Wadkin NV User manual
MANUFACTURERS
E.C.
DECLARATION
OF
CONFORMITY
The following machine has undergone "Conformity Assessment" and
is
"self"
certificated
in
accordance with:-
Supply of Machinery (Safety) Regulations 1992
and Amendment No. 2063
COMPANY
WADKIN LTD
Green Lane Road
Leicester
LES
4PF
RESPONSIBLE
PERSON
Mr A Lott (Managing Director)
MACHINE
DESCRIPTION
TYPE
MODEL
PROFILE GRINDING MACHINE
NV
DIRECTIVES COMPLIED WITH
Supply of Machinery (Safety) Regulations 1992
Amendment No. 2063 1994
Draught Proposal GEN/TC 142
ISO
9001
Part 1
TEL +44 116 2769111
PREFACE
IMPORTANT
IT
IS
OUR POLICY AND THAT
OF
OUR SUPPLIERS
TO
CONSTANTLY REVIEW THE DESIGN AND CAPACITY
OF
OUR
PRODUCTS. WITH THIS
IN
MIND WE WOULD REMIND OUR
CUSTOMERS THAT WHILE THE DIMENSIONS AND
PERFORMANCE DATA CONTAINED HEREIN ARE CURRENT
AT
THE TIME
OF
GOING TO PRESS, IT
IS
POSSIBLE THAT
DUE TO THE INCORPORATION
OF
THE LATEST
DEVELOPMENTS TO ENHANCE PERFORMANCE,
DIMENSIONS AND SUPPLIERS MAY VARY FROM THOSE
ILLUSTRATED.
THIS MANUAL
IS
WRITTEN AS A GENERAL GUIDE. A TYPICAL
MACHINE
IS
SHOWN TO ILLUSTRATE THE MAIN FEATURES.
Failure to comply with instructions
in
this book
may invalidate the guarantee.
TEL +44 116 2769111
BE
CAREFUL
THIS MACHINE CAN
BE
DANGEROUS
IF IMPROPERLY USED
Always use guards.
Keep clear until rotation has ceased.
Always operate as instructed
and
in
accordance with good practice.
Read instruction manual before installing,
operating or maintaining machine.
Manufactured
by:
WADKIN PLC
Green Lane Road
Leicester
LE5 4PF
England
Telephone No.: 0116 276 9111
Fax
No.:
0116 274 2389
~
NATIONAi.
mEonmoN
Of
CEKTiflCATION
BODIES
CE
TEL +44 116 2769111
HEALTH AND SAFETY
The CE mark
on
this machine signifies that
an
EC
declaration of conformity is drawn up indicating
that the machine is manufactured
in
accordance
with the Essential Health and Safety
Requirements ofthe 'Supply
of
Machinery (Safety)
Regulations 1992'.
The 'requirements for supply
of
relevant
machinery'
in
the General Requirement
of
the
Regulations are not only that the machine satisfies
the relevant essential health and safety
requirements, but also that 'the manufacture .....
carries out the necessary research or tests
on
components, fittings or the complete machine
to
determine whether by its design or construction
the machine is capable of being erected
and
put
into service safely'.
Persons who install this machine have duties
under the 'Provision
and
use of Work Equipment
Regulations 1992'.
An
indication of these duties
is
given
in
the following extracts, but the user should
be
familiar with the full implications of the
regulations.
REGULATION 5 requires that;
Every employer shall ensure that work equipment
is
so
constructed or adapted
as
to
be
suitable for
the purpose for which it is used or provided.
In
selecting work equipment, every employer shall
have regard to the working conditions and to the
risks to health and safety of persons which exist
in
the premises or undertakings
in
which that work
equipment is to
be
used
and any additional risk
posed
by
the use ofthat work equipment.
Every employer shall ensure that work equipment
is
used only for the operations for which,
and
under conditions for which, it is suitable.
In
this regulation 'suitable' means suitable
in
any
respect which it is reasonably foreseeable will
affect health orsafety
of
any person.
The Provision and
Use
of
Work Equipment
Regulations also include requirements
as
follows:-
regulation 6 - maintenance
regulation 7 - specific risks
regulation 8 - information and instructions
regulation 9 - training
Note:-
Attention is drawn to those requirements
of
the
'Woodworking Machines Regulations 1974' which
are
not replaced
by
the Supply of Machinery
(Safety) Regulations or other, e.g; Regulation 13
of the Woodworking Machinery Regulation, -
'Training', still applies.
Whilst the prime duty for ensuring health
and
safety rests with employers, employees too have
legal duties, particularly under sections 7 and 8 of
the Health
and
Safety at Work Act. They include :-
Taking reasonable care for their
own
health
and
safety
and
that of others who may
be
affected
by
what they
do
or don't do;
co-operating with their employer
on
health
and
safety;
.not interfering with or misusing anything provided
for their health, safety and welfare.
These duties
on
employees have been
supplemented
by
regulation
12
of the
Management of Health
and
Safety at Work
Regulations 1992. One
of
the new requirements
is
that employees should use correctly all work items
provided
by
their employer
in
accordance with
their training and the instructions they receive to
enable them to
use
the items safely.
Noise
Noise levels
can
vary widely from machine
to
machine depending
on
the conditions
of
use.
Persons exposed
to
high levels, even for a short
time, may experience temporary partial hearing
loss and continuous exposure
to
high levels
can
result
in
permanent hearing damage.
The Noise at Work Regulations
1989
place legal
duties
on
employers to prevent damage to
hearing.
There are three levels
of
noise defined
in
regulation 2;
The first action level :-
a daily personal noise exposure
(LEP,d)
of
85dB(A)
TEL +44 116 2769111
HEAL
TH
AND
SAFETY
The second action level
:-
a daily personal noise exposure
(LEP,d)
of
90dB(A)
The peak action level
:-
a peak sound pressure
of
200 pascals (140dB
re
20pa)
The exposure level is obviously influenced by the
emission level of all the equipment
in
use.
Emission levels for machines
are
provided
in
the
particular machine instruction manual.
These levels are measured
in
accordance with
ISO 7960 under certain specified test conditions,
they do not necessarily represent the highest
noise level, which
is
influenced by many factors,
eg
number of spindles
in
operation, type
and
condition of work piece, spindle speeds etc.
For regulations
and
information
on
relevant
personal protective equipment i.e. ear defenders,
employers should refer to the Personal Protective
Equipment
at
Work Regulations 1992.
Dust
Wood dust
can
be
harmful to health by inhalation
and
skin contact
and
concentrations of small
particles
in
the air
can
form
an
explosive mixture.
The Control of Substances Hazardous to Health
Regulations (COSHH) 1989 place legal duties
on
employers to ensure that :-
the exposure
of
his employees to substances
hazardous to health is either prevented
or,
where
this is not reasonably practicable, adequately
controlled.
..... adequate control to exposure
of
employees to
a substance hazardous to health shall
be
secured
by measures other than the provision
of
personal
protective equipment.
where the measures taken
in
accordance with the
paragraph above
do
not prevent or provide
adequate control
of
exposure
to
substances
hazardous to the health of employees, then
in
addition to taking those methods, the employer
shall provide those employees with such suitable
personal protective equipment
as
will adequately
control their exposure to substances hazardous to
health.
Instructions
for
Use
Machinery manufacturers are required by the
Supply of Machinery Safety Regulations to
provide comprehensive 'Instructions for Use' of
equipment, it
is
important that this information
is
transmitted to the person using the machine.
TEL +44 116 2769111
SAFETY CONSIDERATIONS
IMPORTANT
SAFETY PROCEDURES AND
CONSIDERATIONS
To ensure safe working conditions, persons
operating
and
assisting with the operation
of
this
machine must ensure that they read
and
fully
understand the instructions given within this
manual and have received sufficient training
in
the
use
of
the machine
and
the safety aspects to
be
observed.
Grinding wheels that
are
damaged or improperly
used are dangerous. All users should take
sensible precautions
in
their handling, storage
mounting
and
use.
If a grinding wheel breaks whilst running, pieces
fly from the wheel. The wheel guard must always
be
used.
The grinding process produces sparks
and
dust.
Eye protection must always
be
used. Coolant
should always
be
used to prevent airborne dust.
Safety requirements for installing, operating
and
maintaining the machine are described
in
the
relevant sections ofthis manual.
Keep the floor area around the machine clean
and
free from refuse.
Do
not allow the floor around the
machine to become slippery.
Stop the machine
and
report immediately to a
person
in
authority any actual or potential
malfunction or operator hazard.
Do
not attempt to
repair
or
rectify the machine unless qualified
and
authorised
to
do
so.
The operator must not leave the machine running
whilst unattended.
Never by-pass interlocks.
Note :-Persons under the
age
of 18 years must
not operate the machine except during a course of
training under the supervision of a trained
operator.
WARNING:-
Failure
to
observe correct operating procedures
prior to
and
during operation of this machine
can
result
in
severe injury.
DO
NOT attempt
to
operate the machine while
under the influence of anything that reduces your
alertness.
TEL +44 116 2769111
INDEX
Section Title Page
4 Operating Instructions
4.1
Safety
4:
1
4.2 The Grinding Wheel
4:2
4.3 Dressing the Wheel
4:5
4.4 Mounting the Cutterhead
4:9
4.5 Stylus
4:
10
4.6 Positioning the Template
4:
11
4.7 Head Adjustment
4:
12
4.8 Coolant Application
4:
13
4.9 Carriage Control
4:
13
4.10 Rough Grinding
4:
14
4.11
Finish Grinding
4:
15
4.12 Side Relief
4:
16
4.13 Measuring
4:
17
4.14 Variable Speed (Optional extra)
4:
17
4.15 Grinding Segmental Tooling
4:
18
4.16 Grinding Planerheads
4:
18
4.17 Care of the Machine
4:
19
TEL +44 116 2769111
Section
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
INDEX
INDEX
Machine and Test Numbers
Preface
Manufacturer
Health and Safety
Safety Considerations
General Description
Machine Layout
Intended Uses
Technical Specification
Profile Grinding Theory
Installation
Moving the Machine
Space requirements
Foundations
Levelling
Transit Clamps
Electrical Supply
Lighting
Cleaning
Preparation for Use
Training
Coolant System
Controls
Template Making
Working Height
Tools and Accessories
Testing the Machine
1 : 1
1 : 2
1 : 3
1 : 5
2:
1
2:
1
2:
1
2:3
2:3
2:5
2:5
2:5
3:
1
3:
1
3:3
3:4
3:5
3:5
3:5
TEL +44 116 2769111
Section
Maintenance
Safety
Cleaning
Lubrication
INDEX
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Wheel Mounting and Guard
Coolant System
6
Electrical System
Machine Alignments
Illustrated Parts List
Dresser
Template
Slide
Carriage
Stylus I Cutter Rest Slide
Head
APPENDIX
A.1
Approved Lubricants
A.2 Grinding Coolant Data
A.
3 Anti-bacterial Solution Data
A.4 Tools etc Supplied with Machine
A.5
Accessories
Available
A.6 Suggested Spares
A.
7 Electrical Circuit Diagram
5:
1
5:
1
5:
1
5:
1
5:2
5:2
5:2
6:2
6:8
6:
16
6:
20
6:
26
TEL +44 116 2769111
GENERAL DESCRIPTION
SECTION 1 : GENERAL DESCRIPTION
1.1
MACHINE LAYOUT
Fig.
1a
1 Arbor
2 Counterbalance
3 Arbor support
4 Coolant tank
5 Coolant nozzle
6 Coolant drip tray
7 Cutterhead
8 Dresser
g Dresser location
1o Electrical cabinet
11
Template slide
12 Head motor
1 . 1
Wheel guard
Head rise
and
fall
Head tilt
Carriage
Worklamp
Stylus
SECTION
1
TEL +44 116 2769111
GENERAL
DESCRIPTION
SECTION 1
1.2 INTENDED USES
The Wadkin profile grinding machine type NV
is
a
tool grinding machine designed for the grinding
and
re-grinding
of
various types of cutters used
primarily
in
the woodworking industry.
Profile grinding is used for the grinding
and
re-
grinding of shaped profiles onto cutters used for
producing timber mouldings.
The blank cutters are set into the cutterhead prior
to profile grinding, and the cutterhead mounted
onto the grinder. A 'mirror image' template, made
1 :
1,
ensures that all the cutters are not only
ground to the same shape, but they are also
in
the
same position laterally, and
as
near
as
possible
radially. The finished ground block containing
2,
4,
6,
8 or more knives
is
transferred to the machine
on
which it is to
be
used, without further
movement ofthe cutters.
A bi-linear carriage is used to support the
cutterhead
on
a free rotating arbor, together with
the template and dresser unit. A cutter rest and
stylus are mounted offthe grinding head
in
front of
the wheel.
1 . 2
The template
is
made to match the required
timber profile,
and
the grinding wheel is dressed to
match the form
of
the stylus.
Grinding
is
a manual operation requmng the
operator to keep the cutter
in
contact with the
cutter rest
and
move the carriage to keep the
template
in
contact with the stylus.
A wet grinding coolant system is provided to
prevent burning of the cutters
and
to remove the
dust
and
debris generated during the grinding
process.
Note: This machine
is
not designed for the
grinding of aluminium, magnesium or other
materials which might create risks of fire or
explosion.
It
is
not designed for
use
in
an
explosive atmosphere.
TEL +44 116 2769111
GENERAL DESCRIPTION
1.3 TECHNICAL SPECIFICATION
MACHINE CAPACITY
Maximum length of cutter profile :
Model NV230...........................................
Model NV300...........................................
Maximum cutting circle : .....................................
Minimum cutting circle : ......................................
Maximum depth of profile : ...................................
GRINDING WHEELS
Diameter ..................................................
Width .......................................................
Dressed width ...........................................
Bore .........................................................
SPINDLE SPEED :
With 50
Hz
supply ...................................
With
60
Hz
supply ...................................
Variable speed (option) ............................
MOTOR OUTPUTS
Profile grinding spindle .............................
Coolant pump ..........................................
COOLANT SYSTEM
Tank
capacity-
maximum ........................
-minimum .........................
WORKLAMP
MACHINE DIMENSIONS
Height ......................................................
Width .......................................................
Depth .......................................................
Weight (nett) ............................................
Note
230mm
310mm
300mm
75mm
40mm
230mm
5mm
SECTION 1
4.7
mm
or3.0
mm
31.75 mm
3000 rpm
3600 rpm
1500 -3000 rpm
1.5 Kw
0.06 Kw
36 litre
18 litre
24v I
20w
Halogen
1500
mm
1270
mm
1100
mm
450
kg
(9")
(12.25")
(11.8")
{3")
(1.5T')
{9")
(0.197")
{1.25
11
)
(2 h.p.)
{0.08 h.p.)
. (8 galls)
(4 galls)
(59")
(50")
(43")
(990 lbs)
This unit will operate between
41
& 104 Deg. F (5 to 40 Deg. C); upto 3300ft (1000m); 20% to 95%
RH
(non condensing); and transportation and storage conditions of
-13
to
131
Deg. F (-25 to 55 Deg. C).
1 . 3
TEL +44 116 2769111
GENERAL DESCRIPTION SECTION 1
NOISE EMISSION VALUES
MACHINE CRITERIA :
The machine was free standing
on
a concrete
floor, not bolted down and not
on
any vibration
dampening.
GRINDING CRITERIA :
Knives : Solid HSS 8 mm x 60
mm
serrated back
Wheel:
Speed:
Depth
of
cut :
GW
203, 230 mm dia.
3000 rpm
0.3mm
The figures quoted
in
the noise emission chart are
emission levels and not necessarily safe working
levels.
Whilst there is a correlation between emission
levels and exposure levels, this cannot
be
used
reliably to determine whether or not further
precautions are required to achieve safe working
levels.
Factors that influence the actual level of exposure
to
the work force include the duration
of
exposure,
the characteristics
of
the work room, sources
of
noise etc. i.e. the number of machines and other
adjacent processes, also the permissible exposure
levels can vary from countr)'
to
countr)'.
Emission levels, however will enable the user of
the machine to make a better evaluation of the
'hazard
and
risk'.
NOISE EMISSION CHART
MODEL:-
NV
TYPE
:-
NV
300 50Hz
415v
DECLARED NOISE EMISSION VALUE
in
accordance with ISO
4871
Idling
Declared A-weighted sound power level
L
WAd
,in
dB
re
1 pW. ............................................ 74
Declared A-weighted emission sound level
(L
pAd)
in
dB
re
20 µPa at the operator's position ..............
61
Environmental correction factor (K) .....
..
.
...
.........
..
...... 3
values determined according to specific test code ISO 3744
VIBRATION LEVEL
At carriage ............................ Less than 2.5
m/s2
Values determined using the machine and
grinding criteria described above.
1 . 4
Operating
85
72
TEL +44 116 2769111
GENERAL DESCRIPTION
SECTION
1
1.4 PROFILE GRINDING THEORY
PROFILE DEVELOPMENT
The profile ground
on
a cutter
is
a geometrically
developed shape of that profile which is to
be
machined onto the timber.
If the cutting action of a shaped cutter is
examined,
Fig.
1b,
it will
be
observed that the
outer cutting edge reaches the maximum depth of
cut before the inner, and that the maximum depth
of cut for both edges occurs when the edge
passes a line drawn through the horizontal plane
of the cutterhead, ( X - X
).
Fig.
1b
Note : Profile depth P2
is
larger than
P1.
1 .5
Ifthe cutting angle
(A)
was o0, the cutter would
be
ground
in
the horizontal plane ( X - X )
and
the
finished profile would match the template.
However, most cutterheads have a cutting angle
(A)
of
between
15°
and 45°. This necessitates the
use of the cutter rest, to allow rotation of the
cutterhead whilst grinding.
TEL +44 116 2769111
GENERAL
DESCRIPTION
SECTION 1
GRINDING
PROFILE
THE
DEVELOPED
On
the grinderthe cutterhead is rotated
so
that the
cutter comes into contact with a fixed height rest,
so
ensuring that the cutter is brought into the
same plane ( X - X ) and angle (A)
as
it is when
cutting. This means that although the template is
an
exact 1 : 1 mirror image
of
the finished article
(P
1
),
because the grinding occurs at the same
angle at which cutting takes place, a 'developed'
shape
(P
2)
is
actually ground onto the cutter. This
automatically elongates the profile
so
that it
G
Fig. 1c
1.
6
produces the correct depth
of
mould
on
the
finished article.
The cutter rest also ensures that each cutting edge
ground
is
in
the same plane
as
the template.
I
~
I
I
---$---
--t--
I
TEL +44 116 2769111
GENERAL DESCRIPTION
SECTION
1
CUTIER
REST GAP
Theoretically the cutter rest and the ground edge
of
the cutter should be at the same point, [ the
theoretical grinding point
],
however for practical
considerations there must
be
a gap (G) between
the cutter rest and the wheel. Fig.
1c.
There should
be
a gap
of
about 0.5 mm for finish
grinding to achieve the best accuracy of profile
shape. The gap
can
be increased
up
to 2 mm
when roughing out blank cutters to allow greater
coolant flow for cooling and washing away debris.
The height of the cutter rest is also important to
maintain the theoretical grinding point level with
the horizontal plane ( X - X ) of the cutterhead.
Deviations will create inaccuracies
in
depth
of
profile
and
require compensation when grinding
side relief. The cutter rest should
be
kept
in
good
condition and replaced when worn.
CUTIING
ANGLES AND CLEARANCE
The cutting angle
(A)
(Fig.
1b)
theoretically varies
from the top to the bottom of the profile
as
the
cutterhead rotates. The angle is however
determined
by
the particular cutterhead
and
cannot
be
altered
on
the profile grinder.
The clearance angle (8) (Fig.
1b)
is
set
on
the
grinder by raising or lowering the position of the
grinding wheel. The angle chosen will depend
on
the type of cutter, type of timber, jointing
requirements etc. for the job
in
hand.
SIDE RELIEF
Side relief (or side clearance) may
be
necessary
to prevent rubbing or burning
of
the cutters when
machining timber, depending
on
the profile shape.
When the profile has been finish ground the head
(wheel) is tilted to the left or right to grind side
relief using the same template setting. The
objective is to grind clearance without altering the
shape
of
the ground profile. This
is
achieved
in
practice
by
leaving a small land or unground
1. 7
portion ofthe ground profile. The smaller the land,
the longerthe cutter will perform without burning.
The machine
is
arranged such that the wheel tilts
about the theoretical grinding point and a
minimum land
is
produced.
In
practice however
factors such
as
worn cutter rests, cutter rest gap,
etc. may cause a larger land or alteration of the
ground profile to occur. This should
be
compensated for by adjustment of the left I right
template position.
Normally a relief angle of about
5°
is sufficient but
can
be
increased up to
as
much
as
15°
if
required.
Some profiles such
as
grooving cutters require
both left
and
right side relief.
a)
Side relief
not
required
b)
Side relief required
Fig. 1d
TEL +44 116 2769111
INSTALLATION
SECT\ON
2
SECTION
2:
INSTALLATION
2.1
MOVING THE MACHINE
Verify the weight of the machine which is given
in
the Technical Specification (see section 1.3).
Ensure that all lifting equipment
used
is
capable of
lifting this weight
as
a minimum.
Always
use
the lifting points provided. Lifting using
other parts of the machine
can
be
dangerous
and
can
cause damage to the machine.
Fig.
2a Lifting points
The machine
is
designed
to
be
easily lifted
and
manoeuvred using a fork lift truck. The forks
should
be
at least 850 mm (34") long, not more
than 125 mm (5") x 63 mm
(2
1/2")
in
section,
and
capable of lifting the machine weight.
Carefully slide the forks directly
in~o
the
rectangular hollow steel lifting sections
and
lift
ensuring that the machine body remains parallel
with the floor.
If slings are used to move the machine, place a
suitable sling through each
of
the rectangular
hollow steel sections
of
the machine base
and
bring one
end
of each up behind the rear coolant
tray and the other end of each up the front of the
machine.
It
is
very important to ensure that the lifting slings
are suitably arranged to enable the machine to
be
lifted
so
that the body is parallel to the floor prior
to its siting. Take care to ensure that the slings
do
not cause damage to the sheet metal covers etc.
during lifting.
2.
1
Note: Transit clamps are fitted by Wadkin to
prevent damage to the machine during transit. If
the machine
is
moved at a later date it
is
important that the transit clamps
are
re-fitted
before the machine is moved.
2.2 SPACE REQUIREMENTS
The foundation plan Fig. 2b shows minimum
distances for positioning the machine near
to
walls
etc.
It
should
be
noted that these
are
minimum
distances
and
more space should
be
provided
if
possible for ease of access during routine
maintenance.
It
is
recommended that a workbench or table
be
located within easy reach of the machine for
loading cutterheads onto arbors etc.
An
area
should also
be
provided for work
in
progress.
The operator's working area
at
the front of the
machine should allow sufficient space for safe
loading
and
unloading of the machine. The actual
size will depend
on
the layout of the toolroom,
location of workbench etc. The working area
should not
be
cramped.
2.3 FOUNDATIONS
If the floor consists of 100 -150 mm
(4
-6")
of
solid concrete
no
special foundation
is
necessary.
M12 'Hilti' type holding down bolts (not supplied)
can
be
used
to secure the machine to the floor.
A good wooden floor should provide adequate
foundation for the machine provided that it does
not transmit vibration from adjacent machinery.
The machine should
be
bolted down before use.
Final bolting down
is
carried out during final
levelling.
TEL +44 116 2769111
E
E
0
N
N
250mrn
Fig.
2b Foundation plan
INSTALLATION
1290mm
~-----------~
-l===t
2.2
SECTION 2
250mm
4 x M12
4 x 016
E
E
0
N
TEL +44 116 2769111
Popular Grinder manuals by other brands
Hilti
Hilti AG 125-7SE Original operating instructions
Cornwell Tools
Cornwell Tools Blue Power CAT540R operating instructions
EINHELL
EINHELL Pro Work PWS 115 operating instructions
Milwaukee
Milwaukee 6130-33 Operator's manual
Clarke
Clarke CGP75F Operation & maintenance instructions
stayer
stayer SAB Series operating instructions