KNECHT A 95 User manual

Operating Instructions
Circular and Sickle Knife Grinding Machine
Status 05.2018 ■Version 1.5 | Translation
A 95

3
Circular and Sickle Knife Grinding Machine A 95
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Phone [phone]
Fax [phone]
[email protected]
www.knecht.eu
Documents for the machine operator
Operating Instructions
Date of issue of the operating instructions
May 28, 2018
Copyright
The copyright for these operating instructions as well as other documents for the machine operator is held
by KNECHT Maschinenbau GmbH. These documents will be delivered only to our customers and to opera-
tors of our products and are a part of the machine.
These documents may neither be reproduced, nor made accessible to third parties, including rival firms,
without our express permission.
Operating Instructions

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1. Important notes 8
1.1 Foreword 8
1.2 Warnings and symbols in the operating instructions 8
1.3 Warning plates and their meaning 9
1.3.1 Warning and prohibition signs on/in the grinding machine 9
1.3.2 General mandatory signs 9
1.4 Rating plate and machine serial number 10
1.5 Figure and item numbers in the operating instructions 10
2. Safety 11
2.1 Basic safety instructions 11
2.1.1 Observe notes in the operating instructions 11
2.1.2 Operator's duty 11
2.1.3 Obligations on the part of the personnel 11
2.1.4 Hazards associated with handling the machine 11
2.1.5 Malfunctions 12
2.2 Use as intended 12
2.3 Warranty and Liability 12
2.4 Safety regulations 13
2.4.1 Organizational measures 13
2.4.2 Protective devices 13
2.4.3 Informal safety measures 13
2.4.4 Selection and qualifications of the personnel 13
2.4.5 Machine control system 14
2.4.6 Safety measures in normal operation 14
2.4.7 Dangers due to electrical power 14
2.4.8 Particular danger zones 14
2.4.9 Servicing (maintenance, repair) and fault rectification 15
2.4.10 Structural alterations to the grinding machine 15
2.4.11 Cleaning the grinding machine 15
2.4.12 Oils and greases 15
2.4.13 Relocation of the grinding machine 15
3. Description 17
3.1 Intended Use 17
3.2 Technical specifications 17
3.3 Functional description 18
3.4 Description of the assemblies 19
3.4.1 Switching the grinding machine on/ off 22
3.4.2 Control panel 23
3.4.3 Layout of the user interface (main screen) 24
Table of Contents

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4. Transport 26
4.1 Transport Aids 26
4.2 Transport damage 26
4.3 Transport to another installation site 26
5. Installation 27
5.1 Selection of qualified personnel 27
5.2 Installation site 27
5.3 Supply connections 27
5.4 Settings 27
5.5 Initial commissioning of the grinding machine 28
6. Commissioning 29
7. Operation 31
7.1 Switching on the grinding machine 31
7.2 Grinding the knives 31
7.2.1 Loading the grinding program 31
7.2.2 Clamping the knife 33
7.3 Adjusting the polishing unit (optional) 36
7.4 Dressing the front / rear grinding wheels 37
7.5 Changing the front/rear grinding wheels 38
7.6 Changing the profiling wheel (optional) 40
8. Control system 41
8.1 Settings 41
8.2 Serrating (Re-serrating) 42
8.3 Axes in manual mode 45
8.4 Grinding data 47
8.4.1 Data 48
8.4.2 Contour 48
8.4.3 Serration 49
8.4.4 Change position 49
8.4.5 Steps 50
8.4.6 Feed 50
8.5 Manual Functions 51
8.5.1 General 51
8.5.2 Front grinding wheel 52
8.5.3 Rear grinding wheel 52
Table of Contents

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8.5.4 Serration unit 53
8.5.5 Polishing unit 53
8.6 Message texts 54
8.7 Options 54
8.8 Knife contour 55
8.8.1 Axial runout 56
8.8.2 Contour deviation 56
8.9 Knife selection 56
8.10 Setting up an internet connection 57
9. Care and maintenance 58
9.1 Coolant 58
9.1.1 Coolant additive 58
9.2 Cleaning the grinding machine 58
9.3 Greasing the grinding wheel slide 59
9.4 Greasing the angle adjustment slide 59
9.5 Greasing the serrating unit (optional) 60
9.6 Greasing the polishing unit (optional) 60
9.7 Greasing the compound slide rest 61
10. Malfunctions 62
10.1 Faults 62
10.1.1 Grinding 62
10.1.2 Machine 62
10.1.3 Measuring 63
10.1.4 Serrating 63
11. Disassembly and disposal 65
11.1 Disassembly 65
11.2 Disposal 65
12. Service, spare parts and accessories 66
12.1 Postal Address 66
12.2 Service 66
12.3 Spare parts 66
12.4 Accessories 67
12.4.1 Abrasives used 67
Table of Contents

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Table of Contents
13. Appendix 68
13.1 EC Declaration of Conformity 68

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1.1 Foreword
These operating instructions are meant to make it easier to get to know the circular and sickle
knife grinding machine, also referred to in this document as “grinding machine”, and to use it
properly for the intended purpose.
The operating instructions contain important information on how to operate the grinding ma-
chine safely, properly and cost-effectively. Observance of these instructions helps to avoid dan-
gers, reduce repair costs and downtimes, and increase the reliability and service life of the grinding
machine.
The operating instructions must always be accessible at the place of use of the grinding machine.
The operating instructions must be read and used by all persons entrusted with working on the
grinding machine, e.g. those entrusted with:
• transportation, installation, commissioning and
• operation, including fault elimination in the process flow, as well as
• servicing (maintenance, repair).
In addition to the operating instructions and the binding accident prevention regulations applica-
ble in the country and place of use of the machine, the generally acknowledged rules of technolo-
gy with regard to safe and professional work practices are to be observed.
1.2 Warnings and symbols in the operating instructions
Heeding the following safety alert symbols/designations used in the operating instructions is
absolutely necessary:
The hazard triangle with the signal word “CAUTION” is used as a work
safety indication for all work which could result in death or physical injury.
Special care and caution must be taken when carrying out such jobs.
ATTENTION
The signal word “ATTENTION” is used to call attention to hazards which
could result in damage and/or destruction of the grinding machine or its
environment.
NOTICE The signal word “NOTE” calls attention to tips on use and useful informa-
tion.
1. Important notes
CAUTION

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1.3 Warning plates and their meaning
1.3.1 Warning and prohibition signs on/ in the grinding machine
The following warning and prohibition signs have been affixed to the grinding machine:
CAUTION! DANGEROUS ELECTRICAL VOLTAGE
(warning notice on the control panel)
On being connected to the voltage supply (3x 400 V), the grinding
machine becomes electrically live and touching its live parts directly
could be life-threatening.
Live machine parts may be opened only by authorized, trained
personnel.
The grinding machine must be separated from the mains supply
before carrying out servicing, maintenance and repair jobs on it.
CAUTION! RISK OF INJURY FROM ABRASIVE PARTICLES
DURING DRESSING (warning notice on the dressing device)
Dressing the grinding wheel gives rise to abrasive particles that
could enter the eyes.
Wearing safety glasses is mandatory when carrying out such jobs.
1.3.2 General mandatory signs
The following general mandatory signs must be observed:
CAUTION! RISK OF INJURY FROM THE BLADE
Work on the grinding machine involves the sharpening of knives
which could cause serious cut injuries due to their sharpness.
Protective gloves must be worn when clamping and unclamping
the knives.
Be careful when transporting blades! Use the protective devices
provided by the knife manufacturer. Wear protective gloves and
apron.
1. Important notes

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1.4 Rating plate and machine serial number
The rating plate is located on the left side of the
machine.
The machine number is located on the rating plate
and on the front left of the machine.
1.5 Figure and item numbers in the operating instructions
If the text refers to a machine component shown in a figure, then a figure or item number is add-
ed in brackets after the machine component.
Example: (6-1/1) denotes figure number 6-1, item 1.
Open the safety doors.
Set the coolant hose (6-1/1) as illustrated in the figure. The
distance between the rear grinding wheel (6-1/2) and the
front grinding wheel (6-1/3) should be approx. 5 cm. The
coolant hose must not touch the grinding wheels.
1. Important notes
Figure 1-1 Rating plate
Figure 1-2 Machine serial number
Figure 6-1 Setting the coolant hose
1
2
1
3

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2.1 Basic safety instructions
2.1.1 Observe notes in the operating instructions
The basic prerequisite for safe handling and uninterrupted operation of this grinding machine is
knowledge of the basic safety instructions and regulations.
• These operating instructions contain important notes on how to operate the grinding machine
safely.
• All persons carrying out work on the grinding machine must follow these operating instructions,
in particular the safety notices.
• In addition, the accident prevention rules and regulations applicable at the place of use of the
machine must also be observed.
2.1.2 Operator's duty
The operator is obliged to allow only those persons to work on the grinding machine, who
• are familiar with the basic occupational safety and accident prevention regulations and have
been trained and instructed in the handling of the grinding machine,
• have read the operating instructions, particularly the “Safety” section, and have read and
understood the warning notes. They have given a signed confirmation of this in writing.
Checks are also carried out at regular intervals to ensure that worker is fulfilling his employee
obligation to observe safety at work.
2.1.3 Obligations on the part of the personnel
All the personnel working on the grinding machine shall be obliged to
• observe the basic occupational safety and accident prevention regulations,
• read the operating instructions, particularly the “Safety” chapter, and the warning notes. They
must provide signed confirmation of this in writing.
2.1.4 Hazards associated with handling the machine
The grinding machine has been built to the latest technological standards and the acknowledged
rules of technical safety. In spite of that, its use presents inherent risks which could result in bodily
harm or even death of the user or third persons, or impairment of the grinding machine or other
property.
The grinding machine may only be used:
• for the intended purpose, and
• in faultless condition with regard to safety-relevant aspects.
2. Safety

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2. Safety
Faults that could impair safety must be eliminated immediately.
2.1.5 Malfunctions
If safety-relevant malfunctions occur in the grinding machine, or if the processing behavior indi-
cates that such malfunctions may have occurred, the grinding machine must be stopped immedi-
ately until such time as the malfunction has been found and eliminated.
The malfunctions must be eliminated by authorized technical staff.
2.2 Use as intended
The grinding machine is only meant for grinding and serrating circular and sickle knives. Before
starting work on a knife, check that the knife fits on the holder plate. Only then may the knife be
clamped onto the holder plate.
Any other use is considered improper use. KNECHT Maschinenbau GmbH assumes no liability for
damages resulting from improper use. The user alone bears the risk in such cases.
Use as intended includes the observance of all the instructions in the operating instructions.
The grinding machine is being used improperly, if, e.g.,
• knives are sharpened without holder plate.
• devices are not fastened properly.
2.3 Warranty and Liability
Warranty and liability claims in case of personal injuries or property damage are excluded if such
damage is attributable to one or more of the following causes:
• improper use of the grinding machine,
• improper transportation, commissioning, operation and maintenance of the grinding machine,
• operating the grinding machine with defective safety devices, or improperly attached or
malfunctioning safety and protective equipment,
• ignoring the operating instructions with regard to transportation, commissioning, operation,
maintenance and repair of the grinding machine,
• unauthorized structural alterations to the grinding machine,
• unauthorized modification, e.g. of the drive conditions (power and speed), and
• insufficient monitoring of machine parts that are exposed to wear.

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• use of unapproved replacement and wear parts
Use only original replacement and wear parts. If parts are purchased from external suppliers, it
cannot be guaranteed that they will be constructed and manufactured to withstand the stresses
and provide the required level of safety.
2.4 Safety regulations
2.4.1 Organizational measures
All the existent safety devices must be checked regularly.
Observe prescribed intervals for recurring maintenance work or as specified in the operating
instructions.
2.4.2 Protective devices
Before commissioning the grinding machine, it must be ensured that all protective equipment is
properly mounted and in functional condition.
Protective equipment may be removed only after the machine has stopped and has been secured
against accidental restarting of the grinding machine.
If sub-components are supplied, the protective equipment must be correctly attached by the
operator according to the instructions.
2.4.3 Informal safety measures
The operating instructions must be permanently available at the place of use of the grinding
machine. In addition to the operating instructions, the generally applicable as well as the locally
relevant accident prevention regulations must also be made available and observed.
All the safety alert symbols and danger warnings on the grinding machine must be complete and
clearly legible.
2.4.4 Selection and qualifications of the personnel
Only trained and instructed personnel may work on the grinding machine. The minimum legal
age for employment must be observed.
The responsibilities of the personnel must be clearly assigned, i.e. commissioning, operation,
maintenance and repair, etc.
Personnel still undergoing training or instruction may only be allowed to work on the grinding
machine under the permanent supervision of an experienced person!
2. Safety

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2.4.5 Machine control system
Do not make any changes to the software program under any circumstances. Parameters that the
operator can set himself are excluded from this prohibition (e.g. setting the number of cycles).
Only trained and instructed personnel are allowed to activate the control unit.
2.4.6 Safety measures in normal operation
Refrain from any method of working which may pose a risk to safety. Only operate the grinding
machine if all the safety devices are installed and fully functional.
Check the grinding machine for external signs of damage and correct operation of the safety
devices at least once every shift.
Report any changes (including operating behavior) immediately to the competent depart-
ment/person. Where required, shut down the grinding machine immediately and secure against
restarting.
Before switching on the grinding machine, ensure that no one is exposed to any risk from the
start-up of the machine.
If there are any functional faults, stop the machine immediately and secure against restarting.
Have the faults eliminated immediately.
2.4.7 Dangers due to electrical power
The switch cabinet must always remain secured against access. Only authorized personnel must
be allowed to access it.
Work on electrical units or operating materials may only be performed by a qualified electrician in
accordance with electrical rules.
Defects, such as damaged cables, cable connections, etc., must be immediately rectified by an
authorized electrician.
Cables marked in yellow are electrically live even when the main switch
is in off position.
CAUTION
2.4.8 Particular danger zones
In the area of the grinding wheels, profiling wheel and polishing brushes, there is a hazard of
pinching and being drawn in (e.g. clothing, fingers and hair). Suitable personal protective equip-
ment must be worn.
2. Safety

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2.4.9 Servicing (maintenance, repair) and fault rectification
Maintenance work is to be carried out on schedule by trained personnel. Inform operating
personnel before starting repair work. The responsible supervisor is to be named. For all service
work, the grinding machine is to be disconnected from the power supply and secured against
accidental restarting. Pull out the mains plug. Cordon off the servicing area,
as far as possible.
After completion of the maintenance work and fault rectification, install all the safety devices
and check whether they are fully functional.
2.4.10 Structural alterations to the grinding machine
Modifications, retrofitting or rebuilds of the grinding machine are not allowed without the
permission of the manufacturer. This also applies to the installation and adjustment of safety
devices.
No alterations may be carried out without prior written permission from KNECHT Maschinenbau
GmbH.
Immediately replace machine parts which are not in perfect condition.
Use only original replacement and wear parts. If parts are purchased from external suppliers, it
cannot be guaranteed that they will be constructed and manufactured to withstand the stresses
and provide the required level of safety.
2.4.11 Cleaning the grinding machine
Cleaning agents and materials used must be handled properly and disposed of in an environ-
ment-friendly manner.
Ensure that wear and replacement parts are disposed of in a safe and environmentally friendly
way.
2.4.12 Oils and greases
When handling lubricants/oils and greases, follow the safety regulations for the product. Observe
special instructions for the foodstuffs sector.
2.4.13 Relocation of the grinding machine
Even when moving the machine a short distance from its site, disconnect it from all external
power supply sources. Before restarting the machine, connect it properly to the current supply.
When loading or unloading, only use hoisting and load lifting equipment with sufficient
load-bearing capacity. Appoint a qualified banksman (signaler) for the lifting process.
No persons other than those entrusted with this work may be present in the loading and
installation area.
2. Safety

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2. Safety
Only lift the grinding machine correctly with hoisting gear in accordance with the operating
instructions (attachment points for hoisting equipment, etc.). Only use suitable transport vehicles
with sufficient load-bearing capacity. Attach the load securely. Use suitable attachment points.
When putting in operation again, proceed only as instructed in the operating instructions.

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3. Description
3.1 Intended Use
The A 95 circular and sickle knife grinding machine is only meant to grind circular knives, sickle
knives or similar cutting tools (hereinafter referred to as “knife”) with a radius up to 600 mm in
an automatic process.
Optionally, the knives can be measured for axial runout, serrated and the blade can be polished.
3.2 Technical specifications
Height ������������������������������������������������������������ approx. 2200 mm
Width ������������������������������������������������������������� approx. 2300 mm
Depth ������������������������������������������������������������� approx. 1300 mm
Required space (WxDxH) ������������������������� approx. 3300 mm x 2100 mm x 2250 mm
Weight ��������������������������������������������������������������� approx. 800 kg
Voltage supply ������������������������������������������������������������� 3x 400 V
Mains frequency ��������������������������������������������������������������� 50 Hz
Output ����������������������������������������������������������������������� 9 kW
Power consumption ����������������������������������������������������������� 11 kW
Energy consumption ������������������������������������������������������������ 14 A
Back-up fuse ������������������������������������������������������������������� 32 A
Control voltage ������������������������������������������������������������ + 24 V DC
Compressed air ����������������������������������������������������� 6.5 bar (50 l/min)
Measured A-evaluated emission sound pressure level ����������������������������� 72 dB (A)
at workstation LpA*
Speed of front/rear grinding wheels �������������������������������������� 0-1000 1/min
Front/rear grinding wheel ����������������������������������������������� d.100x60xd.40
Speed of profiling wheel (optional) ������������������������������������������� 2600 rpm
Profiling wheel (optional) ������������������������������������������������� d.200x5xd.17
*) Dual number noise emission value information according to EN ISO 4871.
Emission sound pressure level according to EN ISO 11201. Uncertainty KpA in decibels: 3.
The grinding operation was carried out on a sickle knife (type known to be manufactured by
KNECHT Maschinenbau GmbH)

2277 mm
2191 mm
1286 mm
2277 mm
2191 mm
1286 mm
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Figure 3-1 Dimensions in mm
3. Description
3.3 Functional description
The A 95 circular and sickle knife grinding machine is used to grind circular and sickle knives with
a radius up to 600 mm in an automatic process. Optionally, they can also be used to measure
knives for radial runout, serrate/re-serrate knives, as well as polish knife blades.
The knife is clamped onto a holder plate that suits the knife size and is processed fully automati-
cally after program start.
In case of emergency, the grinding machine can immediately be stopped by pressing the “Emer-
gency Stop” button.
CoG CoG

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3. Description
3.4 Description of the assemblies
1 Serrating unit and laser measuring device (optional)
2 Laser (pivoted)
3 Front and rear grinding unit
4 SP 195 holder plate with X axis, Z axis and B axis
5 Water tray
6 Adjustable machine feet
7 Polishing unit (optional)
8 Safety doors
9 Control panel
2
1
8
9
3
6
5
4
Figure 3-2 General view of the grinding machine
7

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3. Description
1 Servo motor for grinding wheels
2 Coolant hose
3 Scale for rear angle adjustment (concealed)
4 Rear grinding wheel
5 Front grinding wheel
6 Scale for front angle adjustment
1 Laser button (optional)
2 X axis
3 B axis
4 Z axis
5 Profiling wheel (optional)
6 SP 195 holder plate
Figure 3-3 Grinding unit
Figure 3-4 Holder plate
1
3
4
5
4
6
2
6
1
2
3
5
1

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1 Water separator (6 bar)
2 Terminal block
3 Compressed air connection (6.5 bar)
4 Rear grinding wheel pressure reducer
(4 bar)
5 Pressure monitoring
6 Front grinding wheel pressure reducer
(4 bar)
7 Coolant tap
.
1 Coolant pump (concealed)
2 Star knob
3. Description
Figure 3-6 Water tray with sieve and coolant
pump
Figure 3-5 Pneumatic system
1
5
6
7
2
2
3
4
1
2