KNECHT USK 230 B - HV 208 II Operating Instructions Manual
Operating Instructions
USK 230 B - HV 208 II
Automatic Grinding Machine
Status 10.2019 Version 1.0 | Translation
Operating Instructions
USK 230 B - HV 208 II automatic grinding machine
Manufacturer
KNECHT Maschinenbau GmbH
Witschwender Straße 26
88368 Bergatreute
Germany
Telephone +49 -7527-928-0
Fax +49 -7527-928-32
mail@knecht.eu
www.knecht.eu
Documents for machine operator
Operating Instructions
Date of issue of the operating instructions
October 29, 2019
Copyright
The copyright for these operating instructions as well as other documents for the machine operator is held
by KNECHT Maschinenbau GmbH. They are provided only to customers and operators of our products and
are included with the machine.
These documents may neither be reproduced, nor made accessible to third parties, in particular rival firms,
without our express permission.
3
Table of Contents
1. Important notes 7
1.1 Preface to the operating instructions 7
1.2 Warnings and symbols in the operating instructions 7
1.3 Warning signs and their meaning 8
1.3.1 Warning and prohibitory signs on the grinding machine 8
1.3.2 General mandatory signs 8
1.4 Rating plate and serial number 9
1.5 Figure and position numbers in the operating instructions 9
2. Safety 10
2.1 Basic safety instructions 10
2.1.1 Observe notes in the operating instructions 10
2.1.2 Obligation on the part of the operator 10
2.1.3 Obligation on the part of the personnel 10
2.1.4 Hazards involved in handling the grinding machine 10
2.1.5 Malfunctions 11
2.2 Intended use 11
2.3 Warranty and liability 11
2.4 Safety regulations 12
2.4.1 Organizational measures 12
2.4.2 Protective equipment 12
2.4.3 Informal safety measures 12
2.4.4 Selection and qualification of personnel 12
2.4.5 Machine control system 13
2.4.6 Safety measures in normal operation 13
2.4.7 Hazards due to electrical power sources 13
2.4.8 Particular hazard zones 13
2.4.9 Servicing (maintenance, repair) and fault elimination 13
2.4.10 Structural modifications to the grinding machine 14
2.4.11 Cleaning the machine 14
2.4.12 Oils and greases 14
2.4.13 Relocation of the grinding machine 14
3. Description 15
3.1 Intended use 15
3.2 Technical specifications 15
3.3 Functional description 16
3.4 Description of components 17
3.4.1 USK 230 B control panel 18
3.4.2 Coolant unit 18
3.4.3 HV 208 copy grinding device 19
3.4.4 Switching the copy grinding device on / off 19
3.4.5 HV 208 control panel 20
3.4.6 Layout of user interface (main screen) 21
3.4.7 SP 110 copy grinding plate 22
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Table of Contents
4. Transport 23
4.1 Means of transport 23
4.2 Transport damage 23
4.3 Transport to another installation site 23
5. Installation 24
5.1 Selection of qualified personnel 24
5.2 Installation site 24
5.3 Supply connections 24
5.4 Settings 24
5.5 Initial start-up of the grinding machine 25
6. Commissioning 26
7. Operation 29
7.1 General grinding fundamentals 29
7.2 Switching on the copy grinding device 30
7.3 Grinding the cutter knife 30
7.3. 1 Mounting the copy grinding plate 30
7.3.2 Setting the balance weight 32
7.3.3 Setting the grinding angle 33
7.3.4 Switching on the USK 230 grinding machine 33
7.3.5 Starting the grinding process 33
7.3.6 Canceling the grinding process 35
7.4 Replacing the copy grinding plate 36
7.5 Deburr cutter knife with the finned brush 38
7.6 Grinding hand knives on the wet-grinding belt 39
7.7 Changing the wet-grinding belt 40
7.7.1 Belt adjustment 41
7.8 Replacing the finned brush 42
8. Control 43
8.1 Main screen 43
8.2 Selecting product files 44
8.3 Renaming, creating, and deleting product files 45
8.3.1 Renaming product file 45
8.3.2 Renaming product file 46
8.3.3 Deleting product file 46
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Table of Contents
8.4 Editing product file parameters 47
8.4.1 Meaning of the “Grind” parameter 48
8.4.2 Meaning of the “Feed Cycles” parameter 50
8.5 Machine data 52
8.5.1 Grinding 52
8.5.2 Coolant controls 53
8.5.3 Settings 53
8.6 Language 54
8.7 Setting up an internet connection 55
9. Care and maintenance 56
9.1 Cleaning 56
9.2 Lubrication and maintenance 56
9.2.1 Lubrication schedule and lubricant table 57
10. Malfunctions 58
10.1 Malfunctions 58
11. Disassembly and disposal 59
11.1 Disassembly 59
11.2 Disposal 59
12. Service, spare parts and accessories 60
12.1 Postal address 60
12.2 Service 60
12.3 Spare parts 60
12.4 Accessories 61
12.4.1 Abrasives used, etc. 61
13. Annex 62
13.1 EC Declaration of Conformity 62
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1. Important notes
1.1 Preface to the operating instructions
These operating instructions are intended to make it easier to get to know the automatic 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 machine safely, properly and cost-effectively. Observance of these instructions helps to avoid hazards,
avoid repair expenses and downtimes, and to increase the reliability as well as 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
• Upkeep (maintenance, repair).
In addition to the operating instructions and the binding accident prevention regulations applicable in the country and place of use of the machine, the generally acknowledged rules of technology 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 a work safety
indicator for all work for which there is a risk of serious or fatal injury.
Special care and caution must be exercised when carrying out such work.
CAUTION
”ATTENTION” is used to draw attention to particular points in order to
ATTENTION
NOTICE
avoid damage to and / or destruction of the grinding machine and its
environment.
”NOTICE” refers to user tips and especially useful information.
7
1. Important notes
1.3 Warning signs and their meaning
1.3.1 Warning and prohibitory signs on the grinding machine
The following warning and prohibitory signs are located on / in the grinding machine:
CAUTION! DANGEROUS ELECTRICAL VOLTAGE
(warning notice on the rear panel)
On being connected to the current supply (3x 400 V), the grinding
machine becomes electrically live and touching its live parts directly
could be life-threatening.
Current-carrying device parts may only be opened by authorized
personnel.
The grinding machine must be separated from the mains supply
before carrying out servicing, maintenance and repair work on it.
CAUTION! RISK OF INJURY FROM ABRASIVE PARTICLES
(mandatory sign on the front plate)
Grinding, polishing and deburring gives rise to grinding particles
which could enter the eyes.
Wearing protective goggles is mandatory when carrying out such
work.
1.3.2 General mandatory signs
The following general mandatory signs must be followed:
CAUTION! RISK OF INJURY FROM KNIFE
Working with the grinding machine involves grinding knives that
could cause serious cut injuries due to their sharpness.
Protective gloves must be worn when clamping and releasing
knives.
Caution when transporting blades. Use the protective equipment
provided by the knife manufacturer. Wear safety shoes and safety
apron.
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1. Important notes
1.4 Rating plate and serial number
The rating plate is located on the rear panel of the
grinding machine.
Figure 1-1 Rating plate
The machine serial number is located on the rating
plate and on the back and right on the base plate
of the belt protection hood.
Figure 1-2 Machine serial number
1.5 Figure and position numbers in the operating instructions
If there is a reference to a machine component in the text which is depicted in an image, the
figure and item number will be given in parentheses.
Example: (7-4/1) means Figure number 7-4, item 1.
Place knife (7-4/1) on the mounting for the copy grinding
plate and turn latch (7-4/2) onto knife.
2
Figure 7-4 Clamping the knife
1
9
2. Safety
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 rules and regulations regarding accident prevention at the place of use are to be
observed.
2.1.2 Obligation on the part of the operator
The operator is obliged to allow only those persons to work on the grinding machine, who
• are familiar with the occupational safety and accident prevention regulations and have received
instruction in handling the grinding machine,
• have read and understood the operating instructions, in particular the section entitled “Safety”
and the warning notes, and have provided signed confirmation of this.
The safety-related work of personnel will be monitored at regular intervals.
2.1.3 Obligation on the part of the personnel
All personnel working on the grinding machine shall be obliged, before starting work, to
• observe basic occupational safety and accident prevention regulations,
• read the operating instructions, particularly the section entitled “Safety” and the warning notes,
and provide signed confirmation of this.
2.1.4 Hazards involved in handling the grinding machine
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The grinding machine has been built to the latest technological standards and the acknowledged
rules of technical safety. In spite of this, its use poses inherent risks which could result in bodily
harm or even death of the user or third persons, or impairment of the grinding machine or other
property.
The grinding machine may be used only:
• for its intended purpose
• in faultless condition with regard to safety-related aspects.
Malfunctions that may impair safety are to be rectified immediately.
2. Safety
2.1.5 Malfunctions
If safety-relevant malfunctions occur with the grinding machine, or if the processing behavior
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 authorized trained personnel to eliminate the malfunctions.
2.2 Intended use
The grinding machine can be used universally for all standard cutter knives, as well as circular
knives, hand knives, and other cutting tools.
Other than hand knives (e.g. carving knives), all the knives must be clamped to suitable grinding
plates. Before starting work on a flat knife, first check that the knife fits onto the grinding plate.
Only then may the knife be clamped onto the grinding plate.
Any other use is considered to be improper. The company KNECHT Maschinenbau GmbH is not
liable for any damage arising from this. The user alone bears this risk.
Use as intended includes the observance of all the notes in the operating instructions.
The grinding machine is being used improperly if, for example:
• flat knives are ground without using the grinding plate.
• fixtures are not properly attached.
• knives are sharpened / polished in the opposite direction of the cutting edge on the wet-grinding
belt or the finned brush.
2.3 Warranty and liability
Warranty and liability claims in case of personal injury 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 using improperly attached or
malfunctioning safety and protective equipment,
• failure to observe the instructions with regard to transportation, commissioning, operation,
maintenance and repair of the grinding machine,
• unauthorized structural alterations to the grinding machine,
• unauthorized modification, e.g. of the drive conditions (output and speed), and
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2. Safety
• failure to monitor machine parts that are subject to wear, and
• use of unapproved replacement and wear parts.
Use only original replacement and wear parts. When using external parts, it cannot be guaranteed
that they are constructed and manufactured to be suitable and safe.
2.4 Safety regulations
2.4.1 Organizational measures
Inspect all available safety devices regularly.
Observe prescribed intervals for recurring maintenance work or as specified in the operating
instructions!
2.4.2 Protective equipment
Before commissioning the grinding machine, ensure that all protective equipment is properly
mounted and in functional condition.
Protective equipment may be removed only after the grinding machine has stopped and has been
secured against accidental restart.
When subcomponents are provided, the protective equipment must be attached by the operator
as stipulated.
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 safety alert symbols and danger warnings on the grinding machine must be complete and
clearly legible.
2.4.4 Selection and qualification of personnel
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Only trained and instructed personnel may work on the grinding machine. Observe the legally
permitted minimum age!
The responsibilities of personnel with respect to commissioning, operation, maintenance, and
repair must be clearly specified.
Personnel still undergoing training or instruction may only work on the grinding machine under
the permanent supervision of an experienced person!
2. Safety
2.4.5 Machine control system
Only trained and instructed personnel are permitted to activate the machine.
2.4.6 Safety measures in normal operation
Do not operate the machine in any unsafe manner. 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 present (including those of the operating behavior) to the responsible office
or person. If necessary, shut down the grinding machine and secure it against restart.
Before activating the grinding machine, ensure that no one will be injured by the start-up of the
machine.
In the event of a malfunction, immediately stop the grinding machine and secure it against
restart. Rectify malfunctions immediately.
2.4.7 Hazards due to electrical power sources
Work on electrical systems or operating materials may only be performed by a qualified
electrician, in accordance with electrical regulations.
Defects, such as damaged cables, cable connections etc. must be immediately rectified by an
authorized specialist.
2.4.8 Particular hazard zones
In the area around the wet-grinding belt and finned brush, clothing, fingers, and hair may be
pinched and drawn in; exercise caution. Wear suitable personal protective equipment.
2.4.9 Servicing (maintenance, repair) and fault elimination
Maintenance work is to be carried out on schedule by trained personnel. Inform operating
personnel before beginning repair work. Designate a supervisor responsible for this.
For all upkeep work, the grinding machine is to be disconnected from the power supply and
secured against accidental restart. Remove power plug. Cordon off the maintenance area where
required.
After completing maintenance work and fault rectification, install all safety devices and verify that
they are fully functional.
13
2. Safety
2.4.10 Structural modifications to the grinding machine
Modifications to or retrofits or rebuilds of the grinding machine are not allowed without the permission of the manufacturer. This also applies for installation and configuring the safety devices.
Any conversion work requires the written permission from KNECHT Maschinenbau GmbH.
Immediately replace any machine parts that are not in a serviceable state.
Use only original replacement and wear parts. When using external parts, it cannot be guaranteed
that they are constructed and manufactured to be suitable and safe.
2.4.11 Cleaning the machine
Handle any cleaning agents and materials used properly and dispose of them in an environmentally-friendly manner.
Dispose of parts subject to wear and replacement parts in a safe and environmentally-friendly
manner.
2.4.12 Oils and greases
When using lubricants and grease, follow the safety provisions applicable to the product. Comply
with the special regulations for the foodstuffs sector.
2.4.13 Relocation of the grinding machine
Disconnect the grinding machine from any external power, even if adjusting its position slightly.
Before restarting the grinding machine, properly connect it to the power supply.
When loading or unloading, only use suspension devices and load suspension devices with sufficient load-bearing capacity. Designate suitable lifting devices for the lifting process.
Ensure that no one, who is not certified for this work, is located where the machine is unloaded
and installed.
Only lift the grinding machine correctly with a suspension device in accordance with the operating
instructions (attachment points for load suspension devices, etc.). Use only a suitable transport
vehicle with sufficient carrying capacity. Secure loads safely. Use suitable attachment points. When
recommissioning, do so only in accordance with the operating instructions.
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3. Description
3.1 Intended use
The USK 230 B - HV 208 II automatic grinding machine is used for grinding, deburring, and
polishing all standard cutter knives as well as hand knives and other cutting tools.
3.2 Technical specifications
Height ������������������������������������������������������������������� 1361 mm
Width �������������������������������������������������������������������� 1800 mm
Depth �������������������������������������������������������������������� 1943 mm
Space requirement (WxDxH) �������������������������������������� 2800 x 2800 x 200 mm
Weight (USK 230 B) ����������������������������������������������������������� 140 kg
Weight (HV 208) �������������������������������������������������������������� 170 kg
Current supply* ������������������������������������������������������������ 3x 400 V
Mains frequency* �������������������������������������������������������������� 50 Hz
Output (USK 230 B)* ���������������������������������������������������������� 2.6 kW
Output (HV 208)* ����������������������������������������������������������� 0.18 kW
Power consumption (USK 230 B)* ����������������������������������������������� 3.2 kW
Power consumption (HV 208)* ������������������������������������������������ 0.35 kW
Current consumption (USK 230 B)* ����������������������������������������������� 5.8 A
Current consumption (HV 208)* ������������������������������������������������� 0.5 A
Back-up fuse (USK 230 B) �������������������������������������������������������� 16 A
Back-up fuse (HV 208) ����������������������������������������������������������� 10 A
Measured A-weighted emission sound pressure level ���������������������� approx. 80 dB (A)
at workstation LpA**
Compressed air connection ������������������������������������������������������ 6 bar
Air consumption ������������������������������������������������������������ 50 l / min
Idle noise level of the wet-grinding belt ����������������������������������������� 80 dB (A)
Operating noise level of the wet-grinding belt ����������������������������������� 84 dB (A)
Operating noise level of the finned brush ��������������������������������������� 86 dB (A)
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1361
3. Description
*) This information may change depending on the electrical power supply.
**) Two-digit sound emission value according to EN ISO 4871 (measurement uncertainty KpA. 3 dB(A)).
Emission sound pressure level according to EN ISO 11201.
A K 24 cutter knife from KNECHT Maschinenbau GmbH was ground.
1943
Figure 3-1 Dimensions in mm
3.3 Functional description
The automatic grinding machine can be used to grind, deburr, and polish linear, sickle-shaped,
and circular knives.
1800
CoG CoG
All knives other than hand knives must be clamped onto grinding plates and ground on the
wet-grinding belt with the respective attachments.
The grinding angle is set continuously between 5° and 35° on the copy grinding device.
Knives are deburred and polished on the finned brushes without attachments.
16
3. Description
3.4 Description of components
1
2
3
7
8
4
5
6
Figure 3-2 Overall view of automatic grinding machine
1 Work light
2 Control panel for USK 230 B
3 Finned brush
4 Water tray
5 Water tank
6 Machine feet
7 Control panel for HV 208 copy grinding device
8 Wet-grinding belt
9 Toolbox
9
17
3. Description
3.4.1 USK 230 B control panel
1 2
Figure 3-3 Control panel
3.4.2 Coolant unit
1 Wet-grinding belt ON / OFF
2 Coolant pump ON / OFF
1
2
Figure 3-4 Coolant unit
1
1 Coolant pump
2 Water tank
The grinding machine has a flow gauge (3-5/1)
which automatically interrupts the program flow if
there is no coolant flow.
The flow gauge is located on the top side of the
machine and must be cleaned regularly.
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Figure 3-5 Flow gauge
3. Description
3.4.3 HV 208 copy grinding device
1
2
1 Locking lever
2 Balance weight
3
3 Handwheel to set grinding angle
Figure 3-6 HV 208 copy grinding device
3.4.4 Switching the copy grinding device on / off
The main switch (3-7/1) is located on the left side
of the copy grinding device.
Turning the main switch from “0” to “I” switches
on the copy grinding device.
1
Figure 3-7 Copy grinding device main switch
Turning the main switch from “I” to “0” switches
off the copy grinding device.
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3. Description
3.4.5 HV 208 control panel
1 2
Figure 3-8 Control panel
1 Touch panel
2 “Emergency off” button
3 “Control ON” button: Activates controls (when button flashing)
4 “Start / Stop” button: Starts grinding program
5 “Change copy plate” button: manually runs the copy grinding plate
6 “Knife feed forward” button: Drive knife up to wet-grinding belt
7 “Knife feed back” button: Drive knife back from wet-grinding belt
8 “Manual / Automatic” selector switch
876543
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