Trelawny TPG650 Troubleshooting guide

OPERATION & MAINTENANCE
TPG650
PLANETARY FLOOR GRINDER

OPERATION
Foreword
Thank you for your purchase of the
TRELAWNY TPG650 Floor Grin er.
This manual contains the necessary
maintenance information for you to
ensure proper operation an care for
this machine.
It is essential or you to read
t h r o u g h t h e s e m a n u a l s
thoroughly.
In the unlikely event that you
experience problems with your
TPG650, please o not hesitate to
contact your local Trelawny ealer or
agent. W e a lwa ys welcom e
fee back an comments from our
value customers.
General In ormation
Before operating, perf orming
maintenance or repairing the
TPG650 FLOOR GRINDER this
m anua l m us t be rea an
un erstoo by the operator, if in any
oubt, ask your supervisor before
using this equipment.
Local safety regulations must be
followe at all times. Failure to follow
these instructions coul result in
amage to the TPG650 an /or
personal injury.
Trelawny SPT Limite isclaims all
responsibility for amage to persons
or objects arising as a consequence
of incorrect han ling of the machine,
failure to inspect the machine for
amage or other faults that may
influence the operation prior to
starting work, or failure to follow the
safety regulations liste or applicable
to the job site.
This machine is primarily esigne
for the smoothing of concrete,
marble an terrazzo surfaces.
It can be use both in oors an out.
This machine must not be use in a
fixture.
Sa ety
WEAR SAFETY BOOTS, FACE
MASK, SHATTERPROOF
GLASSES, HELMET, GLOVES an
any other personal protective
equipment require for the working
con itions. Avoi loose clothing; this
may become trappe in moving
parts an cause serious injury.
TO AVOID NUISANCE DUST,
connect an in ustrial vacuum
cleaner (minimum 3000 watts or
equivalent) to the 50mm (2”) vacuum
port situate at the rear of the
machine.
BE VERY CAREFUL WITH HOT
COMPONENTS.
The segments an tool hea s can
get very hot in use. Always use
gloves when changing or replacing
the grin ing segments.
DO NOT OPERATE ELECTRIC
VERSIONS IN WET CONDITIONS.
CAUTION THIS MACHINE IS
HEAVY. It weighs (260kg/573lbs).
Do not lift this machine manually,
use a hoist or crane with the grin er
securely fastene to a pallet.
Risk o Hand-arm
Vibration injury
These tools may cause Han -arm
Vibration Syn rome injury if their use
is not a equately manage .
Although the vibration from this
machine is low, we a vise you to
carry out a risk assessment an to
implement measures such as;
limiting exposure time [i.e. actual
operation time, not total time at
work].
Use job rotation an ensure the tools
are use correctly, ensuring the tools
are maintaine accor ing to our
recommen ations, an ensure that
the operators wear personal
p r o te c t iv e e q u i pm e n t [ P P E ]
particularly gloves an clothing to
keep them warm an ry.
Employers shoul consi er setting
up a programm e of health
su r ve i l lan c e to es ta bl i s h a
benchmark for each operator an to
etect early symptoms of vibration
injury.
We are not aware of any PPE that
provi es protection against vibration
injury by attenuating vibration
emissions.
See ‘Speci ications’ section or
vibration emission data.
Further a vice is available from our
Technical Department.
We strongly a vise you to visit the
Health & Safety Executive website
http://www.hse.gov.uk/vibration
This site provi es excellent a vice
an information on HAV an
currently, inclu es a Han -arm
Vibration Exposure Calculator that is
easy to use to work out the aily
vibration exposure for each of your
operators.
Media Types &
Application Guide
Grinding Segments
All the XP an HP Range can be
use wet or ry.
XP1, XP2 Segments.
(Soft bon e iamon (Concrete))
Generally use for har material,
granite, cure concrete or terrazzo.
XP2, XP3 Segments.
(Har bon e iamon (Asphalt))
Generally use for me ium to soft or
m o r e a b r a s i v e m a t e r i a l s
(i.e. green concrete less than 48hrs
ol ) an me ium strength concrete,
asphalt or a hesives.
XP4, XP6 Segments.
Generally use on terrazzo after
using XP1 - XP3
(Baracuda™)
Generally this special segment is
use for removing a hesive or heavy
coatings an is available in a heavy
uty (Max) or a light uty (Light).
The “Light” is i eal for the quick
removal of extremely har coatings.
The “Max” can be use for the
flattening of uneven concrete or for
the removal of asphalt topping.
(Resin bound polishing discs)
PD400, PD800, PD1500 an
PD3000.
Universal polishing iscs, wet
application only.
Generally use on terrazzo an
concrete floors.
(See page 4 for more information)

Media Types
Barracu a ™ Max
(-L or -R) on H-Plate
Quick removal of a hesive an coatings.
Flattening of bumpy concrete surface. Removal of
asphalt topping.
Barracu a ™ Light
(-L or -R) on H-Plate
Quick removal of a hesive an coatings.
Removal of extremely har coatings. Perfect for
light machines. (Less than 10kg).
XP1 (Soft Bon )
30/40 grit
For extremely har concrete. First step grin ing an
levelling of slightly rough or uneven concrete floors.
XP2 (Normal Bon )
30/40 grit
Universal.
First step grin ing an levelling of slightly rough or
uneven concrete floors.
XP3 (Har Bon )
30/40 grit
For new an soft concrete. First step grin ing an
levelling of slightly rough or uneven concrete floors.
XP4 - 50/60 grit
XP6 - 60/70 grit
(Terrazzo)
Step 2 grin ing to remove the scratches after using
XP-1 or XP-3.
HP10 - 100 grit
Universal.
Grin ing an polishing of concrete floor after using
XP-6
HP15 - 150 grit
Universal.
Grin ing an polishing of concrete floor after using
XP-6
HP20 - 200 grit Universal.
Wet grin ing is recommen e .
HP30 - 300 grit Universal.
Wet grin ing is recommen e .
HP40 - 400 grit
HP60 - 600 grit
Universal. Wet grin ing is recommen e .
Universal. Wet grin ing is recommen e .
365.5495
365.5496
365.5501
365.5502
365.5503
365.5504
365.5506
365.5510
365.5515
365.5520
365.5530
365.5540
365.5560
XL-400
400 grit, universal, wet application.
Polishing of terrazzo/concrete floor after using
HP-40 or HP-60
XL-800 800 grit, universal, wet application.
Polishing of terrazzo/concrete floor after using PD-400
XL-1500 1500 grit, universal, wet application.
Polishing of terrazzo/concrete floor after using PD-800
XL-3000 3000 grit, universal, wet application.
Polishing of terrazzo/concrete floor after using PD-1500
365.5604
365.5608
365.5618
365.5630
365.5602 XL-200
200 grit, universal, wet application.
Polishing of terrazzo/concrete floor after using
HP-30 or HP-40
Polishing Discs
Professional resin boun iamon -polishing iscs.

Maintenance
To start the machine, hol the
“Hol to run lever” against the
han le bar, ensure that you have a
soli stance then press the green
start button.
A just the spee as require
continue to hol the “hol to run”
lever against the han le bar.
The machine may oscillate slightly
uring use, which is normal.
Move the machine slowly backwar s
an forwar s an overlap each strip
by 10cm (4”), complete a small area
noting the performance.
Release the ‘hol to run’ lever to
stop the machine an inspect the
finish pro uce .
If require change the gra e of the
iamon segments or spee of
rotation, recheck performance an
surface finish.
: EMERGENCY SHUTDOWN :
Release the “Hol to run lever”
on the han le bar.
Pre-Start Check
ALL VERSIONS
Check all bolts an screws for
tightness. Ensure that all fittings are
secure.
The TPG650 is supplie with a
specially commissione frequency
inverter, starter switch an electric
motor.
Each unit is fully teste an the
overloa relays have been calibrate
a n s e t a c c or i n g t o t h e
manufactures specifications.
In the event of malfunction on a new
machine, the owner shoul first
check that the power supply on site
is suitable an a equate.
All cables must be fully uncoile an
never left wrappe aroun cable
reels or tie in loops.
415v Motor
Take particular care when using
415v Machines, ensure that the
electrical supply is earthe an that
breakers an fuses are correct for
the loa ing.
The 415v motor requires a minimum
of a 16amp, 380v power supply.
Always use the shortest possible
length of extension cable. To avoi
voltage rop the cable must have a
minimum core wire size of 2.5mm
2
cross-section area.
Maximum length of cable 30 meters.
Starting
Check over the whole area to be
worke .
It is important to check the area to
ensure that there are no obstacles or
protrusions that will amage the
machine or the segments.
This is a “flat” surface grin er.
If the surface is very bumpy or
uneven, use the Trelawny TFP200
or TFP250 Floor Planer to level the
floor first, before starting to use the
TPG650.
Ensure that the machine is starte
on a level surface.
Machine Operation
Connect a suitable commercial
vacuum which has been esigne
for the collection of concrete ust
an possibly toxic paint particles,
Trelawny can supply special HEPA
filtere vacuums suitable for these
applications.
For wet grin ing, fill the reservoir
with approximately 40 litres of water.
When filling, ensure that no water
splashes onto any electrical
components.
On the frame below the tank, there is
a valve to regulate the flow of water.
Control Box
The green ‘START’ button operates
a soft start circuit an is the only way
to start the machine.
Use the re ‘STOP’ button or release
the ‘Hol to run lever’ to stop the
machine.
When changing the irection of
rotation, be sure to let the machine
completely stop before changing
irection.
Be careful with
HOT COMPONENTS.
The iscs an iamon segments are
hot uring an for some time after
operation.
Do not touch them until they have
coole own.
Important:
If using the Barracu a™ inserts
ensure that the irection of rotation
is set to FORWARD - “FOR”.
These special inserts shoul only be
use in the forwar rotation
irection.
Use the spee regulator to a just the
grin ing hea spee .
Rotary irection switch,
“FOR” - Forwar .
“OFF”.
“REV” - Reverse.

Maintenance
Carefully tilt the machine backwar s
to rest on its han le bar.
Place a heavy object (10kg san
bag, etc.) across the upper part of
the han le bar or rope own for
a itional security.
Remove the ust cover rubber ring
(Velcro fit)
Remove any buil up of material
from aroun the grin ing isc, the
hol ing pins, springs an nuts.
Push own on one of the hol ing
pins nuts by han an rotate the pin
90 eg, repeat with the two pins.
Remove the isc.
Note that the centres of the iscs are
ifferent epen ing on the irection
the iscs rotate:-
(Flower Part No 365.5710)
(Triangle Part No 365.5720)
Remove the three star screws
retaining each of the segments to
the isc.
(Torx or TX male (size 30 bit))
Replacement is the reverse of
stripping, the segments are han e
an cannot be fitte the wrong way
roun .
Tighten the segment screws initially
by han , finally tighten using a
wrench, o not over tighten.
Refit the grin ing iscs, these can
only be fitte onto the correct hub.
Push own on one of the hol ing
pins nuts by han an rotate the pin
90 eg, repeat with the two pins.
Ensure that the pin has locate into
its recess, an that the isc is
secure.
Repeat with the other iscs.
Remove the weight from the han le
bar an /or remove the security rope.
Carefully return the machine to its
upright position an move the han le
bar to is normal working position an
secure with the two pins.
Re-a just the ust cover rubber ring.
Shut Down
Simply release the “hol to run”
lever.
After the machine has completely
coole , clean off any concrete ust
from external components an
remove any heavy buil up of
concrete ust from insi e the front
ust skirt.
Take care when using hoses or
pressure washers an clean within
the ust skirt area only.
Do not hose own any of the
external surfaces.
Do not to allow water to be irecte
at or splashe onto the electric
motor or any of the electrical
components.
Once clean an ry, cover the
machine to protect it an store the
grin er in a ry place.
Grinding Segment
Replacement
Switch off the machine an allow the
grin ing hea segments to cool
completely, isconnect machine
from its power supply.
IMPORTANT
Do not use a mix of ol an new
grin ing segments, this will cause
rapi wear of the new segments an
coul cause the machine to become
unc ontr ollable, unst able an
angerous in use.
Drain all water from the tank.
Place the machine on a flat an level
surface.
Remove the a itional weight from
the machine if fitte .
Remove the retaining pin from the
han le bar height a justment pin
an raise the han le bar to a near
upright position (vertical).
Replace the a justment pin an
secure with the retaining pin.
Machine Storage
Long period storage:
over 3months
Allow the machine to cool
completely.
Clean outsi e of machine.
Remove any buil up of material
from insi e of grin ing isc area.
Inspect the grin ing segments for
wear; replace any worn parts as
require .
Ensure that the machine is
completely ry.
Cover the machine to protect it.
Store the machine in a ry place.

FAULT CAUSE
Machine oes not start. Check that the stop button on the control panel is in the up position.
Check the electricity connections between the machine an the electricity supply is
secure.
Check that the fuse(s) at the mains outlet haven’t blown.
Check that the circuit breaker switches insi e the electric box are in the “on” position.
Check the connections between the frequency controller an the motor.
Machine stops. Check that the circuit breaker switches insi e the electric box are in the “on” position.
Check that the cable isn't warm. If so, check wire iameter section is correct.
Check if there is a signal of failure on the screen of the frequency converter (See below).
Grin er is slow or erratic. Check for heavy buil up of irt on the grin ing isk.
Check that the segments are not worn own an that they are securely fixe to the isk.
The grin ing iscs turn, but
the main isc is stationary. The top belt has broken, contact your nearest reseller.
The motor runs but nothing
turns un erneath. The main belt has broken, contact your nearest reseller.
If problem has not been cure by any of the above actions, contact your local Trelawny SPT ealership for assistance.
Fault Finding
FREQUENCY CONVERTER
MONITOR ERROR CODES
Do not investigate any electrical problem on this machine unless you are a
quali ied electrician, a separate manual is available or this control box.

TECHNICAL SPECIFICATIONS
(k) ** Equals the factor of uncertainty, which allows for variations in measurement an pro uction. Vibration Data figures are tri-axial, which gives the
total vibration emission. Because of various factors, the range of vibration from these tools may vary 1.6m/s
2
& 5m/s
2
. The vibration is epen ent on
the task, the operators grip an power source etc.
NOTE: The above vibration levels were obtaine from tri-axial measurements to comply with the requirements of “The Control of Vibration at Work
Regulations 2005*” an the revisions to the (8662) now EN ISO 28927 an EN ISO 20643 series of stan ar s. These values are at least 1.4 times
larger than the values obtaine from single axis measurements.
*Base on European Union Council Directive 2002/44/EC (Physical Agents (Vibration) Directive)
This tool has been esigne an pro uce in accor ance with the following irectives:
2006/42/EC Machinery Directive
73/23/EC Low Voltage Directive
If your company has any problem with our pro ucts or woul like to iscuss the possibility of an improvement being ma e to them, then please o not
hesitate to contact us. Your comments are both important an appreciate .
Trelawny SPT Lt
Trelawny House, 13 High own Roa , Sy enham In ustrial Estate, Leamington Spa, Warwickshire,
CV31 1XT, Unite King om
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.trelawnyspt.com
© TSPT UK 2009 Part No: 735.6650 issue 2
SURFACE PREPARATION TECHNOLOGY
All rights reserve . Any unauthorise use or copying of the contents or part thereof is prohibite .
This applies to tra emarks, mo el enominations, part numbers an rawings.
Use only genuine Trelawny spares.
The use o non-Trelawny spare parts invalidates the warranty.
Height (Han le in working position) 83mm(Lower) & 108mm(Higher) 32.5”(Lower) & 42.5”(Higher)
Height (Han le in raise position) 1920 mm 75.6”
Wi th 700 mm 27.5”
Length 1220 mm 48”
Cutting wi th 650 mm 25.5 inch
Average epth of cut ( epen ent on concrete) 1 mm
Disc rpm (Variable) 300 to 1400 rpm
Working istance from wall 40 mm 1.58”
Water tank capacity 40 litres (8.5 galls)
Weight 260kg 573lbs
Electric Motor
Dual voltage 7.5kW 400v 50/60hz
Noise L
wA
SWL 93.5 B (A)
Vibration (AEQ) at the Han le Bar
Noise level measure in accor ance with EN ISO 15744: 1999
Vibration measure in accor ance with EN ISO 28927
EN ISO 20643
a=1.6 m/s
2
(K= +40% -0%)