Floorex Products Satellite 480 Generation3 User manual

V07082019
SATELLITE 480 (SP) Generation3
SAFETY & OPERATORS
MANUAL & PARTS LISTING
CAUTION: Read the instruction manual before using the appliance.

Page1 SATELLITE 480 Generation3
Floorex Products 1800 356 673
Contents
Specifications........................................................................................................................................................ 2
Safety instructions ................................................................................................................................................ 3
Safety instructions ................................................................................................................................................ 4
Operating Instructions........................................................................................................................................... 5
Operating Instructions........................................................................................................................................... 6
Handle Positions ................................................................................................................................................... 7
Tooling position & Magnetic plugs .......................................................................................................................... 8
Magnetic plugs ..................................................................................................................................................... 9
SP plugs ............................................................................................................................................................... 9
Axle height adjustment........................................................................................................................................ 10
Display Functions ................................................................................................................................................ 11
Electrical safety................................................................................................................................................... 12
Problem solving .................................................................................................................................................. 13
Diamonds ........................................................................................................................................................... 14
Wiring Diagram................................................................................................................................................... 15
Main Machine Breakdown .................................................................................................................................... 16
Handle Breakdown .............................................................................................................................................. 17
Disk Breakdown .................................................................................................................................................. 18
Handle Lock Breakdown ...................................................................................................................................... 19
Motor Breakdown................................................................................................................................................ 20
Axle Breakdown .................................................................................................................................................. 21
Screen Breakdown .............................................................................................................................................. 22
SP Plug Breakdown (for SP machines only)........................................................................................................... 24
SP Drive Boss Breakdown (for SP machines only).................................................................................................. 25
SP Shrouds Breakdown (for SP machines only) ..................................................................................................... 26
Warranty ............................................................................................................................................................ 27

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1800 356 673 Floorex Products
Specifications
Satellite 480 Generation3
Weight
160kg (182kg including weights)
Head Pressure
112kg (134kg with weights on head)
Dimensions
543 x 1007 x 1447 (Width x Height x Length)
Rated Voltage
230 Volt 50 Hz
Rated Watts
2200W
Grinding Path
480mm

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Floorex Products 1800 356 673
Safety instructions
1. Read and understand the instructions on the machine and in this manual and engine manual (if applicable).
Different models may have different parts and controls.
2. Equipment should only be operated by trained personnel, in good physical condition and mental health (not
fatigued). The operator and maintenance personnel must physically be able to handle the bulk weight and
power of this machine.
3. The SATELLITE 480 Generation3 must only be used according to the instructions given in this manual. Any
other work methods or practices could result in injury or death
4. The SATELLITE 480 Generation3 has different positions in which the handle can be locked into. These are
described in this manual as ‘OPERATE’, ‘TOOLING POSITION’ and LIFT/STORAGE’. See Handle Positions for
diagrams of these positions. When to use and when not to use these positions is described throughout this
manual
5. This is a one person machine. Maintain a safe operating distance to other personnel. Remember ‘one
machine, one operator’.
6. This equipment is intended for commercial use.
7. For the operators’ safety and the safety of others, always keep all guards and shrouds in place.
8. The weights are there to assist the machine in operation. Always remove them from the handle before folding
it to the tooling mode or storage mode
9. Never start or run machine when it is unattended.
10. Check for wear on magnetic plugs every 3 hours of use
11. This machine is only intended for use on floor surfaces such as concrete, terrazzo and other hard floor
surfaces.
12. The handle height is adjustable with different positions for operator comfort. These positions are shown next
to the locking mechanism as ‘OPERATE’. The SATELLITE 480 must never be started or used with the handle
in any other position other than the ‘OPERATE’ positions’
13. Never attempt to adjust the handle position when the machine is in operation.
14. Never start or run machine with the handle folded or when disk(s) are not in contact with the surface.
15. Do not lend or rent machine without the operating and safety instructions for the machine (and the engine, if
applicable).
16. Wear clothing suitable for the job and for the work place including, safety shoes, hard hat, hearing protection,
non-fogging vented safety goggles, and dust mask suitable for dust.
17. Keep body parts or any loose clothing away from moving parts. Failure to comply could result in bodily injury.

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Safety instructions
18. Do not modify machine in any way. Only use genuine SATELLITE parts and accessories.
19. Repairs should be performed by qualified persons only.
20. Ensure parts have stopped moving and disconnect power or spark plug when servicing or changing blades or
accessories.
21. Never operate machine in rain or if heavy moisture is present.
22. Petrol is extremely flammable and poisonous. Petrol should only be dispensed in well ventilated areas, and
only when engine is cool.
23. WARNING! POISONOUS EXHAUST GASES. Do not operate petrol powered equipment, including generators,
without adequate ventilation. Carbon monoxide is and invisible odourless gas that can harm or can kill.
24. Do not operate SATELLITE 480 with any covers or doors removed or open.
25. The SATELLITE 480 can produce sound pressure levels greater than 85db. The operator must wear approved
safety ear protection.
26. Do not allow the supply cord to come in contact with the cutting blade/head or other moving parts of this
machine.
27. WARNING! As with any diamond tooling, breathable silica or other hazardous dusts may be generated by use
and maintenance of this machine. The dust can cause severe and permanent lung damage, cancer, and or
other serious diseases. Do not breathe the dust. Do not rely on your sight or smell to determine if dust is in
the air. Silica may be in the air without a visible dust cloud. If air monitoring for silica is not provided by your
employer at your work site, you must wear appropriate respiratory protection when operating or maintaining
this equipment. Consult your employer for proper respiratory protection.

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Floorex Products 1800 356 673
Operating Instructions
28. Wear clothes suitable for the job and for the work place including, safety shoes, hard hat, hearing protection,
non-fogging vented safety goggles, and dust respirator suitable for dust.
29. The SATELLITE 480 Generation3 must only be used according to the instructions given in this manual. Any
other work methods or practices could result in injury or death
30. WARNING! Disconnect power before moving the Handle to the ‘TOOLING POSITION’or ‘LIFT’ positions.
31. WARNING! POISONOUS EXHAUST GASES. Do not operate petrol powered equipment, including generators,
without adequate ventilation. Carbon monoxide is and invisible odourless gas that can harm or can kill.
32. Be sure all equipment is tested and tagged prior to use on any job.
33. Inspect entire area to be ground before grinding and remove any bolts or concrete nails (etc) that could
damage tooling or the machine and which could cause a hazardous situation.
34. Ensure there are no obstacles or existing structures that could present a hazard to the operator. If so, take
necessary action to eliminate the hazard.
35. Fold handle to the ‘TOOLING’ position and ensure it is locked in place, then tilt machine back so handle is
resting along the floor.
36. The machine takes a set of three (3) tools. Be sure the tools are of even height.
37. Install appropriate diamond tooling or other available tooling into the machine. Only use genuine SATELLITE
tooling. Failure to comply could result in bodily injury. See section ‘TOOLING POSITION’ for illustrations on
how to remove and install tooling
38. Tilt machine back onto the disk and put the handle in one of the ‘OPERATE’ positions. Adjust the position to
one that you are comfortable with.
39. Never attempt to adjust the handle position when the machine is in operation.
40. Connect machine to suitable power outlet. Only use heavy duty power lead suitable for high current use
(preferably 2.5mm² cable), no longer than 15 meters.
41. If no power is available within the specified distance, have a qualified person install a suitable power outlet
closer to your work. Alternatively use 4mm² cable for up to 40 meters.
42. Connect a suitable dust extractor to the machine via a 38 or 50mm flexible hose. The machine is designed to
take the standard 50mm hose ends to make connection of dust extractors easy and hassle free.
43. Keep machine clear of drainage pits, grates, steps or major lips or such hazard. Failure to comply could result
in bodily injury and or could damage the machine or property.
44. Ensure machine is on a level surface and handle is in one of the ‘OPERATE’ positions
45. This machine is designed to operate with the wheels in contact with the floor at all times. Do not operate with
wheels off the floor.

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Operating Instructions
46. The SATELLITE 480 Generation3 has axle height adjustment to make it easy to adjust the machine so it
doesn’t cause fatigue on the operator. To set axle height, adjust the axle height leaver to the vertical position,
or midpoint. This is a good starting point. After initial operation the axle can be adjusted. The axle lever must
be set as far back (toward operator) as possible without creating excess force on the operator during
operation.
47. Switch on the dust extractor.
48. Hold the handles firmly and switch the SATELLITE 480 Generation3 on by pushing the green button.
49. The controls on the SAT480 Generation3 include an over load device. It is there to protect the controls and
motor from irreparable damage. If it trips it indicates a problem. (i.e.; undersize power lead or poor power to
your power supply). Refer earlier in this section for recommendations on power leads. Rectify the problem or
decrease load on the Satellite 480 by using tooling with more surface area, or place weights supplied on the
brackets on handle for this purpose.
50. Continuing to use the SATELLITE 480 when constant tripping occurs, VOIDS THE WARRANTY.
51. Do not attempt to make any adjustments while the machine is in operation. Any adjustments must only be
performed when machine is stopped and power disconnected.
52. In the event of the machine pulling to one side all the time; adjust the axle height to obtain the best result.
(See ‘AXLE HEIGHT’). This machine is designed to operate with the wheels in contact with the floor at all
times. Do not operate with wheels off the floor.
53. After a few minutes of grinding check the wear of the diamond tooling. This will pay handsomely if the
diamonds are wearing out fast due to soft concrete / abrasive concrete. There is a wide range of diamonds
available to suit every need. See Section ‘DIAMOND TOOLING SELECTION GUIDE’.
54. Check for wear on magnetic plugs every 3 hours of use
55. See Section ‘PROBLEM SOLVING’ for tips on how to grind faster on tough concrete and how other problems
can be rectified.
56. WARNING! As with any diamond tooling, breathable silica or other hazardous dusts may be generated by use
and maintenance of this machine. The dust can cause severe and permanent lung damage, cancer, and or
other serious diseases. Do not breathe the dust. Do not rely on your sight or smell to determine if dust is in
the air. Silica may be in the air without a visible dust cloud. If air monitoring for silica is not provided by your
employer at your work site, you must wear appropriate respiratory protection when operating or maintaining
this equipment. Consult your employer for proper respiratory protection.

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Floorex Products 1800 356 673
Handle Positions
57. The handle on this machine can be locked in different positions for different purposes. These positions must
only be used for the purpose intended as outlined in this manual. . Failure to comply could result in bodily
injury.
58. These positions are shown below and when and where to use them is outlined throughout this manual.
Operate Position (3
positions available)
Lift / Storage Position
Tilt Onto Back
Tooling Position

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Tooling position & Magnetic plugs
59. It is very important to remove all plugs from the unit before installing standard Diamond Plugs. This includes
Magnetic and for the SP machines, the SP Drive System.
60. To remove tooling from the magnetic plugs, Tilt the machine to the tooling position as per instructions in the
operating instructions and grasp hold of the diamond disk and give it a sharp pull away from the main black
disk.
61. To remove the plug from the main black disk strike the black disk beside the taper insert as shown below.
62.
63. The magnetic plugs must be cleaned from dust and other debris every time you change satellite disks. The
insert should go in all the way up into the plug up to the step on the insert.
64. If the insert is getting signs of wear on the top it is because the insert hole has debris in it or hard packed
dust against the magnet.
65.
66. Clean out the hole in the plug where the insert goes. Ensure there are no particles or pieces of steel (such as
staples ETC). The hole where the insert goes in the plug can be cleaned with a screwdriver to remove packed
dust etc.
If the insert does not go all
the way in it will result in
wear on the face of the insert

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Magnetic plugs
67. Ensure the insert is not worn to less than 20mm diameter where the blade runs on the insert. This is
equivalent to the diameter of the section above it.
68.
69. Put the insert through the satellite disk and install the two parts onto the plug ensuring the insert goes
completely into the plug.
SP plugs
70. The SP versions of the Satellite machines don’t have magnetic plugs supplied. The SP versions have the SP
plug with a disc retaining rubber ring that retains the diamond tooling onto the machine.
71. Magnetic Plugs can be used but the SP plugs must be removed before to prevent damage to the unit.
72. The disc retaining rubber ring must be checked for wear or splitting before each operation to ensure the
safety of the machine is not compromised.
73. The SP Machines must be used with original manufacturer’s diamond tooling with the drive holes to assure
safe operation. Using aftermarket tooling could void the warranty on the machine and could cause an unsafe
operation.
74. To remove the diamonds on the SP machines simply pull the tag on the disc retaining rubber ring. To reinstall
the tooling fit the disc and then work the ring over the face of the plug and into the grove making sure the
ring is bedded correctly in the grove.
Disc retaining
rubber ring

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Axle height adjustment
75. This machine is designed to operate with the wheels in contact with the floor at all times. Do not operate with
wheels off the floor.
76. There is a level bubble provided (located behind the motor) for levelling the machine for best user experience
and coupling life. It does not change the grinding results in any way.
77. The axle lever should be set so the bubble is up to the forward line on the spirit level. This assures the
longevity of the coupling life and gives the nicest position for ease of use. (Assuming the floor is level)
Level Bubble
Axle Lever

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Display Functions
78. The Generation3 Grinders feature a display screen with a backlight. This is a new feature that greatly
enhances the user experience in that the operator knows what the machine is doing, taking a lot of the guess
work out of the job.
79. There are 3 things the meter measures.
a. Voltage
b. Amps Draw
c. Hours Run
80. When you first plug the machine in, the display will be similar to the “READY” screen below.
81. This Screen shows the voltage of the supply and also the hours that machine has been running for.
82. When you start to use the machine the “RUNNING” display will show. This screen shows the Voltage and the
amps while the machine is in operation. The bottom line shows the LOAD as a percentage of motor power
available. Running the machine over 100% for extended periods will result in the overload tripping to protect
the machine.
83. With the HVA meter on the satellite it is now possible to check a lot of the things your electrician will check if
there are power issues. Common problems that can be identified are;
a. Voltage drop when under load due too long or under size extension leads. This often causes the
Amps to increase in proportion to the voltage loss.
b. High amps when voltage is still within 10% of normal. Caused by high load jobs like aggressive
diamonds or when polishing.
84. Hours run is only counted when machine is being used (over 0.5 Amps) and counted with accuracy of two
decimal places
a. The first decimal place is a 10th of an hour being 6 minutes
b. The second decimal place is a 10th of 6 minutes being 36 seconds.
240.5V 10.2A
LOAD 95%
RUNNING Screen
240.5V 0.0A
0000001.01 HOURS
READY Screen

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Electrical safety
85. All electrical maintenance and repairs are to be carried out by qualified persons only.
86. CAUTION - Line terminals may be alive when main switch is in the off position. Disconnect the machine
completely before performing any maintenance or repairs.
87. WARNING - DO NOT operate the machine with any electrical panels open.
88. WARNING - The controls on the SAT480 Generation3 include an over load device. It is there to protect the
controls and motor from irreparable damage. If it trips it indicates a problem. (i.e.; undersize power lead or
poor power to your power supply). Refer earlier in this manual for recommendations on power leads. Rectify
the problem or decrease load on the Satellite 480 by using tooling with more surface area, or place weights
supplied on the brackets on handle for this purpose.
89. Continuing to use the SATELLITE 480 when constant tripping occurs, VOIDS THE WARRANTY!
90. Never operate machine in the rain or if heavy moisture is present.
91. The overload is there to protect you and the machine from harm. DO NOT bypass or adjust the over load in
any way. If it is faulty, only replace with original part that is identical to the faulty one.
92. Never bypass over current devices in this machine.
93. Never connect or disconnect power cables with voltage present or while under load.
94. Disconnect all power connections and observe lock out / tag out procedures before attempting to carry out
any maintenance or repair on any equipment.
95. Avoid any contact with any rotating parts or driven parts.
96. Never use equipment that has not been tested and tagged (including cords).
97. Before connecting the machine to power, check the condition of all power leads and cables on, or used in
conjunction with the machine. DO NOT USE it if any faults, cuts, wear marks, etc… Get qualified persons to
repair and re-tag it as required by regulations in your country.
98. Connect machine to suitable power outlet. Only use heavy duty power lead suitable for high current use
(preferably 2.5 mm2 cable), no longer than 15 meters.
99. If no power is available within the specified distance have a qualified person install a suitable power outlet
closer to your work. Alternatively use 4 mm² cable for up to 40 meters.
100. Do not operate SATELLITE 480 with any covers or doors removed or open.

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Problem solving
102. Diamond Grinding has many variables. When you understand some of these, you can solve a lot of
problems without a lot of bother and expense.
NOTE: THIS IS A GUIDE ONLY
PROBLEM
CAUSE
REMEDY
EXPLAINATION
Machine will not start
/ run.
No power is present at
cable end.
Check the power is present
with another tool.
Using another tool confirms power
is present
Machine is trying to
start on glue or other
sticky substance.
Clear a patch with a scraper
and grind into the glue a
little at a time.
This means it only tackles a small
amount of glue at a time and
keeps the glue residue coated with
dust, preventing glue sticking and
building up on the diamonds.
Power lead is too small
in capacity or too long.
Upgrade the power lead to
2.5mm² (15meters max) or
4mm² (40 meters max).
The long / small capacity cable is
too restrictive and can’t allow
enough power through for the
machine to start / run properly.
Use weight on the handle.
The weight on the handle reduces
the load on the machine thus
reducing the current.
Machine is not
grinding at all.
No blades /
accessories in unit.
Fit blades. Note; check wear
on machine.
Very hard concrete or
glazed topping on
concrete.
Turn dust extractor down /
restrict flow. Only just
control the dust from
escaping.
The extra dust accumulating on
the floor acts as an abrasive
between the segments and the
floor thus exposing the diamonds
better.
Place river sand or cement
on the floor.
The sand is an abrasive as
described above.
Use softer grade of diamond
tooling.
The softer grade will expose the
diamonds better.
Use coarser diamond
tooling.
The coarser diamond tooling can
get through hard toppings without
wearing out the diamonds too
fast.
Reverse the rotation of the
machine (switch on the
bottom of the motor box)
The tooling exposes the diamonds
when reversed. This works best
when using plugs.
The diamonds are
wearing out too fast.
The concrete is:
*Soft
*Abrasive
*Rain Damaged
*A rough finish
(Scarified or shot
blasted).
Use a powerful dust
extractor to remove as much
dust as possible.
The dust, as described acts as an
abrasive between the segments
exposing the diamonds
prematurely, wasting them.
Use harder diamond matrix.
The harder segments don’t expose
as easily.
Use tooling with more
segments or area² of
segment.
The tooling with more segments
or area² doesn’t have the same
weight on them, reducing wear.
The diamonds are too
soft or too few.
Use weights on the handle
This reduces the weight on the
diamonds thus reducing the wear
on them.

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Diamonds
Scan Below to see diamonds suited to the Satellite 480 Machine

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Wiring Diagram

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Main Machine Breakdown

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Handle Breakdown

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Disk Breakdown

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Handle Lock Breakdown