Chennai Metco BAINPOL VT User manual
BAINPOL VT
8"/10"/12(Disc Size)
Instruction Manual
Variable Speed Single Disc
Table Top Polisher
Chennai Metco
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Intended usage
This Bainpol VT polishing machine is used in metallurgical lab for the purpose of polishing to get superior
surface finish so that, it can be used for viewing the microstructure or for any process/test such as Micro
Vickers’ hardness test that require a smooth surface finish. Excellent surfaces finishes are obtained through
proper selection of the abrasive papers, polishing cloth and polishing paste or suspensions.
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Contents
1. Safety -------------------------------------------------------------------------------------- 5
2. Transport ----------------------------------------------------------------------------------- 12
3. System Features and Principles of Operation ---------------------------------------- 16
4. Machine Layout ---------------------------------------------------------------------------------- 18
5. Installation ---------------------------------------------------------------------------------- 19
6. Operation --------------------------------------------------------------------------------- 21
7. Maintenance and Inspection ----------------------------------------------------------- 22
8. Troubleshooting-------------------------------------------------------------------------------- 23
9. Dismantling ------------------------------------------------------------------------------- 26
10. Technical Specification ---------------------------------------------------------------------- 27
11. Electrical Circuit ---------------------------------------------------------------------- 28
12. Warranty certificate ---------------------------------------------------------------------- 29
13. Contact ---------------------------------------------------------------------------------- 30
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Take a Moment to familiarize yourself with the location and names
of the Bainpol VT components.
1.Coolant Jet 2. Coolant Valve 3. Feather Touch panel 4. FRB Cover 5. Polishing Dsic 6. Water Splash Guard 7.
Emeregency Stop
Feather Touch Board (Front Panel)
a.RPM/Time Increment, b.RPM/Time Decrement, c.Disc Forward/Reverse
d.Disc Stop/Run, e.Power On/Off, f. Digital Display
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1. SAFETY
1 Safety
1.1 Proper Use
1.1.1 Principle
The Bainpol polishing machines are designed in accordance with recognized technical research and
experience and safety regulation. Failure or ignorance to properly install, operate and maintain the
machine/system may result in a high risk of serious or fatal injury to users or third parties or result in
unnecessary damage of the flow of process or the system or other equipment.
1.1.2 Permissible Operation
The machine/system is a technical working appliance, designed exclusively to grind/polish sectioned
and mounted (sometimes non-mounted) materials for metallographic purposes. The machine/system is a
technical means of achieving, exclusively, low volume grinding/polishing of materials. Any other usage
is regarded improper. Any liability on the part of the user for damages resulting from an improper
machine usage is excluded. The risk has to be borne entirely by the user. The following are some
examples of the machine/system misuse:
Using on other industry or application.
Using other than recommended lubrication oil on the machine.
Untrained personnel operated this machine/system
Proper usage also includes compliance with operating, servicing and maintenance requirement
specified by the manufacturer.
1.1.3 Safe operation of machine
The machine must only be used in a technically error – free condition and according to proper operating
practice in a safe and risk conscious manner while observing and heeding all caution or danger tags
attached to the machine or included in this manual. Malfunction that can impair safety must be remedied
immediately.
1.2 Level of hazard
Symbols are used to call attention to hazards or unsafe practices which could result in an injury or
property damage. The signal words, defined below, indicate the level of the hazards. The message after
the signal word provides information for preventing or avoiding the hazards. While reading your manual
pay close attention to areas labeled the signal words.
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1.3 Safety information
Read and understand all the instruction and safety information in this manual. Everyone who works on or
around this equipment including, but not limited to, operator, maintenance personnel, and supervisory
personnel must read and understand the information in this chapter prior to commencing work on or around
this equipment. Failure to conform to the information in this chapter could lead to property damage or
serious personal injury including possible loss of body parts or death. This chapter only describes proper
safety procedures to follow when working with this equipment. Please refer to the instruction manuals
delivered together with the installation of your equipment. Please ensure that all work described in this
manual is carried out in a good environment / workshop using proper tools and equipment.
1.4 Protection for Installation, Operation and Maintenance Personnel
In addition to the safety information included in this section, always observe all specific safety information
included with the instructions in balance of this manual. As manufactured this equipment has been equipped
with safety devices which correspond to current technology standard in accordance with the prescribed
applications of this equipment. However, residual risks remain to which attention is drawn individually
within this machine manual.
Instruction obligation: The operating company must verify that:
Personnel have the necessary technical, equipment-specific, and safety knowledge or that is
achieved by means of relevant training before the equipment is installed, operated, or
maintained.
Personnel have the necessary competence to be able to work on accordance with the regulations
and instruction.
Indicates an imminently hazardous situation, if not
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous, if not avoided,
might result in minor or moderate injury. It can also
indicate possible loss of materials or damage to the
equipment.
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Before initial startup, personnel have to read and understand all instructions contained within the
supplied documentation.
Equipment obligation: The operating company is required to equip personnel with the necessary protective
clothing as follows:
Safety shoes
Safety gloves
Safety goggles
1.5 Protection for Third parties
The operating company must also make persons who are not charged with the operating or maintenance of
the equipment aware of the dangers.
1.6 Common Sense of safety
Accidents frequently occur due to carelessness or lack of knowledge. To avoid potential problems, review
the information in the section before attempting to install, setup, operate, or maintain this equipment. Think
safety at all the times. Do not let familiarity with the equipment lead to unsafe short cuts. The following
common sense safety practices must be observed at all times.
1. Follow all procedures and precautions in the manual carefully and completely.
2. Only attempt repair or adjustments for which proper training has been completed.
3. Always observe all safety warnings and notices on the machine and in the manual.
4. Do not remove or otherwise alter any guards or panel unless the machine is completely shut
down and has been made inoperable. Be sure to replace these items before restarting the
machine.
5. Never operate the equipment without guards and safety mechanisms in place and functional.
6. Do not allow foreign object to fall into machine.
7. Always use the proper tools for performance of any operation on the machine. Whenever
feasible, use voltage-isolated tools.
8. Do not touch any parts of the machine which may have become hot during operation.
9. Do not wear neck ties, jewelry, loose clothing, and long hair.
10. Wear or use gloves, goggles, safety shields, ear protection, and other employer recommended
safety equipment. Wear protective clothing to prevent burns.
11. Disconnect power and lock out all switches before attempting to adjust or manipulate any
moving parts or mechanism on the equipment.
12. Be aware that there are high voltages in this device when power is connected. Power must be
disconnected when the device is being repaired. However, because there are certain checks and
adjustment that can be made only with any power connected, it is imperative that only trained
personnel, aware of the safety hazards involved and familiar with this type of work and
necessary safety precautions, be permitted to perform this work.
13. Maintain good housekeeping practices to prevent slips, falls, cuts, burns, and other possible
accidents. Keep the area all necessary items properly organized.
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14.
Even though the plant may be equipped
protection, portable fire extinguishers should be available to the machine operator. To be
effective, portable extinguishers must be reliable, the proper type for each class of fire that may
occur in the
area, in sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged a
operable by are personnel who are trained to use them effectively and promptly.
1.7 Hazard Warning Label
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
potentially present during operation and maintenance activities.
Hazard warning labels are in appropriate sizes and colors
symbols that show hazard types, in addition to descriptions of warning contents.
1.7.1
Types of Hazards Warning Label
The following safety warning labels appear on the system.
1.7.2
Location of Hazard Warning Label
Personnel are requested to confirm the location
of, read and thoroughly understand contents of
all of hazard warning labels applied to
machine prior to work.
“Warning of Dangerous Electric V
Users are
warning labels. Make sure to apply new labels upon
replacement of the peeled off or worn out labels
Even though the plant may be equipped
with automatic sprinklers or other means of the fire
protection, portable fire extinguishers should be available to the machine operator. To be
effective, portable extinguishers must be reliable, the proper type for each class of fire that may
area, in sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged a
operable by are personnel who are trained to use them effectively and promptly.
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
potentially present during operation and maintenance activities.
Hazard warning labels are in appropriate sizes and colors
that catch attention of personnel’s eyes and have
symbols that show hazard types, in addition to descriptions of warning contents.
Types of Hazards Warning Label
The following safety warning labels appear on the system.
Location of Hazard Warning Label
Personnel are requested to confirm the location
of, read and thoroughly understand contents of
all of hazard warning labels applied to
this
machine prior to work.
“Warning of Dangerous Electric V
oltage”
Users are
NOT
allowed to change the location of hazard
warning labels. Make sure to apply new labels upon
replacement of the peeled off or worn out labels
Page 8
with automatic sprinklers or other means of the fire
protection, portable fire extinguishers should be available to the machine operator. To be
effective, portable extinguishers must be reliable, the proper type for each class of fire that may
area, in sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged a
s required, and
operable by are personnel who are trained to use them effectively and promptly.
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
that catch attention of personnel’s eyes and have
symbols that show hazard types, in addition to descriptions of warning contents.
Personnel are requested to confirm the location
of, read and thoroughly understand contents of
allowed to change the location of hazard
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Electrical Control
This warning label is labeled on the “Electrical Control Board” which contains voltage
sections that can physically damage inside.
Electric system inside the Electrical Control Panels contains highly hazardous high voltage
sections.
Turn off the system Main Switch before maintenance, to prevent electric shock accidents due to
contact with such high voltage section.
1.8 Safety devices
1.8.1 Main Switch
The system is provided with a main power switch to interruption of power supply. The system must be
switched off via the Main Switch. To be safe, the main switch is to be switched off when the
following works are carried out:
Cleaning
Maintenance
Repair
The Main switch is located on the rear side of the machine. ‘ON’ or ‘OFF’ is mentioned over the switch
and a light is provided to indicate if the main switch is on.
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1.9
Turning off the machine
1.9.1 Main Switch turn-off
The purpose of turning off the main-switch is to prevent unexpected startup and release of accumulated energy
in order to protect any personnel during maintenance and inspection process. The main-switch is placed at the
back so that the machine wouldn’t start by mis-pressing buttons in the front when the main-switch is turned off.
1.10 Disposing Individual Component
Machine frame and all mechanical machine components are made of steel, light metal and plastics.
These materials are recyclable.
Take non-reusable difficult waste, lubricant and batteries, to the appropriate waste disposal point.
Anyone who carries out servicing of this machine is
requested to recognize the importance of switching off the
main switch before any service.
If the system
is still operating, carry out the shut down
procedure and ensure the system is completely stopped
before lockout.
When more than one person performs service
at the
same time, appoint a "supervisor" who supervises all the
persons.
Supervisor is requested to be aware of working status
all the time, and to carry out the service procedure.
Reusable raw material and problem material.
Environmental pollution.
Protect the environment by correctly disposing
of a recycling raw materials and problem
materials
Be careful wh
ile handling waste fluid, which
may corrode
skin and clothing upon contact.
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Seal any used parts possibly exposed to toxic or corrosive material prior, in inside of vinyl bags. Apply
certain marking to all of the disposal bags to identify possible contamination.
Drained water or suspensions during working must be collected in the proper way and disposed to the
correct waste point.
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2. Transport
2.1 Unpacking and Inspection
Inspect equipment and shipping crate immediately upon receipt. Check the packing slip carefully and make sure
all the materials have been received as indicated on the packing ticket. If any damage apparent, you should both
report it to the trucking delivery person and contact the transportation company immediately. When submitting
a claim for shipping damage, request that the carrier inspect the shipping container and equipment.
2.2 Unpacking Location Environment /Cautions
Do not unpack in a location where any of the following conditions apply.
• Unbalanced
• Location with direct humidity (including rain and fog) intrusion
• Location with possible acute temperature change
• Location with strong vibration; also, do not place any product onsuch location
• Dusty
2.3 Transporting Machine with Box/Crate
Equipment and tools to be used:
Interrupt the unpacking procedure and contact the
responsible forwarder once any obvious abnormality such
as abnormal noise/odor is found during unpacking.
Before lifting and placing on the table, care
should be taken so that the equipment with the
Risk of death or severe crushing of limbs
Pallet jack or lift manually using hands according to the total weight to
be transported
Do not stand in front of the transport item during transport
Proper size of pallet shall be use or transportation
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Pallet Jack
The forklift or lift truck employed must fulfill the following minimum requirements:
• Carrying capacity according to the total weight (machine/system and transport packing), see shipping papers.
• Length of the forks should be at least 920 mm
• The distance between forks should be such that the mass of equipment is rested on a stable manner over them.
i. Insert the pallet jack carefully under the box so that, the entire area of the box rests over the fork stem.
ii. Lift it to a safe level so that, the box can be moved with ease.
2.4 Unload Distribution Box
Equipment and tools to be used:
Risk of death or severe crushing of limbs
Pallet jack or lift manually using hands according to the total
weight to be transported
Do not stand in front of the transport item during transport
Proper size of pallet shall be use or transportation
Before lifting and placing on the table, care
should be taken so that the equipment with the
box lays flat parallel to the floor
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Pallet Jack
The pallet jack employed must fulfill the following minimum requirements:
• Carrying capacity according to the total weight (machine/system and transport packing), see shipping papers.
• Length of the forks should be at least 920 mm
• The distance between forks should be such that the mass of equipment is rested on a stable manner over them.
Note: The centre of gravity of Distribution Box is not in the center and depends on the outfitting of the unit.
i. Place the Distribution Box into proper size of empty pallet.
ii. Place the pallet jack insertion position on the pallet.
iii. Move the pallet jack and transport to the installation site.
iv. Place Distribution Box according to installation plan.
2.5 Unload the Bainpol Polishing Machines
Risk of death or severe crushing of limbs
Pallet jack or lift manually using hands according to the total weight to
be transported
Do not stand in front of the transport item during transport
Proper size of pallet shall be use or transportation
Before lifting and placing on the table,
care
should be taken so that the equipment with the
box lays flat parallel to the floor
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With proper man power(requires two or three humans), depending on the weight of the machine, the
machine is lifted and placed on the table.
i. Two/ three people should insert their hands below the base of the polishing machine.
In case if the machine is too big to handle and is to be placed on the floor, the machine is carefully
lifted from the pallet trolley and placed on the spot.
ii. Lift the machine in a coordinated manner so that, the machine stays flat while lifting
iii. Place the machine over the desired spot and then retract hands.
2.6 Relocating the polishing Machine
2.6.1 Preparing for repositioning
Turn off the Main Switch of Electrical Control Panel and remove attachment of the main power
supply to system.
Remove the connecting pipe between Oil Tank and Distribution Box.
Secure all the parts on the polishing machine
2.6.2 Repositioning of unit
Repeat the step on Section 2.4
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3. System Features and Principles of Operation
3 Machine Features and Principle of Operation
3.1 Introduction
The Bainpol polishing machines are exclusively designed for polishing materials for metallographic
analysis. Polishing, in one or more final steps, in specimen preparation is to get mirror finished surface. This
process is necessary to get a clear view of the microstructure in the specimen. Depending on the type/model, the
machine offers that, the polishing programs can be programmed through a Programmable Logic Unit (PLC)
for polishing sections efficiently. For this reason, the user can increase the quality and quantity of the surface
finish obtained during polishing. In primitive models of polishing machines, graphical display board is used to
display the parameters of polishing.
3.2 Machine Description
Bainpol polishing machines are exclusively designed for the metallurgical sample polishing. The
machine consists of a motor that rotates the disc(s) through a belt drive mechanism. Depending on the
requirement, the machine comes with or without a stand.
The range of machine consists of Manual, semi-automatic or fully automatic types depending upon the
degree of automation required. The automated movement offers precision and reproducibility. The manual
polishing machines is designed to offer maximum user friendliness and safe polishing action. The advanced
touch screen option in select models allows the user to enter and store the polishing parameters for easy storage
and retrieval of polishing data.
3.3 Machine Content
The Bainpol Machines consists of the following assemblies
Electrical Control Panel assembly
Lubricant assembly
Mechanical Assembly
3.3.1 Electrical Control Assembly
The electrical assembly consists of rotation start, rotation stop, lubricant/coolant on and off and rotation-
direction-swap. In automated machines there is a separate head that can apply a controlled force on to the
specimen during polishing. This requires a compressor to derive pneumatic pressure. The force, speed of
rotation of head (in which the specimens are held), speed of rotation of the disc on which the abrasive disc is
attached to can be adjusted through the PLC. In semi-automatic polishing machines, a separate motor powers
the head and there is no requirement of compressor since there is no application of pneumatic forces. The safety
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feature in electrical assembly includes disc rotation starts only when the main switch is on. The
coolant/lubricant on/off is used to control the lubrication action during polishing.
3.3.2 Coolant/Lubrication assembly
There is an opening for water supply through which water for cooling/lubrication is input. A pipe provision is
given to feed out the used water that has abrasives and debris. For safe operation, the outlet should be fixed to a
proper sewage system and the incoming input water should be of proper quality. A tap is provided to control the
flow of water.
3.3.2 Mechanical Assembly
The mechanical assembly consists of the motor with belt drive to drive aluminum discs on which the abrasive
discs are fixed. The sample to be polished comes in contact with the abrasive disc that is already in motion as a
result of which material removal occurs. The mechanical assembly ensures vibration and chatter free polishing
operation.
3.4 Working principle of the Bainpol Polishing Machines
Initially the system electric motor operates continuously after the electricity connected and the Main Switch is
activated on the Electrical Control panel. Once the parameters have been set and the rotation start button is
pressed, the discs start rotating. The rotation-direction-swap button is pressed to change the direction of rotation
of the wheel. The Motor starts rotating and so the disc starts rotating. The ‘+’ and ‘-‘ buttons are used to
increase and decrease the speed of rotation of the disc respectively. The change in speed can be made during the
rotation itself. The lubricant flow is turned on or off using the ‘lubricant’ button. All changes are done through
PLC touch screen control in automatic polishing machines. Once the polishing is finished, the lubricant supply
is stopped and the Main switch is turned off.
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4. Machine Layout
Foot Print
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5. Installation
5.1 Installation Environment
Temperature : 5 to 40°C
Humidity : 20 to 80% RH (no condensation)
5.2 Installation Space
Machine external dimensions (refer to Section 10.9) + working space (900 mm)of footprint space
Machine height (refer to Section 10.9) + working space of height wise (500 mm) space is necessary
5.3 Environment and Operating Conditions
Ambient Temperature: 2 to 40º C when system is operational
Ambient humidity: 10 to 80% RH (no condensation) when system is operational.
Vibration: 2m/s or less at 10 to 50 Hz
Air cleanliness: An air dust volume of 0.2 mg/m3 or less is preferred.
In addition, there should be very little corrosive matter such as hydrogen sulfide, zincate gas and chloride. In
addition, user should aware of following operating condition and environment for the system:
• The unit should be installed in an area where there is a good ventilation. Do not locate unit in area of
wide ambient temperature variation, such as near vent or outdoor entrances.
• Do not place the unit near combustible material or hazardous fumes or vapor.
• Make sure the unit is leveled when operation.
• Do not position the unit in a manner that would make it difficult to operate the Main Switch and
Emergency Stop button (at Electrical Control Panel).
Do not install the unit at the location at potentially
flammable and/or explosive atmosphere
Do not install the unit in a corrosive environment. A
corrosive environment may lead to poor performance and
deterioration of unit.
The system is not designed
to be used at the location as
potentially flammable and /or explosive atmosphere
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5.4 Making pipe connection
5.4.1 Connecting water supply Machine
PU6 tubes are used to input water into the polishing machine. A pipe whose diameter is 50 mm fits with the
outlet valve of the polishing machine that is used to take out the used water.
5.5 Making Wiring connection
• The connection data can be seen from the wiring diagrams ( the wiring diagrams are sullied with
machine )
• The electrical connections require a plug to supply single phase current
• Check the main voltage present against the voltage identified on the name plate to see if they match
• Check the phase sequence (Pole – compliant connection)
• User must connect the incoming power supply to the terminal block as shown.
Do not loosen fitting to arrive at proper position or leak
may occur.
Over tightening may cause piper fitting to deform and
damage to the joining fitting
Remove all foreign matter from inside the piping
Working on the electrical equipment must b entrusted
only to a trained and qualified electrician. The work has to
be carried out according to the rules for electrical
engineering
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