STRAIGHT GLASS EDGING MACHINE OPERATING AND MAINTENANCE INSTRUCTIONS. IMPORTANT NOTICE: Read all operating instructions before operating machine

Transcription

1 E-Z EDGER 1100 STRAIGHT GLASS EDGING MACHINE OPERATING AND MAINTENANCE INSTRUCTIONS IMPORTANT NOTICE: Read all operating instructions before operating machine Manufactured by: Abrasive Technology, Inc Green Meadows Dr P.O. Box 545 Lewis Center, OH

2 FORWORD Everyone who is to operate this machine should read this manual and become familiar with its contents and the safety precautions involved BEFORE operating the machine. Your Abrasive Technology E-Z EDGER 1100 has been engineered and produced to give you excellent service with minimum maintenance. This manual has been prepared to assist you in the proper operation and basic maintenance of your machine. WARNING This machine, as with all machinery having moving parts and/or electrical components, should be operated and serviced with care. Do not plug or unplug the power cord with the power switch in the ON position. Always follow safety precautions when operating, servicing, and/or doing maintenance. When operating this machine, protective measures such as wearing safety glasses and protective gloves should be taken. The E-Z EDGER 1100 is equipped with a three-prong AC cord. Grounding is necessary for operator protection and to help prevent damage due to any potential electrical shorts. For operator safety, it is imperative that a properly wired three-prong AC outlet be used to power this machine. CAUTION For optimum performance from your E-Z EDGER 1100, an input line voltage of at least 108 VAC for 115 VAC models or 207 VAC for 230 VAC models should be available at the AC outlet for the machine. A lesser line voltage could cause the wheel drive motor to overheat. Avoid using long extension cords. They can cause power loss to the machine and are a common cause of low-voltage conditions. If an extension cord must be used it should be a three-wire type that is no longer than 50-feet in length and a minimum of 14-gauge wire size. It should be noted that, due to the horsepower and heat-rise ratings for the motor, it is normal for the motor to run hot to the touch. BE SURE TO FILL IN THE WARRANTY CARD NOW AND MAIL IT TO VALIDATE YOUR WARRANTY.

3 SECTION I. 1. GENERAL - The E-Z EDGER 1100 (Figure 1) has been designed to produce a satin finish on the edge of industrial glass. Depending on the diamond wheels installed in the machine, a quality flat, pencil, or seamed edge can be obtained. Since the E-Z EDGER 1100 can edge long glass strips of up to 1/2-inch thick, it is an ideal machine for edging jalousie strips, automotive glass, small mirrors, table tops, and windows. The E-Z EDGER 1100, being a compact and portable unit that requires only power and coolant hookups, is also an ideal unit for use on the jobsite. The required coolant hookup may be made to an existing coolant system or to an optional five-gallon recirculating coolant system available from Abrasive Technology, Inc. Although the coolant hookup may be made directly to a tap water supply, it is strongly recommended that a coolant system using a rustinhibitor and lubrication coolant solution (such as Abrasive Technology s Liquid Ice ) be used. The use of a coolant with a rust-inhibitor solution will prolong both machine and diamond wheel life and provide lubricity for a freer cutting action from the diamond wheels. 9 8 E-Z EDGER 1100 The edging system for flat glass 5 Figure SECTION II PREPARATION FOR OPERATION 1. Place the E-Z EDGER 1100 on a suitable sturdy work bench or table. Keep in mind the weight that must be supported includes the weight of the glass (which is often considerable). 2. Connect the drain hose (1, Figure 1) to the drain outlet at the rear of the machine; use the supplied hose clamp to secure the drain hose in place. abrasive technology, inc. 6

4 3. Place the flow control valve (2, Figure 1) (at the rear of the machine) in the OFF position. 4. Connect the Abrasive Technology recirculating coolant system to the E-Z EDGER 1100 by performing the following substeps: a. Line the coolant tank with the plastic liner. Ensure that the liner fits snugly on the bottom of tank and that the balance of the liner overlaps the top of the tank. b. Add coolant mixture to the coolant tank in the ratio outlined on the coolant container. c. Set the coolant tank at the rear of the machine. d. Insert the coolant drain hose from machine into the coolant tank. e. Place the submersible coolant pump inside the coolant tank. Push the free end of the coolant feed hose, connected to the submersible pump, over the tapered fitting at the end of the flow control valve (7, Figure 1). f. Insert the submersible coolant pump power cord plug into the connector receptacle at the side of the machine near the wheel drive motor cover. 5. Adjust the four (4) leveling feet (3, Figure 1) so that all four (4) feet make firm contact with the top surface of the work bench or table. For best results, the machine should tilt slightly toward the coolant drain hose (about 1/2 bubble off plumb). 6. Set the vertical support guide (8, Figure 1) to the proper height by placing the glass in the guide track (4, Figure 1) and adjusting the location of the support guide so that the guide roller (9, Figure 1) rests on top of the glass. 7. Set the guide track (4, Figure 1) height by placing the glass in the guide track for the diamond grinding wheel. Slide the glass to the center of the wheel. Adjust the height using the track support bolt (5, Figure 1) to move the track up or down until the leading edge of the glass lightly touches the diamond grinding wheel. Tighten the lock bolt (6, Figure 1) hand tight against the bottom of the track. Repeat this step with the glass in the guide track for the polishing wheel INITIAL OPERATION 1. With the power switch in the OFF position, insert the machine power plug into the proper AC outlet. 2. Place the power switch in the ON position. The wheel drive will begin rotating at high speed.

5 3. Slowly open the flow-control valve until the streams of coolant from the two coolant spouts cross over each other POLISHING GLASS 1. While holding the glass strip in place and without touching the diamond wheels, position the glass toward the rear of the diamond grinding wheel guide track (end of machine with coolant drain hose). With one continuous smooth motion, pull the glass strip forward straight across the groove of the diamond wheel and through the vertical support guide roller at approximately 15 seconds per foot. If skip marks are present, rerun the glass over the diamond wheel. Always start an edging sequence with the glass positioned toward the rear of the guide track, and then guide it smoothly forward. Do not use a back-and-forth motion, as the glass is edged properly only when its movement is opposite the direction of rotation of the diamond wheels. Follow the arrow (left to right). Do not use excessive downward pressure on the glass or transverse the glass too fast over the diamond wheel. Firing (red glow or sparks) will occur, resulting in a poor edge, and the wheel(s) can wear out of round prematurely. In most cases, the weight of the glass will provide sufficient downward force to achieve the proper edge. If applicable, repeat the above action with the same glass strip positioned over the polishing wheel. 2. If required, readjust the coolant flow control valve, and/or the coolant nozzle position, to provide minimum firing of the glass where it makes contact with the diamond wheel and/or polishing wheel. 3. Readjust guide track height as necessary. (See step 6, section 2)

6 APPENDIX A-1. OPERATING SUPPLIES AND ACCESSORIES The following is a listing of operating supplies and accessories available for use with the E-Z EDGER 1100: ATI Part No. Description R Submersible Coolant Pump, Tank, and Liners 115 VAC 50 / 60 Hz. R Submersible Coolant Pump, Tank, and Liners 230 VAC 50 / 60 Hz. R Work Bench C Liquid Ice Coolant; case, 24 Disposable Bottles C633XP950F Fine Dressing Stick C633XP950C Medium Dressing Stick R Guide Extension Strip (30 x 3 1/2 x 1/2 ) Table A-1 Machine Specifications Width Inches Height Inches (without vertical support column) Depth Inches Weight (with Two Mounted Wheels) Pounds A-2 ELECTRICAL REQUIREMENTS (all Single Phase): Model Numbers C C C C Voltage 115 VAC 230 VAC 115 VAC 230 VAC Frequency 60 Hz. 60 Hz. 50 Hz. 50 Hz. Current 13 A 6.5 A 13 A 6.5 A A 20-ampere branch circuit breaker is recommended for 115 VAC machines. A 15-ampere branch circuit breaker is recommended for 230 VAC machines.

7 A-3 COLOR CODING OF POWER CORD CONDUCTORS: 115 VAC Machines: (In accordance with USA National Electric Code) Line Black Neutral White Safety (Earth) Green 230 VAC Machines: Export* USA Line Brown Black Neutral Blue White Safety (Earth) Yellow / Green Green A-4. PERIODIC MAINTENANCE A-4-1. GENERAL This section of the manual provides information for the periodic maintenance required to keep the machine in good working order. Table A-4-1 lists the required maintenance tasks and recommended intervals. Depending on the type(s) and quantities of glass being edged, the recommended intervals between maintenance tasks may be increased or decreased based upon the judgment of the user and in keeping with good maintenance practices. Description Table A-4-1 Periodic Maintenance Required Time Interval 1. Clean Machine After daily use N/A 2. Lubrication None required N/A Hourly or more often if 3. Check Coolant level * heavy spray mist is N/A present during operation Instructions (if applicable) 4. Clean Coolant Tank * After daily use N/A When diamond grinding 5. Stone Wheels (Dressing) or polishing cycles slow Section A-4-2 considerably When diamond grinding 6. Retruing of Wheels or polishing wheels lose Section A-4-3 their form 7.Replacement of As needed when wheels Wheels have worn considerably Section A-4-4 * Only if recirculating coolant system is being used.

8 A-4-2. MAINTENANCE OF DIAMOND GRINDING WHEELS AND POLISHING WHEELS Two types of abrasive dressing sticks are supplied with the E-Z EDGER 1100 to sharpen the cutting action of metal bonded diamond wheels and polishing wheels. The Abrasive Technology, Inc. Part No. C633XP950F fine dressing stick is used to sharpen metal bonded diamond grinding wheels (MF and FF type wheels). The Abrasive Technology, Inc. Part No. C633XP950C medium dressing stick is used to sharpen bonded polishing wheels (SF type wheels). Dressing sticks should be soaked thoroughly in coolant before using. The fewer times that diamond grinding and polishing wheels are stoned, the longer they will last. It is recommended that diamond wheels be stoned when it appears that they are slowing down in their grinding ability. Stoning may also become necessary when firing appears indicating a dull diamond wheel. It is recommended that polishing wheels be stoned when they take on a shiny appearance. A STONING BONDED MF AND FF TYPE DIAMOND GRINDING WHEELS - When the stoning of a diamond grinding wheel becomes necessary (See Table A-4-1, No. 5), remove the coolant pump power plug from PUMP connector receptacle on the E-Z EDGER Turn the power switch to the ON position and allow the wheels to achieve full speed. Place a coolant soaked fine (white) dressing stick (Part No. C633XP950F) against the diamond grinding wheel for a few seconds. When the wheel freely removes stock from the dressing stick, dull diamonds have been pulled from the bond and/or bonding material has been removed to expose new diamonds. A properly stoned diamond wheel will take on a uniformly dull matte finish without any shiny spots. At this point, stop the stoning process and reconnect the coolant system to the E-Z EDGER A STONING BONDED SF TYPE POLISHING WHEEL When the stoning of a polishing wheel becomes necessary (See Table A-4-1, No. 5), remove the coolant pump power plug from PUMP connector receptacle on the E-Z EDGER Turn the power switch to the ON position and allow the wheel(s) to achieve full speed. Place a coolant soaked medium (grey) dressing stick (Part No. C633XP950C) against the polishing wheel for a few seconds. A properly stoned polishing

9 wheel will take on a uniformly dull matte finish without any shiny spots. At this point of the stoning process, reconnect coolant system to the E-Z EDGER A-4-3. RETRUING OF DIAMOND WHEELS When a metal bonded diamond grinding wheel loses its form and does not produce the proper edge (produces chips or a wavy finish) it must be retrued. Diamond wheels must be removed from the machine and sent to Abrasive Technology, Inc. for retruing. To minimize lost time, keep a spare set of wheels on hand. See Section A-4-4 for the procedure on removing wheels. A-4-4. REPLACEMENT OF DIAMOND GRINDING OR POLISHING WHEELS Perform the following steps to replace either or both wheel(s): 1. Place the power switch in the OFF position. Disconnect all power to the machine by removing the power cord plug from the AC wall outlet. 2. Remove the wheel access door by pulling it straight up. NOTE During the following step, the hexagon head bolt is loosened and removed from the wheel drive motor shaft by turning the bolt in a counter-clockwise direction. 3. Place a 9/16-inch, open-end wrench over the hexagon head bolt that secures the wheels to the wheel drive motor shaft. Hold the wheels and rap the wrench with a mallet, using the least force necessary, to loosen the hexagon head bolt; remove the bolt. 4. If installed, remove the wheel washer end plate and wheel(s). Pay careful attention to the order and orientation in which these are on the spindle so that you can reassemble them correctly. 5. Clean the wheel adapter, wheel washer, and end plate. 6. To prevent rust, apply a thin coat of non-sulphur grease or white petroleum jelly to the sides and hub of each wheel. 7. Reinstall the replacement wheel(s), wheel washer, end plate, and hexagon head bolt in the same order as was found initially. Use the 9/16-inch, open-end wrench to secure the wheels in place. Hand applied force should be sufficient.

10 8. Disconnect the coolant pump plug from the AC outlet on the machine. Insert the machine power cord into the AC outlet. Place the POWER switch in ON position and then in the OFF position. While the wheels are coasting, check for wobble or bounce which would indicate that an out-of-true condition exists. Such a condition would cause excessive chipping of the glass and the wheel(s) to run out-of-true pre-maturely. Should an out-of-true condition be observed: Remove the power from the machine, loosen the hexagon head bolt, and rotate the diamond grinding wheel 90 degrees. Tighten the hexagon head bolt and retest for trueness. Repeat this action, if necessary, rotating the wheel an additional 90 degrees. If wobble or bounce is still present after repeating this procedure three (3) times, then the wheel needs to be retrued. Refer to Section A-4-3, Retruing of Diamond Wheels. 9. Apply a thin film of grease to the bottom and side edges of the wheel access door. Reinstall the wheel access door. 10. Reactivate the coolant system. If required, readjust the coolant manifold spouts. A-4-5. TROUBLESHOOTING Table A-4-5 lists typical malfunctions and possible causes. Consult this table whenever an operating problem becomes apparent.

11 Table A-4-5. Troubleshooting Chart, E-Z EDGER 1100 Condition Possible Cause Correction 1. Wheel drive motor and coolant a. No voltage at AC wall outlet. a. Reset in-house circuit breaker. pump, if used, do not operate. No b. Power cord defective. b. Repair or replace power cord. voltage present at ACCESSORY c. Power ON/OFF switch or c. Repair defective wiring or receptacle. associated wiring defect. replace defective switch. 2. Wheel drive motor does not a. Wheel drive motor or a. Repair wiring or replace operate. Coolant pump operates. associated wiring defect. defective wheel drive motor. 3. Wheel drive motor operates, a. Coolant pump defective. a. Test by plugging coolant pump but coolant pump does not. cord directly into AC wall outlet and replace pump if necessary. b. PUMP connector receptacle or b. Repair wiring or replace associated wiring defect. defective PUMP receptacle. 4. Excessive machine vibration. a. Glass sludge buildup around a. Remove glass sludge buildup. or between wheels causing an unbalanced condition. b. Correct by following instructions b. Wheels not running true. in Paragraph A-4-4 Step 8.

12 Table A-4-5. Troubleshooting Chart, E-Z EDGER 1100 Condition Possible Cause Correction 5. Slow roughing and/or a. Diamond wheel cutting too a. Stone diamond wheels. finishing cycle. slow. Refer to Section A Reduced coolant flow. a. Coolant level low. a. Add coolant b. Coolant feed hose kinked or b. Route properly; Clean or clogged. replace. c. Coolant fittings, flow control c. Clean, straighten or replace. valve or coolant manifold clogged or bent. d. Pump impeller clogged or d. Clean or replace defective worn excessively. coolant pump. 7. Excessive firing of glass a. Incorrect coolant flow or a. Adjust as described in when being edged. spout adjustment. Section 2-2, Step 2. b. Excessive downward pressure b. Use proper edging procedure is being exerted on glass or (See Section 2-3.) glass is being transversed across the diamond wheel too fast. c. Diamond wheel needs c. Stone diamond wheel. stoning.

13 A-5. REPLACEMENT PARTS LIST A-5-1. GENERAL This section of the manual contains the replaceable parts listing for the E-Z EDGER When ordering parts, please list the part number, description, and quantity desired. Call Abrasive Technology, Inc. for information on parts not on this list. A-5-2. REPLACEMENT PARTS LIST ATI PART NO. REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ. R WHEEL DRIVE MOTOR 5/8 SHAFT, 1/2 HP, 115 / 230 VOLT, 50 / 60 HZ. R MOTOR BEARING R BRUSHES R FIBERGLASS SUPPORT 4 x 1 1/8 x 1/4 R UHMW POLYETHYLENE GUIDE TRACKS R WHEEL ACCESS DOOR - PAINTED R KNOB FOR WHEEL ACCESS DOOR R COMBINATION COVER PLATE 115 / 230 VOLT R SQUARE TWO-GANG BOX R AMP, 115 VOLT, POWER CORD w/plug (U.S.) R AMP, 230 VOLT, POWER CORD w/plug (U.S.) R CARRYING HANDLE

14 ATI PART NO. REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ. R PLASTIC FLEX HOSE SEGMENTS - 1/4 R FLOW CONTROL VALVE 1/4 R T -CONNECTOR FOR COOLANT HOSE R PLASTIC FLEX HOSE NOZZLE TIP - 1 1/4 R DRAIN HOSE R WHEEL ADAPTER FOR 5/8î SHANK 1 1/4 AH R POLISHING WHEEL END PLATE 4 X 3/8 AH R PLASTIC FLEX HOSE FITTING - 1/4 NPT R LEVELING LEG R /8-16 COUPLING NUTS R NYLON HEX (CAP) NUTS R NYLON FLAT WASHER FOR 5/16 SCREW R SUBMERSIBLE PUMP KIT, 115 VOLT R SUBMERSIBLE PUMP KIT, 230 VOLT R FIBERGLASS CHANNEL FOR VERTICAL GUIDE R GUIDE ROLLER R VERTICAL SUPPORT GUIDE

15 abrasive technology, inc Green Meadows Dr. P.O. Box 545 Lewis Center, OH USA Fax: (800)