1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up...
Transcript of 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up...
![Page 1: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/1.jpg)
Max
10 Fa
b M
anual
1", 1
1/2 "
, & 2"
Duct B
oard
Mach
ine A
dju
stmen
ts Manual
Glass Master Grooving Machine Adjustments Manual
![Page 2: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/2.jpg)
Knauf Air Duct Fabrication Manual �
Grooving Machine
Introduction and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 InitialInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Roller Adjustment, Maintenance, and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ResurfacingPinchRollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 PinchRollerSpacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SpacingAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 AdjustingtheToolBars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Adjustment of Individual Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tools#1,and#R1(A,E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 ToolsB,C,D(#3,#2,and#3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 ToolsGandA(#5and#8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 90°V-GrooveTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 StraightCutoff(SCO)Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 BladeLifeandReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 TabSettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Tooling Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 StandardTooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Preferred(Reverse)Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 V-GrooveTooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 V-GrooveToolingSetup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table of Contents
�
![Page 3: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/3.jpg)
Introduction and Scope
Properadjustmentofgroovingmachinesisessentialtoproducingqualityairductboardsectionsatlowestpossiblecontractorcost .SeveralmodelshavebeenproducedbyGlassMastersincema-chineswerefirstintroducedintotheairhandlingmarket .However,thebasicdesignconceptremainsthesametodayaswhenfirstproduced .Regardlessofthemodeloryearofproduction,thebasicmechanicalprinciplesofadjustmentdiscussedinthefollowingpagesstillapply .TheE-215machineisthebaseuponwhichallothermodelsaremanufactured .E-215machinesinusefaroutnumberallothermodelsinuseatthistime .Forthepurposeofsimplicity,thismanualfocusesonadjustmentandmaintenanceproceduresapplyingtotheE-215basemodel .AlsoincludedisbriefinformationonhowotherglassmastermodelsdifferfromtheE-215 .Twobasictypesoffabricationcanbepreformedbyallglassmastergroovingmachines:ShiplapandV-grooveconfigurations .Bothtypesoffabricationareincludedinthiswork,althoughtheV-groovemethodisnotrecommendedifmodularductconstructionprinciplesaretobeused .Also,sincetheinitialproductionofGlassMastermachines,additionaltoolshavebeenintroducedtoachievespecificpurposes .Alltoolswillbedis-cussedatlength .Evaluationofcutductboards,groovingmachinemaintenance,repair,andtrouble-shooting,arealsoincluded .
Initial InspectionInitially,theusershouldperformavisualinspectionofthemachine .Removeallcuttingtoolsandexaminerollersfirst .TheE-215incorporatesaseriesofsixrollerstopullthefiberglassductboardpastasetofstationarycuttingknives .Twosetsofpinchrolls,onesetinfrontandoneinback,griptheboardtomoveitthroughthemachine .Twosupportrollersarestationedbetweenthepinchroll-erstokeeptheductboardlevel .Figure1showstheleftendplateremovedtorevealrollersanddrivetrain .Notethatallrollersare"driven ."Checktoseethattherearenorollersthatcanbeturnedfreelybyhand .Ifyoucanturnanyofthesixrollersmorethan⅛ofarevolutionitindicatestoomuchchainslack .Youshouldalsoinspectthegritsurfaceofthetwoupperdriverollers,makingsuretherollersareabletodrivetheductboardstraightthrough .Inspectionofthefootswitch,plug,andelectricalcordsarealsoveryimportant .
Note: Electricalrepairsshouldonlybemadebyqualifiedpersonel .
Fig .1 .E-215drivechain
![Page 4: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/4.jpg)
Knauf Air Duct Fabrication Manual �
Grooving Machine
Ifoneormorerollersdoesturnbyhand,examinedrivegearstobesurelockingAllenscrewsaretightagainstkeysandthatkeyslotsareinplace(seeFigure2) .Makesurethesprocketsareinlinewhenre-tightening .Toavoidprematurewear,allgearsshouldbeoperatinginthesameplane .
Resurfacing pinch rollersOnearlymodels,thetoppinchrollerinfrontandthetoppinchrollerinbackwerecoatedattheGlassMasterfactorywithanabrasivesubstance(crushednutshellheldinplacebyepoxypaint) .Thishelpedtherollersgriptheairstreamsurfaceoftheductboardandpullitpastthestationaryknives .However,normalusagewearsthegritofftheserollers .Asmoreandmoregritiswornoffandthedriverollersbecomesmoother,theductboardoftenwillnotpassthroughthemachineinastraightline .Theboardwillinvariablybegintosliptotherightorleft,wastingmaterialandneedlesslyaddingtofabricationcost .
Whenthisoccurs,fabricatorsoftenattempttocorrecttheproblembyclosingthegapbetweenthepinchrollers .This is not recom-mended.Closingthepinchrollergapcancauseirreparabledamagetotheductboard;theglassfibersareliterallycrushed,theboardbecomeslimp,andthefoilwrinklesandbeginstocomeloosefromthefiberglass .
Resurfacingthepinchrollersiseasilydoneinthefield .ThisisbestaccomplishedusingrollsofindustrialgradeemeryclothandsprayadhesiveavailablefromGlassMaster .No other roll resurfacing method is recommended.Thecorrectresurfacingprocedureisasfollows:1 . Thoroughlycleanthepinchrolltoberesurfaced .2 . Applysprayadhesiveevenlytothepinchrollerfromoneendto
theother .3 . Unrolltheemeryclothandsecureittooneendofthecleaned
rollerwithapoprivet .4 . Applysprayadhesivetotheundersideoftheemerycloth .When
theadhesiveistacky,windtherollspirallyandevenlyalongtheentirelengthoftheroller,makingsurewrapsofemeryclotharetightlybuttedtogether .Whenyoureachtheotherendoftheroll,securetheemeryclothwithapoprivet .CompleteinstructionsandtechnicalassistanceisavailablefromGlassMasteroryourKnaufRep .
Note: Onlythetopfrontandtopbackrollersshouldbeabrasive-coated,usingemeryclothandsprayadhesivebymeansofthemethodpre-viouslydescribed .Ifthebottompinchrollersorthelevelingrollersarecoated,thiswilldamagethefoilfacingoftheductboard .Alsochangingthespacingbetweenpinchrollersdoesnothingtochangethedepthoftheknifecuts .
Roller Adjustment, Maintenance, and Repair
Fig .2 .KeyslotsandAllenscrew
Figure3 .Resurfacingdriverollerwithemeryclothsothatnogapsoccurbetweenwraps
2_�
![Page 5: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/5.jpg)
Roller Adjustment, Maintenance, and Repair
Fig .4 .Factorypinchrollerspacingmustbemaintained
Pinch roller spacingSpacingbetweenthepinchrollersiscritical .RollerspacingshouldneverbecloseddowntighterthanthespacingsetattheGlassMastermachinefactory .Thosefactoryspacingare: For1"ductboard ⅝" (16mm) For1½"ductboard 15/16" (24mm) For2"ductboard 1¼" (32mm)Withagood,grittysurfaceontheupperdriverollers,theycanbespacedevenfartherapartandstillpulltheductboardstraight
throughthemachinewithoutdamagingit .
Spacing adjustment:Properadjustmentofthedistancebetweenpinchrollerscanbeac-complishedeasily .First,loosenthechainidler(seeninthebottomleftcornerofFigure1) .Itisattachedtotheleftrollerplate .Loosenthetwo9/16"(14mm)boltsholdingtheidler .Theseboltsarelocatedontheinsideoftheleftendbelowthefourbottomrollersandthetoolbar .Important: Loosenthesetwobolts,makerequiredadjust-ments,thenpulloutwardandtightenbothbolts .Onthetopofthemachinethereare¾"(18mm)boltsonthefrontedgesofbothendpanels .IfyourE-215hasfourbolts,fourseparaterollerspacingadjustmentsmustbemade,twoateachendofthemachine .IfyourE-215hastwosuchbolts,bothfrontandrearrollerscanbeadjustedsimultaneously .Rollerspacingshouldbemaintainedatthespecifiedfactoryspacingfortheductboardthick-nessinuse(seepage4)alongtheentirelengthofthemachine .
TheGlassMasterE-215wasdesignedtogrooveductboardupto2"(51mm)thick .Ifboardsthickerthan1"(25mm)aretobegrooved,thechainmechanismwhichdrivesallrollersmustbeadjustedtoprovidemoreslackinthechainastherollersaremovedfartherapart .
1 . Adjustrollersfordesiredductboardthickness .2 . Takeupslackinchainandtightenchainidler .
Fig .5 .Pinchrollerheightadjustmentbolt
![Page 6: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/6.jpg)
Knauf Air Duct Fabrication Manual �
Grooving Machine
Inordertoensureevencutsalongtheentirelengthofthetoolbarsandtopreventrollersfromdevelopingwarpandsag,laterGlassMasterE-215machineshaveTeflon®"Y"bracesaddedtotherolleronwhichthetoolbladesride .
LubricationTheGlassMasterE-215machinetransmissionisfilledatthefactory .Whileanoilinspectionplugislocatedonthemachinetrans-mission,itshouldnotbenecessarytochecktheoillevel .
Lubricatingthedrivechainisnotrecommended;thiscausesglassfiberstosticktothechain,causingprematurewear .
Adjusting the Tool BarTheGlassMasterE-215machineisconstructedwithtwotubularsteeltoolbars .Thecuttingtoolsarepositionedbetween,andreston,thetoolbarsforfabrication .Theverticalpositionofthetoolbarsdirectlyaffectsthedepthofallcuts .Properpositioningofthetoolbarisabsolutelyessential .Toolbarsaremountedonaplatethatcanbemovedupordownoneachendofthemachine .
Roller Adjustment, Maintenance, and Repair
Fig .7 .Toolbarmountingbracketnuts
Fig .6 .Idlerarmadjustmentbolts
4_�
![Page 7: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/7.jpg)
First,loosenthetwo9/16"(16mm)nutsonthemountingbracket .Next,toraiseorloweroneendofthetoolbars,tightenorloosenthevertical9/16"(16mm)boltjusttotherightofthewrenchinfigure7 .Theotherendofthetoolbarsareconstructedexactlythesame .Bothendsofthetoolbarsmustbeadjustedinexactlythesamemannertokeepthetoolbarslevelalongthelengthofthemachine .Caremustalsobetakentoensurethatthefronttoolbariskeptlevelwiththereartoolbarinthedepthofthemachine .ProperheightofthetoolbarsisdeterminedbyusingeithertheA(#8)orG(#5)tool .Thebladesonthesetoolsareattachedbytwoscrewswhichcanbeloosenedtoallowfinebladeadjustment .Positionthebladehalfwayintheslottedholestoallowforfuturefinetuning,thensetthetoolonthebar(seeFigure8) .Do not lock it down.
Thebottomofthetoolbladeshouldrestfirmlyonthecuttingrollersothatitactuallydragsontherollerasitturns(seeFigure8) .Adjustthetoolbarverticallyuntilthefrontedgeofthetoolholderrisesslightlyoffthetoolbar(seeFigure9) .Tightenthetwo9/16"(16mm)boltsonthemountingbracketandrepeatthisprocessattheotherendofthetoolbars .Checktomakesurethetoolsarenotsetsolowthattheycutortearthefoilfacingoftheductboard .
Withthetoolbarsproperlyadjustedinthisposition,adjustmentoftheothertoolsisquitesimple .
Note:
SomenewerGlassMastergroovingmachinesfeaturetoolbarsthatdonotrequireadjustmentandareweldedintoplace .Adjustmentforductboardthicknessismadebychangingtoolassemblies .
Adjustment of Individual Tools
Fig .9Loweringtoolbaruntilfrontedgeoftoolholderisoffthetoolbarslightly .
Fig .8UsingA(#8)orG(#5)tooltoadjusttoolbarheight
![Page 8: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/8.jpg)
Knauf Air Duct Fabrication Manual �
Grooving Machine
TheGlassMasterE-215machinehasbeentooledtocuteithermodifiedshiplaporV-groovecuts .Formodifiedshiplapconfigura-tion,fabricationtools#1,#2,#3,#4,#5,#R1,#8,andSCOorA,B,C,D,E,F,G,andSCOwereshippedwiththemachine .
Tools #1, and #R1 (A, E):Thesetwotoolsaredesignedtocutthefemaleshiplap .Adjustmentisverysimple:Setallthetoolstocutonehalfthethicknessoftheductboard .Loosenthetwoscrewsinthebladeholderandmovethebladeverticallyuntilhalfoftheboardthicknessisremoved(seeFigure10) .Ifmoreorlessthanhalfthethicknessofthefiberglassisremoved,theductsectionwillnotfolduptoformaperfectrectangleorsquare .Verylittleattentionisnormallypaidtothedepthofthiscutinthefield,yetunlessthesebladesareproperlyadjusteditisdifficulttoputtwosectionsofducttogetherandmaintainastraightductrun .
Tools B, C, D (#3, #2, #3)Thesethreetoolsareusedtocutrightandlefthandshiplapssothatfoldingtheductboardcanbeaccomplished .ToolsBandD(#3)areexactlythesame .ToolC(#2)isthereverseofToolsBandD .(#3) .Adjustmentofallthreetoolsisexactlythesame .Groovesformedbythesetoolsmustbecutprecisely .Ifcuttooshallow,theboardscannoteasilybefoldedandthefinishedductsectionwillnotstandwith90°corners .Ifcuttoodeeply,theductwillbewobblyandflimsyandthefoilfacingcanbedamagedorcut .Fineadjustmentisaccomplishedbylooseningthefourscrews,whichholdthetwoseparatebladestothetoolholder,andmovingthemverticallytoachievethepropercut .
Adjustment of Individual Tools
Fig .10 .Properdepthofcutforfemaleshiplap
Fig .11 .AdjustmentscrewsontoolsB,C,D(#3,#2,#3also#4)
6_�
![Page 9: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/9.jpg)
Positionthebladewithasinglebendsothatitmakeslightcontactwiththerollerasitturns .Positionthetrailingbladesothatitcutsflushwiththemoldedshiplap,oraboutonehalfthethicknessoftheductboard .Whenthebladesarecorrectlypositioned,theglassfibersinthebottomofthedeepestgrooveshouldbeapproximately1⁄8" or less allowing easy folding and closing of duct section.
AperfectcutisseeninFigure13 .Notethatthereremainsapproxi-mately⅛"(3mm)offiberglassinthebottomofthedeepestgroove,andthatthenextgrooveiscutevenwiththefactoryformedfemaleshiplap .Withthistypeofcut,aductsectionwillfoldtogetherwithjustenoughresistancetomakethecompletedsectionstandstraightwith90°corners .
Tools G and A (#5 and #8): Correctadjustmentofthesetwotoolstakesalittlemorecaretoachieveandtomaintainthanmostothertools .Thesetoolsareusedtoformstapleflapsandtomakeendcaps .Allofthefiberglassmustbecleanedoffthefoilfacing .Whenthisbladeisnotsetproperlytheresultscanbefieldcrewsandshoppersonneldoingtheworkofthemachinebyhand .Labordollarsarespentunneces-sarilybecausemachineoperatorsdonotadjustthistoolproperly .Forproperadjustment,setthebladesothatitpressesdownfirmlyonthecuttingroller .
Adjustment of Individual Tools
Fig .13 .PropercutdepthusingtoolsB,C,D(#3,#2,#3also#4)
Fig .14 .ToolsG(#5)andA(#8)mustpressfirmlyonthecuttingroller .
Fig .12 .Settrailingbladetocutflushwithfactorymoldedshiplap
![Page 10: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/10.jpg)
Knauf Air Duct Fabrication Manual �
Grooving Machine
Aftertheoriginalbladeiswornorbroken,thereplacementbladeisoftenputbackbyplacingscrewsinthewrongholessothatthebladeactuallyrestsbetweenthelevelingrollers .Noamountofadjustmentcanproduceacleanstapleflapifthebladedoesnotmakeconstantfirmcontactwiththecuttingroller .IfbladesaretobeinstalledontheGlassMasterE-215machine,usethetwoinsideholestosetthem .IfbladesaretobeinstalledonGlassMaster300-SM,E-200,orE-410machines,usethetwooutsideholes .
Note: TheGlassMasterE-200requiresdifferentG(#5)andA(#8)blades .The300-SMrequiresanextractingblade .Forinformation,contactGlassMasteroryourKnaufrepresentative .
Loosenthetwoscrewsholdingthebladeandadjustitsothat,whentheholderissetintothetoolbar,thefrontedgeofthetoolholderwillpressdownslightlybeforeitislockedinplace .Theaddedspringwillcausethebladetocleanallthefiberglasswhileleavingthefoilfacingunharmed .
Adjustment of Individual Tools
Fig .15 .Properreplacementbladeposition,ToolsG(#5)andA(#8)
Fig .16 .Oxydizedfinishwillbewornoffproperlypositionedblade
SM-300,GM-12E-115,E-215
8_�
![Page 11: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/11.jpg)
90° V-Groove toolsInV-groovefabrication,the90°toolsareusedtoreplacethecutsmadebythetoolsusedinthemodifiedshiplapmethod .AdjustmentofV-groovesiseasilyaccomplishedbecausethereismoretoler-anceforadjustmenterror .TheV-groovemethodiscommonlyusedforfabricatinginsulationboardforinstallationonsheetmetalductexteriorsurfacesinadditiontoapplicationscallingforformingtheentireductfromfiberglassboards .
Themethodisnotrecommendedwhenfollowingmodularductcon-structionprinciples;manyfittingscannotbesuccessfullyfabricatedfromV-groovedductboard .
Twoscrewsfastentheone-piecebladetothetoolholder .Loosenthescrewsandadjustthebladeupordownuntilitrestslightlyonthecuttingroller .Cornerswilleasilyfold,andtheductwillstandstraightwith90°corners .
Straight Cut-off (SCO) Tools:Theseareusedtocutallthewaythroughthefiberglassandthefoilfacingattheendofastretch-out .Verylittleadjustmentisnecessary,sinceastraightverticalcutisproduced .However,ductboardsectionsareoftenruinedbytheuseofdullcut-offblades .Thereinforcingscrimintheductboardfoilfacingisdifficulttocut,andtheSCOtoolisusedtocuteverysectionofductboardthatpassesthroughthemachine .Therefore,theSCObladewearsoutabouttwiceasfastasmostoftheotherblades,andshouldbereplacedorsharpenedassoonasitnolongerproducesacleancut .Therearetwoadjustmentscrews,butallthatisnecessaryistopullthebladetoitslowestpositionandtighten .
Adjustment of Individual Tools
Fig .17 .ProperV-groovecutwhenusing90°blades .Aperfectcutisseenabove .Notethatthereremainsapproximately⅛"(3mm)offiberglassinthebottomofthegroove .
![Page 12: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/12.jpg)
Knauf Air Duct Fabrication Manual ��
Grooving Machine
Blade Life and ReplacementAlthoughalltoolbladeswilleventuallyneedtobereplaced,somewearoutfasterthanothers .Ithasbeenestimatedthatasinglesetoftoolbladescanlastthroughtwelvetofourteentruckloadsoffiberglassductboard .Thisisnottrueforallbladesinaset,however;asnotedabove,SCOtoolbladeswearoutfasterandshouldbereplacedabouttwiceasoftenasotherblades .ThesameistrueforbladesoftoolsG(#5)andA(#8) .Dullbladesplaceexcessivestressontheductboard,sometimescausingtheductboardtoturnsidewaysinthemachine .Thiswastesmaterialandaddstocost .
Onlyshort-termgaincanbeaccomplishedbyattemptingtosharpentoolblades .AllGlassMastertoolbladesarehardenedatthefactory;sharpeningwithagrinderorfileseldomproducesasatisfactoryedge .Itisanexcellentideaalwaystoretainasparesetofblades,especiallyforG(#5),A(#8),andSCOtools .
Visualinspectionofdullbladeswillrevealwornandraggededges .However,abettermethodfordetectingdullbladesistolookcloselyatsectionsofgroovedductboard .Whentheedgesofcutsbecomewavyandendcutsareragged,thereisstrongevidenceofwornblades .Bladesbegintofollowthegrainofthefiberglassastheypassthroughtheductboardinsteadofcuttingthroughthegrain .
Tab SettingsInsidedimensionsoffabricatedfiberglassductaredeterminedbymeasuringbetweensetsoftabspositionedontopoftheindividualtools .E-215toolholdersareshippedfromthefactorywithdimen-sionsproperlyset,butearlytabsystemswereadheredtothesurfaceofthetoolholdersonlywithsprayadhesive .Afterrepeatedusage,tabscanslipcausingactualductdimensionstovary .Everyshopshouldmeasurethefinishedgroovesectionofductboardtodetermineifactualductdimensionsareaccurate .Ifnot,adjustthetabsaccordingly .Afterdeterminingthepropertabsetting,pop-rivetthetabstothetoolholderstoensureagainstfutureslippage .AllcurrentlyproducedGlassMastertoolholdersaremanufacturedwithtabspop-rivetedtothetoolholders .
Adjustment of Individual Tools
�0_��
![Page 13: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/13.jpg)
Differenttoolingarrangementscanbeusedtoaccomplishdifferentpurposes .ThemachineownerwhousestheGlassMastertofabricateonlyonetypeofductmaynotbetakingfullestadvantageoftheproductivecapabilitiesofthemachineandmaynotbeusingrawmaterialcost-effectively .Toolingcanbearrangedtoproduceone-pieceduct,two-piece"L"duct,two-piece"U"duct,four-pieceduct,endcaps,andotherspecialtyproductssuchastriangles .
Greatestuseofdrop-offcanbeachievedwhenacombinationoftheseisproducedfromasingleboard .DuctboardoptimizationprogramsareavailablefromGlassMaster .Asectionofone-piecefiberglassductcanbefabricatedfasterthananyotherpossibletoolingarrangement,regardlessofwhetherthemodifiedshiplaporV-groovemethodisused .However,ifonlyone-pieceductisfabricated,asignificantamountofdrop-offremains .Utilizationofdrop-offcanbeaccomplishedbyfabricatingendcaps,two-piece"L"duct,andtwo-piece"U"duct .
Sinceeverysquarefootofdrop-offcoststhesameastherestoftheductboard,utilizationofeverysquarefootishighlydesirable .Carefulboardutilizationpaysdividends .
Standard ToolingIntheStandardtoolingset-up,thestapleflapisfabricatedbythenext-to-last(G,or#5+SCO)tool(SCObeingthelasttool) .Asnoted,properadjustmentofG(#5)andA(#8)toolsisnoteasytoachieveandtomaintain .ThisisespeciallytrueoftheG(#5)toolintheStandardtoolingset-up .Whenproperlyadjusted,theG(#5)toolwillcutalltheglassfibersoffthestapleflap,leavingthefacingbareandundamaged .However,theStandardtoolingset-upplacestheG(#5)tool,whichmakesthemostdifficultcut,intheweakestareaofthetoolbars .Itisalsothemostdifficulttooltomoveandreset,yetitmustbemovedeverytimetheductdimensionchanges .
Tooling arrangements
Fig21 .Standardtoolingcutoninsulationboard .
Fig .18 .StandardToolingArrangement
1
![Page 14: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/14.jpg)
Knauf Air Duct Fabrication Manual ��
Grooving Machine
Preferred (Reverse) ToolingThisistherecommendedmethodoftoolarrangementintheindus-try .TheA(#8)toolisthereverseoftheG(#5)tool;itispositionedfirstinlineandnevermoves .Itisstationedatthestrongestareaofthetoolbars--wheretheyarefastenedtothebulkheadofthemachine .Thisproducesthestapleflapattheleftsideoftheductboardasitpassesthroughthemachine,formingaconsistentlycleanstapleflaprequiringlesshandlabortoremoveglassfibers .Cut-offismadenexttotheR1tool(whichisthereverseofthe#1,orF,tool)where½"ofthethicknessofthefiberglassremainsadheredtothefoilfacing .Thisresultsinacleanercut-off .ItismucheasiertosettheA(#8)toolproperlyandlockitinplace,neverhavingtomoveit,thanitistoworkwiththeproblemspresentedbytheG(#5)tool .
ThereisanaddedbenefitforoperatorsusingCloseMasterma-chinestocloseandtapethelongitudinalseamsofductsections .IfPreferredtoolingisused,thefactoryfemaleendoftheductsection(theendonwhichthefoilfacingisadheredtothefiberglass)enterstheGlassMastermachinefirst .IftheStandardtoolingset-upisused,themaleendwithitsloosefoilfacingflapenterstheCloseMastermachinefirst,oftenleavingtheoperatorwithapartiallyclosedductmodulebecausetheclosuretapeisnotpickedupimmediately .Forthisreason,reversetoolingmustbeusedforclosingmoduleswiththeCloseMastermachine .Thetoolsmaybe#8,3,2,3,R1orA,B,C,D,E,SCO .
Tooling arrangements
Fig .19 .ReverseToolingArrangement
E
SCO
D
C
B
A
Fig22 .Reversetoolingcut
�2_��
![Page 15: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/15.jpg)
Tooling arrangements
Tool arrangements for one-piece duct
Preferred(Reverse)
A 8" B 10" C 8" D 10" E SCO
8 8" 3 10" 2 8" 3 10" R1 SCO
Standard
1 10" 2 8" 3 10" 4 8" 5 SCO
Tool arrangements for two-piece "U" style duct
Preferred(Reverse)
F 10" B 8" C 10" E SCO
Fillercap: A 8" G SCO
1 10" 3 8" 2 10" R1 SCO
Fillercap: 8 8" 5 SCO
Standard
1 8" 2 10" 3 8" R1 SCO
Fillercap: 8 10" 5 SCO
Toolsshouldbearrangedandspacedaccordingtothefollowingchartstoaccomplishthesecuts .Thesedimensionsarecriticalforcorrectfittingfabrication .Theexampleshownwillproducea10"x8"(254mmx203mm)ductmodule .
![Page 16: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/16.jpg)
Knauf Air Duct Fabrication Manual ��
Grooving Machine
Tooling arrangements
Tool arrangements for two-piece "L" style duct (two sections required)
Preferred (Reverse)
A 8" B 10" E SCO A 8" B 10" E SCO
8 8" 3 10" R1 SCO 8 8" 3 10" R1 SCO
Standard
1 10" 2 8" 5 SCO 1 10" 2 8" 5 SCO
�4_��
![Page 17: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/17.jpg)
V-Groove ToolingAllofthepossibletoolingarrangementsformodifiedshiplapcanbeaccomplishedutilizingtheV-grooveconceptwiththeexceptionoffour-pieceduct .ThetwomajorproblemswiththeV-grooveconceptarethatfittingsaremoredifficulttofabricate(somearenotpossible)andthefinishedductsystemhaslessstructuralintegritythanwiththemodifiedshiplapmethod .ThemachineshowninFigure24issetuptofabricatean8"x10"(203mmx254mm)one-pieceductsection .
Tooling arrangements
V-Groove Tooling Set-up ToolarrangementsfortheotherpossibilitiesusingtheV-grooveconcept .
V-Groovetoolingforone-pieceduct
1 10" 90° 8" 90° 10" 90° 8" 5 SCO
V-groovetoolingfortwo-piece"U"styleduct(2pieces)
1 10" 90° 8" 90° 10" R1 SCO 8 8" 5
V-groovetoolingfortwo-piece"L"styleduct(2piecesrequired)
1 10" 90° 8" 5 SCO 1 10" 90° 8" 5 SCO
ReversetoolingcanbeutilizedwitheithershiplaporV-groovecuttingmethods .Allone-piece,two-piece"L",andtwo-piece"U",plusendcaps,canbemadeusingReversetooling .
Fig .24 .V-GrooveToolingArrangement
![Page 18: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/18.jpg)
Knauf Air Duct Fabrication Manual ��
Grooving Machine
Parts Replacement
Fig .23 .Newtoolwithslottedscrewholes,heavygaugemetal
�6_��
SomemodificationsareavailableinrecentGlassMastermachinecomponents .Asmentionedinthesectiononrollerrepair,replace-mentemeryclothandsprayadhesiveareavailable .Straightcut-offtoolshavebeenredesignedandshiplapbladeshavebeenslightlychanged .Newertoolshaveslottedscrewholesandaremadeofheaviergaugemetal .Manyoldertoolsbecomebentandmaybehardtosetandadjust .Toremedytheproblemwitholdertools,replacementrubberheadedboltsandmodifiedclampsarealsoavailable .Moresignificantchangeshavebeenmadetothetoolholders .Forfurtherinformation,consultyourdistributororGlassMasterCorporation .
Replacementpartsandbladesmaybeobtainedfromyourlocaldistributororfrom:GlassMasterCorporation,2420McIverLane,Suite101,Carrollton,TX75006-6500Tollfreephone:(800)874-9135 .Fax:972-247-0477 .Website:www .glass-master .com
![Page 19: 1 , 1 Glass Master Grooving Machine Adjustments Manual · Preferred (Reverse) Tooling . ... Take up slack in chain and tighten chain idler . Fig . 5 . Pinch roller height adjustment](https://reader034.fdocuments.in/reader034/viewer/2022050314/5f77086ee69ef54e0061e847/html5/thumbnails/19.jpg)
At Knauf, we manufacture a wide variety of products that serve a common goal, helping to make the most of our planet’s energy resources. A family-owned global company, we understand and are committed to high standards in quality, performance and environ-mental responsibility. Every step we take today toward energy conservation helps ensure better lives for generations to come.
leed eligible Product Use of this product may help building projects meet green building standards as set by the Leadership in Energy and Environmental Design (LEED) Green Building Rating System. Credit 4.1 - 4.2 Recycled Content Credit 5.1 - 5.2 Regional Materials
NOTESKnauf Insulation GmbH complies with ISO 9002 in the prevention, detection and correction of problems in production and service areas.
Knauf Insulation GmbH One Knauf driveShelbyville, IN 46176
Sales and Marketing (800) 825-4434, ext. 8283
Technical Support (800) 825-4434, ext. 8212
Customer Service (866) 445-2365
Fax (317) 398-3675
World Wide Web www.KnaufInsulation.com
©2006 Knauf Insulation GmbH.