BMR EVEREST 620 14A User manual

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EVEREST 620 14A
MANUALE USO E MANUTENZIONE
USE AND MAINTENANCE MANUAL
EVEREST 620 14A
Matricola: 653

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EVEREST 620 14A
Chapter 1 General information
1.1 Manual
Dati del manuale
Everest 620 14A Instruction Manual
• Edition: 100
• Printed: August 2008
Intended for
• Transporters.
• Installation engineers.
• Machine operators.
• Maintenance engineers.
1.2 Intellectual property
This manual contains confidential information. All rights are reserved. It must not be
reproduced or photocopied, in part or in full, without the express consent, in writing, of BMR
S.p.A. This material may only be used by clients who have received the manual with their
machine and is only intended to be used for the purposes of installation, maintenance or use
of the particular machine referred to in the manual.
BMR S.p.A. declares that the information contained in this manual adheres to the technical
and safety specifications for this machine. The manufacturers assume no responsibility
for direct or indirect damage to persons, objects or domestic animals due to misuse of the
manual or the machine.
BMR S.p.A. reserves the right to modify or improve this document or machine or a
machine of the same model but different registration number referred to in this manual. The
information contained in this manual refers specifically to the machine stated in section 1.5 -
Machine Description, on page 3.

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EVEREST 620 14A
1.3 Conventions
Standard terminology
• Left and right: relevant to the operator when facing the control panel.
• Qualified staff: people who have been authorised by the system safety manager to carry
out any necessary activity and recognise and avoid any potential danger, having acquired the
necessary training, experience and qualifications and having familiarised themselves with the
relevant regulations, instructions and accident prevention measures as well as the service
conditions.
Typography standards
Italics: Indicate the title of a chapter, section, subsection, paragraph, table or figure in this manual
or in another referenced publication.
IPE: Individual Protective Equipment.
Where N indicates a generic number (e.g. ): Graphic representation of a control or
signalling device (e.g. buttons, switches or leds).
Where L represents a generic letter (e.g. ): Graphic representation of a machine part.
NOTE Provides important information outside of the text referred to.
WARNING Indicates procedures where incomplete or partial compliance may
cause damage to the machine or the equipment connected to it.
DANGER Indicates procedures where failure to observe or fully observe
safety measures can cause injury to or damage the health of the
operator.
1.4 Manufacturers details
BMR S.p.A.
Via G. FATTORI, 6
42019 SCANDIANO (RE)
Italia
Tel. [phone] - 985123
Fax [phone]

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EVEREST 620 14A
Tipo-Type Matricola Nr.- Serial Number Anno - Year
1.5 Machine Description
Type: Polishing machine for granite, stoneware and hard stones.
Model: Everest 620 14A
Registration no.: 00433
Year of manufacture: 2008
Machine configurations:
• 14 mandrels
• Slab guiding device with manual adjustment
• Mobile bridge
Fig. 1.1 Identification platelet

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EVEREST 620 14A
1.6 Using the manual
Read carefully the sections on General Information, in Chapter 1, Safety Information, in Chapter
2, and Machine Specifications in Chapter 3.
For information on installing, using, maintaining and disposing of the machine, please consult the
relevant chapter.
NOTE This manual must be kept in a safe place, which is easily accessed when needed, for
the entire operational life of the machine. If sold, it must be sold complete with this manual.
1.7 Assistance
This manual is no substitute for the experience of trained and qualified installation engineers,
operators or maintenance engineers in ensuring maximum machine performance and maximum
efficiency of maintenance work. The Technical Assistance Service can provide information on cor-
respondence, training and maintenance interventions by telephone.
Requests for assistance
Technical Assistance Service
To contact the Technical Assistance Service:
BMR S.p.A. Via G. Fattori, 6
42019 Scandiano (RE)
Italy
Tel. [phone]
Fax [phone]
Please specify the machine type, model and registration number when requesting assistance.
Requests for parts
Please specify the following information when requesting parts:
• Machine type
• Relevant registration number printed on the platelet
• Year of manufacture
• Reference number of required part as provided next to the catalogue illustration.

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EVEREST 620 14A
Longueur Largeur Hauteur
10500 620 mm 30 mm
1.8 Machine details
This machine has been designed to be used as follows:
Operations
This machine has been designed and produced for polishing granite, stoneware
and hard stone slabs.
Materials
Granite, stoneware and general hard stone slabs must not exceed the following
dimensions:
Working environment
This machine has been designed and produced to be used in closed environments, protected from
outside weather conditions.
Power supply
This machine is powered by electric and pneumatic energy, which is then converted into mechanical
energy.
Improper use
Any condition which is not expressly indicated above is considered improper use, particular examples are:
• Operation in explosive environments.
• Operation in flammable environments.
• Cleaning electrical parts with water jets.
Machine structure
This section describes the most important parts of the machine and their functions
Principal machine parts
Below are the main parts of the EVEREST polishing machine:
• Base structure.
• Mandrel bridge.
• Polishing mandrels.
• Slab guiding devices.
• Planetary honing/polishing heads.
• Tangential honing/polishing heads.
• Rotary motor for honing/polishing head mandrel.
• Pneumatic cylinders for vertical honing head movement
• Main control panel.
• Control panel – polishing/honing heads.
• Electrical cabinet.
• Filter set.

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EVEREST 620 14A
UNIX 2 polishing mandrel
The mandrel is the drive unit for the flattening, honing and polishing tools for granite and glazed
stoneware; the satellite plateau, tangential unit and other parts used in the abovementioned
operations are connected to this part.
The structure is made from mechanical cast iron with a rotating sleeve mounted on bearings
connected to a vertical sliding shaft driven by two cemented keys fitted at 180° with precision
guidance by means of two high-quality bronze supports.
The rotation system uses grooved pulleys and highly durable trapezoid belts, providing low noise
output and safe machine operation; motor pulley variations also allow the speed to be adapted
according to the material to be polished. It is supplied with a 15 hp (11kw) 1450 r/m motor with a
shaft speed of 435 r/m as standard. Other versions are available on request.
Vertical operations occur by means of two pneumatic cylinders with maximum movement of 160
mm, functioning with a dual pressure/counterpressure system, meaning the weight of the lower
head can be reduced if necessary.
Tangential head on oscillating feet
The tangential head is suitable for polishing granite, glazed stoneware and general hard materials.
The high performance of the abrasives and high quality surface finishes are obtained through the
high number of strokes and the optimum grinding heads cutting angle.
The head is supplied in four working dimensions:
• Diameter 400.
• Diameter 450.
• Diameter 470.
• Diameter 510.
This can be installed on either the mandrels supplied by the machine producer or those supplied
by other producers.
Mandrel bridge
This is activated when the machine is used to process pieces over 400mm in width. It consists
of one robust metal beam sliding on tempered, rectified steel rollers on two lateral supports
which are also made of metal with interchangeable tracks made from tempered steel in oil bath.
The capacity of the machine is for 4 to 20 mandrels, applied on the upper part of the lengthwise
axle which forms a homogenous, well balanced structural set. Bridges with 16 or more mandrels
rest in a central position on a welded beam, equipped with tempered steel tracks which are
interchangeable and in an oil bath with an identical roller unit to that of the shoulders.
Machines measuring 900 in width feature bridge movement controlled by a variable step motor
reducer with a manually adjusted movement run. Run variation is from 0 to 920mm.
The to and fro motion is perpendicular to the direction of flow of the material and is guided by
a double contrast system with both rollers and slide shoes, which are opposed and adjustable
and by a transmission shaft which connects a pair of tempered helicoid tooth gears which slide
on racks fixed to the supports. Machines equipped with a swinging bridge can also work wide
formats up to 200 mm. This is achieved by blocking the bridge in countermachine.

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EVEREST 620 14A
ATTENTION The oscillating motion with variable step gearmotor system allows pieces of over 300
mm in width to be polished with the mobile bridge, so that, compared to fixed bridge
machines, more pieces can be processed at higher levels of quality.
How the machine works
The EVEREST honing and polishing machine with tangential head system works on a continuous
honing and polishing cycle.
The machine consists of a honing unit mounted on a base structure which contains a conveyor belt
running longitudinally with an adjustable slab guide. Tension for this guide is provided by two rollers
at each end, one driven by a gearmotor and the other idle. Abrasive are cooled by a watering
system, which also ensures that the belt remains clean while in use.
Operating heads are controlled by a pneumatic system.
The honing unit consists of a number of modular, identical heads which are bolted onto a welded
sheet-steel beam. Each head consists of two cast iron bodies: the upper one housing the electric
rotation motor and bell for the vertical pneumatic cylinder and the lower one (bolted to the beam)
containing the head mandrel.
1.9 EC Declaration of Conformity
Consult EC Declaration of Conformity.
1.10 Guarantee
General Warranty Conditions
The machine warranty is valid for a period of 12 months from the date of delivery, on the un-
derstanding that it will be used for eight hours a day. The warranty period will be reduced to 6
months if used for more than eight hours a day.
The warranty guarantees that the manufacturers will repair or replace parts which are faulty
due to evident manufacturing errors free of charge, ex factory and in the fastest possible time,
provided that the machine has been used according to the manufacturer’s conditions regar-
ding installation, conduction, maintenance and performance limits. Travel expenses, shipment,
labour costs etc will be charged to the customer.
This commitment excludes the manufacturers from responsibility for direct or indirect damage
to the machine and machine breakdowns.
Parts not covered by the warranty
Parts which are produced by other companies and not by the manufacturers are not covered by the
warranty, including:
• Motors.
• Electrical parts.
• Cylinders.
• Pneumatic components.
• Hydraulic parts.
• All materials which are not directly guaranteed by the producer.

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EVEREST 620 14A
The high quality materials and mechanisms are designed for this type of machine, which may
be modified at any time, including after placement of the order, if the manufacturers consider the
improvements to be essential.
The manufacturer is not responsible for damage or injury caused directly or indirectly to people or
objects during shipment or usage, or from faulty parts supplied by third parties.
Special types of warranty will be specifically indicated in the sales contract.
Cancellation of Warranty
The warranty will be cancelled under the following circumstances:
• Improper use of the machine (see page 5 – Improper Use).
• Use of parts which are not specified in Chapter 6 – Maintenance.
• Installation procedures which do not respect the conditions specified in Chapter 4 – Installation.
• Connections which do not conform to specifications in Chapter 4 –Installation.
• Use of non original parts or parts not specified by BMR S.p.A.
Requesting Assistance Under Warranty Conditions
Any requests for parts or technical assistance covered by the warranty must be made to BMR
S.p.A. or an authorized dealer as soon as a fault is discovered which is covered by the General
Conditions on page 7.
WARNING We advise using only original parts as displayed in the manual.
Always provide the machine type, model and registration number when requesting parts or as-
sistance covered by the warranty. This information can be found on the machine identification
platelet.
NOTE BMR S.p.A. will accept no responsibility for injuries to persons and/or objects
caused by malfunctions if the customer fails to observe the conditions set out in
this manual.

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EVEREST 620 14A
Chapter 2 Safety Information
2.1 Safety Criteria
This machine has been designed and manufactured according to the criteria and conditions regarding
safety requirements as set out in Machine Directive 89/392/CEE and successive modifications,
Low Voltage Directive 73/23/CEE and successive modifications and Electromagnetic Compatibility
Directive 89/336/CEE and successive modifications.
The detailed risk analysis carried out by the manufacturer has eliminated the majority of risks,
whether foreseeable or reasonably foreseeable, connected to machine operating conditions.
Complete documentation regarding the safety measures undertaken is contained in the machine
technical file, deposited at BMR S.p.A.
All instructions, procedures and recommendations contained in this manual and all current legislation
regarding safety in the workplace, including legislation regarding use of protective equipment and
devices, whether individual or integrated into the machine, must be scrupulously adhered to.
DANGER Loose clothing, ties, necklaces or watches must never be worn when
operating the machine as they can be caught up in the moving parts.
NOTE BMR S.p.A. accepts no responsibility for any damage to persons,
animals or objects caused by failure to respect the safety measures and
recommendations contained in the documentation supplied.

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EVEREST 620 14A
2.2 Qualifications necessary for personnel working with
the machine
Operation Qualifications necessary
Transportation Qualified transporter who has read the contents of:
Chapter 2 Safety Information,
4.3 Transport on page 21 of this manual.
Installation Qualified electrician and qualified mechanic who have read the
contents of:
Chapter 2 Safety Information,
Chapter 3 Machine characteristics,
Chapter 4 Installation.
Programming and fine
tuning
Qualified programmer and tester who have read the contents
of:
Chapter 2 Safety information,
Chapter 3 Machine characteristics,
Chapter 5 Use.
Use Trained operator who has read the contents of:
Chapter 2 Safety information,
Chapter 3 Machine characteristics,
Chapter 5 Use.
Maintenance Three people are authorised to carry out maintenance
operations on this machine:
• Mechanical maintenance engineer: qualified person capable
of operating the machine in normal conditions with protective
devices opened, adjusting mechanical parts, carrying out
maintenance and repair interventions. Not qualified to carry out
electrical operations with power supply connected.
• Electrical maintenance engineer: qualified person capable
of operating the machine in normal conditions with protective
devices opened and carrying out any electrical work,
maintenance or repairs. Authorised to carry out electrical
maintenance operations inside electrical cabinet with power
supply connected.
• Technician: qualified person provided by BMR S.p.A. to carry
out repairs of a complex nature under special circumstances,
according to work agreed with the customer.
Demolition Qualified mechanic who has read the contents of:
Chapter 2 Safety information,
Chapter 8 Demolition.
NOTE BMR S.p.A. accepts no responsibility for any damage to persons, animals
or objects caused by employment of unqualified staff.

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EVEREST 620 14A
A
B
C
2.3 Protection
Definition
All safety measures which consist of specific technical measures (repairs, safety devices) taken
to protect people from dangers which cannot reasonably be limited through precautionary
measures are considered to be protection.
Mobile and fixed repairs
• All transmission parts are protected with bolted housing, covered by regulation EN 953.
• Rear housing for access to honing head operative range.
• Repairs to edge of conveyor belt near belt drive rolls.
• Front hatch for access to honing head operative range.
• Machine traverse protection net
Fig. 2.1 Fixed and mobile repairs
Passive safety devices
DEFINITION:
Passive safety devices are devices or measures which eliminate or reduce risks to the operator
without need for active intervention by the operator.

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EVEREST 620 14A
3
3
1
1
2
Devices
Interlocking devices
DEFINITION:
Interlocking devices are devices which cause the machine to stop or those which prevent the machine
from starting up if the necessary safety conditions are not in place. Examples include interlocking
micro limit switches which detect active mobile protective devices.
The machine uses the following micro limit switches:
1. The honing head operative range is protected by hatches equipped with micro timeswitches which
prevent the operator from coming into contact with moving parts. The hatch opens a few seconds
(approx. 10) after the switch has been pressed so that the head has come to a complete stop.
2. Limit switch for presence of material (situated at machine entrance, stops the belt and raises
heads).
3. Limit switch for abrasive terminal honing/polishing heads stops heads rotating, raises them and
activates a flashing signal situated above the electric panel.
Fig. 2.2 Limit switch

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EVEREST 620 14A
Active safety devices
DEFINITION:
Active safety devices are devices or measures which eliminate or reduce risks and which require
active intervention by an operator who is capable of explaining the reasons for the preventive
action.
Emergency stops
The emergency stop button, situated under the main machine control panel allows the operator
to stop the machine in the event of an emergency.
Safety measures
• The electrical safety devices ensure protection against electrical shocks, through direct or
indirect contact, in accordance with CEI EN 60204-1 regulations.
• All electrical parts which use dangerously high levels of power and voltage are located in the
electrical cabinet displaying the code IP54, in accordance with CEI EN 60204-1 regulations.
Control and power supply voltages for all accessible parts is set at 110 V and both feature
protection against short circuits and accidental phase to earth contact.
• The entire control panel voltage is set at 110 V, in accordance with CEI EN 60204-1
regulations.
DANGER It is dangerous to tamper with protective coverings, for both the operator
and any other people who are exposed.
NOTE BMR S.p.A. accepts no responsibility for injuries to persons,
animals or objects caused by tampering with protective devices.
2.4 Dangerous parts and residual risks
DEFINITION:
A dangerous part is defined as any internal part, or part near the machine where people are
exposed to risks of injury or damage to health.
During some machine maintenance operations, each of which are indicated in this manual,
there are residual risks for the operator. These can be eliminated by carefully following
the procedures set out in this manual and by adopting the suggested individual protective
measures.
Protective gloves must be worn.
Protective helmets must be worn.
Protective footwear must be worn.

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EVEREST 620 14A
Ear protection must be worn.
Eye protection must be worn.
Rubber boots must be worn.
Protective overalls must be worn.
Dangerous areas and residual risks during installation
Areas containing abrasive materials.
This carries the following risks:
• Risk of impact with the operator.
• Risk of friction and abrasion.
The operator must use the following IPE:
• Protective gloves.
• Protective overalls.
Area of movement of packed or non packed machines.
This carries the following risks:
• Risk of impact with the operator.
• Risk of crushing.
The operator must use the following IPE:
• Protective helmet.
• Protective footwear.
• Protective gloves.
Dangerous areas and residual risks during use
Area surrounding the machine.
This carries the following risks:
• Risk of slipping.
The operator must use the following IPE:
• Rubber boots with anti-slip sole
• Protective gloves.

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EVEREST 620 14A
Dangerous areas and residual risks during maintenance operations
Areas with abrasive parts. This carries the following risks:
• Risk of impact with the operator.
• Risk of friction and abrasion.
The operator must use the following IPE:
• Protective gloves.
• Protective overalls.
Dust particles are carried away by the water during machine operation; if the machine is inactive
for a certain period of time when being repaired, maintained or cleaned, dust sediment dries and the
dust particles can create the following risks if inhaled:
• damage to the respiratory system over time.
Machine operators must use the following IPE:
• protective mask for respiratory system.
Area surrounding the machine. The following risks exist:
• injury to eyes due to use of compressed air and irritant substances during maintenance
operations.
Machine operators must use the following IPE:
• Eye protection.
The following risks are present in areas with abrasive parts:
• Crushing. If the electric and pneumatic power supply is switched off (when the machine is
completely inactive), the polishing heads drop down under the force of gravity.
The following IPE must be used by the operator:
• Protective helmet.
NOTE BMR S.p.A. accepts no responsibility for injuries to persons, animals or objects
caused by failure to observe the relevant precautions or use the required IPE.

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EVEREST 620 14A
2.5 Noise
The following data regards airborne noise produced by the machine, which is measured according
to the conditions of the Machine Directive (89/392/CEE and successive modifications).
Empty
• Equivalent, weighted, continuous noise pressure level A, in the workplace:
76 dB(A).
• Noise levels emitted by the machine: 80 dB(A).
Loaded
• Equivalent, weighted, continuous noise pressure level A, in the workplace: 81 dB(A).
• Sound power from machine: 87 dB(A).
• Noise data measured according to regulations: UNI 7712.
These levels are measured during normal working conditions.
Information on the dangers of airborne noise
The levels of airborne noise produced which are quoted do not necessarily imply levels of
exposure which are safe for the operator. Levels of exposure for the operator are obviously
linked to noise produced by the machine, however other factors also influence operator exposure
levels. These factors include length of time of exposure, the type of environment in which it is
situated and the presence of other machines. Noise levels stated for the machine allow the user to
estimate the dangers related to air noise.
DANGER Continuous use of the machine can cause daily exposure to be equal
to or above 90 dB(A)
IPE (e.g. ear defenders) must be worn.
For information on other protective measures to be adopted in Italy, please
refer to Legislative Decree 277, of 15/08/2007.

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EVEREST 620 14A
Chapter 3 Machine specifications
3.1 Technical specifications
Machine size
Length 10500 mm
Width 2400 mm
Height 2200 mm
Power supply
Electrical system
Electrical power supply
Voltage 400/440 ±10% V triphase
Frequency 50/60 ±1% Hz
Conveyor belt motor power 5.5 kW
Bridge motor power 5.5 kW
Mandrel motor power 14 x 11 kW
Total installed electric power 154 kW
Electrical power supply tolerance
Voltage
Continuous voltage: ±10% of nominal voltage.
Frequency
±1% of continuous nominal frequency.
±2% of nominal frequency for short periods.
Harmonics
For all harmonics from second to fifth, harmonic distortion is no higher than 10 % of effective total
voltage between live conductors. Further distortion is admitted for all the harmonics between the sixth
and the thirtieth at 2% of the effective total value between live conductors.
Imbalance in three-phase supply voltage
Neither the inverse sequence component, nor the zero sequence component should exceed 2% of
the direct voltage sequence component.

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EVEREST 620 14A
Voltage pulses
These should last no longer than 1.5 ms with rise/fall times between 500 ns and 500 μs and a
peak value no higher than 200% of effective nominal supply voltage.
Power disconnections
The power supply must not be interrupted and voltage should not reach zero for longer than 3 ms
at whatever point in the wave.
Losses of voltage
Losses of voltage should not exceed 20% of peak supply voltage for more than one cycle. A time
gap of over 1 s is necessary between two instances of voltage loss.
Pneumatic system
Working pressure 6 bar
Maximum pressure 8 bar
Refrigeration water pressure 2÷3 bar
Total refrigeration water consumption 400 l/min
Hydraulic refrigeration system
Responsibility
NOTE BMR S.p.A. accepts no responsibility for
problems, breakdowns or malfunctions which may
arise due to failure to respect the stated power
supply values.
3.2 Performance data
Table of performance data
Number of polishing heads 14
Conveyor belt speed 11 m/min
Maximum machinable thickness 30 mm
Maximum machinable width 620 mm
Swinging pins tangential head
diameter
438 m

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EVEREST 620 14A
Chapter 4 Installation
4.1 Dangerous areas and residual risks during installation
Protective gloves must be worn.
Protective helmets must be worn.
Protective footwear must be worn.
Protective overalls must be worn.
Areas containing abrasive materials.This carries the following risks:
• Risk of impact with the operator.
• Risk of friction and abrasion.
The operator must use the following IPE:
• Protective gloves.
• Protective overalls.
Area of movement of packed or non packed machines.
This carries the following risks:
• Risk of impact with the operator.
• Risk of crushing.
The operator must use the following IPE:
• Protective helmet.
• Protective footwear.
• Protective gloves.
DANGER During machine unloading, lifting and moving operations, personnel must wear
proper IPE i.e. gloves, boots and helmets, and use the correct equipment.