KNECHT W 40 User manual

Status 06.2018 ■Version 2.2 | Translation
Operating Instructions
W 40
Fully Automatic Surface Grinding Machine

3
Fully Automatic Surface Grinding Machine W 40
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
June 20, 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, in particular rival firms.
Operating Instructions

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1. Important notes 7
1.1 Foreword 7
1.2 Warnings and symbols in the operating instructions 7
1.3 Warning plates and their meaning 8
1.3.1 Warning and prohibition signs on/in the grinding machine 8
1.3.2 General mandatory signs 8
1.4 Rating plate and machine serial number 9
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 the handling of 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 Organisational 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 20
3.4.2 Control system in general 20
3.4.3 Layout of the user interface (main screen) 22
3.4.4 Belt filter coolant unit 23
Table of Contents

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4. Transport 24
4.1 Transport Aids 24
4.2 Transport Damage 24
4.3 Transport to another installation site 24
5. Installation 25
5.1 Selection of qualified personnel 25
5.2 Installation Site 25
5.3 Supply Connections 25
5.4 Settings 25
5.5 Initial commissioning of the grinding machine 26
6. Commissioning 27
7. Operation 29
7.1 Switching on the grinding machine 29
7.2 Rotary table 29
7.3 Workpiece holder 29
7.4 Defining the working position 30
7.5 Adjusting the coolant supply 31
7.6 Grinding of mincing plates 32
7.7 Grinding of mincing knives 33
7.8 Dressing the corundum grinding wheel 35
7.9 Changing the grinding wheel 37
8. Control system 38
8.1 Fully automatic grinding 38
8.2 Automatic grinding with manual touching 39
8.3 Manual grinding 41
8.4 Activating the product file 43
8.5 Renaming, creating and deleting the product file 44
8.5.1 Renaming the product file 45
8.5.2 Creating the product file 45
8.5.3 Deleting the product file 45
8.6 Editing the parameters of the product file 46
8.6.1 Meaning of the parameter “RECIPE DATA” 47
8.6.2 Meaning of the parameter “Process data” 48
8.6.3 Meaning of the parameter “Polishing [1]” and “Polishing [2]” 50
8.7 Language 51
Table of Contents

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9. Care and maintenance 52
9.1 Coolant additive 52
9.1.1 Cooling lubricant maintenance plan 52
9.2 Lubrication 53
9.2.1 Additional lubrication interval 53
9.2.2 Lubrication schedule and lubricant table 54
9.3 Maintenance plan 55
9.4 Cleaning 56
10. Disassembly and disposal 58
10.1 Disassembly 58
10.2 Disposal 58
11. Service, spare parts and accessories 59
11.1 Postal Address 59
11.2 Service 59
11.3 Spare parts 59
11.4 Accessories 60
11.4.1 Grinding wheels used 60
12. Appendix 61
12.1 EC Declaration of Conformity 61
Table of Contents

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1.1 Foreword
These operating instructions are meant to make it easier to get to know the fully automatic sur-
face 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 ma-
chine 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
• Transport, installation, commissioning
• Operation, including troubleshooting 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 technol-
ogy 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 if special attention is not paid while carrying out particular
jobs.
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 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 authorised, 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
observed.
1.3.2 General mandatory signs
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 be worn when changing the coolant (see
Safety Data Sheet on “Coolant Lubricant”).
1. Important notes

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1.4 Rating plate and machine serial number
The rating plate is located on the right side of the
machine behind the control panel
.
The machine serial number is located on the rat-
ing plate and in the machine room, visible through
the opening of the extraction unit.
1. Important notes
Figure 1-2 Machine serial number
Figure 1-1 Rating Plate

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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
added in brackets after the machine component.
Example: (7-1/1) denotes figure number 7-1, item 1.
The workpieces are placed on the rotary table (7-1/1) for
machining. The rotary table has an electric magnet for
fixing the workpiece. The strength of the magnetic field is
divided into six levels and can be controlled.
The rotary table is powered by a spur gear. Two speeds are
available.
1. Important notes
Figure 7-1 Rotary table
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 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 un-
derstood the warning notes. They have given a signed confirmation of this in writing.
Checks are also carried out at regular intervals to determine whether the worker is fulfilling his
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 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 parties, 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

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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 behaviour
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 authorised 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 of the magnetic table.
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.,
• 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,
• unauthorised structural alterations to the grinding machine,
• unauthorised 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 Organisational 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 is important to ensure that all protective equip-
ment 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 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

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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.
Only trained and instructed personnel are allowed to switch on the machine.
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 behaviour) 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, 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
authorised specialist.
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 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. 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 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 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 environmen-
tally 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 oils and greases, follow the safety instructions 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
installation area.
2. Safety

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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.
2. Safety

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3. Description
3.1 Intended Use
The W 40 fully automatic surface grinding machine grinds mincing plates and knives, as well as
mincer blade sets with a diameter up to 400 mm.
3.2 Technical specifications
Height ������������������������������������������������������������ approx. 1800 mm
Width (incl. belt filter coolant unit) ������������������������������������ approx. 1800 mm
Depth ������������������������������������������������������������� approx. 1800 mm
Required space (WxDxH) ������������������������� approx. 3400 mm x 2600 mm x 1800 mm
Weight �������������������������������������������������������������� approx. 1200 kg
Weight of belt filter coolant unit ������������������������������������������������� 90 kg
Voltage supply* ������������������������������������������������������������ 3x 400 V
Mains frequency* �������������������������������������������������������������� 50 Hz
Connected load* �������������������������������������������������������������� 9 kW
Rated voltage* ����������������������������������������������������������������� 35 A
Back-up fuse ������������������������������������������������������������������� 25 A
Measured A-evaluated emission sound pressure level ����������������������������� 75 dB (A)
at workstation LpA**
Rotary table diameter ��������������������������������������������������������� 400 mm
Rotary table speed ����������������������������������������������������� 31 and 62 rpm
Grinding wheel diameter ������������������������������������������������������ 200 mm
Rotary table speed ���������������������������������������������������� 100 - 3000 rpm
Cutting speed with grinding wheel d.200 ��������������������������������������� 1-30 m/s
*) This data may vary depending on the electrical power supply.
**) Noise emission information according to EN ISO 3746.
A mincing plate from Turbocut (d.200 mm) was ground.

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Figure 3-1 Dimensions in mm
3. Description
3.3 Functional Description
With the W 40 surface grinding machine, mincing plates and knives with a diameter up to
400 mm can be ground fully automatically.
ATTENTION The mincing plate must not protrudeover the
magnetic table.
The mincing plates are fixed on the rotary table of the W 40 surface grinding machine via mag-
netic tension and aligned with the help of 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 a boron nitride grinding wheel as standard. However, corundum
grinding wheels can be used as well.
ATTENTION Only abrasives that are approved by KNECHT
Maschinenbau GmbH may be used.
An extraction unit (air purifying system) is integrated in the machine. Furthermore, there is a belt
filter coolant unit in the machine.
approx. 1200 mm approx. 1800 mm
approx. 1800 mm
approx. 1800 mm
CoG CoG

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3. Description
3.4 Description of the assemblies
-
1 Control panel
2 Safety doors
3 Working place light (concealed)
4 Flexible jointed coolant hose
5 Grinding unit (z-axis)
6 Rotary table (y-axis) (concealed)
7 Coolant tap
8 Belt filter coolant unit
9 Adjustable machine feet
10 Extraction unit
5
6
7
8
4
3
10
1
2
9
Figure 3-2 General view of the grinding machine

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3. Description
3.4.1 Switching the grinding machine on / off
The main switch (3-3/1) of the grinding machine is
located on the backside of the switch cabinet.
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.
2 Connection for internet
3 Connection for coolant pump
4 Connection for belt filter coolant unit
3.4.2 Control system in general
The machine is controlled via the control panel on
the right side of the machine.
The program is automatically loaded when the
machine is switched on. The user interface is
activated only when the “Control ON” button is
pressed.
The machine is operated via the touch panel (3-
4/1) and the buttons (3-4/2).
Figure 3-3 Main switch
2
1
3
4
Figure 3-4 Control panel
1
2

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1 “Magnet On/ Off” button: Switches the
rotary table magnet on/off
2 “Start/ Stop” button: Starts or stops the
selected product file
3 “Control On” button: Activates the controls
4 “Feed” button: Manually increases the trav-
erse speed of the axes
5 “Step” button: Feeds the grinding wheel in
defined steps
6 “Coolant On/ Off” button: Switches the
coolant pump on/ off
7 “Emergency Stop” button
3. Description
Figure 3-5 Control panel
1
4567
2 3