AmeriBrade HYPER-DISC User manual

AmeriBrade LLC
Rev-A2 09/14/2023
HYPER-DISC MANUAL
Hyper-Disc Bench Grinder Setup, Maintenance and
Troubleshooting

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Contents
1. WARNING: DANGER..............................................................................................................................2
2. Assemble the Pedestal Stand. Skip to Step 3 if you did not order a Pedestal Stand............................3
3. Mount the Dual-Swivel Mount and VFD bracket to your bench top or to your Pedestal Stand. If you
did not order a Dual-Swivel Mount, Skip to Step 4.......................................................................................4
4. Mount the Motor to the Dual-Swivel Mount, or to your bench-top (whichever is applicable for the
items you purchased) Dual-Swivel shown below: ........................................................................................6
5. Plug Motor into VFD and Secure Plug...................................................................................................7
6. Set-Up Accessories................................................................................................................................8
7. Install Work-Rest.................................................................................................................................17
8. Shut Down...........................................................................................................................................19
9. Maintenance.......................................................................................................................................19
10. Troubleshooting..............................................................................................................................21
Trips Breaker...........................................................................................................................................21
Bogs Down Easily Under Load.................................................................................................................21
Slows Down and Speeds Up Spontaneously...........................................................................................23
Won’t Start..............................................................................................................................................24
Other VFD Errors.....................................................................................................................................24
Vibration .................................................................................................................................................24
Broken Components ...............................................................................................................................25

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1. WARNING: DANGER
a. Rotating abrasive equipment can be extremely dangerous if used
without proper training or if best safety practices are not strictly
adhered to.
b. Specifically, due to the versatile nature of the Hyper-Disc Bench
Grinder, the operator needs to pay close attention to the proper use
of the full variety of abrasives he attaches. The operator must make
sure it is being ran in the proper rotation direction, at a safe speed,
while presenting the workpiece in a safe and stable position to avoid
death, serious injury, or property damage. Sharp objects being
thrown by misused high-speed abrasives can easily impale the
operator or anyone in the rotation plane of the machine.
c. Make sure to use appropriate personal protection equipment for
eyes, ears, feet, lungs, etc.
d. Grinding dust can be harmful to your health. Make sure to wear
proper respiratory protection while grinding based on the materials
being used.
e. Secure long hair and do not wear loose clothing or dangling jewelry
while operating the machine.

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2. Assemble the Pedestal Stand. Skip to Step 3 if you did not order a
Pedestal Stand.
a. Hardware and feet will be included in a small white box labeled as
follows:
b. The 3/8 cap screws require a 5/16 allen wrench
c. The leveling casters use a ¾ wrench or socket
d. Watch this video to see more details about Pedestal Stand Assembly:
https://youtu.be/lMoHw2YIHoQ

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3. Mount the Dual-Swivel Mount and VFD bracket to your bench top
or to your Pedestal Stand. If you did not order a Dual-Swivel
Mount, Skip to Step 4.
a. Where to find the Hardware:
i. Bench-top mounting: If you are mounting the Dual-Swivel
Mount to your own platform, you will need to provide the
appropriate length hardware based on the thickness of your
mounting surface. Use 3/8” diameter carriage bolts. (Save the
56C Face Mount Kit of hardware for Step 3)
ii. Pedestal Stand mounting: the hardware can be found with the
rest of the pedestal hardware in a small bag labeled as shown:
b. The carriage bolts should be installed from the top and the nuts
installed from the bottom.
Continued on Next Page:

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c. The VFD is mounted by sharing the rear 2 of the 4 carriage bolts
fastening the Dual-Swivel mount to the Pillar. Refer to the image
below for how to orient the VFD mount relative to the Dual-Swivel
Mount.
d. Orientation:
i. Bench-top mounting: the bent flange of the dual swivel mount
(indicated with an arrow in the image below) should hang over
the front-edge of your work bench on the side you will be
standing while using the machine.
ii. Pedestal-mounting: All 4 sides of the pedestal pillar are the
same, so it doesn’t matter which way you decide to attach the
dual-swivel mount to the pillar.

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4. Mount the Motor to the Dual-Swivel Mount, or to your bench-top
(whichever is applicable for the items you purchased) Dual-Swivel shown below:
a. Motor Orientation:
i. Without Dual-Swivel Mount: the motor foot will face down flat
on the mounting surface.
ii. With Dual-Swivel Mount: Make sure the motor’s electrical box
is oriented to the top of the machine as shown above.
b. Where to find the hardware:
i. For mounting to Bench-Top: If you are mounting the motor to
your own platform, you will need to provide the appropriate
length hardware based on the thickness of your mounting
surface. We suggest 5/16” diameter carriage bolts.
ii. For mounting motor directly to a Pedestal Stand (no Dual-
Swivel Mount): Contact AmeriBrade for this special case. We
will need to provide an adapter to allow the motor foot to bolt
to the pedestal stand.
iii. For mounting to a Dual-Swivel Mount: the hardware will be
plastic wrapped to the Dual-Swivel Mount in a small bag
labeled as follows:

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5. Plug Motor into VFD and Secure Plug
a. Plug the male cord on the motor into the female receptacle coming
from the VFD. Make sure to align the indicated L-shaped pin of the
plug with the L-shaped slot of the receptacle. Twist the plug in the
direction shown to secure the connection.
b. Find the included plastic tie-strap (i.e. zip-tie) taped to the front of
the VFD. Pass it over the plug and through the indicated rectangular
holes in the VFD mount(see below). Tighten the plastic tie-strap to
keep the plug in place while the motor pivots on the Dual-Swivel
Mount.

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6. Set-Up Accessories
a. Accessories are installed by sliding the female accessory coupler onto
the male shaft coupler and tightening the knurled draw-nut with one
hand while holding the accessory from spinning with the other hand.
Once the draw-nut seats the taper, the accessory can be driven
either forward or reverse without coming loose. HOWEVER, use
caution for each accessory to make sure it is being run in the correct
rotation direction and speed for the application. Each abrasive has its
own unique limitations and must be fully understood before use to
avoid death, serious injury, or property damage. Contact the abrasive
supplier if you are not sure of the maximum speed or proper use
procedures. Sharp objects being thrown by a misused high-speed
abrasive can easily impale an operator or anyone in the rotation
plane of the machine.
Continued on Next page:

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b. Accessories are removed by using one hand to turn the draw-nut the
opposite direction as before and the other hand to keep the
accessory from turning. If your hand strength is not sufficient to
loosen the draw-nut, use the provided multi-spanner wrench on the
back of the draw-nut to break it loose (shown below). The multi-
spanner wrench can be stored on the magnets behind the VFD in the
approximate area indicated below.
Specific Accessory Setup Continued on Following Pages:

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c. Discs
i. Flat and Tapered discs will come pre-assembled to the female
Disc-Coupler. Simply install the female disc-coupler on the
male shaft-coupler as described in section 6a and adhere an
abrasive sheet before use. Peel and Stick Adhesive (PSA) discs
can be used for a very strong bond. Alternatively, basic
sandpaper can be adhered using 3M-Super-77-adhesive-spray
or 3m-Feathering-Adhesive for a less aggressive bond that is
more easily replaced. Cleaning of excess adhesive should be
done with an appropriate solvent for that adhesive. Wear
appropriate personal protective equipment while handling
solvents.
d. 1/4” Arbor
i. Coming soon to run the “Super-Wheel” from Pops Knife Supply
and any other abrasives that mount to a ¼” diameter shaft.

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e. 1/2” Spindle Sanding Arbor
i. The 1/2” Spindle Sanding Arbor and included rubber sleeves
pair with the Dual-Swivel mount to allow you to utilize the
hyper-disc as a vertical spindle sander.
ii. Install the accessory coupler for the ½” Spindle Sanding Arbor
as described in section 6a.
iii. Choose which size rubber sleeve you’d like to use and slide it
on the arbor.
iv. Install an abrasive spiral band drum corresponding in size to
the chosen rubber sleeve.
v. Install the ½” washer and nut, then tighten the nut sufficiently
to bulge the rubber sleeve and grip the sanding drum
internally.
Continued On Next Page:

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vi. Install the work rest receiver on the face of the dual swivel
mount as shown below by aligning the rounded pins in their
corresponding hole and slot, then tighten the captive thumb
screw in the center. The multi-spanner can be used if hand
strength doesn’t seem sufficient:
vii. Install the work rest assembly into the receiver and tighten the
adjustable handles as shown below:
Continued on Next Page:

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viii. Install the spindle sanding work rest plate on the magnetic
work rest platform, as shown below, by aligning the rounded
pins in their corresponding hole and slot, then tighten the
captive thumb screw in the center. The multi-spanner can be
used if hand strength doesn’t seem sufficient:
ix. Rotate the dual swivel mount into the vertical orientation.
1. Start with the lower joint of the knuckle. Lift up on the
retractable pin (indicated below) to rotate the motor 90
degrees as shown. Release the pin to allow it to lock into
place. Continued on Next Page:

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2. Next, rotate the upper joint of the knuckle. Pull on the
retractable pin (indicated below) to rotate the motor 90
degrees as shown. The fan end of the motor will lower
towards the floor and the spindle will point up. Release
the pin to allow it to lock into place.

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f. 5/8” Arbor
i. The 5/8” arbor is a very universal attachment for running
things such as wire wheels, buffing wheels, or any other
abrasive designed for a traditional bench grinder. Since the
Hyper-Disc allows you to run in forward or reverse, make sure
to install the keyed lock washer(indicated below) between the
abrasive and the arbor nut to prevent the grinding torque from
loosening the nut.
ii. While using airway buffing wheels, make sure to use safety
flanges inside and outside of the buff to keep the rim of the
crimped hub from coming apart during use. If you want to be
able to use the buffing wheels in forward or reverse, you must
use the keyed safety flange (indicated below) from AmeriBrade
to prevent the buffing torque from loosening the arbor nut.

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g. Keyed 3/4” Arbor
i. The Keyed 3/4” Arbor allows you to run 4” wide unmounted
abrasive wheels with a quad-keyed or smooth-bore hub. This
style of wheel can be purchased as non-woven flap wheels,
wire wheels, nylon brushes and more. An example is shown
below. Install the piece of key stock(indicated below) in the
arbor before installing the abrasive wheel if the hub of the
wheel can accept it. This will allow for extra driving torque
without spinning on the arbor. Clamp the wheel onto the arbor
with the provided flange nut. In our experience, this style of
wheel varies in bore diameter considerably. Depending on
your abrasive supplier, the hub may be a tight or a loose fit on
the arbor.
h. Leather Slicker/Edge Burnishing Arbor
i. Coming Soon

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7. Install Work-Rest
a. Install the work rest receiver on the face of the dual swivel mount as
shown below by aligning the rounded pins in their corresponding
hole and slot, then tighten the captive thumb screw in the center.
The multi-spanner can be used if hand strength doesn’t seem
sufficient:
b. Install the accessory you plan to use, such as a disc:
Continued on Next Page:

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c. Install the work rest assembly into the receiver and tighten the
adjustable handles as shown below:
d. Install the desired work rest plate on the magnetic work rest
platform, as shown below, by aligning the rounded pins in their
corresponding hole and slot, then tighten the captive thumb screw in
the center. The multi-spanner can be used if hand strength doesn’t
seem sufficient:
Continued on Next Page:

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e. Adjust the work rest angle by loosening the adjustable handles on
each end, repositioning the work rest, then re-tightening the
adjustable handles.
8. Shut Down
a. Push the Start/Stop switch down to shut down the machine and wait
for the grinder to slow to a stop. Do not leave the Fwd/Stop/Rev
switch in the center Stop position for extended periods of time
without shutting off the Start/Stop switch. This may shorten the life
of your motor and/or controller.
9. Maintenance
a. If the grinder will not be in use for extended periods of time:
i. Unplug the machine from power
ii. Apply anti-seize to the threads of the Draw-Nut to prevent
seizing to accessory couplers.
iii. Apply wax or oil to the male shaft coupler to prevent it from
seizing in the bore of the mating female accessory coupler.
b. Do not leave the male motor shaft coupler exposed longer than is
necessary to change accessories. The grinder should be stored with
an accessory installed in order to protect the precision shaft coupler
from damage.
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