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Model M-200 Portable Valve Grinder User's Manual

2014-1-7 10:22:09   views

2.Technical Parameter
3.Parts List
4.Getting started and safety instructions
5.Installation& Operation Method
6.Grinding Process

1.M-200 Valve Grinder Overview

Model M-200  valve grinder is widely used in the industries such power generation, petroleum, chemical, metallurgy and paper making as a high-tech product with national patent. It has the following characteristics:
 Light, compact, and easy to carry
 Split-type assembly makes installation easy and fast
 Available in various field work
 Applicable in grinding gate, check valves and flanges made of various materials
 Grinding automatically after the installation is adjusted well
 Reasonable structure design, perfect Metabo motor and high-quality imported grinding materials contribute to the grinding 3-10 times as fast as the manual one
 Stepless and adjustable speed, stable power transmission and accurate lapping make the sealing face in complete contact.

2. M-200 Valve Grinder Technical Parameter

 Grinding scope: DN80~200
 Motor power: 1020W
 Rated Voltages: 220V
 Dimensions for the minimum opening of the valves: B>45mm
 Allowed adjustable length: L600mm
 Operating weight: 20kg

3. M-200 Valve Grinder Parts list

The said grinder is composed of motors, driving shafts, guiding rails, adjustable supports, telescopic arms, overhanging arms, lapping discs as well as positioning screws. Various seats or overhanging arms can be fit for different lapping objects.

4. Getting started and safety instruction
4.1  Switch in 220V, single phase AC power, whose socket should be in compliance with the plug of the motors.
4.2  The motors shall be used in the following way:
 The rev speed shall be increasingly fast when the button is pressed more and more heavily.
 The motor shall turn clockwise or counter-clockwise following the relevant switch, the rev speed could also be adjusted by the turn knob, which shall be idle when perpendicular with the motor spindle line.
 The rev speeds up when the speed handwheel, beside the switch, is turned clockwise per the arrow direction imprinted on the wheel, vice versa.
 In general, the motor is recommended to start up after the handwheel is turned to the lowest position, then, on pressing the control button (viz. lock button,  is located on the rear hand grip of the motor)the motor shall continue to run by itself, the expected rev can be attained finally by the use of the handwheel. When switching off, the lock button will be released automatically on pressing the switch after the rev is on the lower side, the motor shall stop after the switch is released.
4.3 Prior to grinding, check the surface to be lapped to remove the excessive materials if any, in order that neither lapping discs shall be bumped nor the lapping angle will be altered.
4.4 Remove the dirt from the lapping discs or films and keep them clean.
4.5 Cut the double side adhesive grinding paper ( cloth) in conformity with the diameter of grinding films, and then stick it to the clean lapping seat (disc) .
4.6 In case that the valve to be lapped is watery or in high temperature, the emery grinding films can be screwed onto the discs for grinding. During lapping, the water or kerosene could be added to adequate extent to facilitate cutting off, grinding as well as flushing of accumulated dust or scraps.
4.7 Disconnect the plug from the power source after the grinder switches off in order to avoid the accidental starting and personal or grinder injury.
4.8 Apply little MoS2(butter) onto the gears.

5.M-200 Valve Grinder  Installation& Operation Method

5.1 Gate Valve Seat Lapping
5.1.1 Lapping Disc Selection
     Choose the adequate lapping discs from the total of 8 kinds accompanied with the grinder in compliance with the size of the seal face of valve seats, if the additional discs with different sizes are needed, please study the structure of the available and fabricate them on your own.
5.1.2 Lapping Disc Mounting
     Stick the lapping discs onto the flange discs of overhanging arms and mount them in place, after screwed up, the lapping discs should be ready to rotate.
5.1.3 When clamping the fixed seat, the three points of the seats have to be fastened stably onto the valve flanges, the clamping methods are as follows:
 Direct clamping: the seat is fastened directly onto the valve body in     accordance with the seal face to be lapped, inclusive of valve body with flanges; for those without flanges, lap the coupling flanges.
 Indirect clamping: the seat is fastened with the help of foreign object to match the environment of the seal face to be lapped.
For instance, fasten the seats by use of supplied plate pinches and screws of valve bodies. Whatever you choose, the seats have to be fastened in smooth and stable manner, not in heavily inclined plane.( Be minded that the seats have to be in the center line of the surface to be lapped in case of gate valves lapping) after the seat is fixed, tighten up the adjustable supports by use of plate pinches and screws on the seats, with surface of adjustable support beyond that to be lapped.

5.1.4 Finalizing the length of telescopic arms
     Per the distance between the seat and bottom of seal face of valves, measured by the tapes, adjust the telescopic arms to match the distance from external diameter of the lapping discs to the center of positioning assembly. In case that telescopic arms are not long enough, the positioning assembly can be adjusted on the guiding rails to guarantee the lapping discs in contact with the surface to be lapped, finally fasten the hand grips.

5.1.5 Installing the motor
     After loosening off the screws, insert the motor into the drive shaft, and screw up after it is in place.
     Caution: the connectors of motor have to be installed into place; the motors have to be fastened.

5.1.6 Assembly and Adjustment
 By use of center of positioning screws, insert into the positioning hole of the adjustable support the telescopic arm assembled with lapping discs.
 Fasten the hand grips.
 Adjust the lapping discs and press the film onto the surfaces to be lapped.
C Adjust the handwheel to make the lapping films in loose contact with the surface to be lapped (the lapping discs are able to be rotated by hand).
C Adjust by set screws of positioning assembly the lapping discs in terms of its upper and lower positions to make them cover the surface to be lapped.
C Adjust by hand grips the lapping discs in terms of left and right positions to make them cover the surface to be lapped. In one word, adjust the center of film of lapping disc on the center of band to be lapped, and make sure it sticks evenly to the surface to be lapped. In case the alignment is unlikely, check the surface to be lapped exposed on lapping films to see if the distances are equal or not.

5.1.7 Test run
     After the grinder is assembled, adjust the feed handwheel until lapping discs are in contact with the surfaces to be lapped, and it moves slightly when its position is changed by hand. Then adjust it further to make sure the lapping films are covered on the surface to be lapped.

5.1.8 Startup
     The grinder can get started after it is adjusted to normal state, turn on the motor to get the lapping discs to run idle at low speed, when feeding by hand wheels, small amount is recommended, after preferred 1/4 circle at the very beginning, the feed should be less and less. The rev is better to be at 200 rev/min when grinding the small sized valves.

5.1.9 Check and replace grinding papers (cloth) after switching off the grinder
     After cutting off, check the lapped surface and paper (cloth). In case the adhesive is hard to remove, acetone is recommended. On completion of inspection or paper(cloth) replacement, it is unnecessary to adjust the guiding rails, which can be placed into the positioning holes of the adjustable supports with set screws of positioning assembly to continue grinding, with hand grips fastened.

5.2 Gate Disc Lapping

5.2.1 Fix the adjustable support with the base plate accompanied with the grinder.

5.2.2 Fix the gate disc with the positioning support and two nuts at the front of the base plate, and adjust the angle in accordance with valve core with smaller base plate until the universal joint neither bends nor rotates. If the disc is too large to fix on the base plate, install the adjustable support in reverse and place on the appropriate flat plate the disc to be lapped.
5.2.3 Refer to Sub-clause 5.1 for additional operating methods.

5.3 Refer to Sub-clause 5.1 &5.2 for different valves and flange discs to install and operate.


6. M-200 Valve Grinder Grinding Process

6.1 Rough Grinding
   Dry grind with either lapping film stuck with grinding paper (cloth) #60-#120 or emery.


6.2 Fine Grinding
   Dry grind with lapping film stuck with paper(cloth) around #240 for the purpose of polishing.


6.3 Precision Grinding
 Precisely grind with film stuck with paper(cloth) above #400.
 Precisely grind with face-to-face grinding plates stuck with paper(cloth) #400 to attain sealing and pressure-proof effect. The face-to-face plates can be fabricated on your own, and be ready to use after lapped on Grade-0 flat plates by hand or the said grinder, please refer to the supplied unadjustable lapping discs for structure.
Warning: Do not use water when grinding with paper( cloth).

7. Maintenance
 Apply MoS2(butter) onto the gears prior to use.
 Periodically clean gears during operation.
 When the grinding is over, carefully clean all parts of Valve Grinder Grinding, remove the grinding paper (cloth) and store it in the tool box after applied with oil.


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