U N I V E R S A L P H O T O N I C S I N C O R P O R A T E D WORLD HEADQUAR ARTERS 495 WEST JOHN STREET HICKSVILLE, NY 11801 USA 516.935.4000 800.645.7173 WWW.UNIVERSALPHO UNIVERSALPHOTONICS.COMCOM ISO 9001: 2000 CERTIFIED O PERA TING M ANUAL AL DAMA LG-450 / LG-750L MD SERIESS ERIES ADVDAMA4501203
I. USE II. III. IV. SAFETY REGULATIONS OPERATING CONDITIONS CHANGING AND ADJUSTING THE TOOLS V. APPLICATION RANGE VI. VII. SMOOTHING SPEED MAINTENANCE VIII. SPARE PARTS IX. TECHNICAL DATA X. ACCESSORIES 2 3 5 7 9 12 13 15 16 17
USE The DAMA LG-450 and LG-750 deburring machines are based on state-ofthe-art technology and have been designed to provide operational safety when all operation guidelines are complied with. The DAMA LG-450 and LG-750 are approved for smoothing the edges of prismatic glass components. This should must be done only with the appropriate tools, namely original UPI supplied smoothing wheels or equivalent products. The maximum diameter of the smoothing wheel must not exceed 30 mm. The machine may only be set up, operated and repaired by authorized, trained and instructed personnel. Please follow this Operating Manual for maximum efficiency and safety. The manufacturer of the machine is not liable for damages due to improper or inappropriate use. Risk is assumed exclusively by the user. Conversions or modifications of the machine should be performed only after consulting with the manufacturer and following the manufacturer s directions. The user exclusively, is liable for conversions or modifications made without the involvement of the manufacturer. 2
SAFETY REGULATIONS The DAMA LG-450 and LG-750 deburring machines are designed for operational safety. However, the machine may become dangerous if used by untrained personnel in an improper or inappropriate manner. Such dangers can only be avoided by correct, professional operation. The general regulations on the prevention of accidents must be reviewed and complied with. Any person involved in any way with the DAMA LG-450 and LG-750 deburring machine must have read and understood the entire Operating Manual. Any action which might impair the safety of the machine must be refrained from. Safety goggles should be worn whenever working on the machine. Never tilt up the prism slide before the machine is switched off and the tool spindle (smoothing wheel) has come to a complete standstill. Never touch the tool or the tool spindle while the machine is switched on. Switch the machine off before changing the smoothing wheel. Switch off the cooling water pump and shut off the cooling water supply before tilting up the prism slide. 3
SAFETY REGULATIONS The machine must not be switched on while the prism slide is in the tilted up position. In case of a voltage drop (interruption of the water supply) switch off the main-switch and pull the cable plug from the plug socket. Pull directly at the plug and never at the main-cable. The company operating the machine is obliged to run it in a technically impeccable condition only; disturbances which impair the safety must be eliminated immediately. ANY WORK ON ELECTRICAL EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PROFESSIONALS ONLY. 4
OPERATING CONDITIONS Place the DAMA LG-450 and/or LG-750 on a suitable horizontal surface. Care must be taken that the base is solid. The surface on which the machine stands must not be enclosed on the sides, so that any escaping cooling water cannot enter the machine from below. THE UNDERSIDE OF THE MACHINE IS NOT WATERTIGHT. The inclined position of the machine must not be altered so that the cooling water can drain freely. The machine is inherently solid and requires no extra fastening to the workstation. Install the cooling unit and connect the water hoses to the machine. MAKE SURE THAT MAIN ON/OFF SWITCH IS SWITCHED OFF. MACHINE OPERATION: Install a suitable tool. Set the optimal speed with the potentiometer (see table "Smoothing Speed"). Set the desired edge chamfer height at the graduated knob. Each revolution of the knob changes the height by 1 mm x 45. Millimeters are read off the linear scale, the tenths at the rotary knob (from figure to figure 0.1 mm). 5
OPERATING CONDITIONS MACHINE OPERATION : Switch on the machine and the cooling water pump. Check that the cooling water nozzles are correctly set. Correct the height and direction of the jets if necessary. Move the prism slide to the end position fully on the right. Place the workpiece in the prisms and support them against the side stop. Hold tight with both hands and pull it together with the prism slide against the rotation, i.e., from the right to left, over the smoothing wheel. The tool spindle, and thereby also the smoothing wheel, turn counterclockwise. In case of edge chamfering greater than 1.5 mm x 45, the prisms are opened so far that the tool could be touched by the fingers. DANGER OF INJURY! Fingertips must not reach through the gap while processing. When machining small workpieces it is absolutely necessary to use a bigger support piece. 6
CHANGING & ADJUSTING TOOLS The smoothing wheel must be positioned precisely (height-wise) to avoid collision damage to the guide prism from the tool. The clearance between the smoothing wheel and the prism's bottom edge should be at least 0.3 mm. The distance between the receiving spindle and the guide prisms is set at the factory to 15 mm. When mounting the smoothing wheel on the clamping mandrel, care must be taken that the distance between the top edge of the smoothing wheel and the flange bottom edge of the clamping mandrel is 14.7 mm. Use suitable spacer discs if necessary. DIAMOND WHEEL CHANGING PROCEDURE (REFER TO FIGURE 1, PAGE 11): Switch off machine and the cooling water pump. Move the prism slide (1) to the end position (left or right), then tilt it forward. Take care that the widening device which might be installed on the prisms does not collide with the main switch or the knob of the potentiometer. Loosen the radial bolt (8) and remove the existing smoothing wheel. Insert the new smoothing wheel (mounted on the clamping mandrel, see above) in the receptacle right to the mechanical stop. Tighten the radial bolt (8). 7
CHANGING & ADJUSTING TOOLS TOOL CHANGING PROCEDURE (REFER TO FIGURE 1, PAGE 11): Check the supporting roller (3) and the slideway (2) and wipe off any contamination. Carefully pivot the prism slide back to the working position. Check (with e.g. a feeler gauge) that the smoothing wheel does not collide with the prism slide. The gap between the smoothing wheel and the prism's bottom edge must be at least 0.3 mm. Set the desired chamfer height at the hand knob. The machine is ready for operation. 8
APPLICATION RANGE The rigid, but easy-running prism slide permits sensitive processing of precise edges on small workpieces (from 2 x 2 mm), as well as, exact edge chamfering on very heavy (up to 40 kg) and big parts. MACHINING OF LARGE SURFACE WORKPIECE (REFER TO FIGURE 1, PAGE 11) If large-surface or long workpieces are to be machined, it is recommended to use the prism widening device. Screw-fasten the holder (10) to the square profile pipe of the slide, align the guide rod (11) parallel to the prism surface and clamp it tight. MACHINING OF THIN PLATES (REFER TO FIGURE 1, PAGE 11) Plates from a thickness of 1.5 mm can be deburred on DAMA LG-450. If thinner components have to be machined, the clearance between the smoothing wheel and the bottom edge of the prisms must be reduced. Switch off the machine and the cooling water pump. Tilt away the prism slide. Loosen radial bolt (8). Place a feeler gauge of 0.15 mm on the smoothing wheel, then tilt the prism slide back in place. 9
APPLICATION RANGE Press the smoothing wheel slightly against the prisms and tighten the radial bolt (below the prisms). A clearance of 0.15 mm results between smoothing wheel and prism slide. Carefully move the prism slide and check with the feeler gauge over the full length that the smoothing wheel does not touch the prisms. If it does, correct the heights as necessary. If thin plates have to be machined frequently, it is recommended to correct the height of the smoothing wheel directly on the clamping mandrel (by means of an additional spacer disc). 10
APPLICATION RANGE FIGURE 1 11
SMOOTHING SPEED The speed, and thereby also the smoothing speed, are set with the potentiometer. POTENTIOMETER STAGE SPEED R/MIN SMOOTHING SPEED IN M/SEC. (SMOOTHING WHEEL 30MM) 2 10000 15 3 11000 16,5 4 12000 18 5 13000 19,5 6 14000 21 7 15000 22,5 8 16000 24 9 17000 25,5 10 18000 27 11 19000 28,5 12 20000 30 12
MAINTENANCE CLEANING DAILY Wash and wipe the water collection and the body of the cooling nozzle with clean water. Lubricate the guide shaft, running roller and roller track with a few drops of oil. WEEKLY Clean the cooling nozzle bore 1 mm. If required, unscrew the nozzles, flush the water channels in the cooling nozzle body and blow it clean. NEVER CLEAN THE SPINDLE AND THE GUIDE ELEMENTS WITH COMPRESSED AIR. THE FOLLOWING CHECKLIST AND MAINTENANCE JOBS MUST BE PERFORMED BY AUTHORIZED PERSONNEL AT SIX (6) MONTH INTERVALS. Check the machine housing for tightness. Check the main switch for correct functioning. Check the drive belts and replace them if necessary 13
MAINTENANCE REPLACEMENT OF DRIVE BELTS Disconnect the machine from the main supply, pull the cable from the plug socket. Remove the smoothing wheel and the prism widening device, turn the machine upside down. Remove the base cover. ATTENTION: DO NOT TOUCH ELECTRICAL PARTS Loosen the prestressing spring. Remove the old drive belts and replace with new ones (always replace the full set, not just individual belts). Make sure the belts are in the correct positions. Tighten the prestressing spring until it is 31 +/- 1 mm (almost up to block length. Put the base cover back in place. 14
SPARE PARTS MD SERIES PART NUMBER PART MD3247 MD3246 MD3233 MD3231 TOOL SPINDLE RADIAL BOLT M6X6 - STAINLESS GEAR TRAIN SET OF DRIVE BELTS (1 PAIR) MD3243 MD3241 COOLING NOZZLE BODY COOLING NOZZLE MD3235 O-RING 5 X 1,5 MD3240 MD3228 MD3234 MD3230 MD3232 DB0816 WATER TAP, COMPLETE MOTOR 1X110V/60HZ, 220W POTENTIOMETER SPINDLE CONTROL BOARD ENGRA MAIN SWITCH DIAMOND TOOL COMPLETE 15
TECHNICAL DATA LG-450 LG-750 MAIN CONNECTIONS 1 X 110 V/60 HZ 1 X 110 V/60 HZ MOTOR CAPACITY 0,22 KW 0,22 KW RATED CURRENT 2,2 A 2,2 A SPINDLE SPEED 10 000 TO 20 000 R./MIN. STEPLESS 10 000 TO 20 000 R./MIN. STEPLESS TOOL RECEPTACLE SPINDLE BORE 8 MM SPINDLE BORE 8 MM MACHINE: LENGTH APP. 33 1/2 (850 MM) APP. 56 3/4 (1445 MM) WIDTH APP. 12 3/4 (325 MM) APP. 12 3/4 (325 MM) HEIGHT APP. 9 1/2 (240 MM) APP. 9 1/2 (240 MM) PRISM LENGTH APP. 17 3/4 (450 MM) APP. 29 1/2 (750 MM) SLIDE PATH APP. 10 3/4 (270 MM) APP. 27 1/2 (700 MM) MACHINE WEIGHT APP. 44 LBS. (20 KG) APP. 96 LBS. (44 KG) 16
ACCESSORIESCESSORIES Adjustable support assembly for longer glass plates. Water cooling unit with cooling tank, pump and connecting pipes, on-off switch for individual use. DIAMOND WHEELS FOR DAMA LG-450 AND LG-750 ( Ø 30 mm, Height 11 mm, W 3,0 mm, Bore Ø 8H7) PRODUCT NUMBER BODY BOND MICRON SIZE CONCENTRATION DB0812 BRASS D2 12 C 50 DB0816 BRASS BZ 16 C 50 DB0825 BRASS BZ 25 C 50 DB0846 BRASS BZ 46 C 50 DB0864 BRASS BZ 64 C 50 DB0876 BRASS BZ 76 C 50 17
ACCESSORIESCESSORIES To place an order contact one of our expert customer service representatives at: UNIVERSAL PHOTONICS, INC. DAMA OPTIKMASCHINEN AG 516.935.4000 800.645.7173 495 WEST JOHN STREET HICKSVILLE, NY 11801 EMAIL: INFO@UNIVERSALPHOTONICS.COM TO VIEW OUR FULL ADVANTAGE MACHINE LINE INCLUDING DAMA OPTIKMASCHINEN, VISIT US ON LINE AT WWW.UNIVERSALPHOTONICS.COM 18