a heavy object (10kg sand bag, etc.) across the upper part of the handle bar or rope down for additional security. Remove any build up of material from around the grinding disc, the holding pins, springs and nuts. Using a Soft Headed Mallet apply force to the outside edge of the Quick Release tools hitting the tools inwards. When hitting the tool be careful not to hit the diamond or the metal bonding. Repeat for rest of tools on the Machine. To replace simply slide the Quick Release tools into the Taper Slot. Apply force with use of a soft headed mallet striking the tools outwards. Repeat for remaining tools. Remove the weight from the handle bar and/or remove the security rope. Carefully return the machine to its upright position and move the handle bar to is normal working position and secure with the two pins.

Plate Removal:

Push down on one of the holding pins nuts by hand and rotate the pin 90deg, repeat with the two pins. Remove the disc. Note that the centres of the discs are different depending on the direction the discs rotate:- (Flower Part No 365.5835F)(Triangle Part No 365.5835T) Refit the Tool Plates, these can only be fitted onto the correct hub. Push down on one of the holding pins nuts by hand and rotate the pin 90deg, repeat with the two pins. Ensure that the pin has located into its recess, and that the disc is secure. Repeat with the other plates. Re-adjust the dust cover rubber ring.

Shut Down Simply Press the Black „STOP‟ Button. After the machine has completely cooled, clean off any concrete dust from external components and remove any heavy build up of concrete dust from inside the front dust skirt. Take care when using hoses or pressure washers and clean within the dust skirt area only. Do not hose down any of the external surfaces. Do not to allow water to be directed at or splashed onto the electric motor or any of the electrical components. Once clean and dry, cover the machine to protect it and store the grinder in a dry place.

Grinding Tool Replacement Switch off the machine and allow the grinding head tools to cool completely, disconnect machine from its power supply. IMPORTANT Do not use a mix of old and new grinding tools, this will cause rapid wear of the new tools and could cause the machine to become uncontrol lable, unstable and dangerous in use. Drain all water from the tank. Place the machine on a flat and level surface. Remove the additional weight from the machine if fitted. Remove the retaining pin from the handle bar height adjustment pin and raise the handle bar to a near upright position (vertical). Replace the adjustment pin and secure with the retaining pin.

Old Screw Fit System: After removing the plate from the machine (Using the steps provided previously).

Remove the three star screws retaining each of the tools to the disc. (Torx or TX male (size 30 bit)) Replacement is the reverse of stripping, the diamond tools are handed and cannot be fitted the wrong way round. Tighten the tool screws initially by hand, finally tighten using a wrench, do not over tighten.

Belt:

A belt replacement guide can be f o u n d o n l i n e a t h t t p : / /trelawnyspt.com/ or can be sent by request. Life time of the belts are expected to be between 4 & 6 years dependent on ambient temperature.

Machine Storage Long period storage: over 3months Allow the machine to cool completely. Clean outside of machine. Remove any build up of material from inside of grinding disc area. Inspect the grinding tools for wear; replace any worn parts as required. Ensure that the machine is completely dry. Cover the machine to protect it. Store the machine in a dry place.

Exploded View - Gear Box

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Exploded View - Plate Holder

Parts List - Plate Holder

ITEM No Part No Description

32 365.2260H Driving Disk Ring

33 365.2260I Driving Disk - Coupling

51 365.2260G Driving Disk- Stud Ring

52 365.2260K Driving Disk Base

54 365.2260L Disk Holding Pin

64 365.2248C Oil Seal Ø 62 x Ø 45 x 9

31A 365.2260A Axis Coupling

31B 365.2260B Frictional Disk

31C 365.2260C Drive Coupling

31D 365.2260D Compress ring (2 piece set)

31E 365.2260E Torque Cover

53A 365.2260M Driving Disk - Central Block 1

53B 365.2260N Driving Disk - Central Block 2

AV1 365.9146A Anti-Vibration Element 1

AV2 365.9146B Anti-Vibration Element 2

AV3 365.9146C Anti-Vibration Element 3

AV4 365.9146D Anti-Vibration Element 4

K01 365.2260F Keyway

L01 365.2260J Compress Spring for disk holding pin

S01 853.0816 CS Head Screw M8 x 16

S09 831.1030 Hexagon H.T. Bolt M10 x 30

S10 853.0616 CS Head Screw M6 x 16

S11 824.0600 Anti-Vibration Nut M6

S12 824.0800 Anti-Vibration Nut M8

Exploded View - Machine Assembly

T01

T02

T03

T05

Parts List - Machine Assembly

ITEM No Part No Description

13- 15 365.2230A Motor Support

16 365.2230B Holding Block

17 365.2230C Dust Cover Support

21 365.2225 Dust Cover

36 365.2242 Oil Seal Ø120 x Ø150 x 12

37 365.2243 Oil Seal Ø130 x Ø160 x 12

12A 365.2241A Motor Coupling part on Motor Shaft

12B 365.2241B Flex Element

12C 365.2241C Motor Coupling part on Central Axis

Motor 365.9575 Motor

S05 852.0812 Button Head Screw M8 x 12

S06 806.0650 Socket Cap Screw M6 x 50

S07 853.0825 CS Head Screw M8 x 25

S08 831.1230 Hexagon H.T bolt M12 x 30

T01 365.2235 Handle

T02 365.2220 Water Container

T03 365.2200 Frame

T04 365.2219 Wheel

Electrical Control Box - Parts

Part Part No Description

M22-A

365.9570A

Fixing Adaptor

M22-K01

365.9570B

Contact Block

M22-K10

365.9570C

Contact Block

M22-LED-W

365.9570D

LED Element

M22-PV

365.9570E

Emergency Stop Button

M22-XZK-GB99

365.9570F

E-stop label 33x50mm

M22-WRK3

365.9570G

3 Position 60° Rotary Switch

M22-R4K7

365.9570H

Rotary Potentiometer

M22-DDL-WS-X1/X0

365.9570I

Start/Stop Button

M22-T-DD

365.9570J

Transparent diaphragm

FAULT CAUSE

Machine does not start. Check that the stop button on the control panel is in the up position. Check the electricity connections between the machine and the electricity supply is secure. Check that the fuse(s) at the mains outlet haven‟t blown. Check that the circuit breaker switches inside the electric box are in the “on” position. Check the connections between the frequency controller and the motor.

Machine stops. Check that the circuit breaker switches inside the electric box are in the “on” position. Check that the cable isn't warm. If so, check wire diameter section is correct. Check if there is a signal of failure on the screen of the frequency converter (See below).

Grinder is slow or erratic. Check for heavy build up of dirt on the grinding disk. Check that the segments are not worn down and that they are securely fixed to the disk.

The grinding discs turn, but the main disc is stationary.

The top belt has broken, contact your nearest reseller.

The motor runs but nothing turns underneath.

The main belt has broken, contact your nearest reseller.

If problem has not been cured by any of the above actions, contact your local Trelawny SPT dealership for assistance.

Fault Finding

FREQUENCY CONVERTER MONITOR ERROR CODES

Do not investigate any electrical problem on this machine unless you are a qualified electrician, a separate manual is available for this control box.

Electrical Diagram 1

Electrical Diagram 2

TECHNICAL SPECIFICATIONS

(k) ** Equals the factor of uncertainty, which allows for variations in measurement and production. Vibration Data figures are tri-axial, which gives the total vibration emission. Because of various factors, the range of vibration from these tools may vary 1.6m/s2 & 5m/s2 . The vibration is dependent on

the task, the operators grip and power source etc.

NOTE: The above vibration levels were obtained from tri-axial measurements to comply with the requirements of “The Control of Vibration at Work Regulations 2005*” and the revisions to the (8662) now EN ISO 28927:2012 and EN ISO 20643:2005 series of standards. These values are at least 1.4 times larger than the values obtained from single axis measurements.

*Based on European Union Council Directive 2002/44/EC (Physical Agents (Vibration) Directive) This tool has been designed and produced in accordance with the following directives: 2006/42/EC Machinery Directive 2006/95/EC Low Voltage Directive If your company has any problem with our products or would like to discuss the possibility of an improvement being made to them, then please do not hesitate to contact us. Your comments are both important and appreciated.

All rights reserved. Any unauthorised use or copying of the contents or part thereof is prohibited. This applies to trademarks, model denominations, part numbers and drawings.

Use only genuine Trelawny spares. The use of non-Trelawny spare parts invalidates the warranty.

Height (Handle in working position) 83mm(Lower) & 108mm(Higher) 32.5”(Lower) & 42.5”(Higher)

Height (Handle in raised position) 1920 mm 75.6”

Width 700 mm 27.5”

Length 1220 mm 48”

Cutting width 650 mm 25.5 inch

Average depth of cut (dependent on concrete) 1 mm

Disc rpm (Variable) 300 to 1400 rpm

Working distance from wall 40 mm 1.58”

Water tank capacity 40 litres (8.5 galls)

Weight 260kg 573lbs

Electric Motor

Dual voltage 7.5kW 400v 50/60hz

Noise LwA SWL 87.2 dB (A)

Vibration (AEQ) at the Handle Bar a=1.97 m/s2 (K= 0.9m/s²)

Noise level measured in accordance with EN ISO 15744: 2008

Vibration measured in accordance with EN ISO 28927:2012

EN ISO 20643:2005

Trelawny SPT Ltd 13 Highdown Road, Sydenham Industrial Estate, Leamington Spa, Warwickshire, CV31 1XT, United Kingdom Telephone: +44 (0)1926 883781 - Fax: +44 (0)1926 450352 Email: sales@trelawny.co.uk © TSPT UK 2009 Part No: 735.6650 issue 15.5.17 www.trelawnyspt.co.uk