ez edger™ 1100 - Abrasive Technology

ez edger™ 1100 - Abrasive Technology
EZEdger1100Manual
10/15/04
1:08 PM
Page 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.
8400 Green Meadows Dr • P.O. Box 545 • Lewis Center, OH 43035
www.abrasive-tech.com
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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.
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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.
8
9
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SECTION II
5
3
2-1. 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.
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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.
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.
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3. Slowly open the flow-control valve until the streams of coolant
from the two coolant spouts cross over each other.
2-3. 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)
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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
R40013620
Submersible Coolant Pump, Tank, and Liners 115
VAC 50 / 60 Hz.
R40013640
Submersible Coolant Pump, Tank, and Liners 230
VAC 50 / 60 Hz.
R40018920
Work Bench
C6341477024 Liquid Ice Coolant; case, 24 Disposable Bottles
C633XP950F Fine Dressing Stick
C633XP950C Medium Dressing Stick
R40040007-2 Guide Extension Strip (30” x 3 1/2” x 1/2”)
Table A-1 Machine Specifications
Width
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 Inches
Height - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 Inches
(without vertical support column)
Depth
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18 Inches
Weight (with Two Mounted Wheels) - - - - - - - - - - - - - - - 56 Pounds
A-2 ELECTRICAL REQUIREMENTS (all Single Phase):
Model Numbers
C2851100
C2851001
C2851002
C2851003
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.
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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 diamond grinding
or polishing 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
Section A-4-4
* Only if recirculating coolant system is being used.
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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-4-2-1. 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™ 1100. 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™ 1100.
A-4-2-2. 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™ 1100. 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
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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™ 1100.
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.
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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.
a. Wheel drive motor or
associated wiring defect.
a. Coolant pump defective.
2. Wheel drive motor does not
operate. Coolant pump operates.
3. Wheel drive motor operates,
but coolant pump does not.
a. Glass sludge buildup around
or between wheels causing an
unbalanced condition.
b. Wheels not running true.
b. Correct by following instructions
in Paragraph A-4-4 Step 8.
a. Remove glass sludge buildup.
a. Test by plugging coolant pump
cord directly into AC wall outlet
and replace pump if necessary.
b. Repair wiring or replace
defective PUMP receptacle.
a. Repair wiring or replace
defective wheel drive motor.
a. Reset in-house circuit breaker.
b. Repair or replace power cord.
c. Repair defective wiring or
replace defective switch.
1:08 PM
4. Excessive machine vibration.
a. No voltage at AC wall outlet.
b. Power cord defective.
c. 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.
Correction
10/15/04
b. PUMP connector receptacle or
associated wiring defect.
Possible Cause
Condition
Table A-4-5. Troubleshooting Chart, E-Z EDGER 1100
EZEdger1100Manual
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Possible Cause
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.
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.
Condition
5. Slow roughing and/or
finishing cycle.
6. Reduced coolant flow.
7. Excessive “firing” of glass
when being edged.
c. Stone diamond wheel.
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a. Adjust as described in
Section 2-2, Step 2.
b. Use proper edging procedure
(See Section 2-3.)
10/15/04
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 A-4-2
Correction
Table A-4-5. Troubleshooting Chart, E-Z EDGER 1100
EZEdger1100Manual
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REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
WHEEL DRIVE MOTOR 5/8” SHAFT, 1/2 HP, 115 / 230 VOLT, 50 / 60 HZ.
MOTOR BEARING
BRUSHES
FIBERGLASS SUPPORT 4” x 1 1/8” x 1/4”
UHMW POLYETHYLENE GUIDE TRACKS
WHEEL ACCESS DOOR - PAINTED
KNOB FOR WHEEL ACCESS DOOR
COMBINATION COVER PLATE 115 / 230 VOLT
SQUARE TWO-GANG BOX
15 AMP, 115 VOLT, POWER CORD w/PLUG (U.S.)
15 AMP, 230 VOLT, POWER CORD w/PLUG (U.S.)
CARRYING HANDLE
R40300490-1
R4003001
R4004001
R4004003-2
R40040007-1
R40111480-1
R40201130
R40040010
R40040011
R40410060
R40426120
R40040006
10/15/04
ATI PART NO.
A-5-2. REPLACEMENT PARTS LIST
This section of the manual contains the replaceable parts listing for the E-Z EDGER™ 1100. 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-5-1. GENERAL
A-5. REPLACEMENT PARTS LIST
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REPLACEMENTS PARTS LIST 115 / 230 VOLT 50 / 60 HZ.
PLASTIC FLEX HOSE SEGMENTS - 1/4”
FLOW CONTROL VALVE 1/4”
“T”-CONNECTOR FOR COOLANT HOSE
PLASTIC FLEX HOSE NOZZLE TIP - 1 1/4”
DRAIN HOSE
WHEEL ADAPTER FOR 5/8î SHANK 1 1/4” AH
POLISHING WHEEL END PLATE 4” X 3/8” AH
PLASTIC FLEX HOSE FITTING - 1/4” NPT
LEVELING LEG
3/8”-16 COUPLING NUTS
NYLON HEX (CAP) NUTS
NYLON FLAT WASHER FOR 5/16” SCREW
SUBMERSIBLE PUMP KIT, 115 VOLT
SUBMERSIBLE PUMP KIT, 230 VOLT
FIBERGLASS CHANNEL FOR VERTICAL GUIDE
GUIDE ROLLER
VERTICAL SUPPORT GUIDE
ATI PART NO.
R40494200
R40204680
R40410350
R40494230-1
R40105300
R40113560
R40116090
R40494260
R40011560
R40040012
R40040015
R40203940
R40350070
R40350130
R40040003-6
R40050005-13
R40050005-1
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abrasive
technology, inc.
®
8400 Green Meadows Dr. • P.O. Box 545
Lewis Center, OH 43035 USA
740-548-4100 Fax: 740-548-7617
www.abrasive-tech.com
(800) 964-8324
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