KNECHT W 200 II User manual

Status 11.2019 Version 1.1 | Translation
Operating Instructions
Surface Grinding Machine
W 200 II

3
Surface Grinding Machine W 200 II
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.knecht.eu
Documents for machine operator
Operating Instructions
Date of issue of the operating instructions
November 13, 2019
Copyright
The copyright for these operating instructions as well as other documents for the machine operator is held
by KNECHT Maschinenbau GmbH. They are provided only to customers and operators of our products and
are included with the machine.
These documents may neither be reproduced, nor made accessible to third parties, in particular rival firms,
without our express permission.
Operating Instructions

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1. Important notes 7
1.1 Preface to the operating instructions 7
1.2 Warnings and symbols in the operating instructions 7
1.3 Warning signs and their meaning 8
1.3.1 Warning and prohibition signs on the grinding machine 8
1.3.2 General mandatory signs 8
1.4 Rating plate and serial number 9
1.5 Figure and item numbers in the operating instructions 9
2. Safety 10
2.1 Basic safety instructions 10
2.1.1 Observe notes in the operating instructions 10
2.1.2 Obligation on the part of the operator 10
2.1.3 Obligation on the part of the personnel 10
2.1.4 Hazards involved in handling the grinding machine 10
2.1.5 Malfunction 11
2.2 Intended use 11
2.3 Warranty and liability 11
2.4 Safety regulations 12
2.4.1 Organizational measures 12
2.4.2 Protective equipment 12
2.4.3 Informal safety measures 12
2.4.4 Selection and qualification of personnel 12
2.4.5 Machine control system 13
2.4.6 Safety measures in normal operation 13
2.4.7 Hazards due to electrical power sources 13
2.4.8 Particular hazard zones 13
2.4.9 Servicing (maintenance, repair) and fault elimination 13
2.4.10 Structural modifications to the grinding machine 14
2.4.11 Cleaning the machine 14
2.4.12 Oils and greases 14
2.4.13 Relocation of the grinding machine 14
3. Description 15
3.1 Intended use 15
3.2 Technical specifications 15
3.3 Functional description 16
3.4 Description of modules 17
3.4.1 Switching the grinding machine on/off 19
3.4.2 Control panel 19
3.4.3 Coolant unit 20
Table of Contents

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4. Transport 21
4.1 Transport aids 21
4.2 Transport damage 21
4.3 Transport to another installation site 21
5. Installation 22
5.1 Selection of qualified personnel 22
5.2 Installation site 22
5.3 Supply connections 22
5.4 Settings 22
5.5 Using the grinding machine for the first time 23
6. Commissioning 24
7. Operation 26
7.1 Switching on the grinding machine 26
7.2 Rotary table 26
7.3 “Grinding unit” control lever 26
7.4 Workpiece mounting with centering piece 27
7.5 Determining working position 28
7.6 Configuring the coolant supply 29
7.7 Grinding mincing plates 30
7.8 Surface grinding mincing knives 32
7.9 Changing the CBN grinding wheel 34
8. Care and maintenance 35
8.1 Coolant additive 35
8.1.1 Cooling lubricant maintenance plan 35
8.2 Lubrication 36
8.2 Lubrication schedule and lubricant table 36
8.3 Cleaning 36
9. Disassembly and disposal 37
9.1 Disassembly 37
9.2 Disposal 37
Table of Contents

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10. Service, spare parts and accessories 38
10.1 Postal address 38
10.2 Service 38
10.3 Spare parts 38
10.4 Accessories 39
10.4.1 Grinding wheels used 39
11. Annex 40
11.1 EC Declaration of Conformity 40
Table of Contents

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1.1 Preface to the operating instructions
These operating instructions are intended to make it easier to get to know the surface grind-
ing machine, 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
machine safely, properly and cost-effectively. Observance of these instructions helps to avoid
hazards, repair costs and downtimes, and increases 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
• operation, including fault elimination in the process flow, as well as
• upkeep (maintenance, repair).
In addition to the operating instructions and the binding accident prevention regulations
applicable in the country and place of use of the machine, the generally acknowledged rules of
technology 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 a work safety
indicator for all work for which there is a risk of serious or fatal injury.
Special care and caution must be taken when carrying out such work.
ATTENTION
”ATTENTION” is used to draw attention to particular points in order
to avoid damage and/ or destruction of the grinding machine and its
environment.
NOTICE ”NOTICE” refers to user tips and especially useful information.
1. Important notes
CAUTION

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1.3 Warning signs and their meaning
1.3.1 Warning and prohibition signs on the grinding machine
The following warning and prohibition signs have been affixed to the grinding machine:
CAUTION! DANGEROUS ELECTRIC VOLTAGE
(Warning signs on switch cabinet)
On being connected to the current supply (3x 400 V), the grinding
machine becomes electrically live and touching its live parts directly
could be life-threatening.
Current-carrying device parts may only be opened by authorized
personnel.
The grinding machine must be separated from the mains supply
before carrying out servicing, maintenance and repair work on it.
CAUTION! RISK OF INJURY FROM ABRASIVE PARTICLES
(mandatory sign on the front plate)
Grinding and dressing gives rise to grinding particles which could
enter the eyes.
Wearing protective goggles is mandatory when carrying out such
work.
1.3.2 General mandatory signs
The following general mandatory signs must be followed:
CAUTION! RISK OF INJURY FROM KNIFE
Work on the grinding machine involves grinding knives that could
cause cut injuries due to the sharp blades.
Wearing protective gloves is mandatory when carrying out such
work.
Caution when transporting blades.
Protective gloves should also be worn when changing the coolant
(see Chapter 8.1).
1. Important notes

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1.4 Rating plate and serial number
The rating plate is to be found on the right-hand
side of the machine.
The machine serial number is to be found on the
rating plate and in the machine room, visible due
to the KNECHT logo.
1.5 Figure and item numbers in the operating instructions
If there is a reference to a machine component in the text which is depicted in an image, the
figure and item number will be given in parentheses.
Example: (7-5/1) means Figure number 7-5, item 1.
The workpieces are mounted and correctly aligned on
the rotary table by means of centering pieces (7-5/1) and
the follower (7-5/2). The corresponding centering piece is
placed in the bore at the center of the rotary table.
The follower is used to attach smaller workpieces to the
rotary table.
1. Important notes
Figure 1-1 Rating plate
Figure 1-2 Machine serial number
Figure 7-5 Centering piece and follower
2
1

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2.1 Basic safety instructions
2.1.1 Observe notes in the operating instructions
The basic prerequisite for the 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 rules and regulations regarding accident prevention at the place of use are to be
observed.
2.1.2 Obligation on the part of the operator
The operator is obliged to allow only those persons to work on the grinding machine, who
• are familiar with the occupational safety and accident prevention regulations and have received
instruction in handling the grinding machine,
• have read and understood the operating instructions, in particular the section entitled “Safety”
and the warning notes, and have provided signed confirmation of this.
The safety-related work of personnel will be monitored at regular intervals.
2.1.3 Obligation on the part of the personnel
All personnel working on the grinding machine shall be obliged, before starting work, to
• observe basic occupational safety and accident prevention regulations,
• read the operating instructions, particularly the section entitled “Safety” and the warning notes,
and provide signed confirmation of this.
2.1.4 Hazards involved in handling the grinding 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 be used only:
• for its intended purpose,
• in faultless condition with regard to safety-related aspects.
2. Safety

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2. Safety
Malfunctions that may impair safety are to be rectified immediately.
2.1.5 Malfunction
If safety-relevant malfunctions occur with the grinding machine, or if the processing behavior
indicates that such malfunctions may have occurred, the grinding machine must be stopped
immediately and until such time as the malfunction has been found and eliminated.
Allow only authorized trained personnel to eliminate the malfunctions.
2.2 Intended use
The grinding machine is designed solely for surface grinding mincing plates and knives, also
referred to in the following as workpieces.
All knives must be clamped in the center on the rotary table.
Any other use is considered to be improper. The company KNECHT Maschinenbau GmbH is not
liable for any damage arising from this. The user alone bears this risk.
Use as intended includes the observance of all the notes in the operating instructions.
The grinding machine is being used improperly, if for example:
• fixtures are not properly attached.
• workpieces other than mincing plates and knives are being ground.
2.3 Warranty and liability
Warranty and liability claims in case of personal injury 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 using improperly attached or
malfunctioning safety and protective equipment
• failure to observe the 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 (output 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. When using external parts, it cannot be guaranteed
that they are constructed and manufactured to be suitable and safe.
2.4 Safety regulations
2.4.1 Organizational measures
Inspect all available safety devices regularly.
Observe prescribed intervals for recurring maintenance work or as specified in the operating
instructions!
2.4.2 Protective equipment
Before commissioning the grinding machine, ensure that all protective equipment is properly
mounted and in functional condition.
Protective equipment may be removed only after the grinding machine has stopped and has been
secured against accidental restart.
When spare parts are supplied, the protective equipment must be attached by the operator as
stipulated.
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 safety alert symbols and danger warnings on the grinding machine must be complete and
clearly legible.
2.4.4 Selection and qualification of personnel
Only trained and instructed personnel may work on the grinding machine. Observe the legally
permitted minimum age!
The responsibilities of personnel with respect to commissioning, operation, maintenance, and
repair must be clearly specified.
Personnel still undergoing training or instruction may only 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
Only trained and instructed personnel are permitted to activate the machine.
2.4.6 Safety measures in normal operation
Do not operate the machine in any unsafe manner. 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 present (including those of the operating behavior) to the responsible office
or person. If necessary, shutdown the grinding machine and secure it against restart.
Before activating the grinding machine, ensure that no one will be injured by the start-up of the
machine.
In the event of a malfunction, immediately stop the grinding machine and secure it against re-
start. Rectify malfunctions immediately.
2.4.7 Hazards due to electrical power sources
Work on electrical systems or operating materials may only be performed by a qualified electri-
cian, in accordance with electrical regulations.
Defects such as damaged cables, cable connections, etc., must be rectified immediately by an
authorized specialist.
Cables marked in yellow are electrically live even when the main switch
is in the off position.
CAUTION
2.4.8 Particular hazard zones
In the area of the grinding wheel, there is a danger of pinching and being drawn in (e.g. clothing,
fingers and hair). Wear suitable personal protective equipment.
2.4.9 Servicing (maintenance, repair) and fault elimination
Maintenance work is to be carried out on schedule by trained personnel. Inform operating
personnel before beginning repair work. Designate a supervisor responsible for this.
For all upkeep work, the grinding machine is to be disconnected from the power supply and
secured against accidental restart. Remove power plug. Cordon off the maintenance area, where
required.
2. Safety

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After completing maintenance work and fault rectification, install all safety devices and verify that
they are fully functional.
2.4.10 Structural modifications to the grinding machine
Modifications, retrofitting or rebuilds of the grinding machine are not allowed without the per-
mission of the manufacturer. This also applies for installation and configuring the safety devices.
Any conversion work requires the written permission from KNECHT Maschinenbau GmbH.
Immediately replace any machine parts that are not in a serviceable state.
Use only original replacement and wear parts. When using external parts, it cannot be guaranteed
that they are constructed and manufactured to be suitable and safe.
2.4.11 Cleaning the machine
Handle any cleaning agents and materials used properly and dispose of them in an environmen-
tally-friendly manner.
Dispose of parts subject to wear and replacement parts in a safe and environmentally-friendly
manner.
2.4.12 Oils and greases
When using lubricants and grease, follow the safety provisions applicable to the product. Comply
with the special regulations for the foodstuffs sector.
2.4.13 Relocation of the grinding machine
Disconnect the grinding machine from any external power, even if adjusting its position slightly.
Before restarting the grinding machine, properly connect it to the power supply.
When loading or unloading, only use suspension devices and load suspension devices with suffi-
cient load-bearing capacity. Designate suitable lifting devices for the lifting process.
Ensure that no one, who is not certified for this work, is located where the machine is unloaded
and installed.
Only lift the grinding machine correctly with a suspension device in accordance with the operating
instructions (attachment points for load suspension devices, etc.). Use only a suitable transport
vehicle with sufficient carrying capacity. Secure loads safely. Use suitable attachment points. When
putting the machine into operation again, proceed only as instructed in the operating instructions.
2. Safety

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3. Description
3.1 Intended use
The W 200 II surface grinding machine grinds mincing plates and knives with a diameter of up to
200 mm.
3.2 Technical specifications
Height (maximum when lever is at top) ��������������������������������� approx. 1950 mm
Width (incl. suction unit) ��������������������������������������������� approx. 1263 mm
Depth (maximum, when lever is in forward position) ������������������������ approx. 980 mm
Weight ��������������������������������������������������������������� approx. 320 kg
Weight (incl. suction unit) ����������������������������������������������� approx. 400 kg
Current supply* ������������������������������������������������������������ 3x 400 V
Mains frequency* �������������������������������������������������������������� 50 Hz
Output* ��������������������������������������������������������������������� 3.5 kW
Power consumption* ����������������������������������������������������������� 6 kW
Energy consumption* ������������������������������������������������������������ 7 A
Back-up fuse ������������������������������������������������������������������� 16 A
Measured A-evaluated emission sound pressure level ����������������������������� 78 dB (A)
at workstation LpA**
Rotary table diameter ��������������������������������������������������������� 200 mm
Rotary table speed ���������������������������������������������������������� 53 1/ min
Grinding wheel diameter ������������������������������������������������������ 100 mm
Grinding wheel speed ���������������������������������������������������� 4500 1/ min
Cutting speed with grinding wheel d.100*** ������������������������������������ 24 m/ s
*) This information may change depending on the electrical power supply.
**) Sound emission value according to EN ISO 11202 (measurement uncertainty KpA 2.5 dB(A)).
***) Beware! The cutting speed of 24 m/s is reached at 50 Hz. An electrical supply with a higher frequency
results in higher cutting speeds. Only approved abrasives may be used.
A mincing plate with a diameter of200 mm was ground.

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Figure 3-1 Dimensions in mm
3. Description
3.3 Functional description
The W 200 II surface grinding machine is capable of surface grinding mincing plates and knives
with a diameter of up to 200 mm.
ATTENTION The mincing plate may not protrude over
the rotary table.
The mincing plates are fixed on the rotary table of the W 200 II surface grinding machine by
means of centering pieces and followers.
For the purpose of surface grinding, mincing knives are attached to a mincing plate using the
centering piece for knives included.
Special mounts are available for unusual applications.
The machine is supplied as standard with CBN grinding wheels.
The W 200 II is optionally supplied with an air purification system (referred to in the following as
the suction unit).
ATTENTION Abrasives may only be used if they are ap-
proved by KNECHT Maschinenbau GmbH.
ca. 1263 mm
ca. 850 mm
ca. 1950 mm
ca. 1263 mm
ca. 850 mm
ca. 1950 mm
CoGCoG

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3. Description
3.4 Description of modules
1 Protective door
2 Stainless steel table
3 Suction unit (optional)
4 Control lever “Grinding unit”
5 Control panel
6 Coolant unit
7 Adjustable machine feet
2
1
3
5
7
6
4
Figure 3-2 General view of grinding machine

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3. Description
Figure 3-3 Interior
1 Grinding unit
2 Coolant hose
3 “Grinding unit” stop
4 Locking pin
5 LED work light
2
3
5
1
4

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3. Description
3.4.1 Switching the grinding machine on / off
The main switch is located at the front of the
control panel.
Turning the main switch from “0” to “I” switches
on the grinding machine.
Turning the main switch from “I” to “0” switches
off the grinding machine.
3.4.2 Control panel
The machine is operated via the control panel of
the PLC control.
The mechanical components are operated using
the control buttons and switches.
1 “Grinding wheel On/ Off” button: Switch
grinding wheel on/ off
2 “Rotary table On/ Off” button: Switch rota-
ry table movement on/ off
3 “Coolant On/ Off” button: Switch coolant
pump on/ off
4 “Control ON” button Activate PLC control
5 “Drives On/ Off” button: Switch drives for
grinding wheel, rotary table, coolant pump
and suction unit on/ off
6 “Emergency stop” button
Figure 3-4 Main switch
Figure 3-5 Control panel
1 2 3
54
6

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3. Description
3.4.3 Coolant unit
The coolant unit is located in the base of the
machine.
During grinding, the workpiece has to be perma-
nently cooled.
For this purpose, put approx. 35 liters of water
with coolant additive into the water tank.
Figure 3-6 Coolant unit

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When transporting, observe the local applicable safety and accident
prevention regulations.
Transport the grinding machine with the machine feet facing down-
wards.
CAUTION
4.1 Transport aids
When transporting and setting up the grinding machine, use only adequately dimensioned
transport aids, e.g. truck, forklift or hydraulic lifting truck.
When using a forklift or a lifting truck, move the fork under the grinding machine.
Note the machine’s center of gravity when transporting. The center of gravity (CoG) is shown in
figure 3-1.
4.2 Transport damage
If damage is detected after unloading when receiving a delivery, notify KNECHT Maschinenbau
GmbH and the forwarding agent immediately. Refer directly to an independent specialist as
needed.
Remove the packaging and shipping straps. Remove the shipping straps on the grinding machine.
Dispose of packaging in an environment-friendly manner.
4.3 Transport to another installation site
For transport to another installation site, ensure that the space requirements are fulfilled (see
Chapter 3.2).
A permissible electrical connection must be provided at the new installation site.
The grinding machine must sit tightly and securely.
Work on the electrical unit is only to be carried out by an authorized
specialist. Observe the local applicable safety and accident prevention
regulations.
CAUTION
4. Transport