prepmaster PM200 User manual

Operating Manual
PM200

PM200 Operating Manual
2
Table of Contents
1.0 Technical Data.............................................1
2.0 Safety Advice .............................................3
3.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Transportation............................................13
5.0 Starting Up the Machine....................................14
6.0 Operation of the Machine...................................16
7.0 Maintenance .............................................17
8.0 Troubleshooting / Diagnostics ..............................19
9.0 STI Reference Guide & Procedures ..........................21
[10.14]
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.
Prep/Master®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 or instances of abuse or neglect.

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1.0 Technical Data
1.1 Rating
1.2 Unit Specifications
1.3 Operative Range and Correct Usage
1.4 Stand-by Power Supply (Generator)
1.5 Advice for Operators of Grinding Machines
1.6 Machine Type Designation
1.1 Rating
Machine: Prep/Master®Grinder
Machine-Type: PM200
Manufacturer: Substrate Technology
1384 Bungalow Rd.
Morris IL 60450 USA
+1.815.941.4800
www.substratetechnology.com
1.2 Unit Specifications
Dimensions:
Length 40 in. 101.6 cm
Width 21 in. 53 cm
Height 35.5-39 in. 90-99 cm
Weight 124 lbs 56 Kg
Connected loads of the electrical system:
Power 5 HP
Electrical Connection 220V / Single Phase 16Amp

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1.3 Operative Range and Correct Usage
The grinder PM200 is designed to operate on flat horizontal surfaces. The
machine cannot 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 assumes all risks.
1.4 Stand–by Power Supply (Generator)
If the grinder PM200 is operated using a generator, the generator must be
operated in accordance with the local electrical code. This applies especially to
the protective grounding of such unit in order to ensure that all safety devices
are functioning and to be able to eliminate possible damage to electrical
components.
1.5 Advice for Operators of Grinding Machines
During the operation of the grinder PM200, depending on the type of surface,
it may be possible to exceed the acceptable noise level of 85 dB(A). This
depends 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 hearing protection equipment.
1.6 Machine Type Designation
Machine Type: Prep/Master®PM200
Working Width: 9.5 in / 24 cm
Drive: Manual
Grinding Capacity: Variable
Dust Hose Connection: 2 in / 5 cm
Recommended Dust Collector Dust Collector 2003P

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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.
Electrical Warning
Warning against dangerous voltages.

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2.2 Organizational Measures
The Operating Instructions are to be kept near the location where the machine is
located and must be reachable 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.
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.

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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 when the
machine is running!

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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 2.5 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.
• 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.
The PM200 is designed with removable RH and LH side
guards (A).This allows the operator to work along walls
when these guards are taken off.
Only if necessary or exclusively, work along wall
surfaces with Side Box taken off; however, remount the
Side Box immediately after completion of the project.
The electrical parts of the machine must be inspected regularly. Please note
in particular, the specified recurring inspections according BGV A3 or local
regulations. Defects such as loose connections or scorched cables must be
rectified immediately. Call a skilled electrician or the IMPACTS customer service.
• 2-inch Dust Hose
• Tool to remove the blade guards
• Handle adjustment

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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.
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.
• 5HP 240V SMvector Drive
• Power cable

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• 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.
3.0 General Information
3.1 Operative Range
3.2 Scope of Supply
3.3 Operating Features
3.4 Electric Motor
3.5 Cutting Area
3.6 Coupler & Tool Plate
3.7 Variable Speed Drive
3.8 Tool Change
3.9 Care & Maintenance
3.1 Operative Range
The STI Prep/Master®PM200 is a grinding machine with a single, mono-rotational head 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 IMPACTS
DC2003P.
3.2 Scope of Supply
Provided with machine:
• Prep/Master®PM200
• Manual (1)

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3.3 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.
Auto/Man and Prog/Run
These buttons are used for drive diagnostics
and programming and are not used.
Dead Man Switch
Dead Man 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. 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.
3.4 Electric Motor
The power plant of the Prep/Master®grinder is the electric motor. The motor is responsible
for turning the electric motor 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.
3.5 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 port.
• SML Drive remote keypad
• Emergency Stop Switch
(Deadman Switch)

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3.6 Coupler & Tool Plate
The grinder is outfitted with a coupler and tool plate. The coupler allows for the flex of the tool
plate and smooth operation of machine. The tool plate holds the diamond tools. 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.
3.7 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.
3.8 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. Then push machine down by the handle in
a controlled manner until the grinder is resting on the top handle.* The tools are loosened
by pushing them toward center of the plate. New tools are attached by placing EG tabs in
slots and pushing them toward the outside edge of the plate. 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.
3.9 Care & Maintenance
Special attendance and regular maintenance of the machine and its parts are imperative
for functioning and safety. In order to prevent unnecessary downtimes it is recommended to
keep original spare and wear parts on stock.
The following maintenance should take place before and after every operation of
machine:
1. Clean all surfaces with a dry, lint free cloth.
2. Inspect all electrical cables for cuts and replace damaged chords.
3. Check all electrical connections are secure and snug.
4. Inspect gear box for any signs of oil leakage and repair as required.
5. Verify functionality of Dead Man Switch.
All persons in the proximity of the machine in operation must wear safety
glasses with lateral protection and safety shoes. The machine operator must
wear close-fitting protective clothing.

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4.0 Transportation
4.1 General Notes
4.2 Transportation
4.3 Transportation by Vehicle
4.4 Operation Conditions
4.1 General Notes
Before the machine used for the first time, STI authorized dealers offer a course to familiarize
maintenance and operating personnel with all elements of the machine. We are not liable for
damage caused by incorrect use of the machine by personnel not trained by STI.
4.2 Transportation
In order to transport the machine from a vehicle to the working area, you need to tilt the
machine down and roll it on its main drive wheels.
When transporting the machine with hoisting equipment like a crane or a lift, check the total
weight permitted. (See Chapter 1 — dimensions)
Please use only appropriate, allowed, and qualified hoisting equipment as well as ropes and
chains. You will find the weight of the equipment in chapter 1 or on the serial plate on the
machine.
Do not fix any rope or chain to the handle. The machine must be placed on a pallet or
platform designed to hold the weight of the machine and the platform or pallet can then be
lifted or hoisted from the appropriate points.
4.3 Transportation by Vehicle
When transporting the machine with vehicle, proceed in such a manner that damage due to
the effects of use of force or incorrect loading and unloading is avoided. Use straps to tighten
the machine to the cabin of the vehicle.
Use at least two straps, or tighten the machine with one strap to the cabin wall of the vehicle.
Make sure, that all parts of the machine are fixed.
4.4 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 ¼ inch are no barriers for the machine.
The machine must be operated in accordance with instructions given in Chapter 5—Initial
operation.

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5.0 Starting Up the Machine
5.1 Preparing for Initial Operation
5.2 Initial operation
5.1 Preparing for Initial Operation
Before start up ensure all existing protective housings are fitted and the filter unit is
connected correctly.
All persons in the proximity of the machine must wear safety glasses with lateral
protection as well as safety shoes. The operator is obliged to wear close-fitting
protective clothing.
Carefully handle all plugs, cables, hoses, and operating devices. Avoid any contact
with live wires.
Work on the electrical system has to be done only by qualified specialists.
Check the surface to be treated; it should be free of for loose parts (stones, screws,
etc.). The surface needs sweeping if necessary. Ensure that the machine can run over all
inequalities on the surface. Small inequalities like floor joints aren’t a barrier for the machine.
In order to avoid downtimes a regular inspection is essential. 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 empty.
Please comply with the local waste treatment regulations
considering the removed material.
• Check the electrical connections for dirt and foreign
body deposits.
• Check the electrical motors for dirt and other contaminants.
• Adjustment Knob to
level the head
• Adjustment Rod

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Before start-up operators and other personnel must be familiar with the safety
regulations given in this manual.
1. Place the grinder in the area where work is to begin.
2. Check the main power cable and the dust hose for damage. Replace or repair all
damaged parts before starting the machine.
3. Connect the grinder and the filter unit with the dust hose.
4. Connect the supply cable of the PM200 with the site supply. Make sure that the correct
electric supply is available.
5.2 Initial Operation
All persons near the machine must wear safety glasses with lateral protection,
ear protection as well as safety shoes. The operator is obliged to wear close
fitted protective clothing.
Before start-up the operating personnel must be familiar with the safety regulations given in
this manual.
Attention! Before you plug the equipment to a power supply make sure the
power supply is equivalent to the data shown on the machine label.
The start of the grinder and the filter unit is affected in the following sequence:
1. Switch on the filter unit.
2. Adjust speed of motor on keypad.
3. Press start and immediately begin moving machine side-to-side or in a straight line.
Failure to move machine immediately will leave gouges in the flooring surface.
4. To shut down machine, press the red "stop" key on keypad.
Do not overfill the bin to avoid dust exposure when opening the bin. Comply
with the local waste treatment regulations considering the removed material.

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6.0 Operation of the Machine
6.1 Daily Operation
6.2 Failure
6.3 Safety Switch Off
6.4 Restart
6.1 Daily Operation
Normal start-up and operation of the Grinder is not different as has been described in
Chapter 5—Initial operation.
Carry out grinding operation in parallel tracks in a way that the dust hose and electric cable
do not become twisted.
Make sure that no vehicles, such as forklift trucks 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, means different hardness or
different coating thicknesses, a uniform grinding result will be achieved by varying the speed
of movement over the surface.
6.2 Failure
Irrespective of the following information, the local safety regulations are valid in any case for
the operation of the machine.
Assure all turning machine parts have come to standstill before inspection or maintenance
work starts. Always arrange the Safety Off as described in Chapter 2.
6.3 Safety Switch Off
The machine must be set into its “Safety Off Position” before starting any kind of
maintenance or repair work.
See Chapter 2—Safety Instructions.

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6.4 Restart
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.
See Chapter 5—Initial Operation.
7.0 Maintenance
7.1 Recommendations
7.2 Maintenance and Inspection
7.3 Maintenance
7.1 Recommendations
Prior to any repair work on the machine and its drives, secure the machine against
unintentional switch-on. Put the machine to its Safety Off Position as described
in chapter 2.
Failures due to inadequate or incorrect maintenance may generate very high repair
costs and long stoppage periods of the machine. Regular maintenance is essential.
Safety and service life of the machine depend, among other things, on proper maintenance.
The following table will show recommendations about time, inspection and maintenance for
the normal use of the machine.
The time indications are based on uninterrupted operation. When the indicated number of
working hours is not achieved during the corresponding period, the period can be extended.
Due to 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.
Our specialists would be happy to give you advice.

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7.2 Maintenance and Inspection
Operating Hours / Time Period Inspection Points / Maintenance Instructions
Daily — Prior to Operation • Check all electrical cables for cuts or damage
• Check the hose connections for tightness and
fixed seat.
• Check the hose to the filter for damages.
• Make sure that the dustbin of the filter has been
dumped.
• Check Morflex Coupler, tool plate, and diamond
tooling for wear and damage.
• Check that shroud and rubber seal are in good
working condition.
• Check the electric connections for sediments of
dirt or foreign bodies.
• Check the electric motor for dirt and other
contaminants.
• Check gearbox assembly for any leaks of oil
from motor and top and bottom of gear box.
Daily — After Operation • Check for debris, if any, in the dust ports under
gear box as well as at handle.
• Check for dirt build up on variable speed drive
and electric motor.
7.3 Maintenance
Only those repair works are described which occur within the context of maintenance or
which are required to replace wear parts.
If you replace parts yourself for specific reasons, the following instructions and work
sequence have to be observed.
You should also stock all spare or wear parts that cannot be supplied quickly. As a rule,
production standstill periods are more expensive than cost for the corresponding spare part.
Screws that have been removed must be replaced with those of the same quality (strength,
material) and design.
Prior to any repair work on the machine and its drives, secure the machine
against unintentional switching-on. Pull out the main plug in order to do this.
Store the plug near the machine to avoid accidents.