Double motor belt grinding machine
SDBC 400/2-MV-F 2
Overhead lamps Electric cabinet LED lamps Belt arms Motors Pedestal Stop pedals Pic. 1 SDBC 400/2-MV-F 3
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MACHINE DESCRIPTION 6 GENERAL FEATURES 6 PROTECTION DEVICES 6 MATERIALS 7 MACHINE INSTALLATION 8 LIFTING INSTRUCTIONS 8 INSTALLATION 8 ELECTRICAL CONNECTION 8 CONNECTION TO THE DUST EXTRACTOR 8 CONNECTION OF THE PNEUMATIC SYSTEM 8 LAMPS 9 SAFETY RULES 9 USER S CLOTHES 9 ACCESS TO THE MACHINE AND TO THE WORKING AREA 9 CLEANING OF THE WORKING AREA 9 FORBIDDEN PROCESSES 10 USE AND SERVICE 11 TOOLS 11 MACHINE CLEANING 11 CONTACT WHEEL INSTALLATION 11 ELECTROMAGNETIC DISC BRAKING 12 BRAKING TORQUE SETTING 12 PNEUMATIC BELT ARM 13 BELT INSTALLATION 13 BELT ALIGNMENT 13 CONTROLS 14 MOTOR START 14 SPEED ADJUSTMENT 14 STOP 14 LAMPS 15 DOOR INTERLOCKS 16 SAFETY RELAY 20 ELECTRICALS 22 SDBC 400/2-MV-F 5
MACHINE DESCRIPTION GENERAL FEATURES The SDBC 400/2 Mv F belt grinding machine is engineered for manual grinding operations of metal parts. This machine can only use abrasive belts on contact wheel. The use of any other tool is forbidden. These are the components of the machine: pedestal 2 self braking motors 2 pneumatic belt arms electric cabinet with 24V control panel and e stop foot pedals lamps This machine is engineered to be used by two operators Table 1: technical data MOD. SDBC 400/2 MV F POWER SUPPLY 3P + T 400 V 50 Hz MOTOR RATING [KW] 3+3 SPEED [RPM] from 0 to 3000 IP 54 THERMAL CLASS F PROTECTION DEVICES The machine is equipped with safety devices needed to ensure the safety of the operator. These devices must not be removed or deactivated for any reason o o o Self braking motors: the electric motors installed on the SDBC belt grinders are equipped with an intrinsic safety electromagnetic brake. This item guarantees smooth and effective decelerations. While there s no power supply, the brake keeps the shaft locked. The brake will step in only in case of emergency stop. The standard stop procedure involves a smooth deceleration driven by the inverter. Protection/extraction guards: they absolve the functions of mechanical protection of the rotating tool and the one of piping the dust produced during the work. Equipped with extraction pipes, they must be connected to a dust exhauster according to the quantity and quality of the dust. The closing of the guards is assured by the safety position switch with locked engagement (ABB TLS GD2), controlled by the safety relay (PNOZ X1 by Pilz) and by a timer. Safety circuit: the machine has its own separate safety circuit. Two big emergency stop buttons on each motor, one on the control panel and the foot pedals are able to activate the emergency braking of the motors. o Electric equipment: in compliance with the norm UNI EN 60204 1. o Pneumatic valve: it s fitted inside the belt protection guard, so it can t be switched when the machine is running. SDBC 400/2-MV-F 6
IMPORTANT: NEVER REMOVE THE PROTECTION GUARDS. THEY MUST ALWAYS GUARANTEE THE MECHANICAL PROTECTION AND THE CONVOYMENT OF THE DUST PRODUCED BY THE WORK. M ATERIALS The machine is engineered for surface finishing of metallic components. IMPORTANT This machine is not suitable to process aluminum alloy with magnesium. Can t be used in ATEX environments. SDBC 400/2-MV-F 7
L IFTING INSTRUCTIONS MACHINE INSTALLATION Before moving the machine, make sure that the hoist has an adequate capacity to guarantee the moving in absolute safety. Use n 2 lifting band of adequate capacity. The length must be about 2m. Place them around the motors. Be careful while moving. Machine weight: 700 kg INSTALLATION The machine must be bolted to the floor. Use the 4 holes on the base of the machine. E LECTRICAL CONNECTION Check if the power supply is in compliance with the machine specifications: 3 phase + ground, 400V 50Hz. Connect the machine to the power supply as per the schematics at the end of the manual. Check the rotation sense: it must follow the arrow printed on the motor and on the front of the machine. The wheels will move from the top to the bottom in front view. If the rotation sense is wrong, swap 2 of the 3 phase of the power supply. IMPORTANT The use of the machine with a wrong rotation sense is extremely dangerous. Never run the machine with the wrong rotation sense. C ONNECTION TO THE DUST EXTRACTOR The machine has got 2 extraction pipes ø120 mm. The first one is below the contact wheel, the second one on the back of the belt guard. Both pipes must be connected to a proper dust extractor, using flexible pipes. We suggest to use a dust extractor able to guarantee a capacity of at least 700 m3/h for each pipe. C ONNECTION OF THE PNEUMATIC SYSTEM Connect the machine to the air source through the air inlet placed on the back of the machine. Use a ø8 mm pipe. Pic. 2 SDBC 400/2-MV-F 8
L AMPS The machine is supplied with two overhead fluorescent lamps and two LED lamps with adjustable arm. They are already connected to the machine electric cabinet. There is a main lamp switch on the electric cabinet. Once the overhead lamps are on, the two LED lamps can be turned on or off independently. SAFETY RULES This machine can be dangerous if used under improper circumstances. Read the following notes and observe them during the work. o o o o o o o o Keep the machine and the work area neat, clean and orderly. Keep all the machine guards in place. Do not touch rotating parts. Ensure you know how to stop the machine before starting it. Do not operate the machine in excess of its rated capacity. Do not wear rings, watches, ties or loose sleeved clothing. Wear adequate safety protections equipment (glasses, gloves ) Stop the machine immediately anything unexpected happens. The operators must stand in front of the contact wheels. They must be able to reach easily the e stop foot pedals and the control panel. The operator should keep the part to be processed firmly with both hands, be careful not to touch the rotating parts of the machine. U SER S CLOTHES The clothes of the user must be in compliance to the essential safety requirements in force in the country. In general the user must wear accident prevention shoes. For service operations in zone characterized by heat emission, use fire proof gloves. The user during the work must wear gloves and protection glasses. A CCESS TO THE MACHINE AND TO THE WORKING AREA The working area cannot be enclosed by stairs, truck or others accessories that limit the mobility. The access to the working area must be forbid to persons not assigned to the work. C LEANING OF THE WORKING AREA The working area must be cleaned in order to guarantee to the operator the possibility to move around the machine in safety conditions. The area must not have oil spots, grease or other liquid, and it hasn t to be obstructed by various materials. SDBC 400/2-MV-F 9
F ORBIDDEN PROCESSES IT S FORBBIDDEN THE USE OF THE MACHINE FOR FINISHING OF CORNICES OR OBJECTS WITH ASPERITY OR HOOKING POINTS THAT COULD BE DRAGGED DURING THE ROTATION, INVOLVING SERIOUS DANGER FOR THE OPERATOR. Inner finishing operations of closed surfaces like rings, cornices, flanges must be done using portable machines tools, hand hold and with the piece hardly kept by suitable fixing equipment. IMPORTANT IT S SEVERELY FORBIDDEN TO REMOVE THE PROTECTION GUARDS. SDBC 400/2-MV-F 10
T OOLS The machine can use the following consumables: Abrasive belts: length 2500 mm, width up to 80 mm Contact wheels: ø250 mm, width up to 80 mm USE AND SERVICE M ACHINE CLEANING A periodic cleaning of the machine is important to guarantee a correct and long lasting work. It s very important to remove the dust accumulated on the area below the protecting covers and inside the tension pulleys, as they may become unbalanced. C ONTACT WHEEL INSTALLATION This is the procedure to install/replace the contact wheel: 1. Turn off the machine (main switch off). 2. Open the door of the protection guard, releasing the top and bottom latches. 3. Remove the safety bolt and the bronze locking nut. 4. Install the contact wheel on the shaft. Use spacers in order to keep the wheel centered in the protection guard. 5. Lock the wheel with the bronze nut, and secure it while keeping the shaft locked using the supplied spanners. Install the safety bolt at the end of the shaft. Close the door of the protection guard and adjust the side protections and the top flap. They must always be as close as possible to the wheel, to clear any fingerpoint. Top flap Wheel Side protections Pic. 3 SDBC 400/2-MV-F 11
E LECTROMAGNETIC DISC BRAKING This brake is engineered to ensure, at rest, the intrinsic safety. When the electromagnet (1) is excited, the armature plate (2) is attracted to the electromagnet thanks to the springs (3). In this way he disc (4), coupled with the shaft thanks to the splined hub, can rotate freely. When there s no tension, the springs pull the armature plate against the disc, braking the shaft. BRAKING TORQUE SETTING The K7 brake that equips the SDBC 400/2 MV F machine can be adjusted according to the braking torque, the load, the speed and the braking time. It s possible to adjust the braking changing the distance between the electromagnet and the adjuster ring. Adjust the braking torque according to the following table, which shows the braking torque in relation to the distance from the electromagnet to the adjuster ring. DISTANCE BETWEEN ELECTROMAGNET AND ADJUSTER RING [mm] 6 5 4 3 2 1 Table 2 BRAKING TORQUE [Nm] 11 23 34 43 57 68 According to pic. 4, follow these instructions: o Switch off the machine o Gain access to the brake room o Rotate the adjuster ring to change the distance Pic. 4 SDBC 400/2-MV-F 12
PNEUMATIC BELT ARM BELT INSTALLATION Turn off the machine Once the interlock is unlocked, release the two latches and open the belt guard. Install the belt on the contact wheel and on the tension pulley. Tension the belt using the lever of the pneumatic valve, which can be reached only inside the guard. If necessary adjust the pressure using the F.R.L. installed on the machine. Close the door guard and proceed with the alignment. We suggest to keep the pressure at 2 bar. Higher pressures could damage the belt stretcher and could be dangerous. Interlock BELT ALIGNMENT Make sure that the belt door is closed and the belt is correctly installed and tensioned. Start the machine at 300 rpm. The belt should be centered on the contact wheel. If it s not, slowly rotate the alignment knob until the belt reaches the correct position. Alignment lever Pic. 5 Valve lever Pic. 6 SDBC 400/2-MV-F 13
C ONTROLS MOTOR START Rotate the main isolator switch on the control panel in position I: the power lamp on the control panel will light. Press the reset blue button (D) of the motor that needs to be started: the brake is released and door interlock locked. It s not possible to activate the ready to start mode if the emergencies are not cleared or if the wheel guard is open. Check if the wheel is free to rotate without any interference. Press the green button (A) to start the motor. SPEED ADJUSTMENT Use the buttons arrow up and arrow down (C) to adjust the rotational speed of the motor. It can be set from 0 to 3000 rpm. The speed value can be read on the display on the control panel (F). STOP Press the red stop button (B) on the control panel: the motor drive will slow down the motor smoothly. It s possible to restart the motor pressing the green button again. The last used speed will be reached and the safety system will remain engaged (brake released and interlock engaged). The machine is equipped with different e stops which act in a different way: Red mushroom button on the control panel (E): it stops the 2 motors, engaging the brakes and deactivating both safety circuits. Stop pedals: both of them will stop stops the 2 motors, engaging the brakes and deactivating both safety circuits. Big mushroom buttons on the motors: each one will act only on its motor, engaging the brake and releasing the safety circuit on one side of the machine only. Pic. 7 SDBC 400/2-MV-F 14
L AMPS Overhead lamps specifications: 2x58W neon tubes per each lamp Philips colour 84 To turn on and off the lamps use the switch on the electric cabinet. It s possible to adjust the lamps both in horizontal and vertical way: Simply unlock the screws A or B and adjust the lamps in the desired position. Then lock the screws again. Mind the heavy weight for the vertical adjustment! Pic. 8 Pic. 9 SDBC 400/2-MV-F 15
D OOR INTERLOCKS SDBC 400/2-MV-F 16
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S AFETY RELAY SDBC 400/2-MV-F 20
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E LECTRICALS SDBC 400/2-MV-F 22
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CICLOPE S.r.l. Via degli Abeti 48/50 20064 Gorgonzola (Milan) Italy Tel: +39 029513676 Fax: +39 029510579 www.ciclopesrl.com info@ciclopesrl.com SDBC 400/2-MV-F 30