Husqvarna PG820 User's Manual
Contents
1. 6B CFR K Husgvarna Operator s manual Please read the operator s manual carefully and make sure you understand the instructions before using the machine Manual de Husqvarna instruccio RR y asegurese de PG 8 8 O entender su contenido antes de utilizar la maguina Bedienungsanweisung PG820 Lesen Sie die Bedienungsanweisung sorgfaltig durch und machen Sie sich mit dem Inhalt vertraut bevor Sie das Gerat benutzen Manuel d utilisation Lire attentivement et bien assimiler le manuel d utilisation avant d utiliser la machine GB ES DE FR HUSQVARNA CONSTRUCTION PRODUCTS Contents English Contents Key to symbols 4 Safety Instructions 6 Introduction 7 Transport 7 Storage 7 What is what 8 Setting up Operation 10 Changing the diamonds 12 Variable speed drives frequency converters 13 Faults and trouble shooting 16 Diamonds 18 Diamond selection 19 Maintenance 23 Maintenance schedule 27 Technical data 28 English 3 Key to symbols Key to symbols The symbols below are used on the machine and in this Operator s Manual It is important that the user understands the significance of these in order to work with the machine safely Please read the operator s manual carefully and make sure you under stand the instructions before using the machine WARNING Dust forms when grinding which can cause injuries if inhaled Use an approved breathing mask Always provide for g2. pressive strength rating the harder the concrete and therefore the harder it will be to grind However other factors beside compressive strength ratings determine how hard the floor will be and therefore the correct diamond selection Since grind ing normally only deals with the surface of the concrete top 5mm or 1 4 inch often the way the concrete floor has been finished or the condition of the surface will have a greater bearing on what type of diamond to select rather than the compressive strength rating of the concrete SURFACE FACTORS TO CONSIDER WHEN MAK ING A DIAMOND SELECTION Generally speaking if a concrete surface is very smooth i e Most likely it has been heavily trowelled helicoptered the concrete will behave as if ithas a high compressive strength and therefore require a soft bond segment Accordingly if a concrete surface is coarse aggressive e g rain damaged shot blasted scarified exposed aggregate e t c the concrete will behave as if ithas a low compressive strength and therefore require a hard bond segment Surface coatings contaminants e g Epoxy coatings ceramic tile adhesives levelling compounds screeds will often have a larger bearing on what diamond to se lect than will the compressive strength of the concrete As a general rule when grinding a concrete slab for the first time and you are unsure about its hardness always begin with harder bond diamonds under the machine Thi
3. are tight pound if required Suggested thread locking compound Loctite 680 Inspect heads for slop Examine machine heads while machine tipped back Daily broken fingers if using Disconnect Planetary Drive motor small motor and run spring steel heads discs at lowest speed Check to see how concentric true grinding heads are running Check effectiveness of Remove planetary head motor gearbox system and Weekly planetary seal check for presence of dust under machine cover Check condition of Remove planetary head motor gearbox system and in Weekly with Planetary Seal chain ring spect chain links in chain ring Ensure links are clean and free from build up Check condition of Remove planetary head motor gearbox system and Weekly with Planetary Seal Drive Sprocket inspect condition of planetary drive sprocket Inspect internal compo Remove belt tensioner cover plate and check inside 6 monthly nents of machine machine for dust moisture or belt fragments Ensure to re seal cover plate with silicone sealant Clean contents of elec Blow out inside of electrical cabinet and variable speed Every 2 months trical cabinet drives or frequency converters with DRY compressed air IMOPRTANT Prior to removing belt tensioner cover plate ensure cover plate and area surrounding cover plate are totally clean Avoid debris from enter ing into inside of machine English 27 Technical Data Grinding width Grinding
4. Drive Technol ogy system is the planetary head drive system which is powered by the secondary or small motor and gearbox arrangement This system is on the outside of the machine and will require routine maintenance The planetary drive system can be seen as illustrated diagram 1 Diagram 1 Grinding heads motor Motor terminal box Machine cover Gearbox mounting bracket Gearbox flange bracket Gearbox Motor terminal box CON OO fF C0 PN a Planetary drive motor 1 Diagram 1 Planetary Drive System Beneath the gearbox and concealed by the mounting brackets and machine cover there is a planetary drive sprocket situated on the output shaft of the gearbox This planetary sprocket engages with the chain ring also located beneath the machine cover and together form the main drive mechanism for the plan etary drive system This system is a dry system i e it is not required for there to be lubrication between the planetary drive sprocket and chain ring to allow any dust that may come into contact with the chain ring to fall back out again IMOPRTANT AN Lubrication of this system will cause dust to build up in chain ring and drastically shorten the life of both the chain ring and planetary drive sprocket Diagram 2 Diagram 3 1 Planetary drive sprocket 2 Gearbox flange bracket Diagram 3 1 Machine cover 2 Chain ring Diagram 4 1 Planetary seal As the chain ring a
5. on soft floors The opposite will occur when decreasing the number of segments under the machine WET AND DRY GRINDING When using diamond segments wet the following principles apply e Production rates will be higher than dry grinding e Diamond segments will wear faster due to pres ence of slurry and therefore harder bonds can be used when comparing with dry grinding e Scratches from diamond grit will be deeper When using diamond segments dry the following prin ciples apply e Production rates will be slower on harder materials than if wet grinding e Softer bond segments will be required in order to encourage segment wear as there will be not slurry to help diamond segments to wear e Scratches from diamond grit will not be as deep compared to if it were also used for wet grinding e There will be more heat generated by the diamond segment Summary of diamond principles Diamond segmenis need to wear in order to achieve productivity Diamond segment wear can be influenced by the following factors e Pressure e Hardness of bond e Diamond grit size e Presence of water e Number of segments under the machine e Adding an additional abrasive e g sand silicone carbide on the floor will increase wear o Diamondselecton Full set of single segments Full set of twin segments Generally speaking the faster a diamond segment wears the faster the productivity will be By
6. Y STOP button is pressed it shuts down the drive frequency converter Frequently powering up and down of the drive frequency converter will reduce the life span of the drive frequency converter IMPORTANT Planetary head and grinding heads are set to both turn in the same direction i e both in clockwise rotation or both in counter clock wise rotation Clockwise rotation of speed control will in crease speed of planetary head and grinding heads Grinding satellite heads Dust extraction port Planetary head Control panel English 9 Setting up Operation Setting up Operation Position grinder on the working area Make sure there are diamonds underneath machine and that the head locks shear pins are tight IMPORTANT When using the machine each grinding head must always have the same diamond type and number of diamonds as the other grind ing heads Each grinding head must have diamonds the same height as the other grind ing heads Adjust rubber skirt so that a good seal is established between the floor and head of machine see picture below Ensure join in skirt is at the front of the ma chine Setting of the skirt is essential to obtain good dust extraction and eliminate the possibility of airborne dust when dry grinding Set handle to most comfortable working height using adjustment lever IMPORTANT L V It is recommended that this height be set as close as possible to th
7. amonds As different applications require different selections of diamond tools there will be many occasions when the grinding discs need to be changed Following is a guide for this procedure Preparation 1 Ensure STOP RUN switch is in STOP position as unintentional starting of machine while changing discs can result in serious injury 2 Have a set of gloves ready as diamonds can get very hot during dry grinding applications Changing 1 Set handle in upright position illustrated right 2 Pull back on handle to lift grinding head off the ground 4 Lay machine back on the ground 5 Put on gloves 6 Remove grinding disc by slightly rotating disc and then pull off direction that the discs will need to be ro tated will depend on the direction the machine was last running 7 Check to ensure all head locks shear pins are tight 8 Once new diamonds have been attached reverse procedure to lower machine to ground 9 AS new diamonds may be a different height to set being previously used re adjust skirt to ensure good seal is established with the floor 12 English Variable speed drives freguency converters Variable speed drives frequency converters Each Husqvarna PG 680 amp 820 is equipped with 2 variable speed drive or frequency converter This unit is incorporated into the machine for the following reasons 1 Functional e Manipulate incoming power to enable increase decr
8. and stability The head mate is situated above the head plate and is held in place by a series of holes head pin holes 1 Head plate 2 Head pins 1 Head mate 2 Head pin hole Between the head plate and head mate are 3 white silicone springs which give shock absorption and flex ibility in the system The head pins are able to move within the head pin holes creating a shock absorber type system similar to that in most motor vehicles Over an extended period of time the head pin holes wear open Along with this the head pins wear and reduce in diameter This combined wearing of the two creates excessive movement or slop within the grind ing heads This slop will eventually cause vibration whilst the machine is operating Routine checks for slop in the grinding heads are recommended Life expectancy for grinding heads can vary between 6 and 12 months depending on amount of usage Replacement heads are available and simply bolt into place when the old ones are removed English 23 Maintenance Spring Steel Heads The below diagrams illustrate the main parts comprising this type of grinding head Diagram 1 1 Spring steel spring 2 Head plate 3 Cushion ring 4 Head mate Diagram 1 Spring Steel Head Diagram 2 Spring steel springs Bolts Silicone spring Head mate Cushion ring Head buddy Spacers Head plate CON O G fF C0 PN 24 English Between the
9. ble speed drives Ensure the chassis or frame section of the machine is secured down at all times when in transit The machine should always be transported under cover limiting the exposed to natural elements in particular rain and snow IMPORTANT The machine should not be lifted by handle motor chassis or other parts Transportation of the machine is best done on a pallet skid to which the machine must be firmly secured Do not attempt to slide the tines forks from a fork lift under grinding heads unless on a pallet skid Failure to do so can cause irrepa rable damage to grinding heads of machine and internal parts It is recommended that machinery be transported with a set of diamonds attached at all times to ensure pro tection of locking mechanism for diamond plates Storage The machine should always be stored in a dry place when not in use English What is what What is what 1 Hour counter 8 Chassis Frame 2 Electrical cabinet 9 Handle bars 3 Planetary head motor 1 5kW 1Hp 10 Control Panel 4 Grinding Satellite heads motor 11kW 15Hp 11 Handle bar adjuster 5 Lifting lugs 6 Cover Shroud 7 Skirt 8 English What is what The machine can be divided into two main parts These can be identified as follows 1 Chassis Frame section comprising handle bars electrical cabinet steel frame and wheels 2 Head comprising of motors cover grinding satel lite planetar
10. disc Weight Grinding pressure total Grinding pressure per disc Motor Power Power per grinding disc Grinding disc speed Planetary head speed Direction of rotation Power supply 28 English Technical Data PG 820 820mm 32 3x270mm 10 5 440kg 970lbs 335kg 737lbs 112kg 246lbs 3 Phase 380 480V 12 5kW 17 0hp 4 15kW 5 7hp 250 1100rpm 5 65rpm PG 680 680mm 27 3x240mm 9 5 385kg 850lbs 300kg 660lbs 100kg 220lbs 3 Phase 380 480V 12 5kW 17 0hp 4 15kW 5 7hp 600 1200rpm 5 Orpm Independent FWD REV direction control on both grinding discs and planetary head 3 phase 3 phase Technical Data EC declaration of conformity Applies to Europe only Husqvarna Construction Products SE 433 81 G teborg Sweden tel 46 31 949000 declares under sole responsibil ity that the Husqvarna PG680 PG820 dating from 2007 serial numbers and onwards the year is clearly stated on the rating plate followed by the serial number complies with the requirements of the COUNCILIS DIRECTIVE of June 22 1998 relating to machinery 98 37 EC annex IIA of May 3 1989 relating to electromagnetic compatibility 89 336 EEC and applicable supplements of December 12 2006 relating to electrical equipment 2006 95 EC The following standards have been applied EN 55014 1 EN55014 2 EN61000 3 2 EN61000 3 3 The supplied machine conforms to the exa
11. e Fault Code Possible Cause Action o 1 OVERCURRENT Motor being worked too hard and Check current being drawn when machine is drawing extra current running Reduce speed setting and current draw back into acceptable limits as described on previous page Short circuit on output side of vari Check wiring in plugs connected to motor cables able speed drives or frequency con or inside connection boxes on motors verters ni Motor failure very rare Have motor tested and replace if reguired 3 EARTH FAULT Short circuit on output side of vari Check wiring in plugs connected to motor cables able speed drives or frequency con or inside connection boxes on motors verters IN Motor failure very rare Have motor tested and replace if reguired 9 UNDERVOLTAGE Insufficient voltage supply to ma Check power supply and ensure correct voltage chine Power supply to variable speed Re connect power to grinder drives or frequency converters has been turned off 11 OUTPUT PHASE Short circuit on output side of vari Check wiring in plugs connected to motor cables SUPERVISION able speed drives or frequency con or inside connection boxes on motors verters Ni Motor failure very rare Have motor tested and replace if reguired 14 UNIT OVER TEM Variable speed drives or freguency Open door on electrical cabinet to increase ven PERATURE converter over temperature due to tilation Have variable speed drives or frequency hi
12. e height of the opera tor s hip bone When the machine is running there will be a grinding force pull to one side that can be felt through the handlebars Use the hip to resist this force instead of trying to control this through the arms such position ing will be much easier for the operator using the machine over prolonged periods of tim 10 English Powering up machine i Ensure the STOP RUN switch is set on Stop rotate counter clockwise ii Plug power supply to machine Only turn power on at switch once fully connected iii Disengage Emergency Stop button twist clock wise iv Depress Power button On doing so a soft clunk should be heard to come from within the electrical cab inet This indicates the line contactors have engaged supplying power to the drives frequency converters Setting Speed and direction On the control panel there is a FORWARD REVERSE and Speed dial knob Generally when starting the machine for the first time on any given application it is advised the speed setting should not exceed 7 initially When the operator is comfortable with the application speed may be increased Setting up Operation Speed and direction setting is often a matter of per sonal choice Operators are encouraged to experiment to find which settings best suit the given applications The following table lists some suggested set ups for different applications Application Ceramic tile adhesiv
13. e removal Carpet glue removal Epoxy paint removal Rain damaged concrete Smoothen exposed aggregate Lippage removal in terrazzo stone tiles Concrete polishing with resin bond pads PIRANHA scraper tool FLEXOR flexible heads Bushhammer Scarrifier tools Re grouting procedure during HiPERFLOOR process IMPORTANT In the above table FWD amp FWD are listed together to indicate direction settings in the same direction i e It can also be REV REV The only application where direction set tings must be in the same directions and also direction specific is when using the PIRA NHA scraper tools In this particular ap plication the setting must be in the REV REV direction Direction of rotation The correlation between FWD REV amp Clockwise Coun ter clockwise rotation can be said as follows if looking at the grinding discs from underneath the machine 1 REV Clockwise 2 EFWD Reverse As mentioned when the machine is in operation it will pull to one side The direction of pull is determined by the planetary head direction of rotation The head of the machine will pull to the right and therefore will be felt on the right hip of the operator when the planetary head is set in the REVERSE direction This sideways pull can be very useful when grinding particularly along a wall Set the machine so that it pulls towards the wall and then control the machine so it can just touch the wall This will ens
14. ease in speed 8 direction change e Regulate current and voltage supply to the motors to ensure motors run at optimum levels e g torque boost 2 Protection Diagnostic Protection e Monitors incoming power to ensure suitability for machine and application being performed e Controls current being drawn by motors to ensure motors are running within safe operational limits to prevent damage to motor e Monitors load on machine to ensure the grinder is not being overloaded thus offering protection for belt bearings and other internal components e Protects motors from faulty power supply e g run ning on 2 phases Diagnostic Identifies electrical faults with the machine and registers fault code e Has monitoring menus that help isolate cause of potential electrical faults e Monitoring menus also enable operator to gauge how hard machine is working Whilst it is not essen tial for an operator to intimately know every feature of the variable speed drives or frequency convert ers it is useful to be familiar with both the fault codes as well as some of the monitoring menus Keypad Display Each variable speed drive or frequency converter has a keypad which will appear as illustrated on the right when the machine has power connected to it COON 0 CG fF C0 PN a Keypad display Run direction fwd or rev Indicates if unit is either stopped or running Up key Left key Down key Reset button Outp
15. for a camera which can be placed on an uneven surface and yet still find a stable footing The half set diamond configuration should only be used when a flat floor finish is not required FULL SET OF DIAMONDS When the diamonds are set up as a full set they tend not to follow the surface of the floor If the floor has undu lations the machine will grind the high areas yet miss the low spots unless the high areas are ground down first The full set diamond configuration should be used when a flat floor finish is desired The below table gives some examples of possible ap plications for the two arrangements Ceramic tie adhesveremoval ko Doo o Carpetgueremoval OO S Epoypanremva OOOO o S Vinyl adhesive removal OOOO Rain damaged concrete o ko o Smoothen exposed aggregate TX Lippage removal in terrazzo stone tles o Ko o Surface polishing of concrete floors o ooo S A Grinding to expose aggregate in concrete polishing application X Remove lippage from terrazzo natural stone tles TX Flatten undulations in concrete floors OK o Re polish floors that have been ground before o O 20 English Diamond selection Selecting the correct diamonds for your application The following suggestions cover the basic principles for diamond selection for different applications bond Twins Flatten floor Hard concrete Flatten floor Medium concrete Flatten floor Soft concrete Ceramic t
16. gh temperature working environ converter tested by service agent ment or faulty temperature sensor 15 MOTOR STALLED Motor being worked too hard and Check current being drawn when machine is drawing extra current running Reduce speed setting and current draw back into acceptable limits as described on previous page Mechanical jam preventing motor Try rotating grinding discs and planetary head by from turning hand to see if jam exists 16 MOTOR OVERTEM Motor being worked too hard and Check current being drawn when machine is PERATURE drawing extra current running Reduce speed setting and current draw back into acceptable limits as described on previous page 16 English Faults and trouble shooting Further problems that may be experienced when using the grinder and potential solutions are as follows Possible Cause Potential Solution GRINDER IS HARD TO HOLD ONTO Not enough diamonds under the machine if grinding thick glue or soft floors too few diamonds under the machine will greatly increase the load on grinder and operator Usually also accompanied by high current draw by large motor Large motor not working this can be caused by fault with motor fault with wiring to motor or fault with large variable speed drive or fre quency converter Drive belt is slipping Drive belt is broken this can be confirmed by turning one of the grinding heads by hand If all grind ing heads rotate
17. gment When suspend ed in a resin binding agent the finished product is referred to as a Resin Bond diamond segment or pad By changing the hardness of the binding agent we can change how fast or slow the diamond abra sive will wear General Principles The following are general rules regarding diamond seg ments in grinding applications As with all general rules there are exceptions or cases when it is not the case DIAMOND GRIT SIZE Changing the size of the diamond grit to a smaller par ticle grit size will effect the performance of the diamond tool in the following ways e Create a finer scratch pattern e Increase the life of the diamond tool The opposite will occur when changing to a larger particle grit size BINDING AGENT METAL BOND OR RESIN BOND Increasing hardness of bond will e Increase life of diamond tool e Decrease production rate e Cause diamond tool to leave finer scratches in dry grinding applications when compared to a softer bond diamond tool with the same diamond grit size The opposite will occur when making the metal or resin bond softer 18 English NUMBER OF DIAMOND SEGMENTS PADS UNDER THE MACHINE Increasing the number of segments under the machine will e Reduce pressure on each individual diamond seg ment Reduce wear rate on diamond segments e Reduce load on the machine and cause the grinder to draw less current e Create a smoother scratch pattern particularly
18. head plate and head mate are a series of white silicone springs spacers and the spring steel spring which give shock absorption and flexibility in the system Unlike with the conventional demolition heads the spring steel heads are able to move in a flexible manner without any moving parts due to the presence of the spring steel spring Over an extended period of time the spring steel spring fatigues and the spring steel fingers begin to break off This creates irregular movement within the grinding heads and will cause vibration when the machine is in operation Routine checks for broken fingers in the spring steel grinding heads are recommended Life expectancy for grinding heads can vary between 6 and 12 months depending on the amount of usage Replacement spring steel springs are available and can be replaced without throwing the grinding head away The spring steel heads can also be made less flexible by the addition of a second spring steel spring Diagram 2 Maintenance Grinding Heads Drive System The grinder comes eguipped with Dual Drive Technolo gy As the grinding discs are driven by the large mo tor via an internal belt and because the belt is sealed inside the machine there is no maintenance regarding this drive system until a major service belt and bearing replacement is due This is typically following 12 36 months of operation Planetary Drive System The second component to the Dual
19. ile adhesive removal Vinyl or Carpet glue removal Hard concrete Vinyl or Carpet glue removal Medium concrete Vinyl or Carpet glue removal Soft concrete Epoxy paint removal Hard concrete Epoxy paint removal Medium concrete Epoxy paint removal Soft concrete Rain damaged concrete Smoothen exposed aggregate Lippage removal in terrazzo stone tiles Surface polishing of concrete floors Hard concrete SOFT Surface polishing of concrete floors Medium concrete MEDIUM CH Surface polishing of concrete floors Soft concrete HARD Grinding to exposed aggregate in concrete Hard concrete SOFT 16 or 30 Grinding to exposed aggregate in concrete Medium con MEDIUM 16 or 30 crete Grinding to exposed aggregate in concrete Soft concrete HARD 16 or 30 Flatten undulation in concrete floors Hard concrete SOFT 16 or 30 Flatten undulation in concrete floors Medium concrete MEDIUM 16 or 30 xX o JS Flatten undulation in concrete floors Soft concrete HARD 16 or 30 X tT NIJA ajoja o English 21 Diamond selection Determining the hardness of concrete All concrete may feel hard particularly if you fall over on it so what do we mean when we talk about hard medium and soft concrete All concretes are measured by their compressive strength and depending on which part of the world you are from different compressive strength indices e g PSi amp MPa Generally speaking the higher the com
20. mple that underwent EC type examination G teborg 16 July 2007 KEDR a Tim Van Der Veen Development Manager English 29 K Husqvarna www husgvarnacp com
21. nd planetary drive sprocket are located beneath the cover of the machine yet on the outside of the machine there lies the potential that they can be exposed to dust and other debris created during the grinding process To prevent this as much as possible a planetary seal has been installed to stop dust and other particles from coming into contact with the planetary drive mecha nism Diagram 4 Planetary seal closeup English 25 Maintenance The effectiveness of the planetary seal can be moni tored by the simple removal of the planetary motor gearbox system by removing the four bolts shown below Remove 2 bolts either side Remove this bolt Remove 2 bolts either side Remove cover off motor terminal box Inspect for dust build up here Remove these bolts If the planetary seal is working effectively there should be a very minimal amount of dust observed under the cover of the machine If there is a build up of 5 6mm 1 4 inch then it is more than likely it is time to remove the machine cover and check the condition of the planetary seal Remove this bolt af Lift off seal If planetary seal is worn or needs replacement contact your Husqvarna Construction Products distributor for a new planetary seal replacement kit 26 English Maintenance schedule Maintenance schedule Hem Check that head locks Tighten head locks and re set in thread locking com Daily
22. ood ventilation Always wear e Approved protective helmet e Approved hearing protection e Protective goggles or a visor e Dust forms when grinding which can cause injuries if inhaled Use dust mask Always wear sturdy non slip boots with steel toe caps Always wear approved protective gloves Inspection and or maintenance should be carried out with the motor switched off and the plug disconnected Visual check Regular cleaning is reguired This product is in accordance with ap plicable EC directives English 5 Safety Instructions Safety Instructions WARNING Under no circumstances may the machine be started without observing the safety instruc tions Should the user fail to comply with these Husqvarna Construction Products Sweden AB or its representatives are free from all liability both directly and indirectly Read through these operating instructions and make sure that you understand the contents before starting to use the machine Should you after reading these safety in structions still feel uncertain about the safety risks involved you must not use the machine please contact your dealer for more informa tion Please read the operator s manual carefully Only qualified staff should be allowed to operate machinery Never use a machine that is faulty Carry out the checks maintenance and service instructions de scribed in this manual All repairs not covered in
23. or wet or dry grinding of marble terraz zo granite and concrete Their applications range from rough grinding through to a polished finish This manual covers the Husgvarna PG 680 820 series of floor grinders eguipped with twin motor drive here after referred to as Dual Drive Technology lt is extremely important all users be familiar with the contents of this manual before commencing operation of either machine Failure to do so may result in damage to machinery or expose operator to unnecessary dangers 1 IMPORTANT Only staff that have received the necessary education both practically and theoretically concerning their usage should operate the machinery Transportation The machine comes equipped with inbuilt advanced electronic systems called variable speed drives or frequency converters These drives enable the variable speed and direction component of each of the motors The drives are located in the steel cabinet mounted on the machine chassis As with all electronic equipment the drives are sensi tive to excessive vibration rough treatment and high levels of dust Much care and attention has been given by the manufacturer to ensure maximal protection is given to the drives Note the shock absorbing mount ing system used to mount the steel cabinet on the machine chassis frame When transporting it is important to ensure the ma chinery is properly secured at all times to eliminate bouncing of the varia
24. re monitored on the large variable speed drive frequency converter Keep the current draw on the small motor under 3 5amps for consistent operation MOTOR CURRENT Monitor Menu This screen displays the current draw of the corre sponding motor i e large variable speed drive fre quency converter monitors function of large motor small variable speed drive frequency converter moni tors function of small motor when the motor is running See comments already covered under OUTPUT FRE QUENCY relating to motor current DC LINK VOLTAGE Monitor Menu This screen displays the quality of the power supply to the machine It will read higher values when the ma chine in standby and lower values when the machine is in operation FAULT HISTORY The fault history menu stores the last series of faults experienced by the variable speed drive frequency converter If there is a recurring fault pattern experi enced by the machine the information can be obtained from the fault history menu For more on faults see trouble shooting faults English 15 Faults and trouble shooting Faults and trouble shooting When either one of the variable speed drives or freguen cy converters in the machine experience a fault and trip out they will cease to run and an error message will ap pear flashing on the keypad display see picture below The following list are the most commonly experienced faults and possible action steps Fault cod
25. s Menus and information they provide The following menu items screens on the variable speed drive freguency converters provide the following useful information to the operator OUTPUT FREGUENCY Monitor Menu This screen tells the operator the freguency the motor is running at when the machine is in operation The value for output freguency should be constant when the machine is running If there is a fluctuation in output frequency when the machine is running gener ally this indicates the motor is running at or near the limit of its programmed current limit The current limits predetermined and set by Husqvarna Constructions Products are as follows 1 Large motor which information is found on the large variable speed drive frequency converter 25 amps 2 Small motor which information is found on the small variable speed drive frequency converter 5 amps If there is a fluctuation in output frequency when the machine is in operation it is advisable to check the motor current as well This can be found by pressing the UP arrow on the keypad 3 times For trouble free operation concerning current issues it is best to keep output current at or around 21 amps for the large mo tor The current draw of the motor can be reduced by reducing the speed of the motor using the speed dial on the control panel near the handle bars Generally speaking most over current problems will be associated with the large motor and therefo
26. s will ensure the least amount of wear on the diamond segments If a hard diamond segment is not suited to the application all it has cost is a little amount of time without wearing out the diamonds If performed the other way around i e a soft segment is used to begin with and the concrete is soft or pos sesses an abrasive surface or surface contaminant it is quite possible to wear out a considerable amount of diamond in very short period of time 22 English Maintenance Maintenance Used correctly the machine is an extremely low main tenance and reliable This section covers the general maintenance items that need attention on a periodic basis There are three main mechanical items to check 1 Grinding Heads 2 Planetary drive system 3 Planetary seal Grinding heads There are 2 different grinding head options 11 Conventional Demolition heads designed for heavy duty preparation grinding where an extremely robust system is required 2 Spring steel head system designed more for finish ing or lighter grinding applications CONVENTIONAL DEMOLITION HEADS The below diagram illustrates the main parts compris ing this type of grinding head Is 2 4 3 1 Head mate 2 Head plate 3 Head lock 4 Head spring The interrelation between the above four components enables a dynamic system which is both robust and flexible The head pins are fixed to the head plate giving rigid ity
27. speed drive and frequency converter is on Check that small variable speed drive or frequency converter is functioning properly unplug both motors set display on keypad to Output Frequency switch machine to RUN see if numbers on screen change from zero and begin counting up If num bers stay on zero small variable speed drive or frequency converter is not receiving run command from witch on control panel Machine needs to be checked by an electrician or Husqvarna Construc tion Products GRINDER IS JUMPING AROUND Grinding heads may be worn out or Check grinding heads for broken parts or excess damaged movement Diamonds may not be fitted cor rectly or different height diamonds may be on the grinding heads Check to ensure all diamonds are fitted correctly and are the same height Head locks may be loose or miss Ing Check to ensure all head locks are present and tight English 17 Diamonds Diamonds Background Diamond abrasives usually consist of 2 components 1 Diamond powder also known as diamond crystals or grit By changing the size of the diamond powder or grit we can change how coarse or fine the scratches will be that are left behind from the grinding process 2 A binding agent metal or resin Diamond powder is mixed and suspended in either a metal or resin binding agent When suspended in a metal binding agent the finished product is referred to as a Metal Bond or Sintered diamond se
28. this manual must be performed by a repairer nominated by either the manufacturer or distributor Always wear personal safety equipment such as sturdy non slip boots ear protection dust mask and approved eye protection The machine should not be used in areas where potential for fire or explosions exist Machinery should only be started when grinding heads are resting on the ground unless carrying out a testing procedure as outlined in this manual The machine should not be started without the rubber dust skirt attached It is essential a good seal between machine and floor be established for safety especially when operating in dry grinding applications When changing the grinding discs ensure power supply to the unit is OFF by engaging the Emergen cy Stop button and the power plug disconnected The machine should not be lifted by handles mo tor chassis or other parts Transportation of the machine is best done on a pallet skid to which the machine must be firmly secured Extreme caution must be used when moving machinery by hand on an inclined plane Even the slightest slope can cause forces momentum making the machinery impossible to brake manually 6 English e Never use the machine if you are tired if you have drunk alcohol or if you are taking medication that could affect your vision your judgement or your co ordination e Never use a machine that has been modified in any way from its original specifica
29. tion e Be on your guard for electrical shocks Avoid having body contact with lightning conductors metal in the ground e Never drag the machine by means of the cord and never pull out the plug by pulling the cord Keep all cords and extension cords away from water oil and sharp edges e Make sure the cord is not pinched in doors fences or the like e Check that the cord and extension cord are intact and in good condition Never use the machine if the cord is damaged hand it in to an authorized service workshop for repair e Do not use a rolled up extension cord e The machine should be connected to an earthed outlet socket e Check that the mains voltage corresponds with that stated on the rating plate on the machine e Ensure the cord is behind you when you start to use the machine so that the cord will not be damaged At no time should lifting of machinery be attempted without mechanical means such as a hoist or fork lift WARNING Overexposure to vibration can lead to circula tory damage or nerve damage in people who have impaired circulation Contact your doctor if you experience symptoms of overex posure to vibration These symptoms include numbness loss of feeling tingling pricking pain loss of strength changes in skin colour or condition These symptoms normally ap pear in the fingers hands or wrists Introduction Introduction The Husgvarna PG 680 820 floor surfacing machines are designed f
30. together belt is not broken If only one grinding head turns belt is broken Increase number of diamonds under machine to reduce load on grinder and operator Check large motor is plugged in Check there are no faults on larger variable speed drive or frequency converter Check that large variable speed drive or frequency converter is on Check that large variable speed drive or frequency converter is func tioning properly unplug both mo tors set display on keypad to Output Frequency switch machine to RUN see if numbers on screen change from zero and begin counting up If num bers stay on zero large variable speed drive or frequency converter is not receiving run command from switch on control panel Machine needs to be checked by an electrician or by Husqvarna Construction Products Remove belt tensioner cover plate on bottom of machine and check there is no water or dust on the inside of the machine that may be causing the belt to slip on the drive pulleys Replace internal drive belt GRINDER SOUNDS LIKE IT IS Small planetary drive motor not Check small planetary drive motor is plugged in OVERREVVING plugged in Small motor not working this can be caused by fault with motor fault with wiring to the motor or fault with large variable speed drive or frequency converter Check small motor is plugged in Check there are no faults on small variable speed drive or fre quency converter Check that small variable
31. ure a grind close to the wall or object Planetary Planetary Grinding disc Grinding disc head direction direction speed p 6 o 7 5 1 3 5 7 7 i 5 8 10 3 Direction is also a matter of personal preference It should be noted however that when both grinding discs and planetary heads are running in the same direction a more powerful grinding force is created be tween the diamond abrasives and floor being ground The end result is higher productivity than when the discs are set to run in opposite directions It is here that you will also experience the beneift of Dual Drive Technology Production tip To improve the cutting efficiency of diamonds change directions on a regular basis This will work both sides of the diamond crystals keeping the abrasives as sharp as possible by creating maxi mal exposure of the diamond crystal Once both a speed and direction have been nominated switch on dust extraction or vacuum de vice IMPORTANT It is highly recommended to use the Husa varna DC 5500 dust extraction system for complete dust control Standing behind machine with handlebars set as described earlier apply a small amount of downward pressure on the handle Switch the machine to run mode using the STOP RUN switch on the control panel The machine should start smoothly and acceler ate to the selected speed over a period of 5 seconds English 11 Changing the diamonds Changing the di
32. ut mode Hertz in this example Output value English 13 Variable speed drives freguency converters MOTOR TOROUE Percentage of motor torgue when machine is running MOTOR POWER Percentage of motor power when machine is running MOTOR VOLTAGE Percentage of motor voltage when machine is running DC LINK VOLTAGE Indicates quality of power supply The menu tree illustrated on this page outlines the important menu options that provide useful information for monitoring and diagnostic purposes when using the machine As can be seen on the menu tree to the right when the machine is turned on the variable speed drives or frequency converters are set to display the Output Fre quency to the motor a zero value will register when the machine is in stand by mode The Output Frequency page also falls under the Monitor Menu It can be seen from the left hand column the two primary menus important to the operator are the Monitor Menu and Fault History menu Navigation through the menu tree is achieved by us ing the up down left and right keys on the keypad see previous page 14 English Parameter Menu i Keypad Control Menu Active Faults Menu Faults History Menu System Menu Expanded Boards Menu Monitor Menu iHi DC Link Voltage Motor Voltage Motor Power iH Motor Torque Motor Current Motor Speed Output Frequency Variable speed drives freguency converter
33. varying the above factors changes can also be made to effect the following e Scratch pattern e Current draw of machine e Flatness of floor see next section e Ease of operation Diamond Holder Disc Position for Diamond segment Half set of single segments Half set of twin segments Diamond selection The following section covers important factors to consider when selecting the diamond segment you are going to use for a given application Grinding disc set up The way diamond segments are set up on the grinding heads of the machine will also greatly influence the performance of the machine the productivity levels and also the finished floor guality There are basically two types of diamond configura tions that can be used when using the grinder 1 Full set of diamonds when there are diamonds placed at each of the six positions on the diamond holder discs see pictures above 2 Half set of diamonds when there are diamonds placed at three alternating positions on the diamond holder discs see pictures above English 19 Diamond selection Full and half sets of diamonds By changing the way the diamonds are set up on the diamond holder discs an operator can significantly ef fect the performance of the machine and therefore the finished product HALF SET OF DIAMONDS When the diamonds are set up as a half set they tend to follow the surface of the floor Similar to a tripod
34. y heads and internal components The machine has been manufactured to allow move ment between the chassis and head via the connection point at the lifting lugs and chassis pins This move ment is important during the grinding process as it creates a floating effect for the head The floating gives the head a self leveling effect negat ing the need to adjust the height of the head as the machine passes over floor areas with different slopes or undulations Control panel The control panel consists of a number of switches and dials giving 8 separate controls see picture Power This button when depressed will turn on power supply to the unit when the EMERGENCY STOP button has been released Emergency Stop When pushed will immediately shut down machine by totally stopping power supply to drives frequency converters in electrical cabinet Head Speed Direction control for planetary head rota tion Fwd Rev Yellow Direction control for planetary head rotation Disc Speed Speed control for grinding heads Fwd Rev Red Direction control for grinding heads Reset Will clear fault function error message on drive frequency converter located in electrical cabinet in case of fault occurring Stop Run To start or stop machine during normal operation IMPORTANT AN It is important to use the STOP RUN switch to control the running of the machine not the EMERGENCY STOP button Each time the EMERGENC
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