KEF-MOTOR A/S Industrivej 3-9 DK 9460 Brovst Tlf. +45 9823 6088 Fax. +45 9823 6144 1. Instruction Manual PSD 200 Industrial Grinders
EU declaration of conformity KEF-MOTOR A/S Industrivej 3-9 DK-9460 Brovst Denmark www.scantool-group.com Tel.: +45 98 23 60 88 Fax: +45 98 23 61 44 hereby declares that KEF Double Ended Grinder PSD 200, 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) 2006/42/EC: 2004/108/EC: 2006/95/EC: Directive on machinery-safety Directive on Electromagnetic Compatibility Low Voltage Equipment Safety directive 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) 2
Table of contents 1 TRANSPORT & HANDLING 4 1.1 TRANSPORT 4 1.2 HANDLING 4 1.3 PLACING 4 2 DIRECTIONS FOR USE 5 2.1 OPERATION 5 2.2 SAFETY RULES FOR STATIONARY POWER TOOLS. 5 2.3 MAINTENANCE 7 3 BELTARM 8 3.1 CHANGING OF GRINDING BELT 8 3.2 USE OF BELTARM 8 4 VFCB-COMPLETE EXHAUST UNIT 9 4.1 ASSEMBLING AND MOUNTING OF VFCB COMPLETE EXHAUST UNIT 9 4.2 MAINTENANCE OF VFCB-EXHAUST UNIT 9 5 SPARE PARTS LIST 10 5.1 DRAWING OF PSD 200 BASIC MODEL 10 5.2 SPARE PARTS LIST FOR PSD 200 BASIC MODEL 10 5.3 SPLIT DRAWING OF PSD 200 COVER 11 5.4 SPARE PARTS LIST FOR PSD 200 COVER 11 5.5 SPLIT DRAWING OF PSD 200 BELT ARM 12 5.6 SPARE PARTS LIST FOR PSD 200 BELTARM 12 5.7 SPLIT DRAWING OF VFCB-EXHAUST SYSTEM FOR PSD 200 13 5.8 SPARE PARTS LIST FOR VFCB-EXHAUST UNIT FOR PSD 200 14 6 TECHNICAL DATA 15 6.1 TECHNICAL SPECIFICATIONS 15 6.2 WIRING DIAGRAM 16 6.3 DISASWICH W/EMERGENCSTOP 17 6.4 GUARANTEE 18 3
1 Transport & Handling 1.1 Transport PSD 200 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). Before use you must control that the outer cover 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 must be able to rotate freely without being loose. The tool rest must be adjusted to a distance of approximately 2 mm from the grinding wheel. The eye shield must be clean and adjusted into the right position and the spark arrester 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. 4
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 or on the surface grinding table by opening the cover. 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 very 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. This is the theme of a new safe-use program for stationary power tools. The safety rules are based on approved practices in industrial and home shops. 2. Keep guard in place and in working order. 3. Ground all tools. If tool is equipped with three-prong plug, it should be plugged into a three-hole electrical receptacle. If an adapter is used to accomodate a two-prong receptacle, the adapter wire must be attached to a known ground. Never remove the third prong. 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. 4. Remove adjusting keys and wrenches. Form habit of checking to see that keys and adjusting wrenches is removed before turning it on. 5. Keep work area clean. Cluttered areas and benches invite accidents. 7. Keep children away. All visitors should be kept in a safe distance from work area. 8. Make workshop kidproof with padlocks, master switches, or by removing starter keys. 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. 5
9. Don t force tool. It will do the job better and be safer at the rate for which it was designed. 10. 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. 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. 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. 16. Disconnect tools before servicing and when changing accessories such as grinding wheels, polishing mops, grinding belts, blades, bits, cutters, etc. 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. 6
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 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 7
3 Beltarm 3.1 Changing of grinding belt When the grinding belt is worn out it must be replaced which is done the following way: The top plate on the cover is opened and the handle is pulled down. This way the pressure on the grinding belt will be lowered, 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 for parallel running. The belt is loosened so that the telescopearm and top wheel can be turned with until the grinding belt runs straightly on the contactwheel. After this the handle is fastened. It is only allowed to do this adjustment by pulling the grinding belt with the hands and NOT with power on the machine. 3.2 Use of beltarm Grinding at the beltarm 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. 8
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.: 4.1) 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 beltarm 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 200 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.: 4.1 4.2 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. 9
5 Spare parts list 5.1 Drawing of PSD 200 basic model Fig.:5.1 5.2 Spare parts list for PSD 200 basic model Pos.nr. Type Ident. Nr. 1 Distance pipe 30x20x15 0744530 2 Screw M6x20 CH Z 0120624 4 Bearing end shield V 1065166 5 O-ring 50x45x3 mm 1385259 6 Wave spring 50x44x0.6 0100331 7 Bearing 6205 2Z/C3 0104221 8 Cable 4x0.75mm² sort 0129420 9 Cable lead-in PG11 0105154 10 Blind stop PG11 2112512 11 Stator housing 1313711 12 Split pin ø4x8 0711179 13 Rotor cpl. 1137123 14 Bearing end shield H 1065166 15 DISA switch 230 V 0188807 16 DISA switch 440 V 0188817 17 Skrew M4x10 0100427 18 Switch for DISA switch 0110049 19 Earth cable 1461327 10
5.3 Split drawing of PSD 200 cover Fig.: 5.2 5.4 Spare parts list for PSD 200 cover Pos.nr. Type Left Right 1 Eye shield 0921815 0921815 2 Nut M5 0737623 0737623 3 Spring wave ring 5mm 0737666 0737666 4 Screw M5x40 0932086 0932086 5 Cover PSD 200 inner 1065373 1065371 6 Spring wave ring 5mm 0737623 0737623 7 Screw M5x12 0100420 0100420 8 Wing nut M6 0924687 0924687 9 Spring 0411124 0411124 10 Disc 6mm 0737631 0737631 11 Tool rest 1299344 1299344 12 Screw M6x55 1268406 1268406 13 Flange inner 0921572 0921572 14 Grinding wheel 200x32xø20 - - 15 Flange outer 0921572 0921572 16 Nut M20 0932299 0932302 17 Screw M4x10 0737607 0737607 18 Cover PSD 200 outer 1065372 1065372 11
5.5 Split drawing of PSD 200 belt arm Fig.: 5.3 5.6 Spare parts list for PSD 200 beltarm Pos. Nr. Type 1 Star handle 0922025 2 Spring holder 2078203 3 Tension spring 0101321 4 Belt roller 2004879 5 Belt arm 0101018 6 Graphite pad 2004896 7 Grinding belt 50x1600-8 External grinding guard 0101025 9 Screw M5x8 1349287 10 Wing nut 0924687 11 spring 0411124 12 Auto disc 5mm 8987610 13 Tool rest 1311344 14 Steel set bolt M6x16 0300604 15 Spring disc 5mm 0737666 16 Machine screw M5x12 0100420 17 Distance piece 1065124 18 Contact wheel 1532170 19 Flange 0921572 20 Nut M20 0744816 12
5.7 Split drawing of VFCB-exhaust system for PSD 200 Fig.: 5.4 13
5.8 Spare parts list for VFCB-exhaust unit for PSD 200 Pos.nr. Type VFCB-220 VFCB-121 1 Fan housing L. outer 0781266 0781266 2 Screw M5x16 CH Z 0120626 0120626 3 Washer DIM 5 Z 0737666 0737666 4 Disc Ø5.5x26,5x2.5 0920026 0920026 5 Fan wheel VFCB alu. 0995703 0995703 6 Screw M6x16 Z 0300604 0300604 7 Washer DIM 6 Z 1323060 1323060 8 Fan housing L. inner 0785628 0785628 9 V-Ring 16A 0654329 0654329 10 Spring 5x5x14 0100609 0100609 11 Screw M8x16 Z 0120510 0120510 12 Auto disc 5/16 Z 5437850 5437850 13 Clamp for VFCB holder 2006726 2006726 14 Fan housing R. inner 0781258 0781258 15 Fan housing R. outer 0785636 0785636 16 Power engine 1043072 1043064 17 Thread piece PG11 0920011 0920011 18 Protection hose 18x13 400mm 0920400 0920400 19 Dust bag 0811793 0811793 20 Screw M4x16 w/round head 2006480 2006480 21 Cork washer 120x9 2006728 2006728 22 Connecting piece exhaust 1444190 1444190 23 Screw M5x10 CH Z 0120628 0120628 24 Washer DIM 5 Z 0737666 0737666 25 Tightening belt 68/85 1944266 1944266 26 Suction hose 2006731 2006731 30 Pedestal for PSD 200 1065094 1065094 31 Table PSD 200* 0113273 0113273 32 Water cup 0771333 0771333 33 Disc ø13x24x2.5 0101494 0101494 34 Screw M12x40 Z 0120839 0120839 Table for PSD 200 with beltarm or deburrer has nr.: 077131 14
6 Technical data 6.1 Technical specifications Model PSD 200 PSD 200 w/beltarm Grinding belt - 50x1600 Motor effect in Watt 1000 1000 Rpm. 2800 2800 Contact wheel - 200x50xø20 Grinding wheel 200x32xø20 - IP class 54 54 Class F F Amp 1,9/3,3 1,9/3,3 Cos 0,81 0,81 Weight 38 The noise level for these machines varies from 76 db(a) (PSD 200/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. 15
6.2 Wiring diagram PSD 200, 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. Voltage Min. Voltage Fig.: 7.2 16
6.3 Disaswich w/emergencstop 17
6.4 Guarantee If within 5 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. 18