STI Prep/Master RC-3030, Operating Manual

Page 1: ...Operating Manual Prep Master RC 3030 Remote Control ...

Page 2: ... Warranty Substrate Technology guarantees that its machines and products are without manufacturing defects The warranty period on machines is one 1 year from the date of sale and the variable speed drive carries a two 2 year warranty from the date of sale Substrate Technology will replace any part that is defective at its own cost within the warranty period This warranty does not cover wear items ...

Page 3: ...t Specifications RC 3030 Dimensions Length 97 in 246 cm Width 30 in 76 cm Height 64 in 163 cm Weight 1 850 lbs 839 Kg Connected loads of the electrical system Power 25 HP 3 phase 18 6kW Power Cord 6 4 Electrical Connection 220 230 VAC 3 Phase 50 60Hz 380 480 VAC 3 Phase 50 60Hz 1 3 Operative Range and Correct Usage The Prep Master RC 3030 is designed to be used on clean dry or wet horizontal surfa...

Page 4: ...n of the Prep Master RC 3030 it may be possible to exceed the acceptable noise level of 85 dB A This is dependent on the different locations and the local circumstances When the noise level is 85 dB A or more the machine operator and the persons working near the machine must wear sound insulating devices 1 6 Machine Type Designation Machine Type Prep Master RC 3030 Working Width 30 in 72 cm Drive ...

Page 5: ...symbol will be shown in these Operating Instructions next to all safety precautions that are to be taken in order to ensure prevention of injury Follow these instructions and take special care in these circumstances In addition to these instructions the general safety precautions and the local accident prevention guidelines are also to be followed Please check whether there are special regulations...

Page 6: ...he machine or its performance the machine must be shut down immediately The cause of the fault has to be established immediately and has to be repaired before starting the work again Changes add ons or conversions of the machine which might have an influence to the safety of the machine must not be undertaken without the permission of the manufacturer This applies in particular to the fitting and ...

Page 7: ...ain Secure the work area around the machine in public areas providing a safety distance of at least 10 feet around the machine Fault must be rectified immediately Start up and switch off operations and control devices have to be handled in accordance with the Operating Instructions All persons in the proximity of the machine must wear safety glasses with lateral protection as well as safety shoes ...

Page 8: ...e local regulations Do not use any aggressive cleaning materials Use lint free cleaning cloths Always tighten any screw connection that is undone during servicing and maintenance work If safety devices need to be dismantled during setting up servicing and repair work these safety devices must be reinstalled and inspected immediately after completion of the servicing and repair work Make sure that ...

Page 9: ... necessary a second person must be deployed who can pull out the plug in an emergency The working area must be sealed with a red and white safety chain and a danger sign Use tools that are insulated against voltages Only start work once you are familiar with the electrical engineering regulations that apply to your area Only use voltage testers that comply with the regulations when troubleshooting...

Page 10: ...and thin coatings A suitable filter unit must be connected to the machine in order to thoroughly collect the dust being produced by the grinding process The proper dust collection system ensures dust free operation of the machine and clean air at the workspace 3 2 Scope of Supply Provided with machine Prep Master RC 3030 Remote Controller Two 2 Rechargeable Batteries Transportation Leg Manual 1 3 ...

Page 11: ...cy Stop Button 2 Reset it by turning button 45 degrees clockwise until knob pops out Swing Weight System The Swing Weight System is used to easily transfer extra weight to the head of the machine over the gear box for grinding head pressure and for transportation or to the back of the machine for tipping the machine back for easy tool change The neutral position located in the center of the machin...

Page 12: ...7 16 1138656 HX M10 x 30 18 4 47577 Stud M18 x 2 5 x 3 LG 19 4 40183 Lock Nut M18 20 1 66374 Sq HD Plug 3 4 14 NPT 21 1 66375 Sq HD Plug 1 NPT 23 1 HR0240 Helical Gear 24 1 HR0242 Housing 25 1 HR0244 Cover 26 1 630309512 Input Pinion 27 4 HR0554 Bearing Cover 28 2 HR0248 Helical Gear 89T RH 29 2 HR0249 Helical Gear 89T LH 30 4 HR0250 Shaft 31 4 884000893 Coupling Flange 33 1 560250240 Motor 25HP 3...

Page 13: ...ight left 2 2 618092302 Gas Spring Set 3 8 618092303 Knobs 4 2 618092304 LED lights 5 2 618092305 Wheels 6 2 618092306 Rechargeable Batteries 3 5 Wear Parts Part Numbers 5 Wheel 6 Rechargeable Batteries 3 Knob 4 LED Light 1 Handle Grip 2 Gas Spring located on swing weight level arms ...

Page 14: ...ol operation 3 6 Handle Settings The handle height is set with the help of two spring loaded knobs on each side of the handle joint To move the handle up or down 1 Pull out the knobs on both sides of the handle joint by twisting clockwise or counter clockwise 45 degrees to place knob in a disengaged position 2 Move the handle to the desired position and then twist knob clockwise or counter clockwi...

Page 15: ...4 Push machine down by handle in a controlled manner until grinder is resting on the floor 5 Inside the gear box tap the tools from the outside edge of the tool to remove from tool plate 6 Remove all debris from tools and tool plate Tools must lay flat against tool plate in order to work properly 7 Install new tools by sliding the tooling outward to fit into slot securely Machine must only be tilt...

Page 16: ...he leg onto the top bolt of the machine 3 Insert and tighten the lower bolt 4 Tip the machine forward into an upright position Use the leg wheels to transport machine safely IMPORTANT When transporting P M machines by vehicle or trailer it is mandatory to move all swing arm weights to the head of grinder Failure to do so may result in damage to the machine handle frame that are not covered under w...

Page 17: ... or tighten the machine with one strap to the cabin wall of the vehicle Make sure that all parts of the machine are fixed 4 5 Operation Conditions Check the surface to be treated for loose parts stones screws etc The surface must be swept if necessary Make sure that the machine can travel over all inequalities on the surface Small inequalities like floor joints less than inch are no barriers for t...

Page 18: ...ssential Carry out the following checks before any start up Check whether all machine parts are assembled safely and correctly Check all screws and other fasteners for tight seat Check the tool holders to ensure that the proper tools are in place and secure Check the tightness of the hose connections and the condition of the hose to the filter Make sure the dust container of the filter unit is emp...

Page 19: ...e 4 Switch on the filter unit 5 Check that the main switch is turned on 6 Turn the Main Power switch to On The machine can be operated manually through the handle s control panel or automatically through the remote controller Refer to Chapter 6 Operation of Machine for preferred mode of operation 7 After start up immediately begin moving the machine in the S Curve pattern see page 9 Chapter 3 3 fo...

Page 20: ... and other equipment run over the electric cable and the dust hose The speed of moving the grinding machine over the work surface will influence the final finish and production In the case that the surface shows different characteristics specifically different hardness or coating thicknesses a uniform grinding result will be achieved by varying the speed of movement over the surface 6 2 Failure Re...

Page 21: ...nual Control 6 EM STOP Lamp Red light is on when Emergency Stop 12 is engaged 7 Power On Off Insert and turn the Start key to the right ON Turn the start key to the left OFF 8 LH SPEED Control knob to adjust left wheel speed 9 RH SPEED Control knob to adjust right wheel speed 10 Trouble Reset Resets the Inverter lifts the power overload When engaged the Inverter Trouble lamp 2 will turn off 11 Mod...

Page 22: ...ise REV or Reset 16 Light Switch LED headlights ON OFF 17 Stop Press button to stop the machine Red light becomes lit 18 Grinder Speed Controls the grinding head s rotation speed 6 6 Simple Procedure for Engaging Manual Control 1 Secure wheels in unlocked state pull and twist all four wheel knobs into OUT position 2 Turn Power 7 to ON Power Lamp 1 becomes lit 3 Turn Mode 11 to Manual Manual Lamp 5...

Page 23: ...n of the grinding heads on the Grinder Selection switch 15 9 Press the Start button 14 to activate the machine 10 Adjust grinder wheel speed with the LH SPEED RH SPEED control knobs 8 9 11 On the handle panel turn the Grinder Speed knob 18 to adjust the grinding speed from 0 to 100 12 Start to move machine in the S Curve motion to begin the grinding process see page 9 Chapter 3 3 for explanation S...

Page 24: ...rn switch to the left to disengage 24 Radio Enabled Lamp Remote Controller s Signal Indicator 25 Steering L R Control lever for moving the machine left L or right R 26 Steering F R Control lever for moving the machine forward F or reverse R 6 9 Simple Procedure for Engaging Remote Control 1 Secure wheels in locked state twist all four wheel knobs into IN position On the Control Panel Machine Back ...

Page 25: ...machine The S curve is a specific movement of the machine that helps to level the floor profile see page 9 Chapter 3 3 for explanation Turn to OFF to run the machine in a straight line for edge work 12 To control direction of the machine use Steering control levers 25 26 13 If necessary on back of machine adjust grinder wheel speed using the LH SPEED RH SPEED control knobs 8 9 14 On the handle pan...

Page 26: ...o different working conditions it cannot be foreseen how frequently inspections for wear checks inspection maintenance and repair works ought to be carried out Prepare a suitable inspection schedule considering your own working conditions 7 2 Maintenance and Inspection Operating Hours Time Period Inspection Points Maintenance Instructions Daily Prior to Operation Check all electrical cables for cu...

Page 27: ...arts Regular wear parts for the gear box is the Morflex Coupler To replace a worn or damaged Morflex Coupler perform the following 1 Remove in 20 bolts from drive plate using a in impact wrench and in socket 2 Use pry tool to remove assembly from drive plate 3 Remove in 20 bolts from tool plate using a in impact wrench and in socket 4 Use pry tool to remove coupler from tool plate 5 Replace with n...

Page 28: ...r Damaged or worn coupler Replace coupler Oil leak under gear box Bad oil seal Replace oil seal Unusual Noise Uneven or loose surface being ground Verify suitability of substrate being ground Loose or damaged tooling Inspect tooling to make sure that all connecting hardware is tight and tool is firmly seated to holder Shroud is dragging on the floor Adjust shroud and tighten to no more than inch a...

Page 29: ... guidance and supervision of a skilled electrician in accordance with the electrical engineering regulations Failure Possible Reasons for Failure Corrective Actions Motor does not start up Missing Phase Check power supply Faulty switch or relays Get diagnosis and replacement by a skilled electrician Emergency Stop Unlock the emergency stop button Motor stops during operation Current power is too h...

Page 30: ...nd adjust speed to 45Hz electric or 2500 RPM propane 3 Upon starting the machine continuously move machine in side to side pattern ensuring that machine is will grind the floor evenly If for any reason the machine cannot be continuously moved i e cord management adjacent work obstacles etc stop the machine until it can be operated as specified above Upon satisfactory completion of surface prep rem...

Page 31: ... hand tools 00L in the tool holders that are turning counter clockwise 2 Place the P M machine in the operating position Attach appropriate power and vacuum dust collection hose to the P M machine 3 With weights in neutral position or off machine start the machine and adjust speed to 40Hz electric or 2500 RPM propane 4 Upon starting the machine continuously move machine in side to side pattern ens...

Page 32: ...d tools that have the same face design and can be clearly identified by the number on back as 1 and 2 Both tools feature the patented EG attachment system Approximate life of 1 is 30 000 SF 2 787 M2 for all P M Machines except 4430 P M Machine 4430 life expectancy is 40 000 SF 3 716 M2 Approximate life of 2 is 35 000 SF 3 251 M2 for all P M Machines except 4430 P M Machine 4430 life expectancy is ...

Page 33: ... set speed to 45Hz on VSD and start machine for propane run at 2500 RPM Upon satisfactory completion of step 5 remove machine from area and vacuum the surface 6 Apply densifier per manufacturer s recommendations and allow surface to dry completely after densifier process has been completed See Section 3 for further information about densifiers 7 Attach the EGT 6 tools to the P M Machine and place ...

Page 34: ...achinery Qualifications The EGT Diamond System is designed to attach to and work perfectly with any Substrate Technology Prep Master machine Quantity of EGT tools will vary by model Prep Master 2807 2818LP P M Jr 6 pieces Prep Master 2420 2418LP 12 pieces Prep Master 3030 3038LP RC 3030 12 pieces Prep Master 4430 4438LP RC 4430 24 pieces Attachment of EGT tools 4 through 8 require Velcro pad adapt...

Page 35: ...cturer s recommendations and allow surface to dry completely after densifier process has been completed See Section 3 for further information about densifiers 4 Attach the CLC 3 tools to the P M machine and place it in operating position Attach appropriate power to the P M machine With 50 of weights on head of machine and 50 in basket over wheels set speed to 45Hz on VSD add water and start machin...

Page 36: ...erlap paths by at least 25 The machine must always be swung side to side approximately 30 degrees The machine should never be quickly pushed across floor to move to areas outside the area that is to be polished The work area must be closed to all non associated workers and equipment The likelihood of contamination by non associated traffic is increased and rogue scratches will be possible as well ...

Page 37: ...e 1 TPS tool life will be variable based upon Epoxy Terrazzo mixture components consistency of epoxy terrazzo placement and adequate dust collection TPS 2 2 2 is a metal bond tool painted orange that has pictured face design and can be clearly identified by the number on back as 2 This tool features the patented EG attachment system The tool is run dry Approximate life of 2 is 30 000 SF 2 787 M2 f...

Page 38: ...z or 2100 RPM with the pocket weights on the handle Not running as recommended will greatly reduce pan life expectancy and may produce burn marks in the floor Never use the pans on machines that have RPM in excess of 250RPM tool speed 5 Attach the TPS 4 tools to the P M Machine and place it in operating position Attach appropriate power to the P M machine With 50 of weights on head of machine and ...

Page 39: ... scratches from previous steps A thorough processing of the epoxy terrazzo can only be achieved by one pass forward and then second pass backward over same path It is compulsory to overlap paths by at least 25 The machine must always be swung side to side approximately 30 degrees The machine should never be quickly pushed across floor to move to areas outside the area that is to be polished The wo...

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