w200 en vonbrit - knecht · pdf filedin en 349 responsible for documentation: jürgen...
TRANSCRIPT
OPERATING INSTRUCTIONS
Mincing Plate Grinding MachineW 200
Knecht Maschinenbau GmbH • 88368 BergatreuteWitschwender Straße 26 • Tel. +49 7527-928-0 • Fax +49 7527-928-32
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EC Declaration of Conformityaccording to EC Directive 2006/42/EC
• Machinery 2006/42/EC• Electromagnetic Compatibility 2004/108/EC
We hereby declare that the machine described below conforms to the basic health and safety require-ments of the relevant EU Directive, both in its design and construction and in the version marketed byus.
This declaration shall cease to be valid should any alterations be made to the machine without ourexpress approval.
Description of machine: Mincing plate grinding machine
Type designation: W 200
Applied harmonised standards,in particular: DIN EN 12100-1
DIN EN 12100-2DIN EN 60204-1ISO 13857DIN EN 349
Responsible for documentation: Jürgen Schoch (BSc Mech Eng)Tel. +49 7527-928-40
Manufacturer: Knecht Maschinenbau GmbHWitschwender Straße 26D-88368 Bergatreute
Complete technical documentation is available.
A set of Operating Instructions for the machine is available both in the original version and in the user'snative language.
Bergatreute, 23 September 2009 Managing Director................................................. .......................................... .................................Location, date Signature Signatory title
Manufacturer
Knecht Maschinenbau GmbHWitschwender Str. 26
D-88368 Bergatreute
Tel. + 49 75 27 - 9 28-0
Fax + 49 75 27 - 9 28-32
Email [email protected]
Documentation for the machine owner
Operating Instructions
Date of issue of the Operating Instructions
23 September 2009
Copyright
The copyright to these Operating Instructions together with the operational documentation is retainedby Knecht Maschinenbau GmbH. They are provided to our customers and the operators of our pro-ducts and are integral to the machine.
These documents may not be copied or made available to third parties - in particular to competitors -without our express permission.
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CONTENTS
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
1. IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Foreword to the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.2 Warning notices and symbols in the Operating Instructions . . . . . . . . . . . . . . . . . . .51.3 Warning signs on / in the grinding machine and their significance . . . . . . . . . . . . . .61.4 Rating plate and machine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.5 Figure and item numbers in the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . .7
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.1.1 Observation of information in the Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .82.1.2 Obligation of the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.1.3 Obligation of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.1.4 Dangers involved in handling the grinding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.1.5 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.3 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4.1 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4.2 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4.3 Informal safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.4.4 Personnel selection and qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.4.5 Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.4.6 Safety measures during normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.4.7 Hazards due to electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.8 Particular danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.9 Servicing (maintenance, repair), troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.10 Structural modifications to the grinding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.11 Cleaning the grinding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.12 Oils and greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.13 Relocation of the grinding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 Designated purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153.4 Description of assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163.5 Function of the control panel elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173.6 Coolant unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183.7 Dressing device (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193.8 Feed lever for grinding wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193.9 Special Allen key for changing the grinding wheel . . . . . . . . . . . . . . . . . . . . . . . . . .203.10 Rotary table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203.11 Centring pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CONTENTS
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4. CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
5. TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5.1 Transportation equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225.2 Damage in transit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225.3 Transportation to another installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.1 Selection of specialist personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236.2 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236.3 Supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236.4 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236.5 Installing the grinding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7. START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8.1 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268.2 Workpiece holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268.3 Defining the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268.4 Adjusting the coolant supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278.5 Grinding mincing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278.6 Surface grinding of mincing knives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298.7 Dressing the grinding wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308.8 Replacing the grinding wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
9. CARE & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
9.1 Coolant additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339.4 Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1. IMPORTANT INFORMATION
1.1 Foreword to the Operating Instructions
These Operating Instructions are intended to help the operator familiarise himself with the grindingmachine and make use of its capabilities in accordance with the designated purpose.
The Operating Instructions contain important information on operating the grinding machine safely,properly and efficiently. Following the information in these Instructions will help avoid risks, reducerepair costs and downtime and increase the reliability and service life of the grinding machine.
The Operating Instructions must be available at all times at the installation site of the grinding machine.
The Operating Instructions must be read and followed by all persons entrusted with work on the grind-ing machine, e.g.
- transportation, installation, start-up
- operation, including troubleshooting and
- servicing (maintenance, repairs).
In addition to these Operating Instructions and any locally applicable directives on accident prevention,all recognised technical regulations governing safe and proper working practices must also beobserved.
1.2 Warning notices and symbols in the Operating Instructions
The following symbols / designations are used in these Operating Instructions and must be strictlyobserved:
This CAUTION symbol denotes a working safety instruction in case of anywork involving risks to life and limb for the operating personnel.
Particular caution and care must be exercised in such cases.
This IMPORTANT warning denotes specific information which must beobserved in order to avoid damaging and / or destroying the grindingmachine or adjacent objects and equipment.
This NOTE indicates tips on application and especially useful information.
IMPORTANT
NOTE
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CAUTION
1.3 Warning signs on / in the grinding machine and their significance
The following warning and mandatory signs can be found on / in the grinding machine:
CAUTION! DANGEROUS ELECTRICAL VOLTAGE (warning sign on switch cabinet)
Once connected to the power supply (3 x 400 V), the grindingmachine is electrically live and thus potentially lethal.
Voltage-carrying components may only be opened by authorisedexperts.
The grinding machine must be disconnected from the mains con-nection before carrying out care, maintenance or repair work.
1. IMPORTANT INFORMATION
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1. IMPORTANT INFORMATION
1.4 Rating plate and machine serial number
The rating plate is located on the right-hand sideof the machine.
Example of a rating plate:
The machine serial number can be found on the rating plate and on the centre slide, identifiable by theKnecht logo in the machine guard.
1.5 Figure and item numbers in the Operating Instructions
Where the text refers to an illustrated part, this is indicated by the figure number followed by the itemnumber in brackets.
Example: (8-1/1) means Fig. 8-1 / item no. 1.
The workpieces are mounted via centring pieces(8-1/1). The centring pieces serve to align the workpiececorrectly on the rotary table.
Fig. 8-1 Workpiece holder
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1
W 200 2009
020855200
3x400 6,68
3,25
2. SAFETY
2.1 Basic safety instructions
2.1.1 Observation of information in the Operating Instructions
A knowledge of the basic safety information and safety regulations is essential for safe use and trouble-free operation of this grinding machine.
• These Operating Instructions contain important information on the safe operation of the grinding machine.
• These Operating Instructions, and in particular the safety instructions, must be observed by all per-sons working on the grinding machine.
• In addition, the accident prevention rules and regulations applicable at the installation site must be observed.
2.1.2 Obligation of the owner
The owner undertakes only to permit persons to work on the grinding machine who
• are familiar with the basic working safety and accident prevention regulations and have been instruct-ed in how to handle the grinding machine,
• have read and understood the Operating Instructions, in particular the “Safety” section and the warn-ing notices, and have confirmed this with their signature.
Safe working practices on the part of all personnel must be examined at regular intervals.
2.1.3 Obligation of personnel
All persons entrusted with work on the grinding machine must first undertake
• to observe the basic regulations governing working safety and accident prevention;
• to read the Operating Instructions, in particular the “Safety” section and the warning notices, and to confirm with their signature that they have understood them.
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2.1.4 Dangers involved in handling the grinding machine
The grinding machine has been constructed in accordance with the state of the art and the recognisedtechnical safety regulations. Nevertheless, the use of the machine may lead to risks to life and limb forthe user or third parties, or damage to the grinding machine or other property. The grinding machinemay only be used:
• for its proper purpose• when it is in a safe operating condition.
Any faults that could undermine safety must be rectified immediately.
2.1.5 Faults
If safety-related faults occur in the grinding machine or if its operating behaviour indicates such faults,the machine must be shut down immediately and not put into service again until the fault has beenfound and rectified.
Faults may only be rectified by authorised personnel.
2.2 Proper use
The grinding machine is only suitable for surface grinding of mincing plates and mincing knives.
All knives must be clamped centrally on the table (magnetic table optional).
Any other use beyond this is deemed inconsistent with the designated purpose. Knecht MaschinenbauGmbH cannot be held liable for any damage resulting from such use, which takes place at the sole riskof the user.
The definition of “proper use” also comprises observation of all notices in these Operating Instructions.
Improper use of the grinding machine includes, for instance
• failure to mount attachments correctly
• grinding workpieces other than mincing plates or mincing knives.
2. SAFETY
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2. SAFETY
2.3 Warranty and liability
Our “General Terms of Sale and Delivery” apply in all cases. These are supplied to the user on con-clusion of the contract at the latest. Any warranty or liability claims for personal injuries or propertydamage are excluded if they can be traced to one of the following causes:
• Improper use of the machine.
• Incorrect transportation, start-up, operation and maintenance of the grinding machine.
• Operation of the grinding machine with defective safety equipment, or incorrectly installed or non-functional safety and protective equipment,
• Failure to observe the information in the Operating Instructions regarding transportation, start-up, operation, maintenance and repair of the grinding machine,
• Unauthorised structural modifications to the grinding machine.
• Unauthorised modifications, e.g. to the drive conditions (power rating and speed).
• Inadequate inspection of machine components subject to wear.
• Use of non-approved replacement and wear parts.
Use only OEM replacement or spare parts. In the case of non-Knecht parts, we cannot guaranteedthat they are designed and manufactured to cope with the relevant stresses, or to the relevant safetystandard.
2.4 Safety regulations
2.4.1 Organisational measures
All safety devices must be inspected regularly.
Prescribed intervals for regular maintenance work or such intervals specified in the OperatingInstructions must be observed!
2.4.2 Safety equipment
Always ensure that all safety equipment is fitted correctly and in working order before putting the grind-ing machine into operation.
Where the unit is delivered in sections for assembly by the operator, the safety equipment must beproperly attached by the operator.
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2. SAFETY
2.4.3 Informal safety measures
Please keep the Operating Instructions to hand at all times at the installation site of the machine.
In addition to these Operating Instructions, the generally and locally applicable regulations governingaccident prevention must also be made available and observed.
All safety and danger notices on the grinding machine must be complete and kept in legible condition.
2.4.4 Personnel selection and qualification
Only trained and instructed personnel may work on the grinding machine. The minimum legal age mustbe observed!
Responsibilities of personnel for start-up, operation, maintenance and repair must be clearly defined.
Personnel undergoing training, instruction, further training or familiarisation may only be allowed towork on the grinding machine under the constant supervision of an experienced member of staff!
2.4.5 Machine control
Only trained and instructed personnel are permitted to switch on the machine.
2.4.6 Safety measures during normal operation
All practices that undermine operating safety are prohibited.
Only operate the grinding machine when all safety devices are fitted and fully operable.
Inspect the grinding machine at least once per shift for outwardly visible damage and for operability ofthe safety devices.
Notify the responsible department or person immediately of any changes (including those in operatingbehaviour). Switch off the grinding machine immediately if necessary and lock it to prevent reactiva-tion.
Before switching on the grinding machine, ensure that no-one can be endangered as a result of themachine starting up.
Should faults occur in the grinding machine, switch off the machine immediately and lock it to preventreactivation. Ensure that faults are rectified immediately.
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2. SAFETY
2.4.7 Hazards due to electrical power
Work on electrical installations or equipment may only be carried out by a qualified electrician inaccordance with electrical regulations.
Defects such as damaged cables, cable connections etc. must be rectified immediately by anauthorised specialist.
2.4.8 Particular danger zones
Pinching hazard and risk of e.g. clothing, fingers or hair being drawn into the grinding wheel. Hazarddue to rotating grinding wheel and table.
2.4.9 Servicing (maintenance, repair), troubleshooting
All maintenance tasks must be performed to schedule and by trained personnel.
Operating personnel must be notified prior to the start of any maintenance or repair work. A responsi-ble supervisor must be appointed.
Before carrying out any maintenance work, always disconnect the grinding machine from the electri-cal power supply and lock it to prevent unexpected reactivation. Disconnect mains plug.
Where necessary, close off the area where maintenance work is being performed.
After completing maintenance work or troubleshooting, reinstall all safety devices and check that theyare operational.
2.4.10 Structural modifications to the grinding machine
No structural modifications may be made to the grinding machine without the permission of the man-ufacturer.
This includes installation or adjustment of safety devices.
No conversion work may be carried out without the prior written consent of Knecht MaschinenbauGmbH.
Any parts that are not fully operational must be replaced immediately.
Use only OEM replacement or spare parts. In the case of non-Knecht parts, we are unable to guar-antee that they are designed and manufactured to cope with the relevant stresses, or to the relevantsafety standard.
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2. SAFETY
2.4.11 Cleaning the grinding machine
All cleaning agents and materials used must be properly handled and disposed of in an environment-friendly manner.
Make sure worn spare and replacement parts are disposed of in a safe and environment-friendly man-ner.
2.4.12 Oils and greases
When handling oils and greases, observe all safety regulations applicable to the product in question.Also observe any special requirements governing food safety.
2.4.13 Relocation of the grinding machine
Disconnect the grinding machine from all external energy sources even if only moving it a short dis-tance. Reconnect the grinding machine correctly to the power supply before poutting it back into oper-ation.For loading and unloading, only use lifting equipment and load-bearing equipment with sufficientcapacity.
Appoint a qualified person to guide the lifting process.
No persons should be present in the loading and installation area apart from those appointed for thistask.
The grinding machine should only be lifted with the correct hoisting equipment and as directed in theOperating Instructions (slinging points for load suspension equipment etc.).
Only use suitable transportation vehicles with sufficient capacity.
Make sure the load is properly secured. The appropriate slinging points must be used. (section 4.1)
Only restart the machine in accordance with the Operating Instructions.
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3. DESCRIPTION
3.1 Designated purpose
The Mincing Plate Grinding Machine W 200 is intended for grinding mincing plates and mincing kniveswith a diameter of up to 200 mm.
3.2 Technical specifications
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1370 mm
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1225 mm (without extractor 805 mm)
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880 mm
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330 kg
Power supply * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 x 400 V
Mains frequency * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz
Output * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 kW
Power input * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kW
Energy consumption * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A
Back-up fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 A
Operating noise level of grinding wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 dB (A)
Rotary table diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm
Rotary table speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 rpm
Grinding wheel diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm
Grinding wheel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4500 rpm
Cutting speed with grinding wheel d.100 ** . . . . . . . . . . . . . . . . . . . . . . . .24 m / second
*) These specifications may vary according to electricity supply.
**) Caution! The cutting speed of 24 m/s is based on 50 Hz. A higher-frequency electrical supply willproduce higher cutting speeds. Only use suitably approved abrasives.
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3. DESCRIPTION
Fig. 3-1 Dimensions in mm
3.3 Functional description
The surface grinding machine W 200 can be used to surface-grind mincing plates and mincing knivesup to a diameter of 200 mm.
The mincing plates are fixed on the rotary table of the W 200 machine using centring pieces and adriver.
To surface-grind mincing knives, it is necessary to fix them on a mincing plate or another suitableadapter.
Special holders are also available for unusual applications.
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3. DESCRIPTION
3.4 Description of assemblies
Fig. 3-2 Overall view of grinding machine
1 Control panel2 Feed lever 3 Working lamp 4 Coolant hose5 Grinding unit 6 Perforated disk / rotary table d. 200 mm7 Splash guard8 Extractor (optional)9 Coolant unit
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1
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3
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4
2
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8
3. DESCRIPTION
3.5 Function of the control panel elements
The machine is operated via the control panel ofthe machine's PLC control system. The mechani-cal components can be operated via the pushbut-tons and switches of the control unit.
Fig. 3-3 Control panel
Switching the grinding machine on / off
The grinding machine is switched on by turningthe main switch from “0” to “I”.
After completing work, or in an emergency, usethe “EMERGENCY STOP” button.
The grinding machine is switched off by turningthe main switch from “I” to “0”.
Fig. 3-4 Main switch
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3. DESCRIPTION
3.6 Coolant unit
The coolant unit is located in the base of themachine.
The workpiece must be cooled continuously dur-ing grinding.
For this purpose, the water tank is filled withapprox. 35 litres of water containing coolant addi-tive.
The coolant is pumped directly to the grindingwheel. The coolant supply can be regulated withthe coolant valve.
Fig. 3-5 Coolant supply
The mechanical components of the grinding machine are not rust-proof!Always use coolant additive.
The coolant hose is flexible. The coolant hose (3-6/1) must be adjusted so as to ensure that theworkpiece (3-6/2) is completely covered withcoolant.
Fig. 3-6 Coolant regulation
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IMPORTANT
12
3. DESCRIPTION
3.7 Dressing device (optional)
Unless a boron nitride grinding wheel is used, theconventional ceramic grinding wheel can run outof true due to uneven wear. In this case, it can bemade true again with a dressing device.
Fig. 3-7 Dressing device
3.8 Feed lever for grinding wheel
The grinding wheel is fed in via the feed lever. Forrapid feed, it can be released and moved up anddown by pressing the button at the tip of the feedlever. The feed lever is locked again electrically onreleasing the button.
Fine feeding is performed by turning the rotaryknob at the tip of the feed lever.
The lever can be adjusted to the ideal working position by turning the fine adjust-ment knob and simultaneously activating the electromechanical locking mecha-nism.
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Fig. 3-8 Feed lever
NOTE
3. DESCRIPTION
3.9 Special Allen key for changing the grinding wheel
The grinding wheel can be easily changed withthe aid of the locking device (3-9/1) and specialAllen key (3-9/2). To remove the grinding wheel,insert the Allen key and release the wheel.
Fig. 3-9 Releasing the grinding wheel
3.10 Rotary table
The workpieces are placed on the rotary table andcentred for machining. They are fixed in place bymeans of centring pieces (3-11/1) and a driver (3-11/2).
Fig. 3-10 Rotary table
3.11 Centring piecesTo ensure optimal alignment of the workpieces,use the correct centring pieces and driver.
Fig. 3-11 Rotary table with workpiece
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1
2
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2
4. CONTROL UNIT
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The machine is operated via the control unit onthe right-hand side of the machine.
After switching on the machine, the control unitmust be activated by pressing the key “ControlOn”. Only then can the machine components beoperated via the relevant pushbuttons.
• Control On:activates the PLC control system.
• Rotary table On/Off:activates/deactivates the rotarymovement of the rotary table.
Grinding wheel On/Off:switches the grinding wheel on andoff.
Fig. 4-1 Control unit
• Coolant On/Off: switches the coolant pump on and off.
Drives On/Off: switches the drives of the grindingwheel, rotary table, coolant pump andextractor on and off. For safety rea-sons, only the coolant pump can beswitched on and off separately here.The extractor can be switched on andoff on the device itself.
5. TRANSPORTATION
5.1 Transportation equipment
The grinding machine may only be transported andinstalled using suitably dimensioned transportation equip-ment with a load-bearing capacity of at least 1.5 t, e.g.lorry, fork-lift, hydraulic lifting truck or overhead crane.
If using a fork-lift or lifting truck, drive the fork under thegrinding machine, taking into account the machine's cen-tre of gravity. Place suitable supports under the base toprotect it against damage. (Support: coolant tank supportplate)
Fig. 5-1 Transportation
5.2 Damage in transit
If damage is found during the acceptance inspection after unloading the machine, please informKnecht Maschinenbau GmbH and the haulage contractor immediately. If necessary, consult an inde-pendent valuator.
Remove the packaging and shipping straps. Remove the shipping straps from the grinding machineand dispose of in an environment-friendly manner.
5.3 Transportation to another installation site
When moving the machine to another installation site, make sure the space requirements areobserved.
An approved electrical connection must be available at the new installation site.
The grinding machine must stand firmly and stably when installed.
All locally applicable safety and accident prevention regulations must beobserved when transporting the grinding machine.
The grinding machine may only be transported feet-downwards.
CAUTION
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Installation work on the electrical system may only be carried out by anauthorised specialist or by our customer service department.
All locally applicable safety and accident prevention regulations must beobserved.CAUTION
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6. ASSEMBLY
6.1 Selection of specialist personnel
6.2 Installation site
When deciding on the installation site, take into account the space requirements for assembly, main-tenance and repair work on the grinding machine. The area behind the machine must be kept clear toallow adequate ventilation.
6.3 Supply connections
The grinding machine is supplied ready for connection with the appropriate connection cable.
Incorrect connection may cause the grinding wheel and the rotary table torotate in the wrong direction.
This in turn can cause the grinding wheel to become loose.
On start-up, first check the rotational direction of the rotary table. The tableshould rotate anti-clockwise.
6.4 Settings
The various components and the electrical system are adjusted at Knecht Maschinenbau GmbH priorto delivery.
On no account may arbitrary changes be made to the set values as this mayresult in damage to the grinding machine.
We recommend that assembly work on the grinding machine be carried out bytrained Knecht personnel. We do not accept liability for damage due to incor-rect assembly.
CAUTION
Make sure the power supply is properly connected.
Observe the specified direction of rotation!
CAUTION
IMPORTANT
IMPORTANT
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6.5 Installing the grinding machine
Deposit the grinding machine on a level floor at the installation site.
Compensate for uneven floors by means of the adjustable machine feet.
Have the on-site power supply installed by a qualified electrician.
Install and inspect all safety devices prior to start-up.
6. ASSEMBLY
All safety devices must be installed and tested for correct operation by a qual-ified specialist before the machine is started.
CAUTION
7. START-UP
Fill coolant unit (Fig. 7-1) with approx. 35 l waterincluding coolant additive. (For concentration, seemanufacturer's instructions). For coolant additive,see section 9.2.
The drain 7-1/1 must be positioned so that the dirtywater can flow into the strainer basket. The strain-er basket is fixed via the notches provided.
Fig. 7-1 Filling the coolant unit
Insert power plug (CEE plug) in the on-site socket (3x400V, 32A) and turn main switch to “I”.
Press luminous key “Control On”. The PLC controlsystem is now activated. Press luminous key“Rotary table On/Off”. The table will start to rotate.
Check the direction of rotation.
The arrow (7-2/1) indicates the rotational directionof the table. The table should rotate anti-clockwise.If necessary, change the pole changer plug around.
Fig. 7-2 Check direction of rotation
After checking the specified direction of rotation, press the luminous key “Rotary table On/Off” again.
All work may only be carried out by authorised specialist personnel.
All locally applicable safety and accident prevention regulations must beobserved.
CAUTION
When the grinding machine is switched on, there is a danger of hands, hairand clothing being drawn in.
Risk of serious injuries.
CAUTION
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8. OPERATION
8.1 Switching on the machine
Turn main switch to “I”.
Press luminous key “Control on”. The PLC control system is now activated.
8.2 Workpiece holder
To insert the workpieces, the rotary table can bemoved to the changeover position. To do this,release the locking device and push the slide allthe way back to the stop using the handle. Thenlock it again.
The workpieces are mounted via centring pieces(8-1/1) and a driver (8-1/2). The centring piecesserve to align the workpiece correctly on therotary table.The correct centring piece is inserted in the borein the centre of the rotary table.
8.3 Defining the working position
The working position of the rotary table variesaccording to the size of the workpiece. The cor-rect working position is reached when the work-piece is gripped from the bore to the outer edge ofthe grinding wheel.
The position of the rotary table is adjusted as fol-lows: Release the locking device. Drag the centrepiece to the working position. Lock the slide inplace again.
The locking device can be rotat-ed by 180° for fine adjustment.
When grinding mincing knives, make sure the grinding wheel does nottouch the collar of the knife.
NOTE
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Fig. 8-2 Position of rotary table
Fig. 8-1 Workpiece holder
IMPORTANT
2
1
8. OPERATION
8.4 Adjusting the coolant supply
The coolant pump is switched on andoff when the control system is activat-ed by pressing the key “Coolant On/Off”. The coolant supply can be regu-lated with the coolant valve (8-3/1). Turning the coolant valveclockwise reduces the coolant supply.Turning anti-clockwise opens thecoolant valve.The coolant hose is flexible and mustbe adjusted so that the coolant flowsdirectly onto the workpiece.
The coolant pump can be switched on and off in automatic mode.
During grinding, make sure the workpiece is always supplied with sufficientcoolant to avoid overheating and consequent damage to the metal structureof the workpiece. Check coolant level regularly.
8.5 Grinding mincing plates
Switch on the machine and activatethe control unit with the luminous key“Control on”.
Position the workpiece on the rotarytable using the centring piece anddriver.
Move the rotary table to the working position asdescribed under 8.3.
Lower the grinding unit using the feed lever till it isjust above the grinding wheel. The grinding wheelshould not touch the workpiece until the drives areswitched on.
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IMPORTANT
Fig. 8-4 Mincing plate on rotary table
Fig. 8-3 Coolant valve
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NOTE
8. OPERATION
Start the rotary table, the grinding wheel, the coolant pump and the extractor by pressingthe key “Drives On/Off”. The coolant pump and extractor can be switched on and off sep-arately. (Direct extraction from unit).
To grind, feed in the grinding unit using the fineadjustment knob on the tip of the feed lever untilsparks can be clearly seen. Run the machinewithout further infeed until sparking decreases.Feed in again until the surface of the workpiecehas been evenly ground. The required surfacequality can be obtained by reducing the rotarytable speed and allowing the machine to spark outbriefly after the last infeed, i.e. grinding with lowpressure.
After grinding, raise the grinding unit until the drives stop automatically.
The workpiece can now be removed and groundon the other side if necessary.
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Fig. 8-5 Coarse/fine feed
8. OPERATION
8.6 Surface grinding of mincing knives
Uneven mincing knives must be surface-groundbefore relief-grinding.
To grind mincing knives, switch on the machineand activate the control unit.
The mincing knife is placed on a surface-groundmincing plate (8-6/1). The bushing is inserted inthe bore of the mincing plate. Centre the mincingplate and mincing knife using a centring piecesuitable for mincing knives. Don't forget the driverfor the mincing plate!
When grinding mincing knives, make sure thegrinding wheel does not touch the collar of theknife. The position of the rotary table can be pre-cisely adjusted using the locking device.
Lower the grinding unit using the feed lever on the right-hand side of the machine till it is just abovethe grinding wheel. The grinding wheel should not touch the workpiece until the drives are switchedon.
Start the rotary table, the grinding wheel, the coolant pump and the extractor by pressingthe key “Drives On/Off”.
To grind, feed in the grinding unit using the fine adjustment knob on the tip of the feed leveruntil sparks can be clearly seen. Run the machine without further infeed until sparkingdecreases. Feed in again until the surface of the workpiece is evenly ground. The requiredsurface quality can be obtained by reducing the rotary table speed and allowing themachine to spark out briefly after the last infeed, i.e. grinding with low pressure.
After completing the grinding process, raise the grinding unit until the drives stop automatically.
The mincing knife can now be removed and ground on the other side if necessary.
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1
Fig. 8-6 Surface grinding of mincing knives
Sharp cutting edge.
Serious cutting injuries are possible.
Wear protective gloves.CAUTION
8. OPERATION
8.7 Dressing the grinding wheel
If sparking decreases during grinding, the grind-ing wheel must be dressed.
Move the slide to the load-ing position. Press theControl On and GrindingWheel On buttons.
Position the table so thatthe groove is perpendicularto the tending side. Insert the dressing device inthe groove and fix in place using the screw. Placethe wheel above the diamond.
The grinding wheel is dressed by moving the slidewith the diamond back and forth by hand whilesimultaneously inching the grinding wheel down-wards.
The grinding wheel is relief-ground.
Hazard from chipping of abrasives. Wear protective goggles.
8.8 Replacing the grinding wheel
To release the grinding wheel, position the lockingpin and loosen the wheel with the special Allenkey. Now unscrew the grinding wheel with thespecial key by turning clockwise. Fit the grindingwheel and tighten with the special key.
Fig. 8-8 Replacing the grinding wheel
To ensure optimal operation, only use abrasives recommended by Knecht.These must be checked for visible damage. Do not use damaged grindingwheels.
Make sure the locking pin is removed before switching on the machine(rotate the wheel once briefly by hand).
IMPORTANT
NOTE
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Fig. 8-7 Dressing the grinding wheel
NOTE
NOTE
8. OPERATION
After changing the grinding wheel, the safety guardof the grinding wheel must be readjusted. To do this,undo the screws on the right and left-hand sides (8-9/1) of the grinding wheel guard and pull out theguard. The grinding wheel should protrude approx.2 cm under the guard. Fix the grinding wheel guardwith the screws in this position.
Fig. 8-9 Grinding wheel guard
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When working on the grinding machine, always observe the applicable localsafety and accident prevention regulations and the “Safety” and “Importantinformation” sections in the Operating Instructions.
Please use only OEM replacement and wear parts. In the case of non-Knechtparts, we are unable to guarantee that they are designed and manufacturedto cope with the relevant stresses and to the relevant safety standard.
CAUTION
1
After fitting the new grinding wheel, a test run must be carried out.
For this purpose, lower the grinding wheel till it is 5 mm above the rotarytable and run it for 5 minutes with the water supply on.
CAUTION
9. CARE & MAINTENANCE
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9.1 Coolant additive
A rust-inhibiting additive must always be added to the cooling water.
(see section 9.4)
9.2 Lubrication
All bearing points are equipped with waterproof, grease-lubricated anti-friction bearings and are there-fore maintenance-free.
The recirculating ball guideway should be lubri-cated with liquid grease at 4-week intervals. Thisis done through the sign with the Knecht logo inthe machine guard.
Fig. 9-1 Lubrication of recirculating ball guideway
The rotary table should be lubricated with liquidgrease at 4-week intervals.
Fig. 9-2 Lubrication of rotary table
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9. CARE & MAINTENANCE
The feed lever should be lubricated as nec-essary with liquid grease.
Fig. 9-3 Lubrication of feed lever
See also explanations in lubrication schedule 9.4.
9.3 Cleaning
The machine must be cleaned after every grinding process, as otherwise the grinding sludge driesand becomes difficult to remove. The filter in the coolant tank must also be emptied and cleaned.Note the correct position of the drainage system.
After cleaning we recommend light lubrication of the machine with an acid-free oil.
See also explanations in lubrication schedule 9.4.
9.4 Lubrication schedule
L u b r i c a t i o n s c h e d u l e a n d l u b r i c a n t t a b l e
Lubrication tasks Interval OEST SHELL ESSO
Recirculating ball 4 weeks LT 0000-EP Rentiax CSZ -guideway
Oiling of machine after every Ondina 1727 Marcol 80parts after cleaning grinding process