HTC Sweden AB HTC 500 User manual

Manual
HTC 500
HTC SWEDEN AB
www.htc-sweden.com
GB

3
Read this first
This manual gives you the information you need to carry out a delivery inspection, commission
and use your machine. Please contact your distributor in the event of any problem when instal-
ling and commissioning. HTC Sweden AB is not responsible in any way for any consequences,
whether direct or indirect, that arise as a result of the machine being used in a way that contra-
dicts these instructions.
• Although all possible measures have been taken to ensure the accuracy and completeness of the informtion
presented in this manual, HTC Sweden AB does not accept any responsibility or liability for errors
or missing information. HTC Sweden AB reserves the right to alter descriptions in this manual without prior
notice.
• No part of this manual may be copied or in any way used without the express written permission of HTC.
Trademarks
The HTC trademark is owned by HTC Sweden AB. Other names and products mentioned in this
manual may be registered trademarks of their respective companies.
© HTC Sweden AB, 2004. Sole rights.

4
CONTENTS
Read this first ........................................................................................................................ 3
Trademarks ........................................................................................................................... 3
Warranty ...............................................................................................................................5
Safety regulations ................................................................................................................. 5
Machine name plate ............................................................................................................. 7
Delivery 7
Unpacking the machine ........................................................................................................ 7
CE marking ........................................................................................................................... 7
DECLARATION OF CONFORMITY ..................................................................................... 8
Annex to DECLARATION OF CONFORMITY ......................................................................9
Introduction .........................................................................................................................10
Description of the machine ................................................................................................. 11
Dry/wet grinding ................................................................................................................. 13
Control buttons – function description ................................................................................ 13
HTC 500 Frequency controlled ...........................................................................................13
HTC 500 Soft start .............................................................................................................. 13
Mounting/dismantling of grinding discs ............................................................................... 14
Mounting and replacement of tools ....................................................................................15
Operation ............................................................................................................................16
Measures prior to start .......................................................................................................16
Start of machine ................................................................................................................. 16
Technical data ..................................................................................................................... 17
Environment .......................................................................................................................18
Chassis ...............................................................................................................................18
Electrical system ................................................................................................................ 18
Maintenance ....................................................................................................................... 18
Parts and service ................................................................................................................ 18
Exploded diagram HTC 500 ............................................................................................... 19
Exploded diagram HTC 500 ............................................................................................... 20
Parts list HTC 500 .............................................................................................................. 21
Parts list HTC 500 .............................................................................................................. 22
Parts list HTC 500 .............................................................................................................. 23
Error codes for frequency converter SJ 100 ....................................................................... 24
Troubleshooting .................................................................................................................. 27
Appendix, soft start HTC 500 ............................................................................................. 28

5
Warranty
See the warranty that accompanies the machine.
Safety regulations
• This machine may only be operated, repaired or in any other way handled by personnel who
have the requisite training and have read this manual.
• Only use this machine for grinding and polishing unhewn stone, terrazzo, concrete or any of
the other materials specified in this manual.
• Only use original tools and original spare parts in the machine. Failure to do so will nullify
the CE marking and warranty.
• Only lift the machine using the intended lifting bow. Do not lift the machine by the handle,
motor, chassis or other parts. Transport the machine securely mounted on a pallet wherever
possible.
• Always keep the machine in a dry and warm area when it is not being used. If this is not the
case, the machine could be damaged due to internal condensation.
• If the machine has to be stored in a cool place, it must be in a heated area at least two (2)
hours before use.
• Do not move the machine manually on an inclined surface. Even a gentle slope can gene-
rate rollng forces that cannot be checked by hand power alone.
• Do not use the machine on an inclined surface.
• Do not use the machine in environments where there is a risk of explosion or fire.
• Wear personal safety equipment such as boots with steel toe caps, goggles, protective glo-
ves and ear muffs.
• Check that all the phases are deenergised before starting the machine. Check using test
tools.
• Do not start the machine with the grinding head raised. Only start the grinder with the rota-
ting discs facing the floor and with the correct tools mounted.
• Do not start the machine without the splashguard mounted which seals between the grin-
ding head and the floor. Also ensure that the splashguard is in satisfactory condition.
• Fill the tank with cold water only.
• No chemicals may be added to the water. Chemicals may cause leakage resulting in danger
of electrical contact and injury.
• Observe caution when filling with water so as to avoid danger of electrical contact and injury.

6
• Only use the water tank for its intended purpose.
• Use a customised dust extractor when dry grinding, such as HTC D26, D30, D55 or larger.
• Always tip up the machine after grinding when removing glue or when wet grinding so that
the machine does not stick to the floor and damage machine parts upon restart.
• The control current must always be cut and the mains connection disconnected when repla-
cing grinding discs.
• The grinding discs may be hot following grinding. Let the machine stand in tipped position
for a few minutes and wear gloves when you remove the grinding discs.
• Cut the current to the machine when repairing.

7
Machine plate
Model and serial number for your machine is shown on the machine plate. This information is
required when ordering spare parts for the machine. Use the space below to note the model and
serial number of your machine for future reference.
MODEL NUMBER ___________________________________________
SERIAL NUMBER ______________________________________________
Delivery
The following items should be included on delivery. Contact your distributor if anything is missing.
• Grinder
• Splash guard
• Manual
Unpacking the machine
• Check carefully if the packaging or the machine has been damaged during delivery. If there
are signs of damage, contact your distributor to report the damage.
• Check that the delivery matches your order. Contact your distributor if you have any ques-
tions.
• Read carefully through the safety instructions and manual before use.
CE marking
CE marking of a product guarantees its free movement within the EU region in line with EU regu-
lations. The CE marking guarantees that the product meets the various directives (EMC directi-
ves and any other requirements in the new procedures directives). The HTC 500 grinder has CE
marking in accordance with the ”Low Voltage Directive” (LVD), the Machinery Directive and the
EMC Directive. The EMC directive stipulates that the electrical equipment must not subject the
surrounding area to electro-magnetic radiation, and that it must also be immune to electromag-
netic interference in the surrounding area.
The following pages include the Manufacturer’s Declaration of Conformity that demonstrates that
the HTC 500 grinder complies with the EMC directives. HTC 500 is classified for use in environ-
ments such as heavy industry Class A.

8
DECLARATION OF CONFORMITY
Declaration of Conformity in accordance with
• The Machinery Directive - 98/37/EC
• The EMC Directive - 89/336/EEC
• The Low Voltage Directive - 73/23/EEC including amendments
• The CE Marking Directive - 93/68/EEC
Type of equipment Grinder
Make HTC
Trademark HTC ___________________
Serial number ___________________
Manufacturer
HTC Sweden AB
Box 69
SE-614 22 Söderköping, Sweden
The annex includes documents that are applicable for verification of conformity.
Additional information on the Machinery Directive
Declaration of Conformity in accordance with Appendix 2A.
The product conforms to the Machinery Directive 89/392/EEC with amendments.
Additional information on the EMC Directive
The equipment conforms to the harmonised EMC standards specified in the annex.
See technical report 97028.
Additional information on the Low Voltage Directive
The product conforms to good operating practices within EES, even though they do not fully con-
form to the standards and other technical specifications outlined in the annex. HTC Sweden AB
has an internal system for quality assurance that guarantees conformity between the manufactu-
red product and the technical documentation.
Additional information on the Low Voltage Directive
CE marking of a product guarantees its free movement within the EU region in line with EU
regulations. The CE marking guarantees that the product meets the various CE directives (EMC
directives and any other requirements in the new procedures directives). The product was CE
marked in 1997.
As manufacturer, we declare under our sole responsibility that the product meets the provisions
laid down in the Directives specified above.
Date: - -
Sten Jeansson
Managing Director

9
Annex to DECLARATION OF CONFORMITY
The following harmonised standards have been applied:
Standards Date Notes
- - -
The following national standards have been applied:
Standards Date Notes
SS-EN 292-1
SS-EN 292-2
The following corporate standards or other technical specifications have been applied:

10
Introduction
The HTC 500 can be used for wet and dry grinding of marble, terrazzo, granite and concrete. It
can be used for both abrasive grinding and polishing.
NOTE:
The machine may only be operated or repaired by personnel who have undergone the
requisite practical and theoretical training.
NOTE:
The instructions in this manual must be observed in order for CE marking to apply.

11
Description of the machine
The machine is built of a number of main components, such as motor, rotating grinding unit, fre-
quency converter, operator panel, chassis, handle bar and wheels. The HTC 500 is available in
two motor options; 115V or 400V.
The machine can either be fitted with soft start or a frequency converter. The difference lies in
the speed of the machine being controlled by a frequency converter from the operator panel. The
rotational direction of the grinding discs can also be changed from the operator panel (read more
on Page 16, Operation). The machine with soft start only has one speed.
The machine is built around a chassis with wheels. Motor with rotating grinding unit mounted at
the bottom of the chassis in such a way that allows some movement between the chassis and
the motor housing. The screws between the bracket and the chassis must not be too tight. Loo-
sen them to allow a little movement. You should be able to turn the washer.
The handle bar can be set at a number of angles. Select a position that suits you.
The water tank is manufactured of rotation cast polyethylene. The water is directed via a hose
with stop cock to the periphery of the large disc. Tank capacity:17 litres
The grinding cover has two connections for an external dust extractor hose, to be used when dry
grinding.
The machine can be fitted with a large number of grinding discs and tools depending on the
type of material to be ground by following a simple procedure. See Pages 14-15 for grinding disc
replacement.
See HTC’s grinding guide for the various tools.
1. Lifting bow 6. Extra weights 11. Adjustable handle
2. Connection, vacuum cleaner 7. Wheel 12. Operator panel
3. Grinding head 8. Mains connection 16-32A 13. Filter
4. Water tank 9. Frequency converter 14. Water hose + valve
5. Motor 10. Hoses with Y-connection
3
2
1
4
5
6
7
8
9
10 11
12
13
14

12
Fig.1
The rotational direction of the motor seen from above through the fan casing. Normal rotational direction is for-
wards.
HTC with frequency converter has always had the same rotational direction, regardless of how the phases are con-
nected. However, HTC soft start is affected by the incoming phases which means you should observe caution in
this respect.
Normal direction

13
Dry/wet grinding
A dust extractor should be connected to the machine when dry grinding. Connect the dust extrac-
tor to both terminals that are located on the machine’s safety cover. If only one terminal is con-
nected, the other terminal must be covered. The capacity of the dust extractor should be adjusted
in line with the capacity of the machine. Fill the tank with cold water when wet grinding and start
the flow through the open valve located on the left side of the chassis under the tank (seen from
the operator).
Control buttons – function description
HTC 500 Frequency controlled
DUTY Operation lamp, indicates when the machine is ready for use.
RESET After an emergency stop or malfunction, the reset button must be pressed for
two seconds before the machine can run.
SPEED Knob to control the rotational speed of the grinding discs. Turn the knob
clockwise to increase the rotational speed and anticlockwise to decrease the
speed.
REV – FWD Used for starting and stopping the machine.
Adjusts the rotational direction of the grinding discs forwards or backwards.
A definition of forwards and backwards is outlined in the figure on Page 12.
ON - OFF For disconnecting or powering up the machine. Must not be used for starting
or stopping the machine.
HTC 500 Soft start
REV – FWD Used for starting the machine. Adjusts the rotational direction of the
grinding discs forwards or backwards. Check that the discs are rotating in the
right direction. Do not change the rotational direction when running, but let
the machine come to a total stop before changing direction in order to avoid
damage to the soft start unit.
STOP Stops the machine
EMERGENCY STOP Cuts the power to the machine. Turn to reset.
Control panel for soft start Control panel for frequency controlled machine

14
Mounting/dismantling of grinding discs
Take the following safety measures when mounting grinding discs:
• Remove any weights.
• Disconnect the power supply and the power cable.
Tip the machine up, and remove the old grinding discs using the enclosed special tool, see pic-
ture. The tools can also be bolted to the machine if required.
Observe caution when working with tools and tool discs:
• The discs may be hot after operating the machine.
Lock the tools using the enclosed special tool following tool change. Tip the machine back in
place. Check the splashguard around the cover to the grinding head. If you do not adjust the
height of the splashguard it may be damaged as the working height of the different tools varies
depending on wear.
Locking of tool plate with special tool.

15
Mounting and replacement of tools
Always cut the mains voltage to the machine when working with the grinding tools. Make a habit
of always disconnecting the mains plug before commencing work.
Start by tipping the machine backwards.
Remember that the grinding tools can be extremely hot if grinding work has recently been carried
out.
The HTC 500 is equipped with our newly patented and copyright protected EZchange™ tool
system. It consists of wings with diamond tools. These wings are folded and pushed into a tool
holder where they are locked using a light blow from a non-rebounding rubber hammer.
Move the grinding tool slightly tilted forwards down into the intended slots in the tool holder to
mount. Now push the tool forwards out from the centre of the tool holder, see Picture 1.
Then lock the tool in the tool holder by administering a few light blows with a rubber hammer, see
Picture 2.
Now mount the tool holder on the machine, turn the machine to working position and check that
the splashguard is properly mounted.
Connect the machine to the mains.
When changing tool, release the grinding tool with a few light blows using a rubber hammer. Now
do everything in reverse order. Strike the tool until it loosens and lift it out of its slot in the tool
holder, see Picture 3.
Picture 1. When
mounting a grinding
tool, you must first
move the tool down
into the slots in the
tool holder.
Picture 2. Now
you can lock the
tool in the tool hol-
der by applying
a few light blows
with a rubber
hammer.
Picture 3. To re-
move a tool apply
a few light blows
to release the
lock, and then lift
it out of its slot.

16
Operation
The following section describes how to operate and use the grinding machine. The section does
not deal with the technical aspects of grinding such as choice of grinding tool etc. For selection of
tool, see the Grinding Guide from HTC.
NOTE:
Only personnel with the requisite training may operate the machine.
It is assumed that the relevant personnel have read the safety regulations,
and that the machine is positioned on the surface intended for grinding, that the surface is not
inclined and that the grinding discs are mounted.
Measures prior to start.
1. Inspect the floor carefully and remove any protruding items such as reinforcement bars and
bolts, as well as any loose material that could get caught in the machine.
2. Set the handle bar in the desired working position.
3. Fit the appropriate tools to the machine.
4. Mount and check the splashguard.
5. Connect the voltage to the terminal on the side of the frequency converter.
6. Check that all the phase indicator lamps are lit (applies to frequency controlled machines).
7. If all the LEDs are not lit, double-check with a suitable tester tool.
8. If the floor is to be dry ground, a dust extractor should be connected and started before star-
ting the machine.
Start of machine
1. Start by energising the frequency converter by turning the On/Off knob. This will light the
”duty” lamp. This means the machine is in standby mode.
2. Set the speed you want to start grinding with. The more uneven the floor, the lower the
speed.
3. Start the machine by selecting the rotational direction.
NOTE:
Do not use the ON / OFF knob to start or stop the rotational direction of the discs.
NOTE:
Only start the machine when all lamps are lit.
Measures, see the chapter for troubleshooting.
NOTE:
Only use HTC original tools.

17
Technical data
HTC 500E HTC 500E HTC 500S
Motor: 4.0 kW 4.0 kW 4.0 kW
Current load (max): 16 A 32 A 16 A
Supply voltage: 3x400V 2x115V 3x400V
Machine weight: 147 kg 147 kg 145 kg
Weight set: 3x10 kg 3x10 kg 3x10 kg
Grinding pressure (ex-
tra weights):
100-(130) kg 100-(130) kg 100-(130) kg
Grinding diameter: 500 mm 500 mm 500 mm
RPM: 300-1300 rpm 300-1300 rpm 750 rpm
Tank volume (water): 17 l 17 l 17 l
Grinding discs: 3x220 3x220 3x220
NOTE:
HTC reserves the right to amend the technical specifications.
555/21.8 973/38.3
527/20.7
1074/42.3
1102/42.4
1494/58.8
1259/49.6

18
Environment
The majority of components in HTC machines are made of recyclable metals and plastics. The
main construction material used is specified below.
Chassis
Frame Steel, electrically galvanized sheet metal
Wheels Polyurethane filled rubber tyres with steel rims
Cover ABS plastic
Water tank Polythene
Electrical system
Cables Copper conductors with PVC jackets
Electronics card Glass-fibre reinforced circuit board laminate
Electronic cabinet Stainless steel plate
Plastic parts can be reused by sorting as hard plastic. Electronic components can be disposed
of as electronic waste. The machine or machine components can of course be returned to HTC
Sweden AB.
Maintenance
Always clean the machine after use. Do not use a pressure washer as this can force water into
various components causing damage. We recommend the regular inspection of seals, especially
the seals by the upper belt. These seals should be inspected once every three months and chan-
ged if worn. The filter to the electrical cabinet should be replaced regularly (See Page 11.)
Parts and service
Any necessary repairs must be carried out by a HTC Service Centre that has the qualified ser-
vice personnel and use HTC’s original parts and accessories. Contact your distributor if you need
spare parts or service.
Addresses to our distributors and service partners are available on our website:
www.htc-sweden.se
Always state model and serial number if you have any questions about your machine.

19
Exploded diagram HTC 500
1
2
3
4
5
6
7
8
9
10
11
12
13
15
14
15 16
11
17
18
19
20
21
22
23
24
25
26 27
28
8
11
11
15
17
2
16

20
Exploded diagram HTC 500
39
34
53
36
37
38
39
40
41 43
44 45
46
47
48 49
50
52
53
55
56
57
58
59
60
61
62
41
63
64
65
66
67
68
69
70
71
72
73
74
75 76
77
78
79
80
81
82
83
84
85
86
87
88
89
90 91
32
34 35
42
51
53
53
54
56
31
29
30
35
42
42
42
33
54
92
93
94