This document describes the Zafferani Glas s.r.l. FLAT 630 series of automatic straight-line edgers, designed for grinding and polishing glass. The manual provides comprehensive information on the machine's operation, maintenance, and technical specifications.
Function Description
The FLAT 630 series machines are automatic straight-line edgers primarily used for grinding and polishing the edges of glass sheets. They are equipped with an inverter system that allows for adjustment of the track speed, which is set via a potentiometer on the electric board. This adjustment is crucial for adapting to the thickness of the glass being worked. The machines are designed to process various glass thicknesses and achieve different edge finishes using a series of grinding and polishing wheels.
The operational process involves:
- Loading Glass: Positioning the glass sheets onto the machine's transport system.
- Grinding and Polishing: The glass passes through a series of wheels that perform grinding and polishing operations. The number and type of wheels vary depending on the specific model (e.g., FLAT 4 FPE, FLAT 5 FPE, FLAT 630, FLAT 8 FPE, FLAT 9 FPE).
- Speed and Pressure Adjustment: The machine allows for adjustment of working pressures for the wheels and track speed to optimize the grinding and polishing process based on glass thickness and desired finish.
- Small Pieces: The machine can process small glass pieces, with specific instructions provided for handling these.
The PLC (Programmable Logic Controller) system manages the working operation and allows for control over various parameters, including:
- Settings of working parameters.
- Production statistics (pieces worked, meters worked, worked hours).
- Diagnostic functions.
- Management of ordinary and extraordinary maintenance.
- Management of alarms in case of malfunction.
Important Technical Specifications
The FLAT 630 series includes several models, each with specific configurations of grinding and polishing wheels and corresponding technical data. Key specifications include:
Power (kW):
- Potenza Motoriduttore traino (Power Motor-reducer track): 0.75 kW for all models (4 FPE, 5 FPE, 630, 8 FPE, 9 FPE).
- Potenza motore mole diamantate (Power motor diamond wheels): 1.8 kW for all models.
- Potenza motore mole lucidanti (Power motor polishing wheels): 1.8 kW for all models.
- Potenza pompa (Pump power): 0.15 kW for all models.
- Potenza motore mole filetti (Power motor wheels for arris): 0.62 kW for all models.
- Potenza installata (Installed power): Varies by model:
- FLAT 4 FPE: 5.8 kW
- FLAT 5 FPE: 7.6 kW
- FLAT 630: 9.5 kW
- FLAT 8 FPE: 10.8 kW
- FLAT 9 FPE: 12.6 kW
Working Thickness (mm):
- Minima spessore lavorabile (Minimum workable thickness): 3 mm for all models.
- Massima spessore lavorabile (Maximum workable thickness):
- FLAT 4 FPE, 5 FPE, 8 FPE, 9 FPE: 22 mm
- FLAT 630: 30 mm
Working Height (cm):
- Minima altezza lavorabile (Minimum workable height): 4 cm for all models.
Machine Dimensions (mm):
- Lunghezza macchina montata (Length of installed machine):
- FLAT 4 FPE: 4310 mm
- FLAT 5 FPE: 4955 mm
- FLAT 630: 5650 mm
- FLAT 8 FPE, 9 FPE: 5915 mm
- Altezza macchina montata (Height of installed machine): 2375 mm for all models.
- Larghezza macchina montata (Width of installed machine): 990 mm for all models.
Weight (kg):
- Peso macchina funzionante (Weight of installed machine):
- FLAT 4 FPE: 1300 kg
- FLAT 5 FPE: 1500 kg
- FLAT 630: 1650 kg
- FLAT 8 FPE: 2150 kg
- FLAT 9 FPE: 2350 kg
Working Tables (Pressure and Speed):
The manual provides detailed tables for recommended working pressures (bar) and track speeds (m/min) for different glass thicknesses (mm) and wheel configurations. For example, for FLAT 630:
- 3 mm glass: 4.0 bar (1st pol), 4.0 bar (2nd pol), 2.0 bar (arris), 1.0 m/min.
- 20 mm glass: 5.5 bar (1st pol), 5.5 bar (2nd pol), 2.0 bar (arris), 0.4 m/min.
Wheel Configuration (FLAT 630):
The FLAT 630 model utilizes 6 wheels:
- Diamantata GREZZA - D.150 - FORO 50 (Diamond COARSE grained) - TURBO D151
- Diamantata MEDIA - D.150 - FORO 50 (Diamond MEDIUM grained) - TURBO D126
- lucidante D.150 - FORO 50 - FASCIA 20 (polishing) - 9R40
- lucidante D.150 - FORO 50 - FASCIA 20 (polishing) - Ce3
- filetto anteriore D.100 - FORO 50 - FASCIA 15 (front arris) - SC 280
- filetto posteriore D.100 - FORO 50 - FASCIA 15 (back arris) - SC 280
Usage Features
Installation and Electrical Connections:
- Leveling: The machine must be leveled using the provided feet.
- Cover Removal: Side external covers need to be removed to access internal components during installation.
- Input-Output Benches Assembly: Detailed steps for assembling the input and output benches, including securing frames and connecting components.
- External Frames Assembly: Instructions for screwing frames to external frames.
- Internal Frames Assembly: Instructions for connecting internal frames to the machine body.
- Horizontal Links Assembly: Securing horizontal links for wheel support.
- External Tank Assembly: Assembling the pump flange, connecting tubes, and filling the water tank.
- Air Connection: Connecting the machine to an air distribution plant with a compressor of 30 Lt capacity, setting the steam gauge at about 6 atmospheres.
- Electrical Connection: Connecting power wires to the terminal of the electrical box. Checking the sense of rotation of the motors and ensuring correct wiring.
Machine Adjustment:
- Air Pressure: Connect the compressed air to point (65) and set the pressure at about 6 bar.
- Glass Thickness Adjustment: Adjust the machine for the thickness of the glass using hand-wheel (1) or the button (1) on the panel board.
- Drive Entrance Bench: If equipped with an adjustable drive entrance bench, set the drive entrance bench at 0 mm cutting.
- Diamond Wheels: Keep the diamond wheels at their lowest level using the hand-wheel (5).
- Pneumatic Wheels: Switch off the pneumatic wheels and set the air pressure gauges to 0 atm.
- First Water Pump: Put a glass on the transport bench and switch on the first water pump and then the motors. Using the switch of the track (60), make the glass go over the diamond wheel and stop the machine.
- Diamond Wheel Adjustment: For models FLAT 4 – FLAT 5, slowly lift the diamond wheel by hand-wheel (5) up to touch the surface to work. This adjustment is made according to the thickness of the glass.
- Diamond Wheel Adjustment (FLAT 630 – FLAT 8 – FLAT 9): Lower the first diamond wheel by 2 numbers of the instrument (99) (0.2 mm). Then reset the instrument (0000). Raise the second diamond wheel up to touch the surface of the glass and reset the relative instrument (0000).
Wear of the Wheels:
- Diamond wheels typically last for ten thousand meters of work, while polishing wheels last less or some thousand meters.
- It is recommended to replace the first diamond wheel after about 0.5 mm of wear and the second diamond wheel after about 0.10 mm.
- The hand-wheel (5) is used to adjust the wheels, and the adjustment should be proportional to the glass thickness.
- If the machine is equipped with an optional adjustable drive entrance bench, the hand-wheel (95) can be used to remove the wheels.
Maintenance Features
General Maintenance Advice:
- Water Tank: The water tank (43) and pump (13) should be changed every day to ensure clean water.
- Polishing Wheels: To get good polishing, refrigerate the polishing wheels with running water connecting the valve (97) directly with the hydro network.
- Grease Pump: Lubricate the track with the grease pump (92) by actioning 5 or 6 times the lever of the pump with the track working.
- Rubber Plate: Check the mechanical bond rubber plate for chain track traction; if it is like new, adjust the hand-wheel (1) on the right pressure and move the red index to indicate the exact thickness of the glass.
- Track System: The grinding machine is equipped with a system of stop and reversing of the track (60).
- Mechanical Bond: After months, the mechanical bond plate may get longer. To fix this, open the little doors on the carters of the track, slacken the grub screw on the outlet of the pinions, slacken the turn nuts, and screw lightly the screw (16) of 1/4 of turn from both sides of the track.
- Track Gears: The track gears (30), (31), (32) should be lubricated with grease.
- Main Pressure Reducer: Discharge the condense of the main pressure reducer (65).
- Lubrication Oil: Check the level of the lubrication oil and discharge is automatic.
PLC Maintenance Management:
The PLC system includes a "Manutenzione" (Maintenance) page that displays important maintenance tasks and their status.
- Cambio H2O vasche (Change H2O tanks): Indicates when water tanks need changing.
- Cambio baffi tenuta acqua (Change water seal baffles): Indicates when water seal baffles need changing.
- Ingrassaggio catene traino (Greasing track chains): Indicates when track chains need greasing.
- Controllo tiraggio catena traino (Check track chain tension): Indicates when track chain tension needs checking.
The system tracks kilometers and hours worked to recommend maintenance intervals. After performing a maintenance task, the "MANUTENZIONE ESEGUITA" (Maintenance Performed) button should be pressed to reset the counter and record the maintenance.
Diagnostic Function:
The "Diagnostica" (Diagnostic) page allows checking the correct functioning of various machine components:
- Limit switch of glass presence.
- Encoder.
- Working angle.
- Thickness of the glass.
- Digital input and output visualization.
- Solenoid override for pneumatic wheels.
Electrical Drawings:
The manual includes electrical drawings found inside the panel board for reference during maintenance and troubleshooting.
This comprehensive approach ensures the longevity, efficiency, and safety of the FLAT 630 series machines.
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