Wadkin Gd User manual

CD

C

"'C

.-

CDJ:

CD

(.)

LL

ca

J::Ea>

en

en"'C

::::SC-

o

.-

::::s

I..

C 0

J:calllll::::

1--':::::

_ c.."'C

C

CD

C

.-

"'C

ca

~

.-

"'Ctn

ca

I..

~

::::s

- 0

LL

::J

C

(!)

........

C

(!)

U)

-

CD

"'C

o

:E

. 0

o Z

ZI-

uCl)

--

w

::2:

I-

c·

o

.-

'0

~

...

-

(/)

c

-

www.DaltonsWadkin.com

[

c

o

[]

D

[J

C

o

[;

[

MANUFACTURERS E.C. DECLARATION OF CONFORMITY

The following machine has undergone "Conformity Assessment" and

is

"self' certified

in

accordance with:-

Supply

of

Machinery (Safety) Regulations 1992

and Amendment No. 2063

COMPANY

WADKIN LTD

Green Lane Road

Leicester

LE54PF

RESPONSIBLE PERSON

Mr

A C Lott (Managing Director)

MACHINE DESCRIPTION

TYPE

MODELS

THROUGH FEED FOUR SIDE

PLANING MACHINE AND MOULDER

GD/GDU

DIRECTIVES COMPLIED WITH

Supply

of

Machinery (Safety) Regulations 1992

Amendment No. 2063 1994

Draught Proposal CENITC 142

ISO

9001

Part 1

SIGNED

ON

BEHALF OF WADKIN PLC

www.DaltonsWadkin.com

[

Contents

[ CONTENTS

C EXTENT OF MANUAL

C Section Page

C Extent

of

Manual

1 HEALTH AND SAFETY

1-1

C

1.1

Health and Safety

1-1

1.1.1 Factories Act

1-1

C 1.1.2 Health and Safety at Work Act 1-2

1.1.3 Electricity Regulations 1-2

1.1.4 Provisions and use

of

Work Equipment Regulations 1-2

0 1.1.5 Woodworking Machines Regulations 1-2

1.1.6 Other Documents for Reference 1-2

1.2 Supply

of

Machinery (Safety) Regulations 1992 1-4

C 1.3 Specific Information 1-4

1.3.1 Noise 1-4

1.3.2 Dust 1-5

C 2 MACHINE SPECIFICATION

2-1

C 3 INSTALLATION

3-1

[l

3.1

Receipt

of

the Machine

3-1

3.2 Preparation for Installation

3-1

3.3 Lifting and Locating the Machine

3-1

C 3.4 Connecting the Services 3-2

3.4.1 Electrical Supply 3-2

3.4.2 Pneumatic Air Supply 3-3

3.4.3 Dust Extraction 3-3

C 4 MACHINE USAGE AND CONTROLS 4-1

C

4-1

Safe Practices 4-1

4.1.1 Pre-operation Checks 4-1

C 4.1.2 Checks During Operation 4-1

4.1.3 Safety Devices 4-2

4.2 Machine Controls 4-2

C 4.2.1 Machine Control Panel 4-2

4.2.2 Outfeed End Controls 4-5

4.2.3 Optional Equipment 4-6

[

[ Page 1

[

www.DaltonsWadkin.com

L

Contents

[ Section Page

[ 5 SETTING-UP THE MACHINE

5-1

['

5.1

General

5-1

5.1.1 Preparation

5-1

, 5.1.2 Remove/Refit Cutter Block

in

Spindle 5-2

[ 5.2 Setting First Bottom Head 5-4

5.3 Setting Fence Side Head 5-6

5.4 Setting Near Side Head 5-8

fl

5.5 Setting Top Head

5-11

5.6 Top Head Pad Pressure and Chipbreaker 5-14

L 5.7 Setting Second Bottom Head 5-16

5.8 Setting the Feed Rolls 5-18

r 5.9 Infeed Table and Fence Adjustment 5-22

[ 6 OPERATION

6-1

6.1

General

6-1

[]

6.1.1 Pre-operation Checks

6-1

6.1.2 Setting Controls and Adjustments

6-1

0 7 MAINTENANCE

7-1

[]

7.1

General

7-1

7.2 Scheduled Maintenance

7-1

7.2.1 Daily 7-2

[ 7.2.2 Monthly 7-2

7.2.3 Three-Monthly 7-2

7.3 Unscheduled Maintenance 7-4

G 7.3.1 Re-tension Top/Bottom Head Drive Belt 7-4

7.3.2 Re-tension Fence/Side Head Drive Belt 7-5

-'

7.3.3 Replace Spindle Drive Belt 7-5

C 7.3.4 Replace Variable Speed Drive Belt 7-6

7.3.5 Replace Shaft-Mounted Top Feed Roll 7-7

7.3.6 Replace Flange-Mounted Top Feed Rolls/Spacers 7-8

C 7.3.7 Replace BottomlTop Head Spindle 7-9

7.3.8 Replace Fence/Near Side Head Spindle 7-10

7.4 Fault Finding 7-12

C 7.4.1 General 7-12

7.4.2 Workpiece Faults 7-12

7.4.3 Machine Faults 7-13

[ 7.5 Lubrication Chart 7-15

7.5.1 Lubricants Specified 7-15

7.5.2 Approved Lubricants 7-15

[ 7.6 Tool and Toolholder Care 7-16

[ Page 2

l

--------.------

www.DaltonsWadkin.com

[

c

[

[,

[

[]

n

u

[

o

c

[;

[}

[

r1

LJ

)'

--~

[

Section

8

8.1

8.1.1

8.1.2

8.1.3

8.2

8.2.1

8.3

8.4

ADDITIONAL EQUIPMENT APPENDICES

Universal Head

Equipment

Reversing Switch

Setting the Universal Head

Grooved Bed

Setting-up the Cutter Block

Intermediate Feed Roll

Random Side Head

GLOSSARY

Page

8-1

8-2

8-9

8-10

8-11

8-12

Contents

Page 3

www.DaltonsWadkin.com

[

['

-'

c

[]

[

r

[

[J

o

[l

[

[J

[

[;

L

[

Extent

of

manual

EXTENT OF MANUAL

This Operation and Maintenance Manual

is

intended

to

provide users with all relevant

information concerning

the

operation

and

maintenance

of

a Through Feed Four Side

Planing and Moulding Machine, Model

GD.

The document is produced

in

seven sections.

Section One gives advice general safety aspects of the machine usage including

references

to

the various current statutory

and

safety regulations

in

force, advice

on

record keeping of machine operation

and

maintenance,

and

also instructions

on

recommended procedures when accepting

and

receiving the machine from the

manufacturer.

Sections Two to Seven provide the information necessary

to

install, operate

and

maintain the machine including procedures for fault finding.

At

the

end

of

the manual

is

a Glossary ofterms

used

throughout the body

of

the manual.

Also, depending

upon

any special machine features and/or nature of operation,

Additional Equipment Appendices are included

to

complement the standard sections

within the manual.

The

policy

of

the

Company

is

one

of

continuous

development,

and

the

company

reserves

the

right

to

alter

specification

without

prior

notice.

No

part

of

this

publication

shall

be

produced

in

any

way

without

the

express

permission

of

the

Company.

Page 1

www.DaltonsWadkin.com

L

[

r:

[

o

[

o

n

u

c

[;

[

C

['

c

[

1.1

1.1.1

Health and safety

1 HEALTH AND SAFETY

This Section covers all aspects of safe operation and safe use of woodworking

machinery.

It

refers

to

various statutory Health

and

Safety regulations,

and

also includes

information

and

advice derived from many years' experience

in

the

in

the building,

operation

and

maintenance ofwoodworking machinery.

It

is

of

the

utmost

importance

that

the

user

or

employer reads

this

Section

of

the

document

and understands clearly all

of

the stated requirements concerning safe

operation

of

the equipment.

Health and Safety

There are a number of statutory regulations which apply

to

the safe operation

of

woodworking machinery

in

the

UK.

These regulations are listed below,

and

the user

is

advised to refer

to

the relevant parts of these regulations and ensure that the

requirements are complied with.

Where the machinery is used outside the

UK,

then the regulations of that country will

apply,

and

should

be

complied with.

Note:

The list below relates

to

the most recent published editions

of

the regulations including

all amendments

and

supplements.

Factories Act.

Health

and

Safety at Work Act.

Electricity Regulations.

Provision

and

use

of

Work Equipment Regulations.

Woodworking Machines Regulations.

Factories

Act

This Act requires that rotating machinery shall

be

of good mechanical construction and

that it shall

be

properly maintained and serviced

by

competent and experienced

persons.

Page

1-1

www.DaltonsWadkin.com

[

c

[

n

o

c

l

""'

.~

c

[

[;

[

1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

Health and safety

Health and Safety

at

Work

Act

This Act imposes obligations

to

apply similar standards

to

those ofthe Factories Act as a

minimum requirement, especially where a machine is installed

in

a place

of

work

where no suitable legislation applies.

Electricity Regulations

These regulations place general requirements

on

the installation

and

maintenance of

electrical equipment. Users should

be

aware of the requirements concerning the

availability of lighting

and

free working space for maintenance personnel, and the

importance of personnel being fully competent

and

trained when working

on

electrical

equipment.

Provision and use

of

Work

Eguipment Regulations

Compliance with these regulations

is

necessary for equipment to

be

considered

to

be

conforming with the

EC

declaration ofconformity.

The regulations also place obligations

on

the user (see Section 1.2).

Woodworking Machines Regulations

These regulations place absolute

legal

requirements

on

employers

and

users to ensure

that

all fitted guards and safety devices are always used, securely fitted,

correctly

adjusted and properly maintained.

The regulations also require that maintenance be undertaken

only

by

suitably

qualified and competent personnel, and that all power supplies are isolated

from

the machine before

any

maintenance is undertaken.

It

is

also required that operators (users) receive suitable

training

and

instruction

into

the

possible dangers arising

from

machine usage and

that

local

working

practices are followed.

Other documents which refer

to

woodworking machinery operation

and

maintenance

in

the UK include:

Noise at Work Regulations.

Control ofSubstances Hazardous

to

Health Regulations.

Page 1-2

www.DaltonsWadkin.com

[

r:

[

o

[}

[

L

[

C

[

Code

of

Practice 8S5304 -Safeguard of Machinery.

Code

of

Practice 8S6854 -Safeguard of Woodworking Machines.

Health and Safety Executive note IND(G) 1(L).

Heallh and safety

Page 1-3

www.DaltonsWadkin.com

[,

[

o

c

D

[

[J

[

1.2

1.3

1.3.1

Health and safety

Supply

of

Machinery (Safety) Regulations 1992

A machine manufactured

in

accordance with the Essential Health

and

Safety

Requirements of

the

Supply of Machinery (Safety) Regulations 1992, complies with the

EC

conformity requirements

and

can

thus have the

CE

mark appended (Harmonised

Standard PREN 12750: 1997) .

These regulations also impose legal requirements

on

both

the

employer

and

the user

of

the machine with regard

to

proper usage, user working conditions, risks of injury and

many more. These requirements are wide ranging,

and

in

some cases specific to only

certain types of machine or process. Some of

the

more general requirements which

apply to woodworking machinery are briefly detailed below.

1

An

employer shall ensure that the equipment

is

constructed/adapted

as

to

be suitable for the purpose that it

is

used.

2

3

In

selecting the equipment, the employer shall have due regard to the

working conditions

and

the risks

to

health

and

safety of persons which

exist

in

the premises

in

which

the

equipment

is

to

be

used.

The employer shall ensure that the equipment

is

used for the operations

for which,

and

under the conditions for which it

is

suitable.

Other requirements include provision of suitable training of users, provision of

suitable documentation (information

and

instructions),

and

declarations of any

specific risks.

Specific Information

Section 4 of this manual -Machine Usage

and

Controls identifies

and

details

general safe working practices

and

specific local practices which should

be

adopted when using the machine.

In

addition

to

this information two hazards,

specific

to

woodworking machinery should

be

considered

in

more detail.

Noise

Noise levels

can

vary widely depending upon the machine

and

the

conditions of

use.

Planing

and

moulding machines produce high noise levels, typically

in

the

region

of95dB

to

115dB when cutting.

The Noise at Work Regulations require that

an

operator

is

not subjected

to

continuous noise levels above 90dB over

an

8 hour period. Thus, some form of

noise protection

is

necessary.

Page 1-4

www.DaltonsWadkin.com

r-

e

[

C

lJ

[ 1.3.2

[;

C

0

C

[

C

~

[

C

Health

and

safety

A machine manufacturer may supply (or provide information) a suitable sound

enclosure. It

is

possible that, given the types of materials available

in

the works

(ie sawmill),a suitable enclosure may

be

produced

on

site.

It should

be

noted however, that even with

an

enclosure, noise levels might still

exceed the 90dB limit (especially at the machine infeed end).

As

a precaution suitable ear protection should be worn

by

all machine

operatives.

Refer

to

use

of

ear defenders in Section 4.1.2

of

this manual.

Dust

Wood dust

can

be harmful to health through inhalation

and

also skin contact.

The Control

of

Substances Hazardous

to

Health Regulations place legal

requirements

on

employers

to

prevent exposure of the user

to

substances

hazardous

to

health or, where prevention

is

not practicable, to adequately control

the

exposure. Adequate control should

be

achieved by measures other than

provision of personal protective equipment.

The Regulations require that airborne dust levels should not exceed 5mgfm3•

Page 1-5

www.DaltonsWadkin.com

[

c

D

o

c

[

c

[

C

c

[

o

Specification

2 MACHINE SPECIFICATION

Machine Details

Model

Dimensi.ons

Services

Capacities and Adjustments

Maximum timber size admitted

Maximum finished work size

Feed speeds

Pneumatic Air Requirement

Motors

Feed motor

Rise and fall motor

Spindle motors

Spindle speed

Note

GD220

Refer to machine Foundation Plan

Refer to the machine Specification

Plate located

on

the machine frame

230mm x 130mm

220mm x 120mm

6 to 22mlmin (standard)

6 bar/0.15m

3/min

2.2kW

0.375kW

5.5kW/7.5kW

6000rev/min (standard)

This unit will operate between

41

& 104 Oeg. F (5 to 40 Oeg. C); upto 3300ft (1000m);

20% to 95% RH (non condensing); and transportation and storage conditions

of

-13

to

131

Oeg. F (-25 to 55 Oeg. C).

Page

2-1

www.DaltonsWadkin.com

[

c

o

D

o

[

C

D

[

-.

.

~

'l

~

"'.

I

3.2

3.3

Installation

3 INSTALLATION

Receipt

of

the t.1achine

Before accepting the machine at its destination check the packages/items against the bill

of loading. Confirm that

all

listed fittings/accessories have been received and carry out a

visual inspection ofthe packages/items for obvious signs of damage.

Report any omissions or damage; note these for any future reference.

Preparation for Installation

Ensure that all the necessary external services are available

ie

electricity, pneumatic air,

etc.,

as

identified

in

Section 2 Machine Specification.

Check also that adequate space is available on the installation site for lifting and

manoeuvring access.

Check that suitable

and

approved lifting equipment

is

available and is of adequate

capacity:

Refer to the Foundation

Plan

for details of the floor area required and for any special

foundations necessary

Ensure that the final location of the machine has

been

levelled.

Lifting and Locating the Machine

Locate lifting slings into the two 'D' lifting points

on

the machine and secure.

Position a steel levelling plate at each machine jacking screw point (refer to the machine

Foundation Plan).

Lift and position the machine

on

the prepared location.

Level the machine (as detailed below) using

an

engineer's level by adjusting the jacking

screws located at each machine foot position.

Levelling longitudinally

With the engineer's level lengthways

on

the table of the machine, adjust the

machine longitudinally by adjusting the jacking screws. Check level at

approximately every 300mm along the machine length. Deviation should not

exceed

O.1mm/m.

Page

3-1

www.DaltonsWadkin.com

[

r:

CJ

[J

G

o 3.4

3.4.1

[:

~

fi

-'

[~

0

[J

G

D

0

[

0

Installation

Levelling transversely

Position the engineer's level across the table (at right angle

to

the fence), and

adjust the machine transversely

by

adjusting the jacking screws. Repeat this

action at points similar

to

the longitudinal checks. Deviation should not exceed

O.1mm/m.

WARNING:

The machine must be firmly bolted down before connecting any services.

Connecting the Services

Electrical Supply

The customer is responsible for

an

electrical supply suitable

to

meet the power

requirements of the machine. These requirements are shown

on

the machine

Specification Plate

on

the machine frame,

and

are also shown

on

the electrical

schematic/connection diagram accompanying the machine.

Electrical connections should

be

made

to

the isolating switch

on

the electrical control

cubicle.

WARNING:

Connection of the supply must be made by a competent and experienced

electrician.

US & Canada -All supply wiring and conduit sizes must be sized

in

accordance

with the NEC (National Electric Code -NPFA 70) and applicable state, county or

jurisdictional codes, or CEC (Canadian Electric Code)

The connection procedure should include, but not

be

limited

to:

Confirm that the supply

is

of

the

correct voltage, phase

and

frequency to that identified

on

the machine SpeCification Plate.

Check that the incoming fuse ratings

can

accommodate

the

full load current shown

machine Specification Plate.

Connect the incoming supply

to

the relevant terminals

on

the

electrical control cubicle

(L

1,

L2

and

L3).

Make a good earth connection

to

the machine.

WARNING:

Before continuing further, refer to Section 4 for advice on safe operation

of

the

machine. Also, ensure that when undertaking any of the following operations all

relevant safety requirements and procedures detailed

in

Section 1 are complied

with.

Page 3-2

www.DaltonsWadkin.com

[

[:

[

o

[

[1

.'

o

c

o

[l

-,

o

[J

c

[

[J

3.4.2

3.4.3

Installation

Close the isolator

on

the electrical control cubicle, and run each spindle

in

turn to ensure

direction

of

rotation is correct:

Bottom horizontal spindles -clockwise when viewed from front.

Top heads -counterclockwise when viewed from front.

Fence side head -counterclockwise when viewed from above.

Near side head -clockwise when viewed from above.

Note:

Incorrect rotation

of

the spindles can be corrected

by

reversing any two

of

the incoming

supply connections

to

the terminals

of

the electrical control cubicle.

WARNING:

Phase changes must

be

made by a competent and experienced electrician.

Pneumatic Air Supply

The customer is responsible for a pneumatic air supply suitable to meet the

requirements

of

the machine as shown on the machine Foundation Plan

(6

bar

O.15

m

3/

min).

The air supply connection

in

the machine base

is

Y-BSP

female.

Check the condition

of

the air connectors, confirm their cleanliness, and make the air

connection.

Dust Extraction

The customer is responsible for the supply and fitting of suitable dust extraction

equipment.

The number and length

of

the flexible connections from the exhaust hood to the machine

should

be

as shown

on

the machine Foundation Plan.

See the machine Foundation Plan for:

Airflow requirements

in

m3/hour.

Cross-sectional dimensions

of

machine extraction connections.

Duct air velocities

in

m/second.

Average pressure drop at machine extraction connections are shown below.

Duct Diameter (mm) Required

Air

Volume

(m3/hour at 30m/sec) Pressure Drop

(Pa)

Page 3-3

www.DaltonsWadkin.com

o

~

o

to

CO

CD

o

CD

~

o

to

~

L...J

www.DaltonsWadkin.com

[

c

[

o

[]

[J

D

[J

o

u

[]

[

4.1

4.1.1

4.1.2

Machine usage and controls

4 MACHINE USAGE AND CONTROLS

Note:

Referalso to Section 1 for information on general statutory requirements when operating

woodworking machinery.

Safe Practices

Safe

and

proper working practices must

be

followed when setting-up

and

operating the

machine. Adequate advice

and

information are readily available

in

the form

of

local

working practices, notices, warnings

and

the inforrnation contained

in

this manual.

IT

IS

THE

OPERATOR'S RESPONSIBILITY

TO

USE

THE MACHINE FOLLOWING

THE PROCEDURES LAID

DOWN

AND ONLY FOR

THE

PURPOSES FOR WHICH IT

WAS DESIGNED.

Pre-operation Checks

All

guards and fences are fitted securely and properly adjusted

to

suit

their

purpose.

Cutter

blocks are

correct

for

the

work

to

be undertaken, are suitable

for

the

spindle

speed, are

securely

fitted and

their

direction

of

rotation

is

correct.

Dust extraction

equipment

is

working correctly.

Machine controls are

functioning

correctly (see Section 4.2).

Adequate

working

space is provided and lighting is available.

All

safety and operating instructions displayed

on

the machine

or

in the

immediate locality have been read and

fully

understood.

Checks During Operation

Proper protective

equipment

is available and employed (goggles, ear defenders,

face mask, etc).

Area around the machine

is

kept clean and free

of

wood

refuse.

Any

machine

malfunction

is

recorded and reported

to

person in authority.

Machine is made

stationary

and electrically isolated before any cleaning

of

work

area

or

ANY adjustments are made

to

the machine

or

ancillary

equipment.

Page

4-1

www.DaltonsWadkin.com

[

[ 4.1.3

[i

[

C

[]

[1

C

0

D

[J

0

[

0

[J

[

C

[

Machine

usage

and

controls

Safety Devices

In

order to avoid injury or accidental damage

to

personnel or equipment, a number of

interlocking features have been incorporated into

the

machine operation. These are:

1 Infeed trip device (1) will trip the operation ofthe machine feed.

The

spindles will

continue

to

run. This trip level

is

set through the height

of

the

beam

setting. (See

Figure 4.1.3).

Before attempting

to

restart the machine electrically isolate the machine.

The

feed must

be

restarted at the control panel after removal ofthe cause

of

the trip.

1

Figure 4.1.3

2 A splinter catching device protects against splinters at the machine infeed (fitted

optionally when the machine

is

specified for splitting use).

3 If the enclosure door is opened during normal operation all spindles

and

feed

rolls stop.

4 With the enclosure open, the machine may be used for setting-up

and

test

purposes only.

5 The machine feed does not operate unless the spindles are running

and

the

enclosure

is

closed.

6 Brakes are fitted

to

all spindles.

Page

4·2

www.DaltonsWadkin.com

[

C 4.2

[ 4.2.1

[

[J

0

C

0

C

[l

C

D

C

D

[

C

Machine

usage

and

controls

Machine Controls

Machine Control Panel

Before using the machine, operators should familiarise themselves with the machine

control panel and other controls.

The machine control panel

is

mounted at the infeed end

of

the machine and consists

of

a number

of

buttons, switches and indicators (see Figure 4.2.1). Depending upon the

model of the machine and special features fitted, the illustration

of

the control panel may

differ slightly from the panel

on

the machine being installed.

Feed Stop/Start (1)

Toggle start/stop button with indicator lamp which controls the operation

of

the feed rolls.

Inch Forward/Reverse (2)

Two buttons and a keyswitch enable the feed to be inched forward or backwards -for

setting-up or other maintenance purposes.

~

Figure 4.2.1

Page 4-3

www.DaltonsWadkin.com

L

[

C

o

c

o

[

o

D

[

Machine

usage

and

controls

Beam Raise/Lower (3)

Two buttons enable the beam to

BE

raised or lowered within predetermined limits.

Similar buttons are also

on

the local control panel located beneath the first top head (see

Figures 4.2.2

and

5.5).

Enclosure Override (4)

Two-position keyswitch which enables the machine drives to operate when the

enclosure is raised -for setting-up and other maintenance purposes.

Emergency Stop (5)

Emergency stop button shuts down machine operation when depressed. Must be

unlocked to reset.

Emergency stop buttons are also located at other

pOints

on

the machine

in

compliance

with Machinery Directive requirements.

Spindle Head Brake Release (6)

Releases the spindle brakes to enable free rotation

of

the spindles for changing cutter

blocks, belts, etc; lamp indication when enabled.

Spindle Start/Stop

(7)

Each spindle has a toggle start/stop button with lamp indicator. These enable spindles to

be

started and stopped independently.

Air Pressure Regulators/Gauges (8)

Sets feed roll pressures.

Other optional controls not shown on Figure 4.2.1, but which can

be

mounted on the

machine control panel include:

Power On/Off

Toggle power on/off button with lamp indicator. Controls power through the control

panel.

Page 4-4

www.DaltonsWadkin.com

Wadkin GD User manual

Popular Industrial Equipment manuals by other brands