PSD 5 BO 50/5 POD 5 - PODA

Transcription

1 KEF-MOTOR A/S Industrivej 3-9 DK 9460 Brovst Tel Fax Instruction Manual PSD 5 BO 50/5 POD 5 - PODA 5 Industrial Grinders

2 Introduction You can connect your dual grinder in many ways. This manual includes the following options for use of your dual grinder: PSD 5 for grinding, BO 50/5 for grinding and belt grinding POD 5 for polishing PODA 5 for polishing and deburring EU declaration of conformity KEF-MOTOR A/S hereby declares that Industrivej 3-9 DK-9460 Brovst Denmark Tel.: Fax: KEF Double Ended Grinder PSD 5, BO 50-5, POD 5 are manufactured in accordance with the provisions of the COUNCIL DIRECTIVE of 17. May 2006 (2006/42/EC) The Machinery Directive (order no. 561 of 25 June 1994 with subsequent amendments) Also on accordance with: The council directive of 19 February 1973 (73/23/EEC) The Low Voltage Directive with later amendments (order no. 797 of 30 August 1994) The council directive of 3 May 1989 (89/336/EEC) The EMC Directive with later amendments (order no. 796 of 5 December 1991 with subsequent amendments) 1

3 Table of contents 1 TRANSPORT & HANDLING TRANSPORT HANDLING PLACING 3 2 DIRECTIONS FOR USE OPERATION SAFETY RULES FOR STATIONARY POWER TOOLS MAINTENANCE 6 3 BELT ARM ASSEMBLY AND MOUNTING OF BELT ARM CHANGING OF GRINDING BELT MAINTENANCE OF BELT ARM USE OF BELT ARM 9 4 VFCB-COMPLETE EXHAUST UNIT ASSEMBLING AND MOUNTING OF VFCB COMPLETE EXHAUST UNIT MAINTENANCE OF VFCB-EXHAUST UNIT 10 5 POLISHING MACHINE ADJUSTMENT THE POLISHING MACHINE DEBURRER ASSEMBLING AND MOUNTING OF DEBURRER CHANGING OF DEBURRER/STEEL BRUSH MAINTENANCE OF DEBURRER/STEEL BRUSH USE OF DEBURRER 12 7 SPARE PARTS MACHINE LINE UP OF PSD PSD 5 BASIC MODEL PSD 5 COVER PSD 5 BELT ARM VFCB-EXHAUST SYSTEM FOR PSD POD 5 W/SPINDLE DEBURRING COVER FOR PODA TECHNICAL DATA TECHNICAL SPECIFICATIONS DIMENSIONS WIRING DIAGRAM DISA SWITCH W/EMERGENCY STOP PSD 5 CONNECTED TO EX16 DUST EXTRACTION GUARANTEE 28 2

4 1 Transport & handling 1.1 Transport PSD 5 Industrial belt grinder and others are delivered on a pallet packed in protective wrapping. 1.2 Handling The machines can easily be transported on the pallet on which they are delivered. If the machine is delivered on a pedestal you must insure that the pedestal is secured to the pallet. 1.3 Placing Mounting of the machine must take place on a firm level ground. It must be fastened to the ground by means of the four fittings which are used to fasten the machine to the pallet. It is provided with no-volt release protection switch and connected for the wanted voltage. The electrical connection must be performed by an authorized electrician, and it is important to control that the motor (and the exhaust unit) have the correct direction or rotation (please see the arrow on the motor). Fig.: 1.1 Before use you must control that the outer cover (A) (se fig.: 1.1) is solidly mounted on the inner cover. The outer cover must stay mounted during use and should only be dismounted during change of grinding wheel. The grinding wheel (B) must be able to rotate freely without being loose. The tool rest (C) must be adjusted to a distance of approximately 2 mm from the grinding wheel. The eye shield (D) must be clean and adjusted into the right position and the spark arrester (E) must also be adjusted to a distance of approximately 5 mm from the grinding wheel and slightly fastened. The first time you start the belt grinder please let it run at max speed without using it for 5 minutes. Make sure to stay in a safe distance during the machine start-up. 3

5 2 Directions for use 2.1 Operation After adjustment and connection the machine is ready for use. The grinding kan take place by the contact wheel (E) or on the surface grinding table by opening the cover (H). When you start grinding please start by letting the material touch the grinding wheel lightly and thereby avoid pressuring the grinding wheel to prolonge the lifetime of it. The lifetime of a grinding belt is also prolonged if you start with a light pressure. Please make sure not to overload the motor. Let it run at max speed before start grinding. Grind at max speed and if possible have the material tightened in clamps as it is safer than holding the material in your hands. Avoid grinding on the side of the grinding wheel unless you are using a cup wheel. Do not stop the grinding wheel by pushing any material against it but let it stop by itself. It is very important to keep the working area well lighted. 2.2 Safety rules for stationary power tools. Follow them to achieve best results and full benefit from your new machine. The good craftsman respects the tools with which he works. He knows they represent years of constantly improved design. He also knows that they are dangerous if misused. The safety rules are based on approved practices in industrial and home shops. 1. Know your power tool. Read the owner s manual carefully. Learn its applications and limitations, as well as the specific potential hazards peculiar to this tool. 2. Keep guard in place and in working order. 4. Remove adjusting keys and wrenches. Form habit of checking to see that keys and adjusting wrenches is removed before turning it on. 3. Ground all tools. If tool is equipped with threeprong plug, it should be plugged into a three-hole electrical receptacle. If an adapter is used to accomodate a twoprong receptacle, the adapter wire must be attached to a known ground. Never remove the third prong. 5. Cluttered areas and benches invite accidents. 6. Avoid dangerous environment. Don t use power tools in damp or wet locations or expose them to rain. Keep your work area well lighted. 6. Keep children away. All visitors should be kept in a safe distance from work area. 4

6 8. Make workshop kidproof with padlocks, master switches, or by removing starter keys. 9. Don t force tool. It will do the job better and be safer at the rate for which it was designed Use right tool. Don t force tool or attachment to do a job it was not designed for. 11. Wear proper apparel. Wear no loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. 12. Always use safety glasses. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses. They are NOT safety glasses. 13. Secure works. Use clamps or vise to hold works, when pratical. It s safer than using your hands and it frees both hands to operate tool. 14. Don t overreach. Keep proper footing and balance at all times. 15. Maintain tools with care. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. 16. Disconnect tools before servicing and when changing accessories such as grinding wheels, polishing mops, grinding belts, blades, bits, cutters, etc. Never leave a running maschine, wait till the Machine has stopped. If parts of the machine are out of order the Machine shold not be used befour it has been repaired. 17. Reduce the risk of unintentional starting. Make sure switch is in off position before plugging in. 18. Use recommended accessories. Consult owner s manual for recommended accessories. Use of improper accessories may cause risk of injury to persons. 19. Never work in a way that can hurt you. Do not stand in a bent position. Stand straight. Alkohol and other drugs are not to be taken while working with the machine. 5

7 2.3 Maintenance Keep the machine in a dry place so the grinding wheels or belts will not risk getting any damp or rain. The grinding wheel will often get uneven because of use and therefore we recommend that you level the grinding wheel off frequently. When the grinding wheel is worn more than 25% we recommend that you change to a new wheel. An uneven grinding wheel causes vibrations which with time will damage the bearings in the machine. Damaged tool rests, eye shields and covers must be replaced to avoid personal damage. When to change the grinding wheel please dismount the spark arrester (A) (see fig.: 2.1), then dismount the outer cover (B). The reverse nut (C) and the outer flange is to be unscrewed, now the outer flange and the grinding wheel can be dismounted. The new grinding wheel is not allowed to exceed the measures shown on the sign on the machine. It is also very important that the hole dimension is correct. The grinding wheels are provided with labels placed around the holes on both sides of the grinding wheel. If these labels are missing or damaged they must be replaced by new ones of the same dimension. The new grinding wheel is to be mounted between the two flanges (D) and the reverse nut (C) screwed on and fastened. The reverse nut (C) is to be fastened so tightly that it can hold the grinding wheel tight but on the other hand it is not to be tightened too much as it can cause unwanted stress in the grinding wheel. Fig.: 2.1 6

8 3 Belt Arm 3.1 Assembly and mounting of belt arm If the grinding machine is mounted with a grinder cover or a deburrer cover these must be removed completely before mounting the belt arm. Mount the telescopearm (A) to the cover (B) by using the fitting for the telescope arm (C) and mounting the cover (B) by putting a screw through the side plate into the holder for the telescopearm (D). The topwheel (E) must be inside the cover (B). Fig.: 3.1 The fitting for the telescopearm (C) is not alloved to be fastened harder than it is still possible to adjust the direction of the grinding belt. The belt arm can be tilted to the wanted inclination. After this the holder for the telescopearm (D) is fastened by tightening the two screws placed in the ring on the holder. The flanges, contact wheel and the reserve nut are now put in (pls. see the drawing of belt arm for order). Please make sure that the top wheel (E) and the contact wheel run parallelly. The position of the contact wheel can be adjusted with the distance rings attached. The topwheel (E) can be loosened and adjusted so that it fits the wanted grinding belt lenght. The same way you can tighten the grinding belt. 7

9 3.2 Changing of grinding belt When the grinding belt is worn out it must be replaced which is done the following way: The top plate (A) (se fig.: 3.2) on the cover is opened and the handle (B) is pulled down. This way the pressure on the grinding belt will be lowered (C), so that it can be dismounted and a new grinding belt can be mounted in reverse order. Please control that the arrows on the back of the grinding belt run in the same direction as they point. When the new grinding belt is mounted it is necessary to adjust by the handle (D) for parallel running. The belt is loosened so that the telescopearm (E) and top wheel (F) can be turned with until the grinding belt runs straightly on the contactwheel. After this the handle is fastened (D). It is only allowed to do this adjustment by pulling the grinding belt with the hands and NOT with power on the machine. Fig.: 3.2 There are many kinds of grinding belts so therefore it is very important to choose the right type of belt. There are many things to consider before choosing the belt: material to be grinded - grit size - belt material - glue. In connection to this we can tell you that there are different kinds of contact wheels with various softnes and shapes for different purposes. 8

10 3.3 Maintenance of belt arm Empty the spark arrester (A) (see fig.: 3.3) to avoid hot sparks damaging or deforming grinding belt and contact wheel. If the machine is equipped with VFCBexhaust unit you must control if the suction channels need cleaning. The dust bag must be emptied when necessary. The contact wheel (B) needs changing if the edges are too rounded. The belt must be replaced when it is defective. Change the graphite pad (C) on the belt arm when necessary. Fig.: 3.3 When changing the contact wheel the grinding belt (D) must be dismounted as described above. The reverse nut (E) must be dismounted and the flange (F) can be taken off with the contact wheel (B). The new contact wheel (B) is to be mounted in reverse order. 3.4 Use of belt arm Grinding at the belt arm can be done either at the contact wheel or on the grinding surface. You can also dismount the grinding surface for direct unsupported grinding on the grinding belt. Let the material touch the grinding belt softly and avoid uneven grinding as it can damage the grinding belt and overload the motor. 9

11 4 VFCB-complete exhaust unit 4.1 Assembling and mounting of VFCB complete exhaust unit The following description of assembling and mounting of VFCB-exhaust unit is valid both if it is a VFCB-220 or if it is a VFCB-121. The mounting order is exactly the same for both models. The guard (A) (see fig.: 5.1) is first mounted on the back of the machine and there after as shown on the VFCB-motor. Dismount the blindstopper at the back of the machine and mount the connector (B). Dismount the switch on the machine without dismounting the wires. Lead the wire (C) through the connector (B) and mount the protection hose (D) on the connector (B). Mount the wires from the VFCB-exhaust unit on the switch (see wiring diagram). Mount the switch again. Dismount the blind guards on the cover or the belt arm and instead mount the guard (E) with exhaust connecting piece, also remember to mount the cork washer (F). Finally adjust the suction hoses (G) and mount the clip washers (H). VFCB-exhaust unit must before use be mounted with suction hoses on the suction connecting piece (I), which then must be connected with central exhaust unit. If the central exhaust unit has no cyclone, the exhaustion from the VFCB-exhaust unit must be connected to a cyclone, which then again is connected to the central exhaustion. If there is no central exhaustion, dust bags (J) can be mounted on the exhaust connecting unit (I). In case the VFCB-exhaust unit is mounted on the PSD 5 double grinder, the casted pipe bendings (K) can be used to mount the VFCB-exhaust unit on the grinding machine by what the guard (A) and the suction hoses (G) with accessories can be left out. Fig.: Maintenance of VFCB-exhaust unit Nothing on a VFCB-exhaust unit requires maintenance except that it is necessary to make sure that the suction hoses are intact and the suction channels are clear. 10

12 5 Deburrer 5.1 Assembling and mounting of deburrer The deburrer cover is to be assembled in the order shown in fig.: 5.1. The four screws in the end cover (A) must be unscrewed and the mounting plate (B) is to be placed on the end cover (A), the four countersinked machine screws M6x20 (C) are retightened. Now the deburrer cover (D) can be remounted through the two slashes in the mounting plate (B). The cover can be repudiated back and forth so the steel brush (G) can be used best possible. The inner flange (F) is put on the shaft with the steel brush (G) and the outer flange (H). At last the reverse nut (I) is screwed on the shaft and tightened. Before the lid on the deburrer cover (D) is closed the eye shield is mounted (J) as shown in fig.: 4.1. If you are not to grind a pipe material you can dismount the grinding system for pipe grinding (K) and the flat grinding system beneath can be used instead. Fig.: Changing of deburrer/steel brush When the steel brush is worn approximately 10 % it must be replaced by a new brush. This is easily done by opening the lid on the deburrer cover (D). Here you dismount the reverse nut (I) and the flange (H) can be taken off with the steel brush. The new steel brush is mounted in reverse order. Often it will be necessary to adjust the grinding system (K) before the new steel brush is put in its place. 11

13 5.3 Maintenance of deburrer/steel brush Nothing on the deburrer/steel brush needs maintenance except that it is necessary to adjust the grinding system as the steel brush is worn. The eye shield and other accessories must be replaced immediately if they are damaged. 5.4 Use of deburrer When the deburrer cover is correctly mounted the grinding system (A) (see fig.: 5.2) needs adjusting which is done by adjusting the height of the grinding system when the screw (B) is unscrewed. The distance to the steel brush is adjusted by loosening the handle (C) below the cover. As mentioned earlier the grinding system for pipe grinding (A) can be dismounted and the flat grinding surface beneath can be used for grinding of plate or bar material. This adjustment of the grinding system can only be made when the machine is NOT plugged. Fig.: 5.2 Before the deburring is started it is important that the motor is running at max speed and the deburring must be done at as high speed as possible. If it is possible please hold the material with clamps as it is safer than holding the material right in your hands. If the motor is helped at stopping the rotation it can result in overheating and destruction. The best result will be achieved if the material is softly put towards to steel brush. Avoid uneven deburring to avoid damaging the steel brush and overloading the motor. Do not stop the steel brush rotation by pressing a material to it but let it rotate freely until it stops by itself. It is very important to have the work space well lighted as well as the Law for Safety and Health at Work Act demands that there must be an exhaust unit mounted on the deburring cover. This is easily done by mounting a VFCB-exhaust unit on the machine. 12

14 6 Polishing machine 6.1 Adjustment the polishing machine. Placing of the machine must take place on a firm and level surface. Now secure the polishing machine to the work table or the floor by using the four holes in the base used for mounting the machine to the pallet. Please wire the machine according to the given voltages stated in this manual and on the motor sign. Check for correct direction of rotation on the motor. All wiring must be performec by an authorized electrician. Fig.: 6.1 Before start operating please check if the polishing discs (A) (see fig.: 6.1) are firmly secured to the rotor. The polishing disc is mounted when the machine is disconnected. The polishing disc (A) must rotate freely without being loose. Checks and adjustments are only to be performed when the machine is disconnected. Make sure to be in a safe distance from the machine while it is running for the first time. 13

15 7 Spare parts In this chapter there are split drawings and matching spare parts lists. 7.1 Machine line up of PSD 5 Fig.: 7.1 (A) Motorpart, (B) Grinding cover, (C) Belt arm, (D) VFCB-exhaust unit. 14

16 7.2 PSD 5 basic model Fig.:7.2 Drawing of PSD 5 basic model Spare parts list for PSD 5 basic model Pos.nr. Type Ident. Nr. 1 Collar bushing E Screw M6x20 CH Z Bearing end shield V O-ring 50x45x3 mm Wave spring 50x44x Bearing Z/C Cable 4x0.75mm² sort Cable lead-in PG Blind stop PG Stator housing Split pin ø4x Rotor cpl Bearing end shield H DISA switch 230 V DISA switch 440 V Skrew M4x Switch for DISA switch Earth cable

17 7.3 PSD 5 cover Spare parts list for PSD 5 cover 16 Fig.: 7.3 Split drawing of PSD 5 cover Pos.nr. Type Cover L Cover R 1 Eye shield for PSD Cross handle Ø32 M6 DIN Disc 6.4x Carriage bolt 6x Nut M10 Z Spring wave ring Spark arrestor PSD 5 L-piece Spark arrestor PSD 5 U- piece Washer DIM 6 Z Flange screw M Screw M5x10 CH Z Washer DIM 5 Z Lid PSD 5 cover Cover PSD 5 indv. Kpl Screw M6x20 CH Z Flange inner Grinding wheel Cardboard labels Flange outer Nut M20x Cover PSD 5 outer Disc 3/8 Z Screw M10x30 Z Grinding system Fittings for cover PSD Nut M

18 7.4 PSD 5 belt arm Fig.: 7.4 Split drawing of PSD 5 belt arm 17

19 Spare parts list for PSD 5 belt arm Order number Pos. Nr. Type Right Left 1 Top screw Sliding pipe for belt stand Machine screw M4x4 Z Lock ring DIM 42, DIN Ball bearings Z Distance pipe ø22/15x Top roll Shaft for top roll Disc for top roll Screw M6x16 CH Z lowered head Pointed screw M5x Holder for top roll Spring for telescope arm Pipe for telescope arm Spring holder for telescope arm Handle for grinding belt M8x Pipe bushing for telescope arm Pipe holder for telescope arm Pipe cotter pin ø5x Håndle for adjustment of grinding belt Fittings for telescope arm Washer DIM 8 Z Screw M8x25 CH Z Distance ring Pointed screw M8x Holder for telescope arm Grinding system Disc 3/8 Z Screw M10x30 Z Box cover for belt arm Washer DIM 5 Z Screw M5x10 CH Z Felt washer Cover plate Distance ring ø30/20x6mm Collar bushing PSD Star handle ø40 M8 DIN Auto disc 5/16 Z Spark arrestor Nut M5 Z Flange inner Contact wheel 200x50x Square table Flange outer Double sticking tape Graphite pad 50x Nut M20x Grinding belt DN-bearing ring for belt arm

20 7.5 VFCB-exhaust system for PSD 5 Fig.: 7.5 Split drawing of VFCB-exhaust system for PSD 5 19

21 Spare parts list for VFCB-exhaust unit for PSD 5 Pos.nr. Type VFCB-220 VFCB Fan housing L. outer Screw M5x16 CH Z Washer DIM 5 Z Disc Ø5.5x26,5x Fan wheel VFCB alu Screw M6x16 Z Washer DIM 6 Z Fan housing L. inner V-Ring 16A Spring 5x5x Screw M8x16 Z Auto disc 5/16 Z Clamp for VFCB holder Fan housing R. inner Fan housing R. outer Power engine Thread piece PG Protection hose 18x13 400mm Dust bag Screw M4x16 w/round head Cork washer 120x Connecting piece exhaust Screw M5x10 CH Z Washer DIM 5 Z Tightening belt 68/ Suction hose Exhaust pipe Cork washer Elbow for VFCB Pedestal for PSD Table PSD 5* Water cup Disc ø13x24x Screw M12x40 Z Table for PSD 5 with belt arm or deburrer has nr.:

22 7.6 Deburring cover for PODA 5 Spare parts list for deburrer for PODA 5 Fig 7.6 Drawing of parts in deburrer Pos.nr. Type Cover R Cover L 1 Disc 6.4x Cross handle ø32 M6 DIN Bolt for wood 6x Eye protective guard PSD Nut M10 Z Washer Chest screw M Safety nut M Pointed screw M5x6 spids Fittings for handle for deb./steel brush Flange Bushing, reducing 32-20mm Steel brush 250x32x Nut M20x Håndle for deburrer/steel brush Holder for grinding system Grinding system for deburrer ST-handle VC. 192/25P-M5x Drawer for grinding system f/deburrer Screw M8x16 CH Auto disc 5/16 Z Washer DIM 8 Z Star handle ø40 M8 DIN Deburrer cover Machine screw M6x20 UHJX Z Mounting plate Termunal box lid MF Machine screw M4x12 Z

23 7.7 POD 5 w/flange Fig 7.7 Split drawing of POD 5 w/flange Spare parts list for POD 5 w/flange Pos.nr. Type Left Right 1 Polishing guard Left Disk 6mm Skrew M6x Distance ring ø20x30x Spindle Polishing Mop ø200x20xø

24 7.8 POD 5 w/spindle Fig 7.8 Split drawing of POD 5 w/spindle Spare parts list for POD 5 w/spindle Pos.nr. Type Left Right 1 Polishing guard Left Disk 6mm Skrew M6x Flange inner Polishing Mop ø200x20xø Flange outer Nut M20x1,

25 8 Technical data 8.1 Technical specifications Model PSD 5 BO 50/5 POD 5 Grinding belt - 50x Motor effect in Watt Rpm Contact wheel - 200x50xø20 - Grinding wheel 200x38xø Polishing Mop to spindle x20xø6 Polishing Mop to flange x20xø20 IP class Class F F F Amp 1,9/3,3 1,9/3,3 1,9/3,3 Cos 0,81 0,81 0,81 Weight The noise level for these machines varies from 76 db(a) (PSD 5/POD 5) to 88 db(a) (BO 50/5) according to the measuring directions in the Department for Work Safety and Health notice nr. 561 on devices of technical aids. Eye and ear protection must be worn during use of the above machines. 8.2 Dimensions Fig.: 7.1 Model A B C D E F G H I J PSD BO 50/

26 8.3 Wiring diagrams PSD 5, BO 50/5 and POD 5 industrial grinding machines can be wired 3 x 400 V, 50/60 Hz or 3 x 230 V 50/60 Hz. Please see wiring diagrams below. Max. Volt Max. Volt 25

27 Disa Switch w/emergency stop

28 8.5 PSD 5 connected to EX16 Dust Extraction 27

29 8.5 Guarantee If within 2 year of purchase this machine supplied by KEF A/S becomes defective due to faulty materials or workmanship we guarantee to repair or replace the machine or defective part or parts free of charge provided that: 1. The product is returned complete to one of our Service Branches or Official Service Agents. 2. The product has not been misused or carelessly handled and in particular has not been used in a manner contrary to the operating instructions. 3. Repairs have not been made or attempted by other than our own Service Staff or the staff of our Official Service Agents. 4. Documentary proof of purchase date is produced when the goods are handed in or sent for repair. 5. Wear parts are not covered by the warranty KEF A/S offers you five years guarantee on the electrical motor if the motor becomes defective or even burns-out within the first 5 years from date of invoice. 28