EWM TGM 40230 Handy User manual

Operating instructions
EN
Electrode grinding machine
TGM 40230 Handy
099-003412-EW501
16.11.2015
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
•Read the operating instructions for all system components!
•Observe accident prevention regulations!
•Observe all local regulations!
•Confirm with a signature where appropriate.
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our customer service
department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the
equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of
liability shall be deemed accepted by the user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and
methods are observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a
result. For this reason, we do not accept any responsibility or liability for losses, damages or
costs arising from incorrect installation, improper operation or incorrect usage and maintenance
or any actions connected to this in any way.
© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
The content of this document has been prepared and reviewed with all reasonable care. The information
provided is subject to change, errors excepted.

Contents
Notes on the use of these operating instructions
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1 Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 General..........................................................................................................................................6
2.4 Transport and installation ..............................................................................................................6
2.4.1 Ambient conditions.........................................................................................................7
2.4.1.1 In operation.....................................................................................................7
2.4.1.2 Transport and storage.....................................................................................7
3Intended use...........................................................................................................................................8
3.1 Applications....................................................................................................................................8
3.2 Documents which also apply.........................................................................................................8
3.2.1 Warranty.........................................................................................................................8
3.2.2 Service documents (spare parts) ...................................................................................8
4Machine description –quick overview ................................................................................................9
5Design and function.............................................................................................................................10
5.1 Presets.........................................................................................................................................11
5.1.1 Selecting the grinding track..........................................................................................11
5.1.2 Preparing electrodes for the grinding process .............................................................12
5.1.3 Setting the grinding angle of the tungsten electrode....................................................13
5.2 Setting the speed.........................................................................................................................14
5.2.1 Guideline values for speed controller setting...............................................................14
5.3 Inserting the electrode.................................................................................................................15
5.4 Grinding the electrode .................................................................................................................16
6Maintenance, care and disposal.........................................................................................................17
6.1 Changing the filter........................................................................................................................18
6.2 Replacing the grinding disk..........................................................................................................19
6.3 Cleaning.......................................................................................................................................20
7Technical data ......................................................................................................................................21
7.1 TGM 40230 Handy.......................................................................................................................21
8Accessories..........................................................................................................................................22
8.1 Replaceable parts........................................................................................................................22
9Appendix A ...........................................................................................................................................23
9.1 Overview of EWM branches ........................................................................................................23

Safety instructions
Notes on the use of these operating instructions
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2 Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
•Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
•The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
•Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
•The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
•The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
•The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
•The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
•The hazard is explained using a symbol at the edge of the page.
Special technical points which users must observe.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
•Insert the welding current lead socket into the relevant socket and lock.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol
Description
Special technical points which users must observe.
Correct
Wrong
Press
Do not press
Press and keep pressed
Turn
Switch
Switch off machine
Switch on machine
ENTER
enter the menu
NAVIGATION
Navigating in the menu
EXIT
Exit the menu
4 s
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.3 General
WARNING
Risk of accidents due to non-compliance with the safety instructions!
Non-compliance with the safety instructions can be fatal!
•Carefully read the safety instructions in this manual!
•Observe the accident prevention regulations and any regional regulations!
•Inform persons in the working area that they must comply with the regulations!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
•Wear suitable ear protection!
•Persons located within the working area must wear suitable ear protection!
CAUTION
Obligations of the operator!
The respective national directives and laws must be observed when operating the
machine!
•National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
•In particular, the directive (89/655/EWG) on the minimum regulations for safety and health
protection when staff members use equipment during work.
•The regulations regarding occupational safety and accident prevention for the respective
country.
•Check at regular intervals that users are adhering to the safety regulations in their work.
•Check the machine at regular intervals according to BGV A3.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
•Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
•Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
2.4 Transport and installation
CAUTION
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
•Disconnect supply lines!

Safety instructions
Transport and installation
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2.4.1 Ambient conditions
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
•Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
•Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
•Observe the ambient conditions!
•Keep the cooling air inlet and outlet clear!
•Observe the minimum distance of 0.5 m from obstacles!
2.4.1.1 In operation
Temperature range of the ambient air:
•-25 °C to +40 °C*
Relative air humidity:
•Up to 50% at 40 °C
•Up to 90% at 20 °C
2.4.1.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
•-30 °C to +70 °C
Relative air humidity
•Up to 90% at 20 °C

Intended use
Applications
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3 Intended use
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
•The equipment must only be used in line with proper usage and by trained or expert staff!
•Do not modify or convert the equipment improperly!
3.1 Applications
TGM 40230 is used for:
•Grinding TIG electrodes.
Any other use of the TGM 4023 is regarded as "improper" and no liability is assumed for any damage
arising therefrom.
3.2 Documents which also apply
3.2.1 Warranty
For more information refer to the "Warranty registration" brochure supplied and our information
regarding warranty, maintenance and testing at www.ewm-group.com!
3.2.2 Service documents (spare parts)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
•Appoint only skilled persons for repair work (trained service personnel)!
Spare parts can be obtained from the relevant authorised dealer.

Machine description –quick overview
Documents which also apply
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4 Machine description – quick overview
Figure 4-1
Item
Symbol
Description 0
1
Infeed channel
2
Guide element for setting the grinding tracks
3
Grinding attachment
4
Depth gauge
5
Grinding attachment clamping bolt
6
On/off switch
7
Filter casing
8
Grinding angle scale
9
Ventilation slot for machine cooling
10
Retaining bolt
11
Motor
12
Speed controller

Design and function
Documents which also apply
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5 Design and function
WARNING
Health risks due to electrode materials!
Welding electrodes may contain materials that are damaging to health!
•Observe the information from the electrode manufacturer!
CAUTION
Open infeed channel!
If the infeed channel is left open, chips and dirt particles can be expelled from the
channel when the grinding disk is running and might get into the eyes or be breathed
in!
•Place the electrode holder in the infeed channel before switching on.
•Allow the grinding disk to come to a stop after switching off before removing the electrode
holder from the infeed channel.
Starting with the electrode in position!
When the machine is started with the electrode in contact, the electrode may tilt and
damage the grinding disk and the machine, as well as cause potential injury!
•When starting the machine, do not place the electrode on the grinding disk!
•Before switching on the machine, check the position of the electrode through the inspection
glass!
Incorrect collet chuck!
Using a collet chuck that does not match the electrode size can mean that the electrode
may become loose, the machine damaged and can also result in injury.
•Only use genuine collet chucks!
•Only use collet chucks that match the relevant electrode diameter!
CAUTION
Excessive pressure!
If too much pressure is exerted from the electrode onto the grinding disk, the electrode
may overheat and become annealed. An annealed electrode can become unusable and
damage the machine!
•Do not press the electrode too forcefully against the grinding disk!
•Turn the electrode evenly during the grinding process!

Design and function
Presets
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5.1 Presets
5.1.1 Selecting the grinding track
If the result is not satisfactory, the grinding machine provides the option to select different tracks on the
disk, depending on the wear of the diamond disk.
Figure 5-1
Item
Symbol
Description 0
1
Guide element for setting the grinding tracks
2
"S" mark
3
Grinding disk
4
Grinding track
5
Clamping bolt
•Unfasten the clamping bolt.
•Lift up the guide element.
•Rotate the guide element by 90°.
•By turning it, position the angle guide exactly underneath the guide element.
•Insert the guide element into the angle guide.
•Re-tighten the clamping screw.
The filter must be replaced whenever the grinding track is changed or if dispersed dust can be
seen constantly in the grinding chamber.

Design and function
Presets
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5.1.2 Preparing electrodes for the grinding process
Various collet chucks modified to the electrode diameter should be used to secure the electrodes for the
grinding process.
Status on delivery!
The collet chuck for an electrode with a diameter of 2.4 mm is pre-fitted in the electrode holder at
the factory.
Figure 5-2
Item
Symbol
Description 0
1
Electrode
2
Collet chuck
3
Electrode holder
Area of application: unalloyed and low-alloy materials
•Select the collet chuck according to the electrode diameter.
•Insert the electrode into the collet chuck.
•Screw the collet chuck into the electrode holder.
Collet chucks supplied!
Collet chucks for electrode diameters of 1.6, 2.4 and 3.2 mm are included as standard. For other
collect chucks, see the - See 8 Accessories chapter.

Design and function
Presets
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5.1.3 Setting the grinding angle of the tungsten electrode
The grinding angle can be set from 15° to 180° in 5° increments. The angle of 180° creates a right-angled
surface at the electrode tip.
Figure 5-3
Item
Symbol
Description 0
1
Clamping bolt
2
Mark
3
Grinding angle scale
•Unfasten the clamping bolt.
•Move the guide until the mark is pointing to the required degree setting.
•Tighten the clamping bolt.

Design and function
Setting the speed
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5.2 Setting the speed
Using a speed that matches the electrode diameter is very important to achieve precise and clean
grinding of the electrode.
Figure 5-4
Item
Symbol
Description 0
1
Motor casing
2
Mains connection cable
- See 7 Technical data chapter
3
Speed controller
•Speed for the individual electrode diameter .
•Set the speed controller to the required value.
- See 5.2.1 Guideline values for speed controller setting chapter
5.2.1 Guideline values for speed controller setting
Electrode diameter
1.0 mm
1.6 mm
2.0 mm
2.4 mm
3.2 mm
4.0 mm
Speed controller setting
3
3
2
2
1
1

Design and function
Inserting the electrode
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5.3 Inserting the electrode
Before every grinding operation:
Set the electrode grinding using the grinding attachment clamping bolt depth gauge.
Figure 5-5
Item
Symbol
Description 0
1
Infeed channel
2
Grinding attachment
3
Depth gauge
4
Electrode holder
5
Inspection glass
6
Electrode
7
Grinding disk
8
Depth gauge setting bolt
•Insert the tungsten electrode into the collet chuck and allow to protrude by approx. 35 mm.
•Screw the collet chuck into the electrode holder.
•Insert the electrode holder into the grinding attachment clamping bolt depth gauge.
•Tighten the tungsten electrode by turning the electrode holder to the right.
•Check that the electrode is seated securely.
•Insert the electrode holder slowly into the infeed channel until the tungsten electrode is over the
grinding disk. Check the process through the inspection glass.
Depth gauge setting bolt
The setting bolt on the rear of the depth gauge can be used to set the grinding of the tungsten
electrode.
•Rotate out: More grinding
•Rotate in: Less grinding

Design and function
Grinding the electrode
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5.4 Grinding the electrode
Figure 5-6
Item
Symbol
Description 0
1
Grinding attachment
2
Infeed channel
3
Stop piece
4
Electrode holder
•Check that the on/off switch is in the "0" position.
•Connect the machine to the power supply.
•Check through the inspection glass that the electrode is not positioned against the grinding disk.
•Switch on machine.
•Move the electrode holder onto the grinding disk while turning it slowly, so that the tungsten electrode
does not anneal. Check the process through the inspection glass.
•Complete the grinding process using light pressure and slow even rotation of the electrode holder.
•The grinding process is complete when the electrode holder limit stop has been reached.
•Switch off the machine and allow it to come to a stop.
•Remove the electrode holder from the infeed channel.
•Insert the electrode holder into the depth gauge and unfasten the electrode by turning to the left.

Maintenance, care and disposal
Grinding the electrode
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6 Maintenance, care and disposal
WARNING
Mains voltage!
All mains and supply lines on the machine being tested must be disconnected before
cleaning or testing.
•Disconnect all mains and supply lines.
Operation without a filter!
Operating the grinding machine without a filter cartridge may mean that poisonous
dust, chips and smoke are expelled from the machine. Chips, dust and smoke from
welding electrodes can represent a health risk!
•Never operate the machine without a filter cartridge in place!
The filter must be replaced whenever the grinding track is changed or if dispersed dust can be
seen constantly in the grinding chamber.
Disposal!
Use the waste disposal bags supplied for single use filters to dispose of used filter cartridges!
Observe local regulations for the disposal of filter cartridges!

Maintenance, care and disposal
Changing the filter
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6.1 Changing the filter
The filter needs to be changed when there are considerable deposits of grinding particles on the
inspection glass.
Figure 6-1
Item
Symbol
Description 0
1
Filter casing
2
Retainer grille
3
Retaining bolt
4
Motor casing
5
Allen key, SW 4
6
Filter cartridge
7
Rubber seal
•Unfasten the retaining bolt on the filter casing.
•Fold down and remove the retainer grille.
•Remove the filter cartridge and dispose of with the waste disposal bag in accordance with regulations.
•Insert a new filter cartridge with the rubber seal in front.
•Hook in the retainer grille on the filter casing and fold up.
•Tighten the retaining bolt hand-tight.

Maintenance, care and disposal
Replacing the grinding disk
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6.2 Replacing the grinding disk
Figure 6-2

Maintenance, care and disposal
Cleaning
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Item
Symbol
Description 0
1
Stop bolt
2
Open-ended spanner, SW 17
3
Grinding attachment
4
Connecting link
5
Allen key, SW 8
6
Grinding attachment clamping bolt
7
Grinding disk
8
Motor casing
9
Open-ended spanner, SW 14
10
Open-ended spanner, SW 13
•Remove the electrode holder.
•Remove the stop bolt using the open-ended spanner (SW 17).
•Remove the connecting link forwards with the inspection glass.
•Unfasten the grinding attachment clamping bolt using the bent-nosed Allan key (SW 8).
•Lift off the grinding head upwards.
•Reverse the grinding disk using an open-ended spanner (SW 14) and unfasten using an open-ended
spanner (SW 13).
•Fit new grinding disk and tighten using the open-ended spanners.
•Fit the grinding attachment.
•Tighten the grinding attachment clamping bolt.
•Fit the connecting link with inspection glass.
•Fit the guide element for setting the grinding tracks.
•Tighten the stop bolt hand-tight.
6.3 Cleaning
The grinding machine must be cleaned at regular intervals to ensure the correct functioning of the
machine in the long-term.
CAUTION
Cleaning!
The machine may become damaged if cleaned with liquids! Removing residues using
compressed air may disturb chips and result in eye damage!
•Do not use any liquids for cleaning!
•Use a small brush or suitable cleaning tool to remove residues!