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Operating Instructions B 500 Automatic Grinding and Polishing Machine Status 11.2016 ■ Version 1.1 | Translation Operating Instructions Automatic Grinding and Polishing Machine B 500 Manufacturer Knecht Maschinenbau GmbH Witschwender Straße 26 88368 Bergatreute Germany Phone +49 -7527-928-0 Fax+49 -7527-928-32 [email protected] www.knecht.eu Documents for the machine operator Operating Instructions Date of issue of the operating instructions November 23, 2016 Copyright The copyright for these operating instructions as well as other documents for the machine operator is held by Knecht Maschinenbau GmbH. These documents will be delivered only to our customers and to operators of our products and are a part of the machine. These documents may neither be reproduced, nor made accessible to third parties, including rival firms, without our express permission. 3 Table of Contents 1. Important notes 1.1Foreword 1.2 Warnings and symbols in the operating instructions 1.3Warning labels on the grinding machine and their meanings 1.4 Rating plate and machine serial number 1.5 Figure and item numbers in the operating instructions 2. Safety 2.1 Basic safety instructions 7 7 7 8 9 10 11 11 2.1.1 Observe notes in the operating instructions 2.1.2 Operator's duty 2.1.3 Obligations on the part of the personnel 2.1.4 Hazards associated with handling the machine 2.1.5Malfunctions 11 11 11 11 12 2.2 2.3 2.4 Use as intended Warranty and Liability Safety regulations 12 12 13 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 Organizational measures Protective devices Informal safety measures Selection and qualifications of the personnel Machine control system Safety measures in normal operation Dangers due to electrical power Particular danger zones Servicing (maintenance, repair) and fault rectification Structural alterations to the grinding machine Cleaning the grinding machine Oils and greases Relocation of the grinding machine 13 13 13 13 14 14 14 14 15 15 15 15 15 3. Description 3.1 3.2 3.3 3.4 Intended Use Technical specifications Functional description Description of the assemblies 17 17 18 19 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 Switching the grinding machine on / off Control panel Layout of the user interface (main screen) Coolant Pump Protective Hood SP 112 Copy clamping plate Grinding Unit Polishing units with polishing paste 21 21 22 24 25 25 25 26 4 17 Table of Contents 4. Transport 4.1 4.2 4.3 Transport Aids Transport damage Transport to another installation site 5. Installation 5.1 Selection of qualified personnel 5.2 Installation site 5.3 Supply connections 5.4Settings 5.5 Initial commissioning of the grinding machine 27 27 27 27 29 29 29 29 29 30 6. Commissioning 31 7. Operation 33 7.1 7.2 7.3 General principles of grinding technology Changing the profile Grinding the cutter knives 33 34 35 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 Switching on the grinding machine Mounting the copy clamping plate Adjusting the grinding angle Aligning the grinding unit Aligning the left polishing unit Aligning the right polishing unit Starting the grinding process 35 35 37 37 38 39 39 7.4 7.5 7.6 7.7 7.8 Changing the copy clamping plate Changing the wet grinding belt Changing the right flap brush Changing the left flap brushes Changing the polishing pastes 40 42 43 44 45 8. Control system 8.1 8.2 8.3 Main Screen Activating the product file Renaming, creating and deleting the product file 46 47 48 8.3.1 8.3.2 8.3.3 Renaming product file Creating the product file Deleting the product file 48 49 49 46 5 Table of Contents 8.4 Editing the parameters of the product file 50 8.4.1 8.4.2 8.4.3 Meaning of “Grinding” parameters Meaning of “Feed Cycles” parameter Meaning of “Polishing Process” parameters 51 53 55 8.5 Settings Data 8.6 Manual Functions 8.7Language 8.8 Setting up an internet connection 9. Care and maintenance 57 59 60 61 62 9.1 Lubrication and Maintenance 62 9.1.1 Lubrication schedule and lubricant table 63 9.2Cleaning 64 9.2.1 Cleaning of sub-structure 65 10.Malfunctions 66 10.1Faults 11. Disassembly and disposal 11.1Disassembly 11.2Disposal 12. Service, spare parts and accessories 66 67 67 67 68 12.1 Postal Address 12.2Service 12.3 Spare parts 12.4Accessories 68 68 68 69 12.4.1 Abrasives used 69 13.Appendix 13.1 6 EC Declaration of Conformity 70 70 1. Important notes 1.1Foreword These operating instructions are meant to make it easier to get to know the automatic grinding and polishing machine, referred to in this document as grinding machine, and to use it properly for the intended purpose. The operating instructions contain important information on how to operate the grinding machine safely, properly and cost-effectively. Observance of these instructions helps to avoid dangers, repair costs and downtimes, and increases the reliability and service life of the grinding machine. The operating instructions must always be accessible at the place of use of the grinding machine. The operating instructions must be read and used by all persons entrusted with working on the grinding machine, e.g. those entrusted with • Transport, installation, commissioning • Operation, including troubleshooting in the process flow, as well as • Servicing (maintenance, repair). In addition to the operating instructions and the binding accident prevention regulations applicable in the country and place of use of the machine, the generally acknowledged rules of technology with regard to safe and professional work practices are to be observed. 1.2 Warnings and symbols in the operating instructions Heeding the following safety alert symbols / designations used in the operating instructions is absolutely necessary: The hazard triangle with the signal word “CAUTION” is used as a work safety indication for all work which could result in death or physical injury. Special care and caution must be taken when carrying out such jobs. CAUTION ATTENTION NOTICE The signal word “ATTENTION” is used to call attention to hazards which could result in damage and / or destruction of the grinding machine or its environment. The signal word “NOTE” calls attention to tips on use and useful information. 7 1. Important notes 1.3Warning labels on the grinding machine and their meanings The following warnings and safety alert signs have been affixed to the grinding machine: CAUTION! DANGEROUS ELECTRICAL VOLTAGE (warning notice on the switch cabinet) On being connected to the voltage supply (3x 400 V), the grinding machine becomes electrically live and touching its live parts directly could be life-threatening. Live machine parts may be opened only by authorized, trained personnel. The grinding machine must be separated from the mains supply before carrying out servicing, maintenance and repair jobs on it. CAUTION! RISK OF INJURY FROM KNIFE (warning notice on the polishing unit) Work on the grinding machine involves the sharpening of knives which could cause serious cut injuries due to their sharpness. Protective gloves must be worn when carrying out such work, in particular when placing the knife. Be careful when transporting blades. Use the protective devices provided by the knife manufacturer. Wear protective gloves and apron. 8 1. Important notes 1.4 Rating plate and machine serial number Maschinenbau GmbH Witschwender Strasse 26 88368 Bergatreute Germany 07527- 928-0 www.knecht.eu The rating plate is located on the left side of the machine. Automatische Schleif- u. Poliermaschine Bauj. TYPE B 500 Masch.-Nr. 820463500 V 400 A KW 8,0 Hz 50 Motor 25 400 n1 1400/min KW 2,2 A 2,5 Hz Y n2 50 Sch Y Polierantrieb rechts V 400 n1 2870/min KW 1,1 A Motor Gew. 900 kg Sch. Schleifbandantrieb V Motor 2016 2,5 Hz n2 50 Sch Y Polierantrieb links V 400 n1 1360/min KW 0,7 A 2 Hz n2 50 Sch Y Figure 1-1 Rating plate The machine number is located on the rating plate and on the top right of the machine. Figure 1-2 Machine serial number 9 1. Important notes 1.5 Figure and item numbers in the operating instructions If the text refers to a machine component shown in a figure, then a figure or item number is added in brackets after the machine component. Example: (7-5/1) denotes figure number 7-5, item 1. Adjusting the grinding angle with the hand wheel (7-5/1). 2 The grinding angle can be read off the scale (7-5/2). 1 Figure 7-5 Adjusting the grinding angle 10 2.Safety 2.1 Basic safety instructions 2.1.1 Observe notes in the operating instructions The basic prerequisite for safe handling and uninterrupted operation of this grinding machine is knowledge of the basic safety instructions and regulations. • These operating instructions contain important notes on how to operate the grinding machine safely. • All persons carrying out work on the grinding machine must follow these operating instructions, in particular the safety notices. • In addition, the accident prevention rules and regulations applicable at the place of use of the machine must also be observed. 2.1.2 Operator's duty The operator is obliged to allow only those persons to work on the grinding machine, who • are familiar with the basic occupational safety and accident prevention regulations and have been trained and instructed in the handling of the grinding machine, • have read the operating instructions, particularly the “Safety” section, and have read and understood the warning notes. They have given a signed confirmation of this in writing. Checks are also carried out at regular intervals to ensure that the worker is fulfilling his employee obligation to observe safety at work. 2.1.3 Obligations on the part of the personnel All the personnel working on the grinding machine shall be obliged to • observe the basic occupational safety and accident prevention regulations, • read the operating instructions, particularly the “Safety” chapter, and the warning notes. They must provide signed confirmation of this in writing. 2.1.4 Hazards associated with handling the machine The grinding machine has been built to the latest technological standards and the acknowledged rules of technical safety. In spite of that, its use presents inherent risks which could result in bodily harm or even death of the user or third persons, or impairment of the grinding machine or other property. The grinding machine may only be used: • for the intended purpose, and • in faultless condition with regard to safety-relevant aspects. 11 2.Safety Faults that could impair safety must be eliminated immediately. 2.1.5Malfunctions If safety-relevant malfunctions occur in the grinding machine, or if the processing behavior indicates that such malfunctions may have occurred, the grinding machine must be stopped immediately until such time as the malfunction has been found and eliminated. The malfunctions must be eliminated by authorized technical staff. 2.2 Use as intended The grinding machine is only meant for the automatic grinding, deburring and polishing of flat machine cutting knives. Before starting work on a flat knife, it must be checked whether the knife fits on the knife holder. Any other use is considered improper use. Knecht Maschinenbau GmbH assumes no liability for damages resulting from improper use. The user alone bears the risk in such cases. Use as intended includes the observance of all the instructions in the operating instructions. The grinding machine is being used improperly, if, e.g., • devices are not fastened properly. • work pieces other than flat machine cutting knives are ground. 2.3 Warranty and Liability Warranty and liability claims in case of personal injuries or property damage are excluded if such damage is attributable to one or more of the following causes: • improper use of the grinding machine, • improper transportation, commissioning, operation and maintenance of the grinding machine, • operating the grinding machine with defective safety devices, or improperly attached or malfunctioning safety and protective equipment, • ignoring the operating instructions with regard to transportation, commissioning, operation, maintenance and repair of the grinding machine, • unauthorized structural alterations to the grinding machine, • unauthorized modification, e.g. of the drive conditions (power and speed), and • insufficient monitoring of machine parts that are exposed to wear 12 2.Safety • use of unapproved replacement and wear parts. Use only original replacement and wear parts. If parts are purchased from external suppliers, it cannot be guaranteed that they will be constructed and manufactured to withstand the stresses and provide the required level of safety. 2.4 Safety regulations 2.4.1 Organizational measures All the existent safety devices must be checked regularly. Observe prescribed intervals for recurring maintenance work or as specified in the operating instructions. 2.4.2 Protective devices Before commissioning the grinding machine, it must be ensured that all protective equipment is properly mounted and in functional condition. Protective equipment may be removed only after the machine has stopped and has been secured against accidental restarting of the grinding machine. If sub-components are supplied, the protective equipment must be correctly attached by the operator according to the instructions. 2.4.3 Informal safety measures The operating instructions must be permanently available at the place of use of the grinding machine. In addition to the operating instructions, the generally applicable as well as the locally relevant accident prevention regulations must also be made available and observed. All the safety alert symbols and danger warnings on the grinding machine must be complete and clearly legible. 2.4.4 Selection and qualifications of the personnel Only trained and instructed personnel may work on the grinding machine. The minimum legal age for employment must be observed. The responsibilities of the personnel must be clearly assigned, i.e. commissioning, operation, maintenance and repair, etc. Personnel still undergoing training or instruction may only work on the grinding machine under the permanent supervision of an experienced person! 13 2.Safety 2.4.5 Machine control system Do not make any changes to the software program under any circumstances. Parameters that the operator can set himself are excluded from this prohibition (e.g. setting the number of cycles). Only trained and instructed personnel is allowed to activate the control unit. 2.4.6 Safety measures in normal operation Refrain from any method of working which may pose a risk to safety. Only operate the grinding machine if all the safety devices are installed and fully functional. Check the grinding machine for external signs of damage and correct operation of the safety devices at least once every shift. Report any changes (including operating behavior) immediately to the competent department / person. Where required, shut down the grinding machine immediately and secure against restarting. Before switching on the grinding machine, ensure that no one is exposed to any risk from the start-up of the machine. If there are any functional faults, stop the machine immediately and secure against restarting. Have the faults eliminated immediately. 2.4.7 Dangers due to electrical power The switch cabinet must always remain secured against access. Only authorized personnel must be allowed to access it. Work on electrical units or operating materials may only be performed by a qualified electrician in accordance with electrical rules. Defects, such as damaged cables, cable connections, etc., must be immediately rectified by an authorized electrician. Cables marked in yellow are electrically live even when the main switch is in off position. CAUTION 2.4.8 Particular danger zones When the grinding belt moves to working position, there is a hazard of pinching in the rear area of the machine. Suitable personal protective equipment must be worn. 14 2.Safety 2.4.9 Servicing (maintenance, repair) and fault rectification Maintenance work is to be carried out on schedule by trained personnel. Inform operating personnel before starting repair work. The responsible supervisor is to be named. For all service work, the grinding machine is to be disconnected from the power supply and secured against accidental restarting. Pull out the mains plug. Cordon off the servicing area, as far as possible. After completion of the maintenance work and fault rectification, install all the safety devices and check whether they are fully functional. 2.4.10 Structural alterations to the grinding machine Modifications, retrofitting or rebuilds of the grinding machine are not allowed without the permission of the manufacturer. This also applies to the installation and adjustment of safety devices. No alterations may be carried out without prior written permission from Knecht Maschinenbau GmbH. Immediately replace machine parts which are not in perfect condition. Use only original replacement and wear parts. If parts are purchased from external suppliers, it cannot be guaranteed that they will be constructed and manufactured to withstand the stresses and provide the required level of safety. 2.4.11 Cleaning the grinding machine Cleaning agents and materials used must be handled properly and disposed of in an environment-friendly manner. Ensure that wear and replacement parts are disposed of in a safe and environmentally friendly way. 2.4.12 Oils and greases When handling lubricants / oils and greases, follow the safety regulations for the product. Observe special instructions for the foodstuffs sector. 2.4.13 Relocation of the grinding machine Even when moving the machine a short distance from its site, disconnect it from all external power supply sources. Before restarting the machine, connect it properly to the current supply. When loading or unloading, only use hoisting and load lifting equipment with sufficient load-bearing capacity. Appoint a qualified banksman (signaler) for the lifting process. No persons other than those entrusted with this work may be present in the loading and installation area. 15 2.Safety Only lift the grinding machine correctly with a suspension device in accordance with the operating instructions (attachment points for load suspension devices, etc.). Only use suitable transport vehicles with sufficient load-bearing capacity. Attach the load securely. Use suitable attachment points. When putting in operation again, proceed only as instructed in the operating instructions. 16 3.Description 3.1 Intended Use The B 500 automatic grinding and polishing machine grinds, deburs and polishes flat machine cutting knives. 3.2 Technical specifications Height ������������������������������������������������������������ approx. 1800 mm Width ������������������������������������������������������������� approx. 1500 mm Depth ������������������������������������������������������������� approx. 1500 mm Weight ���������������������������������������������������������������������� 500 kg Current supply* ������������������������������������������������������������ 3x 400 V Mains frequency* �������������������������������������������������������������� 50 Hz Output* ��������������������������������������������������������������������� 6.5 kW Energy consumption* ��������������������������������������������������������� 10.5 A Back-up fuse* ������������������������������������������������������������������ 16 A Control voltage �������������������������������������������������������������� 24 V DC Pneumatic connection ��������������������������������������������������������� 6.5 bar Measured A-evaluated emission sound pressure level ����������������������������� 72 dB (A) at workstation LpA** Air consumption �������������������������������������������������������� max. 50 l / min Wet grinding belt ������������������������������������������������������ 2200 x 60 mm Flap brushes ���������������������������������������������������������� d.200 x 50 mm *) This data may vary depending on the electrical power supply. **) Dual number noise emission information according to EN ISO 4871. Noise emission value according to EN ISO 11202 (measurement uncertainty KpA. 3 dB(A)) A K 24 cutter knife RR335 by Knecht Maschinenbau GmbH was ground. 17 GoC approx. 1500 mm approx. 1800 mm 3.Description GoC approx. 1500 mm Figure 3-1 Dimensions in mm 3.3 Functional description The grinding and polishing machine can be used to automatically sharpen, deburr and polish linear and convex flat cutter knives in knife size of maximum 700 x 550 mm. The knife is fastened onto a copy clamping plate and is moved along the wet grinding belt or the flap brushes in movements that follow the shape of the knife. Grinding angles between 5° and 35° can be steplessly adjusted on the grinding unit. In case of emergency, the grinding and polishing machine can immediately be stopped by pressing the “Emergency Stop” button. 18 3.Description 3.4 Description of the assemblies 1 8 2 3 4 9 5 6 7 10 11 Figure 3-2 General view of the grinding machine 1 2 3 4 5 6 7 8 9 10 11 Belt protecting hood Belt release lever Hand wheel for height adjustment of “left polishing unit” Rear doors of polishing units (concealed) Control panel Switch cabinet Pneumatic cabinet Hand wheel for height adjustment of “right polishing unit” Protective hood Water tray Adjustable machine feet 19 3.Description 6 7 1 8 2 3 4 5 Figure 3-3 Interior view 1 Splash guard 2 Left polishing unit for knife blade 3Knife 4 SP 112 copy clamping plate 5 Guard plate 6 Grinding unit 7 Work lamp 8 Right polishing unit for backside of knife 20 3.Description 1 2 1 Control knob for pressure regulation Compressed air connection (6.5 bar) 2 Figure 3-4 Pneumatic system 3.4.1 Switching the grinding machine on / off The main switch (3-5/1) is disposed on the rear of the switch cabinet. Turning the main switch from “0” to “I” switches on the grinding machine. 1 Turning the main switch from “I” to “0” switches off the grinding machine. Figure 3-5 Main switch 3.4.2 Control panel 1 2 3 4 5 7 8 9 6 10 1 Display screen 2“Control On” button: Activates the controls (button starts flashing) 3“Start / Stop” button: Starts / stops the grinding program 4 “Change copy clamping plate” button 5“Table forward” button: For moving the table forward 6“Setting Mode” key switch: Position “1” for setting mode 7“Wet grinding belt grinding pressure” selector switch 8“Coolant On / Off” button: Switches the coolant pump on / off 9“Table back” button: For moving the table backward 10 “Emergency Stop” button Figure 3-6 Control panel 21 3.Description 3.4.3 Layout of the user interface (main screen) 1 4 7 10 2 5 8 11 3 6 9 12 13 14 15 16 17 Figure 3-7 Main screen 1 “Table forward”: For moving the table forward 2 “Fast motion Table”: Rapid traverse for table forward / backward 3 “Table back”: For moving the table backward 4 “Grinding belt motor On / Off”: Switches the wet grinding belt on / off 5 “Grinding belt Up / Down”: For raising / lowering the wet grinding belt 6“Polishing paste”: Pulse for applying the polishing paste on the flap brushes (in addition to the automatic cycle) 7 “Left polishing motor On / Off”: For switching the left polishing unit on / off 8 “Left polishing Forward / Backward”: For moving the left polishing unit forward / backward 9“Left polishing brush old”: Press the touch panel button if brushes are worn out. Slide automatically moves 10 mm further. 22 10 “Right polishing motor On / Off”: For switching the right polishing unit on / off 11 “Right polishing Forward / Backward”: For moving the right polishing unit forward / backward 12 “Reset”: For deleting temporary fault messages 13 “F1 Home position”: Moves the table to home position 14 “F2 Prod. selection”: For selecting the product files 15 “F3 Product data”: For changing the product data parameters 16 “F4 Menu”: For managing the settings and language of the user interface 17 “F5 Back”: For going back to the previous screen 3.Description ATTENTION Fast motion highlighted in green: Unit traverses continuously without interruption. Fast motion highlighted in gray: Unit traverses a predefined distance. 23 3.Description 3.4.4 Coolant Pump The grinding machine has a coolant pump (3-8/1) with monitoring function. The coolant pump becomes visible when the right door on the rear side of the machine is opened. 1 The coolant container sunk in the water tray must be filled with water up to 3 cm below the rim (approx. 15 liters). A coolant additive is not required. Figure 3-8 Coolant pump The grinding machine has a flow gage (3-9/1) which automatically interrupts the program flow if there is no coolant flow. 1 The flow gage is in the machine interior and must be cleaned regularly. Figure 3-9 Flow gage The coolant volume is regulated using the coolant tap (3-10/1). 1 Figure 3-10 Coolant tap NOTICE 24 Turning down the tap too far interrupts the program flow. 3.Description 3.4.5 Protective Hood The protective hood (3-11/1) is not locked during the grinding process. If it or one of the rear doors is opened, the program flow is aborted. 1 The copy clamping plate can be changed when the protective hood is open. Figure 3-11 Protective hood 3.4.6 SP 112 Copy clamping plate The knives are clamped onto a copy clamping plate (3-12/1) for machining. A matching copy clamping plate is needed for each knife shape and size. Knives may only be ground using SP 112 copy grinding plates. The knife change takes less than one minute. 1 Copy clamping plates for new knife types are available on request from Knecht Maschinenbau GmbH. Figure 3-12 SP 112 copy clamping holder 3.4.7 Grinding Unit The wet grinding belt (3-13/1) is in idle position above the polishing units (3-13/2 and 3-13/3). 5 1 2 3 It is lowered onto the knife (3-13/4) for grinding. The grinding angle is adjusted using the hand wheel (3-13/5). 4 Figure 3-13 Grinding unit 25 3.Description 3.4.8 Polishing units with polishing paste 3 The grinding machine is equipped with two polishing units ((3-14/1) and (3-14/2)) for polishing the knives. 4 1 2 The polishing unit on the left (3-14/1) swivels forward to polish and deburr the knife blade. The polishing unit on the right (3-14/2) swivels forward to polish the back of the knife. Figure 3-14 Grinding compartment The position of the polishing units relative to the knives is adjusted with the help of the hand wheels ((3-14/3) and (3-14/4)). The polishing paste is applied automatically in each case via a pneumatic cylinder. 26 4.Transport For transporting the machine, the locally applicable safety and accident prevention regulations must be observed. CAUTION Only transport the machine in upright position (with the machine feet facing downwards). ATTENTION 4.1 There are parts jutting out on the underside of the machine which could be easily damaged. Pull out the water tray (3-2/10) before transporting. Drain the water before doing that. Transport Aids For transporting and for setting up the grinding machine, only use adequately dimensioned transport aids with a load-bearing capacity of at least 1.5 t, e.g. truck, forklift or hydraulic lift truck. When using a forklift or a lift truck, move the fork under the grinding machine. Bear in mind the center of gravity of the machine. The center of gravity (CoG) is shown in figure 3-1. 4.2 Transport damage If damage is detected on unloading after acceptance of the delivery, inform Knecht Maschinenbau GmbH and the freight forwarder about it immediately. If required, consult an independent expert immediately. Remove the packaging and shipping straps. Remove the shipping straps on the grinding machine. Dispose of the packaging in an environmentally friendly way. 4.3 Transport to another installation site For transport to another installation site, ensure that the space requirements are fulfilled (see Chapter 3.2). A reliable electrical connection must be provided at the new installation site. The grinding machine must be stable and firmly placed. The machine feet must be adjusted so that there is a slight downward slope towards the back. 27 4.Transport Installations on the electrical and pneumatic system may only be performed by an authorized specialist or our customer service staff. CAUTION 28 Observe the locally applicable safety and accident prevention regulations. 5.Installation 5.1 Selection of qualified personnel It is advisable to have trained Knecht personnel perform the installation work on the grinding machine. CAUTION 5.2 We assume no liability for damage caused by improper installation. Installation site When determining the installation site, bear in mind the space requirement for installation, maintenance and repair work on the grinding machine (see Chapter 3.2). 5.3 Supply connections The grinding machine is delivered ready for connection with the appropriate connection cable. Confirm that the machine is correctly connected to the current supply. CAUTION 5.4Settings The various components and the electrics are adjusted by Knecht Maschinenbau GmbH before delivery. ATTENTION Unauthorized changes to set values are not permitted and may damage the grinding machine. Control parameters may only be changed by accordingly qualified personnel. This person must be familiar with the machine functions and the meaning of the parameters. Other wise, damage to the machine is likely to occur. 29 5.Installation 5.5 Initial commissioning of the grinding machine Place the grinding machine at the installation site on a level base. Level out floor unevenness by adjusting the machine feet (3-2/11) with a flat wrench (SW17) taking care to ensure that there is a slight downward slope towards the back. Have an authorized electrician on site install the voltage supply. Completely install and check the safety devices before commissioning. Have all the safety devices checked for proper function by trained personnel before commissioning. CAUTION Have the compressed air supply installed on site by a qualified expert. Confirm that the machine is correctly connected to the compressed air supply. CAUTION If the machine is connected incorrectly, escaping compressed air and hurtled parts can lead to injuries. Observing the local safety and accident prevention regulations for compressed air is required. 30 6.Commissioning All work on the machine may only be performed by authorized personnel. CAUTION The locally applicable safety and accident prevention regulations must be observed. Fill the water tray (6-1/1) with water. 1 Figure 6-1 Water tray Connect the power plug to the power socket provided on site (3x 400 V, 16 A). Plug in the compressed air hose at the compressed air port (6-2/1). 2 Turn the control knob (6-2/2) to adjust the pressure to 6.5 bar. Close the belt protective hood (3-2/1), rear doors (3-2/4) and protective hood (3-2/9). 1 Figure 6-2 Compressed air port 1 3 Set the main switch (3-5/1) to “I”. Wait for the controls to initialize. Switch on the control unit with the “Control On” button (6-3/1). 2 Figure 6-3 Control panel 31 6.Commissioning Turn the “Setting Mode” key switch (6-3/2) to position “1”. Press the “Change copy clamping plate” button (6-3/3) and check the direction of rotation of the chain pinion (6-4/1). The chain pinion must rotate in clockwise direction. 1 Figure 6-4 Checking the direction of rotation 32 7.Operation 7.1 General principles of grinding technology If a blade has become blunt, material must be removed from its surface to restore it to its original sharpness. For that, the knife in question is ground to produce its cutting edge. If, in the process, a burr appears on the blade, then the grinding process was successful and can be concluded. Now, before the final sharpness is achieved, the burr must be removed in a further step. This is done with a flap brush. As it is not only the sharp cutting edges but also the long service lives that define a blade, the cutting angle is another important indicator of a blade's performance. The smaller the cutting edge angle, the higher the theoretical service life. In practice, however, the cutting edge breaks off and is therefore no longer sharp when the cutting edge angle is too small. The cutting edge angles must therefore lie between 15° and 35°. If the cutting edge angles are less than 15°, the blade becomes so unstable that it breaks at the slightest resistance. If the cutting edge angle is greater than 35°, the blade is extremely stable, but service life will not be as long. One more criterion for judging the properties of a cutting edge is the cutting edge profile. There are three different ground profiles: Tapered grinding Convex grinding Concave grinding Convex ground profiles can mostly be found on cutter blades and hand knives. Tapered and concave ground profiles are predominantly found on circular knives and blades. In general: Adhering to the profiles and the cutting edge angles specified by the manufacturer is required NOTICE If tapered grinds or concave grinds are to be applied, the grinding machine must be equipped with a harder contact disk. 33 7.Operation 7.2 Changing the profile By default, the grinding machine produces a profile for boiled sausage knives. If a flatter profile is to be ground, the grinding cycle counter must be incremented after the 2nd feed. The more often a knife profile is ground, the flatter will be the knife. Figure 7-1 “Feed cycles” product data ATTENTION 34 If a short profile is to be ground, the number of knife feeds must be reduced. Control parameters may only be changed by accordingly qualified personnel. This person must be familiar with the machine functions and the meaning of the parameters. Otherwise, damage to the machine is likely to occur. 7.Operation 7.3 Grinding the cutter knives 7.3.1 Switching on the grinding machine Set the main switch (see figure 3-5/1) to “I”. Wait for the controls to initialize. The main screen appears. Press the “Control On” button (3-6/2). The control unit is now activated. Turn the “Setting Mode” key switch (3-6/6) to position “1”. 7.3.2 Mounting the copy clamping plate Push the copy clamping plate (7-2/1) as far as it will go on the ball bearings of the guide carriage (7-2/2) while pressing against the limit stop with the right hand. Press and hold the “Change copy clamping plate” button (3-6/4) until the copy clamping plate has moved over the limit switch (7-2/3). 1 2 3 Figure 7-2 Mounting the copy clamping plate With the pin in front, push the limit switch cam (7-3/1) under the copy clamping plate and tighten the star knob (7-3/2). 2 1 Figure 7-3 Mounting the limit switch cam 35 7.Operation Place the knife (7-4/1) on the holder of the copy clamping plate and rotate the grinder (7-4/2) on the knife. 1 2 Figure 7-4 Clamping the knife This can result in serious cut injuries. Wear protective gloves. CAUTION ATTENTION NOTICE 36 Before clamping the knife, check whether the copy clamping plate matches the knife (compare labeling of the copy clamping plate with labeling of the knife). Use of a copy clamping plate that does not match the knife can lead to damage to the knife and the copy clamping plate. There is a matching copy clamping plate for each cutter knife type. To prepare the matching grinding plate, Knecht Maschinenbau GmbH needs a knife drawing or a new knife. If possible, specify the cutter type, knife radius and knife type. 7.Operation 7.3.3 Adjusting the grinding angle Adjusting the grinding angle with the hand wheel (7-5/1). 2 The grinding angle can be read off the scale (75/2). 1 Figure 7-5 Adjusting the grinding angle 7.3.4 Aligning the grinding unit Turn the “Setting Mode” key switch (3-6/6) to position “1”. 3 1 2 Move wet grinding belt to working position by pressing the “Grinding belt Up/Down” button (76/2) on the touch panel. Open the coolant tap (3-10/1) roughly halfway. Figure 7-6 Main screen Press the “Table forward” button (7-6/3) on the touch panel until wet grinding belt and knife are almost touching each other. Press the “Change copy grinding plate” button (3-6/4). Check the direction of travel of the copy grinding plate and press the button again as necessary to make the copy grinding plate move in the desired direction. Hold the button in depressed position until the copy grinding plate stops moving. The wet grinding belt is now at the knife tip. 37 7.Operation The grinding unit has been aligned properly if the path of the copy clamping plate is sufficient for grinding the entire blade length. If the blade end does not reach the grinding belt center (see figure 7-7), the limit switch cam (7-3/1) must be re-adjusted. Figure 7-7 Adjusting the path of the copy clamping plate 38 7.Operation 7.3.5 Aligning the left polishing unit As the upper and lower brushes of the left polishing unit wear off with different levels of abrasion over time, the position of the polishing unit must be realigned at regular intervals. 1 Swivel the left polishing unit towards the knife with the “Left Polishing Forward / Backward” (78/1) button in the manual functions on the touch panel. Figure 7-8 Main screen Use the hand wheel to adjust the height (3-2/3) of the “Left Polishing Unit” (3-3/2) so that the knife edge is at the point of intersection of the flap brushes. Figure 7-9 Aligning the left polishing unit ATTENTION Wrong The height of the polishing unit on the left must be adjusted so that the point of intersection of the flap brushes lies on the knife edge. Wrong Right Figure 7-10 Aligning the left polishing unit 39 7.Operation 7.3.6 Aligning the right polishing unit Swivel the right polishing unit towards the knife with the “Right Polishing Forward / Backward” (711/1) button in the manual functions on the touch panel. 1 Figure 7-11 Main screen Use the hand wheel to adjust the height (3-2/8) of the “Right Polishing Unit” (3-3/8) so that the flap brush touches the knife. Figure 7-12 Aligning the right polishing unit 7.3.7 Starting the grinding process 1 Open the coolant tap (3-10/1) roughly halfway. Close the protective hood. Set the “Setting Mode” key switch (7-13/2) to “0” and press the “Start / Stop” button (7-13/1). The grinding program starts. 2 Figure 7-13 Control panel 40 The program flow can be aborted at any time by pressing the “Start / Stop” button (7-13/1). The copy grinding plate will move back to home position. 7.Operation 7.4 Changing the copy clamping plate Never change the copy clamping plate with knives clamped. There is a risk of crushing and pinching at the drive pinion. CAUTION This can result in serious injuries. Only press the “Change copy clamping plate” button (3-6/4) with the copy grinding plate mounted. Loosen the star knob (7-14/2). Take out the limit switch cam (7-14/1). 2 1 Figure 7-14 Changing the copy clamping plate 2 1 Figure 7-15 Control panel Set the “Setting Mode” key switch (7-15/1) to “1” and press the “Change copy grinding plate” button (7-15/2). Check the direction of travel of the copy grinding plate and press the button again as necessary to make the copy grinding plate move in the desired direction. Hold the button in depressed position until the copy grinding plate stops moving. Then detach the copy clamping plate from the guide carriage by hand without twisting it and keep it in a safe place. 41 7.Operation Push the copy clamping plate (7-16/1) as far as it will go onto the ball bearings of the guide carriage (7-16/2) while pressing against the limit stop with the right hand. 1 Press and hold the “Change copy clamping plate” button (7-15/2) until the copy clamping plate has moved 2 - 3 cm. 2 Figure 7-16 Pushing the copy clamping plate onto the guide carriage NOTICE 42 With the pin in front, push the limit switch cam (7-14/1) under the copy clamping plate and tighten the star knob (7-14/2). If the copy clamping plate has not been inserted properly, push it in by hand. 7.Operation 7.5 Changing the wet grinding belt CAUTION For all work on the grinding and polishing machine, the locally applicable safety and accident prevention regulations as well as instructions in the “Safety” and “Important Notes” section of the operating instructions must be observed. Only original grinding belts may be used. ATTENTION Incorrect grinding belts can lead to overheated blades that can cause knife breaks. 1 Pull the belt protective hood (7-17/1) upward and remove. Turn the belt release lever (7-17/3); unload and remove the wet grinding belt (7-17/4). 2 3 Load the new wet grinding belt taking care that the direction of rotation is correct (the direction of rotation of the motor is counter-clockwise). There is a direction arrow on the grinding unit (7-17/2) to check the direction of rotation. 4 Figure 7-17 Changing the wet grinding belt If the wet grinding belt is not running exactly on the contact disk, it can be aligned with the belt control knob (7-18/1). Turning the belt control knob in counter-clockwise direction makes the wet grinding belt run to the left. Turning in clockwise direction makes the belt run to the right. 1 Figure 7-18 Adjusting the wet grinding belt 43 7.Operation 7.6 Changing the right flap brush Close the protective hood. Press “Right Polishing Forward / Backward” button (7-19/1) on the touch panel. 1 The polishing unit on the right swivels forward. Figure 7-19 Main screen Set the “Setting Mode” key switch (3-6/6) to position “1” so that the polishing unit remains in front when the protective hood opens. ATTENTION 1 2 Open the protective hood and insert the bar (7-20/1) in the hole in the clamping flange behind the flap brush. Insert the tap wrench (7-20/2) in the holes of the clamping flange and unscrew in clockwise direction. Exchange the flap brush and screw back the clamping flange in counter-clockwise direction. Figure 7-20 Changing the right flap brush 44 7.Operation 7.7 Changing the left flap brushes Close the protective hood. Press “Left Polishing Forward / Backward” button (7-21/1) on the touch panel. 1 The polishing unit on the left swivels forward. Figure 7-21 Main screen Set the “Setting Mode” key switch (3-6/6) to position “1” so that the polishing unit remains in front when the protective hood opens. ATTENTION 1 2 Open the protective hood and loosen the upper nut (7-22/1) in counter-clockwise direction using the SW22 flat wrench. Loosen the lower nut (722/2) in clockwise direction. Remove the flap brushes and flange and mount the new flap brushes in reverse sequence. Screw the nuts back again. Figure 7-22 Changing the left flap brush 45 7.Operation 7.8 Changing the polishing pastes Open the rear doors and unscrew the clamping claw with an SW17 combination wrench (7-23/1). Take out the polishing paste (7-23/2). 2 Insert new polishing paste. Screw the clamping claw back again. 1 Figure 7-23 Changing the right polishing paste Proceed in the same way for changing the polishing paste on the left (7-24/1). 2 Then screw the clamping claw (7-24/2) back again. 1 Figure 7-24 Changing the left polishing paste ATTENTION A new polishing paste must initially be supported with a plate underneath. This prevents the paste from breaking off. The supporting paste must be removed as soon as approximately half of the polishing paste has been used up. Tighten the clamping claw only lightly until the pyramidal tips are pressed all the way into the paste. Use only original polishing pastes as the knives will otherwise not be sharpened properly. 46 8. Control system 8.1 Main Screen 1 4 7 10 2 5 8 11 3 6 9 12 13 14 15 16 17 Figure 8-1 Main screen 1 “Table forward”: For moving the table forward 2 “Fast motion, table”: Rapid traverse for table forward / backward 3 “Table back”: For moving the table backward 4 “Grinding belt motor On / Off”: Switches the wet grinding belt on / off 5 “Grinding belt Up / Down”: For raising / lowering the wet grinding belt 6“Polishing paste”: Pulse for applying the polishing paste on the flap brushes (in addition to the automatic cycle) 7 “Left polishing motor On / Off”: For switching the left polishing unit on / off 8 “Left polishing Forward / Backward”: For moving the left polishing unit forward / backward 9“Left polishing brush old”: Press the touch panel button if brushes are worn out. Slide automatically moves 10 mm further. 10 “Right polishing motor On / Off”: For switching the right polishing unit on / off 11 “Right polishing Forward / Backward”: For moving the right polishing unit forward / backward 12 “Reset”: For deleting temporary fault messages 13 “F1 Home position”: Moves the table to home position 14 “F2 Prod. selection”: For selecting the product files 15 “F3 Product data”: For changing the product data parameters 16 “F4 Menu”: For managing the settings and language of the user interface 17 “F5 Back”: For going back to the last view 47 8. Control system ATTENTION Fast motion highlighted in green: Unit traverses continuously without interruption. Fast motion highlighted in gray: Unit traverses a predefined distance. 8.2 Activating the product file A separate product file for each grinding task is stored. This product file must be selected and loaded before grinding in automatic mode. The procedure is as follows: Activate the “F2 Prod. Selection” (8-2/1) touch panel button. A new window (8-3) opens. 1 Figure 8-2 Main screen Select the desired file so that it is highlighted in blue. Load the product file in the control unit via the “F4 Activate” (8-3/1) touch panel button. 1 The program automatically switches back to the main screen. Figure 8-3 Selecting the product file 1 Figure 8-4 Main screen 48 The new product file appears in the “Product” row (8-4/1). The new parameters are now loaded by the control unit. 8. Control system 8.3 Renaming, creating and deleting the product file Product files can be renamed, deleted and new ones created by copying. The procedure is as follows: Activate the “F2 Prod. Selection” (8-5/1) touch panel button. 1 A new window (8-6) opens. Figure 8-5 Main screen Select the desired file so that it is highlighted in blue. Select the relevant touch panel button: “F1 Rename” (8-6/1), “F2 Delete” (8-6/2) or “F3 Copy” (8-6/3). 1 2 3 4 5 Figure 8-6 Editing the product file 8.3.1 Renaming product file On pressing “F1 Rename” (8-6/1), a window as displayed in the figure on the left (8-7) opens. 1 Edit the file name (8-7/1) using the keyboard and confirm with “OK” (8-7/2). 2 Figure 8-7 Renaming the product file The window closes. The renamed file appears in the product file directory. Then activate a product file with “F4 Activate” (8-6/4) or return to the main screen with “F5 Back” (8-6/5). 49 8. Control system 8.3.2 Creating the product file On pressing “F3 Copy” (8-6/3), a window as displayed in the figure on the left (8-8) opens. 1 Edit the file name (8-8/1) using the keyboard and confirm with “OK” (8-8/2). The window closes. The new file appears in the product file directory. 2 Continue with Chapter 8.4 to edit the parameters of the product file. Figure 8-8 Creating the product file 8.3.3 Deleting the product file On pressing “F2 Delete” (8-6/2), a pop-up window (8-9/1) opens. Confirm with “Yes” (8-9/2); cancel with “No”. 1 The pop-up window closes. 2 3 Figure 8-9 Deleting the product file 50 4 Then activate a product file with “F4 Activate” (8-9/3) or return to the main screen with “F5 Back” (8-9/4). 8. Control system 8.4 Editing the parameters of the product file The parameters of a product file can be changed as follows: Press the “F3 Product Data” (8-10/1) touch panel button on the main screen. 1 A new window (8-11) opens. Figure 8-10 Main screen There are two different parameter groups: 1 2 “Grinding” (8-11/1): Grinding process data (see Chapter 8.4.1) “Polishing” (8-11/2): Polishing process data (see Chapter 8.4.3) Figure 8-11 Parameter groups The active group is always indicated with a green arrow. To activate a group, press the name. The arrow moves forward and the group is highlighted in blue. 51 8. Control system 8.4.1 Meaning of “Grinding” parameters 1 2 3 4 Figure 8-12 “Grinding” parameters 1 “Touching enabled”: true = touching enabled, false = touching disabled 2 “ Start position for beginning of knife search”: Path that the knife covers for touching in fast motion before speed is reduced (in mm) To change the parameters, tap on the relevant button highlighted in yellow. Tap on “Numbers” to open the window as shown in (8-13); tap on “Values” to open the window as shown in (8-14). Select the desired number and confirm with “OK” (8-13/1). The “Cancel” touch panel button closes the window without accepting the number. 1 Figure 8-13 Editing the “Numbers” parameter 52 8. Control system In the window for “Values”, select between “true” and “false” and confirm with “OK” (8-14/1). The “Cancel” touch panel button closes the window without accepting the value. 1 Figure 8-14 Editing the “Values” parameter ATTENTION Save the changed values with the “F2 Save” (8-12/4) touch panel button. If a current product file is changed, overwrite via the “F1 Activate” (8-12/3) touch panel button of the control system. 53 8. Control system 8.4.2 Meaning of “Feed Cycles” parameter 1 2 3 4 Figure 8-15 “Feed cycles” parameter 1 “ Number of Cycles”: Number of cycles in a particular step; the step is not carried out if the value is “0”. 2 “ Feed”: Path that the knife covers to the next step after completing processing of the previous step (in mm) NOTICE The above parameters refer to the 2nd - 10th step. To change the parameters, tap on the relevant button highlighted in yellow. A window (8-16) opens when you click “Numbers”. 54 8. Control system Select the desired number and confirm with “OK” (8-16/1). The “Cancel” touch panel button closes the window without accepting the number. 1 Figure 8-16 Editing the “Numbers” parameter ATTENTION Save the changed values with the “F2 Save” (8-15/4) touch panel button. If a current product file is changed, overwrite via the “F1 Activate” (8-15/3) touch panel button of the control system. 55 8. Control system 8.4.3 Meaning of “Polishing Process” parameters 1 2 3 4 5 Figure 8-17 “Polishing process” parameter 1“Polishing process enabled”: true = polishing process activated, false = polishing process deactivated 2 “Number of Cycles”: Polishing cycles in a particular polishing process 3“Left polishing unit”: true = left polishing unit activated, false = right polishing unit activated NOTICE The above parameters refer to the 2nd polishing process. To change the parameters, tap on the relevant button highlighted in yellow. Tap on “Numbers” to open the window as shown in (8-18); tap on “Values” to open the window as shown in (8-19). 56 8. Control system Select the desired number and confirm with “OK” (8-18/1). The “Cancel” touch panel button closes the window without accepting the number. 1 Figure 8-18 Editing the “Numbers” parameter In the window for “Values”, select between “true” and “false” and confirm with “OK” (8-19/1). The “Cancel” touch panel button closes the window without accepting the value. 1 Figure 8-19 Editing the “Values” parameter ATTENTION Save the changed values with the “F2 Save” (8-17/5) touch panel button. If a current product file is changed, overwrite via the “F1 Activate” (8-17/4) touch panel button of the control system. 57 8. Control system 8.5 Settings Data The settings data are called via the main menu “F4 Menu” (8-1/16) followed by “F2 Settings Data”. 1 2 3 4 Figure 8-20 Settings data 1 “ Number of cycles up to polishing paste”: Number of grinding cycles before the polishing paste is automatically applied on the flap brushes 2 “ Correction value for worn left polishing brush”: On pressing the touch panel button in the main screen (8-1/9), the slide moves forward by the set value so that the left flap brushes can function optimally (in mm) To change the parameters, tap on the relevant button highlighted in yellow. A window (8-21) opens when you click “Numbers”. 58 8. Control system Select the desired number and confirm with “OK” (8-21/1). The “Cancel” touch panel button closes the window without accepting the number. 1 Figure 8-21 Editing the “Numbers” parameter ATTENTION Save the changed values with the “F2 Save” (8-20/4) touch panel button. If a current product file is changed, overwrite via the “F1 Activate” (8-20/3) touch panel button of the control system. 59 8. Control system 8.6 Manual Functions The manual functions allow you to operate the machine by hand. They are called via the main menu “F4 Menu” (8-1/16) followed by “F3 Manual Functions”. Various functions of the machine can be individually activated / deactivated. ATTENTION Buttons highlighted in green are enabled. Buttons highlighted in gray are disabled. 1 2 3 4 5 Figure 8-22 Manual functions 60 1 S witch the suction system on / off 2 Switch coolant pump on / off 3 Water deflector Up / Down 4 Copy clamping plate Raise / Lower 5 “F5 back”: Takes you back to the previous screen 8. Control system 8.7Language The user interface language can be changed to the language of the country of use. The parameter descriptions are always in English. Press the touch panel button “F5 Back” (8-23/1) to go back to the start screen. 1 Figure 8-23 Main menu Press the “F4 Language” (8-24/1) touch panel button. A new window (8-25) opens. 2 1 Figure 8-24 Start screen The desired language is selected and automatically activated by pressing the corresponding touch panel button (8-25/1). Then return to the start screen by pressing the “F5 Back” (8-25/2) touch panel button. 1 2 The main screen appears when the “F3 Production” (8-24/2) button is pressed. Figure 8-25 Selecting the language 61 8. Control system 8.8 Setting up an internet connection The machine has a network connection port which can be used to establish a direct connection between the machine and Knecht Maschinenbau. The contents of the display screen of the grinding machine are transferred via this connection. In this way, the manufacturer's technicians can perform a diagnosis of the machine, change software settings and install or edit new grinding programs. 1 Figure 8-26 Switch cabinet “Team Viewer”, the program pre-installed on your machine, is needed for setting up the internet connection. An active internet connection must be available. For that, please connect the network cable provided with the machine to the network socket provided on site and the network connection in the switch cabinet (8-26/1). NOTICE 62 Please have the internet connection set up by a network administrator. 9. Care and maintenance 9.1 Lubrication and Maintenance There is one grease fitting each in the front and rear of the guideway housing (9-1/1). 1 4 To access the grease fitting of the polishing unit, the cover plate (9-1/2) and the motor hood (9-1/3) must be removed. 3 2 One shot of the grease gun must be pressed into each grease fitting once a month. The guideways and adjusting spindles for angle adjustment (9-1/4) must be greased once a month. Figure 9-1 Grease fitting The Bowex coupling (9-2/1), the grease fitting (9-2/2) of the swivel mechanism and the knife feed guideways (9-2/3) must be greased once a month. 1 2 3 Figure 9-2 Lubricating points Remove and clean the flow gage (9-3/1) once a month. 1 2 Figure 9-3 Flow gage For this purpose, disconnect the connector (9-3/2) and turn the flow gage in counter-clockwise direction by hand. Clean the measuring probe with a clean cloth. Slightly grease the thread (not the probe) and tighten back again. Re-assemble in reverse sequence. 63 9. Care and maintenance 9.1.1 Lubrication schedule and lubricant table 64 Lubricating activity Interval OEST SHELL EXXON Mobil Lubricate thread of star knobs, clamping lever, flow gage and Bowex coupling 4 weeks Multi-purpose grease L2 Gadus S2 V 100 2 Mobilith SHC 100 Grease machine parts after cleaning After each grinding operation Paraffinum Perliquidum 16L Shell Risella 917 Marcol 82 Lubricate parts with grease fittings (see Figure 9-1) 4 weeks Multi-purpose grease L2 Gadus S2 V 100 2 Mobilith SHC 100 Lubricate guideways and adjusting spindles 4 weeks Multi-purpose grease L2 Gadus S2 V 100 2 Mobilith SHC 100 Lubricate copy clamping plate paths on the guard plate Daily Multi-purpose grease L2 Gadus S2 V 100 2 Mobilith SHC 100 9. Care and maintenance 9.2Cleaning Clean the machine after each grinding process to prevent grinding sludge from drying, hence making it harder to remove. After cleaning, lightly grease the machine with non-corrosive oil (also refer to lubrication schedule in Chapter 9.1.1). The coolant must be changed every week. The copy clamping plate can be lowered for cleaning the machine. To do that, close the protective hood. 1 Press the “F4 Menu” (9-4/1) touch panel button on the main screen. A new window (9-5) opens. Figure 9-4 Main screen Press the “F3 Manual Function” (9-5/1) touch panel button to call the manual function of the machine. 1 Figure 9-5 Menu Press the “Down” button (9-6/1) on the touch panel. The copy clamping plate is lowered and the grinding sludge can be removed with water. 2 1 To raise the copy clamping plate, press the “Up” button (9-6/2) on the touch panel. Figure 9-6 Manual functions ATTENTION Dispose of the coolant in an environmentally friendly way! 65 9. Care and maintenance 9.2.1 Cleaning of sub-structure The guard plate (9-7/1) can be dismantled for cleaning and servicing the sub-structure. 1 2 2 First, open the rear doors (3-2/4) on the backside of the machine and pull out the connector plug underneath the guard plate. Then turn the Allen screws (9-7/2) all the way to the stop in counter-clockwise direction from the front. To do that, use a SW10 Allen wrench. Figure 9-7 Dismantling the guard plate The guard plate can now be pulled forward and out of the machine. Re-assemble the guard plate in reverse sequence. ATTENTION Be careful while re-assembling the guard plate as the limit switch and cable could be damaged otherwise. Flap brushes must not get wet, since they can only absorb polishing paste and can only correctly deburr a knife in dry state. 66 10.Malfunctions 10.1Faults Malfunction Fault Remedy Wet grinding belt moves to and fro, making a lot of noise, and cannot be corrected. Wet-grinding belt is faulty Mount new wet grinding belt Contact disk is damaged or worn out Mount new contact disk Too little coolant in the coolant tank Fill coolant Lines are clogged Clean lines Defective pump Change pump Flow gage is dirty Clean flow gage No burr formation on the knife edge Check condition of wet grinding belt and accordingly increase the number of cycles Polishing unit set incorrectly Re-align polishing unit (see Chapter 7.3.5 and 7.3.6) Pneumatic cylinder of the polishing paste is running rough Clean pneumatic cylinder and check for smooth running Polishing paste sticks to the guideway Uncouple the compressed air hose and check whether the cylinder can be moved by hand. If not, rework the polishing paste with knife. Fault message “Coolant error” on the main screen. Knife is not getting sharpened. Polishing paste not being fed. If a fault is not included in the faults table or if the fault is not eliminated, please contact our service staff (Chapter 12.2). 67 11. Disassembly and disposal 11.1Disassembly All operating materials must be disposed of correctly. Secure moving parts against slipping. The disassembly must be carried out by a qualified specialist company. 11.2Disposal At the end of the machine service life, it must be disposed of by a qualified specialist company. In exceptional cases and in agreement with Knecht Maschinenbau GmbH, the machine can be returned. Operating materials (e.g. grinding belts, flap brushes, coolant etc.) must also be disposed of correctly. 68 12. Service, spare parts and accessories 12.1 Postal Address Knecht Maschinenbau GmbH Witschwender Straße 26 88368 Bergatreute Germany Phone +49 -7527-928-0 Fax +49 -7527-928-32 [email protected] www.knecht.eu 12.2Service Service management: See postal address [email protected] 12.3 Spare parts If you need spare parts, please use the spare parts list provided with the machine. Please place your order as shown below. Please always include the following information: (Example) Machine type Machine serial number Designation of assembly Designation of individual part Item number Drawing number Quantity (B500) (820463500) (4-way paste feed) (Roller) (10) (2000127-8848) (1 pc.) Please feel free to contact us with any questions. 69 12. Service, spare parts and accessories 12.4Accessories 12.4.1 Abrasives used Type Dimension Grain Order number Wet grinding belt 2200x60 80 412A-62-0725 2200x60 100 412A-63-0726 2200x60 120 412A-64-0727 2200x60 240 412A-66-0728 Wet grinding belt, compact grain 2200x60 180 412A-70-0180 Assembled on delivery Sisal flap brush (right) d.200x50xd.25 412J-02-8150 Assembled on delivery Polishing paste (right) 230x60x50 412R-05-0501 Assembled on delivery Sisal flap brush (left) d.180x30xd.17 412J-02-0180 Assembled on delivery Polishing paste (left) 250x40x140 412R-06-0140 Assembled on delivery ATTENTION Remark No other abrasives may be used without the approval of Knecht Maschinenbau GmbH. Knecht Maschinenbau GmbH accepts no liability if other abrasives are used. If you require wet-grinding belts, flap brushes, polishing pastes or other accessories, please contact our sales staff, dealers, or Knecht Maschinenbau GmbH directly. Thank you for buying our product! 70 13.Appendix 13.1 EC Declaration of Conformity in accordance with the EC Directive 2006 / 42 / EC • Machinery Directive 2006 / 42 / EC • Electromagnetic Compatibility Directive 2004 / 108 / EC We hereby declare that the machine mentioned below fulfills the basic health and safety requirements of the relevant EC Directive by virtue of the machine's construction and design and the version placed by us on the market. This declaration becomes void if the machine is modified in any way without our consent. Designation of the machine: Type designation: Automatic Grinding and Polishing Machine B 500 Applicable harmonized standards, in particular: DIN EN ISO 12100-1 DIN EN ISO 12100-2 DIN EN ISO 60204-1 DIN EN 13218 DIN EN 349 Responsible for the documentation: Peter Heine (Dipl. Ing. Mechanical Engineering) Phone +49 -7527-928-15 Manufacturer: Knecht Maschinenbau GmbH Witschwender Straße 26 88368 Bergatreute Germany Complete technical documentation is available. The operating instructions document for the machine is available in its original version and in the native language of the user. Bergatreute, July 26, 2016 –––––––––––––––––––––––––– Place, date ––––––––––––––––––––––––– Signature Managing Director ––––––––––––––––––––––– Signatory details 71 Knecht Maschinenbau GmbH Witschwender Straße 26 ■ 88368 Bergatreute ■ Germany Phone +49 -7527-928-0 ■ Fax +49 -7527-928-32 [email protected] ■ www.knecht.eu
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