Diamatic BG-180EC Operating Manual Download

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BG-180EC Operating

Manual

Safety Advice

Warning against dangerous voltages.

Indications relating to protective devices in electrical
appliances.

Indications where consultation with the
manufacturer is required.

Instructions relating to periodical checks.

Reference to important instructions contained in the
Operating Instructions.

Summary of Contents for BG-180EC

Page 1: ...Operating Manual BG 180EC ...

Page 2: ......

Page 3: ...on Maintenance Electrical systems Fault diagnosis Spare parts Design and specifications are subject to change without notice May 2006 Diamatic Utrechthaven 12 3433 PN Nieuwegein THE NETHERLANDS T 31 0 30 223 8630 F 31 0 30 223 8981 E info diamatic eu I www diamatic eu Nieuwegein ...

Page 4: ......

Page 5: ...BG 180EC Operating Manual Technical Data 1 Contents Chapter 1 1 1 Rating 1 2 Unit specifications 1 3 Operative range and correct usage 1 4 Stand by power supply 1 5 Machine type designation ...

Page 6: ...haven 12 3433 PN Nieuwegein THE NETHERLANDS T 31 0 30 223 8630 F 31 0 30 223 8981 E info diamatic eu I www diamatic eu 1 2 Unit specifications Technical data Grinding machine BG 180EC Power consumption 2 2 KW Connected loads 2 2 KW 220V single phase 12 9A Power consumption 1 5 KW 50Hz 60Hz Connected loads 1 5 KW 110V single phase 12 9A 18A ...

Page 7: ...acturer will not be liable for damage resulting from incorrect usage In these cases the user takes responsibility for all risks 1 4 Stand by power supply Generator If the grinding machine BG 180EC is to be operated using power from a generator the generator must be operated in accordance with the current EN VDE directives this applies to the protective earth conductor in particular in order to ens...

Page 8: ...Operation Manual BG 180EC Technical Data 4 1 5 Machine type designation ...

Page 9: ...ion and qualification 2 4 Safety precautions applicable to some operating sequences 2 5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation 2 6 Definition of the Safety off position 2 7 Particular dangerous aspects of the equipment 2 8 Electrical engineering regulations ...

Page 10: ... next to all safety precautions that are to be taken in order to ensure prevention to life and injury Follow these instructions and take special care in these circumstances In addition to these instructions the general safety precautions and accident prevention guidelines are also to be followed Particular details regarding the economical use of the equipment Information instructions and restricti...

Page 11: ...rous voltages Indications relating to protective devices in electrical appliances Indications where consultation with the manufacturer is required Instructions relating to periodical checks Reference to important instructions contained in the Operating Instructions ...

Page 12: ...procedures and personnel safety Personnel entrusted with working with the machine must read the Operating Instructions before starting work in particular the Safety Instructions chapter To read these instructions after work as commenced is too late This particularly applies to incidental activities such as setting up the equipment carrying out maintenance work or training staff to work with the ma...

Page 13: ...ed Intervals for recurring checks and inspections specified in these Operating Instructions must be complied with To perform maintenance work correctly it is imperative to be equipped with the proper tools for the task in question The location and the operation of fire extinguishers must be made known on each work site Take note of the facilities for reporting of and fighting fires 2 3 Personnel s...

Page 14: ...lled electrician as well as in accordance with the local electrical engineering regulations 2 4 Safety precautions applicable to some operating sequences Do not allow any method of working that impairs safety Recognised official procedures have to be used to ensure the machine is operated in a safe and best conditions Only operate the machine when all safety devices and related safety equipment ar...

Page 15: ...he main cable that are sized and marked in accordance with the overall power consumption of the machine and the valid VDE guidelines 2 5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation Mechanical servicing work Put the machine in the Safety off position as described in chapter 2 6 before carrying out any servicing work on the mac...

Page 16: ...icle Observe the local waste disposal regulations in uncertain situations ask the next higher authority Do not use any aggressive cleaning materials Use lint free cleaning cloths Always make sure to tighten any screw connections that are loosened during servicing and maintenance work If safety devices need to be taken off or dismantled during service and repair these safety devices must be reinsta...

Page 17: ...ait for all drives to stop Pull out mains plug Secure against unintended restart 2 7 Particular dangerous aspects of the equipment Any machine if it is not used according the regulations may be hazardous for operating setting up and service personnel The operating authority is responsible for compliance with the safety regulations during operation and maintenance and for the use of safety devices ...

Page 18: ...t must be inspected regularly Defects such as loose connections or scorched cables must be rectified immediately Call a skilled electrician or our Customer Services A second person must be in attendance whilst the electrical engineer is working on the equipment The work area must be secured against any third party entering the work area by means of a red and white safety chain and a danger sign Us...

Page 19: ... Manual General 1 Contents Chapter 3 3 1 Range of application 3 2 Scope of supply 3 3 Description of the machine 3 4 Operating elements 3 5 Electric components 3 6 Driving part 3 7 Edge grinding 3 8 Care and maintenance ...

Page 20: ...move undulated concrete surfaces To prepare the surface for coatings To polish the surface To remove coating defects To remove glue residue To remove coating from wood floors To renovate wood floors for new coating 3 2 Scope of supply Scope of supply of the machine Grinding machine BG 180EC Dust hose Option Operating manual 1x ...

Page 21: ...igh economic efficiency and easy handling The machine is capable to levelling uneven and undulating floors and edges this process is suitable for an optimisation of surfaces concrete polishing wood sanding and removing tiger striping after shot blasting Alternatively the machine can be used to smooth floor surfaces as a preparation operation for coatings to be applied Depending on the application ...

Page 22: ...hine must be lifted by pushing the handgrip 1 down to floor level till the machine is approximately 10cm from the ground 3 5 Electric components The Switch box is equipped with all control elements and instruments to monitor the grinding machine Fig 3 3 1 Electrical inlet power supply 3 Stop button 5 Terminal safety switch 2 Electrical inlet motor 4 Start button ...

Page 23: ...ne Start button By pressing the green button the motor will start Terminal safety switch The terminal safety switch will turn off the motor when the motor is over overloaded When the motor is overloaded wait a few seconds and press the safety switch in and the motor can be restarted ...

Page 24: ...r the axle there is a buffer and an adapter diamond The diamand plates will be fitt under the adapter diamond with the arbor en blade nut Fig 3 4 1 Motor 2 2Kw 6 Spacer ring 11 Dusthose 2 Cover 7 Adapter diamond 12 Dustcap 3 Frame arm 8 Cover 13 Arbor nut 4 Bearing house 9 Corner caps 14 Blade nut 5 Buffer 10 Weight block ...

Page 25: ...l General 7 3 7 Edge grinding The machine is build to grind edges By sweeping the frame arm to the left or the right and take out one of the two cornercaps you can grind the edges Fig 3 5 1 Quick release pin 3 Cornercap 2 Knob ...

Page 26: ...e genuine parts Generally the grindingmachine BG 180EC requires very little special attention regarding its maintenance After using the BG 180EC clean the machine with air pressure so there is no dust on the machine See to it that any wastes or fibre residues do not remain in the area of the grinding disc Dependent on the use of the machine the pulley should be checked about every 200 hours Before...

Page 27: ...Manual Transport 1 Contents Chapter 4 4 1 Unit specifications 4 2 Manual mode of moving the machine 4 3 Transport with cranes or lifts 4 4 Transport of the machine with vehicle 4 5 Operation of the machine while grinding ...

Page 28: ...l mode of moving the machine To move the machine press down the handgrips see fig 4 1 of the machine until the front part rises approximately 10 cm from the ground It can now be pushed around on its wheels The machine can only be moved around after attachments are disconnected such as Generator if being employed Dust collection unit optional ...

Page 29: ... the lifting means is of sufficient capacity to lift the weight of the machine this gross weight is shown in chapter 4 1 Unit specifications and also shown on the shield type bolted to the machine Fasten any lifting slings to the points 2 or 3 on the machine frame these points are also suitable as a fixing point for fastenings during transportation of the machine on a vehicle ...

Page 30: ...orce or incorrect loading and unloading is avoided Secure the machine with a tightening load strap over the lower frame 3 and frame arm 2 Use at least two straps and tighten down with the load straps to the bodywork of the vehicle 4 5 Operation of the machine while grinding The machine will be operated while grinding in accordance with the instructions given in Chapter 5 2 Initial operation ...

Page 31: ...BG 180EC Operating Manual Initial operation 1 Contents Chapter 5 5 1 Preparation for initial operation 5 2 Initial operation 5 3 Grinding of edges ...

Page 32: ... of doubt ask the local safety officer Check the extension cable for external damages Check the dust hose for damages Connect the grindingmachine and the dust collector unit with the flexible dust hose Use hose clamps at the connections Make sure the dust bin of the dust collector unit is empty If problems with the current supply arise during the assembly or the start up call a qualified person fo...

Page 33: ...ch Connect the machine to the electrical inlet with an extension cable CEE 16 Amp 2 Press down both handgrips 3 until the front part rises approximately 10 cm from the ground Push the start button 4 Now let down the grinding disc on the surface and begin the grinding work Move the machine slowly forwards or reverse dependent on the grinding work See chapter 6 2 Switching off the grinding machine P...

Page 34: ...the following sequence 1 Switching on the grinding machine Disconnect the power supply Loose the tension on the three knobs 02 Take out the quick release pin 01 and turn the frame arm till the quick release pin 01 fits in another gap Tension the three knobs 02 Take out one of the two cornercaps 03 for grinding along edges ...

Page 35: ...Operating Manual Operation 1 Contents Chapter 6 6 1 Operation 6 2 Switching off the machine 6 3 Trouble Shooting 6 4 Safety shutdown 6 5 Restarting after a fault 6 6 Proceedings prior and after stationary period ...

Page 36: ...Before beginning the grinding work check daily for regular tightness of all fasteners especially those of the driving and handling devices Before switching on make sure that all protective housings are fitted and the dust collector unit is correctly connected Handle all plugs cables hoses and operating elements careful Avoid the contact with live wire Before grinding clean the surface to be treate...

Page 37: ... process in chapter 5 2 Initial operation If there are doubts how to start up the machine read chapter 5 1 and 5 2 of this operating manual Make sure that no vehicles such as forklift trucks and other equipment run over the electric cable and the dust hose 6 2 Switching off the machine Fig 6 1 Push the off button on the power box 5 ...

Page 38: ...e inspection or maintenance works make sure that all turning machine parts are stopped Observe the Safety off position chapter 2 6 Irrespective of the information of chapter 7 about repair or maintenance works the local safety regulations are valid in all cases regarding the operation of the machine 6 5 Restarting after a fault Especially observe the regulations of the VBG 4 and also VDE 0701 rega...

Page 39: ...a long stand still period If the grinding machine will be out of action during a long period observe following aspects Clean the machine and cover it with a plastic foil Protect the electric motors from moisture heat dust and shocks 2 After a long stand still period See Chapter 5 Initial operation ...

Page 40: ...Operating Manual BG 180EC Operation 6 Notes ...

Page 41: ...nual Maintenance 1 Contents Chapter 7 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 Grinding disc replacement assembly 7 5 Machine maintenance 7 6 Bearing house maintenance 7 7 Other maintenance ...

Page 42: ...or the normal use of the machine The time indications are based on uninterrupted operation When the indicated number of working hours is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a year Due to different working conditions it cannot be foreseen how frequently inspections for wear checks inspection maintenance an...

Page 43: ...ll safety devices are working correctly Check the power supply cable for damages Check the hose to the dust collector for damage Check whether or not there are any foreign matter in the coupling of the grinding disc Check the grinding disc and the coupling for wear Check the tension of the V belt adjust as is required Check the dust cap for damage Quarterly Clean the machine with a damp cloth Annu...

Page 44: ... will be described If parts are replaced by yourself for a specific reason the following instructions and work sequence should be observed It would be advisable to stock all spare or wear parts that cannot be obtained quickly As a rule production standstill periods are more expensive than the cost for the corresponding spare part Screws that have been removed must be replaced with those of the sam...

Page 45: ...de 5 Loose the blade nut 04 and remove the diamond disc 05 and arbor nut 06 Assembly 7 Clean the adapter diamond 07 8 Place the arbor nut 06 on the adapter diamond 07 9 Place the diamond disc 05 on the arbor nut 06 and turn the blade nut 04 on till the disc begins to turn 10 Push the lock pin 03 down till the disc blockade and turn the blade nut 04 11 Tillt the machine forwards When replacing the ...

Page 46: ...e dusthose connector 10 so the dusthose 11 and the dustcap 12 can be removed Take off the v belt 06 from the bearing house 09 and remove the motor 07 so the frame arm 08 with the bearing house 09 can be disassembled By removing the quick release pin 13 and the knobs 14 the upper 15 and under plate 16 can be disassembled The wheels 19 steer 18 and frame 17 can now be disassembled Assembly Assemble ...

Page 47: ...se 12 Take off the retaining ring 07 v ring seal 08 retaining ring 09 10 and remove the bearing 11 out of the bearing house 12 The lock pin 13 and the spring 14 can always be disassembled Assembly Make sure that the bearings 11 and bearing house 12 are clean and rub the bearings 11 in with a few drops of loctite 641 Assemble the parts in the reverse order that they have been disassembled Prior to ...

Page 48: ...ded and consequently saves additional charges from the job client Clean the machine with a damp cloth Apply Oil to the adjusting pin of the operating lever and other moving parts with clean oil can at regular intervals When no original components wear parts are used every revendication on guarantee expires Always put a diamond disc or blade nut under the adapter diamond when the machine stands sti...

Page 49: ...0EC Operating Manual Electrics 1 Contents Chapter 8 8 1 Directions for electrical engineering 8 2 Electric circuits diagram of E00587 1 230V 12 9A 50Hz 8 3 Electric circuits diagram of E01532 110V 28 0A 50Hz ...

Page 50: ...cian or by trained persons under the guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations Order the electric items with reference to the circuit diagrams in chapter 8 1 or call a Diamatic service centre Observe the regulations of the VBG 4 and also of the VDE0701 Measurement after maintenance and repair works ...

Page 51: ...BG 180EC Operating Manual Electrics 3 8 2 Electric circuits diagram of E00587 1 230V 12 9A 50Hz ...

Page 52: ... nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 2 1 PROJECT Client Name SUPPLIER Order number DATA Arch number Calc number Status Start of project Latest change BLASTRAC BV E00587 1 PJ07 03297T1CF Certified Final 04 07 2007 04 07 2007 GKU Supplier Contact Telephone Telefax Email Highest page number Number of pages Particulars BLASTRAC BV 31 0 30 6018866 31 0 30 6018333 12 8 ...

Page 53: ...nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 3 2 Table of contents Page Summary Engineer Latest change By X 1 2 3 4 5 10 11 12 Frontpage Contents Contents Explanations Symbol explanation Main voltage Plug X0 Terminal strip X1 RJO RJO GKU RJO RJO GKU GKU GKU 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 GKU GKU GKU GKU GKU GKU GKU GKU ...

Page 54: ...oc 2 0 04 07 2007 A Start Eng Print Status 1 04 07 2007 GKU 04 07 2007 Certified Final BLASTRAC BV E00587 1 2 3 4 Contents 5 6 Arch nr Draw nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 4 3 Revision summary Revision Date Engineer Remarks ...

Page 55: ... 5 6 Arch nr Draw nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 5 4 Wire color Main voltage L1 L2 L3 PE Black Black Black Yellow Green Symbol code explanation DP Archive number explanation PJ01 01234T1DR Status 5 Q DR Draft FA For approval CF Certified final 1 Consecutive numbering Symbol letter Page number Group in case used Status Serial number Archive number ...

Page 56: ...rop out delayed Emergency stop NC Contact NO NC Thermal Key switch NO NC Thermostat NO NC P A V M 3 P Pressure switch NO NC Level switch NO NC Relay Relay Time delayed on drop out Relay Time delayed on pick up Relay Impulse Ammeter Voltmeter Working hour counter Current coil Motor Pilot light Horn Valve Transformer Direct voltage supply Terminal clamps Fuses Fuse terminal Earth leakage switch Eart...

Page 57: ... Eng Print Status 1 04 07 2007 GKU 04 07 2007 Certified Final BLASTRAC BV E00587 1 2 3 4 Main voltage 5 6 Arch nr Draw nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 11 10 5W1 X0 L L Supply 220V N N PE PE 5Q1 MS10 7A 1 2 3 4 X1 1 M 5M1 Motor 220V 13A 2 5U1 UM 380 ...

Page 58: ...ng Print Status 1 04 07 2007 GKU 04 07 2007 Certified Final BLASTRAC BV E00587 1 2 3 4 Plug X0 5 6 Arch nr Draw nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 12 11 Internal connection Bridges Terminal X0 5W1 5Q1 1 1 1 L Supply 220V L W5W1 3x 5Q1 3 2 2 N N 3 3 PE PE ...

Page 59: ...t Eng Print Status 1 04 07 2007 GKU 04 07 2007 Certified Final BLASTRAC BV E00587 1 2 3 4 Terminal strip X1 5 6 Arch nr Draw nr 7 PJ07 03297T1CF PJ07 03297T1CF 8 Pages 8 Page 9 12 Internal connection Bridges Terminal X1 5M1 5Q1 2 1 1 M Motor 1 W5M1 3x 5Q1 4 2 2 2 PE PE ...

Page 60: ...Operating Manual BG 180EC Electrics 4 8 3 Electric circuits diagram of E01532 110V 28 0A 50Hz ...

Page 61: ...96T1FA 8 Pages 6 Page 9 2 1 PROJECT Client Name SUPPLIER Draw number Order number DATA Arch number Calc number Status Start of project Latest change E01532 PJ07 03296T1FA PJ07 03296T1FA For approval 04 07 2007 04 07 2007 GKU Supplier Contact Telephone Telefax Email Highest page number Number of pages Particulars ART 4 Techn Systems BV Mr R v d Grint 31 0 35 5822468 31 0 35 6424860 rvdgrint art4 nl...

Page 62: ... contents 5 6 Arch nr Draw nr 7 PJ07 03296T1FA PJ07 03296T1FA 8 Pages 6 Page 9 3 2 Table of contents Page Summary Engineer Latest change By X 1 2 3 4 5 10 Front page Table of contents Revision Summary Explanations Symbol explanation Hoofdstroom GKU GKU GKU GKU GKU GKU 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 04 07 2007 GKU GKU GKU GKU GKU GKU ...

Page 63: ...oc 2 0 Start Eng Print Status 1 04 07 2007 GKU 04 07 2007 For approval ART 4 Techn Systems BV E01532 2 3 4 Revision Summary 5 6 Arch nr Draw nr 7 PJ07 03296T1FA PJ07 03296T1FA 8 Pages 6 Page 9 4 3 Revision summary Revision Date Engineer Remarks ...

Page 64: ...ltage alternating voltage AC Phase Hook up wire Zero Control voltage direct voltage DC Hook up wire Potential free and stranger voltage Potential free Test lead Black Black Black Light blue Yellow Green Red Red Violet Dark blue Dark blue Grey Orange White Symbol code explanation DP Archive number explanation PJ01 01234T1DR Status 5 Q DR Draft FA For approval CF Certified final 1 Consecutive number...

Page 65: ...out delayed Emergency stop NC Contact NO NC Thermal Key switch NO NC Thermostat NO NC P A V M 3 P Pressure switch NO NC Level switch NO NC Relay Relay Time delayed on drop out Relay Time delayed on pick up Relay Impulse Ammeter Voltmeter Working hour counter Current coil Motor Pilot light Horn Valve Transformer Direct voltage supply Terminal clamps Fuses Fuse terminal Earth leakage switch Earth le...

Page 66: ... 2007 GKU 04 07 2007 For approval ART 4 Techn Systems BV E01532 2 3 4 Hoofdstroom 5 6 Arch nr Draw nr 7 PJ07 03296T1FA PJ07 03296T1FA 8 Pages 6 Page 9 10 10W1 AWG12 15 m L1 Supply 110V 50Hz N PE 10Q1 24 0 32 0A GV2 ME32 1 2 3 4 5 6 AWG12 1 m M 10M1 Motor 110V 28 5A 10U1 220V 60Hz ...

Page 67: ...BG 180EC Operating Manual Fault diagnosis 1 Contents Chapter 9 9 1 Fault diagnosis grinding machine 9 2 Fault diagnosis electrical system ...

Page 68: ...ion of the upper belt Unusual noises Defective bearing Wrong tension of the V belt Defective motor bearing Debris deposit on the coupling Check the bearing on the axle drive shaft and replace if necessary Check the tension of the V belt replace the V belt if necessary Change the motor Clean the coupling Reduced or no grinding performance Grinding tools have reached the maximum permissible wear Ina...

Page 69: ...ngineering regulations Prior to any repair works on the machine or its drives the machine must be secured against unintentional switching on Put the machine to its Safety off position Fault Possible cause Remedy Motor does not switch on Missed phase Defective Component Check the mains power supply and next switch on again Fault finding and replace defective component Motor triggers while running M...

Page 70: ...Operating Manual BG 180EC Fault diagnosis 4 Notes ...

Page 71: ...BG 180EC Operating Manual Spare Parts 1 Contents Chapter 10 10 1 Spares Parts List BG 180EC ...

Page 72: ...Switch incl breaker 230V 50Hz 1 E01532 Electro kit 110V 50Hz 1 3 E03550 Locking pin compl 1 4 BE0059 M12x80 hexagon bolt 1 5 BE0073 BE0026 M12 lock nut washer 1 6 478198 Quick release pin 1 7 E02062 Motor 2 2kW 230V 50Hz 1 E03562 Motor 1 5kW 110V 50Hz 1 8 E03259 Pulley 230V 50Hz 1 E03263 Pulley 110V 50Hz 1 ...

Page 73: ...e 1 16 E03563 Leveller 1 17 E03241 Cover 1 18 E03688 Cover 1 19 E03692 Corner caps 2 20 E03695 Dustcap 1 21 E03294 Dustpipe 1 22 BE0048 M8 lock nut 2 23 E03506 Handwheel 2 24 E03289 Adjustable bolt 2 25 BE0074 Retaining ring 6 26 E03276 Wheel axle 1 27 E03253 Wheel 2 28 E03288 Adjustable block 2 29 E03271 Underplate frame 1 30 004583 Dusthose 0 5m 31 E00477 Hexagon socket head shoulder bolt 3 32 E...

Page 74: ...Operating Manual BG 180EC Spare Parts 4 Fig 10 2 ...

Page 75: ...al shaft seal 1 7 BE0076 Retaining ring 1 8 BE0077 Retaining ring 3 9 E03264 Lock pin 1 10 E03705 Spring 1 11 E03245 Bearing 2 12 E03566 Radial shaft seal 1 13 E03243 Bearing house 1 14 E03244 Drive axle 1 15 000118 Flexible coupling 1 16 E03250 Spacer ring 3 17 E03242 Adapter diamond 1 18 ST 91599 Arbor nut 1 19 ST 91588 Blade nut 1 Nuts for higher diamond wheels 18 ST 91587 Arbor nut 1 19 ST 915...

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Diamatic BG-180EC, Operating Manual

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