G.B.C G400, Instruction Manual

Page 1: ...INSTRUCTION MANUAL G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com Versione 01 2017 ELECTRONIC GRINDER G400 ...

Page 2: ...Prescriptions Pag 06 Specific Safety Prescriptions Pag 07 Machine Standard Configuration Pag 08 Machine Technical Specifications Pag 09 Grinding Disc Specifications Pag 10 Control Panel Functions Pag 11 Grinding Disc Mounting and Removal Pag 13 Head Position Adjustment Pag 14 Head Horizontal Travel Pag 15 Head Perpendicular Travel Pag 16 Head Tilting for Backgouging Pag 17 Left Right Head Rotation...

Page 3: ...n to natural persons or to corporate bodies is strictly forbid den unless our prior approval to do so is obtained G B C Industrial Tools S p a informs its customers that any operation carried out on the machines which is not prescribed in this manual entails the automatic invalidation of the warranty G B C Industrial Tools S p a recommends to contact the Maintenance Service in Cazzago San Martino ...

Page 4: ...d G B C Industrial Tools S p A and MSS obligations will cover the defect resolution the general maintenance and the inspection of the parts subject of the claim only The component replacement is at G B C Industrial Tools S p A discretion only The shipmen to costs from and to the MSS as well as the direct and indirect costs rising from repair of the prod uct are at user s charge Any warranty repair...

Page 5: ...F MISUSE OF THE UNIT The grinder G400 represents a revolutionary method of executing grinding processes in the boiler industry granting the following advantages Sensible reduction of the working time in comparison with the existing manual grin ders High material removal rate No thermal alteration on the welding area Consistency of the groove Vibrations free Requires only one operator Improvement o...

Page 6: ... the power source Before every use ensure that the connection to the power source is in compliance with the specifica tions provided by the G B C manual The authorized operator should not in any case disregard the basic safety regulation such as Using gloves and goggles safety gear supplied by the company responsible for the site or for the building To properly illuminate the working area Ensure y...

Page 7: ...mail sales gbcspa com WEAR PROTECTIVE EYEWEAR AGAINST UTRAVIOLET RAYS WEAR HEARING PROTECTIONS WEAR A FACE SHIELD FOR SPARKS AND FUMES The unit must carry a tag indicating the maximum speed of the grinding disc 65 m s which shall always be inferior to the speed sustainable by the grinding disc itself as spe cified by the manufacturer 80 m s The protection arount the grinding disc must cover at lea...

Page 8: ...3 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com The machine is supplied with Control Panel Wired Control 80 120mm Hook Wrench 8mm Allen Key 24mm Socket Wrench 24mm Open End Wrench 17mm Socket Wrench 6mm Allen Key 13mm Open End Wrench Instruction Manual Drawing of machine G400 Wired Control Control Panel Tools Trolley Instruction Manual ...

Page 9: ... Grinding Disc Flange Seat mm 60 Grinding Disc Allowed Thickness mm 8 10 12 14 16 Grinding Disc Peripheral Speed m s 65 With Intact Grinding Disc Head Rotation Left Right 5 With Intact Grinding Disc Head Lateral Tilt 5 On the Left Side Head Tilt on Trolley 0 45 Head Installed on the Trolley Gouging Depth mm 0 120 With Intact Grinding Disc Gouging Force N 150 Rotation Speed of the Positioners min m...

Page 10: ...m such figures are in compliance with the regulation EN 60745 Therefore according to the evaluation of the environmental risk of the workplace regulated by the Law Decree 81 08 and following variations actuating the directive2003 10 CE according to the Art 190 of the above mentioned Decree the staff responsible of the G400 must be formed and educated in renard to the above said regulation and must...

Page 11: ... Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com 1 Absortion Digital Display 2 Switch Grinding Wheel Grinding Tape 3 Circuit Breaker Indicator 4 Tension Indicator 5 ON OFF General Switch 6 Emergency Stop 7 Grinding Wheel Motor STOP 8 Grinding Wheel Motor START 9 Cycle Start 10 Grinding Disc Absorption Adjustment 11 Grinding Tape Absorption Adjustment 1 8 9 2 5 6 7 3 4 11 10 ...

Page 12: ...rial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com WIRED CONTROL FUNCTIONS 1 Emergency Stop 2 Grinding Disc Motor START 3 Head Feeding 4 Head Left Translation 5 Tension Indicator 6 Grinding Disc Motor STOP 7 Head Return 8 Head Right Translation 6 7 5 8 1 2 3 4 ...

Page 13: ...e back plate on the opposite side to hold it in place Turn the nut and remove the flange Replace the grinding disc reposition the flange and the nut and use the hexagonal tubular wrench to secure the parts in place again using the hook wrench to hold the back plate on the opposite side Due to the allowed manufacturing tolerances you may note that the grinding disc might slightly in and out of the ...

Page 14: ...Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com The head tilt adjustment is achieved by rotating the handwheel in one way or another This will cause the head to tilt accordingly N B It is advisable that the head tilt does not exceed 10 45 and possibly that the head axis is lined up with the workpiece to be worked ...

Page 15: ... 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com The head of the G400 can be translated on the horizontal axis by pushing the buttons indi cated by the arrows below N B The stroke of the head is 0 160mm 0 6 5 16 ...

Page 16: ...ustrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com The head of the G400 can be translated on the perpendicular axis moved towards or away from the workpiece by pushing the buttons indicated by the arrows below N B The stroke of the head is 0 140mm 0 5 1 2 ...

Page 17: ...4 email sales gbcspa com The procedure described below is the correct one to perform a perfect groove back gou ging 1 Using the Allen key supplied with the machine loose the screw that locks the joint as shown in the picture below 2 Use the socket wrench supplied with the machine and rotate the threaded pin in the di rection indicated by the arrow until you reach the deisred tilting N B The max ti...

Page 18: ...e head left and right in order to achieve a perfect alighment of the head with the workpiece to back gouge The procedure to do so is the following 1 Use the Allen key supplied with the machine loose the screw pointed by the big arrow in the below picture 2 Use the open end wrench supplied with the machine and turn the tie rod in the direction required until the head reaches the desired position 3 ...

Page 19: ...ollers on which the edge of the workpiece can lean against having the counter roller to act as an end stop device or you can find other expedients that grant the same result Sometimes the grinding disc is not parallel to the welding groove longitudinal axis you ha ve to gouge and needs therefore to be slightly tilted so that you can achieve a perfect U shaped groove The correct degree is defined b...

Page 20: ...l Instructions Rev 01 2017 in compliance with the 1 7 4 of the Machines Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com ...

Page 21: ...l Instructions Rev 01 2017 in compliance with the 1 7 4 of the Machines Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com ...

Page 22: ...r source and proceed as described below 1 Turn ON the main power switch The digital display and the white indicator will turn on 2 Press the white button Auxiliary that will remain turned on N B If the light does not stay on you will have to invert the electric phase 3 Set the head in the desired position until the red light turns off N B The red light off indicates that the head has disengaged th...

Page 23: ...ini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com 4 Move the switch on grinding disc mode or on grinding tape mode depending on which of the two you have currently installed on the machine 5 Press the button Motor Start The grinding disc will start and the green indicator on the wired remote control will start blinking 4 5 ...

Page 24: ...e attachment that is being used The absorption value range is different for the attachments Disc 6 15 Grinding tape 5 7 For the first approach it is highly recommended to set the lowest value of the scale in order not to gouge beyond the root weld as this would compromise the entire work piece It is thefore recommended to assess any necessary increase during the opera tions Keep pressed the head f...

Page 25: ...feeding button indicated in the picture until the grinding disc touches the workpiece Hold the button pressed until the head reaches the maximum workload previously set on the potentiometer and its value stabilizes Hold the button for 3 seconds to memorize this value and the machine will work controlling and subsequently release the same Press the green flashing button the machine will now work wi...

Page 26: ...A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 email sales gbcspa com 3 Adjust the push load by acting on the knobs according to the actual use grinding disc or grinding belt N B The push load is shown on the digital display 4 Press the red button located on the wired remote control to stop the Auto Mode 4 3 ...

Page 27: ...of the greaser in the grease inlet located on the outer side of the part Follow the steps below to carry out this operation safely 1 Remove the gringing disc protection 2 Remove the gringing disc 3 Grease the part Pic 1 N B Every 300 working hours perform a thorough check of the toothed belt Follow the steps below to carry out this operation safely 1 Remove the screws that hold the protection in p...