Optimum Optigring GT 25 User manual

EN
Operating Manual
Version 1.0.2
Surface grinding machine
Part no. 3111030
Part no. 3111025
Part no. 3111040
GT25

Version 1.0.2 - 2020-09-152 Translation of original instructions
GT25 | GT30 | GT40
EN
GT25_GT30_GT40_GBIVZ.fm
Table of contents
1 Safety
1.1 Glossary of symbols ...................................................................................................................................... 7
1.2 Rating plate.................................................................................................................................................... 7
1.3 Safety instructions (warning notes)................................................................................................................ 8
1.3.1 Classification of hazards.................................................................................................................. 8
1.3.2 Other pictograms.............................................................................................................................. 8
1.4 Intended use.................................................................................................................................................. 9
1.5 Reasonably foreseeable misuse.................................................................................................................... 9
1.5.1 Avoiding misuse............................................................................................................................. 10
1.6 Dangers that can be caused by the surface grinding machine.................................................................... 11
1.7 Qualification of personnel............................................................................................................................ 12
1.7.1 Target group................................................................................................................................... 12
1.7.2 Authorized personnel..................................................................................................................... 13
1.8 Operator positions ....................................................................................................................................... 13
1.9 Safety devices ............................................................................................................................................. 13
1.9.1 Lockable master switch.................................................................................................................. 14
1.9.2 Emergency stop button.................................................................................................................. 15
1.9.3 Control-related safeguarding.......................................................................................................... 15
1.9.4 Prohibition, warning and mandatory signs..................................................................................... 15
1.10 Safety check................................................................................................................................................ 15
1.11 Personal protective equipment.................................................................................................................... 16
1.12 Safety during operation................................................................................................................................ 17
1.13 Safety during maintenance.......................................................................................................................... 17
1.14 Switching off and securing the surface grinding machine............................................................................ 17
1.14.1 Using lifting equipment................................................................................................................... 18
1.14.2 Mechanical maintenance ............................................................................................................... 18
1.15 Accident report............................................................................................................................................. 18
1.16 Electronics................................................................................................................................................... 18
1.17 Inspection deadlines.................................................................................................................................... 19
1.18 Clamping devices for workpieces and tools................................................................................................. 19
1.19 Environmental protection and water conservation....................................................................................... 19
1.20 Hydraulic system ......................................................................................................................................... 19
2 Technical data
3 Delivery, interdepartmental transport, assembly and commissioning
3.1 Notes on transport, installation, commissioning .......................................................................................... 22
3.1.1 General risks during internal transport........................................................................................... 22
3.2 Assembly and commissioning ..................................................................................................................... 23
3.3 Unpacking the machine............................................................................................................................... 23
3.3.1 Standard accessories..................................................................................................................... 23
3.3.2 Optional accessories:..................................................................................................................... 23
3.3.3 Load stop in unpacked condition.................................................................................................... 23
3.4 Set-up and assembly................................................................................................................................... 24
3.5 Installation site requirements....................................................................................................................... 24
3.6 Installation plan............................................................................................................................................ 26
3.6.1 Anchored mounting........................................................................................................................ 27
3.6.2 Free mounting................................................................................................................................ 28
3.6.3 Aligning the machine...................................................................................................................... 28
3.7 Removing the transport locks...................................................................................................................... 28
3.8 Installation of the collecting trays on GT40.................................................................................................. 30
3.9 Cleaning the machine.................................................................................................................................. 30
3.10 Top up central lubrication ............................................................................................................................ 31
3.10.1 Central lubrication supply points.................................................................................................... 33
3.11 Connecting the hydraulic system................................................................................................................. 34
3.11.1 Fill in hydraulic oil........................................................................................................................... 35
3.12 Coolant circuit.............................................................................................................................................. 35
3.13 Electrical connection.................................................................................................................................... 37
3.13.1 Electrical connection of hydraulic and coolant pump..................................................................... 38
3.14 First commissioning..................................................................................................................................... 38
3.14.1 Warming up the machine............................................................................................................... 38

Version 1.0.2 - 2020-09-15 3Translation of original instructions
GT25 | GT30 | GT40 EN
GT25_GT30_GT40_GBIVZ.fm
4Operation
4.1 Safety...........................................................................................................................................................39
4.2 Control and indicating elements...................................................................................................................40
4.3 Control panel................................................................................................................................................41
4.4 Grinding table oscillation ..............................................................................................................................42
4.5 Selector switch for operating mode..............................................................................................................42
4.6 Push buttons for grinding head up and down in Jog mode ..........................................................................42
4.7 Setting up the oscillating path and the traverse path in the transverse axis ................................................43
4.7.1 Transverse axis - Z axis..................................................................................................................43
4.7.2 Oscillation, longitudinal axis - X axis...............................................................................................43
4.8 Manual surface grinding...............................................................................................................................43
4.8.1 Electronic hand wheel.....................................................................................................................44
4.8.2 Switching on the crossfeed.............................................................................................................44
4.8.3 Switching on the oscillation.............................................................................................................45
4.9 Automatic surface grinding...........................................................................................................................45
4.9.1 Input screen - Display screen.........................................................................................................45
4.9.2 Surface grinding NC sequence program ........................................................................................47
4.9.3 Plunge grinding NC sequence program..........................................................................................48
4.10 Switching on the machine ............................................................................................................................49
4.10.1 Switching the grinding wheel on .....................................................................................................49
4.11 Switching the machine off ............................................................................................................................49
4.11.1 Resetting the NC sequence control, switching off ..........................................................................49
4.12 Resetting an emergency stop condition .......................................................................................................49
4.13 Power failure, Restoring readiness for operation .........................................................................................50
4.14 Mounting the grinding wheel ........................................................................................................................50
4.14.1 Mounting the grinding wheel on the flange.....................................................................................50
4.14.2 Balancing the grinding wheel..........................................................................................................51
4.14.3 Mounting the grinding wheel with flange on the spindle .................................................................52
4.15 Condition electromagnet and hydraulic pump..............................................................................................53
4.16 Displays in the HMI ......................................................................................................................................53
4.16.1 Output signals.................................................................................................................................53
4.16.2 Input signals....................................................................................................................................54
4.16.3 Alarm Menu ....................................................................................................................................54
4.17 Selection of a grinding wheel .......................................................................................................................55
4.18 Dressing the grinding wheel.........................................................................................................................58
4.19 Operation of central lubrication ....................................................................................................................58
4.20 Digital Readout.............................................................................................................................................58
5 Operation DPA31
5.1 Parameter settings.......................................................................................................................................59
5.1.1 Explanation of the Parameters .......................................................................................................60
5.2 Description of the Keys ................................................................................................................................61
5.3 Reference marker function...........................................................................................................................64
5.4 Machine zero point function .........................................................................................................................64
5.5 Calculator function........................................................................................................................................65
5.6 Functions for milling machines.....................................................................................................................66
5.6.1 Coordinate points along a diagonal line..........................................................................................66
5.6.2 Coordinate Points on a Circle or Arc ..............................................................................................67
5.6.3 Inclined Plane .................................................................................................................................70
5.6.4 Arc ..................................................................................................................................................71
5.7 Functions for milling machines and lathes ...................................................................................................74
5.7.1 Tool Data Function .........................................................................................................................74
5.7.2 Recall of tool data...........................................................................................................................74
6 Maintenance
6.1 Operating material........................................................................................................................................75
6.1.1 Machine lubricants..........................................................................................................................75
6.1.2 Coolants..........................................................................................................................................75
6.2 Safety...........................................................................................................................................................75
6.2.1 Preparation.....................................................................................................................................76
6.2.2 Restarting .......................................................................................................................................76
6.3 Repair...........................................................................................................................................................76
6.3.1 Customer service technician...........................................................................................................76
6.4 Inspection and maintenance ........................................................................................................................78

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6.5 Filling points, operating equipment.............................................................................................................. 80
6.6 Directional arm for oscillation....................................................................................................................... 81
6.7 Hydraulic system ......................................................................................................................................... 83
6.7.1 Inspection and exchange of hydraulic hoses.................................................................................83
6.7.2 Personnel qualified to inspect hydraulic systems...........................................................................83
6.8 Cooling lubricants and tanks........................................................................................................................ 84
6.8.1 Inspection plan for water-mixed cooling lubricants ........................................................................ 85
7 Ersatzteile - Spare parts
7.1 Ersatzteilbestellung - Ordering spare parts ................................................................................................. 86
7.2 Hotline Ersatzteile - Spare parts Hotline...................................................................................................... 86
7.3 Service Hotline............................................................................................................................................. 86
7.4 GT25 - Tischbaugruppe - Table assembly .................................................................................................. 87
7.5 GT25 - Säulenbaugruppe - Column assembly ............................................................................................ 89
7.6 GT25 - Manuelle Längstischbewegung - Manual longitudinal table movement .......................................... 90
7.7 GT25 - Baugruppe Quervorschub - Cross feed assembly........................................................................... 92
7.8 GT25 - Hubeinrichtung - Elevating assembly.............................................................................................. 93
7.9 GT25 - Hydraulikzylinder - Hydraulic cylinder.............................................................................................. 94
7.10 GT25 - Spindeleinheit - Spindle unit............................................................................................................ 96
7.11 GT25 - Hydraulik - Hydraulic ....................................................................................................................... 97
7.12 GT25 - Wegmesssystem - Path measuring system .................................................................................... 98
7.13 GT30 - Tischbaugruppe - Table assembly .................................................................................................. 99
7.14 GT30 - Säulenbaugruppe - Column assembly .......................................................................................... 101
7.15 GT30 - Manuelle Längstischbewegung - Manual longitudinal table movement ........................................ 102
7.16 GT30 - Baugruppe Quervorschub - Cross feed assembly.........................................................................103
7.17 GT30 - Hubeinrichtung - Elevating assembly ............................................................................................ 104
7.18 GT30 - Hydraulikzylinder - Hydraulic cylinder............................................................................................ 105
7.19 GT30 - Spindeleinheit - Spindle unit.......................................................................................................... 107
7.20 GT30 - Hydraulik - Hydraulic ..................................................................................................................... 108
7.21 GT30 - Wegmesssystem - Path measuring system .................................................................................. 109
7.22 GT40 - Tischbaugruppe - Table assembly ................................................................................................ 110
7.23 GT40 - Säulenbaugruppe - Column assembly .......................................................................................... 111
7.24 GT40 - Manueller Längstischvorschub - Table longitudinal manual feed assembly.................................. 112
7.25 GT40 - Baugruppe Quervorschub - Cross feed assembly.........................................................................113
7.26 GT40 - Hubeinrichtung - Elevating assembly ............................................................................................ 114
7.27 GT40 - Hydraulikzylinder - Hydraulic cylinder............................................................................................ 116
7.28 GT40 - Spindeleinheit - Spindle unit.......................................................................................................... 118
7.29 GT40 - Hydraulik - Hydraulic ..................................................................................................................... 119
7.30 GT40 - Wegmesssystem - Path measuring system .................................................................................. 120
7.31 GT25 | GT30 - Schaltplan - Wiring diagram .............................................................................................. 121
7.31.1 Hauptversorgung - Main power.................................................................................................... 121
7.31.2 Motoranschluss - Motor power..................................................................................................... 122
7.31.3 220V Leistungsanschluss - 220V power......................................................................................123
7.31.4 220V Steuerung - 220V control.................................................................................................... 124
7.31.5 Servoantrieb - Servo drive ........................................................................................................... 125
7.31.6 24V DC Steuerung - DC 24V control - 1-2...................................................................................126
7.31.7 24V DC Steuerung - DC 24V control - 2-2...................................................................................127
7.31.8 PLC and HMI................................................................................................................................ 128
7.31.9 PLC Eingang - PLC input - 1-2..................................................................................................... 129
7.31.10 PLC Eingang - PLC input - 2-2..................................................................................................... 130
7.31.11 PLC Ausgang - PLC output - 1-2 ................................................................................................. 131
7.31.12 PLC Ausgang - PLC output - 2-2 ................................................................................................. 132
7.31.13 Anhang elektronisches Handrad - Appendix machine pulse generator....................................... 133
7.31.14 Anhang Klemmendiagramm - Appendix terminal diagram........................................................... 134
7.31.15 Anhang Anschlüsse zum Bedienpanel - Appendix control panel connection .............................. 135
7.31.16 Anhang PLC Eingänge / Ausgänge - Appendix PLC Input / Output ............................................ 136
7.31.17 Anhang Bedienpanel - Appendix control panel............................................................................ 137
7.31.18 Anhang Schaltschrank Einbauorte - Appendix electric cabinet components............................... 138
7.32 GT40 - Schaltplan - Wiring diagram .......................................................................................................... 141
7.32.1 Hauptversorgung - Main power.................................................................................................... 141
7.32.2 Motoranschluss - Motor power..................................................................................................... 142
7.32.3 220V Leistungsanschluss - 220V power......................................................................................143
7.32.4 220V Steuerung - 220V control.................................................................................................... 144

Version 1.0.2 - 2020-09-15 5Translation of original instructions
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7.32.5 Servoantrieb - Servo drive............................................................................................................145
7.32.6 24V DC Steuerung - DC 24V control - 1-2....................................................................................146
7.32.7 24V DC Steuerung - DC 24V control - 2-2....................................................................................147
7.32.8 PLC and HMI ................................................................................................................................148
7.32.9 PLC Eingang - PLC input - 1-2 .....................................................................................................149
7.32.10 PLC Eingang - PLC input - 2-2 .....................................................................................................150
7.32.11 PLC Ausgang - PLC output - 1-2..................................................................................................151
7.32.12 PLC Ausgang - PLC output - 2-2..................................................................................................152
7.32.13 Anhang elektronisches Handrad - Appendix machine pulse generator........................................153
7.32.14 Anhang Bedienpanel - Appendix control panel.............................................................................154
8 Malfunctions
9 Appendix
9.1 Copyright....................................................................................................................................................161
9.2 Changes.....................................................................................................................................................161
9.3 Change information manual .......................................................................................................................161
9.4 Product follow-up........................................................................................................................................161
9.5 Liability claims for defects / warranty..........................................................................................................161
9.6 Storage.......................................................................................................................................................162
9.7 Advice for disposal / Options of re-use.......................................................................................................163
9.7.1 Decommissioning .........................................................................................................................163
9.7.2 Disposal of new device packaging................................................................................................163
9.7.3 Disposal of the machine ...............................................................................................................163
9.7.4 Disposal of electrical and electronic components.........................................................................163
9.7.5 Disposal of lubricants and coolants ..............................................................................................164
9.8 Disposal through municipal collection facilities ..........................................................................................164
9.9 Genauigkeitsbericht - Accuracy report.......................................................................................................165

Version 1.0.2 - 2020-09-156 Translation of original instructions
GT25 | GT30 | GT40
EN
_preface_GB.fm
Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions
and convince by an outstanding price performance ratio. Continuous enhancements and prod-
uct innovations guarantee state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get
familiar with the machine. Please also make sure that all persons operating the machine have
read and understood the operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, opera-
tion and maintenanceof the machine. The continuous observance of all notes included in this
manual guarantee the safety of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information
for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which
the operator must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the
current state of construction of your machine. Being the manufacturer we are continuously
seeking for improvements and renewal of the products. Therefore, changes might be performed
without prior notice. The illustrations of the machine may be different from the illustrations in
these instructions with regard to a few details. However, this does not have any influence on
the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors
are reserved!
Your suggestion with regard to these operating instructions are an important contribution to
optimising our work which we offer to our customers. For any questions or suggestions for
improvement, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are
not able to solve your problem with a help of these operating instructions, please
contact your specialised dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Fax (+49)0951 / 96555 - 888
Email: in[email protected]
Internet: www.optimum-machines.com

Safety
Version 1.0.2 - 2020-09-15 7Translation of original instructions
GT25 | GT30 | GT40 EN
GT25_GT30_GT40_GB_1.fm
1 Safety
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the surface grinding machine,
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operating instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the surface
grinding machine.
Always keep this documentation close to the surface grinding machine.
1.1 Glossary of symbols
provides further instructions
calls on you to act
listings
1.2 Rating plate
GT 25
DE Flächenschleifmaschine
EN Surface grinding machine
FR Rectieuse plane
ES Recticadora
IT Retticatrice
CS Bruska na plocho
DA Overadesliber
EL ΡΕΚΤΙΦΙΕ ΕΠΙΦΑΝΕΙΩΝ
FI Tasohiomakone
HU Síkköszörű gép
NL Vlakslijpmachine
PL Szlierka magnetyczna do
płaszczyzn
PT Recticadora de planos
RO Masina de recticat
RU Плоскошлифовальный станок
SK Bruska na plocho
SL Ploskovni brusilni stroj
SV Planslipmaskin
TR Yüzey Taşlama Makinesi
NO
SN
Year
Netto
2.2 KW
400 V ~50 Hz
2 840 min-1
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland
3111025 1 700 kg
GT 30
DE Flächenschleifmaschine
EN Surface grinding machine
FR Rectieuse plane
ES Recticadora
IT Retticatrice
CS Bruska na plocho
DA Overadesliber
EL ΡΕΚΤΙΦΙΕ ΕΠΙΦΑΝΕΙΩΝ
FI Tasohiomakone
HU Síkköszörű gép
NL Vlakslijpmachine
PL Szlierka magnetyczna do
płaszczyzn
PT Recticadora de planos
RO Masina de recticat
RU Плоскошлифовальный станок
SK Bruska na plocho
SL Ploskovni brusilni stroj
SV Planslipmaskin
TR Yüzey Taşlama Makinesi
NO
SN
Year
Netto
4 KW
400 V ~50 Hz
1 450 min-1
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland
3111030 2 650 kg
GT 40
DE Flächenschleifmaschine
EN Surface grinding machine
FR Rectieuse plane
ES Recticadora
IT Retticatrice
CS Bruska na plocho
DA Overadesliber
EL ΡΕΚΤΙΦΙΕ ΕΠΙΦΑΝΕΙΩΝ
FI Tasohiomakone
HU Síkköszörű gép
NL Vlakslijpmachine
PL Szlierka magnetyczna do
płaszczyzn
PT Recticadora de planos
RO Masina de recticat
RU Плоскошлифовальный станок
SK Bruska na plocho
SL Ploskovni brusilni stroj
SV Planslipmaskin
TR Yüzey Taşlama Makinesi
NO
SN
Year
Netto
4 KW
400 V ~50 Hz
1 450 min-1
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland
3111040 3 250 kg

Safety
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1.3 Safety instructions (warning notes)
1.3.1 Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.3.2 Other pictograms
Symbol Alarm expression Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION! A danger or unsafe procedure that can cause personal injury or damage
to property.
ATTENTION!
Situation that could lead to damage to the surface grinding machine and
the product as well as to other damage.
No risk of injury to persons.
INFORMATION
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
general danger with a warning of injury to hands, hazardous electrical
voltage, Risk of impact, dan- ger of crushing
Activation forbidden! Do not step into the
machine! Do not extinguish with water! Do not clean with compressed air!
Wear safety shoes! Use ear protection! Wear protective glasses! Wear protective gloves!

Safety
Version 1.0.2 - 2020-09-15 9Translation of original instructions
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1.4 Intended use
WARNING!
If the surface grinding machine is not used as intended,
this may result in hazards for personnel,
the surface grinding machine and other material assets of the operator may be
endangered,
the function of the surface grinding machine may be affected.
The surface grinding machine is used exclusively for precision grinding of plane steel work-
pieces. The surface grinding machine must only be installed and operated in a dry and well-
ventilated areas. The machine integrated coolant system is only intended for water-miscible
cooling lubricants.
The surface grinding machine is designed and constructed for use in non-explosive environ-
ments.
If the surface grinding machine is used in any way other than described above, modified without
authorization of Optimum Maschinen Germany GmbH, then the surface grinding machine is
being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire, if any constructive, tech-
nicalor procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
It is also part of intended use that you
comply with the performance limits of the surface grinding machine,
observe the operating instructions,
the inspection and maintenance instructions are observed.
WARNING!
Extremely severe injuries due to non-intended use.
It is forbidden to make any modifications or alternations to the operating parameters
values of the surface grinding machine. They could pose an accident hazard to persons
and cause damage to the surface grinding machine.
1.5 Reasonably foreseeable misuse
Any use other than that specified under "Intended use" or any use beyond that described will be
deemed non-intended use and is not permissible.
Any other use must be discussed with the manufacturer.
Warning: biological hazard! Warning: suspended loads! Warning of oxidizing
substances! Caution, danger of explosive substances!
Warning: danger of
slipping! Protect the environment! Contact address

Safety
Version 1.0.2 - 2020-09-1510 Translation of original instructions
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GT25_GT30_GT40_GB_1.fm
Only metallic, cold and non-flammable materials may be machined with the surface grinding
machine.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning.
Operators must be duly qualified.
1.5.1 Avoiding misuse
INFORMATION
The surface grinding machine with step motor control is built to comply with EMC Class C2 to
EN 61800-3. The control and drive components of the surface grinding machine are approved
for industrial and commercial use in industrial supply networks. Use in public supply networks
requires a different configuration and/or additional measures.
WARNING!
The class C2 (machine tools) is not intended to be used in residential facilities, where
the power is supplied via a public low voltage supply system. In these areas, it may be
difficult to guarantee electromagnetic compatibility due to conducted and emitted
interference.
Regular balancing of the grinding wheel. For this purpose, a balancing device is supplied
with the surface grinding machine.
Adaptation of the oscillating speed and the transverse feed to the material and the work-
piece.
Mount the workpiece firmly and vibration-free on the electromagnet.
Risk of fire and explosion due to the use of flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using inflamma-
ble auxiliary materials (e.g. spirit), you need to take additional preventive measures in order
to avoid health risks.
WARNING!
Risk of breakage of the grinding wheel or workpieces being thrown away.
The magnetizable workpiece must always be attached to the electromagnet in a plane
and fixed manner. Check the secure fastening.
Use cooling and lubricating agents to increase the durability of the grinding wheel and to
improve the surface quality.
Clamping the workpiece on a clean and undamaged clamping surface on the electromag-
net.

Safety
Version 1.0.2 - 2020-09-15 11Translation of original instructions
GT25 | GT30 | GT40 EN
GT25_GT30_GT40_GB_1.fm
Overview of the EMC categories:
Categorie C1
- required limit values Class B Group 1 according to EN 55011
Categorie C2
- Required limit values class A Group 1 according to EN 55011, Installation by EMC expertsand warning:
“This is a product of category C2 according to EN 61800-3. This product may cause radio interference in
a residential area. In this case, it may be necessary for the operator to take appropriate action.“
Categorie C3
- Required limit values class A group 2 according to EN 55011, whereby these limit values are below those
of class A group 1, plus warning: “This type is not suitable for connection to a public low-voltage network
supplying residential buildings. When connecting to a public low voltage network, radio frequency inter-
ference is expected.“
1.6 Dangers that can be caused by the surface grinding machine
The surface grinding machine was tested for operational safety. The construction and type are
state of the art.
Nevertheless, there is still a residual risk, because the surface grinding machine works with
rotating parts,
electrical voltage and currents,
an automatic feed,
a limited NC control.
We have minimized the risk to people's health from these hazards through design and safety
technology.
If the surface grinding machine is operated and maintained by insufficiently qualified personnel,
hazards can arise from the surface grinding machine due to incorrect operation or improper
maintenance.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
and strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
can endanger the surface grinding machine and other material assets,
the functionality of the grinding machine may be compromised.
Always switch off the surface grinding machine and disconnect it from the mains, when clean-
ing or maintenance work is carried out.
This machine
Categorie C1 C2 C3 C4
Environment Residential area Business area
Industrial area Industrial area
Voltage / Current < 1000 V > 1000 V
EMC knowledge no requirement Installation and commissioning by an EMC expert

Safety
Version 1.0.2 - 2020-09-1512 Translation of original instructions
GT25 | GT30 | GT40
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GT25_GT30_GT40_GB_1.fm
WARNING!
The surface grinding machine may only be used with fully functional safety devices.
Disconnect the surface grinding machine immediately, whenever you detect a failure in
the safety devices or when they are not fitted!
All additional parts of the machine which had been added by the customer need to be
equipped with the prescribed safety devices.
This is your responsibility being the operating company!  Safety devices on page 13
1.7 Qualification of personnel
1.7.1 Target group
This manual is addressed to
the operating companies,
operators having sufficient specialist knowledge,
the maintenance personnel.
Consequently, the warning notes refer both to the use of the surface grinding machine and to
its maintenance.
Determine clearly and explicitly who will be responsible for the different activities on the sur-
face grinding machine (operation, setting up, maintenance and repair). Please note the name of
the responsible person into an operators´s log.
INFORMATION
Unclear responsibilities constitute a safety risk!
Always lock the main switch after switching off the surface grinding machine. This will prevent it
from being used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator has been instructed by the operating company regarding the assigned tasks and
possible risks in case of improper behaviour. The user may only carry out tasks that exceed
normal operation if this is stated in these instructions and the operator has explicitly entrusted
him with the task.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys-
tem and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of relevant
regulations, qualified personnel are able to perform the assigned tasks and to independently
recognise and avoid any possible dangers.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.

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1.7.2 Authorized personnel
INFORMATION
Sufficient expertise is required for working on the surface grinding machine. Without the
necessary training, nobody may work on the machine, even for a short time.
WARNING!
Inappropriate operation and maintenance of the surface grinding machine constitutes a
danger for the personnel, objects and the environment.
Only authorized personnel may operate the surface grinding machine!
Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.
Obligations of the operating company
train the personnel,
instruct the personnel in regular intervals (at least once a year) on
- all safety regulations relevant to the surface grinding machine,
- operation of the surface grinding machine,
- generally accepted engineering standards.
- possible emergency situations,
checking the level of knowledge of the personnel,
documentation of the trainings/instructions in an logbook,
require personnel to confirm participation in training/instructions by means of a signature,
checking whether the personnel is working safety and risk-conscious and observes the
operating instructions.
define and document the inspection deadlines for the machine in accordance with the Fac-
tory Safety Act and perform an operational risk analysis in accordance with the Work Safety
Act.
Obligations of the operator
have obtained a training regarding the handling of the surface grinding machine,
keep an operator‘s log,
before taking the machine in operation
- have read and understood the operating manual,
- be familiar with all safety devices and instructions.
Additional requirements apply for work on the following machine components:
Electric components or operating materials: They must only be performed by a qualified
electrician or person working under the instructions and supervision of a qualified electri-
cian.
1.8 Operator positions
The operator position is in front of the surface grinding machine on the control panel.
CAUTION!
Risk of impact and crushing due to the oscillating movement of the table. Pay attention
to people passing the machine by an maximum oscillating speed set and/or protect the
oscillation area with suitable measures.
1.9 Safety devices
The surface grinding machine must only be operated with fully functional safety devices.
Stop the surface grinding machine immediately if there is a failure on the safety device or
becomes ineffective.

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It is your responsibility!
If a safety device has been deactivated or is defective, the surface grinding machine can only
be used again if you
have eliminated the cause of the fault and
you have verified that there is no danger to personnel or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other persons working with the surface grinding machine. The possible
consequences include:
injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
contact with rotating or moving parts,
fatal electrocution,
pulling-in of clothes.
WARNING!
Although the isolating safety devices provided and delivered with the machine are
designed to reduce the risks of coolants, workpieces being ejected or parts of tools,
breaking off grinding wheel or workpieces breaking off, they cannot eliminate these
risks completely. Always work carefully and observe the limit values of the grinding
process.
The surface grinding machine features the following safety devices:
a lockable master switch,
an emergency stop button,
a protective cover on the grinding wheel with position switch
A coolant splash guard around the grinding table.
1.9.1 Lockable master switch
In the "0" position, the lockable master switch can be secured against accidental or non-author-
ised switching on by means of a padlock.
The power supply is interrupted by switching off the master switch.
Except for the areas marked by the pictogram in the margin. In these areas there might be volt-
age, even if the master switch is switched-off.
WARNING!
Dangerous voltage even if the master switch is switched off.
The areas marked by the pictogram might contain live parts, even if the master switch is
switched off.

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1.9.2 Emergency stop button
CAUTION!
Only press the emergency-stop button in a genuine emergency. You may not use the
emergency stop button to stop the machine during normal operation. The life time of the
emergency stop button is not designed for operational shut-down of the machine.
CAUTION!
Depending on the mass moment of inertia the grinding wheel continues to rotate for a
while.
The emergency stop button switches off the control voltage and thus stops the drives. Turn the
knob to the right to unlock and release the emergency stop button.
The emergency stop switch is used to stop the surface grinding machine in an emergency.
After pressing the button, turn the knob of the switch to the right in order to be able to switch the
machine on again via the push button <SB1> , control voltage on.
1.9.3 Control-related safeguarding
WARNING!
If you bypass a control device, you endanger yourself and other people working on the
surface grinding machine.
injuries due to tools, workpieces or fragments hereof which are flying off at high
speed,
contact with rotating parts,
fatal electrocution,
pulling-in of clothes.
If, in exceptional cases (e.g. electrical repairs), you briefly bypass a control device, you must
constantly monitor the surface grinding machine during this time.
1.9.4 Prohibition, warning and mandatory signs
INFORMATION
All warning and mandatory signs must be legible. They must be checked regularly.
1.10 Safety check
Check the surface grinding machine at least once per shift. Inform the person responsible
immediately of any damage, defects or changes in the operating function.
Check all safety devices
at the beginning of each shift (when the machine is operated continuously),
once per day (during one-shift operation),
once per week (when operated occasionally),
after all maintenance and repair work.
Check whether the prohibition, warning and instruction signs and the markings on the surface
grinding machine
are legible (clean them, if necessary)
and complete (replace them, if necessary).
INFORMATION
Organise the checks according to the following table;

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1.11 Personal protective equipment
For certain work, personal protective equipment is required.
Protect your face and your eyes: Wear a safety helmet with facial protection when performing
work where your face and eyes are exposed to hazards.
Wear protective gloves when handling pieces or tools with sharp edges.
Wear safety shoes when you assemble, disassemble or transport heavy components.
Use ear protection if the noise level (emission) in the workplace exceeds 80 dB (A).
Before starting work make sure that the required personnel protective equipment is available at
the work place.
CAUTION!
Dirty or contaminated personnel protective equipment can cause illness. They must be
cleaned after each use and at least once a week.
General check
Equipment Check OK
Protective housing on the grinding
wheel Not damaged and functional
Signs, Markings Installed and legible
Grinding wheel Grinding wheel pulled off ?
Grinding wheel with flange Balanced ?
Date: Checked by (signature):
Functional check
Equipment Check OK
Emergency-stop
push button After actuating the emergency stop switch, the surface grinding machine must switch off.
Protective cover grinding wheel The grinding wheel drive can only be switched on when
the protective cover is closed.
Date: Checked by (signature):

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1.12 Safety during operation
WARNING!
Before switching on the surface grinding machine, make sure that no persons are
endangered and no objects are damaged.
Avoid any unsafe work methods:
The instructions mentioned in these operating instructions have to be strictly observed dur-
ing assembly, operation, maintenance and repair.
Do not work on the surface grinding machine if your ability to concentrate is reduced for any
reason, such as the influence of medication.
Clamp the workpiece securely and firmly on the table using the electromagnet before you
switch on the surface grinder.
During the NC-controlled operation of the surface grinding machine, the operator must not
leave the operator's station.
The surface grinding machine may only be used for grinding metal workpieces. No combus-
tible material or material made of wood or plastic may be used.
Only use personnel with experience in surface grinding to operate and maintain the surface
grinding machine.
The Operating Instructions must be read before using the surface grinding machine for the
first time.
Before the grinding process, check the grinding wheel and its correct direction of rotation.
Let the grinding wheel run freely for about 5 minutes.
Before starting the surface grinding machine, ensure sufficient safety clearance between
the workpiece and the grinding wheel.
The area around the surface grinding machine must be kept clean and dry. Remove waste
and material removal.
Use the electromagnetic clamping device to fix the workpiece, clean the clamping device
before fixing the workpiece, regrind if scratches occur.
Never leave the surface grinding machine unattended during operation. Switch off the sur-
face grinding machine before leaving.
After switching off the spindle motor, let the grinding wheel run out freely. Never brake the
grinding wheel with your hand, the honing device or other objects.
Never readjust the coolant supply during wet grinding. Switch off the coolant supply before
switching off the spindle motor.
1.13 Safety during maintenance
Inform the operators in good time of any maintenance and repair works.
Report all safety-relevant changes to the surface grinding machine or its operating behaviour.
Any changes must be documented, the operating instructions updated and machine operators
instructed accordingly.
1.14 Switching off and securing the surface grinding machine
Switch off the surface grinding machine at the main switch before starting maintenance and
repair work.
Use a padlock to prevent the switch from being turned on without authorization and keep the
key in a safe place.
All machine parts as well as all dangerous voltages are switched off.
Excepted are only the positions which are marked with the adjoining pictogram. These positions
may be live, even if the main switch is switched off.
Attach a warning sign to the surface grinder.

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WARNING!
Live parts and moves of machine parts can injure you or others dangerously!
Take extreme care if you do not switch off
the surface grinding machine by turning off the master switch due to required works
(e.g. functional control).
1.14.1 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension gear that might break under load can
cause severe injuries or even death. Observe the accident prevention regulations issued
by your Employers Liability Insurance Association or other supervisory authorities
responsible for your company.
Check that the lifting and load-suspension equipment are of sufficient load-bearing
capability and are in perfect condition. Fasten the loads carefully. Never walk under
suspended loads!
1.14.2 Mechanical maintenance
Remove or install protection safety devices before starting or after completing any mainte-
nance work; this include:
covers,
safety instructions and warning signs,
grounding cables.
If you remove protective or safety devices, re-fit them immediately after the completing the
work.
Check if they are working properly!
1.15 Accident report
Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses).
There are many possible causes for "near misses".
The sooner they are notified, the quicker the causes can be eliminated.
INFORMATION
We draw your attention to specific hazards when carrying out work with and on the surface
grinding machine in the description of this work.
1.16 Electronics
Have the machine and/or the electric equipment checked regularly. Immediately eliminate all
defects such as loose connections, defective wires, etc.
A second person must be present during work on live components to disconnect the power in
the event of an emergency. Disconnect the machine immediately if there is a malfunction in the
power supply!
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection.
The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,
by a qualified electrician or under the supervision and direction of a qualified electrician,
prior to initial commissioning and after modifications or repairs, prior to recommissioning
and at certain intervals.

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The intervals must be set so that foreseeable defects can be detected in a timely manner, when
they occur.
The relevant electro-technical rules must be followed during the inspection.
The inspection prior to initial commissioning is not required if the operator receives confirma-
tion from the manufacturer or installer that the electrical systems and operating equipment com-
ply with the accident prevention regulations, see conformity declaration.
Permanently installed electrical systems and operating equipment are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements in the scope of operation (e.g. monitoring the insulation resistance).
1.17 Inspection deadlines
Define and document the inspection deadlines for the machine in accordance with § 3 of the
Factory Safety Act and perform an operational risk analysis in accordance with § 6 of the Work
Safety Act. Also use the inspection intervals in the maintenance section as reference values.
1.18 Clamping devices for workpieces and tools
ATTENTION!
Attention when taking over existing clamping devices. Pleased thoroughly check that the
clamping device is appropriate for your surface grinding machine.
Only use clamping devices with a complete inherent rigidity.
After collision damage, consult the manufacturer of the clamping device to obtain
information on possible further use of the clamping device.
Correctly insert the workpiece and make sure that the machine is proper working
condition.
1.19 Environmental protection and water conservation
Your surface grinding machine is a HBV-System according to §19g Water Resources Act (Sys-
tem for the use of water hazardous substances)
When operating, shutting down or dismantling the surface grinding machine or parts thereof,
the requirements of the Water Resources Act (WHG) must be observed. Detailed information
regarding this can be found in the Ordinance on Installations for the Handling of Substances
Hazardous to Water (VAwS).
1.20 Hydraulic system
The system is under a pressure of up to 10 MPa (100 bar). The hydraulic system is used for
table movement to the left and right.
WARNING!
Serious injuries from hydraulic liquid escaping under high pressure!
Possible loss of the eyesight!
Make sure that the hydraulic system is depressurised before opening a component or a
pipe. Wear protective goggles and protective clothing when working on the hydraulic
system.
The hydraulic system might still be under pressure, even after the central power supply
of the machine is switched off.
If you have got hydraulic fluid in your eyes, rinse them immediately with plenty of water.
Immediately seek medical assistance.

Technical data
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2 Technical data
GT25 GT30 GT40
Surface grinding table
Table length x width 254 x 508 mm 305 x 635 mm 406 x 813 mm
T - slot size / number 14 mm / 1 14 mm / 1 14 mm / 3
Electric magnetic clamping plate 250 x 500 mm 300 x 600 mm 400 x 800 mm
max. load grinding table including
electro-magnetic clamping plate 180 kg 270 kg 500 kg
max. workpiece size 508 x 254 x 350 mm 635 x 305 x 405 mm 813 x 406 x 405 mm
maximum distance
spindle center - grinding table 450 mm 580 mm 580 mm
Oscillation speed of the table 5 - 25 m/min 5 - 25 m/min 5 - 25 m/min
Maximum oscillation in X axis 560 mm 765 mm 830 mm
Maximum travel in Y axis 275 mm 340 mm 420 mm
step less cross feed (Y axis) 0.1 - 8 mm 0.1 - 8 mm 0.1 - 8 mm
Rapid traverse adjustment in the
Y axis
990 mm/min 990 mm/min 990 mm/min
Scale division on handwheel 0.02 mm 0.02 mm 0.02 mm
Step widths of the rapid traverse
feed in
Z axis
0,005 | 0,01 | 0,02 | 0,03 |
0,04 | 0,05 0,005 | 0,01 | 0,02 | 0,03 | 0,04 | 0,05 0,005 | 0,01 | 0,02 | 0,03 | 0,04 | 0,05
Rapid traverse adjustment in the Z
axis 480 mm/min 480 mm/min 480 mm/min
Scale division on handwheel 0.005 mm 0.005 mm 0.005 mm
Constant spindle speed at ~50Hz
connection 2850 rpm 1450 rpm 1450 rpm
Constant spindle speed at ~60Hz
connection 3450 rpm 1750 rpm 1750 rpm
Grinding wheel peripheral speed
at ~50 Hz connection 33 m/s 27 m/s 27 m/s
Grinding wheel peripheral speed
at ~60 Hz connection 37 m/s 32 m/s 32 m/s
Size of the grinding wheel Ø 200 x 20mm , shaft Ø
31.75 Ø 350 x 40 , shaft Ø 127 mm Ø 350 x 40mm , shaft Ø 127
Grain size of the grinding wheel 46 46 46
Type of grinding wheel Corundum grinding wheel
Coolant tank capacity 0.052 m30.1 m30.1 m3
Coolant pump
Delivery height
Flow rate
70 W
4m
11 l/min
90 W
5m
33 l/min
90 W
5m
33 l/min
Hydraulic motor 0.75 kW 2.2 kW 2.2 kW
X
Y
Z