Bernhard ANGLEMASTER 3000DX User Manual/Instruction Manual Download

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BERNHARD AND COMPANY LTD

Bilton Road • Rugby • England • CV22 7DT
Tel +44 1788 811600 • Fax +44 1788 812640

Email:

[email protected]

USA Toll Free

1-888 GRIND IT

(1-888 474 6348)

If you have any service or operational problems contact your distributor,

or phone our

Technical Helpline (USA only) – 1-888 474 6348

Bernhard and Company Ltd, England –

(+44) 1788 811600

or email

[email protected]

use the technical support feedback form on our web site

www.expressdual.com

www.bernhard.co.uk

SHARPER SOLUTIONS

Summary of Contents for ANGLEMASTER 3000DX

Page 1: ...lly before using the Anglemaster This manual should be kept in a safe place so that it can be used for future reference User s Guide Instruction Manual ANGLEMASTER 3000DX Anglemaster 3000DX Bedknife Grinder AM3000DX_2007 02 ENG Membrane Control Panel ...

Page 2: ...ack form on our web site www expressdual com or www bernhard co uk Contents Identification of Pictograms 3 Control Box Layout 4 Understanding the Machine 5 Safety 6 Set Up and Installation 7 Setting Up 9 Setting Angles of Cut 15 Grinding the Blade 17 Electrical Fault Finding 18 Maintenance 20 Parts List 21 Wiring Diagrams 37 Bedknife Mounting Guide 40 BERNHARD AND COMPANY LTD Bilton Road Rugby Eng...

Page 3: ...ARE MOVING COMPONENTS KEEP HANDS AND OTHER OBJECTS CLEAR 1 LIFT HERE 2 DO NOT LIFT HERE TOTAL WEIGHT OF MACHINE KG WEAR EYE EAR AND BREATHING PROTECTION MAXIMUM GRINDSTONE DIAMETER 150mm MAXIMUM SPEED 3800 Rev Min BEWARE MOVING GRINDSTONE AND SHAFT Identification of Pictograms ...

Page 4: ... TRAVERSE CONTROL COOLANT PUMP GRINDSTONE CONTROL MAGNET CONTROL Bottom EMERGENCY STOP Twist anti clockwise to release VARIABLE SPEED MOUNTING BAR ROTATION SERVICE SWITCH RESET 0 ANGLE INCREASE DECREASE ANGLE DESIRED ANGLE Where you want to be CURRENT ANGLE Where you are ...

Page 5: ... head carriage Drives along a fixed damped chain run Traverse is physically engaged using the over centre lever on the left front of the carriage Coolant pump Fitted into the top of the coolant reservoir settlement tank which is located inside the cabinet in the base of the machine Emergency stop Pressing the large red mushroom headed button will stop ALL motors The button will be locked into the ...

Page 6: ...s are to be ground ear defenders should ideally be worn The maximum noise with a heavy cut on a 36 bedknife has been measured at 85 decibels 1 7 Ensure that all electrical connections are sound and that cables are safely routed 1 8 NEVER fit or use any grinding stone other than those supplied specifically for use on the ANGLEMASTER 1 9 NEVER fit or use a grinding stone that has been dropped or dam...

Page 7: ...INS STRAPS FORKS MUST ONLY BE CARRIED OUT AS INDICATED BY LABELS ON THE MACHINE NOT BY MEANS OF THE TRAVERSE GUIDE RAILS Hex head bolt 2 3 For transit purposes the blade mounting bar is locked in position at both ends Some units may be shipped with a hex head bolt in the right hand clamp If so the clamp lock down lever is in the tool drawer of the machine cabinet Remove replace the hex head bolt w...

Page 8: ...HED 2 5 Coolant Check the location of the settlement tray in the coolant tank on the shelf in the cabinet under the left hand side of the machine Check the connection of the coolant supply hose to the pump outlet The soluble additive may be used in the coolant tank and should be mixed according to the manufacturer s instructions at 1 11 2 capful of additive per FULL tank of water This fluid is sui...

Page 9: ...th adjustable universal bedknife mounting brackets adjustable quadrant brackets may also be supplied which can easily be set to correspond with bed bar fixing holes In this way the bedknife is supported on the machine in a way that resembles as closely as possible its mounting in a cutting unit Special adapters are available when required for certain units 3 2 2 Attach adjustable support plate 2 t...

Page 10: ... be easily mounted 3 2 7 Universal Brackets If using the Universal Bedknife Mounting Brackets Slide the mounting bracket assembly to the bedknife assembly and locate bedknife using tapered pin or cup support according to it s mounting type 3 2 8 Lock the bracket end to the Anglemaster mounting bar then lock the support plate in position using locking knob adjustable lever 3 2 9 Rotate the mounting...

Page 11: ...et ensuring that when both ends are tightened the bedknife is still resting on the mounting bar In order to minimize the possibility of distorting very light bedbars it is advisable to fit a flat washer between bedbar and mounting quadrant 3 2 11 Rotate the two spring loaded alignment stops to that they retract and sit against the front of the mounting bar beneath the overhang of the bedknife When...

Page 12: ...bedknife so that it is presented to the grinding stone at the required angle NOTE The mounting bar cannot be rotated using the switch if the magnets are not switched on OR the grind motor or traverse motor are running 3 Setting Up Continued Rotate the mounting bar Down to rotate the bar towards the operator Up to rotate the bar away from the operator ...

Page 13: ... mounting bar misalignment could result in the slide block feed screws jamming 3 5 Grinding stone dressing A diamond dresser is supplied fitted to the grinding head The grinding stone should be dressed periodically by adjusting the dresser towards the stone then rotating the control knob back and forth making a few light passes of the dresser to ensure that the stone does not become loaded clogged...

Page 14: ...e socket at the rear of the motor and undo the grindstone nut with the box spanner provided Before fitting a replacement stone the new stone should be carefully examined for damage It should be held loosely and rung by tapping gently with a non metallic object such as a screwdriver handle A sound stone will make a clear ringing noise Reject a stone that sounds dead Ensure that there is no loose gr...

Page 15: ...rotating the manual control wheel on top of the drive enclosure at the right hand end of the mounting bar NOTE The mounting bar cannot be rotated using the switch if the magnets are not switched on OR the grind motor is running 4 3 Press reset button to set the current position of bedknife left hand Where you are display shows zero Now the bedknife blade and machine are both set to 0 On a brand ne...

Page 16: ...le for rough conditions On new bedknives add max 1 to the scratch setting ie that angle ground at the factory When the Where you are value equals the desired Where you want to be angle it changes to read Top Lower the guard This example Setting 7 degrees on top face a Use and buttons adjust the right hand Where to want to be display to 7 b Display reads t 07 c Now apply a relief grind reverse angl...

Page 17: ...raverse engaged grind the bedknife until it sparks out only occasional sparks seen as grinding stone passes the blade no real metal removal Traverse speed can be adjusted via the potentiometer knob adjacent to the start stop button on the control box 5 2 Grinding the Front Face of the bedknife Back the grindstone off the bedknife and stop the grinding motor Push Up control button rotating the moun...

Page 18: ...on control pendant is not locked in STOP position 6 1 5 Check for open circuit on overload terminals 95 and 96 press overload reset button to correct 6 1 6 Check that reset button on clear control box lid is not permanently in contact with red button on overload Adjust as required 6 1 7 Listen for the functioning of all contactors relays in the control box by operating the individual motor control...

Page 19: ... resulting from a low voltage supply 6 4 Mounting Bar Motor If the voltage is correct at the motor terminals check for an error message at the invertor display 6 5 Grinding Motor If the voltage is correct at motor terminals check the current amps at terminals T2 T3 on thermal overload contactor then at MAIN plug on Control PCB If the current exceeds the full load current indicated on the motor pla...

Page 20: ...ere the chain ends are attached to the machine chassis The springs at these points should NOT be fully compressed as they provide damping at the change in traverse direction 7 4 Rails Rails should be kept as clean as possible Although the rear rail is cleaned by wipers attached to the carriage cover some dust debris will still collect on this rail Wipe the rails down daily and spray with WD40 at t...

Page 21: ...______________ 34 ELECTRICAL DRAWER __________________________________ 35 SAFETY GUARD ________________________________________ 36 Ref Name of Part Qty Part BASE FRAME _______________________________________________ 1 Base Cabinet 1 A6304 2 Bottom Drawer 1 A6308 3 Top Drawer 1 A6309 4 Coolant Tank 1 A6315 5 Coolant Tank Stop Bracket 1 A6316 6 Drawer Handle 4 A6110 7 Button Head Screw M6 x 10 8 A51...

Page 22: ...22 ANGLEMASTER AM3000DX Bernhard and Company Limited 8 Parts List Continued BASE FRAME ...

Page 23: ...332 6 Drawer Handle 2 A6110 7 Button Head Screw M6 x 8 4 A5158 8 Button Head Screw M5 x 6 8 A5138 9 Eccentric for Slide Block 4 A9211 10 Bearing 4 A7723 11 Hex Head Bolt M6 x 12 4 A5718 12 Rail Adjuster Bolt M10 x 50 2 A5755 13 Nut M10 2 A5503 14 Brass Cap 2 A9222 15 Nut M10 4 A5503 16 Socket Grub Screw M8 x 30 8 A5188 17 Reversing Stop 2 A4115 18 4 Lobe Knob M8 x 45 2 A6133 19 Buffer for Reversin...

Page 24: ...24 ANGLEMASTER AM3000DX Bernhard and Company Limited MAIN FRAME 8 Parts List Continued ...

Page 25: ...6350 3 Grinding Wheel Guard 1 A6330 4 Adjustable Spark Guard 1 A6301 5 Clamp Ring 1 A6444 6 Wiper Plate 2 A4104 7 Wiper Felt 2 A6766 8 Magnet 3 A6704 9 Grommet Strip 1 A8219 10 Wing Knob M6 x 8 2 A6144 11 Washer M6 4 A6144 12 Button Head Screw M6 x 8 2 A5158 13 Button Head Screw M6 x 8 4 A5158 14 Button Head Screw M5 x 8 3 A5205 15 Button Head Screw M5 x 8 4 A5205 8 Parts List Continued ...

Page 26: ...26 ANGLEMASTER AM3000DX Bernhard and Company Limited DUST TRAY GUARDS 8 Parts List Continued ...

Page 27: ...0 2 A6119 23 Washer M10 4 A5310 24 Kip Lever M10 x 15 2 A6181 25 Captive Nut M10 2 A9023 26 Taper Pin 2 A9119 28 Taper Pin Plate 2 A4089 29 Eccentric Pin Handle 2 A4184 30 Ball Knob 2 A6115 31 Lever Stop 2 A9062 32 Nut M8 2 A5519 33 Circlip 25mm 2 A5603 34 Mounting Bar Finger 2 A4085 35 Spring M8 x 30 2 A6752 36 Nyloc Nut M6 2 A5517 37 Quadrant Pivot Pin 2 A9105 38 Centre Jacking Screw Bracket 1 A...

Page 28: ...mpany Limited 8 Parts List Continued 14 8 15 10 12 13 1 2 3 4 17 19 16 17 18 23 21 20 23 22 24 25 26 28 29 30 31 32 33 35 36 34 37 38 40 41 42 44 11 43 45 48 46 7 48 5 9 58 6 7 49 50 51 52 53 54 55 56 57 MOUNTING BAR with membrane keypad m c ...

Page 29: ...006 14 5mm Spring 2 A6718 15 Grub Screw M6 x 6 4 A5156 16 Toggle Latch 1 A6884 17 Halfnut M16 1 A5527 18 Grub screw M6 x 30 1 A5215 19 Nyloc Nut M12 1 A5507 20 Shoulder Bolt M8 x 12 x 6 1 A5165 21 Bearing 7 A7713 22 Hex Head Bolt M12 x 30 1 A5713 23 Special Washer M12 1 A5211 24 Pan Head Screw M4 x 20 2 A5412 25 Microswitch 1 A8133 26 Cap Head Screw M6 x 25 11 A5152 27 Nut M6 3 A5516 28 Jib Strip ...

Page 30: ...30 ANGLEMASTER AM3000DX Bernhard and Company Limited 8 Parts List Continued ...

Page 31: ...9 Motor Spacer Plate long 1 R4113 20 Motor 60 Hz 1 A6006 Motor 50Hz 1 A6004 Motor 3 Phase 1 A6005 21 Hex Head Bolt M8 x 25 4 A5723 22 Washer M8 12 A5321 23 Grinding Wheel Ext Shaft 1 A9053 24 Grinding Wheel Parallel Cup 1 A6507 Grinding Wheel Taper Cup not shown 1 A6520 25 Mills Pin M6 x 10 1 A5468 26 Extension Shaft Flange 1 A9054 27 Extension Shaft Nut 1 A9055 28 S k t Cap H d Screw M6 x 25 1 A5...

Page 32: ...32 ANGLEMASTER AM3000DX Bernhard and Company Limited MAIN MOTOR AND SLIDE 8 Parts List Continued ...

Page 33: ...ty Part MOTOR GUARD _____________________________________________ 1 Guard 1 A6335 2 Handle 1 A6110 3 Stay Put Hose Tap 1 A6773 4 Hose Tail 1 A6726 5 Washer M12 1 A5315 6 Button Head Screw M5 x 6 6 A5138 7 Button Head Screw M6 x 8 2 A5158 MOTOR GUARD 8 Parts List Continued ...

Page 34: ... A8073 5 Contact Block N C 1 A8888 6 Membrane key panel 1 A3331 7 Service key switch 1 A3060 8 Pyxis display PCB for membrane keypad 1 A3502 9 Lyra interface PCB for membrane keypad 1 A3503 10 Lead set for membrane keypad 1 A3507 11 Button Head Screw M5 x 10 4 A5129 12 Crinkle Washer M5 4 A5319 13 Nut M5 4 A5512 14 1k Potentiometer 1 A8014 15 Hex Head Bolt M10 x 40 2 A5737 8 Parts List Continued C...

Page 35: ... 7 Reset Button 1 A8130 8 10 way Socket 1 A8003 9 10 way Plug to Carriage 1 A8002 10 3 pole Socket 2 A8026 11 3 pole Plug to Coolant Pump Magnets 2 A8025 12 Vela i o module for membrane keypad 1 A3504 13 Hours run meter 24v DC 1 A8206 14 Mains Power Supply Plug 1 A8125 15 Power Supply Lead USA 1 A8211 Europe 1 A8212 UK 1 A8213 16 4 pole Socket for Interlocks 1 A8028 UK Europe 17 4 pole Plug for In...

Page 36: ...2007 on ___________________________________ 1 Rear Guard Back Box 1 A06310 2 Front Guard 1 A04323 3 Hinge 800056 2 A06109 4 AM3000 New Light Cover 1 A03181 5 Long Light 1 A08239 6 Large Bridge Handle 1 A06108 7 Microswitch 1 A08225 8 2mm Polycarbonate Guard Window 1 A03384 9 20x20 Knock In 2 A06101 1 7 8 9 2 6 5 4 3 ...

Page 37: ... TO SHEET 2 454 PLUG4 4 3 2 1 E E L N MAGNET 211 210 PLUG4 3 2 1 E 33 34 M4 PUMP PLUG1 3 2 1 E HOUR METER ELTIME 10 4 9 8 7 6 5 TO SHEET 2 TO SHEET 2 TO SHEET 2 0 99 HIGH VOLTAGE AC 100 199 LOW VOLTAGE AC REGULATED LOW VOLTAGE DC 400 UNREGULATED LOW VOLTAGE DC 200 399 WIRE NUMBER ID SHEET KEY POWER 100 9 10 100 VA T1 GRIND MOTOR M1 TRAV MOTOR M2 13 O L 15 CLAMP MAGNET CAPACITOR TRAVERSE VACUUM MAI...

Page 38: ...ET 3 FROM SHEET 3 FROM SHEET 3 FROM SHEET 3 FROM SHEET 3 Q4 ESTOP ESTOP RX TX 5VDC 0VDC ESTOP COM Q7 Q6 COM2 Q5 COM1 Q3 Q2 Q1 Q0 COM0 AN GND AN1 OUT CH1A CH1B CH0A CH0B 24VDC GND ESTOP GUARD O L EARTH 24VAC DC 0VAC DC VELA I O FROM SHEET 1 FROM SHEET 1 FROM SHEET 1 FROM SHEET 1 FROM SHEET 1 475 473 471 474 456 FROM SHEET 1 451 100 FROM SHEET 1 FROM SHEET 1 101 FROM SHEET 1 452 453 FROM SHEET 1 ...

Page 39: ...EET 3 GND ANO IN 5V M BAR SENSOR 513 514 512 6 3 TO SHEET 2 TO SHEET 2 TO SHEET 2 TO SHEET 2 TO SHEET 2 TO SHEET 2 TO SHEET 2 TO SHEET 2 RX ESTOP0 ESTOP1 TX GND 5V 6 10 404 403 491 490 PYXIS DISPLAY RX GND 5V 5V LYRA I FACE SERV GND SERV ESTOP ESTOP ANO IN GND 5V GND TX SQ1 ESTOP SQ2 ...

Page 40: ...ay to the correct angle for that blade 7 Small 9 Medium 12 Large the angle for that blade as ground by the manufacturer there is no wear yet Add a maximum of 1 to this setting before truing the face of the blade Scratch too back Scratch too forward Too Back Too Forward Correct Press the RESET button to set the left Where you are display to the current angle of Zero ANGLEMASTER 3000DX Rotate to Top...

Page 41: ...eft Where you are display changes from T 90 to F 01 and the right Where you want to be display changes to Front A B C Press DOWN to rotate mounting bar so the left Where you are current angle changes from 00 towards 07 where it will automatically stop and indicate TOP º º This example Desired Angle 07 Press or buttons to change the right Where you want to be display to the required angle Press UP ...

Page 42: ...he motors will shut down if the safety enclosure is opened The control panel for all Express Dual and Anglemaster models 3000 3000DX and 5000 will also be fitted with a key operated service switch This provides a manual override to by pass the interlock switch for relevant service and maintenance purposes only and should only be used by suitably qualified personnel The service key should be remove...

Page 43: ...6348 If you have any service or operational problems contact your distributor or phone our Technical Helpline USA only 1 888 474 6348 or Bernhard and Company Ltd England 44 1788 811600 or email techsupport bernhard co uk use the technical support feedback form on our web site www expressdual com or www bernhard co uk SHARPER SOLUTIONS Bernhard and Company Limited ...

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