EZ Edger 2000 Manual - Abrasive Technology

EZ Edger 2000 Manual - Abrasive Technology
E -Z ED GER™ 2000
CIRCULAR GLASS EDGING MACHINE
OPERATING AND MAINTENANCE
INSTRUCTIONS
IMPORTANT NOTICE:
Read all operating instructions before
operating machine
Manufactured by: Abrasive Technology
8400 Green Meadows Dr • P.O. Box 545 • Lewis Center, OH 43035 USA
INTRODUCTION
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 E-Z EDGER™ 2000 glass beveling machine 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™ 2000 machine 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 machine, 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.
SECTION I.
1. GENERAL - The E-Z EDGER™ 2000 glass beveling machine (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 this machine
can edge a 10-inch to 60-inch diameter glass up to 3/8 inches thick, as
well as a 10-inch to 44-inch diameter 1/2 inch thick glass, it is an ideal
machine for edging mirrors, table tops, and windows. Requiring only
power and coolant hookups, this machine is compact and portable making it ideal for use on the jobsite. The required coolant hookup may be
made to an existing coolant system or to our optional five-gallon recirculating coolant system.
Although the coolant hookup may be made directly to a tap water supply, it is strongly recommended that a coolant system using a rust
inhibitor and lubrication coolant solution (such as our “Liquid Ice” brand)
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.
Figure 1
SECTION II
2-1. PREPARATION FOR OPERATION
1. Place the E-Z EDGER™ 2000 machine 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.
3. Place the flow control valve (2, Figure 1) (at the rear of the
machine) in the OFF position.
4. Connect the recirculating coolant system to the E-Z EDGER™
2000 machine 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 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 (6, 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 five (5) leveling feet (3, Figure 1) so that all five (5) 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. Connect upright (4, Figure 1) to base using the 3 supplied bolts
and nuts.
7. Plug in the glass-drive motor (5, Figure 1) to outlet marked
“AccMax3A’.
8. Loosen knob (7, Figure 1) and slide the roller guide onto the
upright. Adjust the roller guide to the desired glass diameter by lining up the bottom of the guide with the scale on the upright. Then,
tighten the knob.
2-2. 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.
3. Slowly open the flow-control valve until the streams of coolant
from the two coolant spouts cross over each other.
4. Proceed with Section 2-3.
2-3. POLISHING GLASS
1. Turn the main power switch to the OFF position and allow the
grinding wheels time to stop rotating.
2. Carefully place the glass to be edged on the E-Z Edger™ 2000
machine’s rubber drive wheel and metal bond diamond grinding
wheel.
3. Lift upper guide roller (8, Figure 1) and slide the glass into the
wheel slot nearest the upright. The spring loaded guide roller will
trap the glass in the proper position relative to the bottom wheels.
4. Carefully lift the glass off the diamond wheel by rotating the liftoff
handle (9, Figure 1) clockwise to the upper position. The handle
will lock into place.
5. Turn the main power switch of the E-Z Edger™ 2000 machine to
the ON position.
6. Carefully lower the glass onto the roughing wheel by rotating the
lift-off handle counterclockwise.
7. Allow the glass to rotate on the roughing wheel until the desired
edge is achieved (usually 1 - 3 revolutions), carefully rotate the
lift-off handle clockwise to the upper position, as in Step 3 above.
8. Turn the main power switch to the OFF position.
9. If desired, repeat the sequence above with the glass on the polishing wheel side.
10. Carefully remove the finished glass.
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™ 2000 glass beveling machine:
AT Part No. Description
R40013620
Submersible Coolant Pump, Tank, and Liners
115 VAC 50 / 60 Hz.
R40013640
Submersible Coolant Pump, Tank, and Liners
230 VAC 50 / 60 Hz.
C6341477024
Liquid Ice Coolant, case 24 Disposable Bottles
C6330009
Fine Dressing Stick
C6330008
Coarse Dressing Stick
Table A-1 Machine Specifications
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Inches
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Inches*
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Inches
Weight (with Two Mounted Wheels) . . . . . . . . . . . . . . . . . . .105 Pounds
*72” high with column
A-2 ELECTRICAL REQUIREMENTS (all Single Phase):
Model Numbers
C2852000
C2852001
C2852002
C2852003
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.
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.
Table A-4-1 Periodic Maintenance Required
Description
Time Interval
Instructions
(if applicable)
1. Clean Machine
After daily use
N/A
2. Lubrication
None required
N/A
3. Check Coolant level *
Hourly or more often if
heavy spray mist is
present during operation
N/A
4. Clean Coolant Tank *
After daily use
N/A
5. Stone Wheels (Dressing)
When roughing or finishing
cycles slow considerably
Section A-4-2
6. Retruing of Wheels
When diamond grinding
or polishing wheels lose
their form
Section A-4-3
7.Replacement of
Wheels
As needed when wheels
have worn considerably
* Only if recirculating coolant system is being used.
Section A-4-4
A-4-2. MAINTENANCE OF DIAMOND GRINDING WHEELS AND
POLISHING WHEELS
Two types of abrasive dressing sticks are supplied with the E-Z
EDGER™ 2000 machine to sharpen the cutting action of the metal
bonded diamond grinding wheels and polishing wheels. Our fine
dressing stick (Part No. C633XP950F) is used to sharpen the diamond grinding wheels (MF and FF type wheels). Our medium
dressing stick (Part No. C633XP950C) 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 the polishing
wheels be stoned when they take on a shiny appearance.
A-4-2-1. STONING BONDED MF AND FF TYPE 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™ 2000 machine.
Turn the power switch to the ON position and allow the
wheel(s) to achieve full speed. Place a coolant soaked
fine (white) dressing stick (Part No. C633XP950F) against
the 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 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™ 2000 machine.
A-4-2-2. STONING BONDED SF TYPE FINISHING 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™
2000 machine. 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 wheel will take on a uniformly dull matte finish without any shiny spots. At this
point of the stoning process, reconnect the coolant system to the E-Z EDGER™ 2000 glass beveling machine.
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
us 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.
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 prematurely.
Should an out-of-true condition be observed: Turn the
machine off, 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 A4-3, 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.
a. Fuse bad.
b. Wheel drive motor
associated wiring defect.
a. Fuse bad.
b. Coolant pump defective.
2. Wheel drive motor does not
operate. Coolant pump and glass
drive motor operates.
3. Wheel drive motor and glass
drive motor operate, but
coolant pump does not.
4. Wheel drive motor and coolant
pump operate, but glass drive
motor does not.
a. Fuse bad.
b. No voltage at AC wall outlet.
c. Power cord defective.
d. Power ON/OFF switch or
associated wiring defect.
1. Wheel drive motor and coolant
pump, if used, do not operate. No
voltage present at ACCESSORY
receptacle.
c. Glass drive motor connector
receptacle or associated wiring
defective.
a. Fuse bad.
b. Glass drive motor defective.
c. PUMP connector receptacle or
associated wiring defect.
Possible Cause
Condition
Table A-4-5. Troubleshooting Chart
a. Check fuse and replace if bad.
b. Test by plugging in glass drive
motor cord directly into AC
wall outlet.
c. Repair wiring or replace
defective receptacle.
a. Check fuse and replace if bad.
b. Test by plugging coolant pump
cord directly into AC wall outlet,
replace pump if necessary.
c. Repair wiring or replace
defective PUMP receptacle.
a. Check fuse and replace if bad.
b. Repair wiring or replace
defective wheel drive motor.
a. Check fuse and replace if bad.
b. Reset in-house circuit breaker.
c. Repair or replace power cord.
d. Repair defective wiring or
replace defective switch.
Correction
a. Treat as a combination of
3 and 4 above.
a. Treat as a combination of
2 and 4 above.
a. Treat as a combination of
2 and 3 above.
a. Glass sludge buildup around
or between diamond wheels
causing an unbalanced condition.
b. Diamond wheels not running true.
a. Diamond wheel cutting too slow.
a. Coolant level low.
b. Coolant feed hose kinked or
clogged.
c. Coolant fittings, flow control
valve or coolant manifold
clogged or bent.
d. Pump impeller clogged or worn
excessively.
5. Wheel drive motor operates, but
coolant pump and glass drive
do not.
6. Wheel drive motor and glass
drive motor do not operate; but
coolant pump does.
7. Wheel drive motor and coolant
pump do not operate, but glass
drive motor does.
8. Excessive machine vibration.
9. Slow roughing and/or finishing
cycle.
10. Reduced coolant flow.
d. Clean or replace defective
coolant pump.
a. Add coolant.
b. Route properly; clean or
replace.
c. Clean, straighten or replace.
a. Stone diamond wheels. Refer
to Section 3-2.
b. Correct by following instructions
in Section 3-4 Step 8.
a. Remove glass sludge buildup.
a. Treat as a combination of
2 and 3 above.
a. Treat as a combination of
2 and 4 above.
a. Treat as a combination of
3 and 4 above.
a. Incorrect coolant flow or spout
adjustment.
b. Excessive downward pressure
is being exerted on glass or
glass is being transversed
across the diamond wheel too
fast.
c. Diamond wheel needs stoning.
c. Stone diamond wheel.
(See Section A-4-2)
a. Adjust as described in
Section 2-2, Step 2.
b. Use proper edging procedure
(See Section 2-3)
REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
WHL. DRIVE MOTOR 5/8” SHAFT, 115 / 230 VOLT, 50 / 60 HZ.
WHL DRIVE MOTOR 3/4” SHAFT, 115 / 230 VOLT, 60 HZ.
MOTOR COVER - PAINTED
FIBERGLASS UPRIGHT 4” X 1 1/8” X 1/4”
MYLAR SCALE
AC RECEPTACLE, 3-WIRE, DOMESTIC, 230 VAC
AC RECEPTACLE, 3-WIRE, DOMESTIC, 115 VAC
FUSE HOLDER w/MOUNTING BRACKET
ATI PART NO.
R40300490-2
R40300490
R40030005
R40040003-1
R40050005-9
R40426100
R40426110
R40430210
A-5-2. REPLACEMENT PARTS LIST
R40111480-1
R40410350
R40494260
R40106410
R40202850
R40494240
R40116090
R40011560
ATI PART NO.
WHEEL ACCESS DOOR - PAINTED
“T”-CONNECTOR FOR COOLANT HOSE
PLASTIC FLEX HOSE FITTING - 1/4” NPT
COOLANT FEED HOSE
FEMALE NIPPLE, 1/4” X 5/16” TAPERED
PLASTIC FLEX HOSE NOZZLE TIP - 1 1/4”
POLISHING WHEEL END PLATE, 4” X 3/8” AH
LEVELING LEG
REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
This section of the manual contains the replaceable parts listing for the E-Z EDGER™ 2000 machine. When
ordering parts, please list the part number, description, and quantity desired. Call our customer service department for information on parts not on this list.
A-5-1. GENERAL
A-5. REPLACEMENT PARTS LIST
11. Excessive “firing” of glass when
being edged.
REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
MOTOR BEARING NO. HCSF S202-10-TRL
PLASTIC FLEX HOSE SEGMENTS - 1/4”
FLOW CONTROL VALVE 1/4”
15 AMP, 230 VOLT, POWER CORD w/PLUG (U.S.)
15 AMP, 115 VOLT, POWER CORD w/PLUG (U.S.)
SWITCH DPST (PRIMARY POWER)
DRAIN HOSE
WHEEL ADAPTOR FOR 3/4” SHANK. 1 1/4” AH
WHEEL ADAPTOR FOR 5/8” SHANK, 1 1/4” AH
KNOB FOR WHEEL ACCESS DOOR
ATI PART NO.
R40030006
R40494200
R40204680
R40426120
R40410060
R40470190
R40106300
R40113370
R40113560
R40201130
REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
LIFT-OFF ASSEMBLY
NYLON ROLLER FOR LIFT-OFF ASSEMBLY
DRIVE MOTOR ASSEMBLY, 115 / 230 VAC, 50 / 60 HZ.
COUPLING ASSEMBLY
DUAL DRIVE WHEEL ASSEMBLY
SLIDING ROLLER GUIDE ASSEMBLY
UPPER GUIDE ROLLER
SUBMERSIBLE PUMP KIT, 115 VOLT
SUBMERSIBLE PUMP KIT, 230 VOLT
ATI PART NO.
R40050001
R40050001-1
R40050002-5
R40050003
R40050004
R40050005
R40050005-7
R40350070
R40350130
abrasive technology
®
WORLD HEADQUARTERS
United States
Ph: 1.740.548.4100
Fax: 1.740.548.7617
EUROPEAN HEADQUARTERS
United Kingdom
Ph: 44.20.7471.0200
Fax: 44.20.7471.0202
ASIAN HEADQUARTERS
Singapore
Ph: 65.6270.6878
Fax: 65.6270.6877
www.abrasive-tech.com
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