Bavelloni -Poweredge

D Z.BavelloniA Glaston Technologies company

Z. Bavelloni S.p.A.Via Milano, 9322070 Bregnano (Co) ItalyTel. 0039.031.728311Fax. 0039.031.7286358http://www.bavelloni.comE-mail: [email protected]

EditionCode N°

::

08/10/200358951800-30 Rev 001 GB ENGLISH

DOUBLE-EDGING MACHINEFOR PENCIL EDGE

MANUAL FOR USE ANDMAINTENANCE

Models "V3÷V4"

D Z.BavelloniA Glaston Technologies company

Z. Bavelloni S.p.A.Via Milano, 9322070 Bregnano (Co) ItalyTel. 0039.031.728311Fax. 0039.031.7286358http://www.bavelloni.comE-mail: [email protected]

Edition : 08/10/2003 GB ENGLISH

DOUBLE-EDGING MACHINEFOR PENCIL EDGE

Models: V3 ÷ V4

MANUAL FOR USE ANDMAINTENANCE

© Copyright Bavelloni 2003

Copying and/or disclosure, including partial, of this manual is forbidden without prior writtenauthorization by Z: Bavelloni S.p.A.

ORIGINAL DOCUMENT ISSUED IN ITALIANBY THE MANUFACTURER

This document is an integrating part of themachine and it must be conserved in aneasily accessible place for the entireduration of the machine itself.

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v3_v4-ing-index-rev001.doc - 10/03

INDEXCHAPTER PAGE

1. GENERAL INFORMATION..................................................................................1.11.1 INTRODUCTION ........................................................................................................... 1.11.2 LIST OF EFFECTIVE PAGES....................................................................................... 1.21.3 IDENTIFICATION OF MACHINE AND MANUFACTURER .......................................... 1.31.4 GLOSSARY................................................................................................................... 1.41.5 ABBREVIATIONS.......................................................................................................... 1.41.6 APPLICABLE NORMATIVE DOCUMENTS.................................................................. 1.51.7 REQUESTS FOR ASSISTANCE AND SPARE PARTS ............................................... 1.6

2. SAFETY INSTRUCTIONS ...................................................................................2.12.1 GENERAL SAFETY RULES ......................................................................................... 2.12.2 SAFETY IN HANDLING AND INSTALLATION............................................................. 2.12.3 SAFETY DURING USE ................................................................................................. 2.22.4 SAFETY DURING THE MAINTENANCE PHASE......................................................... 2.22.5 DANGEROUS AREAS .................................................................................................. 2.32.6 RESIDUAL RISKS......................................................................................................... 2.4

2.6.1 APPLICABLE INDIVIDUAL PROTECTION DEVICES.................................................. 2.4

3. TECHNICAL INFORMATION...............................................................................3.13.1 GENERAL DESCRIPTION OF THE MACHINE............................................................ 3.13.2 DESCRIPTION OF MODELS........................................................................................ 3.23.3 DESCRIPTION OF MAIN COMPONENTS................................................................... 3.33.4 CONFIGURATION VARIANTS ..................................................................................... 3.43.5 OPERATING CYCLE .................................................................................................... 3.53.6 SAFETY DEVICES........................................................................................................ 3.7

3.6.1 ELECTRO-MECHANICAL SAFETY DEVICES AND ELECTRICAL INTERLOCKS..... 3.83.6.2 SAFETY DEVICES OF THE ELECTRICAL CUBICLE.................................................. 3.8

3.7 POSITION OF SAFETY SIGNALS................................................................................ 3.93.8 ACCESSORIES SUPPLIED WITH THE MACHINE.................................................... 3.103.9 ACCESSORIES UPON REQUEST............................................................................. 3.11

3.9.1 CORNER CHAMFERING SPINDLE FOLLOWING THE GLASS SHEET .................. 3.113.10 TECHNICAL DATA...................................................................................................... 3.12

3.10.1 TOOLS......................................................................................................................... 3.143.11 NOISE.......................................................................................................................... 3.15

4. HANDLING AND INSTALLATION.......................................................................4.1

5. MACHINE ADJUSTMENT ...................................................................................5.15.1 TESTING ....................................................................................................................... 5.15.2 BREAKING-IN ............................................................................................................... 5.15.3 ADJUSTMENT OF SPRUNG BRIDGE OPENING ....................................................... 5.15.4 ADJUSTMENT OF GLASS PROGRESS SPEED......................................................... 5.15.5 SIDE STRIKER PLANE ADJUSTMENT ....................................................................... 5.2

5.5.1 ADJUSTMENT OF SQUARING CENTERING DEVICES............................................. 5.35.5.2 ADJUSTMENT OF SIDE MOTORIZED STRIKERS ..................................................... 5.5

5.6 ADJUSTMENT OF GLASS SHEET PRESSERS.......................................................... 5.55.7 ADJUSTMENT OF PROJECTION ................................................................................ 5.65.8 ADJUSTMENT OF DIAMOND WHEELS...................................................................... 5.6

5.8.1 VERTICAL CENTERING AND SLANTING OF THE DIAMOND WHEEL..................... 5.75.8.2 HORIZONTAL POSITIONING OF THE DIAMOND WHEEL ........................................ 5.85.8.3 ADJUSTMENT AFTER REPLACING DIAMOND WHEELS ......................................... 5.9

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5.9 ADJUSTMENT OF POLISHING WHEELS ................................................................... 5.95.9.1 SLANTING OF THE POLISHING WHEEL.................................................................. 5.105.9.2 HORIZONTAL POSITIONING OF THE POLISHING WHEEL.................................... 5.115.9.3 ADJUSTMENT OF THE POLISHING WHEELS ......................................................... 5.12

5.10 ADJUSTMENT OF POLISHING WHEEL TRIGGERING: MULTIHEADSYSTEM ...................................................................................................................... 5.12

5.11 WORKING PRESSURE ADJUSTMENT..................................................................... 5.135.12 ADJUSTMENT OF THE CORNER CHAMFERING UNIT........................................... 5.14

5.12.1 THE CORNER CHAMFERING SPINDLES................................................................. 5.145.12.2 OPERATION CYCLE OF THE CORNER CHAMFERING SPINDLES ....................... 5.155.12.3 DEPTH OF CORNER GRINDING............................................................................... 5.175.12.4 TRANSVERSAL ADJUSTMENT OF THE CORNER CHAMFERING SPINDLES...... 5.175.12.5 LONGITUDONAL ADJUSTMENT OF CONER CHAMFERING SPINDLES .............. 5.185.12.6 VERTICAL ADJUSTMENT OF CORNER CHAMFERING SPINDLES....................... 5.185.12.7 UNTRIGGERING THE CORNER CHAMFERING SPINDLE...................................... 5.18

5.13 ADJUSTMENT OF THE SQUARING SYSTEM.......................................................... 5.195.13.1 THE SQUARING SYSTEM ......................................................................................... 5.195.13.2 OPERATION CYCLE OF THE SQUARING UNIT OF THE SINGLE MACHINE........ 5.205.13.3 OPERATION CYCLE OF THE SQUARING UNIT ON DOUBLE-EDGING LINE ....... 5.215.13.4 ADJUSTMENT OF FRONT STOPS OF THE SQUARING UNIT................................ 5.22

5.14 FILLING THE WATER TANK ...................................................................................... 5.23

6. USE AND OPERATION .......................................................................................6.16.1 DESCRIPTION OF CONTROLS................................................................................... 6.1

6.1.1 CONTROL PANEL ........................................................................................................ 6.16.1.2 CONTROL ON THE ELECTRICAL CUBICLE .............................................................. 6.46.1.3 CONTROLS ON OUTSIDE PUSHBUTTON PANELS.................................................. 6.4

6.2 WORKING SITE OF THE OPERATOR ........................................................................ 6.56.3 START ........................................................................................................................... 6.5

6.3.1 AUTOMATIC CYCLE .................................................................................................... 6.56.3.2 MANUAL CYCLE........................................................................................................... 6.56.3.3 AUTOMATIC CYCLE START ON THE SINGLE MACHINE......................................... 6.66.3.4 AUTOMATIC CYCLE START ON THE DOUBLE-EDGING LINE ................................ 6.6

6.4 NORMAL STOP............................................................................................................. 6.76.5 EMERGENCY SHUTDOWN ......................................................................................... 6.76.6 MACHINE RE-START AFTER EMERGENCY SHUTDOWN ....................................... 6.86.7 INSTRUCTIONS FOR GOOD MACHINE WORKING .................................................. 6.9

6.7.1 CORRECT USE OF WHEELS .................................................................................... 6.10

7. MAINTENANCE...................................................................................................7.17.1 ROUTINE MAINTENANCE ........................................................................................... 7.1

7.1.1 GENERAL CLEANING .................................................................................................. 7.17.1.2 MAINTENANCE PROGRAM CHART ........................................................................... 7.27.1.3 MAINTENANCE OF THE AIR TREATMENT UNIT (FRL) ............................................ 7.37.1.4 MAINTENANCE OF THE WHEEL COOLING SYSTEM............................................... 7.57.1.5 MAINTENANCE OF THE GUIDE AND SLIDING SYSTEM OF THE MOVABLE

BRIDGE ......................................................................................................................... 7.77.1.6 CLEANING THE LIMIT-MICROSWITCHES ................................................................. 7.87.1.7 LUBRIFICATION OF THE TRANSMISSION SHAFT.................................................... 7.87.1.8 LUBRICATION OF THE MOTORVARIATOR UNIT OF THE CONVEYOR.................. 7.97.1.9 CLEANING THE AIR FILTER OF THE ELECTRICAL CUBICLE ............................... 7.107.1.10 DRESSING THE DIAMOND WHEELS ....................................................................... 7.107.1.11 REFORMING OF THE DIAMOND WHEEL EDGE ..................................................... 7.10

7.2 CHART OF LUBRICANTS .......................................................................................... 7.117.3 SPECIAL MAINTENANCE .......................................................................................... 7.12

7.3.1 REPLACEMENT OF THE SPINDLE TRANSMISSION BELT FORDIAMOND/POLISHING SPINDLES ............................................................................ 7.12

7.3.2 REPLACING THE BEARINGS OF DIAMOND/POLISHNG SPINDLES ..................... 7.12

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7.3.3 REPLACING THE STRIKER STAKES OF THE CORNER CHAMFERINGSPINDLE ..................................................................................................................... 7.13

7.3.4 REPLACING THE TRANSMISSION BELT OF THE CORNER CHAMFERINGSPINDLE ..................................................................................................................... 7.14

7.3.5 REPLACING BEARINGS OF THE CORNER CHAMFERING SPINDLE ................... 7.147.3.6 REPLACING THE LOWER BELT OF THE CONVEYANCE SYSTEM....................... 7.157.3.7 REPLACING THE UPPER BELT OF THE CONVEYANCE SYSTEM........................ 7.167.3.8 REPLACING THE MOTORIZED ENTRANCE/EXIT TRANSMISSION UNIT............. 7.17

8. DEFECTS - CAUSES - SOLUTIONS...................................................................8.18.1 WORKING DEFECTS ................................................................................................... 8.18.2 BREAKDOWN ............................................................................................................... 8.2

9. REPLACEMENT OF PARTS ...............................................................................9.19.1 REPLACING THE DIAMOND WHEELS ....................................................................... 9.19.2 REPLACING THE POLISHING WHEELS..................................................................... 9.29.3 REPLACING THE CORNERING CHAMFERING WHEELS......................................... 9.29.4 MOST FREQUENTLY USED SPARE PARTS.............................................................. 9.3

10. DEMOLITION.....................................................................................................10.110.1 MACHINE DISABLING................................................................................................ 10.110.2 DIFFERENTIATED DIVISION OF MATERIAL............................................................ 10.1

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REV. 001 v3_v4-ing-cap01-rev001.doc - 10.03 page 1.1

1. GENERAL INFORMATION

Read this manual carefully before starting any adjustment ormaintenance operations on the machine. Pay particular attentionmost of all during first approach with the machine, to getacquainted with the commands and relevant operations.

1.1 INTRODUCTION• The information in this manual is for operators who may get involved with the

machine during its entire life; particularly to operators transporting and installingthe machine, those who use it and the operators in charge of ordinarymaintenance.Observance of procedures and prescriptions described in the manual guaranteesafe working to the operators and keeping the machine efficient.

• This manual contains safety messages, identified by graphic boxes like the onesfollowing herebelow. Each box consists in a symbol connected to a particularfunction (danger, attention, and warning) and the description of the messageinvolved in that particular situation.

!DANGER:A situation or operation which may cause great hazard to persons andobjects, probably causing serious injuries or even death

ATTENTION:Particular warning which if neglected, may cause minor injuries ordamage to one’s health or to the machine, thus jeopardizing itsperformance

WARNING:General information for the machine operator, or warning which ifneglected, may shorten the life of the machine or of its components.

• The parts of text requiring the utmost attention are printed in bold type.• For information only, this manual might include some illustrations representing the

machine without its safety guards. Therefore, never use the machine without itssafety guards and protections.

• Each reference to table numbers (TAV. ----) in this manual apply to the enclosure/s“SCHEMES OF SYSTEMS and TABLES OF SPARE PARTS”, being part of theinstructions for use.

• Illustrations and drawings contained in this manual refer to a left-hand " V4"machine. The right-hand machines are specular.

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1.2 LIST OF EFFECTIVE PAGES

This manual is valid only if made up of the below pages.

Page Rev Page Rev Page Rev Page Rev Page Rev

6.4 0016.5 0016.6 0016.7 001

- Cover- Frontispiece- Index

6.8 0016.9 001

1.1 001 6.10 0011.2 001 7.1 0011.3 001 7.2 0011.4 001 7.3 0011.5 001 7.4 0011.6 001 7.5 0011.7 001 7.6 0012.1 001 7.7 0012.2 001 7.8 0012.3 001 7.9 0012.4 001 7.10 0013.1 001 7.11 0013.2 001 7.12 0013.3 001 7.13 0013.4 001 7.14 0013.5 001 7.15 0013.6 001 7.16 0013.7 001 7.17 0013.8 001 8.1 0013.9 001 8.2 001

3.10 001 9.1 0013.11 001 9.2 0013.12 001 9.3 0013.13 001 9.4 0013.14 001 9.5 0013.15 001 10.1 0014.1 001 10.2 0015.1 0015.2 0015.3 0015.4 0015.5 0015.6 0015.7 0015.8 0015.9 001

5.10 0015.11 0015.12 0015.13 0015.14 0015.15 0015.16 0015.17 0015.18 0015.19 0015.20 0015.21 0015.22 0015.23 0016.1 0016.2 0016.3 001

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1.3 IDENTIFICATION OF MACHINE AND MANUFACTURER

All information concerning marking on the machine is on the plates shown in thebelow drawing.

1 - Name and address of the manufacturer2 - Model / Type of machine3 - Year of construction4 - Number of the wiring diagram5 - Frequency.

6 - Current input7 - Serial number (Work order number).8 - Power installed9 - Input voltage10 - CE marking

9

8

7

23

45

10

6

1

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1.4 GLOSSARY

Operator Person or persons in charge of installation, operation, adjustment,maintenance, cleaning, repair and transport of the machine.

Dangerousarea

Any area inside and/or near a machine where a person is exposed to therisk of injury or damage to one’s health

Exposedperson

Any person who is entirely or partially in a dangerous area.

Qualified staff Persons who on account of their training, experience, instruction and aswell for their knowledge on standards, prescriptions and provisionsconcerning accident prevention and service conditions are authorized bythe person in charge of installation safety to carry out all activitiesnecessary, and are able to recognize and avoid any possible danger.

Ordinarymaintenance

Servicing necessary to restore normal machine operating conditions, tobe carried out in predetermined time and according to the conditionsdescribed in relevant maintenance manual.

Specialmaintenance

Servicing for repair or replacement of machine parts not contemplated inordinary maintenance.

Set-up Ensemble of operations to perform in order to prepare the machine tocarry out a certain process.

Double-edging line

Ensemble of two double-edging machines interconnected by a transfer,for grinding the four sides of a sheet in just one working cycle.Further machines can be interfaced to the double-edging line, either onthe material feed side or the exit side.

Transfer Automatic machine to transfer sheets of material from one grindingmachine to another, with rotation or deviation of the trajectory of the 90°piece.

Automaticloader

Machine coupled to the first grinding machine of a double-edging line, forcontinuous feed of sheets.

Deviator Particular type of transfer. When available in a double-edging line it isalways connected to the exit side of the second grinding machine.

1.5 ABBREVIATIONS

MB1 First grinding machine of a double-edging line

MB2 Second grinding machine of a double-edging line

TFP First transfer of a double-edging line: positioned between MB1 and MB2.

DFP Deviator of a double-edging line: positioned after MB2.

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1.6 APPLICABLE NORMATIVE DOCUMENTSInstructions for use have been prepared in compliance with the following standardsand directives. The contents of the instructions for machine use illustratecompliance of essential safety requirements.

Machinery Directive 98/37/CE. item 1.6item 1.7.4

ServiceInstructions for use

Standard UNI EN 292" Machinery Safety – Fundamentalconcepts, general project principals”

Part 1Part 2

Terminology, basic methodology.Technical specifications andprinciples

The adopted measures comply with the following standards and directives:

Directive 98/37/CE. Machine directive.

Directive 89/654/CEE Safety in work sites

Directive 89/655/CEE Use of work equipment

Directive 89/656/CEE Use of devices for individual protection

Directive 90/269/CEE Manual load handling

Directive 86/188/CEE Noise in work sites.

Directive 89/686/CEE Devices for individual protection

Standard UNI EN 292 -1-2 Machine safety - Fundamental concepts, general project principles

Standard UNI EN 294 Safety distance to prevent upper limbs from reaching dangerous areas

Standard UNI EN 349 Minimum distance to avoid crushing parts of the human body

Standard UNI EN 418 Equipment for emergency stop. Operational aspects – Project principles

Standard EN 953 General requisites to project and construct fixed and mobile guards

Standard ISO 7000 Graphic signs for equipment use.

Standard EN 60204-1 Safety in machine use – electrical equipment.

Standard CEI EN 61000-4-2 Electro-magnetic compatibilityElectrostatic discharge immunity test

Standard CEI EN 61000-4-3 Electromagnetic compatibility:Radiated, radio-frequency, electromagnetic field immunity test

Standard CEI EN 61000-4-4 Electromagnetic compatibility:Electrical fast transient/burst immunity test

Standard CEI EN 61000-4-5 Electromagnetic compatibility:Surge immunity test

Standard CEI EN 61000-4-11 Electromagnetic compatibility:Voltage dips, short interruptions and voltage variations immunity tests

Standard CEI EN 61000-4-12 Electromagnetic compatibilityOscillatory waves immunity test

Standard CEI EN 61131 Programmable controllers

Standard EN 55022 Features of radio disturbance – Measure limits and methods

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1.7 REQUESTS FOR ASSISTANCE AND SPARE PARTSFill up the order form for spare parts at page 1.1.7 according to the belowinstructions, and send it to:

Z. Bavelloni S.p.AVia Milano, 93 - 22070 Bregnano (Co) ItalyTel. (031) 72.83.11 r.a. - Fax (031) 77.30.84After Sales Service Fax: (031) 72.83.65http://www.bavelloni.comE-mail: [email protected]

Via Landri, 25 - 24060 Costa di Mezzate (Bg) ItalyTel. (035) 68.22.80 4 linee ric. aut. - Fax (035) 68.25.70After Sales Service Fax: (035) 68.11.86

1) Indicate the information you can find on themachine plate: see chap. 1.3 to find its position.

2) Indicate the table or figure of reference, partnumber, (if any) code n° of spare part, relevantdescription and quantity to order. You can findthis information from the maintenance manual,diagrams of systems and/or of spare parttables.

RIFERIMENTOReference (Tav., Fig.)

POS.Ref.

CODICECode

DESCRIZIONEDescription

N° Pz.Q. ty

TAV. 085 14 22106100 BEARING 2

FACSIMILE DA FOTOCOPIARE PER ORDINI FACSIMILE TO PHOTOCOPY FOR ORDERS


MODULO DI ORDINAZIONE PARTI DI RICAMBIOSpare parts order form

RIFERIMENTOReference (Tav., Fig.)

POS.Ref.

CODICECode

DESCRIZIONEDescription

N° Pz.Q. ty

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2. SAFETY INSTRUCTIONS

Read these instructions carefully before accomplishing anyoperations on the machine.The manufacturer declines all responsibilities for damages caused topersons or objects due to non-observance of safety rules.

2.1 GENERAL SAFETY RULES1. The operator must be qualified in using a complex machine.2. Any operation on the machine, especially use, maintenance, installation and

handling are prohibited to unauthorized or unqualified people.3. Wear appropriate clothing. Do not wear loose clothing, neckties, rings, bracelets

or other jewellery that could get caught in the moving parts of the machine.Wear slop-slip footwear and protective headgear to collect long hair.

4. Use protective cut-guard and antiabrasion gloves, suitable to handle glasssheets.

5. Do not assume positions which could cause loss of balance.6. Never remove the safety guards protecting operating personnel from coming

into contact with moving parts and subsequent injury.7. Strictly follow the safety messages in the manual (danger, attention and

warning), and warning labels required on the machine.8. Keep all unauthorised persons clear of the machine.9. Do not use the machine to work material different than what is specified in the

manual.10. Do not use the machine to carry out work different than what is indicated in this

manual.11. Do not use material of different size than allowed in the technical details.

2.2 SAFETY IN HANDLING AND INSTALLATION1. Loading, unloading and installation operations must be done in compliance to

the instructions of chapter 4, by trained staff qualified for such tasks.2. Make sure there are no unauthorized people in the area intended for machine

handling operations.3. The area intended for the machine must be well illuminated.4. Only a skilled person must perform machine electrical installation in compliance

with local electrical standards.5. An adequately sized conductor (not inferior to that of the power mains) must

connect the machine to an earthing system.

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2.3 SAFETY DURING USE1. Make sure no servicing or cleaning operations are taking place before starting

the machine.2. Make sure all safety protections are installed correctly before starting to work.3. Make a habit to check the clamping wrenches for wheels or that any other

foreign body is removed from the machine before turning it on.4. Make sure nobody except the appointed person/s are in the work area before

starting to work.5. Check pressure values set-up on gauges before machine start.6. Always enter the glass sheet at the side specified in the instructions for use.7. Do not enter the dangerous areas of the machine while it is working.8. Do not leave the machine energized and unguarded.9. Keep the work area clean. Wet and cluttered work areas and benches are often

the cause of accidents.10. Prevent accidental start-up. Take all steps necessary to prevent accidental

machine start-up (e.g. press the emergency pushbutton before makingadjustments to the machine). Whenever the machine is left unoperating for longtime, set the main switch to "0" or "OFF" and apply a lock.

11. Use the manual-operating mode only in the cases envisaged in the manual foruse.

12. It is not allowed for persons other than the operator entitled and authorized touse the machine to accede to manual controls.

13. It is strictly forbidden to use the machine for work other than what is indicated inthis manual.

14. Only a qualified and skilled electrician can accede inside the electrical cubicle.15. Periodically check the screws and bolts clamping machine moving parts are well

tightened.16. Periodically check that safety devices work properly.

2.4 SAFETY DURING THE MAINTENANCE PHASE1. Make sure the machine is disconnected from the electrical and pneumatical

systems before performing any maintenance operations. Put a padlock on thegeneral input switch.

2. Do not lubricate, repair or adjust the machine while it is working.3. Service the machine regularly. Keep wheels clean and dressed for best cutting

results and to reduce safety risks. Follow instructions for machine lubricationand wheel replacement.

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4. Use original spare parts. Consult the handbook for recommended spare parts.The use of other spare parts could lead to damage to the machine or jeopardizemachine performance, besides causing injury to the persons working on it.

5. Before starting the machine make sure there are no damages to guards or otherparts.Check the conditions, alignment and fitting of moving parts, damagedcomponents or any auxiliary structure which could hamper correct machineoperation.Repair or replace damaged guards and parts.

6. Before starting up the machine, check that screws and bolts are tightened onmachine moving parts.

7. Prevent accidental start-up. Take all steps necessary to prevent accidentalmachine start-up (e.g. press the emergency pushbutton before makingadjustments to the machine).

8. Delimit maintenance area and mark it by signals.9. Always keep the machine lubricated in its main areas, with lubricants indicated

in the instructions.

2.5 DANGEROUS AREAS

A=

B=

C=

Machine working.

Machine feed and wheelinspection door open: during wheeldressing and checkover of waterflow onto tools.

Area inside the energizedelectrical cubicle during servicing

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2.6 RESIDUAL RISKSSome servicing procedures appropriately indicated in the manual, expose theoperator to risks otherwise impossible to eliminate. Residual risks can beeliminated by carefully following the procedures indicated in the manual andadopting individual protection devices indicated each time.

2.6.1 APPLICABLE INDIVIDUAL PROTECTION DEVICES

Helmet protecting against risks of objects falling from above,or collision against obstacles.

Protective apron against accidental cutting by sharp glassparts: for material loading, unloading and handling phases.

Gloves protecting against cuts and abrasion when handlingglass sheets.

Glasses protecting against risks of chips of powder coming outduring tool dressing operations.

Slop-slip footwear with anti-crush toe.

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3. TECHNICAL INFORMATION

3.1 GENERAL DESCRIPTION OF THE MACHINE"V" machines are automatic straight-line edging machines, horizontal and double-edgers, to process flat glass sheet and mirror profiles. Processing is done by a setof peripheral diamond and polishing wheels.Corner chamfering is automatic by means of an additional device (upon request).The position of the fixed bridge, as to the direction of speed progress definesmachine orientation: right or left.These machines can be connected to another grinding machine of same model, tomake a double-edging line able to grind and square a glass sheet in just oneworking cycle.

These machines are designed to be used in an industrial site, in areas specificallyequipped to work glass and protected against outside atmospheric agents. Just oneoperator, helped by another person during loading and unloading phases ifnecessary can drive each machine. A suitable lifting device must be used forhandling big and heavy glass sheets (more than 30 Kg).The operator must be qualified in using a complex machine, properly instructed andhave a specific preparation in the glass-working field.

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3.2 DESCRIPTION OF MODELS

Position of the wheel as to glass sheet entrance1 2 3 4 5

V3 Half-polished edge

D1 D2 L1 DS(*)

V4 Polished edge

D1 D2 L1 L2 DS(*)

Wheel identification marksD(x) = Diamond pencil edge n° x. DS(*) = Diamond for corner chamfer (upon request)L(x) = Polishing pencil edge n° x.

90°

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3.3 DESCRIPTION OF MAIN COMPONENTS

1 Electrical cubicle 13 Upper conveyor2 Control panel 14 Glass presser pad3 Operator/NC interface 15 Lower conveyor4 Machine base 16 Conveyance motorvariator5 Water tank and covering grill 17 Working spindles6 Water pump 18 Panel for spindle control and adjustment7 F.R.L. unit 19 Exit side supporting bracket: idle wheels8 Fixed bridge 20 Lubrication pump9 Movable bridge 21 Glass sheet squaring unit10 Inlet side supporting bracket: idle wheels 22 Operation motor of sprung bridge11 Side sprung wheel striker 23 Transmission shaft12 Side fixed wheel striker

10

1617

14

23

5

18

13

7

4

6

22

32

812

11

9

15

19

20

21

1

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3.4 CONFIGURATION VARIANTSParts that can be installed on the machine to replace the side supporting brackets,when the grinding machine is connected to other machines: for example indouble-edging lines.

DESCRIPTION EXAMPLES OF APPLICABILITY

Motorized entrance unit

• MB1 entrance from roller• MB2 entrance from transfer

Motorized exit unit

• Exit from MB1 to transfer.• MB2 exit to transfer/deviator

Long motorized exit unit

• MB2 exit to washing machine

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3.5 OPERATING CYCLEMain phases of a working cycle are described and illustrated here following.

The operator startsspindles and machineconveyance

In this area the operatorloads the glass sheet towork, by lying it by handon the side supportingbrackets. Another personcan help him, or he canuse suitable hoistingequipment. The sheet ispushed towards themouth of the automaticconveyance system.

The sheet goes inside themachine, allowing theselected wheels to carryout processing set-up bythe operator.

In this area the operatorcan unload the sheet byhand, helped if necessaryby another person or bysuitable hoistingequipment.

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WORKABLE MATERIAL: - Glass sheets, including laminated glass and mirrors.

APPLICATIONS: - Grinding and polishing by abrasive wheels and others

PROCESSING:Level of finishing varies accordingto the model purchased: seechapter 3.2

- Edge grinding and polishing, pencil edge: (A).- Corner chamfering (upon request): - (B).- Sheet squaring: (C), obtained by two different

working cycles.

TOOLS: - Set of diamond and polishing wheels

COOLING: - Water jets directly onto the tool

SHEET CLAMPING: - Between the fixed and movable side of the machineinward conveyor

FUNCTION CONTROL: - By numerical control

= Water

A B

C

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3.6 SAFETY DEVICES

1 Main switchIn "0" or "0FF" position, the machine is disconnected from the electrical power mains. Tampering isprevented when the switch is locked in this position by a padlock. It is possible to open the door of theelectrical cubicle only in this position.

2Emergency pushbuttonStopping the machine immediately when a sudden dangerous situation occurs. The device must bereset to start working again.

3 Pressure switchStopping the machine for emergency if input pressure of the pneumatic system is below 4 Bar.

4 Fixed protections (*)Preventing the operator from putting his hands and arms in the conveyance mechanism and savingfrom water spraying and particles due to glass breakage.

5 Fixed protectionPreventing the operator from putting his hands and arms in the conveyance mechanism and savingfrom water spraying and particles due to glass breakage.

6 Fixed protectionEliminating the risk of crushing the operator’s lower limbs due to movement of the cable-holding chain.

7 Fixed protection (*)Eliminating the risk of stumbling into the cables connecting the electrical cubicle to the machine.

8 Fixed protectionEliminating the risk of crushing the operator’s upper limbs near strikers and the control cylinder for thesquaring unit.

9 Fixed protectionEliminating the risk of tangling, dragging and crushing lower limbs into the transmission belt ofdiamond and polishing spindles.

(*) = Not visible in the drawing

2

23

2

1

5 4

6

22

7

8

9

V3 - V4


3.6.1 ELECTRO-MECHANICAL SAFETY DEVICES AND ELECTRICAL INTERLOCKS

• Tripping of the water pump thermal protection causes machine emergency stop.If any other thermal protection trips the glass conveyance system stops,keeping current processing waiting (all wheels are triggered with polishingwheels stopped in the position they were when damage occurred).

• Glass conveyance works only when all selected wheels start.

• Glass forward conveyance does not work if the first diamond wheel couplestops.

• Glass conveyance stops when a diamond wheel untriggers while operating.Therefore conveyance must be started again.

• Bridge opening while the conveyor is running is inhibited.

• Opening and closing of the movable bridge beyond limits indicated in thetechnical details (min. and max. workable size) is inhibited by safetymicroswitches, even when the intermediate bridge is installed.

3.6.2 SAFETY DEVICES OF THE ELECTRICAL CUBICLE

!

DANGER:The devices listed here following supply warnings and protection to theoperators.Only a person qualified in electrical servicing can work with theelectrical cubicle open and energized.

10 Flash-lightWarning the operator the electrical cubicle is energized. The indication is given by three red lightsflashing in cyclical phase.

11

Microswitch release enabled to reset the main switchThe main switch (1) trips ("OFF" or "0" position) automatically when opening a door without a mainswitch giving access to the electrical cubicle.It must be pushed to reset the main switch. Normally, this condition is guaranteed when the doors ofthe electrical cubicle are closed.

1 11 1010

V3 - V4


3.7 POSITION OF SAFETY SIGNALS

1 Wearing a helmet iscompulsory 7 Do not interfere while the

machine is working

2 Wearing overalls iscompulsory 8 Do not remove or

disconnect safety devices

3 Wearing protectivegloves is compulsory 9 Danger! Organs in

movement

4 Wearing protectiveshoes is compulsory 10 Danger of electrocution

5 Wearing protectiveglasses is compulsory 11 Danger in general

6 Reading the instructionmanual is compulsory

1, 2, 3, 4, 7, 8, 9

10

5, 6, 11

V3 - V4


3.8 ACCESSORIES SUPPLIED WITH THE MACHINEThe machine is supplied with the following parts:

Equipment to hoist bridges:

Intermediate bridge

Accessory to install the sprung bridge:n°2 pieces each supply

Tool kit:

1 Tool kit2 Grey paint 7038.3 Wheel dressing tool

4 Set of fixed and combined wrenches:(8-10; 13-17;14-15; 19-22; 24; 30-32)

5 Articulated T-wrench 19 mm: hexagonal head.

6 Kit of socket head screws ART. 280 + 2.5 mmsocket head screw

Cable- covering stands between theelectrical cubicle and the machine:

1

23

4

56

V3 - V4


3.9 ACCESSORIES UPON REQUEST

3.9.1 CORNER CHAMFERING SPINDLE FOLLOWING THE GLASS SHEET

This unit is to grind the fourperimetral edges of the glass sheetbeing worked by diamond wheel.Refer to chapter 5 for description ofthe spindle.

V3 - V4


3.10 TECHNICAL DATA

MODELS

TYPE V3 V4

Workable glass thickness: mm (*) 2 ÷ 12

According to width of the lower belt of the conveyor systemMin. workable dimensions:

19 mm belt 25 mm belt 38 mm belt

Without corner chamferingdevice 80x80 100 x 100 120 x 120

With corner chamfering devicemm

(*)

120 x 120 130 x 130 150 x 150

1000 1000 x 1000

1200 1200 x 1200

1600 1600 x 1600

2000 2000 x 2000

Max. workable dimensions: (Dmax) mm

2600 2600 x 2600

Progress speed: m/min (*) 0 ÷ 18

Pneumatic feed:

Pressure Bar 6Capacity Nl/min

(*)

3

Water input:

Head m 10Capacity l/min

(*)

450

Electric input:

Rated voltage See wiring diagramTolerance ± 10% of rated voltage

Dips and small interruptions ofpower mains

(*)

In compliance with:

- CEI EN 61000-4-2÷5- CEI EN 61000-4-11÷12- CEI EN 61131- EN 55022

Total power installed: Kw (*) 20 24.5

10001200 540

1600 7202000 900

Capacity of water tanks: litri

2600 1170

(*) = ALL

V3 - V4


MODELS

TYPE V3 V4

Total length (L) mm (*) 3450

1000 22601200 24601600 28602000 3260

Width of machine body (W) mm

2600 3860

Total width (W1) mm (*) Parameter (W) + 1300 mm

Total height (H) mm (*) 1250

Height of working plane (H1) Mm (*) 920 ÷ 950

10001200 33001600 34702000 3640

Total weight(With empty water tank):Tolerance ± 5 %

Kg

2600 3750

Weight of electrical cabinet Kg 180

Numerical control (*) RS200

Operator interface (*) CN 23

Programmable control (PLC) (*) Integrated in the NC

Screen (*) Liquid Crystal Display (LCD)

Operative keyboard (*) Sensitive keys

(*) = ALL

V3 - V4


3.10.1 TOOLS

Standard equipment for each model available is described in chapter 3.2 and inthe following chart:

Rotation speed [rpm]Wheelmark Type Operation Diameter

[mm] With 50 Hz motor With 60 Hz motor

D1 Peripheral Pencil edge grinding 200 4450 4450

D2 " " " " "

L1 " Pencil edge polishing " 2800 3360

L2 " " " " "

DS Peripheral Corner chamfering 50 5000 6000

V3 - V4


3.11 NOISEEmission of noise during machine use depends on many factors; such asconditions of wheels and relevant cutting capacity, type of work done, conditions ofspindle bearings etc.

Methods used in measuring

Measuring points: Operator’s working place: Seedrawing and chapter 6.

Height from the ground: 1.6 m

InstrumentPhonometer type CRL 412(produced according to IEC651 rule)

Site where measuringtakes place

Industrial construction inreinforced concrete: size 51 x19 x 10 m

Position of the machinewhere measuring takesplace

30 x 6 mt from the reflectingwall

Max. sound pressure level: [ dBA ]

Mea

surin

gpo

ints

V3 V4

1 742 743 794 74

All wheels running, noworking performed

5 77

1 802 843 864 84

100 x 490 x 4 sheetTotal removal: 2mm (1 mmfor each side)Speed: 3 m/min

5 86

1 802 873 874 87M

ost i

mpo

rtan

t wor

king

con

ditio

ns(*

)

100 x 490 x 4 sheetTotal removal: 2mm (1 mmfor each side)Speed: 10 m/min

5 87(*) = Accomplished with new Z. BAVELLONI wheels in standard configuration: see paragraph 3.10.1.

V3 - V4


4. HANDLING AND INSTALLATION

Refer to the installation manual of the machine.

V3 - V4

REV. 001 v3_v4-ing-cap05-rev001.doc - 10/03 page 5.1

5. MACHINE ADJUSTMENT

ATTENTION:Machine adjustment, either if the machine is on or off, must be done byjust one operator in completely safe conditions, following theprocedures described in this chapter.

5.1 TESTINGMachine is tested at Z. Bavelloni S.p.A. Co. before being delivered to the customer.Testing guarantees normal machine working according to requirements and workingprograms ordered by the customer.

5.2 BREAKING-INGenerally, no breaking-in period is necessary, being done during testing at theZ. BAVELLONI factory, except the motorvariators: see chapter 7.

5.3 ADJUSTMENT OF SPRUNG BRIDGE OPENINGUsually necessary to set-up the finished measure of the piece being worked. Do itat the machine control panel by means of the operator interface: see programmingmanual concerning setting up a new bridge set-point.

5.4 ADJUSTMENT OF GLASS PROGRESS SPEED

To be done at the control panel of themachine, by means of the operatorinterface: see the NC programmingmanual “SPEED SET-UP…”Adjustment is done by the servomotor(1) connected to the motorvariator (2)of the conveyor. The encoder (3) fit tothe transmission shaft surveys instantspeed of glass conveyance.

ATTENTION:Speed adjustment must always be done while the conveyor is moving.

3

12

V3 - V4


5.5 SIDE STRIKER PLANE ADJUSTMENT

Applicable to single machine or first grinding machine of a double-edger

• Loosen the handle (A).• Rotate the spindle (B) and set-up at the indicator (C) the required value for glass

removal.• Position the striker and clamp it by tightening the handle (A).

Striker on fixed bridge

A =

X =

X+2A =

Glass removal; according to:• Glass sheet thickness• Precision of cut• Glass progress speed

Finished measure of the piece,determined by the position of thebridge: see paragraph 5.3.

Size of the glass to put into themachine

• Loosen the handle (A).• Turn the handle (B) to position the striker.• Tighten the handle (A) to clamp the striker to its position.

Striker with sprung wheels

mm 1/10 mm

360° = 1 mmBA

C

BA

A

A

B

V3 - V4


Adjust the striker on the fixed bridge each time you want to change the quantity ofglass the diamond wheels must remove. Then, approach the striker with sprungrollers to the glass edge, giving the springs a sufficient preloading value toguarantee glass thrusting towards the fixed striker wheels.

WARNING:The sprung striker must be moved away from the glass when using thesquaring system on the single grinding machine.

5.5.1 ADJUSTMENT OF SQUARING CENTERING DEVICES

On double-edgers, side strikers of the second grinding machine (MB2) are replacedby glass centering devices making part of the squaring system (chapter 5).

Longitudinal positioning of centering devices

• Loosen the handle (A).• While the glass sheet is in squaring position, make the striker slide by hand and

stop the centering wheels (R1-R2) at about halfway length (L) of the sheet.• Clamp the striker in its position by tightening the handle (A).

Centering device on fixed bridge Centering device on movable bridge

A

R2

A

R1

V3 - V4


Transversal positioning of centering devices

• Loosen the handle (B).• Turn the handwheel (C) and set the required value of glass removal on the

indicator (G).• Adjust the centering device on the sprung bridge so that the glass sheet is

pushed with enough force to keep it in contact with the roller (R1) of the strikercentering device (the one on the fixed bridge). This adjustment occurs duringmachine installation and afterwards it must be checked periodically. Proceed asfollows:• Extend the pistons of the cylinder centering devices, darkening for example

the photoelectric cell (F) of the squaring system.• Measure distance (M) between R1 and R2 of centering devices.• Turn the handwheel (C) so that distance (M) among the rollers is less than

about 10 mm as to the width of glass sheet in entrance.• Check working pressure in the cylinder (D) is correct on the manometer (E):

paragraph 5.11.• Clamp centering devices in their position by tightening the handle (B).

Centering device on fixed bridge

Centering device on movable bridge

F

R1

B

mm 1/10 mm

360° = 1 mm

E

B

D

C

G

G

C

B

R2

V3 - V4


5.5.2 ADJUSTMENT OF SIDE MOTORIZED STRIKERS

The striker planes are powered for particular applications, for example with loadercoupled in inlet to the first grinding machine of the double-edger.Adjustment is done the same way as for the side strikers (fixed type and withsprung rollers): see paragraph 5.5

5.6 ADJUSTMENT OF GLASS SHEET PRESSERSThe position of pressers must be adjusted at each change of glass thickness beingworked.The machine is equipped with two identical devices: one on the movable bridge andone on the fixed bridge.

• Loosen the handle (A).• Turn the handwheel (B), visualizing glass sheet being worked on the indicator

(C).• Clamp in its position, tightening the handle (A).

A

B

C

V3 - V4


5.7 ADJUSTMENT OF PROJECTIONThe diamond wheels carry out glass removal; then the glass sheet protrudes fromthe conveyor belt for “X” minimum value, prefixed during machine testing.The value of projection is not a fixed datum: for example, it may change accordingto machine configuration (adding corner chamfering spindles upon request), or dueto particular working needs. In these cases it is necessary to adjust the machine:strikers, spindles, centering devices, etc. The technicians in charge of After-SalesService at Z. Bavelloni S.p.A must do these operations: see paragraph 1.7.

X= projection

BELT

GLASS

5.8 ADJUSTMENT OF DIAMOND WHEELSThe diamond spindle assembly allows three different wheel adjustments:1. Vertical centering: function of glass thickness to be worked (paragraph 5.8.1).2. Slanting: function of glass thickness to be worked and of throat width of the

wheel (paragraph 5.8.1).3. Horizontal positioning: function of glass sheet to be removed and of wheel

consumption (par. 5.8.2).

V3 - V4


5.8.1 VERTICAL CENTERING AND SLANTING OF THE DIAMOND WHEEL

Preliminarily, check the size of the wheel throat is suitable to the glass sheetthickness to be worked.

• Loosen the handle (A).• Turn the hexagon (B) and set glass thickness to be worked on the indicator (C).• Slant the spindle by hand up to the angle required (α). Slanting is set-up on the

graduated scale (D).• Clamp the wheel in its position by tightening the handle (A).

WARNING:Check correct wheel consumption periodically making sure the wheelworks correctly on the glass; the thickness of the glass must take up allthe width of the wheel throat.

C

B

A

D

V3 - V4


5.8.2 HORIZONTAL POSITIONING OF THE DIAMOND WHEEL

Adjust the wheel turning the hand wheel (A); the position is visible on the indicator(B).

WARNING:Check electrical input of spindles on the manometers (C) frequently.This parameter supplies a direct indication on how the wheel isworking.

Recovery of wheel consumption is done manually, making the spindles go aheadenough to restore correct value of current input.

mm 1/10 mm

360° = 1 mm

B

C

A

B

V3 - V4


5.8.3 ADJUSTMENT AFTER REPLACING DIAMOND WHEELS

• Position the side striker on the fixed bridge to "0" (for the MB2 adjust thecentering device on the fixed bridge): see paragraph 5.5.

• Put a 5/6 mm thick glass sheet already ground and make it go forward on theconveyor until it reaches and surpasses the position of the second couple ofdiamond wheels.

• Turn the machine off and set it to security conditions.

• Make the wheels approach the glass: paragraph 5.8.2. Do this operation byturning the wheel by hand, until wheel rubbing is perceived when it touches theglass.

• Back up the first couple of wheels 0,3 mm.

• Turn the machine on, back up the glass sheet out of the wheel working area.

• Set-up the most suitable value for glass removal: paragraph 5.5

• Grind the glass until the second couple of wheels leaves its print.

• Back up the glass sheet, take it out of the machine and check the working doneon both sides of the glass.

5.9 ADJUSTMENT OF POLISHING WHEELSThe polishing wheel assembly allows two different wheel adjustments.

1. Slanting: function of the glass thickness to work.2. Horizontal positioning: to polish the glass sheet edge.

V3 - V4


5.9.1 SLANTING OF THE POLISHING WHEEL

The polishing wheel must not be replaced when glass thickness changes; spindleinclination must be corrected so that the entire band of the wheel lies on the sheetedge.

• Loosen the handle (A).• Slant the spindle by hand according to the required angle (α). Slanting must

be set-up on the graduated scale (B), expressed in thickness (S) of glassto be worked.

AB

V3 - V4


5.9.2 HORIZONTAL POSITIONING OF THE POLISHING WHEEL

The horizontal movement of polishing wheels is given by an electropneumaticalsystem (TAV 076), managed by numerical control and by dedicated controls on thecontrol panel: see chapter 6.

• The selectors to turn the wheels on and off, control respectively forwarding/andbacking up of relevant wheel towards/from the glass sheet.

• The polishing wheels must be backed up simultaneously when necessary.

• Adjust the handle (B) of the mechanical clamp (A) to restrict the spindlepneumatic stroke.

• Polishing the edge, featured by a strong thrust of the wheel against the glasssheet, is automatically controlled by the multihead system, according to theposition of the sheet inside the machine: see paragraph 5.10.

• Two flow regulators fixed on the operation cylinder (C) adjust the speed ofspindle movement. Rotation of ring nuts (D) and (E) respectively changeprogress and backing speed of the wheel.This adjustment is not very frequent after machine testing and installation.

C

B

A D

E

C

V3 - V4


5.9.3 ADJUSTMENT OF THE POLISHING WHEELS

• Make a test by putting an already ground glass sheet go forward on themachine conveyor, stopping it a little after the position ofthe last couple of wheels installed on the machine.

• Select polishing wheels at the control panel: the wheels go forward until theytouch the glass.

• Adjust working pressure of the wheels: see paragraph 5.11.

• Make the glass go forward and start polishing part of the sheet.

• Invert working direction of the conveyor and remove the sheet.

• Analyze work done by each wheel and correct working pressure if necessary.

• Checking polishing again.

5.10 ADJUSTMENT OF POLISHING WHEEL TRIGGERING: MULTIHEADSYSTEMThis system is integrated in the NC program and makes polishing wheels work onlywhen the glass passes in relevant working area and as long as it remains there.Wheel triggering is determined by a microswitch (A), operated by the glass sheet inentrance, enabling calculation of distance (X) corresponding to the point where thewheel must push the glass (entrance), and calculation of distance (Y) at which thewheel stops polishing (exit and detachment). After detachment, the wheels stop intheir position waiting for the next glass sheet.

Y

X

X=Y=

A

Qualified staff must do these adjustments.• Use the screw (B) to adjust the microswitch (A) triggering point.

• Calibration and adjustment of the “multihead” system is done from the NCprogram: see relevant manual.

A

B

V3 - V4


5.11 WORKING PRESSURE ADJUSTMENT

Reference values

Working pressure of polishing wheels [R9(*) + M9(**)]:Changing according to glass thickness being worked, the type of wheel used andworking quality you want to obtain. 1 ÷ 2 Bar

Glass sheet squaring system:- Pressers [R2(*) + M2(**)]:

changing according to glass sheet to be worked 3 ÷ 4 Bar- Sprung bridge centering device [R8(*) + M8(**)]: only on double-edging lines. 1 Bar

Corner chamfering spindles following the glass sheet (uponrequest)- Counter pressure [R10(*) + M10(**)] 1 Bar- Pressure [R11(*) + M11(**)]. 1 Bar

(*) = pressure regulator. (**) = Checkover gauge

WARNING:Correct calibration is done by always increasing pressure.

R9 M9R2 M2 R9 M9

R11

M11

R10

M10

M8R8

V3 - V4


5.12 ADJUSTMENT OF THE CORNER CHAMFERING UNITThis unit is to grind the four peripheral edges of the glass sheet being worked bydiamond wheel. Therefore, the corner chamfering spindles following the glasssheet is used.

ATTENTION:For installation of the corner chamfering unit, done after machine initialtesting phase, it is necessary to re-determine minimum part of glasssheet projecting from the grinding machine conveyance belt.Contact Z. BAVELLONI S.p.A. Technical Assistance: seeparagraph 1.7.

5.12.1 THE CORNER CHAMFERING SPINDLESThe corner chamfering unit is made of a unit (H) integral with the machine base anda moving unit (H1) where the spindle assembly is installed. The moving unit has twopossibilities of movement: longitudinal (Y), by means of a pneumatic cylinder (1)and transversal (X), contrasted by a spring (A).To make maintenance easy, the spindle is of the tilting type and can be excludedfrom glass sheet working by backing it up by hand and clamping it in position by theback stop (S).

A1

H

H1

S

V3 - V4


5.12.2 OPERATION CYCLE OF THE CORNER CHAMFERING SPINDLES

The spindle following the glass sheet moves longitudinally during corner chamferingphase and is pushed by the glass during front corner processing and follows theglass to work the back corner. In both phases, there is a spring for transversaltightening guaranteeing the correct time for contact of the wheel on the glass.Corner grinding is done in four phases:

PHASE 1 • The glass intercepts the spindle

along its trajectory and while thecorner is ground it drags thespindle longitudinally, andovercomes the counterpressureapplied to the valve (C).

• The corner chamfering spindlebacks up transversally when oneof the following conditions isreached:

a) the transversal force resultingfrom glass sheet thrust on thespindle overcomes thepreloading value applied tospring (A).

b) the piston of the pneumaticcylinder (1) reaches thelimitswitch.

• Spindle back-up makes

microswitch (3) cut in. The latterstores the arrival of the glasssheet.

PHASE 2: • The spindle goes back to rest

position, recalled by thecounterpressure (C), still inpneumatic cylinder (1). Duringreturn movement the spindleruns on the edge of the glass byidle striker stakes (4), dislocatedon the wheel perimeter.

21

F

AC D

3

PHASE 1

2

1

F

AC D

3

4

PHASE 2

V3 - V4


PHASE 3

• Once the glass sheet tail is

reached, the spindle (F),advances again being pushedby spring (A) and makes themicroswitch (3) cut in for thesecond time.

• Sensor (3) enables to applypressure to the valve (D), withconsequent longitudinalmovement of the spindle in thedirection following the glass.

WARNING:Adjustment of valve (D) determines the speed during the phase ofglass sheet following. Progress speed must always be higher thanglass sheet movement.

PHASE 4 • Once corner processing is

finished, the spindlesurmounts on the glass sheetedge and runs along it until themicroswitch (2) cuts in.

• This sensor takes pressurefrom the valve (D) thereforeallowing the spindle to go backto its rest position, recalled bypressure applied to the valve(C).

2

1

F

AC D

3

PHASE 3

2

1

F

A C D

3

PHASE 4

V3 - V4


5.12.3 DEPTH OF CORNER GRINDING

Working of chamfers with standard size (≅ 0,5 ÷ 1 mm) is guaranteed due toadjustments made during the testing phase.If you need to increase the corner size beyond this limit, you must replace thestriker stakes (2) with smaller ones.In any case, contact the After-Sales Service at Z. Bavelloni S.p.A.: seeparagraph 1.7.

d1 < d

ATTENTION:According to cases, the size of striker stakes is not the only modificationto make on the machine to obtain bigger cornersModifications not approved by the manufacturer on the machine maycause serious damage to the machine and diminish efficiency of theprotections arranged for the machine operator’s safety.

5.12.4 TRANSVERSAL ADJUSTMENT OF THE CORNER CHAMFERING SPINDLES

Adjust spring tension (A) if sheet progress and corner chamfering spindles followingthe glass are in regular conditions, you will find the back corners are smaller thanthe front ones.

Proceed by steps:

• Loosen the lock nut (C).

• Adjust spring (A) tensioning by means ofnut (B).

• Tighten the lock nut (C).

• Work a glass sheet with small thicknessand minimum format at 5/6 m/min. speed.Check the size of the back corner as to thefront one.

• Repeat this procedure until the size ofback corners is equal to front ones.

Too much tensioning of the screw (A) maybreak the glass sheet being worked. B

CA

V3 - V4


5.12.5 LONGITUDONAL ADJUSTMENT OF CONER CHAMFERING SPINDLES

Operate on the valves mounted on the pneumatic cylinder of the spindle.

• Adjust the valve (D) to change speedrequired to follow the sheet.This parameter must always be biggerthan glass progress speed.Adjustment is correct when the size of theback corner is the same as the front one.

• Adjust the valve (C) to change return speedin spindle position.

5.12.6 VERTICAL ADJUSTMENT OF CORNER CHAMFERING SPINDLES

Adjust vertical position of the wheel to center it as to the thickness of glass sheetbeing worked or to make its wear out even.

• Loosen the screws (A): one for eachside.

• Turn the screw (B) until you reach theadjustment required.

• Clamp screws (A).

5.12.7 UNTRIGGERING THE CORNER CHAMFERING SPINDLE

• Back up the spindle by means of thehandle (A).

• Put the clamp (S) in order to make thespindle keep its backward position.

DC

V3 - V4


5.13 ADJUSTMENT OF THE SQUARING SYSTEMThe squaring unit is mounted on the machine entrance and allows obtaining a sheetwith perpendicular sides.The squaring system on the double-edging machine line is installed only on thesecond machine of the line.

5.13.1 THE SQUARING SYSTEM

This system consists in:

1) Front sheet stop: adjustable type2) Centering device ( ) or side striker on fixed bridge ( ).3) Glass sheet pressers.4) Photoelectric cell for glass sheet presence5) Sensor to reset the squaring cycle.6) Timer (T0): ( ).

7) Timer (T1).8) Timer (T2).9) Timer (T3).

( ) = Only on the second machine of the double-edging line.

( ) = Only on single machine.

( ) = Only on double-edging line.

2

4

3

511

3

4

3

511

3

2 2

7 8 9 6 7 8 9

Single machine Double-edging line(*) = Constant value PT = Potentiometer on control panel.

(**) = Parameter to be changed by the operator CNC = Set-up by the NC program.

V3 - V4


5.13.2 OPERATION CYCLE OF THE SQUARING UNIT OF THE SINGLE MACHINE

The operator must load the sheet on the side support brackets, and rest it on thestriker rollers (2). The long side of the glass, already ground, must be directedtowards the front stops (1).

Squaring sequence occurs in four phases:

1. The operator transfers the sheet on the belts of the conveyor system. Thephotoelectric cell (4) feels the presence of the glass sheet and controls squaringcycle start after T1 time. This time allows the operator to approach and line upthe glass sheet perfectly to the front stops (1).

2. When T2 time passes, the pressers (3) go down and press against the lowerbelts of the conveyor.

3. After T3 time, starting from the descent of pressers, the front stops (1) moveaway allowing glass sheet to advance.

4. When the sensor (5) feels the passage of the glass sheet tail, it commands thepressers (3) to go up and the front stops to approach (1) arranging the machinefor a new squaring cycle.

V3 - V4


5.13.3 OPERATION CYCLE OF THE SQUARING UNIT ON DOUBLE-EDGING LINE

The glass sheet with the long side worked by the first grinding machine of the line ismoved from the transfer on to the conveyance belts of the second grindingmachine.

Squaring sequence occurs in five phases:

1. The glass sheet intercepts the photoelectric cell (4) and after the T0 time it restson the front stops (1), starting the automatic squaring cycle.

2. Time delay (T1) allows the glass conveyance system to position the side of thesheet already ground perfectly against the front stops (1). At the end of thisphase the centering devices extend themselves (2), positioning the glass sheettransversally to the direction of progress. The centering device piston mountedon the fixed bridge is the reference one and anticipates the one mounted on thesprung bridge.

3. After the T2 time, starting from the intervention of centering devices, thepressers go down (3); they press against the glass which is centered andsquared, against the lower belts of the conveyor.

4. After the T3 time, starting from presser descent, the front stops (!) and centeringdevices allowing glass progress, move away.

5. Passage of the glass tail, surveyed by the sensor (5), controls presser ascent(3) and front stop (!) approach (1), preparing the machine for a new squaringcycle.

V3 - V4


5.13.4 ADJUSTMENT OF FRONT STOPS OF THE SQUARING UNIT

Adjust the position of one of the two front stops, as you like, if during machine useyou find processing of the piece out of square.

• Remove the protection carter of thesquaring unit.

• Loosen the screws (A).• Adjust the screw (B) to approach or

move away the front stop (C) for thesquaring difference (X) measured on theworking piece.

• Clamp by tightening screws (A).• Install the protection carter.• Try to grind a sheet to check if

adjustment is correct.

A

A

BC

V3 - V4


5.14 FILLING THE WATER TANK

• Close the discharge tap (A).

• Fill the tank with water till the level of grill (B) is reached.

B

A

V3 - V4


6. USE AND OPERATION

ATTENTION:The operator must accomplish his basic training before starting to workwith the machine.

So it is necessary to:

− Read and learn the instructions for use;− Attend complete instruction organized by Z. Bavelloni

S.p.A. concerning use of the machine;− Strictly adhere to the SAFETY INSTRUCTIONS of

chapter 2.

6.1 DESCRIPTION OF CONTROLS

6.1.1 CONTROL PANEL

The panel shown herewith shows the utmost configuration arranged on the double-edging grinding machines contemplated in this manual.The real quantity of controls and their arrangement on the control panel depends onthe type of machine purchased.Use the following tables to determine configuration.

NU = Not used (*) = Only on "V4 "model

V3 - V4


Controls for all configurations

Pos. Description Pos. Description

IO1 Interface with the operator of machinenumerical control. S4 Selector for CUTTING IN/OUT the glass sheet

squaring unit.

P1 Emergency pushbutton S22, S23 Selector for CUTTING IN/OUT diamond wheels forpencil edge.

S1Key selector to trigger the line:(2 positions OFF/ON), with extractable keyonly in OFF position.

S24, S25 Selector for CUTTING IN/OUT polishing wheels forpencil edge.

Configuration of controls for single machine


PT1 Potentiometer to set-up start delay of thesheet squaring sequence. S21 Selector for CUTTING IN/OUT corner chamfering

spindles (UPON REQUEST).

Configuration of controls (upon request) for loader on line[not arranged on the single machine]


P8 Loader cycle start P9 Loader cycle stop

Configuration of controls for single machine or first machine of a double-edging line


PL1Luminous mushroom-head button tobackward polishing wheels; warning lamplights with wheels backward

P3 Pushbutton for forward conveyance (steadyoperation)

PL2 Luminous pushbutton to operate the spindlemotors and water pump P4 Pushbutton for glass sheet conveyance stop

PL3Pushbutton to stop spindle motors and waterpump; warning lamp lights when one or morethermal protections trip.

S33-position (1,0,2), key selector to choose operationmode (dressing, automatic, coolant flow control). Thekey can be extracted in position (1-2), correspondingto both manual cycles.

P2 Pushbutton for backward conveyance(unsteady operation)

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Configuration of controls for first 90° transfer of a line


S7Selector with 3 positions for lower conveyoroperation by bridge belts: pos. FORWARD /BACKWARD / STOP

S8 Selector for commutation of the transfer movabletable in DOWN / UP position

Configuration of controls for second machine of a double-edging line


PL4 Same as PL1 S6 Same as S3

PL5 Same as PL2 S21 Selector for CUTTING IN/OUT corner chamferingspindles (UPON REQUEST).

PL6 Same as PL3 S26 Same as S22

P5 Same as P2 S27 Same as S23



Configuration of controls for second 90° transfer of a line[upon request for all configurations]


S9 Same as S7 S10 Same as S8

Configuration of controls (upon request) for washing machine in line[not arranged on single machine]


P10 Pushbutton to start washing machineprogress (steady type of operation). P11 Pushbutton to stop washing machine conveyor.

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6.1.2 CONTROL ON THE ELECTRICAL CUBICLE

Single machine and double-edgng line Double-edging line

Main switch with padlock in "0" (OFF) position.

Position the switch on "I" (ON) to give voltage to the electrical cubicle.

6.1.3 CONTROLS ON OUTSIDE PUSHBUTTON PANELS

They are only on the double-edging line at the entrance side of MB2 machine.

Forward glass conveyance (*).To reset squaring unit while conveyoris moving (**).

Glass conveyance STOP

Backward glass conveyance

Change time (T1) for the centeringdevices of the squaring system to cutin: paragraph 5.13.3.

(*) = Pressed once(**) = Pressed twice.

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6.2 WORKING SITE OF THE OPERATOR

1 -2 -

Control positionGlass sheet loading

3 -4-5 -

Glass sheet unloadingInspection and adjustment

6.3 STARTAt each work shift or at first daily start, check preventively if the emergency stopdevices (cap. 6.5) and safety devices (cap. 3) work.The machine can work only in the automatic or manual modes.

6.3.1 AUTOMATIC CYCLE

It is the mode for machine normal use. In these conditions the NC programmingsystem governs each working phase.

6.3.2 MANUAL CYCLE

The use of manual controls is arranged only for:

• Machine adjustment and maintenance.• TestingThe machine is also arranged with two dedicated manual cycles, which can beselected at the control panel, to carry out the following operations:

• Tool dressing: cycle . Enabling spindle rotation and inhibiting the operationof the water pump.

• Checkover of coolant flow on tools and washing the system: cycle .Enabling water pump flow and inhibiting spindle rotation.

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6.3.3 AUTOMATIC CYCLE START ON THE SINGLE MACHINE

1. Adjust the position of side strikers according to the quantity of glass to beremoved.

2. Adjust glass pressers according to glass thickness to work.3. Position the wheels according to processing to be done.4. Select spindles to use at the control panel (controls S21 ÷ S25). The other

spindles must be backed.5. Give power to the grinding machine, by rotating the main switch to position

"I" (ON).6. Check on the interface panel pos. IO1 if the NC is started and the first screen

page is visible: see programming manual.

7. Give power to the control circuits at low voltage: selector (S1) .

8. Turn the selector (S3) to the automatic mode: .9. Enter required working parameters on the NC: refer to NC programming

manual.

10. Start the spindles selected and the water pump: pushbutton (PL2) .

11. Start the forward conveyance of the glass sheet: pushbutton (P3) .12. Load a glass sheet of suitable size (chapter 5.5) on the side entrance support

brackets and push it until it reaches the mouth of the conveyor system, keepingit touching the side reference striker.To load heavy sheets, use a suitable lifting equipment.

13. Unload the glass sheet from the side exit support brackets, when the sheet isdisengaged from machine conveyance system.

WARNING:Glass sheets can be loaded inside the machine even in quicksequence, as long as they have same thickness and length; it is notnecessary to wait for completion of its working cycle.

6.3.4 AUTOMATIC CYCLE START ON THE DOUBLE-EDGING LINE

The double-edging line start-up depends on how the machine is made up. Consultthe manual of the double-edging line for detailed information.

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6.4 NORMAL STOP

ATTENTION:Make sure the machine is disengaged and there are no pieces beingprocessed.

• Stop the conveyor: pushbutton .

• Stop spindle motors and water pump: pushbutton .

If the machine remains inoperative for long time:

• Cut off power of the electrical cubicle by turning the main switch to "0" (OFF).• Section electrical input of power mains.• Untrigger pneumatic feed.

6.5 EMERGENCY SHUTDOWNIf a dangerous situation occurs suddenly, the machine can be stopped immediatelyby the following devices:

Single machine and double-edging line Double-edging line

• Main switch (A), on the electricalcubicle.

• Emergency pushbuttons (B) on thecontrol panel.

• Emergency pushbuttons (C), in the glasssheet entrance area

• Emergency pushbuttons (D), in the glasssheet exit area.

An emergency power unit is situated in the electrical cubicle. The unit willimmediately cut in when the emergency pushbuttons are pressed, therebymaintaining the persistence of the emergency until reset is done, see paragraph6.6.

AA

B

BC

C

DD

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6.6 MACHINE RE-START AFTER EMERGENCY SHUTDOWN

• Reset the triggered emergency device.

• Reset normal operating conditions ofthe safety central unit.

The key of the selector is consignedto the machine operator; there mustbe no duplication of this key.

• Start spindles and water pump.

• Start the glass sheet conveyancesystem.

If emergency shutdown occurred by means of the main switch, restart the machineaccording to paragraph 6.3.3: item 5 to 11.

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6.7 INSTRUCTIONS FOR GOOD MACHINE WORKINGFollowing herewith are some instructions to keep the machine in perfect efficiencyand to obtain maximum product quality:

• Avoid voltage variations on the electrical input line of the factory, as they maycause poor grinding quality. If necessary, apply a voltage stabilizer on themachine input line.

WARNING:Input values on ammeters change according to different parameters(work speed, removal, glass thickness, working pressure, type of wheelsand voltage change). Therefore no unique correct or valid input can bedetermined for all situations.

• Clean the water tanks frequently according to the quantity of water used and/orto the production capacity of the machine. If you work with water very dirty ofglass powder, the latter will go continuously into the cycle and causes scratcheson the bevel.

• Absolutely avoid working with a small quantity of water as the circulation wouldbe more forced and would not allow decanting of the glass powder, causingconsequences already described. Moreover, the coolant water warms upquickly causing wheels to lose their cut, consequently slowing down productivityand affecting quality.

• Processing laminated glass makes wheel working conditions worse, due to theplastic threading clogging them and causing defects on the glass sheet surface.In this case, we suggest checking wheel conditions frequently.

• Always keep the water pump filter in the tanks clean, especially when workinglaminated glass. Plastic threads could clog the passage of water and damage orbreak the glass being processed.

• Check periodically that the direction of water jets and quantity of water on thetools is correct. Dust depositing inside pipes for lack of cleaning, causespressure to diminish and as well, less water to flow on the wheels, causingworking defects.

• We suggest that when starting to work, the machine must warm up for about 5minutes so the motors will reach the right temperature. Besides, back up thepolishing wheels by means of the mushroom-head button on the control panel.

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6.7.1 CORRECT USE OF WHEELS

• Check periodically consumption of the wheel.

• Adjust working speed according to the thickness of glass and quantity of glassto remove.Speed too high or too much removal of glass causes burning and chipping onthe sides along the glass sheet edge.

• Give correct pressure to the polishing wheels according to the glass thicknessto be worked.

WARNING:Too high pressure causes:− a faster wheel wearing (wheels get round)− a defective glass surface with grooves and rounding towards the

arrises and corners.When pressure is too low the diamond wheel leaves grinding traces onthe glass profile.

• Slant the diamond and polishing spindles so that glass thickness wears thewheel band up completely: see paragraphs: 5.8.1 e 5.9.1.

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7. MAINTENANCE

7.1 ROUTINE MAINTENANCE

WARNING:The user must carry out operations for routine maintenance accordingto what is specified here following and to safety conditions ofchapter 2.

7.1.1 GENERAL CLEANING

Periodical machine cleaning allows keeping it always efficient, and makes it lastlonger; this is an important safety factor.

• Remove safety protections and accurately clean the parts with a jet ofcompressed air, eliminating powder and possible residuals.

• Wash it by hand with water, without using jets.

• Dry and grease painted mechanical parts with petrol, to reduce formingincrustation.

• Clean the electrical cubicle and the control panel with a damp cloth only.

• Keep conveyor belts clean.

• Remove glass powder deposits from motors and relevant cooling fins.

• Do not use dissolvents on the painted parts.

Protect the machine adequately if you intend not using the machine for a long time.

• Disconnect the electrical cubicle and mains feed (electrical and pneumatical).

• Empty the water tank and clean it: see paragraph 7.1.4

• Cover the machine with adequate material.

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7.1.2 MAINTENANCE PROGRAM CHART

Frequency

Hours of workmonths

Part Operation10 50 200 300

( )

400 1000 2000 4000

(*)

6 Para

grap

h

− Condensationdischarge •

− Control of levels •− Oil topping-up •

Air treatmentunit

− Replacement offiltering element •

7.1.3

− Checkover ofwater level •

− Clean tank andchange water •

− Clean the watertank filter. •

− Clean the wheelbox •

Wheel coolingsystem

− Checkover ofwater flow •

7.1.4

− Lubrication ofwormscrew •

•− Checkover of oil

pump level •Guide and slidesystem of themoving bridge

− Lubrication ofguides •

7.1.5

Emergencystop controls

− Operationcheckover • 6.5

6.6Micro-limitswitches

− Clean the controlstems • •

(**) 7.1.6

Transmissionshaft − Brush with grease • 7.1.7

− Checkover of oillevel. •

− First oil change •Conveyorreduction unit

− Change oil afterthe first time •

7.1.8

− Checkover of oillevel •

− First oil change •Conveyormotorvariator

− Change oil afterthe first time •

7.1.8

Electricalcubicle − Clean air filters • 7.1.9

(*) = 15000 hrs with synthetic oil(**) = Moving bridge extrastroke( ) = Breaking in

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7.1.3 MAINTENANCE OF THE AIR TREATMENT UNIT (FRL)The machine has a regulating manual/semi-automatic filter to separate solid andliquid impurity in the air.The regulating filter is the item upstream the system and allows adjusting workingpressure of the machine to the required value, which however, must not be morethan mains pressure.

WARNING:Discharge condensation that accumulates in the tank (2) at the end ofeach work shift and whenever the level reaches maximum value visibleon the indicator (3).

The filter can be set for two different function modes.

Manual position: to drain condensation, operateon ring nut (1), rotate it counterclockwise and pushit upwards. When drainage is finished, pull the ringnut downwards and rotate clockwise.

Half-automatic position: condensation isautomatically drained when feeding pressure ismissing. However, it is possible to draincondensation even when there is pressure, bypushing the ring nut (1) upwards.

To go from manual to semi-automatic mode, rotatethe ring nut (1) counterclockwise.To go from semi-automatic to manual mode, rotatethe ring nut (1) clockwise, pulling it downwards.

In case of replacement, (every 1000 hoursof work) or just to clean the filtering element, proceed as follows:

• Disconnect the air feed pipe and depressurizethe tank (2), draining condensation.

• Unhook the tank (2), following the sequence ofoperations (A).

• Unscrew the protective filter screen.• Clean by a jet of compressed air, or replace

the filtering element in sintered bronze.• Screw the protective screen again.• Hook the tank to the filter body following the

sequence of operations (B).• Restore air mains feed.

A B

1

2

3

1

23

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The lubricator allows mixing compressed air going into the machine with oil mistafter the former has been filtered and adjusted to correct work pressure by meansof the regulating filter.Adjust the percentage of oil to put into the system by means of screw (3).Check total consumption of oil occurs after about 400 working hours.

WARNING:Put oil into the lubricator tank (2) when level is below the minimumindicated by relevant notch, visible on indicator (4): see paragraph 7.2

Topping up must be done after disconnecting the air feed mains from the FRL unit:

• Unscrew cap (1).

• Release the tank (2), by following sequenceof "A".

• Fill the tank with oil till the notch showingmaximum level is reached, visible onindicator (4). Total capacity of the tank is37 cm3.

• Connect tank (2) to the lubricator body,following the sequence of operations "B".

• Tighten the cap (1);

• Restore air feed to the FRL unit.

A B

1

2

3

2

1 3

4

V3 - V4


7.1.4 MAINTENANCE OF THE WHEEL COOLING SYSTEM

• Check daily that coolant mixture inside thetank reaches the grill (B); if necessary, topup with water.

A

Replace coolant mixture completely every 50hours of work and clean the tank.

• Open the tap (A) and drain the water.• Remove the grill (B).• Remove glass powder collected inside the

tank and collect it in a container in order to berecycled.

• Remove clamping screws (C).• Open the inspection door (D) and clean the

wheel protection boxes inside.

A

B

• Close the tap (A).• Fill the tank with a mixture of water and

Z. Bav. emulsible oil 10/90 diluted 0,1%, untilthe level of the grill cover is reached (B).

B

A

CC

D

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Before starting work:Run a washing cycle of the system and check if there are any clots of glass dustinside the system clogging the nozzles spraying water onto tools.

ATTENTION:This operation must be done using only the manual mode available forthis operation, enabling only water pump operation and untriggeringspindle and conveyance operations.

WARNING:The following procedure is valid also for periodical checkover of thedirection of water flow onto tools.

• Feed the machine.

• Select operation mode at thecontrol panel.

• Feed the control circuits with low

voltage: selector .• Start the water pump: pushbutton

.• Open the wheel inspection door

(D).• Check water flow is abundant,

continuous and correctly directedonto all tools.

• Stop the machine.• If necessary, dismount and clean

the collectors and nozzles (E) andcorrect the direction of the waterjet.

D

E

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7.1.5 MAINTENANCE OF THE GUIDE AND SLIDING SYSTEM OF THE MOVABLEBRIDGE

• Before every movement of the bridge:give a lubrication impulse by means of thepump handle (A).

• Every 50 hours: pump the oil during acomplete opening and closing cycle of thebridge.

• Every 50 hours: check the quantity of oilinside the receptacle of the generallubrication pump; if necessary, restoremaximum level with oil according to thelubricants chart: see paragraph 7.2.

A

B

B

C

Every six months:

• Close the moving bridge completely.• Dismount the guide-protecting carters (B) of

the base and put some grease on the guides(C) using a brush: see paragraph 7.2.

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7.1.6 CLEANING THE LIMIT-MICROSWITCHES

• Clean the stems of the microswitch (A) forextrastroke of the intermediate bridge every50 hours and the corner chamferingspindles (upon request) if installed; cleanthe stems of the microswitches (B).

• Clean the stems of the four microswitches(C) of the bridge extrastroke every 6months; they are protected by the baseplateguide-carters. Do this when lubricating thesliding guides of the movable bridge: seeparagraph 7.1.5.

• Give power to the machine and operate bothlimitswitches by hand, checking there is thealarm for bridge in extrastroke on the NCinterfacing panel.

7.1.7 LUBRIFICATION OF THE TRANSMISSION SHAFT

• Clean and protect the transmission shaft(D) every 50 hours: see paragraph 7.2.

A

B

C

D

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7.1.8 LUBRICATION OF THE MOTORVARIATOR UNIT OF THE CONVEYOR

Check the oil level of the reduction unit every 50hours and top up if necessary: see paragraph 7.2.

After the first 300 hours, replace the oil and washthe inside of the reduction unit.

Change the oil every 4000 hours. If synthetic oil isused, change after about 15000 hours of work.The quantity of oil to use is about 2,6 liters. Afterfilling, check the exact oil level.Use mineral oil with viscosity class ISO VG 460 or anequivalent product for operations at ambienttemperature ranging from 20°C to 40°C. If synthetic oilis used, viscosity must be ISO VG 320.For operation at low ambient temperature rangingfrom 0°C to 20°C, use mineral or synthetic oil withviscosity ISO VG 220.

If the reduction unit is inoperating for a long time in anambient with high percentage of humidity, it isrecommended to fill it completely with oil. Normal levelof lubricant must be restored when the unit startsworking again.

Check the oil level in the variator every 50hours and top up if necessary: seeparagraph 7.2

Change the oil and if possible wash thevariator accurately inside after the first 300hours.

Change oil every 2000 hours.The amount of oil to put is about 3,8 liters.Check the exact level after filling with oil.

WARNING:Avoid mixing mineral based oil with synthetic oil.

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7.1.9 CLEANING THE AIR FILTER OF THE ELECTRICAL CUBICLE

Clean the air filters of the electrical cubicle every 200hours.

• Remove the cover of the filter protection (A) of theelectrical cubicle.

• Pull out the filtering element and clean it, byblowing compressed air.

• Put the filter in its place.• Remount the cover and push it until you hear the

fixing elements release on the frame.

7.1.10 DRESSING THE DIAMOND WHEELS

This term implies the removal of glass dust from the diamond wheel cutting surface,thereby restoring its efficacy and original characteristics The proceeding is done in themachine and must be done using only the operation mode dedicated to this purpose:

45° ÷ 50°

ω

• Move the abrasive stick continuously( ) over the wheel surface whiledressing The surface of the stick willbe consumed in a uniform fashion,without creating grooves that coulddamage the wheel.

• Wet the stick occasionally to cool it.

• Unload all glass sheets in the machine.

• Select the operation mode at the controlpanel, to enable spindle rotation only,untriggering the water pump.

• Select the wheel to dress at the controlpanel.

• Feed the control circuits with low voltage:

selector .• Fit the "CORINDONE" abrasive stick in the

dressing tool supplied as accessory.

• WEAR PROTECTIVE EYEGLASSES ANDGLOVES.

• Start the selected spindle: .• Open the wheel inspection door and dress the

wheel as in the drawing, keeping the tool in youhands.

7.1.11 REFORMING OF THE DIAMOND WHEEL EDGE

To be done out of the machine to restore original profile to the wheel. A machine onpurpose must be used for this.

A

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7.2 CHART OF LUBRICANTS

Part Type oflubricant Name / Degrees Producer

DTE 21 MOBILTELLUS C10 SHELL

OSO 10 AGIPHYSPIN AWS 10 CASTROL

Air treating unit Mineral oil

SPINESSO 10 ESSO

Gui

des

Grease STARBURAGS NBU-12or equivalent KLUEBER

MOBILGEAR 629 MOBILOMALA 150 SHELLBLASIA 150 AGIP

ALPHA SP 150 CASTROLENERGOL GR-XP 150 BP

Guide andslide system

of themovablebridge

Gen

eral

lubr

icat

ion

pum

p

Mineral oil

SPARTAN EP 150 ESSO

Transmission shaft Grease STARBURAGS NBU-12or equivalent KLUEBER

Ta (0 ÷ 20°C) Ta (20 ÷ 40°C)Synthetic oil ISO VG 220 ISO VG 320Ta (0 ÷ 20°C) Ta (20 ÷ 40°C)

MOBILGEAR 630 MOBILGEAR 634 MOBILOMALA EP 220 OMALA EP 460 SHELL

BLASIA 220 BLASIA 460 AGIPALPHA SP 220 ALPHA SP 460 CASTROL

ENERGOL GR-XP 220 ENERGOL GR-XP 460 BP

Conveyor reductionunit Mineral oil

SPARTAN EP 220 SPARTAN EP 460 ESSOATF 220 MOBIL

ATF DEXRON III SHELLATF DEXRON AGIPTQ DEXRON II CASTROLAUTRAN MBX BP

Conveyor variator Mineral oil

AUTOMATIC TRANSFLUID DEXRON D ESSO

Ta = Ambient temperature.

WARNING:The lubricants in the chart must be disposed of after use according to thelaws in force in the country where the machine is installed

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7.3 SPECIAL MAINTENANCE

WARNING:This maintenance is needed in case of damage or wear of components.Specialized staff qualified for that purpose must do special maintenanceoperations.

7.3.1 REPLACEMENT OF THE SPINDLE TRANSMISSION BELT FORDIAMOND/POLISHING SPINDLES

• Remove the two screws (1), one foreach side, the carter (2) and loosen thefour screws (3).

• Loosen the screws (4) and replace thebelt (5).

• Make sure the throats of the frictionsurface of the belt (5) are all inside theirseatings, both on the spindle pulley andthe electric motor.

• Stretch the belt and reassemble thecarter (2).

7.3.2 REPLACING THE BEARINGS OF DIAMOND/POLISHNG SPINDLES

Make reference to TAV. 359, TAV. 399 and TAV. 606:

• Remove the wheel (17), see chapter 9, and the transmission belt (19), seeparagraph 7.3.1.

• Remove the screws (8) and separate the spindle from the rest of the unit..• Go to a work bench.• Disassemble the spindle and replace the bearings (4), (11) and gasket (12).• Reassemble the spindle: lubricate parts accurately and remount it on the unit.

1

2

3

4

5

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7.3.3 REPLACING THE STRIKER STAKES OF THE CORNER CHAMFERINGSPINDLE

This operation can be done directly in the machine.

• Make sure the spindle is forward position: the pin(S) must not be engaged.

• Unscrew the screws (A), tilt the unit backward byusing the handle (B) until horizontal position isreached (C).

• Remove screws (D) and flange (E).

• Remove the plastic stakes from theirseating and relevant pins as well.

• Replace the stakes and remount theunit.

D

E

C

S

B

A

A

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7.3.4 REPLACING THE TRANSMISSION BELT OF THE CORNER CHAMFERINGSPINDLE

• Remove screws (A) and carter (B).

• Loosen the screw (C) and move the drivepulley (D) enough to loosen the belt (E).

• Replace the belt and stretch it again withoutstrain.

• Tighten the screw (C).strongly

• Install the carter (B).

WARNING:Check the throats of friction surfaces of the belt are all correctly inserted intorelevant pulley seatings.

7.3.5 REPLACING BEARINGS OF THE CORNER CHAMFERING SPINDLE

Refer to TAV. 389 and TAV. 391:

• Tilt the spindle and remove the carter and transmission belt: (see paragraphs7.3.3 and 7.3.4).

• Remove the screws (21) and separate the spindle from the rest of the unit.

• Go to a work bench and disassemble the spindle, replace bearings (8), (17) and(19) gasket (16).

• Lubricate parts accurately, replace the ring nut (11) and reassemble the spindle.

• Reassemble the corner chamfering unit.

A

B

C

ED

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7.3.6 REPLACING THE LOWER BELT OF THE CONVEYANCE SYSTEM

• Remove the carters (A) and (B).

• Loosen screws (C) and (D).

• Tighten the screw (E) until the belt is loose (F).

• Replace the belt and tighten (*).

• Clamp nuts (C) and (D), reassemble theprotection carters.

(*) = Contact the After-Sales Service at Z. Bavelloni S.p.A.: (see paragraph 1.7).

A

B

C E

F

D

F

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7.3.7 REPLACING THE UPPER BELT OF THE CONVEYANCE SYSTEM

• Remove the protection carter of the belt anditem (A).

• Unscrew the clamping screws (B) of thetransmission shaft.

• Loosen the eight screws (C) of the clampingring (F) and extract the transmission shaftenough in order to remove the belt.

• Loosen the nut (D) and unscrew the screw(E) until the belt is loose.

• Replace the belt and stretch it (*), then clampthe nut (D).

• Insert the free end of the transmission shaftinside the clamping ring (F).

• Give power to the machine and close thebridge the most possible, leaving only thespace necessary to accede by a key in theclamping ring area.

• Turn the machine off and set it to securityconditions.

• Loosen the screws (C) of the clamping ring,with cross sequence.

• Tighten the clamping screws (B) of thetransmission shaft.

• Remount the protection carter of the belt.

(*) = Contact the After-Sales Service at Z. Bavelloni S.p.A.: (see paragraph 1.7).

C A

B

D

E

F

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7.3.8 REPLACING THE MOTORIZED ENTRANCE/EXIT TRANSMISSION UNIT

The self-welding belt (A) is installed on the grinding machine only in particularmachine configurations: see paragraph 3.4.

Examples for installing the belt

The spare belt is supplied in rolls, in meters and must be installed and welded.For replacement do as follows:

• Cut a piece of belt in length (L1): see drawing.

• Position the belt on the pullies and weld it with suitable equipment.

A

AA

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8. DEFECTS - CAUSES - SOLUTIONS

8.1 WORKING DEFECTSThe reasons producing working defects are many. Therefore, in the event, start theidentification of the problem without making the frequent mistake of blaming thewheels for each and every defect, just because the wheels are the tools doing thework.When searching for the reason of a defect, proceed by elimination according to thechart herebelow:

Defect Possible causes Solutions Chapter torefer to:

Too much glass removal as to workspeed Reduce glass removal 5.5High conveyance speed as tothickness being worked Reduce conveyor speed 5.4Pressure of the first polishing wheeltoo low Adjust work pressure 5.11

6.7.1

• White scratches• Burning

Water sprays not correctly positionedtowards wheel working area, orclogged

Check the tool cooling system 7.1.4

6.7

Too much pressure on somepolishing wheel Adjust work pressure 5.11

6.7.1• Irregular white

scratches

Defective wheel Replace the wheel 9

• Shiny waves

• Rounded cornersToo much pressure of polishingwheels Adjust work pressure 5.11

6.7.1

• Irregular scratches onlaminated sheets

Gummed diamond wheels Dress the wheels 7.1.10

Too much emulsible oil mixed withcooling water

Restore correct dilution of oil in wateror replace the cooling mix.

5.147.1.4

Pressure of polishing wheels notcorrect Adjust work pressure 5.11

6.7.1Diamond wheels are not well adjustedand glass removal is irregular Adjust diamond wheels 5.8High conveyance speed Reduce conveyance speed 5.4

• Uneven polishing

Diamond wheels need dressing Dress the wheels 7.1.10

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Working defects ………….continues

Defects Possible causes Solutions Chapter torefer to:

The diamond wheels are not welladjusted.

Check wheel cut and absorption 5.87.1.10• Lack of polishing on

the corners Uncalibrated multihead system Correct areas of polishing wheeltriggering in/out on the sheet. 5.10

Too much glass removal as to workspeed Reduce glass removal 5.5Speed too high as to thickness beingworked Reduce conveyance speed 5.4No water going to the diamondwheels Check tool cooling system 7.1.4

• Chipping along theglass sheet edge

Diamond wheels need dressing Dress the wheels 7.1.10

• Glass sheet sides arenot straight

Difference in speed between the twolower belts of the conveyance system

Adjust belt stretching (contact theAfter-Sales Service atZ. Bavelloni S.p.A.).

1.7

• Bigger size irregularcorners

The striker stakes of the cornerchamfering spindle are worn out. I Replace the striker stakes 7.3.3The corner chamfering wheel is wornout Replace the wheel 9.3• Small size front and

back corners The corner chamfering wheel is wornout unevenly. Adjust wheel height. 5.12.6Too much conveyance speed Adjust conveyance speed 5.4Speed of the corner chamferingspindle following the glass too low

Adjust longitudinal movement of thecorner chamfering spindle 5.12.5• Small size back

corners Insufficient stretching of the spring ofthe corner chamfering spindle

Adjust transversal movement of thecorner chamfering spindle 5.12.4

8.2 BREAKDOWN

Problem Possible causes Solutions

Vibration of the solenoid valves Input mains pressure and workpressure not correct. Adjust work pressure.

A motor stops and does notrestart.

The magneto-thermal protectiontriggered: pushbutton (PL3) or (PL6) onthe control panel lights up.

Open the electrical cubicle and restore theprotection switch.

Overload due to mechanical orelectrical causes. Check the cause of overload and eliminate.One or more motors keep on

stopping during work Too much voltage jump on the electricline of the factory

Apply a voltage stabilizer on the machineinput line.

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9. REPLACEMENT OF PARTS

ATTENTION:Qualified staff must perform the operations described in this chapteraccording to the following specifications and the safety conditions ofchapter 2.

ATTENTION:Some machine parts are subject to frequent wear and must bereplaced as specified here following, and disposed of according to thelaws in force.

9.1 REPLACING THE DIAMOND WHEELS

• Be sure the machine is off and that all mainsinputs are disconnected.

• Remove the screws (A) and open the wheelinspection door (B).

• Unscrew the nut (C) until the wheel (D) andthe plate (E) are free from the spindle shaft.

• Untighten the screw (F) and separate the plate(E) of the wheel.

• Clean and grease the shoulder flangeaccurately (G).

• Check the size of the new wheel (seeparagraph 3.10.1), join it to the plate (E) withthe screw (F) and install it on the spindleshaft, making sure it is inside the pin (H).

• Clamp the wheel firmly with your hand to thespindle shaft by screwing the nut (C).

AA

B

C

DEF

H

G

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9.2 REPLACING THE POLISHING WHEELS

• Make sure the machine is off and in securityconditions and that all mains inputs aredisconnected.

• Remove the clamping screws and open thewheel inspection door (A).

• Untighten the screw (B), remove the plate (C)and replace the wheel (D), making sure togrease the shoulder flange accurately (E)and make sure the wheel is inside the pin (F).

• Clamp the wheel firmly with your hand to thespindle shaft by screwing the nut (B).

9.3 REPLACING THE CORNERING CHAMFERING WHEELS

• Make sure the machine is off and in securityconditions and that all mains inputs aredisconnected.

• Make sure the spindle is in forward position:the pin (S) must be disengaged.

• Untighten the screws (A), tilt the spindle unitbackwards by means of the handle (B) until itreaches horizontal position (C).

• Keep the end of the spindle shaft (D) clamped,unclamp the nut (E) and replace the wheel (F).

• Reset the spindle into vertical position, installand tighten the screws (A).

F

E

A

B

CD

S

B

A

A

C E

D

F

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9.4 MOST FREQUENTLY USED SPARE PARTSThe list indicates the most frequently used spare parts during machine service.If other parts are needed, make reference to the “SCHEMES OF SYSTEMS ANDTABLES OF SPARE PARTS” and “WIRING DIAGRAMS”.

CODE Nr DESCRIPTION Pos. REFERENCE Measureunit

Q.ty

11080170 Assembly of rubber coatedwheel D 65. 1 N° 4

11081410 Roller assembly D 50. 2 " 4

22200841 Rubber ring for roller 3 " 6

21009400 OR gasket for presser 4 " 16

23113946 Photocell of squaring unit 5 " 1

21608860 Belt transmission of diamondspindles 2

21608850 Belt transmission of polishingspindles

6 "

2

21203002 Indicator of the diamondspindle position 7 " 1

1

2

3

4

6

7

5

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Q.ty

21203045 Indicator of glass thicknesson diamond spindle 8 N° 1

22120300 Guide for diamond / polishingspindle slide 9 " 4

22120405 Cage with rollers to guide thediamond/polishing spindle 10 " 2

11081590 Brake cylinder assembly ofpolishing wheel 11 " 1

23148309 Conveyor / bridge encoder 12 " 1

22200785( )

Rhombus roller on centeringdevices of the squaring unit 13 " 2

21645001( ) Round self-welding belt D. 6. 14 m 2

= Item installed on the machine only if making part of a line

8

10

9

11

12

13

14

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Q.ty

058171700 Front left stop pad of thesquaring unit

N° 1

058171800 Front right stop pad of thesquaring unit

15" 1

21608770 Belt of corner chamferingspindle 16 " 1

( ) Striker stakes of the cornerchamfering spindle 17 " 6

( ) Upper conveyance belt 18 " 2

( ) Lower conveyance belt 19 " 2

( ) Sliding block 20 " 10

( ) Sliding block to guide the belt 21 " 2

( ) = Uncodified items, changeable according to the machine purchased: contactthe After-Sales Service at Z. Bavelloni S.p.A. (paragraph 1.7).

15

16

1717171717

18

19

21

20

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10. DEMOLITION

Once the machine has reached the end of its life it must be disabled and unusablefor the purpose it was designed and built.The raw materials making the machine must be separated to allow recycling and/ordisposal, according to the laws in force.

ATTENTION:Only staff adequately trained and equipped must perform theoperations for machine demolition.

10.1 MACHINE DISABLING• Turn the machine off according to the procedure for normal stop

(paragraph 6.4).

• Disconnect the electric mains input cable and air feed of the F.R.L. unit from theelectrical cubicle. Operate on areas according to paragraph 4.8“CONNECTIONS“

• Empty the water tank.

• Dismantle the main parts from the machine, see chapter 4, according to theinformation supplied by the After-Sales Service at Z. Bavelloni S.p.A.

• In case of handling the parts, make reference to chapter 4

10.2 DIFFERENTIATED DIVISION OF MATERIAL• Detach and separate residuals of glass powder from the tank and wheel

protection boxes.

• Recover the oil inside the variator, reduction units and inside the lubricationsystem.

• Disconnect all electric cables and separate the copper and copper alloy partssuch as: electrical conductors, coils, etc..

• Remove and separate the interface with NC operator and all electronic cardslinked to it from the electrical cubicle.

• Separate the batteries.

• Remove and separate plastic parts such as:water and air pipes, knobs, guards, covers and pushbuttons, the tank grill,etc….,

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• Remove and separate rubber parts such as:belts, rollers and bellows, etc.

• Dismantle frames in structural aluminium and separate them.

• Dismantle and separate parts prevalently in iron, such as:the baseplate, bridges and carters, the electrical cubicle, the tank, drip racks,etc..

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