SURFACE GRINDERS - INSTRUCTION MANUAL REVISION 0 PFG- 2550AH/AHR C3060AH/AHR 4080AH/AHR MANUFACTURED DATE: SERIAL NO:TABLE OF CONTENTS Preface ... Dimension Drawing Part A. Installation Instruction .. 1.Selection of Location 2.Diagram of Minimum Space for Machine . 3.Foundation . 4. Unpacking §.Carriage . 6.Remove the Setting Plates _ 7.Clean the Machine 8.Leveling ....... 9.Placement of Hydraulic System . 10. Installation of Coolant System 11. Installation of Electromagnetic Chuck 12. Installation of Dust Suction Device 13.Connection of Power Line . Part B. Operation Instruction ... 1.General Safety Regulation ... 2.Construction Identification and Function Introduction . Construction Identification Capacity of Machine ..., Allowable Machining Load of Machine . Traveling Direction .... Panel Location Diagram and Function . Grinding Wheel Selection and Mounting . Cross Movement of Saddle ... Longitudinal Wovenent of Table Vertical Movement of Wheel Head .. 0 Automatic Denagnetization .. 1 Chuck before Grinding Operation . 2 Operation Testing ... 3 General Operation Mode a1 2-2 23 2-4 2-5 oe 2-7 28 2-9 21 1 2-1 2-13.Maintenance 3-1 Cautions . 3-2 Lubrication : 34 34 ‘3 Maintenance of Hydraulic System B-37 4 Cleaning of Coolant System and Dust Suction System B-38 4.Trouble Shooting ... B-39 5.Warning Indicator Specification . B-45 Part C. Electric Diagram and Parts List ... 1.The Difference Table of All Machine Model 2. Installation Instruction and Drawing 3.Circuit Diagram .. 4.Material Partlist Part D. Complete Drawing and Parts List ContentsPREFACE, This instruction manual is used for the safe operation and maintenance of the Precision Surface Grinding Machine made by PERFECT Machinery Co. This instructions manual should be kept close to the machine or the place the operators can easily access to it. The operators should be well trained so that safe operation and maintenance can be assured. This machine is designed completely abide by the rules regulated in the EC Machinery Directive (98/371/EEC) and other recommendations mentioned in the relative EN harmonic standards. Therefore, it is very important to be carefully in using of the machine for the purpose of ensuring security. Proper management and training based on the instruction for safety operation is important and should be completely followed for avoidance of operators being injured. In case of accident, the reasons should be analyzed to prevent similar accidents from happening again in the future. Do not modify electrical circuits, machine, electrical components and machine parts without being authorized by our company. Our company shall bear no liability for any hazard, properties loss, and personnel injury in case of arbitrary modification. All the figures and diagrams in this instructions manual provided most up to date information related to the type of machine the client bought. On receiving the machine, customers are required to make sure the model number on the cover of instructions manual is same as the machine one bought. In the condition of proper usage and maintenance, PERFECT Machinery Co. warrantees one-year after-service for new machines failure under the normal working condition. If the damage of the machine is due to improper operation or maintenance or other natural or man made disaster, then this warranty should be excluded. Please check all the parts and accessories according to the packing list when you receive the machine. Do not hesitate to contact our local dealers or headquarters of PERFECT Machinery Co. in Taiwan. If there is any complaint or service requirement, please directly contact our local distributorsDIMENSION DRAWING MODEL | __ PFG-2550 PFG-C3060 PFG-4080 A | 88%" 250mm) | 100%" (2550nm) 117%" (29800m) B 57°(1450mm) | 65"(1650mm)_| 76%" (1950an) C__[ 69%" 770mm) | 70"1780mm)_| 74%" 1900am) D__| 19%" 490mm) | 19%" (600mm) | 21%" 550mm) E 2” GOmm) 3%" (B0mm) | _ 3%" (95mm) F T C80nn) 14°(355nm) | 14” (355mm) ¢ 3am) 1%" 38am) _| 2° G0. 8nn) E 9%" (250mm) | 11%" (300mm) | 15%” 400mm) 1 6%" 170mm) 9” (230mm) 9X" 235mm) I 6%" (55mm) | 6%" 170mm) | 103” (265mm) K__| 11%" 300mm) [ 14x" Gt5mm) | 20%" (520mm) L 4" 5mm) 4" 5mm) % G5mm) —2-A. INSTALLATION INSTRUCTION1.SELECTION OF LOCATION To upgrade the operation efficiency and accuracy of precision machine, a proper foundation is required. It is recommended to locate precision grinding machine in a plant with permanent temperature (about 20°C) and without the influence of damping, chemical gas or trembling. The machine body is not allowed to be exposed to sunshine or rains. Precision grinding machine shall not be adjacent to machines such as planing machine, milling machine, molding or punching machine. Otherwise, it will result in poor grinding accuracy. A distance of at lest 500mm is required from machine to wall and objects or between machines to ensure easy reparation, cleaning and maintenance of machine as well as easy opening of the door of electric cabinet. (refer to figure | and 2) 2.DIAGRAM OF MINIMUM SPACE FOR MACHINE: UNITS: am MODEL A B Height PFG-2550AH 3250 2400 2000 PFG-C3060AH 3550 2550 2060 PEG-4080AH 3980 2900 2150 | A-L3. FOUNDATION (a) With special torque-resistant capability at the base, this machine requires no particular foundation. Only provide 15cm thick of concrete on the floor and leave space for components adjustment for leveling. (Rerfer to.Figure 3 and 4) for foundation diagram. 200, ro r cq Oo] L i ~ “ i AP 4 1 | t i “HF 7. 7 Tt B Figre 3 UNITS: mm MODEL A B PRG-2550 885 730, Refer to Figure 3 UNITS :mn MODEL A B c D PEG-C3060_ 397 585, 590 700 PRG-4080 465 710 930 Refer to Figure 4 A-3Note: Do not use wood foundation since its nature is unstable so that the machine may move gradually. Install the machine on the first or second floor. Take the stress of ceiling and foundation into careful consideration to see if machine load can be set safely. ~ — (b) Use the anchor bolts. Lock the anchor on the machine by nuts, and let the thread portion at least 30mm for adjust. Lay down the machine slowly to aim anchor bolts at foundation holes. Leveling the machine by taper block. Fill up foundation holes with concrete. (Refer to Figure 5) With M12_bait- UNPACKING ~ Remove first the top cover of wooden case and then the plates on four sides. (as shown in figure 6) Carefully take out fittings at first, if necessary. Remove the set screws used for holding the machine on the base. (as shown in figure 7) Cautions: (1) Be careful of the nails and burrs on the dismantled plates. (2) Wear gloves while dismantling the case. SIDE PLATE] OOD BASE Figure 6 3 BS Figure 7 As35. CARRIAGE 5-1 LIFTING Use following equipment to lift the machine. UNITS: kgs MODEL Weight PFG-2550. 1350 PFG-C3060 1700 PRG-4080 2300 (1) Grane:4 Tons Capacity (2) Wire cable: $ 16mm 2000amx4 (3) Sling bolt:4 pes First fasten the sling bolts on the machine base then set the wire cables on the sling blots and the hook, as figure 8. RCaution For Lifting: (1) Lift the machine with the slowest speed of crane. (2) Maintain machine balance during lifting. Lay down the machine carefully and slowly to the desired location to prevent effect in precision. (3) Protect the machine with soft cloth or hard paper board at the places the wire cables may touch. (4) Prevent wire cables from contacting the saddle so as not to damage the saddle guide ways. (5) During lifting, nobody is allowed to stand beneath machine. Keep persons away from the dangerous range at least two meters. 5-2 CARRIAGE BY FORK LIFT AND ROLLING BAR (AS SHOWN IN FIGURE 9) Use fork lift with safety load more than 4 tons or rolling bars to transport the machine to the final location in case of lack of a crane. In this event, it is not necessary to remove the base packing plate. (1) During carriage by fork lift, lift the machine from back. Be careful and move it slowly while laying down the machine to avoid bad effects on mechanical precision. (2) When transporting the machine with rollers one has to make sure that no violent shock on the machine is allowed. Lay down the machine carefully and slowly to table or saddle guide ways, bearing and rollers. Do not apply any pressure on the saddle. AT6 Grcenter of gravity dicbout 450mm Dios smal os possible Figre 9 CAUTIONS: (1) During carriage, always keep balance of gravity center of prevent machine from tilting. (2) In case of using fork lift, let the gravity center of machine tilt backwards. (3) In case of using rollers, make sure the delivery path is flat enough prior to carriage. (4) Fork lift should be operated by a qualified person.5-3 LAY DOWN THE MACHINE Before laying down the machine, fix the adjusting screws on the base (refer to Figure 10), make the machine as close as possible to the floor, and position the leveling pads in place(refer to Figure 3 and 4 in page A-3) so as to increase the stability of machine. In the event of transporting a machine by fork lift or rollers, remove the set screws which secure machine on wooden base before laying down the machine (refer to Figure 7 in page A-5). 1. Leveling screw 2. Nut 3. Leveling pad Figure 10 A-96.REMOVE THE ANCHOR PLATES When the machine is positioned and no need to change location again, remove the Anchor plates. (Refer to drawing) Note:(1) Properly preserve the removed Anchor plates which may be used again when the machine requires carriage in the future. However, if the plates are lost, it is recommended to contact local distributor or our company for purchase or manufacturing in your country. (2) Do not force the front/rear or left/right hand-wheels to revolve before Anchor plates are removed. do, 7.CLEAN THE MACHINE All the machine are provided with anti-rust treatment. The moving parts are lubricated with grease and fixture points and dye lack portions are applied with anti-rust oil. Use a soft cloth with kerosene to clean the parts surface covered by anti-rust oil. If the grease on the parts is fouled, use soft cloth to.clean these parts and apply new clean grease again. A-10co Aims sie ns co FOR C3060 8. LEVELING Use following tools to adjust machine leveling: (1) Two precision spirit levels(spec:0.2nm/100nm or 0.001in /4ft) (2) Two open-end wrenches Firstly clean the table. Set one spirit level at the longitudinal direction and the other at cross of the table.(as shown in Figure 11)If only one spirit level is available, move the level from one direction to the other. repeatedly to check the level of machine. f weve Figure 11 Leveling procedures(with reference to Fig.10 in page A-9):Loosen setting nut. Turn and adjust the four adjusting bolts till leveling is indicated by the spirit levelers. Secure the adjusting bolts. Tighten setting nut. Inspect leveling again using spirit levelers. Note: For a new machine, it is necessary for weekly leveling. When the foundation is proved to be steady, perform leveling every six months instead. A-ll9. PLACEMENT OF HYDRAULIC SYSTEM Connect the circuit of hydraulic motor to the electric box Note: About weight of the hydraulic tank, all serial with full oi] refer to the following. Be careful of lifting. UNITS: kg MODEL Weight PRG-2550 180 PRG-C3060 180. PRG-4080 230 9-1 FILL HYDRAULIC OIL In order to ensure trouble-free operation, hydraulic system should be supplied with correct oil. Please refer to the following for the qualified oil information. BRAND, OTL MODEL SHELL TELLUS32 ESSO NUTO_H32 MOBIL VALCUOLINE 1405 MOBIL D.T.E Light 4 Capacity of the hydraulic oil tank can refer to the following table. Fill the oil through the oil inlet on the tank and examine the oil level come to the middle point of the meter. UNITS: liters MODEL CAPACITY PPG-2550. 60. PRG-C3060 60 PRG-4080 120 Note:(1) Do not switch on hydraulic pump motor before hydraulic oil is filled. (2) The pressure of hydraulic system has been adjusted (about 12-16kg/cm* ) in our factory before delivery. (3) Do not adjust it in normal condition. A-1210. INSTALLATION OF COOLANT SYSTEM (1) The coolant system is usually located at the left side of the machine as show in figure 12, please connect the hose of coolant pump (see figure 12 as shown) to the steel pipe which fixed at the right handside of column. After the power cable of coolant pump motor is plugged to the plug in electric box or machine base. (2) Please add uniformly mixing coolant to tank. First add 1/3 water into the tank, pour in the soluble coolant then fill water to the top level of the tank and stir it well. We suggest the mixing ratio for normal surface grinding is 1/60 to 1/80. (3) Push the button SB7 on the control panel to start the coolant pump motor. Adjust the throttle valve attaching on the wheel grind to control the coolant flow rate. J vise ES Bol bt Figure 12 A-13Note:1, When start the coolant pump, please check the rotation direction of pump with the direction indicated by an arrow. 2, Do not start the coolant pump except the tank has been filled with coolant. 3. Please do not supply the coolant to grinding wheel when the wheel is stopping or starting. Because supply coolant that may easily caused or grinding wheel to be unblanced. 4, Don’t splash Spindle and Wheel Flange with Coolant liquid so as not to damage bearing of spindle and lose balance with Grinding Wheel in soaking 10-1 THE CHOICE OF COOLANT The choice of different types of mixture ratio of the coolant is according to the material of the workpiece. We recommend to use the coolant which Have the character as below: (1) It is a visible, soluble, and high pressure endurable, non-foam coolant. (It is convenient to check the workpiece while rinding.) (2) It can not contain the toxic materials such as Nitride, Phenolic Silicone and so on. (3) It is unflammable.11. INSTALLATION OF ELECTROMAGNETIC CHUCK Elecomagnetic chuck specification: MODEL DIMENSION VOLTAGE, WEIGHT PFG-2550 250 500mm DC_110V 60kg PFG-C3060 300 600mm DC 110V, 85kg PFG-4080_ 400 800mm DC_110V 135ke (1) Unpacking and lifting Remove the top cover of the wooden case first, then take out two outer hexagon head screws and set them on the both sides of electromagnetic chuck. Use the lifting ropes to hook the screws and lift it up. (2) Mounting on table Clean the surface of the table and the bottom of the chuck, then put the electromagnetic chuck on the center of the table lightly. Put the T-Type screw blot in T-slot of the table then put the setting plate on the blot and tighten the nut to set the electromagnetic chuck, as Figure 13. Magnetic chuck (3) Connecting the power Connect the socket of the electromagnetic, chuck with the plug on the right side of the electric box. Setting piece Figure 13 T-Type, screw THSlot Note: When the electromagnetic chuck out of work, the breaker of the main power will be started automatically to keep security. ACLS12. INSTALLATION OF DUST SUCTION DEVICE (1) The suction device is usually located at the left side of the machine. First, please connect the hose of suction device to the suction nozzle which is on the wheel guard. Then plug the power cable of dust suction device to the electric box. (2) Push the button SB7 on the control panel to start the suction notor. (3) Be sure that the rotation of motor is same as indicating direction on the motor housing. If direction is incorrect, this system will cause noise. Please change any two pover supply lines in the system box. 13.CONNECTION OF POWER LINE (1) Make sure the power voltage is same as machine voltage. (2) The main power line can be connected into the electric box to be tightened to the terminal through the button of the box. (3) Use 4 cords and the cross sectional area is at least 4.Onm* for the power line, connected to ground and over voltage protector according to the local electricity regulations. (4) For wiring to different voltage, be sure to rewire hydraulic pump motor, spindle motor and transformer to the correct voltages. And to replace fuses to protect the electrical components. Using the current chart as refer to part C, or contact our agents for detail. Note: Do not use machine if its voltage preset is different from external power supply. Contact electric technician for reparation if necessary. A-16B.OPERATION INSTRUCTIONS B-0PFG-2550AH/PFG-C3060AH/PFG-4080AH B-11.GENERAL SAFETY REGURATIONS (1) This machine is only used for metal grinding. No flammable materials such as wood or plastic shall be used. (2) The owners shall be carefully select qualified operators with proper grinding training to operate and maintain the machine. (3) The owners shall demand operators to participate in safety seminars and practices. (4) Read this instructions manual carefully before operating machine. During operation or reparation, pay attention to the directions on the non-plate attached to the machine. (5) All the guards and doors shall be closed at all times except that maintenance in required. (6) Removing or replacement of workpiece is not allowed when table is moving or workpiece is close to grinding wheel. (1 Do not attempt to clear the chips from workpiece before finishing of grinding. (8 Check. grinding wheel and make sure the spindle turns at clockwise direction before actuating spindle motor. Let grinding wheel to tun idly for at least five minutes. @ Before starting machine, make sure the stop button and emergency stop button are at positioned “OFF” (disengaged). (10) Wear goggles, mouthpiece(especially during dry grinding), and safety shoes when operating machine. (1D Do not wear loose clothes, long sleeves and neckties during operation. (12) Wear protective hair covering or hold hat to prevent long hair from falling down during operation. (13) Keep the area around machine clean and dry. Remove clogs and scrap. (14) Use electromagnetic chuck to hold workpiece. Clean the surface of the chuck before holding. Regrind the chuck surface if any scratch on it. B-2(15) (16) an (1g) (19) (20) (21) (22) (23) (24) (25) (26) Be careful of sharp angles and high temperature while loading and unloading workpiece. Use a crane to help loading/unloading large workpiece with weight over 25kg. Before grinding, make sure workpiece is fasten securely. Use suitable clamps to fix workpieces. Make sure of a safety height between workpiece and grinding wheel to prevent the grinding wheel from impacting workpiece when the spindle motor is started. Never leave machine running unintentional. Turn power off before leaving. During grinding, clear all unnecessary object other than workpiece from the machine. After switching off the spindle motor, allow the spindle to stop freely. Never attempt to stop the grinding wheel by hand or other objects. During wet grinding, do not try to adjust nozzle after spindle starts. Stop coolant before switching off spindle motor. Never modify the mechanical purposes and capacity of machine without being approved. Only an operator is allowed to operate the machine. Never open electric box without being approved. Consult the electrical technician or qualified electrical engineers for electric trouble. shooting. This machine can not be used in the explosive environment. Other safely regulation should follow the local laws. Read instruction manual carefully which related to the operation. B-32.CONSTRUCTION IDENTIFICATION AND FUNCTION INTRODUCTION 2-1 CONSTRUCTION IDENTIFICATION ‘NO. Name of Parts NO. Name of Parts 1 Column 10 | Table stroke adjusting unit 2 Parallel wheel dresser iL Saddle crossfeed_handwheel 3 Spindle head 12 Control panel 4 Suction device 13, Control panel support 5 Splash guard 14 | Wheelhead elevating handwheel 6 Table 15 Electric box 7 Table movement handwheel 16 Hydraulic tank 8 Saddle 17 Base 9 Coolant system2-2 CAPACITY OF MACHINE UNITS: mm(inch) Specifications PRG-2550 PFG-3060 PFG-4080 |Table size 250x 500(10"« 20") | 300x 600(12"x 24") | 400x 800(16"x 32") Max. table travel 270x $50(10%"x 22") | 340x 700(13"x 27") | 450x 86018" 34") Max. surface ground 250x_500(10" 20°) [300x 600(12"x 24") | 400x 80016" 32") lax. distance center of 350 300 350 spindle to table (20") (20") (22") Standard magnetic chuck | 250x 500(10"x 20") |300x 600(12"% 24") | 400x 800(16"% 32") size [Table speed 5-25M/nim 3-25M/ nim 3-25N7mim (200"~1000"/miny | (200"~1000"/miny | _¢200"~1000"/min) |Auto cross feed 0.1-12mm 0.1-20mm 0.1-20mm increment (0.004"-0,8") (0.004"-0.8") [Power cross feed 900m ain 900mm /nin 900navmin (46"/min) (36"/min) (36" min) [Cross feed on hand 1 rev 4.0(0.2") 5.0(0.2") 5.00.2") Wheel 1gra| _0.02(0.001") 0.020.001") 0.02¢0.001") Rapid power wheel head | 55Omn/min(13"/min) | 550mn/min(13"/min) | 260nm/min(13"/min) \60 He (Optional) (Optional) (Optional lAuto. down feed (Optional) (Optional) (Optional) WVertical dow feed Irev 2.0(0.05") 2.0(0.05") 7.00.05") jon wheel head lgra 0.01(0.0002") 0.01(0.0002") 0.005(0.0002") lWheel speed ‘6082 /3500RPHC 6082 /1750RPU 602! T7S0RPH S0tiz/2900RPM S082 /1450RPU S082 / 1 450RPM Wheel dimension 180x 13x 31.75 355x 38x 127 355x SOx 127 (1% Bex hey (14% 14% 5") 6" 2" 5") Spindle motor ‘HPI 5kW ‘SHP/3. 7KW ‘SHP/3.7kW(7% , 1OHP) laydraulic drive THP/O. 76K HPO. T6EN HPT. SEW JAuto cross feed motor 2HP10.15KW 2uPIO. WSKw 2xP10. 15H Rapid head elevation YUP IO.15kW HP 10.15kH JERI. 1Skw jnotor (Optional) (Optional) (Optional) [Coolant pump AHP/O.93KW Y¥P/0.093KW HHPO.093KW [Dust suction motor YEP O. 4k AEP/O.4kW JAP /0.4kW JWolage P20V~440V 220¥~440V 220¥-4400 Sound pressure level below 785A) below 78d5(A) below 78dB(A) B-52-3 ALLOWABLE MACHINING LOAD OF MACHINE The maximum allowable machining load of this machine is recommended an follows: Total Maximum Safety Load: NUITS: kg [Ewooer A B c Prc-2550 | 190 60 250 PFG-3060_| 215 85 300 prc-4080_[ 265 | 135 | 400 | 2-4 TRAVELING DIRECTION X=Longitudinal travel of table Y=Vertical travel of wheel head Z-Cross travel of saddle x,PANEL CLOCATION DIAGRAM BSRIRISRo 8 ~ g 82-5-1 INTRODUCTION TO THE FUNCTIONS OF MAIN: CONTROL PANEL .. (=) PV1: ELECTROMAGNETIC CHUCK LAMP. Lights are display for the electromagnetic chuck voltage. 12. SBO: EMERGENCY STOP BUTTON. To disconnect control power. + © 3. © SB1 AND SB2: POWER ON 1 AND POWER OFF 0. To start control power or stop control power. 6 ©: 4. ©» SB3 AND SB4:SPINDLE START 1 AND SPINDLE SHUT OFF 0. To start spindle motor or stop spindle motor. e @ soe) 0 5 © SB5 AND SB6: HYDRAULIC ON 1 AND HYDRAULIC OFF 0. To start hydraulic motor or stop hydraulic motor. oe so © SB7 AND SB8: COOLANT SYSTEM ON 1 AND COOLANT SYSTEM OFF 0. To start coolant motor or stop coolant motor.Ht @)r / 7. ‘SB9 AND SB10: CROSS FEED MANUAL ON 1 AND CROSS FEED MANUAL OFF 0. When "SA5” turn left can start cross feed for cross feed backward. a @ Pr 8. or SB11 AND SB12: CROSS TRAVEL SETTING FOR FORWARD AND BACKWARD. When push the “SB11” button, it will be set cross travel to forward or push the “SB12” button, it will be set cross travel to backward. He) @ 19. So ‘$B29, SB30 AND SB28: RAPID HEAD ELEVATION. When push the ”SB30” button, grind head will be up or push the "$B29”" and "SB28”" concurrently, the grind head can be down feed. e2e 10. © SAL: CROSS FEED AUTO OR MANUAL SELECTION. (OPTION) Left-manual . Middle- automatic criss-cross grinding. Right-automatic cross feed grinding. OTe LL. «) SAG: MAGNETIC SELECTION SWITCH. Left-magnetized. Middle-lack of magnetic force. Right-demagnetized. feon Qo 12. > RP? RP7: DEMAGNETIZATION TIME ADJUSTMENT. Increase at clockwise adjusting. Decrease at counter-clockwise adjusting. Oo SoC 13. RPS RP6: MAGNETIZED VOLTAGE ADJUSTMENT. Increase at clockwise adjusting. Decrease at counter-clockwise adjusting. SD oO 14. * RP RPI: CROSS FEED ADJUSTMENT. Increase at clockwise adjusting. Decrease at counter-clockwise adjusting. B-102-6 GRINDING WHEEL SELECTION AND MOUNTING 2-6-1 GRINDING WHEEL SELECTION The wheel which can be used in a high speed rotation machinery, is an universal grinding tool for the grinding of varied materials. It will eject chips and dust while grinding. For the purpose of keeping operators in good health, the following items should be taken care : (The grind wheel should not be made of crystalline silicic acid. (2)Use the standard grinding wheel. of ISO. (3)Make a sound tegt of the grinding wheel before using it. The method of test are: a. Testing tools: Use wood hammer for thick wheel, and use screw driver handle for thin wheel. b. Tap the wheel about 45 degrees each side of the vertical center line and about 25 or 50 mm from the periphery as by the spots in figure 2-5. a Light Wheels Heavy Wheels suspend from hole by Support on clean hard floor small pin or finger Figure 2-5 c. Chuck whole circumference for small cracks. d. A good grinding wheel will give a clear sound at any tap point. e. Wheels must be dry and free from saw dust when applying the ring test, otherwise the sound will be deadened. B-ll