prepmaster STI-2807 User manual

Operating Manual
STI-2807
STI-2817LP
STI-2807
STI-2817LP

Substrate Technology, Inc.
1384 Bungalow Rd.
Morris, IL 60450 USA
[phone]
[phone] Fax
www.substratetechnology.com
[12.09]

Operating Manual STI-2807 | STI-2817LP
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Table of Contents
1.0 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.0 Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.0 Starting Up the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.0 Operation of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.0 Troubleshooting / Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.0 STI Reference Guide & Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Please note: The following safety instructions must be followed
as shown in this operating manual. Failure to do so may result
in hazard to health or possible death.

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1.0 Technical Data
1.1 Rating
1.2 Unit Specifications: STI-2807
1.3 Unit Specifications: STI-2817LP
1.4 Operative Range and Correct Usage
1.5 Stand-by Power Supply (Generator) (STI-2807 only)
1.6 Advice for Operators of Grinding Machines
1.7 Machine Type Designation
1.1 Rating
Machine: Prep/Master®Grinder
Machine-Types: STI-2807 | STI-2817LP
Manufacturer: Substrate Technology
1384 Bungalow Rd.
Morris IL 60450 USA
[phone]
www.substratetechnology.com
1.2 Unit Specifications: STI-2807
Dimensions:
Length 63 in 160 cm
Width 28 in 71 cm
Height 50 in 127 cm
Weight 684 lbs. 310 Kg
Connected loads of the electrical system:
Power 7.5 HP
Electrical Connection 230V/50-60Hz-1 Phase or 3 Phase
400V/50-60Hz 3-Phase
depending on ordered unit

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1.3 Unit Specifications: STI-2817LP
Dimensions:
Length 72 in 183 cm
Width 28 in 71 cm
Height 53 in 135 cm
Weight 585 lbs. 265 Kg
1.4 Operative Range and Correct Usage
The safety instructions must be followed as shown in this operating manual.
Failure to do so may result in hazard to health or possible death.
The Prep/Master®STI-2807 | STI-2817LP is designed to be used on clean, dry
or wet horizontal surfaces without obstacles. The machine can not be used for
other purposes. The manufacturer will not be liable for damages resulting from
such incorrect usage. In case of wrong usage the user is responsible for all risks.
1.5 Stand–by Power Supply (Generator)
If the Prep/Master®STI-2807 is operated using a generator, the generator
must be operated in accordance with the current local electrical directives (this
applies in special to the protective ground conductor) in order to ensure that all
safety devices are functioning and to be able to eliminate possible damage to
electrical components.
1.6 Advice for Operators of Grinding Machines
During the operation of the Prep/Master® STI-2807 | STI-2817LP 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 others working near the machine must
wear sound–insulating devices.

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1.7 Machine Type Designation
Machine Type: Prep/Master®STI-2807 | STI-2817LP
Working Width: 28 in / 71 cm
Drive: Manual
Grinding Capacity: Variable
Dust Hose Connection: 3 in / 8 cm
2.0 Safety Instructions
2.1 Explanation of Warnings and Symbols
2.2 Organizational Measures
2.3 Personnel Selection and Qualification
2.4 Safety Precautions Applicable to Different Operating Conditions
2.5 Repair Work, Maintenance Activities, and Default Repair on the Job Site
2.6 Definition of the Safety-off Position
2.7 Dangerous Aspects of the Machine
2.8 Electrical Engineering Regulations
2.9 Special Instructions
The following safety instructions must be followed as shown
here. Failure to do so may result in hazard to health or possible
death.
2.1 Explanation of Warnings and Symbols
The following symbols are used in the operating instructions to highlight areas
of particular importance:
Operational Safety
This 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 for the particular job site.
Safety Goggles/ Ear Protection
Information, instructions, and restrictions with regards to possible risks to persons
or extensive material damages.

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Electrical Warning
Warning against dangerous voltages.
2.2 Organizational Measures
The Operating Instructions are to be kept near the location where the machine is
located and must be accessible all the time!
In addition to the Operating Instructions general and legal regulations regarding accident
prevention and environmental protection must be with and indicated every time!
Such duties may for example relate to the handling of hazardous substances or to the
provision and wearing of personal protection equipment as well as compliance with local
traffic regulations.
The Operating Instructions must be supplemented by instructions including the duty
to supervise and report relating to particular local working practices, for example work
organization, work procedures, and personnel allocation.
Personnel entrusted with working with the machine must have read the Operating
Instructions before starting the work; in particular the chapter about Safety Instructions.
These have to be read before starting any work with the machine. This particularly applies
to incidental activities such as setting up the machine, carrying out maintenance work, or
training staff to work with the machine.
From time to time the working practices of the staff are to be checked regarding awareness
of safety and hazards.
Personnel must tie back long hair and not wear loose clothing or jewelry and rings. There is a
risk of injury through getting stuck or being drawn into moving machinery.
Use personal protection equipment if necessary or required by regulations!
Take notice of all safety and hazard notices on the machine.
All safety and hazard notices on the machine must be kept complete and legible.
If safety-critical changes occur to the 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.

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This applies in particular to the fitting and adjustment of safety devices and to welding on
major and load bearing parts.
Spare parts must always comply with the technical requirements and the specifications of the
manufacturer. This is always guaranteed with original spare parts of the manufacturer.
Inspection intervals and intervals for recurring checks specified in these Operating
Instructions must be complied with. At the same time it is necessary to meet the legal
requirements.
To perform maintenance work correctly it is important to be equipped with proper tools for the
task in question.
The location and the operation of fire extinguishers must be made known on each building
site!
Take note of the facilities for fire reporting and fighting fires!
2.3 Personnel Selection and Qualification
Fundamental duties:
Only reliable personnel are allowed to work on the machine
Only trained personnel can be used to operate the machine. Note the statutory minimum
age! Specify clearly the responsibilities of personnel for operation, setting up, servicing and
maintenance work!
Make sure that only authorized personnel operate or work on the machine.
Select clearly the machine operator. Define his/her responsibilities also with regard to traffic
safety regulations and empower him/her to decline instructions from third parties which are
not complying with the safety requirements.
Personnel being trained or made acquainted with the equipment may only be deployed under
constant supervision of an experienced person.
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.

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2.4 Safety Precautions Applicable to Different Operating Conditions
Avoid any method of working that impairs safety!
All precautions have to be taken, that the machine will only be used in a safe and functional
status.
Only operate the machine when all safety devices and related safety
equipment, e.g. detachable safety devices, emergency stops, and suction
devices are present and operational!
The machine has to be checked visually at least once a day for any damage and defects.
In the event of operational malfunctions the machine must be shut down immediately and
secured. The fault must be rectified before starting the machine again!
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. Ear protection may be required. The
operator is obliged to wear close fitting protective clothing.
Use only extension cables for extending the main cable that are sized and marked
in accordance with the overall power consumption of the machine and the valid
local guidelines..
Before starting the machine make sure that nobody can be endangered when the machines
starts running.
Do not switch off or remove the exhaust and ventilation devices from the Prep/
Master®2817! Any fault (red light on dash board) of the emissions control
sensor must be addressed immediately and machine must be shutdown until
fault is rectified. Ignoring this safety directive can result in hazard to health
or possible death.

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2.5 Repair Work, Maintenance Activities, and Default Repair on the Job Site
Before starting any servicing work on the machine, put the machine in the
Safety off position as described in chapter 2.6 in order to prevent the machine
from being switched on accidentally.
Please follow any special safety instructions in the various chapters on servicing the
machine. (See chapter 7.)
Adjustments, servicing, and inspection work and inspection intervals specified in these
Operating Instructions as well as any information on the replacement on parts and systems
of the machine must be undertaken and / or complied with.
These activities can only be undertaken by qualified personnel.
Before starting any maintenance or repair work the operator of the machine has to be
informed about it.
During all work related to the use, the re-erection or the adjustment of the machine and of
the safety devices as well as inspection, maintenance and repair, the start up and shut off
procedures have to be done in accordance with the Operating Instructions.
For the machine to be shut off completely for repair or maintenance work the plug has to be
disconnected in order to prevent the machine from being switched on accidentally.
The dust bin of a connected dust collector has to be emptied before transportation. Please
handle in accordance with the regulation how to dispose the dust and make sure that you
meet the 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 process materials and replacement parts are disposed of safely and in an
environmentally-friendly manner!
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.
Make sure that electrical components used for replacement purpose comply with the original
parts and are correctly adjusted if necessary.

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2.6 Definition of the Safety-off Position
Definition:
The safety off position is the position of the machine when it cannot generate any hazard.
Putting the machine in the safety-off position means:
Switch off the grinder.•
Switch off the dust collector.•
Wait for standstill of all drives.•
Pull out main plugs (STI-2807). / Turn off propane supply at tank and remove key from• ignition (STI-2817LP).
Secure the machine against unintended start up.•
2.7 Dangerous Aspects of the Machine
Every machine, if it is not used according to the regulations, may be hazardous
for operating, setting-up and service personnel. The operating authority is
responsible for compliance with the safety regulations during operation and
maintenance of safety devices supplied with the machine as well as the
provision of appropriate additional safety devices.
2.8 Electrical Engineering Regulations
Never start machine in the tilted position. The machine must only be started
when all guards and dust collection parts are attached and machine is
standing flat on work surface.
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.
Use only extension cables for extending the main cable that are sized and
marked in accordance with the overall power consumption of the machine and
the valid VDE guidelines. In case there is any question ask the manufacturer
or a skilled electrician.

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If work on electrified parts is 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.
From time to time check voltage tester to ensure that they are operationally
efficient.
2.9 Special Instruction
Use only proper and default free tools for your work. Damaged tools have to be repaired
immediately or to be replaced.
Use during your work for your own safety the required safety equipment and safety clothes
(e.g. safety glasses, safety shoes, safety gloves).
Please instruct your operators and the repair personnel about the following
points:
Cleaning and repair work are only allowed if the machine is shut off (safety off position).•
During work on the machine, be certain that the machine cannot be started.•
Opening or removing safety devices while the machine is running are not allowed.•
Replace all safety covers and devices after cleaning, repair, and maintenance work.•
Do not touch moving parts and do not walk into the working path of the machine.•
Before restarting machine, make sure all personnel are a safe distance away from the• work area after initial start up.

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3.0 General Information
3.1 Operative Range
3.2 Scope of Supply
3.3 STI-2807 (Electric Model) Exploded Diagram & Part Numbers
3.4 STI-2817LP (Propane Model) Exploded Diagram & Part Numbers
3.5 STI-2817LP Controller Exploded Diagram & Part Numbers
3.6 STI-2807 Operating Features
3.7 STI-2817LP Operating Features
3.8 Electric Motor (STI-2807 only)
3.9 Cutting Area
3.10 Couplers & Tool Plates / Stone Holders
3.11 Variable Speed Drive (STI-2807 only)
3.12 Tool Change
3.13 Care & Maintenance
3.1 Operative Range
The STI Prep/Master®STI-2807 | STI-2817LP is a grinding machine with counter rotating
heads that is used for preparation and polishing of horizontal surfaces. Grinding the surface
according to STI specifications thoroughly removes surface contaminants, coats of paint,
sealants, 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. STI recommends the STI Planet
Vac dust collector.
3.2 Scope of Supply
Provided with machine:
Prep/Master• ®STI-2807 | STI-2817LP
Manual (1)•

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3.3 STI-2807 (Electric Model) Exploded Diagram & Part Numbers

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Item # Qty. Part # Description [for STI-2807 (electric)]
102 2 2807-102 Electrical Connector
103 1 2807-103 Stainless Steel Water Tank
104 1 2807-104 7.5HP/230V Variable Speed Drive
105 1 2807-105 6/4 Power Cable - 25 ft.
106 1 2807-106 6/4 Power Cable - 5 ft.
107 3 2807-107 Electric Elbow
108 1 2807-108 Water Valve
109 2 2807-109 Handle Caster
110 2 2807-110 Main Caster
111 1 2807-111 Axle
112 2 2807-112 3 in. Vacuum Hose (25 ft.)
113 1 2807-113 Rubber Dust Band
114 2 2807-114 Handle Grips
115 4 2807-115 Rubber Isolation Mounts
116 4 2807-116 Clevis Pin
117 1 2807-117 2807 Prep/Master®Handle Assembly
118 4 2807-118 Pocket Weights
119 1 2807-119 Stainless Steel Adjustable Shroud
120 2 2807-120 Adjustable Shroud Clamps
121 2 2807-121 Weight Basket
122 1 2807-122 Emergency Stop Button
123 4 2807-123 Leveler Clamps (Same part as 2807-120)

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3.4 STI-2817LP (Propane Model) Exploded Diagram & Part Numbers

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Item # Qty. Part # Description [for STI-2817LP (propane)]
1 1 GEAR BOX GEAR BOX
2 1 MP120800 BATTERY, DEKA, SEAMATE, AGM
3 1 MP4787 CLUTCH, ASM., MODEL 5215-63
4 1 MP333800 REGULATOR, CG2/Z2, ASM.
5 10 NB6501 INSERT, 1/4-20, COMPRESSION TYPE
6 2 MP296401 PANEL, ACCESS, FINISHED
7 10 NB025700 WASHER, LOCK, 1/4"
8 10 NB026000 BOLT, HEX, 1/4-20 x 1", SS
9 1 MP106000 CYLINDER, PAINTED, STEEL, W/DECAL, SAFE
10 1 MP344900 PULLEY, 6", W/ 1.5" BORE
11 1 MP281500 TANK, WATER
12 1 MP344200 BRACKET, TANK, LP
13 1 MP344501 PLATE, COVER, FRONT
14 1 MP113600 SOLENOID, 12V, SIDE TERMINAL
15 1 MP071800 TENSIONER, PULLEY, 3", ASM.
16 4 WEIGHT BASKET WEIGHT BASKET
17 3 NB049300 SCREW, FLANGE, 1/4-20 X 1/2, ZINC
18 1 MP345001 PLATE, SPACER, TENSIONER
19 1 MP344601 BRACKET, ENGINE
20 1 MP344101 BRACKET, WATER TANK & DASH
21 1 MP120500 BRACKET, MUFFLER, MEAN MACHINE
22 3 NB9845 NUT, KEPS, 1/4-20
23 1 Handle PREP/MASTER®HANDLE ASM.
24 1 MP041100 STRAP, TANK
25 1 MP344800 ENGINE, KAW., 17HP, PREP/MASTER®, ASM.
26 1 MX1080 WASHER, FLAT, 3/8
27 3 MX1075 WASHER, LOCK, 3/8"
28 1 NB6044 SCREW, CAP, 3/8 X 1 1/4
29 4 NB025000 BOLT, HEX, 5/16-18 X 1 1/2", SS
30 4 NB026300 NUT, LOCK, 5/16", SS
31 1 NB8130 CLAMP, 3/4" ID, RETAINER
32 1 MP152800 GASKET, FLAT, EPDM, CAP, SCREW
33 1 MP152700 CAP, SCREW, 6"
34 2 NB6851 SCREW, CAP, HH, 3/8-16 X 3/4
35 1 MP273200 STRAP, BATTERY, ADJUSTABLE
36 1 MP300800 VALVE, WATER, ASM.
37 1 MP8038 BELT, BX-38 (FOR USE ON STI-2817)

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Item # Qty. Part # Description
1 1 MP290400 CABLE, CONTROL, FLOW, 20"
2 1 KC2509904 SWITCH, STARTER
3 1 MP180000 SWITCH, ROCKER, 12V, DPST, W/LIGHT
4 1 MP280400 METER, HOUR/TACH, PANEL MOUNT
5 4 NB9510 NUT, SPIN LOCK, 10-24
6 1 MP246100 CABLE, THROTTLE, 62"
7 1 MP344700 DECAL, DASH, PREP/MASTER®
8 1 MP345100 MODULE, SAFE-SENSE, BASIC, ASM
9 2 NB008600 SPACER, NYLON, .50 O.D., .25 I.D., 1 L
10 2 NB027500 SCREW, #10-24 x 1-1/2", SS
11 2 NB034100 SCREW, PAN HD, #10-24 X 1/2", SS
12 1 MP341100 SWITCH, KILL, ENGINE, W/LANYARD
13 1 SA023400 LED, REPLACEMENT, KIT
3.5 STI-2817LP Controller Exploded Diagram & Part Numbers

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3.6 STI-2807 Operating Features
The Variable Speed Drive is carrying all controls and instruments used for supervision and
control of the machine.
Key Button Controls Start/ Stop
Pushing the Key Button "Start" will switch the controls on and start the motor. Pushing the
Key Button “Stop” will stop the motor running.
Arrow up and Arrow Down
While powered but without the motor running, the red Arrow Up and red Arrow Down buttons
can be used to set the motor speed faster or slower than the base RPM of the motor.
Rotation
While powered but without the motor running, the “Rotation” button is used to change the
rotation of the motor. Press the “Rotation” button and press “Enter” within 2 seconds to
change the motor rotation. To change back to previous rotation repeat the process
Auto/Man and Prog/Run
These buttons are used for drive diagnostics and programming and are not used.
Emergency Stop Button
The Emergency Stop Button is intended to be used for the safety of the operator and
protection of the machine from excess damage in the event of an emergency. The Lanyard
must be worn by operator for this safety device to work properly.
Manual On/Off Switch – If Equipped
The On/Off switch is used to turn off all power supplied to the grinder.
3.7 STI-2817LP Operating Features
Key Controls Start/ Stop
Turning the key to "Start" will start the motor. Pushing the Rocker Switch will engage the
clutch and start tools turning.
Kill Switch
Kill Switch is intended to be used for the safety of the operator and protection of the machine
from excess damage in the event of an emergency. Push the Kill Switch to shut down the
motor.

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3.8 Electric Motor
The power plant of the Prep/Master®STI-2807 grinder is the electric motor. The
motor is responsible for turning the gears which turn the abrasive tools on the
floor. The motor is controlled exclusively by the Variable Speed Drive which inputs
specific power to generate a given RPM.
3.9 Cutting Area
The area inside the stainless steel shroud and directly beneath the gear deck is the cutting
area. This is the area in which the tools turn to produce the grinding action. It is also the area
that keeps the dust from grinding contained and subsequently evacuated through the dust
collection ports.
3.10 Couplers & Tool Plates / Stone Holders
The grinder is outfitted with couplers and tool plates OR stone holders. The couplers attach
to the tool plates and provide flex for smooth operation of the diamond tools. The tool plate/
stone holder holds the tools in place for the grinding application.
3.11 Variable Speed Drive
The variable speed drive is responsible for monitoring incoming power as well as
changing the electronic frequency to allow the motor to run at different speeds.
This unit is a closed panel that is intended to be operated only with the keypad.
3.12 Tool Change
In order to change the tools, the operator must first ensure that the grinder is switched off
and disconnected from the electrical source. The operator should then place all the saddle
weights provided in the weight holders on either side of the variable speed drive.* Then push
machine down by the handle in a controlled manner until the grinder is resting on the top
casters. The operator then loosens the attachment hardware holding the abrasive tools in
place and re-installs with preferred abrasive tool.
* Machine must only be tilted back on firm, level surface. There is danger of machine falling if
all weights are not used and surface is not level.