OPTIMUM Maschinen OPTIgrind GT 22 User manual

EN
Operating Manual
Version 1.0
Surface grinding machine
Part no. 3111020

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Table of contents
1 Safety
1.1 Glossary of symbols ...................................................................................................................................... 6
1.2 Rating plate.................................................................................................................................................... 6
1.3 Safety instructions (warning notes)................................................................................................................ 7
1.3.1 Classification of hazards.................................................................................................................. 7
1.3.2 Other pictograms.............................................................................................................................. 7
1.4 Intended use.................................................................................................................................................. 8
1.5 Reasonably foreseeable misuse.................................................................................................................... 8
1.5.1 Avoiding misuse............................................................................................................................... 9
1.6 Dangers that can be caused by the surface grinding machine...................................................................... 9
1.7 Qualification of personnel............................................................................................................................ 10
1.7.1 Target group................................................................................................................................... 10
1.7.2 Authorized personnel..................................................................................................................... 11
1.8 Operator positions ....................................................................................................................................... 11
1.9 Safety devices ............................................................................................................................................. 11
1.9.1 Lockable master switch.................................................................................................................. 12
1.9.2 Emergency stop button.................................................................................................................. 12
1.9.3 Control-related safeguarding.......................................................................................................... 12
1.9.4 Prohibition, warning and mandatory signs ..................................................................................... 13
1.10 Safety check................................................................................................................................................ 13
1.11 Personal protective equipment.................................................................................................................... 14
1.12 Safety during operation................................................................................................................................ 14
1.13 Safety during maintenance.......................................................................................................................... 15
1.14 Switching off and securing the surface grinding machine............................................................................ 15
1.14.1 Using lifting equipment................................................................................................................... 15
1.14.2 Mechanical maintenance ............................................................................................................... 15
1.15 Accident report............................................................................................................................................. 15
1.16 Electronics................................................................................................................................................... 16
1.17 Inspection deadlines.................................................................................................................................... 16
1.18 Clamping devices for workpieces and tools................................................................................................. 17
1.19 Environmental protection and water conservation....................................................................................... 17
2 Technical data
3 Delivery, interdepartmental transport, assembly and commissioning
3.1 Notes on transport, installation, commissioning .......................................................................................... 20
3.1.1 General risks during internal transport........................................................................................... 20
3.2 Unpacking the machine............................................................................................................................... 21
3.2.1 Standard accessories..................................................................................................................... 21
3.2.2 Optional accessories:..................................................................................................................... 21
3.2.3 Load attachment point in unpacked condition................................................................................21
3.3 Set-up and assembly................................................................................................................................... 22
3.4 Installation site requirements....................................................................................................................... 22
3.5 Installation plan............................................................................................................................................ 24
3.5.1 Anchored mounting........................................................................................................................ 24
3.5.2 Free mounting................................................................................................................................ 25
3.5.3 Aligning the machine...................................................................................................................... 25
3.6 Removing the transport locks...................................................................................................................... 25
3.7 Cleaning the machine.................................................................................................................................. 26
3.8 Top up central lubrication ............................................................................................................................ 26
3.9 Coolant circuit.............................................................................................................................................. 26
3.10 Electrical connection.................................................................................................................................... 27
3.11 First commissioning..................................................................................................................................... 27
3.11.1 Warming up the machine............................................................................................................... 27
4Operation
4.1 Control and indicating elements .................................................................................................................. 28
4.2 Safety........................................................................................................................................................... 29
4.3 Control panel ............................................................................................................................................... 29
4.4 Grinding table oscillation.............................................................................................................................. 30
4.5 Magnetic attachment ................................................................................................................................... 31
4.6 Switching on the machine............................................................................................................................ 31

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4.6.1 Switching the grinding wheel on .....................................................................................................31
4.7 Switching the machine off ............................................................................................................................31
4.8 Resetting an emergency stop condition .......................................................................................................31
4.9 Mounting the grinding wheel ........................................................................................................................32
4.9.1 Mounting the grinding wheel on the flange.....................................................................................32
4.9.2 Balancing the grinding wheel..........................................................................................................33
4.10 Mounting the grinding wheel with flange on the spindle...............................................................................34
4.11 Selection of a grinding wheel .......................................................................................................................34
4.12 Dressing the grinding wheel.........................................................................................................................37
4.13 Digital Readout.............................................................................................................................................37
5 Operation DPA31
5.1 Parameter settings.......................................................................................................................................38
5.1.1 Explanation of the Parameters .......................................................................................................39
5.2 Description of the Keys ................................................................................................................................40
5.3 Reference marker function...........................................................................................................................43
5.4 Machine zero point function .........................................................................................................................43
5.5 Calculator function........................................................................................................................................44
5.6 Functions for milling machines.....................................................................................................................45
5.6.1 Coordinate points along a diagonal line..........................................................................................45
5.6.2 Coordinate Points on a Circle or Arc ..............................................................................................46
5.6.3 Inclined Plane .................................................................................................................................49
5.6.4 Arc ..................................................................................................................................................50
5.7 Functions for milling machines and lathes ...................................................................................................53
5.7.1 Tool Data Function .........................................................................................................................53
5.7.2 Recall of tool data...........................................................................................................................53
6 Maintenance
6.1 Operating material........................................................................................................................................54
6.1.1 Machine lubricants..........................................................................................................................54
6.1.2 Coolants..........................................................................................................................................54
6.2 Safety...........................................................................................................................................................54
6.2.1 Preparation.....................................................................................................................................55
6.2.2 Restarting .......................................................................................................................................55
6.3 Repair...........................................................................................................................................................55
6.3.1 Customer service technician...........................................................................................................55
6.4 Inspection and maintenance ........................................................................................................................56
6.5 Filling points, operating equipment...............................................................................................................58
6.6 Cooling lubricants and tanks........................................................................................................................59
6.6.1 Inspection plan for water-mixed cooling lubricants.........................................................................60
7 Ersatzteile - Spare parts
7.1 Ersatzteilbestellung - Ordering spare parts..................................................................................................61
7.2 Hotline Ersatzteile - Spare parts Hotline ......................................................................................................61
7.3 Service Hotline.............................................................................................................................................61
7.4 Ersatzteilzeichnungen - Spare part drawings...............................................................................................62
A Übersicht - Overview.........................................................................................................................62
B Tischbaugruppe - Table assembly....................................................................................................63
C Manuelle Längstischbewegung - Manual longitudinal table movement............................................64
D Manueller Quervorschub - Manual cross feed assembly..................................................................65
E Manuelle Hubeinrichtung - Manual elevating assembly....................................................................66
7.5 GT22 - Spindeleinheit - Spindle unit.............................................................................................................67
7.6 GT22 - Wegmesssystem - Path measuring system.....................................................................................67
7.7 Schaltplan - Wiring diagram.........................................................................................................................69
F ..........................................................................................................................................................69
G ..........................................................................................................................................................70
8 Malfunctions
9 Appendix
9.1 Copyright......................................................................................................................................................75
9.2 Changes.......................................................................................................................................................75
9.3 Product follow-up..........................................................................................................................................75
9.4 Liability claims for defects / warranty............................................................................................................75
9.5 Storage.........................................................................................................................................................76
9.6 Advice for disposal / Options of re-use.........................................................................................................77

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9.6.1 Decommissioning........................................................................................................................... 77
9.6.2 Disposal of new device packaging................................................................................................. 77
9.6.3 Disposal of the machine................................................................................................................. 77
9.6.4 Disposal of electrical and electronic components .......................................................................... 77
9.6.5 Disposal of lubricants and coolants................................................................................................ 78
9.7 Disposal through municipal collection facilities............................................................................................ 78
9.8 Terminology/Glossary.................................................................................................................................. 79
9.9 Genauigkeitsbericht - Accuracy report......................................................................................................... 80

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Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions
and convince by an outstanding price performance ratio. Continuous enhancements and prod-
uct innovations guarantee state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get
familiar with the machine. Please also make sure that all persons operating the machine have
read and understood the operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, opera-
tion and maintenanceof the machine. The continuous observance of all notes included in this
manual guarantee the safety of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information
for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which
the operator must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the
current state of construction of your machine. Being the manufacturer we are continuously
seeking for improvements and renewal of the products. Therefore, changes might be performed
without prior notice. The illustrations of the machine may be different from the illustrations in
these instructions with regard to a few details. However, this does not have any influence on
the operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors
are reserved!
Your suggestion with regard to these operating instructions are an important contribution to
optimising our work which we offer to our customers. For any questions or suggestions for
improvement, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are
not able to solve your problem with a help of these operating instructions, please
contact your specialised dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Fax (+49)0951 / 96555 - 888
Email: [e-mail]
Internet: www.optimum-machines.com

Safety
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1 Safety
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the surface grinding machine,
points out the dangers that might arise for you or others if these instructions are not
observed,
informs you about how to avoid dangers.
In addition to these operating instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the surface
grinding machine.
Always keep this documentation close to the surface grinding machine.
1.1 Glossary of symbols
provides further instructions
calls on you to act
listings
1.2 Rating plate
GT 22
NO
SN
Year
Netto
1,5 KW
400 V ~50 Hz
2 850 min-1
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland
3111020 900 kg
DE Flächenschleifmaschine
EN Surface grinding machine
FR Rectieuse plane
ES Recticadora
IT Retticatrice
CS Bruska na plocho
DA Overadesliber
EL ΡΕΚΤΙΦΙΕ ΕΠΙΦΑΝΕΙΩΝ
FI Tasohiomakone
HU Síkköszörű gép
NL Vlakslijpmachine
PL Szlierka magnetyczna do
płaszczyzn
PT Recticadora de planos
RO Masina de recticat
RU Плоскошлифовальный станок
SK Bruska na plocho
SL Ploskovni brusilni stroj
SV Planslipmaskin
TR Yüzey Taşlama Makinesi

Safety
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1.3 Safety instructions (warning notes)
1.3.1 Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.3.2 Other pictograms
Symbol Alarm expression Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION! A danger or unsafe procedure that can cause personal injury or damage to
property.
ATTENTION!
Situation that could lead to damage to the surface grinding machine and the
product as well as to other damage.
No risk of injury to persons.
INFORMATION
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
general danger with a warning of injury to hands, hazardous electrical
voltage, rotating parts.
Activation forbidden! Do not step into the
machine! Do not extinguish with water! Do not clean with compressed air!
Wear safety shoes! Use ear protection! Wear protective glasses! Wear protective gloves!

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1.4 Intended use
WARNING!
If the surface grinding machine is not used as intended,
this may result in hazards for personnel,
the surface grinding machine and other material assets of the operator may be
endangered,
the function of the surface grinding machine may be affected.
The surface grinding machine is used exclusively for precision grinding of plane steel work-
pieces. The surface grinding machine must only be installed and operated in a dry and well-
ventilated areas. The machine integrated coolant system is only intended for water-miscible
cooling lubricants.
The surface grinding machine is designed and constructed for use in non-explosive environ-
ments.
If the surface grinding machine is used in any way other than described above, modified without
authorization of Optimum Maschinen Germany GmbH, then the surface grinding machine is
being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accord-
ance with the intended use.
We expressly point out that the guarantee or CE conformity will expire, if any constructive, tech-
nicalor procedural changes are not performed by the company Optimum Maschinen Germany
GmbH.
It is also part of intended use that you
comply with the performance limits of the surface grinding machine,
observe the operating instructions,
the inspection and maintenance instructions are observed.
WARNING!
Extremely severe injuries due to non-intended use.
It is forbidden to make any modifications or alternations to the operating parameters
values of the surface grinding machine. They could pose an accident hazard to persons
and cause damage to the surface grinding machine.
1.5 Reasonably foreseeable misuse
Any use other than that specified under "Intended use" or any use beyond that described will be
deemed non-intended use and is not permissible.
Any other use must be discussed with the manufacturer.
Warning: biological hazard! Warning: suspended loads! Warning of oxidizing
substances! Caution, danger of explosive substances!
Warning: danger of
slipping! Protect the environment! Contact address

Safety
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Only metallic, cold and non-flammable materials may be machined with the surface grinding
machine.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning.
Operators must be duly qualified.
1.5.1 Avoiding misuse
Regular balancing of the grinding wheel. For this purpose, a balancing device is supplied
with the surface grinding machine.
Adaptation of the manual oscillating speed and the transverse feed to the material and the
workpiece.
Mount the workpiece firmly and vibration-free on the electromagnet.
Risk of fire and explosion due to the use of flammable materials or cooling lubricants.
Before processing inflammable materials (e.g. aluminium, magnesium) or using inflamma-
ble auxiliary materials (e.g. spirit), you need to take additional preventive measures in order
to avoid health risks.
WARNING!
Risk of breakage of the grinding wheel or workpieces being thrown away.
The magnetizable workpiece must always be attached to the permanent magnet in a
plane and fixed manner. Check the secure fastening.
Use cooling and lubricating agents to increase the durability of the grinding wheel and to
improve the surface quality.
Clamping the workpiece on a clean and undamaged clamping surface on the magnet.
1.6 Dangers that can be caused by the surface grinding machine
The surface grinding machine was tested for operational safety. The construction and type are
state of the art.
Nevertheless, there is still a residual risk, because the surface grinding machine works with
rotating parts,
electrical voltage and currents,
We have minimized the risk to people's health from these hazards through design and safety
technology.
If the surface grinding machine is operated and maintained by insufficiently qualified personnel,
hazards can arise from the surface grinding machine due to incorrect operation or improper
maintenance.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
and strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
can endanger the surface grinding machine and other material assets,
the functionality of the grinding machine may be compromised.
Always switch off the surface grinding machine and disconnect it from the mains, when clean-
ing or maintenance work is carried out.

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WARNING!
The surface grinding machine may only be used with fully functional safety devices.
Disconnect the surface grinding machine immediately, whenever you detect a failure in
the safety devices or when they are not fitted!
All additional parts of the machine which had been added by the customer need to be
equipped with the prescribed safety devices.
This is your responsibility being the operating company!  Safety devices on page 11
1.7 Qualification of personnel
1.7.1 Target group
This manual is addressed to
the operating companies,
operators having sufficient specialist knowledge,
the maintenance personnel.
Consequently, the warning notes refer both to the use of the surface grinding machine and to
its maintenance.
Determine clearly and explicitly who will be responsible for the different activities on the sur-
face grinding machine (operation, setting up, maintenance and repair). Please note the name of
the responsible person into an operators´s log.
INFORMATION
Unclear responsibilities constitute a safety risk!
Always lock the main switch after switching off the surface grinding machine. This will prevent it
from being used by unauthorized persons.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator has been instructed by the operating company regarding the assigned tasks and
possible risks in case of improper behaviour. The user may only carry out tasks that exceed
normal operation if this is stated in these instructions and the operator has explicitly entrusted
him with the task.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective
standards and regulations, qualified electricians are able to perform work on the electrical sys-
tem and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of relevant
regulations, qualified personnel are able to perform the assigned tasks and to independently
recognise and avoid any possible dangers.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.