Brobo 250HD User manual

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YOUR BROBO DISTRIBUTOR IS:
PRODUCT AND MAINTENANCE MANUAL
200/250HD BENCH/BUFF GRINDER MANUAL
BROBO WALDOWN (AUST) PTY. LTD.
A.C.N. 098 264 316
A.B.N. 42 098 264 316
65-67 Williams Rd, Dandenong, 3175
PO BOX 4274 Dandenong Sth, 3164
Victoria, AUSTRALIA.
Tel: [phone] Email: [e-mail]
Fax: [phone] Website: www.brobo.com.au
Certified System
Quality
ISO 9001

OPERATING MANUAL FOR 200/250HD SERIES BENCH/BUFF GRINDER
TECHNICAL SPECIFICATION i
CHAPTER 1: Installation of the Machine
1.1 Unpacking and Handling the Machine 1
1.2 Parts Checklist 2
1.3 Minimum Requirements 2
1.4 Anchoring the Grinder Unit 2
1.5 Connection to Power Source 3
CHAPTER 2: Safety and Accident Prevention
2.1 Operation of the Machine 4
2.1.1 Noise Level 4
2.1.2 Power Supply 5
2.2 General Requirements 5
2.3 Advice for the Operator 5
2.4 Machine Safety Devices 6
2.4.1 Reference Standards 6
CHAPTER 3: Main Functions and Operation of the Machine
3.1.1 Motor 7
3.1.2 Safety Eye Shields 7
3.1.3 Grinding Wheel 7
3.1.4 Toolrest 7
3.1.5 Emergency Stop Button 7
3.2 Preparation for Operation 8
3.3 Operation Recommendations 8
CHAPTER 4: Drawings, Layouts, Assembly and Spare Parts
4.1.1 Assembly Drawing (1 of 3) 9
4.1.2 Assembly Drawing (2 of 3) 10
4.1.3 Assembly Drawing (3 of 3) 11
4.1.4 Miscellaneous Part List 12
CHAPTER 5: Maintenance and Selection of Consumables
5.1 Role of the Operator 13
5.2 Maintenance Requirements 13
5.3 General Maintenance of Functioning Components 13
CHAPTER 6: Troubleshoot
6.1 Troubleshooting For Blade and Cutting Problems 15
APPENDIX
i. Hazard/Risk Assessment 16
ii. Warranty 17

TECHNICAL SPECIFICATION
MACHINE
SPECIFICATION
MOTOR RATING
(kW / V / PH)
DESCRIPTION
WHEEL SIZE & TAPED BUFF
ADAPTERS
200HD, 1 PH
(3850260)
0.75kW op. at 4.1 amps @
2800 RPMS (max), 240V, 1PH
Bench Grinder
200mm x 25mm wide x 19.05mm bore
200HD, 3 PH
(3850210)
0.75kW op. at 1.75 amps @
2800 RPMS (max), 415V, 3PH
Bench Grinder
200mm x 25mm wide x 19.05mm bore
200HD, 1PH
(3850280)
0.75kW op. at 4.1 amps @
2800 RPMS (max), 240V, 1PH
Buff Grinder
3/4” x 20 TPI
200HD, 3 PH
(3850230)
0.75kW op. at 1.75 amps @
2800 RPMS (max), 415V, 3PH
Buff Grinder
3/4” x 20 TPI
200HD, 1PH
(3850270)
0.75kW op. at 4.1 amps @
2800 RPMS (max), 240V, 1PH
Bench/Buff Grinder
200mm x 25mm wide x 19.05mm bore,
3/4” x 20 TPI
200HD, 3 PH
(3850220)
0.75kW op. at 1.75 amps @
2800 RPMS (max), 415V, 3PH
Bench/Buff Grinder
200mm x 25mm wide x 19.05mm bore,
3/4” x 20 TPI
250HD, 1 PH
(3500060)
0.75kW op. at 4.1 amps @
2800 RPMS (max), 240V, 1PH
Bench Grinder
250mm x 25mm wide x 19.05mm bore
250HD, 3 PH
(3500010)
0.75kW op. at 1.75 amps @
2800 RPMS (max), 415V, 3PH
Bench Grinder
250mm x 25mm wide x 19.05mm bore
Table Tilting Capacity:
Packed Weight: HD200 –34kgs
HD250 –40kgs
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CHAPTER 1 - Installation of the Machine
1.1 Unpacking and Handling the Machine
Upon receiving the Brobo Group 200HD/250HD Bench/Buff Grinder, the machine should be sitting in the
upright position before opening the packaging.
Carefully remove the packaging surrounding the grinder unit and elevating the machine away from the box,
mindful that the machine should be equally supported. Position the grinder to the desired location, ensuring that
a power outlet is available and within reach of the grinder power cord.
Prior to powering up the grinder, place the desired wheel/buff mop onto the machine spindles. Note that if the
bore sizes on the grinding wheels and/or buffering mops do not fit the spindle, taper adapters and buff adapters
are readily available for purchase from most hardware and tool outlets.
Once the wheels/buffs are securely fasten to the machine, connect the grinder to the mains electrical supply and
power up the machine.
Figure 1. Shipping of Grinder Unit
PLEASE OBSERVE AND FOLLOW THE INSTALLATION INTRUCTIONS ON PAGE 2
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WARNING – OPERATING VOLTAGE VARIATION
The grinder unit has an inbuilt safety electrical system to protect it against voltage variations.
However, for the machine to operate efficiently, ensure that the grinder operates within ± 10% limits
of the recommended voltage on the motor.
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1.2 Parts Checklist
Along with the grinder unit, check that the following accessories, packed "loose", are included as follows:
A. ACCESSORIES
i. 1 Operation Manual
1.3 Minimum Requirements
For the machine to function correctly, the room in which the grinder unit is to be installed must be in the vicinity of,
and satisfy the following conditions:
415/240V Power Supply
Ambient Temperature: From -10 to + 50 degrees C.
Relative Humidity: Not more than 90%.
Lighting: More than 500 LUX.
1.4 Anchoring the Grinder Unit
Prior to anchoring the grinder unit, take into considerations the requirements mentioned in Section 1.3 and
Section 2.2, and other aspects regarding the usage of the machine such as accessibility to grinder parts and safe
access for the operator.
Figure 2. Anchoring Hole Location
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BENCH MOUNT
4 x 6.0 THRU HOLES

VOLTAGE MAIN VOLTAGE
415/240V 3 PH 240V
1.5 Connection to Power Source
Before connecting the machine to the power supply, check that the socket is not connected in series with other
machines. This condition is critical for the ideal operation of the drill (Referring to Figure 3for wiring of “4-CORE”
power supply cable from the machine to a power plug. Check that the spindle rotary direction and change the
phasing if required; clockwise rotation observing top-down on top of the motor pulley.)
Note that single-phase machines are supplied in Australia with 15-amp plug). Furthermore, ensure that all the
electrical leads and cables (including supply leads) are well maintained and should be immediately replaced if cut,
sliced or damaged in any manner.
Figure 3. Connection for “4-CORE” Wire System with Neutral
To connect the machine to the power supply, proceed as follows:
1) Insert the power plug into the socket, while
ensuring that the mains voltage is compatible for
which the grinder is operating at.
2) Inspect that the grinder unit set to OFF position.
3) To prepare the machine for operation, release the STOP/EMERGENCY STOP button by twisting the red
mushroom button. To activate the drill, engage the green START button.
4) If all of the above procedures have been carried out correctly, the grinder should now be operational
The Brobo Group 200HD/250HD Bench/Buff Grinder is now ready for use. Chapter 3 provides a detailed
description of the various functional features of the grinder and its operating cycle.
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WARNING – UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE
The manufacturer declines any responsibility whatsoever, either civil of criminal, in the case of
unauthorised interference or replacement of one or more parts or assemblies on the machine, or if
accessories, tools and consumable materials are used that are different from those recommended
by the manufacturer himself or if the machine is inserted in a plant system and its proper function is
altered.
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CHAPTER 2 - Safety and Accident Prevention
The Brobo Group 200HD/250HD Bench/Buff Grinder has been designed and manufactured in accordance to
Australian Standards. It is HIGHLY RECOMMENDED that the instructions and warnings contained in this
chapter be carefully followed for correct usage of the machine.
2.1 Operation of the Machine
The Brobo Group 200HD/250HD Bench/Buff Grinder is specifically design for grinding of various ferrous metal
sections. This machine involves high-speed revolutions; therefore extreme caution is required when
operating the device.
The employer is responsible for instructing the personnel who, in turn, are obliged to inform the operator of any
accident risks, safety devices, noise emission and accident prevention regulations provided for by national and
international laws governing the use of the machine. The operator must be perfectly aware of the position
and functions of all the machine’s controls.
All those concerned must strictly adhere to ALL instructions, warnings and accident prevention
standards in this manual.
The following definitions are those provided for by the EEC DIRECTIVE ON MACHINERY No. 98/37/CE:
Danger Zone - any zone in and/or around a machine in which the presence of a person constitutes a risk
for the safety and health of that person.
Person Exposed - any person finding him or herself, either completely or partly in a danger zone.
Operator -the person or persons given the responsibility of installing, operating, adjusting, maintaining,
cleaning, repairing and transporting the machine.
2.1.1 Noise Level
The noise level of an idling grinder unit has been measured to be below 85 dBA.This complies with the
Australian Occupational Health and Safety (Noise) Regulations 1992.
Please note that peak impulse noise levels will be experienced due to variables including drill characteristics,
type, and condition. This will also vary accordingly depending on the size and type of sample being drilled.
Under these circumstances, management should make available to the operator(s) the appropriate hearing
protection equipment as prescribed under the above stated act.
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2.1.2 Power Supply
The 415/240V power supply requirements for this machine are of a high level and unauthorised interference and
or inadequate maintenance could result in a situation that could put the operator at risk. A qualified electrical
engineer should be assigned to maintain and repair the system.
2.2 General Requirements
Lighting
Insufficient lighting during the operation of the drill unit would constitute a safety hazard for the people concerned.
For this reason, the user of the machine must provide adequate lighting in the working area to eliminate areas in
shadow, whilst also preventing dazzling illumination sources (reference standard ISO 8995 -2002 ‘Lighting of
Indoor Workplaces’).
Connections
Check that the power supply cables, compressed air supply and/or coolant system complies with, and are
operating within the acceptable range of the drill capabilities. Faulty, damaged or worn components must be
replaced immediately.
Earthing Systems
The installation of the earthing system must comply with the requirements stated in the IEC Standards Part 195:
Earthing and Protection Against Electric Shocks 1998.
2.3 Advice for the Operator
Protective eyewear or goggles must be worn at all times while attending and operating the
grinder unit.
Ensure that hands and arms are kept clear of the working zone when the machine is
operating.
Do not wear oversize clothing with long sleeves and oversize gloves, bracelets, necklaces or
any other loose object that may become entangled in the machine’s tooling bit during drilling.
Long hair must be tied back or placed in a hair net.
Always disconnect the power supply to the machine before carrying out any maintenance
work or adjustments. This includes cases of abnormal operations of the machine.
Always keep the workplace area as clean as possible. Remove equipment, tools or any other
objects from the grinding zone.
Support the work piece on both sides of the machine to prevent it falling or jamming during
the grinding cycle.
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5

Always turn off the machine before carrying out any repair work. Consult the Brobo Group
Engineering Department in the country in which the machine was initially purchased.
2.4 Machine Safety Devices
This product and maintenance manual is not purely intended as a guide for the usage, operation and
maintenance of the grinder unit in a strictly production environment; it is instead an instrument to providing
information on how to use the machine correctly and safely. The following standards listed in section 2.4.1, which
are applicable to the Brobo Group 200HD/250HD Bench/Buff Grinder,are those specified by the EEC
Committee that governs safety of machinery, health and safety at work, personal protection and safeguarding of
the work environment. In addition, the saw also complies with the Australian Standards regarding the
safeguarding and general requirements for electrical equipment.
2.4.1 Reference Standards
MACHINE SAFETY
EEC Directive No. 98/37/CE -Machines Directive
EEC Directive No. 91/368 -94/68 - Amends sections of EEC Directive No. 98/37/CE relating to machine
safety
EEC Directive No. 73/23 - Low Voltage Directive
AS4024.1 -1996 - Safeguarding of Machinery
HEALTH AND SAFETY AT WORK
AS3100 -2002 - General Requirements for Electrical Equipment
Operational Health and Safety (OHS) 1995.81/1995 - Compliance References
EEC Directive No. 80/1107; 83/477; 86/188; 88/188; 88/642 - Protection of workers against risks caused by
exposure to physical, chemical and biological agents in workplace
EEC Directive No. 73/23 and Special EEC Directives No. 89/654;89/655 -Improvements in health and
safety at work
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CHAPTER 3 - Main Functions and Operation of the Machine
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3.1.1 Motor
Available in single phase 240 volts or 3 phases 415 volts, the 1.1KW CMG motor is the heart of the grinder unit
that produces 2800rpms toward the spindles and is operating at suitable speeds for grinding and buffing
applications.
3.1.2 Safety Eye Shields
The reinforced glass safety eye shield serves to protect the user from any debris and particles that might be
dislodged from the grinding/buffing process. The bracket mountings also allow the user to adjust the position of
the eye shield to suit various work piece.
3.1.3 Grinding Wheel
Rated at 40/60 coarseness, the general purpose grinding wheels are provided on all Brobo bench grinding
machines. It is advisable to all operators that grinding/buffing wheels are available for purchase for various
applications from reputable hardware stores. Also note that tapered buff and wire adaptors are available for
purchase from Brobo, sold separately.
3.1.4 Toolrest
As implied, the toolrest provides a stable platform in which the user can rest any toolpiece for resharpening. The
height and positon of the toolrest can be moved accordingly via the adjustable bolts provided.
3.1.5 Emergency Stop Button
In compliance with Australian Standards and ISO 9001, all Brobo grinding/buffing machiens are now provided
with emergency STOP button for ease of access during emegency.
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4
5
KEY:
1. Motor
2. Safety Eye Shields
3. Grinding Wheel
4. Toolrest
5. Emergency STOP Button
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