WerkMaster RASP Floor Sander, THE EDGE Floor Grinder OPERATOR'S MANUAL

OPERATOR’S MANUAL

WerkMaster Grinders and Sanders Inc.

6932 Greenwood Street, Burnaby, BC V5A 1X8 tel: 604.629.8700 | toll free: 1.866.373.WERK | fax: 604.444.4231 www.werkmaster.com | email: [email protected]

LIABILITY LIMITATIONS

The remedies of the user set forth under provisions of warranty outlined at the end of this manual are the exclusive and total liability of WerkMaster Grinders &

Sanders Inc. with the respect to their sale or the equipment and service furnished hereunder, in connection with the performance or breach thereof, or from the sale, delivery, installation, repair or technical direction covered by or furnished under the sale, whether based on contract, warranty, negligence, indemnity, strict liability, or otherwise shall not exceed the purchase price of the unit of equipment upon which such liability is based.

WerkMaster will not in any event be liable to the user, any successors in interest or any beneficiary or assignee relating to this sale for any consequential, incidental, indirect, special or punitive damages arising out of this sale or any breach thereof, or any defects on, or failure of, or malfunction of the equipment under this sale based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other goods, loss by reason of shutdown or non-operation, increased expenses of operation of the equipment, cost of purchase or replacement power of claims of users or customers of the user for service interruption whether or not such loss or damage is based on contract, warranty, negligence, indemnity, strict liability, or otherwise.

WerkMaster reserves the right to modify, alter and improve any part or parts without incurring any obligation to replace any part or parts previously sold without such modified, altered or improved part or parts.

No person is authorized to give any other warranty or to assume any additional obligation on WerkMaster’s behalf unless made in writing and signed by an officer of WerkMaster.

As a condition of these warranties, you are responsible for properly using, maintaining, and caring for your machine as outlined in this Owner’s Manual.

WerkMaster recommends that you maintain copies of all maintenance records and receipts for review by WerkMaster.

USE ONLY GENUINE WERKMASTER PARTS AND ACCESSORIES FOR

YOUR OWN SAFETY, THE SAFETY OF OTHERS AND THE LIFE OF YOUR

MACHINE. THIS WARRANTY IS NOT VALID IF YOUR MACHINE HAS BEEN

MODIFIED WITHOUT WERKMASTER’S AUTHORIZATION OR REPAIRED

WITH UNAUTHORIZED REPLACEMENT PARTS.

CONTENTS

Introduction ..................................................................................................... 1

Machine Descriptions ..................................................................................... 1

Specifications ................................................................................................. 2

Safety Precautions .......................................................................................... 2

Personal Protective Equipment .............................................................................. 2

Physical and Mental Fitness .................................................................................. 2

Safe Operating Distance ........................................................................................ 3

Power ....................................................................................................................... 3

Safe Operating Conditions ..................................................................................... 3

Modifications ........................................................................................................... 3

Power and Connectivity .................................................................................. 4

General Connections .............................................................................................. 4

Single-Phase to Three-Phase Adapter Cord ...................................................... ..4

Pigtails ..................................................................................................................... 4

Stove and Dryer Adapter Plugs ............................................................................. 4

Quick 220 Adapter .................................................................................................. 4

Power Cord Minimum Requirements ..................................................................... 4

Generator Minimum Requirements ....................................................................... 4

Introduction to the Controls ........................................................................... 5

Machine Controls .................................................................................................... 5

VFD Controls ........................................................................................................... 5

Machine Operation .......................................................................................... 5

Changing Tools ....................................................................................................... 6

Adjusting the Dust Skirt .......................................................................................... 6

Adjusting the Handle ............................................................................................... 6

Initial Start Sequence………………………………………………………………...7

Starting the Machine ............................................................................................... 7

Adjusting the Speed ................................................................................................ 7

Stopping the Machine ............................................................................................. 7

Installing and Removing the Pad Driver ................................................................ 8

Rotation Pattern of Tooling Plates ......................................................................... 8

Changing the Primary Belt ………………………………………………………………………… 9

Changing the Secondary Belt .............................................................................. 10

Vacuum or Water Feature Port ..................................................................... 10

Disassembly/Assembly Instructions ……………………………………………12

Maintenance .................................................................................................. 12

Daily ....................................................................................................................... 12

Weekly ................................................................................................................... 12

Monthly .................................................................................................................. 12

Troubleshooting ............................................................................................ 13

Appenix – VFD Troubleshooting and Diagnostics ....................................... 14

Exploded Views and Parts List …………………………………………………...

16

Glossary ........................................................................................................ 20

Warranty Information .................................................................................... 21

OPERATOR’S MANUAL

INTRODUCTION

Congratulations on your purchase of a WerkMaster machine. WerkMaster machines allow professional surface prep, polishing, grinding, edging, buffing and restoration of virtually any surface material, including concrete, terrazzo, stone, and hardwood. This manual is provided to assist you in the operation and maintenance of your WerkMaster.

MACHINE DESCRIPTION

WerkMaster machines include the Scarab, RASP, THE EDGE, Raptor XTi,

TITAN XTi, COLOSSOS XTi and MAGNUM XTi models. To see the complete family of WerkMaster machines visit our website at www.werkmaster.com

.

RASP

•

Designed to meet the needs of contractors, facility services, equipment rentals and DIYers

•

Use on engineered hardwood, solid hardwood, wood decks, plywood subfloors to sand and edge

•

Easily removes glue, wax, varnish, shellac, and aluminum oxide factory finishes

•

Disassembles for easy lifting and transport

•

Lightweight and easy to maneuver

•

Edge to within 1/8” (3 mm) of the wall

•

Features 6 counter rotating heads and the versatility of using either our 5”

(127mm) ULTRA-FLEX full plate tools or the WerkMaster Plug ‘N Go tooling system and sandpapers

•

Variable frequency drive lets you run at speeds from 400 RPM to 1000 RPM

•

Runs 220V or 110V with Quick 220 Adapter

•

Features 3HP 220V high efficiency motor (available with 1.5 HP motor)

•

Change tooling and RASP can be used to grind and polish concrete, terrazzo, and stone

THE EDGE

•

Designed to meet the needs of contractors, facility services, equipment rentals and DIYers

•

Use to grind and polish concrete

•

Disassembles for easy lifting and transport

•

Lightweight and easy to maneuver

•

Edge to within 1/8” (3 mm) of the wall

•

Features 6 counter rotating heads and the versatility of using our 5” (127mm)

ULTRA-FLEX Plug ‘N Go tooling system and sandpapers

•

Variable frequency drive lets you run at speeds from 400 RPM to 1000 RPM

•

Runs 220V single-phase or 110V with Quick 220 Adapter

•

Features 3HP 220V high efficiency motor (available with 1.5 HP motor)

•

Change tooling and THE EDGE can be used to sand, screen and edge engineered hardwood, solid hardwood, wood decks, plywood and sub-floors and to polish terrazzo and stone

Page 1

SPECIFICATIONS

MODEL RASP THE EDGE

230V

Dimensions: l x w in

l x w cm

14.5 x 14.5

37 x 37

Disc size: in / cm 5 / 12.7

Weight: lb / kg 206 / 93.4

Disc Speed: RPM 400-1160

Horsepower: HP 3

Phase: Ph Single

Vacuum Req: CFM 260

Min. Generator: kW

Frequency Hz

5.0+

50 / 60

110V

14.5 x 14.5

37 x 377

5 / 12.7

206 / 93.6

400-1160

1.5

Single

260

5.0+

50 / 60

230V

14.5 x 14.5

37 x 37

5 / 12.7

206 / 93.4

400-1160

3

Single

260

5.0+

50 / 60

SAFETY PRECAUTIONS

110V

14.5 x 14.5

37 x 37

5 / 12.7

206 / 93.4

400-1160

1.5

Single

260

5.0+

50 / 60

Personal Protective

Equipment

Physical and

Mental Fitness

WARNING

Read this manual and all the safety precautions before attempting to operate WerkMaster machines. Failure to follow the safety precautions may result in severe personal injury or death. This product is intended for commercial use.

•

Wear eye and ear protection at all times when operating WerkMaster machines. Use only ANSI/OSHA-approved safety glasses to help prevent eye injury.

•

Wear appropriate clothing and footwear when operating WerkMaster machines. Do not wear loose clothing or jewelry that may become entangled in moving parts.

•

Exposure to wood dust may cause health problems. To reduce your risk, work in a well-ventilated area, use a dust control system such as an industrialstyle vacuum, and wear approved personal safety equipment, such as a dust or particle respirator designed to filter out microscopic particles.

•

Crystalline silica from bricks and concrete and other masonry products may cause health problems. To reduce your risk, work in a well-ventilated area, use a dust control system such as an industrial-style vacuum, and wear approved personal safety equipment, such as a dust or particle respirator designed to filter out microscopic particles.

•

NEVER operate WerkMaster machines under the influence of drugs or alcohol, when taking medications that impair the senses or reactions, or when excessively tired or under stress.

•

Only operate and maintain WerkMaster machines if you are trained in their use and are in good physical condition and mental health. You must be physically able to handle their bulk, weight and power.

Safe Operating Distance

Page 2

Power

Safe Operating Conditions

Modifications

•

WerkMaster machines are to be operated by one person at a time. Maintain a safe operating distance from other personnel. Keep bystanders a safe distance away during operation by blocking off the work area in all directions with roping, safety netting, or other material. Failure to do so may result in someone being injured by flying debris or being exposed to harmful dust and noise.

•

Maintain a safe operating distance from flammable materials. Sparks from the cutting action of WerkMaster machines may ignite flammable materials or vapors.

•

Unplug the WerkMaster’s power cord when not in use and before servicing or changing tooling plates.

•

DO NOT disconnect power by pulling the cord. To disconnect power, grasp the plug, not the cord. Push the plug in and turn clockwise to engage; turn counter-clockwise and pull to remove.

•

DO NOT turn on the WerkMaster while it is tilted back. Any tooling fastened to the WerkMaster may eject and become a lethal projectile.

•

Ground this floor-finishing machine while in use to protect the operator from electric shock. The machine is provided with a three-conductor cord and a three-contact grounding type attachment plug to fit the proper grounding type receptacle. The green (or green and yellow) conductor in the cord is the grounding wire. NEVER connect this wire to other than the grounding pin of the attachment plug.

•

Be sure all safety decals on the machine may be clearly read and understood.

Replace damaged or missing decals immediately.

•

Maintain WerkMaster machines in safe operating condition with all guards in place and secure, all mechanical fasteners tight, all controls in working order, and the grinder configured for the job application, whether concrete, natural stone, wood or other surfaces.

•

To prevent damage to your machine or severe personal injury, avoid protruding slab inserts, nails, screws, Hilti anchors, rebar, embedded bolts or any other debris, pipe extensions, machinery bases, or any objects that transmit sudden shock to the grinding assembly.

•

Inspect the discs carefully before installing. DO NOT use any discs that exhibit signs of damage, as severe personal injury or damage to the equipment could result.

•

NEVER leave WerkMaster machines running unattended.

•

Risk of Explosion: Grinding/polishing concrete surfaces and sanding/finishing wood floors can result in an explosive mixture of fine dust and air. Use this machine only in well-ventilated area free from any flame, match or combustible materials.

Dust generated from sanding wood floors can spontaneously ignite or explode. Promptly dispose of any sanding dust in a metal container clear of any combustibles. Do not dispose in a fire.

DO NOT modify WerkMaster machines. Modifications will void the warranty and may result in injury to persons and damage to the machine.

Page 3

POWER AND CONNECTIVITY

WerkMaster machines are outfitted with a variable-frequency drive (VFD) that allows the desired grinding speed to be selected. Along with controlling the speed of the machine, the VFD features include the following:

•

Undervoltage protection (damages most single-phase motors)

•

Overcurrent protection (prevents nuisance breaker tripping)

•

60 Hz and 50 Hz capability (international)

•

Wide voltage range for 230V models (200–230V)

•

Soft start (smaller generator requirements)

•

Monitor pad speed display

General Connections

DANGER

NEVER open the VFD panel while plugged in or immediately after unplugging the power cord. Severe injury or death may result.

WerkMaster machines come with a variety of different plug configurations. The following table lists the plugs that are typically used.

MODEL RASP THE EDGE

Single-Phase to

Three-Phase Adapter Cord

Pigtails

Quick 220 Adapter

Power Cord

Minimum Requirements

Voltage

Breaker Size

Phase

Configuration

Cord End

230V

20A

Single

3 pole 2 wire 20A

Twist Lock

110V

15A

Single

Straight Blades

230V

20A

Single

3 pole 2 wire 20A

Twist Lock

110V

15A

Single

Straight Blades

WerkMaster machines come in a variety of voltage and phase configurations.

The RASP is typically configured to operate on 208-230V single phase power. It is capable of operating on single-phase 208-230V power, as well as 110V using a Quick 220 Adapter.

Pigtails are plug ends with unfinished bare wire on one end for hooking up to panels. Pigtails are used when connectivity is unknown, when connecting to the power grid of an unfinished building that has no power receptacles, or when operating certain generators. Certified electricians ONLY should make and/or install a pigtail into a panel.

When using the RASP or THE EDGE in a residential environment, source power may be hard to find. Plug two 110V cords from the Quick 220 into the 110V wall outlet on two (2) separate circuits on opposite sides of the panel. Plug the

WerkMaster machine into the Quick 220 adapter.

The following table lists the minimum requirements for power cords.

MODEL RASP THE EDGE

Distance

Minimum Gauge

Requirement

230V

Up to 300 ft

12/3

110V

50 ft

14/3

230V

Up to 300 ft

12/3

110V

50 ft

14/3

Page 4

Generator

Minimum Requirements

The minimum generator requirement for both the RASP and THE EDGE is 5

KW.

WARNING

Exercise extreme caution at all times when working with electrical power.

WerkMaster strongly recommends that only certified electricians be permitted to work with electrical power sources within customers’ facility or on their job site.

INTRODUCTION TO THE CONTROLS

Machine Controls

VFD Controls

The START button (A) is on the handle (Fig 2); the SPEED control (B) is on the

VFD (Fig 1).

The VFD controls are locked out to avoid accidentally changing necessary parameters.

MACHINE OPERATION

WARNING

ALWAYS turn off and disconnect power from the machine when performing any operations to the bottom of the machine. The machine and the tooling may be hot after using.

A D M

C

I B

L

Fig. 1

Fig. 2 Fig. 3

Page 5

J

F

H

E

G

K

D

Fig. 4

Fig. 5 Fig. 6

Changing Tools

To change tooling:

1. Unplug the power cord from the twist lock plug (C). Ensure the handle is in its full upright position (Fig 2). Tilt the machine back (Fig 3). Choose the appropriate tooling holder attachment – magnetic Plug ‘N Go plate (D) for

Metal Bond tools or Foam/Hook and Loop Adapter plate for polishing resins and sandpaper. Insert the 2 shear pins through the compression foam pad

(E) into the rubber grommets on the pad driver (F). Attach the corresponding tooling to the plate.

2. Return the machine to the upright position (Fig 2).

Adjusting the Dust Skirt

The dust skirt (G) serves as a seal for the bottom of the machine to act as a vacuum chamber helping the dust stay contained under the machine. If the skirt is too far from the ground, the dust containment is reduced.

To adjust the skirt:

1. Pull one end of the skirt off the machine until you reach the middle of the skirt.

2. Position the skirt until it is barely touching the ground and repeat with the other end.

Adjusting the Handle

3. Pull the skirt snug. The two ends of the skirt should not touch. You may have a gap of up to ½ inch. Using the fabric connector cover the gap.

CAUTION

Avoid positioning the skirt too low as it will drag against the ground, wearing the skirt out prematurely and possibly preventing smooth machine movement.

To adjust the handle, pull the pin (H). Adjust the handle to a comfortable operating position. Release the pull pin and allow it to click into the positioning hole.

WARNING

Failure to check the pull pin is fully engaged could result in damage to the machine or personal injury as the handle could release unexpectedly when the machine is being operated or tilted back.

Page 6

Initial Start Sequence

Starting the Machine

Adjusting the Speed

Stopping the Machine

When the machine is first plugged in, a start-up screen (I) will flash STOP.

To start the machine, gently squeeze the activation lever (J) and press and release the START button (A).

WARNING

DO NOT lift the machine off the ground while starting it. Doing so could cause the diamonds to release from the machine, resulting in damage to the floor or personal injury.

The speed of the machine can be adjusted when the machine is running or stopped. To adjust the speed, rotate the speed control knob (B) on the VFD clockwise to speed it up, or counterclockwise to slow it down. Always start the machine at the lowest speed and adjust as necessary.

Once the machine reaches the desired speed, the speed will remain constant as long as the load applied remains below 100%. If the machine is running at speed and the load begins to exceed 100%, the machine will reduce its speed as a protective measure to try and alleviate the outstanding load. The current running speed will be displayed. This happens under demanding conditions and is normal.

If the machine is not able to maintain the minimum speed for more than 30 seconds the machine will turn off. This is a normal protective measure. To prevent this from reoccurring alleviate some of the load and then resume operation.

Let go of the activation lever.

When you unplug the machine, the screen will stay lit for a few seconds as the

VFD drains the power from its internal capacitors. This is normal.

DANGER

NEVER open the VFD panel while plugged in or immediately after unplugging the power cord. Severe injury or death may result.

Page 7

Installing and Removing the Pad Driver

To install and remove the pad driver on the bottom of the machine, you will need a 17 mm socket wrench, a soft face mallet, and some medium-strength thread locker (blue Loctite 243 or equivalent).

To remove the pad driver:

1. Slip the 17 mm socket wrench over the pad driver bolt and strike the wrench with the soft face mallet in a counter-clockwise direction.

2. When installing a new pad driver or re-installing an existing one, apply a generous amount of thread locker compound to the bolt and the threaded drive shaft. Insert the bolt through the hole in the pad driver. Reapply thread locking compound every time a pad driver is removed.

3. Line up the bolt to the threaded end of the shaft and start the first couple of threads.

4. Once the bolt is engaged, make sure that the drive shaft is properly seated within the pad driver slot before tightening the bolt all the way.

Rotation Pattern of

Tooling Plates

CAUTION

Failure to seat the pad driver could result in the pad driver slot being damaged, the threads in the shaft being stripped, the machine leaving heavy tool marks, and the tooling overheating.

Discs 1, 2, and 3 rotate clockwise

Discs 4, 5, and 6 rotate counter-clockwise

Bottom of WerkMaster with numbered tooling plates and clockwise and counterclockwise labeling.

Page 8

Changing the Primary

Belt

Motor Mount Assembly Handle

Motor Mount Assembly

Motor Shaft

Primary Driven Housing

Primary Driven Sprocket

Motor Coupling

Thumbscrews

Primary Belt

Belt Tensioner

Pull Pin

Cover Plate

Cover Plate Gasket

Flanged Bearing

Drive Train Top Plate

Secondary Belt

Sprockets

Drive Train Gasket

Drive Train Bottom Plate

Fig. 7

To change the Primary Belt:

1. Disconnect the power and ensure the handle is in the upright position.

2. Unscrew the handle control cable (K) (Fig 5 on p. 6) from the VFD.

3. Remove the pull pins from each handle arm (L) (Fig 2 on p. 5) and roll the handle assembly away from the machine.

4. Remove the four thumbscrews (Fig 7) from the motor mounting assembly.

5. Use the handle in the motor mounting assembly to lift the motor mounting assembly straight up until the motor shaft is completely clear of the base.

6. Remove the four M10 flat socket cap screws on the primary drive housing exposing the primary belt.

7. Loosen the four M8 hex head bolts and the M10 hex head bolt on the belt tensioner and slide forward to relieve tension.

8. Remove and replace the belt.

9. Tighten the M10 hex head bolt on the belt tensioner to 30 in/lb then tighten the four M8 hex head bolts.

10. Replace the primary housing and then replace the four M10 flat socket cap screws on the primary housing.

Page 9

Changing the Secondary

Belt

11. Lower the motor mounting assembly onto the motor shaft making sure to line up the motor coupling with the drive shaft.

12. Replace the four thumbscrews in the motor mounting assembly.

13. Roll the handle assembly back into place and reconnect the handle arms by pushing the pull pins through the holes and into the base.

14. Reconnect the handle control cable in the VFD.

To change the secondary belt:

1. Disconnect power and ensure the handle is in the upright position.

2. Unscrew the handle control from the VFD.

3. Remove the pull pins from each handle arm and roll the handle assembly away from the machine.

4. Remove the four thumbscrews from the motor mounting assembly.

5. Use the handle in the motor mounting assembly to lift the motor mounting assembly straight up until the motor shaft is completely clear of the base.

6. Remove the four M10 flat socket cap screws on the primary drive housing exposing the primary belt.

7. Loosen the four M8 hex head bolts and the M10 hex head bolt on the belt tensioner and slide forward to release tension.

8. Remove the primary driven sprocket by using the set screws and threading into the third hole. When replacing the set screws torque to 240 in/lb.

9. Remove the four hex bolts on the flanged bearing. Then remove the four flat socket cap screws and the two button cap screws. Pull the cover plate off.

10. Remove the gasket.

11. Remove the eleven M8 flat socket cap screws from the drive train top plate.

12. Separate the drive train top plate from the drive train bottom plate exposing the sprockets and belts.

13. Replace the belt and reverse the steps to reassemble.

NOTE: Replace all gaskets every time the gaskets are removed or the

Drive Train is opened.

VACUUM PORT

For the RASP:

1. ALWAYS run vacuum when sanding.

2. The vacuum port accepts a standard 2” vacuum hose cuff.

3. Always refer to vacuum manual.

For THE EDGE:

1. ALWAYS run vacuum when dry grinding.

2. The vacuum port accepts a standard 2” vacuum hose cuff.

3. Always refer to vacuum manual.

DANGER

Use extreme caution when working with electricity and water. Severe injury or death may occur if caution is not used.

Page 10

DISASSEMBLY/ASSEMBLY INSTRUCTIONS

To disassemble:

1. Disconnect power.

2. Unscrew handle control cable (K) from VFD (Fig 5 on p. 5)

3. Remove pull pins (L) from each handle arm and roll handle assembly away from machine (Fig 2 on p. 5).

4. Remove the four thumbscrews (see p. 8) from the motor mounting assembly.

5. Use handle in the motor mounting assembly to lift the motor mounting assembly straight up until motor shaft is completely clear of the base.

6. Located on the bottom of the base is a recessed handle (M) (Fig 3 on p. 5) for carrying the base.

To assemble:

1. Lower the motor mounting assembly onto the motor shaft making sure to line up the motor coupling with the drive shaft.

2. Replace the four thumbscrews in the motor mounting assembly.

3. Roll the handle assembly back into place and reconnect the handle arms by pushing the pull pins through the holes and into the base.

4. Reconnect the handle control cable in the VFD.

5. Connect to power.

Page 11

MAINTENANCE

Daily

Weekly

Monthly

WARNING

Disconnect power before performing any maintenance, cleaning, or repair to your machine.

CAUTION

After wet operation, wash bottom of the machine thoroughly, failure to do

so may result in damaged bearing seals.

Do not use any sharp object or abrasive pad to clean the bearing seals.

This can compromise the bearing seals.

•

Wipe down the machine after every job.

•

Gently remove dirt and debris from the pad driver.

•

Check to ensure the pad driver bolts are tight. If loose, remove pad driver and apply blue thread locker (Locktite 243).

•

Check grommets and replace if necessary.

•

Vacuum, wash and thoroughly dry the underside of the machine.

•

Inspect the plug ends for signs of carbon deposits and arcing.

•

Check all fasteners and tighten if necessary.

•

Inspect bearings seals around shaft for any wear or damage.

•

Inspect the handle wires for damage.

• Blow off the VFD heat sink with compressed air.

•

Using a soft scrub pad, remove any excess dirt build-up from the bottom plate and back side of the pad drivers.

•

Check all strain reliefs and make sure they are tight. (Strain reliefs are the plastic nuts that secure the wires that come out of the handle and VFD.)

•

Clean and lubricate wheels.

•

Using an extremely light abrasive pad, remove any topical rust from the shafts.

Page 12

TROUBLESHOOTING

ISSUE

Machine will not turn on.

VFD turns on but machine will not start.

TEST SOLUTIONS

Check all power connections. Make sure the source power meets the machine’s minimum power requirements (see

Power Cord Minimum Requirements p. 5).

•

Plug in the machine.

•

Check to see if any breakers or fuses are tripped or blown.

•

Check to see the handle activation lever is not depressed.

•

Have a qualified electrician test the source power to see if it meets the machine’s minimum power requirements.

•

Press START button while activation lever is depressed.

Check the VFD display for error codes

(see Appendix p. 14).

Machine runs for a short time and then shuts down.

Check the circuit breaker to see if it is tripped or the fuse if it is blown.

•

If no error code is displayed, check if the control cable is plugged into the machine.

•

If the VFD error code is “low voltage” have a qualified electrician test the source power and make the necessary adjustments to the wiring to supply the machine with its required input power.

•

Check to make sure that the power source has the appropriately sized breaker or fuse to meet the machine’s minimum power requirements.

•

Make sure the generator meets the machine’s minimum power requirements.

•

Have an electrician perform a voltage test while the machine is under load to see if the voltage drops below the machine’s minimum power requirements.

Pad drivers are not turning or only one pad driver is turning.

Disconnect the power and tilt the machine back. Spin one pad by hand.

•

If the pad turns independently, replace the secondary belt. Go to www.werkmaster.com/support.

•

If all pad drivers turn but the motor fan does not turn, replace the primary belt. See Repair & Maintenance videos at www.

Werkmaster.com.

Not all discs are grinding the floor.

Disconnect the power and tilt the machine back. Visually inspect each pad driver height against the adjacent pad driver.

•

Make sure all pad drivers are seated properly on the shafts.

•

Make sure grinding / polishing / sanding media is seated properly on the pad drivers.

•

Make sure grinding / polishing / sanding media is worn evenly and change out any media if uneven.

•

Make sure compression foams are positioned around the bumpers

Excessive noise or vibration is felt or heard while running the machine.

Tooling becomes dislodged from the machine while operating.

The machine handle malfunctions.

Disconnect the power and tilt the machine back. Spin one pad by hand.

Listen for a clicking sound or grit-like feeling.

Disconnect the power and tilt the machine back. Remove and inspect all tooling. This includes the pins, tooling plates, and pad drivers.

Check the handle plug to see if it has come loose.

•

Check that all tooling is in the correct pin holes on the pad drivers.

•

Replace the bearings. Contact technical support: 866-373-9375 for instructions.

•

•

•

If the pin holes are excessively damaged, replace the pad drivers.

If the grommets/bumpers on the pad drivers are damaged, replace the damaged parts.

If the pins on the diamonds or tooling plates are damaged or missing, replace the pins.

•

Secure the handle plug. If the handle controls are still malfunctioning, contact customer service for instructions.

VFD makes popping noise and starts to smoke.

***Disconnect power

immediately!***

Wait for 1–2 hours, then remove the VFD cover and check electronic components for discoloration, scorching, or swelling.

•

Contact a dealer or technical support: 866.373.9375.

VFD screen displays error message or unusual screen display.

Look up the message in the Appendix.

•

Contact technical support: 866.373.9375.

Page 13

APPENDIX – KBDA VFD TROUBLESHOOTING AND DIAGNOSTICS

Digital Readout Codes

The following table shows the 4-digit display readout of drive status, operating parameters, and faults.

WARNING

DISPLAY DESCRIPTION

StoP

Drive Stopped – Indicates that the drive is in Stop Mode. Function No.

4.03 set to “0001.”

–LU–

–OU–

OL

CS

–

DO NOT depend on the LEDs or the 4-Digit Display to no longer be illuminated as a guaranteed POWER OFF condition. Be sure the main power switch or circuit breaker is in the OFF position

BEFORE servicing the drive. t

–t

–PL–

Low Voltage Trip – Indicates that the AC line input voltage is below the Undervoltage Trip Point.

Overvoltage Trip – Indicates that the AC line input voltage is above the Overvoltage Trip Point.

Overload Trip (l

2

t Timeout) –

Indicates that the motor has been overloaded for an extended period of time.

Current Source Trip – Indicates that the current signal output (from the IODA) has been opened.

AC Line Phase Loss Detection –

Indicates that the drive has detected a loss of one of the phases.

DISPLAY DESCRIPTION

Err2

Err4

IODA Error – Indicates that the drive has lost communication with the IODA.

–SC–

Err1

Err3

Keypad Communication Error –

Indicates that the keypad failed to initialize when the drive is powered up.

This is an abnormal condition -

Short Circuit Fault – Indicates that the drive detected a short circuit at the motor (phase- to-phase).

Data Enter Error – Indicates that the drive is in the Program Mode and a non-valid parameter change has been attempted.

Flash Memory Error – Indicates that a flash memory error on the drive has occurred.

This is an abnormal condition – contact

WerkMaster Technical Support at 1-604-

629-8700.

Page 14

APPENDIX – LENZE VFD TROUBLESHOOTING AND DIAGNOSTICS

STATUS WARNING MESSAGES

Status / Warning

CL Current Limit reached

Cause

Motor overload.

Remedy

Press the reset button or unplug the machine for 30 seconds.

Err

FCL

Error

Fast Current Limit

StoP

Output frequency - ) Hz

(outputs U, V, W inhibited)

Invalid data was entered, or an invalid command was attempted.

Overload.

Stop has been commanded from the keypad, terminal strip, or network.

Verify drive/motor are proper size for application.

Apply Start command.

FAULT MESSAGES

The messages below show how they will appear on the display when the drive trips. When looking at the Fault History (P500) the

F_ will not appear in the fault message.

Fault

F_PF

F_cft

F_F1

F_F2

High Temperature fault

Forced Translation fault

EPM fault

Internal faults

Cause

Drive is too hot inside.

An EPM from an old drive put in new drive causes to trip fault.

EPM missing or defective.

Remedy

• Reduce drive load

• Improve cooling

Press (M) mode button twice to reset.

Power down and replace

EPM.

Contact WerkMaster technical support at

1.866.373.9375.

F_FH

F_LF

High DC Bus Voltage fault

Low DC Bus Voltage fault

Mains voltage is too high.

Mains voltage too low.

Check mains voltage.

Check mains voltage.

F_nid

F_OF1

F_OF

F_PF

F_SF

No Motor ID fault An attempt was made to start the drive in Vector or

Enhanced VHz mode prior to performing the Motor Autocalibration.

Grounded motor phase.

Contact WerkMaster technical support at

1.866.373.9375.

Output fault: Ground fault

Output fault:

Transistor fault

Excessive capacitive charging current of the motor cable.

Output short circuit.

Severe motor overload due to

• Mechanical problem

• Drive/motor too small for application

Failed output transistor.

Check motor/motor cable.

Use shorter motor cables with lower charging current.

Check motor/motor cable.

• Check machine/system

• Verify drive/motor are proper size for application

Contact WerkMaster technical support at

1.866.373.9375.

Motor Overload fault Excessive motor load for too long.

Single-Phase fault

Verify drive and motor are proper size for application.

Severe motor overload due to

• Mechanical problem

Drive/motor too small for

• Check machine/system

• Verify drive/motor are proper size for application application

A mains phase has been lost. Check mains voltage.

F_LF Start fault Start command was present when power was applied.

Must wait at least two seconds after power-up to apply Start command.

NOTE: The drive can only be restarted if the error message has been reset.

Page 15

EXPLODED VIEWS AND PARTS LISTS – RASP / EDGE

MOTOR ASSEMBLY PARTS LIST

ITEM QTY PART NUMBER

5

6

7

1

2

3

4

8

9

10

11

12

1

1

4

1

5

9

1

4

8

1

1

2

530-0050-00

120-0093-01

590-0265-00

120-0094-01

590-0190-00

590-0140-00

540-0156-00

540-0375-00

590-0133-00

120-0101-00

540-0335-01

540-0413-00

DESCRIPTIOON

Motor, 3Hp, 3Ph, 230V, 1800 RPM

Motor Mount Assembly

Fastener

Motor Shroud Assembly

Fastener

Fastener

Strain Relief

Vibration Dampener

Fastener

VFD Assembly

Flexible Conduit

Cable Retainer

Page 16

DRIVE TRAIN ASSEMBLY PARTS LIST

ITEM QTY PART NUMBER

5

6

7

1

2

3

4

8

9

10

1

5

1

2

1

1

2

4

11

1

100-1138-01

110-0177-00

520-0060-00

110-0092-01

100-1139-01

110-0182-00

580-0357-00

590-0151-00

590-0338-00

580-0355-01

DESCRIPTIOON

Drive Train Lower Plate

Sprocket, Short Shaft Assembly

Belt

Idler Assembly

Drive Train Upper Plate

Sprocket, Long Shaft Assembly

Pin

Flat Washer

Fastener

Drive Train Gasket

Page 17

17

18

19

20

13

14

15

16

6

7

8

9

10

11

12

21

22

BASE ASSEMBLY PARTS LIST

ITEM QTY PART NUMBER DESCRIPTION

1 1 580-0354-01 Drive Train Cover Gasket

2

3

1

1

110-0181-01

500-0301-00

Cover Assembly

Sprocket

4

5

1

4

500-0107-00

590-0193-00

Taper Lock Bushing

Fastener

6

6

2

4

1

1

1

5

4

4

5

1

4

1

1

2

4

110-0208-00

590-0141-00

520-0061-00

110-0185-01

590-0329-00

590-0124-00

590-0142-00

590-0126-00

500-0306-00

110-0178-01

008-0366-00

008-0310-01

008-0349-01

590-0194-00

590-0140-00

590-0348-00

590-0362-00

Primary Drive Sprocket Assembly

Fastener

Belt

Primary Housing Assembly

Fastener

Fastener

Fastener

Fastener

Four-Bolt Flanged Pillow Block Bearing

Drive Train Assembly

Pad Driver Assembly

Compression Foam

Plug ‘N Go Plate Assembly

Fastener

Fastener

Fastener

Fastener

Page 18

8

ITEM QTY PART NUMBER

5

6

7

1

2

3

4

8

1

1

1

1

1

1

1

1

130-0203-01

590-0300-00

590-0149-00

590-0148-00

590-0196-00

580-0362-00

130-0206-01

540-0185-00

HANDLE ASSEMBLY PARTS LIST

DESCRIPTIOON

Complete Lower Handle Assembly

Fastener

Flat Washer

Flat Washer

Fastener

Pull Pin

Complete Upper Handle Assembly

Four Pin Cord

GLOSSARY

Line Voltage

Page 19

Load Voltage

Pigtail

RPA

VCT

VFD

This is the voltage of a power source when it has no load applied to it. It can also be called “nominal voltage” as the voltage expressed is usually a guideline voltage.

This is the voltage of a power source when a load has been applied to it. As a load is applied to the power source, the resistance of the line is easier to examine. When a voltage-measuring device such as a multimeter is used during operation of the machine, you can clearly see that the voltage drops as soon as a load is applied and rises back when the load is taken off.

Pigtails are plug ends with unfinished bare wire on one end used for hooking up to panels. Pigtails are used when the source power is unknown, when connecting to the power grid of an unfinished building that has no power receptacles, and when running certain generators. Many pigtails are available or can be made up by an electrician.

Rear pivoting assembly.

Vinyl composition tile.

A variable-frequency drive (VFD) is a system for controlling the rotational speed of an alternating current electric motor by controlling the frequency of the electrical power supplied to the motor. A variable frequency drive is a specific type of adjustable-speed drive. Variable-frequency drives are also known as adjustable-frequency drives (AFD), variable-speed drives (VSD), AC drives, microdrives, or inverter drives. Because the voltage is varied along with frequency, these are sometimes also called variable voltage variable frequency

(VVVF) drives.

Page 20

WARRANTY INFORMATION

Terms & Conditions

WerkMaster Grinders & Sanders Inc., herein referred to as WerkMaster, warrants that each new machine, manufactured by WerkMaster to be free from defects in material and workmanship in normal use and service for a period of three years (3) from date of shipment to the original Purchaser or Distributor.

WerkMaster will, at its option, repair or replace, at the WerkMaster factory or at a point designated by WerkMaster, any part which shall appear to the satisfaction of WerkMaster inspection to have been defective in material or workmanship.

WerkMaster reserves the right to modify, alter and improve any part or parts without incurring any obligation to replace any part or parts previously sold without such modified, altered or improved part or parts.

This warranty is in lieu of and excludes all other warranties, expressed, implied, statutory, or otherwise created under applicable law including, but not limited to the warranty of merchantability and the warranty of fitness for a particular purpose. In no event shall the Seller or the Manufacturer of the product be liable for special, incidental, or consequential damages, including loss of profits, whether or not caused by or resulting from the negligence of Seller and/or the

Manufacturer of the product unless specifically provided herein.

In addition, this warranty shall not apply to any products or portions thereof which, at WerkMaster’s discretion, have been subjected to abuse, misuse, improper installation, maintenance, or operation, electrical failure or abnormal conditions, and to products which have been tampered with, altered, modified, repaired, reworked by anyone not approved by the Seller, or used in any manner inconsistent with the provisions of the above or any instructions or specifications provided with or for the product.

Except for conditions or warranties which may not be excluded by law, the Seller makes no warranty of its own on any item warranted by WerkMaster, and makes no warranty on other items unless it delivers to the Purchaser a separate written warranty document specifically warranting the item. The Seller has no authority to make any representation or promise on behalf of WerkMaster or to modify the terms or limitations of this warranty in any way.

Delivery, Damages,

Shortages

Seller shall use reasonable efforts to attempt to cause the Products to be delivered as provided for in these Terms & Conditions. Delivery to the initial common carrier shall constitute the delivery to the Purchaser. Seller’s responsibility, in so far as transportation risks are concerned, ceases upon the delivery of the Products in good condition to such carrier at the F.O.B. point and all the Products shall be shipped at the Purchaser’s risk. Seller shall not be responsible or liable for any loss of income and/or profits, or incidental, special, consequential damages resulting from Seller’s delayed performance in shipment and delivery.

Return of Defective

Products

Defective or failed material shall be held at the Purchaser’s premises until authorization has been granted by Seller to return or dispose of Products.

Products that are to be returned for final inspection must be returned Freight

Prepaid in the most economical way. Credit will be issued for material found to be defective upon Seller’s inspection based on prices at time of purchase.

Page 21

WARRANTY continued

FORCE MAJEURE

Seller’s obligation hereunder are subject to, and Seller shall not be held responsible for, any delay or failure to make delivery of all or any part of the

Product due to labor difficulties, fires, casualties, accidents, acts of the elements, acts of God, transportation difficulties, delays by a common carrier, inability to obtain Product, materials or components or qualified labor sufficient to timely perform part of or all of the obligations contained in these terms and conditions, governmental regulations or actions, strikes, damage to or destruction in whole or part of manufacturing plant, riots, terrorist attacks or incidents, civil commotions, warlike conditions, flood, tidal waves, typhoon, hurricane, earthquake, lightning, explosion or any other causes, contingencies or circumstances within CANADA not subject to the Seller’s control which prevent or hinder the manufacture or delivery of the Products or make the fulfillment of these terms and conditions impracticable. In the event of the occurrence of any of the foregoing, at the option of Seller, Seller shall be excused from the performance under these Terms and Conditions, or the performance of the Seller shall be correspondingly extended. This document sets forth the terms and conditions pursuant to which the purchaser(“Purchaser”) will purchase and

WerkMaster (“Seller”) will sell the products, accessories, attachments

(collectively “the Products”) ordered by the Purchaser. These terms and conditions shall govern and apply to the sale of Seller’s Products to Purchaser, regardless of any terms and conditions appearing on any purchase order or other forms submitted by Purchaser to Seller, or the inconsistency of any terms therein and herein.

swm 05/2017

To get the best protection from your WerkMaster Warranty be sure to register your product(s) online at www.werkmaster.com/warranty .

WerkMaster Grinders and Sanders Inc.

6932 Greenwood Street, Burnaby, BC V5A 1X8 tel: 604.629.8700 | toll free: 1.866.373.WERK | fax: 604.444.4231 www.werkmaster.com | email: [email protected]

Page 22