KNECHT W 300 User manual
Status 07.2018 ■Version 1.3 | Translation
Operating Instructions
Surface Grinding Machine
W 300
3
Surface Grinding Machine W 300
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Phone +49-7527-928-0
Fax +49-7527-928-32
www.knecht.eu
Documents for the machine operator
Operating Instructions
Date of issue of the operating instructions
July 11, 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.
Operating Instructions
4
1. Important notes 7
1.1 Forward to the operating instructions 7
1.2 Warning notes and symbols in the operating instructions 7
1.3 Warning signs and their meaning 8
1.3.1 Warning and prohibition signs on/in the grinding machine 8
1.3.2 General mandatory sign 8
1.4 Rating plate and machine 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 Obligations on the part of the operator 10
2.1.3 Obligations on the part of the personnel 10
2.1.4 Hazards associated with the handling of the machine 10
2.1.5 Malfunctions 11
2.2 Use as intended 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 measure 12
2.4.4 Selection and qualifications of the personnel 12
2.4.5 Machine control 13
2.4.6 Safety measures during normal operation 13
2.4.7 Dangers due to electrical power 13
2.4.8 Particular hazard areas 13
2.4.9 Servicing (maintenance, repair) and fault rectification 13
2.4.10 Structural alterations to the grinding machine 14
2.4.11 Cleaning the grinding machine 14
2.4.12 Lubricants/ oils and greases 14
2.4.13 Relocation of the grinding machine 14
3. Description 15
3.1 Use as intended 15
3.2 Technical specifications 15
3.3 Functional description 16
3.4 Description of the assemblies 17
3.4.1 Switching the grinding machine on/ off 18
3.4.2 Control panel 18
3.4.3 Belt filter or standard coolant unit (optional) 20
Table of Contents
5
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 Initial commissioning of the grinding machine 23
6. Commissioning 24
7. Operation 26
7.1 Switching on the grinding machine 26
7.2 Rotary table 26
7.3 Control lever for rotary table and grinding unit 26
7.4 Workpiece holder with/without centring piece 27
7.5 Defining the working position 28
7.6 Adjusting the coolant supply 29
7.7 Grinding mincing plates 30
7.8 Surface grinding mincing knives 32
7.9 Grinding cutting sets in the original Handtmann quality 35
7.9.1 Grinding Handtmann mincing plates in a plane-parallel manner 35
7.9.2 Grinding Handtmann mincing knives in a plane-parallel manner 36
7.10 Dressing CBN grinding wheels 37
7.11 Grinding wheel replacement 38
7.12 Grinding without a magnet 39
8. Care and maintenance 40
8.1 Coolant additive 40
8.1.1 Maintenance plan cooling lubricant 40
8.2 Lubrication 41
8.2.1 Lubrication schedule and lubricant table 41
8.3 Cleaning 41
Table of Contents
7
1.1 Forward to the operating instructions
These operating instructions are meant to make it easier to get to know the surface grinding
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
dangers, 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
• servicing (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 Warning notes 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 if special attention is not paid while carrying out particular
jobs.
NOTICE The signal word “NOTE” calls attention to tips on use and useful
information.
1. Important notes
CAUTION
8
1.3 Warning signs 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 switch cabinet)
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! PACEMAKERS (prohibition sign on the safety
doors)
A powerful magnet is installed in the machine. To avoid possible
malfunctions in the pacemaker, a minimum distance of 30 cm
between the magnetic clamping plate and the implant must be
complied with.
1.3.2 General mandatory sign
The following general mandatory signs must be observed:
CAUTION! RISK OF INJURY ON THE BLADE
Work on the grinding machine involves the sharpening of blades
which could cause cut injuries due to their sharpness.
Wearing protective gloves is mandatory when carrying out such
jobs.
Be careful when transporting blades.
Protective gloves should also be worn when changing the coolant
(see Chapter 8.1).
1. Important notes
9
1.4 Rating plate and machine serial number
The rating plate is located on the right side of the
machine.
The machine serial number is located on the rating
plate and in the machine room, visible through
the KNECHT logo.
1.5 Figure and item numbers in the operating instructions
If a component of the machine that is shown in a figure is described in the text, it is followed by a
figure or item number in brackets.
Example: (7-5/1) denotes figure number 7-5, item 1.
Small workpieces are held and aligned correctly on the
rotary table via centring pieces (7-5/1). The relevant cen-
tring piece is inserted in the centre of the rotary table.
Large workpieces are aligned in the centre without a
centring piece. The edge of the rotary table and the
grooves can be used as an orientation aid.
The workpiece is clamped with the electromagnetic table.
Before each grinding process, the magnet of the rotary
table must be activated by pressing the “Magnet On /Off”
(3-5/5) button.
1. Important notes
Figure 7-5 Workpiece holder
Figure 1-1 Rating plate
Figure 1-2 Machine serial number
1
10
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 the 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 Obligations 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 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.
It is also checked at regular intervals as to whether the 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
shall give a signed confirmation of this in writing.
2.1.4 Hazards associated with the handling of 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 be used only:
• for the intended purpose, and
• in faultless condition with regard to safety-relevant aspects.
2. Safety
11
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 and until such time as the malfunction has been found and eliminated.
Allow only authorized technical staff to eliminate the malfunctions.
2.2 Use as intended
The grinding machine is only designed for surface grinding mincing plates and knives, also
referred to as workpieces in this document.
All blades must be clamped in the centre on the magnetic rotary table.
Any other use is considered improper use. KNECHT Maschinenbau GmbH does not assume any
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.,
• devices are not fastened properly.
• workpieces other than mincing plates or knives are ground.
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.
12
• 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 level of safety required for operating the grinding machine.
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 equipment
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 measure
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 in the training or instruction phase may only be allowed to work on the grinding
machine under the permanent supervision of an experienced person.
2. Safety
13
2.4.5 Machine control
Only trained and instructed personnel is allowed to switch on the machine.
2.4.6 Safety measures during 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 department/per-
son. 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.
In case of functional faults, immediately stop the machine and secure against restarting. Have the
faults eliminated immediately.
2.4.7 Dangers due to electrical power
Work on electrical units or operating materials may only be performed by a qualified electrician in
accordance with electrical rules.
Defects, such as a damaged cable, cable connections, etc., must be immediately rectified by an
authorized specialist.
Cables marked in yellow are electrically live even when the main switch
is in off position.
CAUTION
2.4.8 Particular hazard areas
In the area of the grinding wheel, there is a hazard of pinching and being drawn in (e.g. clothing,
fingers and hair). Suitable personal protective equipment must be worn.
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.
2. Safety
14
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 per-
mission 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 level of safety required for operating the grinding machine.
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 Lubricants / 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 (signaller) for the lifting process.
No persons other than those entrusted with this work may be present in the loading and installa-
tion area.
Only lift the grinding machine correctly with a suspension device in accordance with the operat-
ing instructions (attachment points for load suspension devices, 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.
2. Safety
15
3. Description
3.1 Use as intended
The surface grinding machine W 300 grinds mincing plates and knives to a diameter of 300 mm
(optional 400 mm).
3.2 Technical specifications
Height (maximum if lever at top) �������������������������������������� approx. 2095 mm
Width (incl. belt filter coolant unit) ������������������������������������ approx. 1665 mm
Depth (incl. belt filter coolant unit and extraction) ������������������������ approx. 1700 mm
Weight ���������������������������������������������������������������������� 650 kg
Weight belt filter coolant unit ���������������������������������������������������� 90 kg
Weight standard coolant unit ���������������������������������������������������� 20 kg
Current supply* ������������������������������������������������������������ 3x 400 V
Mains frequency* �������������������������������������������������������������� 50 Hz
Output* ���������������������������������������������������������������������� 4 kW
Power consumption* ����������������������������������������������������������� 6 kW
Energy consumption* ������������������������������������������������������������ 9 A
Back-up fuse ������������������������������������������������������������������� 25 A
Measured A-evaluated emission sound pressure level ����������������������������� 75 dB (A)
at the workstation LpA**
Rotary table diameter ���������������������������������������� 300 mm (optional 400 mm)
Rotary table speed ����������������������������������������������������� 31 and 62 rpm
Grinding wheel diameter ������������������������������������������������������ 200 mm
Grinding wheel speed ������������������������������������������������������ 3000 rpm
Cutting speed with grinding wheel d.200*** ������������������������������������ 31 m/ s
*) This data may vary depending on the electrical power supply.
**) Noise emission information according to EN ISO 11202 (measurement uncertainty KpA. 2.5 dB(A))
***) Caution! The cutting speed of 31 m/ s is achieved at 50 Hz. With an electrical supply with higher frequency,
faster cutting speeds are reached. Only use approved abrasives.
A mincing plate from Turbocut (d. 200 mm) was ground.
16
Figure 3-1 Dimensions in mm
3. Description
3.3 Functional description
With the surface grinding machine W 300, mincing plates and knives with a diameter of up to
300 mm (optional 400 mm) can be ground.
ATTENTION The mincing plate must not protrude over the
magnetic table.
Mincing plates are fixed on the rotary table of the surface grinding machine W 300 with either
magnetic clamping or, if grinding takes place without magnetic clamping, with centring pieces.
For surface grinding, mincing knives are fixed on a mincing plate with the centring piece for
blades provided.
For unusual applications, special holders are also available.
The machine is supplied with CBN grinding wheels and a belt filter coolant unit as standard.
As an option, the W 300 can be supplied with a standard coolant unit and an air purification unit
(referred to as extraction in this document).
ATTENTION Only abrasives that are approved by KNECHT
Maschinenbau GmbH may be used.
CoG
CoG
17
3. Description
3.4 Description of the assemblies
1 Control panel
2 Safety doors
3 Control lever “grinding unit”
4 Halogen work-lamp
5 Coolant hose
6 Grinding unit
7 Coolant tap
8 Control lever “rotary table”
9 Belt filter coolant unit
10 Adjustable machine feet
11 Extraction (optional)
12 Retaining pin
2
9
6
8
7
12
4
5
1
10
11
3
Figure 3-2 General view of the grinding machine
18
3. Description
3.4.1 Switching the grinding machine on /off
The main switch is on the rear side 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 can be operated via
the buttons, switches and controllers.
Figure 3-3 Main switch
Figure 3-4 Control panel
19
1 “Control On” button: Activates PLC-control
2 Selection switch “Rotary table I/II”: Chang-
es the rotary table feed speed
3 “Coolant On/Off” button: Switches the
coolant pump on/off
4 “Drive On/Off” button: Switches the drive
grinding wheel, rotary table, coolant pump
and extraction on/off (only works with the
magnet switched on)
5 “Magnet On/Off” button: Switches the
rotary table magnet on/ off
6 “Grinding wheel On/Off” button: Switches
the grinding wheel on/off (only works with
the magnet switched on)
7 “Rotary table On/Off” button: Switches the
turning motion of the rotary table on/off
8 “Adhesive force magnet” selection switch:
Controls the rotary table magnetic field
strength
9 “Emergency Stop” button
3. Description
Figure 3-5 Control panel
1 2 3 4
5678
9
20
3. Description
3.4.3 Belt filter or standard coolant unit (optional)
The belt filter coolant unit (3-6) is located on the
left side of the machine.
During grinding, the workpiece must be perma-
nently cooled.
Fill approx. 140 liters of water with coolant addi-
tive into the water tank.
The standard coolant unit (optional) (3-7) is locat-
ed on the left side of the machine.
During grinding, the workpiece must be perma-
nently cooled.
Fill water with coolant additive into the tank. The
maximum fill level is 220 mm.
Figure 3-7 Standard coolant unit (optional)
Figure 3-6 Belt filter coolant unit
21
For transporting the machine, the locally applicable safety and accident
prevention regulations must be observed.
Only transport the machine in upright position (with the machine feet
facing downwards).
CAUTION
4.1 Transport aids
For transporting and for setting up the grinding machine, only use adequately dimensioned
transport aids with a load-bearing capacity of at least 1.5 t, e.g. truck, forklift, hydraulic lift truck.
When using a forklift or a lift truck, move the fork under the grinding machine.
Bear in mind the centre of gravity of the machine. The centre of gravity (CoG) is shown in figure
3-1.
4.2 Transport damage
If damage is detected on unloading after acceptance of the delivery, inform KNECHT Maschinen-
bau GmbH and the freight forwarder about it immediately. If required, consult an independent
expert immediately.
Remove the packaging and shipping straps. Remove the shipping straps on the grinding machine.
Dispose of the packaging in an environmentally friendly way.
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 reliable electrical connection must be provided at the new installation site. The grinding
machine must be stable and firmly placed.
Installations on the electrical system may only be performed by an
authorized specialist or our customer service staff. Observe the locally
applicable safety and accident prevention regulations.
CAUTION
4. Transport
Table of contents
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