Fervi 0552 User manual

USE AND
MAINTENANCE MANUAL
Professional bench grinder
Art. 0552 and Art. 0552/400V
ORIGINAL INSTRUCTIONS
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FOREWORD
Read this manual before any operation
ORIGINAL INSTRUCTIONS
Before starting any operation it is compulsory to read this instruction manual. The guarantee
that the machine will function and perform properly is strictly dependent upon the application
of all the instructions contained in this manual.
Operator Qualification
The operators assigned to using this machine must be supplied with all of the necessary
information and instruction and should be provided with adequate training regarding
safety in pertaining to:
a) The conditions of use of the equipment;
b) Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
81/08.
We guarantee the Machine's conformity to the specifications and technical instructions
described in the Manual on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the manual being updated.
Therefore, see FERVI for information about modifications that could be implemented.
REV. 3 April 2014
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CONTENTS
1 INTRODUCTION ........................................................................................5
1.1 Preface..........................................................................................................................6
2 SAFETY WARNINGS ..................................................................................7
2.1 General safety rules for machine tools..........................................................................7
2.2 Special safety rules for grinders ...................................................................................8
2.3 Safety rules for electrical machine equipment ..............................................................9
2.4 Technical support..........................................................................................................9
2.5 Other provisions ...........................................................................................................9
3 TECHNICAL SPECIFICATIONS .................................................................10
4 DESCRIPTION OF THE MACHINE .............................................................11
4.1 Identification plate .....................................................................................................12
4.2 Pictograms..................................................................................................................12
5 INSTALLATION OF THE MACHINE ........................................................... 14
5.1 Positioning and fastening on the bench ......................................................................14
5.2 Installation of screens and workpiece holder brackets ...............................................15
5.3 Connection to the extraction system...........................................................................16
5.4 Connecting the power plug and start-up test (Art. 0552) ...........................................16
6 SAFETY DEVICES ON THE MACHINE ........................................................ 17
6.1 Electrical safety devices..............................................................................................17
6.2 "Mechanical" Safety Devices ....................................................................................... 18
7 CONTROLS ..............................................................................................19
7.1 On switch (start) ........................................................................................................19
7.2 Stop button .................................................................................................................19
7.3 Emergency Button.......................................................................................................20
8 OPERATION ............................................................................................21
8.1 Instructions for Use ....................................................................................................21
8.2 Using the dry grinding wheel ......................................................................................21
9 MAINTENANCE........................................................................................23
9.1 Routine maintenance ..................................................................................................23
9.2 Replacing the tools .....................................................................................................24
9.2.1 Replacing the Wheel................................................................................................. 25
10 TROUBLESHOOTING ............................................................................. 26
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11 SPARE PARTS .......................................................................................27
12 DISPOSAL OF PARTS AND MATERIALS .................................................28
13 WAREHOUSE STORAGE.........................................................................29
14 WIRING DIAGRAM ............................................................................... 30
14.1 Art. 0552..................................................................................................................30
14.2 Art. 0552/400V........................................................................................................31
15 LIST OF PARTS .....................................................................................32
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1 INTRODUCTION
This manual is delivered with the machine, and it must be regarded as an inseparable part of
it.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
forbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the Professional bench grinder Art. 0552 and Art. 0552/400V and
create a sense of responsibility and knowledge of the possibilities and limits of the device
entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the operator if it is to be used safely and effectively.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, operation and maintenance of the
Professional bench grinder. This is to make all operations the safest and most effective
possible for those who carry out these tasks.
Therefore, it is imperative to strictly comply with the requirements in this manual, a
necessary condition for safe and satisfactory operation of the machine.
Before starting operation, installation and usage of the Professional bench grinder,
authorised personnel must therefore:
carefully read this technical document;
know which protections and safety devices are available on the machine, their location
and how they work.
It is the responsibility of the buyer to ensure that users are properly trained, that they are
aware of all the information and instructions in this document and that they are aware of the
potential risks that exist while working with the Professional bench grinder.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non-observance of the instructions in this manual.
The Professional bench grinder has been designed and built with mechanical guards and
safety devices designed to protect the operator/user from possible injury. It is strictly
forbidden to modify or remove guards, safety devices and caution labels. If this must be done
(for example, for cleaning or repair), make sure that no one can use the machine.
Modifications to the machine carried out by the user must be considered their sole
responsibility, therefore the manufacturer waives any and all responsibility for any
damage caused to persons and/or property resulting from maintenance performed
by unqualified personnel and in a manner unlike the operating procedures shown
below.
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GRAPHIC REPRESENTATION OF SAFETY,OPERATIONAL AND RISK WARNINGS
The following boxes are designed to attract the attention of the reader / user for the proper
and safe use of the machine:
Pay attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1 Preface
For safe and easy operation of the Professional bench grinder, this manual must be read
carefully in order to acquire the necessary knowledge. In other words, durability and
performance are strictly dependent on how it is used.
Even if already familiar with the Professional bench grinder, it is necessary to follow the
instructions contained herein, in addition to the general precautions to be observed while
working.
Acquire full knowledge of the machine.
Read this manual carefully to understand: operation, safety devices and all necessary
precautions. All this is to allow safe use of the machine.
Wear appropriate clothing for the job.
The operator must wear appropriate clothing, so as to prevent the occurrence of
unpleasant accidents.
Maintain the machine with care.
Using the machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2 SAFETY WARNINGS
2.1 General safety rules for machine tools
Risks associated with the use of the machine
Do NOT underestimate the risks related to the use of the machine and stay focused on the
work you are carrying out.
Risks associated with the use of the machine
Despite the implementation of all safety devices for safe use of the machine, it is necessary to
take note of all the accident prevention requirements highlighted in various parts of this
manual.
Risks associated with the use of the machine
Every person who is responsible for the use and maintenance of the machine should first have
read the instruction manual, particularly the chapter dealing with safety.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with the use of the machine
During all work phases with the machine, you should proceed with great caution in
order to avoid damage to persons, to property or to the machine itself.
Please only use the machine for its envisaged uses.
Do not tamper with the safety devices provided by the manufacturer.
Risks associated with the use of the machine
Before starting any work on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection.
1. Always check the efficiency and integrity of the machine.
2. Before connecting the machine to the mains make sure that the switch is in the rest
position.
3. Do not start the machine in an enclosed or poorly ventilated area, or in the presence of
a flammable and/or explosive atmosphere. Do not use the machine in damp and/or wet
locations, or those exposed to rain or humidity.
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4. Avoid starting accidentally.
5. Before starting the machine, get used to ensuring that no remaining adjustment or
maintenance wrenches have remained inserted.
6. Keep the workplace tidy and free from hindrances; disorder causes accidents.
7. Make sure that the work environment is forbidden to children, non-employees and
animals.
8. Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was intended, as described in this instruction
manual.
9. Work without disturbances.
10.Work areas must be well lit.
11.Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate masks.
12.Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can get
caught in the moving parts, causing irreparable injury.
13.Replace worn and/or damaged parts, check that the guards and protection devices work
properly before operating. If necessary, have the machine checked by the service
support personnel. Use only original spare parts.
14.Cut the mains voltage supply to the machine when:
the machine is not being operated;
is left unattended;
you are performing maintenance or adjustment because the machine does not
work properly;
the power cable is damaged;
you are replacing its tool;
in case the machine is being moved to another location;
you are cleaning the machine.
15.Do not use the machine in areas with a risk of fire and/or explosion.
16.It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of mechanical principles and of repair technique procedures.
17.The person responsible for company safety is to make sure that the staff
responsible for using the machine have read and understood this manual in its
entirety.
18.The company safety manager is responsible for monitoring the company's risk
status according to Legislative Decree no. 81/08.
2.2 Special safety rules for grinders
1. Before connecting the machine to the mains, make sure that the rotating parts are not
damaged or badly worn.
2. Do not hold tools in motion (wheels, brushes). Do not lift the machine by holding the
tools.
3. To stop the tools on the machine, always only use the stop command device (red
button).
4. Do not move away from the machine until the tools and other moving parts, have
completely stopped.
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2.3 Safety rules for electrical machine equipment
Risks associated with the use of the machine
1. Do not modify the electrical system in any way. Any attempt in this regard may
jeopardize the operation of electrical devices, thus causing malfunction or accident.
2. Work carried out in the electrical system of the machine must, therefore, be carried out
only by qualified and authorized personnel.
3. If one hears unusual noises, or feels something strange, immediately stop the machine.
Then carry out an inspection and, if necessary, perform any repairs as required.
1. Ensure the supply voltage corresponds to that stated on the label and in the technical
specifications (Art. 0552 230V/50Hz and Art. 0552/400V 400V/50Hz).
2. It is necessary to use a device for the automatic interruption of the power supply in
case of failure, which is to be coordinated with the machine's electrical system. For
more detailed information, contact a trusted electrician.
3. The socket must be earthed and extension cables must have sections that are the
same or greater than the sections of the power cable of the machine.
4. The power supply cable (and its possible extension cable) should never come in contact
with hot objects, sharp edges, wet or oiled surfaces.
5. The power cord should be checked regularly and before each use to check for signs of
damage or wear. If these are not in good condition, replace the cable.
6. Do not use the power cord to lift the machine or to remove the plug from the socket.
2.4 Technical support
For any problems or concerns, please contact, without hesitation the Customer Service
Department of your dealer, who has competent and specialized staff, specific equipment and
spare parts.
2.5 Other provisions
IT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES
The first thing to do when starting work is to check for the presence and integrity of the
protections and the operation of the safety devices.
If any defect is encountered do not use the machine!
Even more so, it is strictly forbidden to modify or remove guards, safety devices,
labels and indication signs.
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3 TECHNICAL SPECIFICATIONS
Model Art. 0552 Art. 0552/400V
Plate data
Weight (kg) 27
Voltage (V) 230 400
Power (W) 900
Frequency (Hz) 50
Size (mm) 520 x 225 x 300
1st Tool
Type of tool Dry grinding wheel
Dimensions (mm) Ø 200 x 25 x 20
Speed (r/min) 2950
Tool 2
Type of tool Dry grinding wheel
Dimensions (mm) Ø 200 x 25 x 20
Speed (r/min) 2950
Idle acoustic pressure level (dB(A)) 59.5 ± 3.2
Operating acoustic pressure level (dB(A)) 67.1 ± 4.0
* The acoustic emission values were measured in compliance with UNI EN ISO 3744:2010.
* The acoustic emission values at the operator's workstation were measured in compliance
with UNI EN ISO 11202:2010.
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4 DESCRIPTION OF THE MACHINE
Figure 1 - General view
1Machine body / motor;
2Start and stop buttons;
3Dry grinding wheel;
4Dry grinding wheel protective screen;
5Grinding wheel protective guard;
6Bracket for supporting the workpiece;
7Fastening holes on the bench;
8Bracket adjustment knob
1
2
4
3
5
6
7
8
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4.1 Identification plate
The following identification plate is attached to the machine (Art. 0552);
Figure 2 – Identification plate.
4.2 Pictograms
The machine has the following warning and attention pictograms (Art. 0552):
Figure 3 – Caution and warning pictograms.
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Pictograms
PLATE IN ITALIAN PLATE IN ENGLISH
LEGGERE LE ISTRUZIONI PRIMA DI UTILIZZARE LA
MACCHINA
NON AVVICINARE LE MANI ALL’UTENSILE IN MOVIMENTO
NON AFFERRARE L’UTENSILE CON LE MANI PER
ARRESTARLO
NON REGOLARE LA MACCHINA MENTRE E’ IN FUNZIONE
INDOSSARE SEMPRE IDONEE PROTEZIONI, QUALI
OCCHIALI E MASCHERINE QUALORA VENGA PRODOTTA
POLVERE
SCOLLEGARE LA MACCHINA DALL’ALIMENTAZIONE
ELETTRICA IN CASO DI RIPARAZIONI O REGOLAZIONI
NON INDOSSARE INDUMENTI SVOLAZZANTI, GIOIELLI,
CATENINE E BRACCIALI CHE POSSONO AGGANCIARSI
ALLA MACCHINA E PROVOCARE DANNI IRREPARABILI
SCOLLEGARE LA MACCHINA DALL’ALIMENTAZIONE
ELETTRICA PRIMA DI ESEGUIRE MANUTENZIONE,
REGOLAZIONI E RIPARAZIONI
READ THE INSTRUCTIONS BEFORE USING THE MACHINE
DO NOT MOVE YOUR HANDS CLOSE TO THE MOVING TOOL
DO NOT GRAB THE TOOL WITH YOUR HANDS TO STOP IT
DO NOT ADJUST THE MACHINE WHEN IT IS IN
OPERATION
ALWAYS WEAR APPROPRIATE SAFETY DEVICES, SUCH AS
GLASSES AND MASKS SHOULD DUST BE PRODUCED
DISCONNECT THE MACHINE FROM POWER SUPPLY WHEN
CARRYING OUT REPAIRS OR ADJUSTMENTS
DO NOT WEAR LOOSE CLOTHING, JEWELLERY,
NECKLACES AND BRACELETS WHICH COULD CATCH ON
THE MACHINE RESULTING IN PERMANENT DAMAGE
DISCONNECT THE MACHINE FROM POWER SUPPLY
BEFORE CARRYING OUT MAINTENANCE, REPAIRS AND
ADJUSTMENTS
ATTENZIONE!
TOGLIERE LA
CORRENTE PRIMA
DI APRIRE IL
CARTER
ATTENTION!
CUT THE POWER
BEFORE OPENING
THE CASING
NON
RIMUOVERE
I DISPOSITIVI DI
SICUREZZA
È severamente
vietata la
rimozione e la
omissione dolosa
D.lgs. 81/08
DO NOT
REMOVE
THE SAFETY
DEVICES
Removal and
intentional
omission is
strictly prohibited
Legislative decree
81/08
ATTENZIONE
È VIETATO ESEGUIRE LAVORI SU
APPARECCHIATURE ELETTRICHE SOTTO
TENSIONE
EVENTUALI DEROGHE DEVONO ESSERE
AUTORIZZATE DAL CAPO RESPONSABILE
IN CONDIZIONI DI PARTICOLARE PERICOLO DEVE
ESSERE PRESENTE UN’ALTRA PERSONA OLTRE A CHI
ESEGUE IL LAVORO
INIZIARE I LAVORI SOLO AD AVVENUTA
ATTAZIONE DELLE MISURE DI SICUREZZA
In ottemperanza al Dgs.81/08 relativo alla prevenzioni
infortuni
ATTENTION
IT IS FORBIDDEN TO PERFORM WORK ON LIVE
ELECTRICAL EQUIPMENT
ANY EXCEPTIONS MUST BE APPROVED BY THE
MANAGER IN CHARGE
IN CONDITIONS OF PARTICULAR DANGER THERE
MUST BE ANOTHER PERSON PRESENT IN ADDITION
TO THE PERSON PERFORMING THE WORK
ONLY BEGIN WORK AFTER IMPLEMENTATION OF
THE SAFETY MEASURES
In accordance with the Legislative Decree 81/08 relating to
accident prevention
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5 INSTALLATION OF THE MACHINE
To install the bench grinder, proceed as follows:
Clean the Machine
Before beginning assembly clean the protective product from the parts of the machine.
5.1 Positioning and fastening on the bench
Loss of stability
Mount the Bench grinding machine on a surface that is solid and strong to avoid it falling over
and so it does not cause vibrations;
Clean the Workbench
Before fixing the machine in place, clean the workbench of any materials and dirt that may be
present.
Place the machine on a workbench (or other supporting surface) that is level, stable and
sturdy and secure it with four bolts in the appropriate fastening holes in the base of the
machine body (see Figure 4).
Figure 4 – Close-up of fastening holes.
In the case of using a steel bench, it is advisable to place between the grinder and the
supporting surface a layer of material which is suitable to reduce the vibrations.
Installation of the machine
Do not install the machine outdoors to avoid deformation, loss of function and damage to the
electrical control circuit.
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5.2 Installation of screens and workpiece holder brackets
1. Mount the transparent protective screens of the dry grinding wheel using the fastening
screws provided. Screw the screen supports to fixed protective device of the grinding
wheel and then install the screen securing it with the through screw and the locking
knob. (see Figure 5).
Position the protective screens so that they do not touch the wheels and there is a
maximum gap (light) of 5 mm, between the metal support of the screen itself and the
wheel (see the screens in Figure 6).
Figure 5 – Assembling the protective screens.
Figure 6 – Adjusting the protective screens.
1. Fit the clamping brackets to the lower end of
the protective dry grinding wheel casing, using
the special screws with knob (see Figure 7).
Position the clamping brackets so that they do
not touch the wheels and there is a maximum
gap (light) of 2 mm between the brackets and
the wheels.
Figure 7 – Bracket adjustment.
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5.3 Connection to the extraction system
Before using the machine, it is necessary to connect an external extraction system to the two
suction outlets located at the rear of the machine on the fixed protective guards, as shown in
the figure below.
Figure 8 – Outlet for the extraction system on the guard
5.4 Connecting the power plug and start-up test (Art. 0552)
1. Insert the power plug into a power
outlet with a grounding wire.
2. Start the machine by pressing the
green switch I (see Figure 11) and
make sure that the rotating direction of
the equipment is consistent with that
indicated by the arrows marked on the
protective casing (caps).
Figure 9 – Close-up of power plug.
3. Before starting the grinding, check the mounted wheels as follows:
making them rotate freely for at least 5 minutes at a peripheral operating speed;
with the guards closed and without the presence of personnel.
Impact from projected parts
During the test run, no operator and no other person should be within range of the machine.
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6 SAFETY DEVICES ON THE MACHINE
6.1 Electrical safety devices
The control device connected to the electrical circuit of the bench grinder is a magnetic
switch with two buttons. This prevents the danger of unwanted and/or accidental starts of
the machine, since the switch can only be activated through a voluntary action suitable for
the given purpose and when the machine is powered.
The start button is also equipped with a protective collar.
The machines are also equipped with an emergency stop button, formed by a plastic cap
placed over the on and off switches, when pressure is applied it acts only on the stop button.
When, in an emergency, pressure is applied to the cap, the dangerous functions stop.
In the event of malfunction or breakdown, the Bench grinding machine is equipped with a
power cable and plug with grounding conductor, which provides a path of least resistance
for electric current and reduces the risk of electric shock.
The plug must be plugged into an appropriate outlet, earthed in accordance with current
regulations. Extension cables must be of a section equal to or greater than the power cable of
the machine.
Electric shock
Improper connection of the machine’s grounding conductor can result in the risk of electric
shock.
It is necessary to connect the machine to a system equipped with a device for the automatic
disconnection of power in the event of a ground fault.
Check with a qualified electrician if you don't understand the grounding instructions
or if you have any doubts about grounding the machine.
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6.2 "Mechanical" Safety Devices
TRANSPARENT SCREENS AND PROTECTIVE CASING
They perform the function of preventing hot splinters, dust or fragments of the grinding wheel
that may detach from being projected into the operator's face.
Checking the safety devices
Each time the grinding wheel is used, check that the safety devices function and are
positioned properly.
In the event of damage and/or breakage, do not use the machine.
Use of PPE
In any event, ALWAYS use appropriate personal protective equipment (PPE), such as:
Gloves Goggles or face
shields
Overalls or
aprons Safety shoes
Figure 10 - Personal Protective Equipment.
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7 CONTROLS
They are located at the base of the machine body. They are used to turn on and off the bench
grinder.
7.1 On switch (start)
The green button (I), is used for starting (turning on) the
bench grinding machine (Figure 11). With this button, the
electric motor is powered and the equipment is set in
rotation (grinding wheels, brush, etc.).
Figure 11 – Start button.
7.2 Stop button
The red button (0), is used for switching off (stop) the bench
grinding machine (Figure 12). With this button, the power to
the electric motor is turned off and the rotation of the
equipment is stopped (grinding wheels, brush, etc.).
Figure 12 – Stop button.
Risk of abrasion
After pressing the off switch (0), the equipment will continue to rotate by inertia.
Do not allow body parts near the wheel or the brush while in motion!
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7.3 Emergency Button
On the control buttons panel there is an emergency stop
button. To stop the machine in case of emergency, press
the red button. When it is pushed, the motion of the
electric motor and the grinding wheels is interrupted.
To restore power to the machine again after an
emergency stop, open the red button and press the
green start button.
Figure 13 – Emergency stop
button cap.
Checking the Emergency Button
Before starting any work on the machine, ensure that the emergency stop button functions.
Risk of abrasion and accidents
After pressing the emergency switch, the equipment will continue to rotate by inertia.
Do not allow body parts near the wheel or the brush while in motion!
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