Operating Manual
STI-2807
STI-2817LP
STI-2817LP
STI-2807
Substrate Technology, Inc.
1384 Bungalow Rd.
Morris, IL 60450 USA
(815) 941-4800
(815) 941-4600 Fax
www.substratetechnology.com
[12.09]
Operating Manual STI-2807 | STI-2817LP
Table of Contents
1.0 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.0 Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.0 Starting Up the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.0 Operation of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.0 Troubleshooting / Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.0 STI Reference Guide & Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Please note: The following safety instructions must be followed
as shown in this operating manual. Failure to do so may result
in hazard to health or possible death.
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STI-2807 | STI-2817LP Operating Manual
1.0 Technical Data
1.1 Rating
1.2 Unit Specifications: STI-2807
1.3 Unit Specifications: STI-2817LP
1.4 Operative Range and Correct Usage
1.5 Stand-by Power Supply (Generator) (STI-2807 only)
1.6 Advice for Operators of Grinding Machines
1.7 Machine Type Designation
1.1 Rating
Machine: Prep/Master® Grinder
Machine-Types: STI-2807 | STI-2817LP
Manufacturer: Substrate Technology
1384 Bungalow Rd.
Morris IL 60450 USA
(815) 941-4800
www.substratetechnology.com
1.2 Unit Specifications: STI-2807
Dimensions:
Length 63 in 160 cm
Width 28 in 71 cm
Height 50 in 127 cm
Weight 684 lbs. 310 Kg
Connected loads of the electrical system:
Power 7.5 HP
Electrical Connection 230V/50-60Hz-1 Phase or 3 Phase
2
400V/50-60Hz 3-Phase
depending on ordered unit
Operating Manual STI-2807 | STI-2817LP
1.3 Unit Specifications: STI-2817LP
Dimensions:
Length 72 in 183 cm
Width 28 in 71 cm
Height 53 in 135 cm
Weight 585 lbs. 265 Kg
1.4 Operative Range and Correct Usage
The safety instructions must be followed as shown in this operating manual.
Failure to do so may result in hazard to health or possible death.
The Prep/Master® STI-2807 | STI-2817LP is designed to be used on clean, dry
or wet horizontal surfaces without obstacles. The machine can not be used for
other purposes. The manufacturer will not be liable for damages resulting from
such incorrect usage. In case of wrong usage the user is responsible for all risks.
1.5 Stand–by Power Supply (Generator)
If the Prep/Master® STI-2807 is operated using a generator, the generator
must be operated in accordance with the current local electrical directives (this
applies in special to the protective ground conductor) in order to ensure that all
safety devices are functioning and to be able to eliminate possible damage to
electrical components.
1.6 Advice for Operators of Grinding Machines
During the operation of the Prep/Master® STI-2807 | STI-2817LP it may be
possible to exceed the acceptable noise level of 85 dB(A). This is dependent on
the different locations and the local circumstances. When the noise level is 85
dB(A) or more, the machine operator and others working near the machine must
wear sound–insulating devices.
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STI-2807 | STI-2817LP Operating Manual
1.7 Machine Type Designation
Machine Type: Prep/Master® STI-2807 | STI-2817LP
Working Width: 28 in / 71 cm
Drive: Manual
Grinding Capacity: Variable
Dust Hose Connection: 3 in / 8 cm
2.0 Safety Instructions
2.1 Explanation of Warnings and Symbols
2.2 Organizational Measures
2.3 Personnel Selection and Qualification
2.4 Safety Precautions Applicable to Different Operating Conditions
2.5 Repair Work, Maintenance Activities, and Default Repair on the Job Site
2.6 Definition of the Safety-off Position
2.7 Dangerous Aspects of the Machine
2.8 Electrical Engineering Regulations
2.9 Special Instructions
The following safety instructions must be followed as shown
here. Failure to do so may result in hazard to health or possible
death.
2.1 Explanation of Warnings and Symbols
The following symbols are used in the operating instructions to highlight areas
of particular importance:
Operational Safety
This symbol will be shown in these Operating Instructions next to all safety
precautions that are to be taken in order to ensure prevention of injury. Follow
these instructions and take special care in these circumstances. In addition to
these instructions, the general safety precautions and the local accident prevention
guidelines are also to be followed. Please check, whether there are special
regulations for the particular job site.
Safety Goggles/ Ear Protection
Information, instructions, and restrictions with regards to possible risks to persons
or extensive material damages.
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Operating Manual STI-2807 | STI-2817LP
Electrical Warning
Warning against dangerous voltages.
2.2 Organizational Measures
The Operating Instructions are to be kept near the location where the machine is
located and must be accessible all the time!
In addition to the Operating Instructions general and legal regulations regarding accident
prevention and environmental protection must be with and indicated every time!
Such duties may for example relate to the handling of hazardous substances or to the
provision and wearing of personal protection equipment as well as compliance with local
traffic regulations.
The Operating Instructions must be supplemented by instructions including the duty
to supervise and report relating to particular local working practices, for example work
organization, work procedures, and personnel allocation.
Personnel entrusted with working with the machine must have read the Operating
Instructions before starting the work; in particular the chapter about Safety Instructions.
These have to be read before starting any work with the machine. This particularly applies
to incidental activities such as setting up the machine, carrying out maintenance work, or
training staff to work with the machine.
From time to time the working practices of the staff are to be checked regarding awareness
of safety and hazards.
Personnel must tie back long hair and not wear loose clothing or jewelry and rings. There is a
risk of injury through getting stuck or being drawn into moving machinery.
Use personal protection equipment if necessary or required by regulations!
Take notice of all safety and hazard notices on the machine.
All safety and hazard notices on the machine must be kept complete and legible.
If safety-critical changes occur to the machine or its performance, the machine must be shut
down immediately! The cause of the fault has to be established immediately and has to be
repaired before starting the work again.
Changes, add-ons, or conversions of the machine which might have an influence
to the safety of the machine must not be undertaken without the permission of the
manufacturer.
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STI-2807 | STI-2817LP Operating Manual
This applies in particular to the fitting and adjustment of safety devices and to welding on
major and load bearing parts.
Spare parts must always comply with the technical requirements and the specifications of the
manufacturer. This is always guaranteed with original spare parts of the manufacturer.
Inspection intervals and intervals for recurring checks specified in these Operating
Instructions must be complied with. At the same time it is necessary to meet the legal
requirements.
To perform maintenance work correctly it is important to be equipped with proper tools for the
task in question.
The location and the operation of fire extinguishers must be made known on each building
site!
Take note of the facilities for fire reporting and fighting fires!
2.3 Personnel Selection and Qualification
Fundamental duties:
Only reliable personnel are allowed to work on the machine
Only trained personnel can be used to operate the machine. Note the statutory minimum
age! Specify clearly the responsibilities of personnel for operation, setting up, servicing and
maintenance work!
Make sure that only authorized personnel operate or work on the machine.
Select clearly the machine operator. Define his/her responsibilities also with regard to traffic
safety regulations and empower him/her to decline instructions from third parties which are
not complying with the safety requirements.
Personnel being trained or made acquainted with the equipment may only be deployed under
constant supervision of an experienced person.
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.
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Operating Manual STI-2807 | STI-2817LP
2.4 Safety Precautions Applicable to Different Operating Conditions
Avoid any method of working that impairs safety!
All precautions have to be taken, that the machine will only be used in a safe and functional
status.
Only operate the machine when all safety devices and related safety
equipment, e.g. detachable safety devices, emergency stops, and suction
devices are present and operational!
The machine has to be checked visually at least once a day for any damage and defects.
In the event of operational malfunctions the machine must be shut down immediately and
secured. The fault must be rectified before starting the machine again!
Secure the work area around the machine in public areas providing a safety
distance of at least 10 feet around the machine.
Fault must be rectified immediately!
Start up and switch off operations and control devices have to be handled in accordance with
the Operating Instructions.
All persons in the proximity of the machine must wear safety glasses with
lateral protection as well as safety shoes. Ear protection may be required. The
operator is obliged to wear close fitting protective clothing.
Use only extension cables for extending the main cable that are sized and marked
in accordance with the overall power consumption of the machine and the valid
local guidelines..
Before starting the machine make sure that nobody can be endangered when the machines
starts running.
Do not switch off or remove the exhaust and ventilation devices from the Prep/
®
Master
sensor must be addressed immediately and machine must be shutdown until
fault is rectified. Ignoring this safety directive can result in hazard to health
or possible death.
2817! Any fault (red light on dash board) of the emissions control
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STI-2807 | STI-2817LP Operating Manual
2.5 Repair Work, Maintenance Activities, and Default Repair on the Job Site
Before starting any servicing work on the machine, put the machine in the
Safety off position as described in chapter 2.6 in order to prevent the machine
from being switched on accidentally.
Please follow any special safety instructions in the various chapters on servicing the
machine. (See chapter 7.)
Adjustments, servicing, and inspection work and inspection intervals specified in these
Operating Instructions as well as any information on the replacement on parts and systems
of the machine must be undertaken and / or complied with.
These activities can only be undertaken by qualified personnel.
Before starting any maintenance or repair work the operator of the machine has to be
informed about it.
During all work related to the use, the re-erection or the adjustment of the machine and of
the safety devices as well as inspection, maintenance and repair, the start up and shut off
procedures have to be done in accordance with the Operating Instructions.
For the machine to be shut off completely for repair or maintenance work the plug has to be
disconnected in order to prevent the machine from being switched on accidentally.
The dust bin of a connected dust collector has to be emptied before transportation. Please
handle in accordance with the regulation how to dispose the dust and make sure that you
meet the local regulations.
Do not use any aggressive cleaning materials!
Use lint-free cleaning cloths.
Always tighten any screw connection that is undone during servicing and maintenance work.
If safety devices need to be dismantled during setting up, servicing and repair work, these
safety devices must be reinstalled and inspected immediately after completion of the
servicing and repair work.
Make sure that process materials and replacement parts are disposed of safely and in an
environmentally-friendly manner!
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.
Make sure that electrical components used for replacement purpose comply with the original
parts and are correctly adjusted if necessary.
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Operating Manual STI-2807 | STI-2817LP
2.6 Definition of the Safety-off Position
Definition:
The safety off position is the position of the machine when it cannot generate any hazard.
Putting the machine in the safety-off position means:
Switch off the grinder.•
Switch off the dust collector.•
Wait for standstill of all drives.•
Pull out main plugs (STI-2807). / Turn off propane supply at tank and remove key from •
ignition (STI-2817LP).
Secure the machine against unintended start up.•
2.7 Dangerous Aspects of the Machine
Every machine, if it is not used according to the regulations, may be hazardous
for operating, setting-up and service personnel. The operating authority is
responsible for compliance with the safety regulations during operation and
maintenance of safety devices supplied with the machine as well as the
provision of appropriate additional safety devices.
2.8 Electrical Engineering Regulations
Never start machine in the tilted position. The machine must only be started
when all guards and dust collection parts are attached and machine is
standing flat on work surface.
Work on the electrical parts of the equipment may only be undertaken by a
skilled electrician or by a trained person under the guidance and supervision
of a skilled electrician as well as in accordance with the electrical engineering
regulations.
Use only extension cables for extending the main cable that are sized and
marked in accordance with the overall power consumption of the machine and
the valid VDE guidelines. In case there is any question ask the manufacturer
or a skilled electrician.
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STI-2807 | STI-2817LP Operating Manual
If work on electrified parts is necessary, a second person must be deployed who
can pull out the plug in an emergency. The working area must be sealed with
a red and white safety chain and a danger sign. Use tools that are insulated
against voltages.
Only start work, once you are familiar with the electrical engineering regulations
that apply to your area.
Only use voltage testers that comply with the regulations when troubleshooting.
From time to time check voltage tester to ensure that they are operationally
efficient.
2.9 Special Instruction
Use only proper and default free tools for your work. Damaged tools have to be repaired
immediately or to be replaced.
Use during your work for your own safety the required safety equipment and safety clothes
(e.g. safety glasses, safety shoes, safety gloves).
Please instruct your operators and the repair personnel about the following
points:
Cleaning and repair work are only allowed if the machine is shut off (safety off position).•
During work on the machine, be certain that the machine cannot be started.•
Opening or removing safety devices while the machine is running are not allowed.•
Replace all safety covers and devices after cleaning, repair, and maintenance work.•
Do not touch moving parts and do not walk into the working path of the machine. •
Before restarting machine, make sure all personnel are a safe distance away from the •
work area after initial start up.
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Operating Manual STI-2807 | STI-2817LP
3.0 General Information
3.1 Operative Range
3.2 Scope of Supply
3.3 STI-2807 (Electric Model) Exploded Diagram & Part Numbers
3.4 STI-2817LP (Propane Model) Exploded Diagram & Part Numbers
3.5 STI-2817LP Controller Exploded Diagram & Part Numbers
3.6 STI-2807 Operating Features
3.7 STI-2817LP Operating Features
3.8 Electric Motor (STI-2807 only)
3.9 Cutting Area
3.10 Couplers & Tool Plates / Stone Holders
3.11 Variable Speed Drive (STI-2807 only)
3.12 Tool Change
3.13 Care & Maintenance
3.1 Operative Range
The STI Prep/Master® STI-2807 | STI-2817LP is a grinding machine with counter rotating
heads that is used for preparation and polishing of horizontal surfaces. Grinding the surface
according to STI specifications thoroughly removes surface contaminants, coats of paint,
sealants, and thin coatings.
A suitable filter unit must be connected to the machine in order to thoroughly collect the dust
being produced by the grinding process. The proper dust collection system ensures dust-free
operation of the machine and clean air at the workspace. STI recommends the STI Planet
Vac dust collector.
3.2 Scope of Supply
Provided with machine:
Prep/Master•
®
STI-2807 | STI-2817LP
Manual (1)•
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STI-2807 | STI-2817LP Operating Manual
3.3 STI-2807 (Electric Model) Exploded Diagram & Part Numbers
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Operating Manual STI-2807 | STI-2817LP
Item # Qty. Part # Description [for STI-2807 (electric)]
102 2 2807-102 Electrical Connector
103 1 2807-103 Stainless Steel Water Tank
104 1 2807-104 7.5HP/230V Variable Speed Drive
105 1 2807-105 6/4 Power Cable - 25 ft.
106 1 2807-106 6/4 Power Cable - 5 ft.
107 3 2807-107 Electric Elbow
108 1 2807-108 Water Valve
109 2 2807-109 Handle Caster
110 2 2807-110 Main Caster
111 1 2807-111 Axle
112 2 2807-112 3 in. Vacuum Hose (25 ft.)
113 1 2807-113 Rubber Dust Band
114 2 2807-114 Handle Grips
115 4 2807-115 Rubber Isolation Mounts
116 4 2807-116 Clevis Pin
117 1 2807-117 2807 Prep/Master
118 4 2807-118 Pocket Weights
119 1 2807-119 Stainless Steel Adjustable Shroud
120 2 2807-120 Adjustable Shroud Clamps
121 2 2807-121 Weight Basket
122 1 2807-122 Emergency Stop Button
123 4 2807-123 Leveler Clamps (Same part as 2807-120)
®
Handle Assembly
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STI-2807 | STI-2817LP Operating Manual
3.4 STI-2817LP (Propane Model) Exploded Diagram & Part Numbers
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Operating Manual STI-2807 | STI-2817LP
Item # Qty. Part # Description [for STI-2817LP (propane)]
1 1 GEAR BOX GEAR BOX
2 1 MP120800 BATTERY, DEKA, SEAMATE, AGM
3 1 MP4787 CLUTCH, ASM., MODEL 5215-63
4 1 MP333800 REGULATOR, CG2/Z2, ASM.
5 10 NB6501 INSERT, 1/4-20, COMPRESSION TYPE
6 2 MP296401 PANEL, ACCESS, FINISHED
7 10 NB025700 WASHER, LOCK, 1/4"
8 10 NB026000 BOLT, HEX, 1/4-20 x 1", SS
9 1 MP106000 CYLINDER, PAINTED, STEEL, W/DECAL, SAFE
10 1 MP344900 PULLEY, 6", W/ 1.5" BORE
11 1 MP281500 TANK, WATER
12 1 MP344200 BRACKET, TANK, LP
13 1 MP344501 PLATE, COVER, FRONT
14 1 MP113600 SOLENOID, 12V, SIDE TERMINAL
15 1 MP071800 TENSIONER, PULLEY, 3", ASM.
16 4 WEIGHT BASKET WEIGHT BASKET
17 3 NB049300 SCREW, FLANGE, 1/4-20 X 1/2, ZINC
18 1 MP345001 PLATE, SPACER, TENSIONER
19 1 MP344601 BRACKET, ENGINE
20 1 MP344101 BRACKET, WATER TANK & DASH
21 1 MP120500 BRACKET, MUFFLER, MEAN MACHINE
22 3 NB9845 NUT, KEPS, 1/4-20
®
23 1 Handle PREP/MASTER
24 1 MP041 100 STRAP, T ANK
25 1 MP344800 ENGINE, KAW., 17HP, PREP/MASTER®, ASM.
26 1 MX1080 WASHER, FLAT, 3/8
27 3 MX1075 WASHER, LOCK, 3/8"
28 1 NB6044 SCREW, CAP, 3/8 X 1 1/4
29 4 NB025000 BOLT, HEX, 5/16-18 X 1 1/2", SS
30 4 NB026300 NUT, LOCK, 5/16", SS
31 1 NB8130 CLAMP, 3/4" ID, RETAINER
32 1 MP152800 GASKET, FLAT, EPDM, CAP, SCREW
33 1 MP152700 CAP, SCREW, 6"
34 2 NB6851 SCREW, CAP, HH, 3/8-16 X 3/4
35 1 MP273200 STRAP, BATTERY, ADJUSTABLE
36 1 MP300800 VALVE, WATER, ASM.
37 1 MP8038 BELT, BX-38 (FOR USE ON STI-2817)
HANDLE ASM.
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STI-2807 | STI-2817LP Operating Manual
3.5 STI-2817LP Controller Exploded Diagram & Part Numbers
Item # Qty. Part # Description
1 1 MP290400 CABLE, CONTROL, FLOW, 20"
2 1 KC2509904 SWITCH, STARTER
3 1 MP180000 SWITCH, ROCKER, 12V, DPST, W/LIGHT
4 1 MP280400 METER, HOUR/TACH, PANEL MOUNT
5 4 NB9510 NUT, SPIN LOCK, 10-24
6 1 MP246100 CABLE, THROTTLE, 62"
7 1 MP344700 DECAL, DASH, PREP/MASTER
8 1 MP345100 MODULE, SAFE-SENSE, BASIC, ASM
9 2 NB008600 SPACER, NYLON, .50 O.D., .25 I.D., 1 L
10 2 NB027500 SCREW, #10-24 x 1-1/2", SS
11 2 NB034100 SCREW, PAN HD, #10-24 X 1/2", SS
12 1 MP341100 SWITCH, KILL, ENGINE, W/LANYARD
13 1 SA023400 LED, REPLACEMENT, KIT
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®
Operating Manual STI-2807 | STI-2817LP
3.6 STI-2807 Operating Features
The Variable Speed Drive is carrying all controls and instruments used for supervision and
control of the machine.
Key Button Controls Start/ Stop
Pushing the Key Button "Start" will switch the controls on and start the motor. Pushing the
Key Button “Stop” will stop the motor running.
Arrow up and Arrow Down
While powered but without the motor running, the red Arrow Up and red Arrow Down buttons
can be used to set the motor speed faster or slower than the base RPM of the motor.
Rotation
While powered but without the motor running, the “Rotation” button is used to change the
rotation of the motor. Press the “Rotation” button and press “Enter” within 2 seconds to
change the motor rotation. To change back to previous rotation repeat the process
Auto/Man and Prog/Run
These buttons are used for drive diagnostics and programming and are not used.
Emergency Stop Button
The Emergency Stop Button is intended to be used for the safety of the operator and
protection of the machine from excess damage in the event of an emergency. The Lanyard
must be worn by operator for this safety device to work properly.
Manual On/Off Switch – If Equipped
The On/Off switch is used to turn off all power supplied to the grinder.
3.7 STI-2817LP Operating Features
Key Controls Start/ Stop
Turning the key to "Start" will start the motor. Pushing the Rocker Switch will engage the
clutch and start tools turning.
Kill Switch
Kill Switch is intended to be used for the safety of the operator and protection of the machine
from excess damage in the event of an emergency. Push the Kill Switch to shut down the
motor.
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STI-2807 | STI-2817LP Operating Manual
3.8 Electric Motor
The power plant of the Prep/Master® STI-2807 grinder is the electric motor. The
motor is responsible for turning the gears which turn the abrasive tools on the
floor. The motor is controlled exclusively by the Variable Speed Drive which inputs
specific power to generate a given RPM.
3.9 Cutting Area
The area inside the stainless steel shroud and directly beneath the gear deck is the cutting
area. This is the area in which the tools turn to produce the grinding action. It is also the area
that keeps the dust from grinding contained and subsequently evacuated through the dust
collection ports.
3.10 Couplers & Tool Plates / Stone Holders
The grinder is outfitted with couplers and tool plates OR stone holders. The couplers attach
to the tool plates and provide flex for smooth operation of the diamond tools. The tool plate/
stone holder holds the tools in place for the grinding application.
3.11 Variable Speed Drive
The variable speed drive is responsible for monitoring incoming power as well as
changing the electronic frequency to allow the motor to run at different speeds.
This unit is a closed panel that is intended to be operated only with the keypad.
3.12 Tool Change
In order to change the tools, the operator must first ensure that the grinder is switched off
and disconnected from the electrical source. The operator should then place all the saddle
weights provided in the weight holders on either side of the variable speed drive.* Then push
machine down by the handle in a controlled manner until the grinder is resting on the top
casters. The operator then loosens the attachment hardware holding the abrasive tools in
place and re-installs with preferred abrasive tool.
* Machine must only be tilted back on firm, level surface. There is danger of machine falling if
all weights are not used and surface is not level.
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Operating Manual STI-2807 | STI-2817LP
3.13 Care & Maintenance
Special attendance and regular maintenance of the machine and its parts are imperative for
functioning and safety.
In order to prevent unnecessary downtimes it is recommended to keep original spare and
wear parts on stock.
The following maintenance should take place before and after every operation of
machine:
Clean all surfaces with a dry, lint free cloth.1.
Inspect all electrical cables/wires for cuts and replace damaged cords.2.
Check all electrical connections are secure and snug.3.
Inspect gear box for any signs of oil leakage and repair as required.4.
Verify functionality of Kill Switch.5.
All persons in the proximity of the machine in operation must wear safety
glasses with lateral protection and safety shoes. The machine operator must
wear close-fitting protective clothing.
4.0 Transportation Instructions
4.1 General Notes
4.2 Transportation
4.3 Transportation by Vehicle
4.4 Operation Conditions
4.1 General Notes
Before the machine used for the first time, STI authorized dealers offer a course to familiarise
maintenance and operating personnel with all elements of the machine. We are not liable for
damage caused by incorrect use of the machine by personnel not trained by STI.
4.2 Transportation
In order to transport the machine from a vehicle to the working area, you need to tilt the
machine down. In order to do so, place the pocket weights in the weight baskets and tilt the
machine back so it rests on the back casters.
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STI-2807 | STI-2817LP Operating Manual
When transporting the machine with hoisting equipment like a crane or a lift, check the total
weight permitted. (See Chapter 1 — dimensions)
Please use only appropriate, allowed, and qualified hoisting equipment as well as ropes and
chains. You will find the weight of the equipment in chapter 1 or on the serial plate on the
machine.
Do not fix any rope or chain to the handle. The machine must be placed on a pallet or
platform designed to hold the weight of the machine and the platform or pallet can then be
lifted or hoisted from the appropriate points.
4.3 Transportation by Vehicle
When transporting the machine with vehicle, proceed in such a manner that damage due to
the effects of use of force or incorrect loading and unloading is avoided. Use straps to tighten
the machine to the cabin of the vehicle.
Use at least two straps, or tighten the machine with one strap to the cabin wall of the vehicle.
Make sure, that all parts of the machine are fixed.
4.4 Operation Conditions
Check the surface to be treated for loose parts (stones, screws, etc.). The surface must
be swept if necessary. Make sure that the machine can travel over all inequalities on the
surface. Small inequalities like floor joints less than ¼ inch are no barriers for the machine.
The machine must be operated in accordance with instructions given in Chapter 5—Initial
operation.
5.0 Start Up
5.1 Preparing for Initial Operation
5.2 Initial Operation: STI-2807
5.3 Initial Operation: STI-2817LP
5.1 Preparing for Initial Operation
Before start up ensure all existing protective housings are fitted and the filter unit is
connected correctly.
All persons in the proximity of the machine must wear safety glasses with
lateral protection as well as safety shoes. The operator is obliged to wear
close-fitting protective clothing.
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Operating Manual STI-2807 | STI-2817LP
Work on the electrical system have to be done only by qualified specialists.
Check the surface to be treated; it should be free of for loose parts (stones, screws,
etc.). The surface needs sweeping if necessary. Ensure that the machine can run over all
inequalities on the surface. Small inequalities like floor joints aren’t a barrier for the machine.
In order to avoid downtimes a regular inspection is essential. Carry out the
following checks before any start-up:
Check whether all machine parts are assembled safely and correctly. •
Check all screws and other fasteners for tight seat. •
Check the tool holders to ensure that the proper tools are in place and secure. •
Check the tightness of the hose connections and the condition of the hose to the filter. •
Make sure the dust container of the filter unit is empty. Please comply with the local waste •
treatment regulations considering the removed material.
Check the electrical connections for dirt and foreign body deposits. •
Check the motor for dirt and other contaminants. •
Before start-up operators and other personnel must be familiar with the safety
regulations given in this manual.
Place the grinder in the area where work is to begin.1.
Place weights on grinding head beside motor.2.
Check the main power cable and the dust hose for damage. Replace or repair all 3.
damaged parts before starting the machine.
Connect the grinder and the filter unit with the dust hose. Use hose clamps at the 4.
connections.
5.2 Initial Operation: STI-2807
All persons near the machine must wear safety glasses with lateral protection,
ear protection as well as safety shoes. The operator is obliged to wear close
fitted protective clothing.
Before start-up the operating personnel must be familiar with the safety regulations given in
this manual.
Attention! Before you plug the equipment to a power supply make sure the
power supply is equivalent to the data shown on the machine label.
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STI-2807 | STI-2817LP Operating Manual
The start of the grinder and the filter unit is affected in the following sequence:
Switching on the filter unit1.
Initial operation of the grinding machine:
Assure the plug is connected correctly to the power source.1.
Assure the dust hose is connected correctly to filter and machine.2.
Check that the main switch is turned on and the dead man switch is in place with the 3.
lanyard around the operator’s wrist.
Press the ‘Start’ button.4.
Immediately begin moving the machine from side to side to prevent the tools from 5.
digging into the concrete surface and creating an uneven profile. For the operation of
the running machine, it is necessary to move the machine from side-to-side to create an
even profile that is consistent in flatness and profile.
When grinding in work area is complete, push the ‘Stop’ button to stop the grinding 6.
motor.
The dustbin of the filter unit needs regular dumping.7.
Do not overfill the bin to avoid dust exposure when opening the bin. Comply with the
local waste treatment regulations considering the removed material.
5.3 Initial Operation: STI-2817LP
All persons near the machine must wear safety glasses with lateral protection,
ear protection as well as safety shoes. The operator is obliged to wear close
fitted protective clothing.
Before start-up the operating personnel must be familiar with the safety regulations given in
this manual.
The start of the grinder and the filter unit is affected in the following sequence:
Switching on the filter unit1.
Initial operation of the grinding machine:
Assure the fuel supply is on and is connected correctly to the fuel tank.1.
Assure the dust hose is connected correctly to filter and machine.2.
Check that throttle is in idle position.3.
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Operating Manual STI-2807 | STI-2817LP
Ensure the Rocker Switch is on the “off” position.4.
Turn the ignition key.5.
Once the digital display reads 2,000 RPM, push the Rocker Switch.6.
Immediately begin moving the machine from side to side to prevent the tools from 7.
digging into the concrete surface and creating an uneven profile. For the operation of
the running machine, it is necessary to move the machine from side-to-side to create an
even profile that is consistent in flatness and profile.
Throttle up to the desired speed.8.
When grinding in work area is complete, throttle down to 2,000 RPM and push the 9.
Rocker Switch.
Turn off ignition key and fuel supply.10.
The dustbin of the filter unit needs regular dumping.11.
Do not overfill the bin to avoid dust exposure when opening the bin. Comply with the
local waste treatment regulations considering the removed material.
6.0 Operation
6.1 Daily Operation
6.2 Failure
6.3 Safety Switch Off
6.4 Restart
6.1 Daily Operation
Normal start-up and operation of the Grinder is not different as has been described in
Chapter 5—Initial operation.
Carry out grinding operation in parallel tracks in a way that the dust hose and electric cable
do not become twisted.
The speed of moving the grinding machine over the work surface will influence the final finish
and production.
In the case that the surface shows different characteristics, means different hardness or
different coating thicknesses, a uniform grinding result will be achieved by varying the speed
of movement over the surface.
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STI-2807 | STI-2817LP Operating Manual
6.2 Failure
Irrespective of the following information, the local safety regulations are valid in any case for
the operation of the machine.
Assure all turning machine parts have came to standstill before inspection or maintenance
work starts. Always arrange the Safety Off as described in Chapter 2.
6.3 Safety Switch Off
The machine must be set into its “Safety Off Position” before starting any kind
of maintenance or repair work.
See Chapter 2—Safety Instructions.
6.4 Restart
All persons in the proximity of the machine must wear safety glasses with
lateral protection as well as safety shoes. Ear protection may be required. The
operator is obliged to wear close fitting protective clothing.
See Chapter 5—Initial Operation.
7.0 Maintenance
7.1 Recommendations
7.2 Maintenance and Inspection
7.3 Maintenance
7.4 Regular Wear Parts
7.5 Service Schedule: STI-2817LP
7.1 Recommendations
Prior to any repair work on the machine and its drives, secure the machine
against unintentional switch-on. Put the machine to its Safety Off Position as
described in chapter 2.
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Operating Manual STI-2807 | STI-2817LP
Failures due to inadequate or incorrect maintenance may generate very high repair costs and
long stoppage periods of the machine. Regular maintenance is essential.
Safety and service life of the machine depend, among other things, on proper maintenance.
The following table will show recommendations about time, inspection and maintenance for
the normal use of the machine.
The time indications are based on uninterrupted operation. When the indicated number of
working hours is not achieved during the corresponding period, the period can be extended.
Due to different working conditions it cannot be foreseen how frequently inspections for wear
checks, inspection, maintenance and repair works ought to be carried out. Prepare a suitable
inspection schedule considering your own working conditions. Our specialists would be glad
to give you advice.
7.2 Maintenance and Inspection
Operating Hours / Time Period Inspection Points / Maintenance Instructions
Daily — Prior to Operation Check all cables/wires for cuts or damage•
Check the hose connections for tightness and •
fixed seat.
Check the hose to the filter for damages. •
Make sure that the dustbin of the filter has been •
dumped.
Check Morflex Coupler, tool plate, and diamond •
tooling for wear and damage.
Check that shroud and rubber seal are in good •
working condition.
Check the electric connections for sediments of •
dirt or foreign bodies.
Check the electric motor/propane tank for dirt •
and other contaminants.
Check gearbox assembly for any leaks of oil •
from motor and top and bottom of gear box.
Daily — After Operation Check for debris, if any, in the dust ports under •
gear box as well as at handle.
Check for dirt build up on variable speed drive •
and electric motor. (STI-2807 only)
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STI-2807 | STI-2817LP Operating Manual
7.3 Maintenance
Only those repair works are described which occur within the context of maintenance or
which are required to replace wear parts. If you replace parts yourself for specific reasons,
the instructions in section 7.4 and work sequence have to be observed.
You should also stock all spare or wear parts that cannot be supplied quickly. As a rule,
production standstill periods are more expensive than the cost for the corresponding spare
part. Screws that have been removed must be replaced with those of the same quality
(strength, material) and design.
Prior to any repair work on the machine and its drives, secure the machine
against unintentional switching-on. Pull out the main plug in order to do this.
Store the plug near the machine to avoid accidents.
7.4 Regular Wear Parts
Regular wear parts consist of the Morflex Coupler.
To replace a worn or damaged Morflex Coupler perform the following:
Remove ½ inch-20 bolts from drive plate using a ½ inch impact wrench and ¾ inch 1.
socket.
Use pry tool to remove assembly from drive plate.2.
Remove ½ inch-20 bolts from tool plate using a ½ inch impact wrench and ¾ inch 3.
socket.
Use pry tool to remove coupler from tool plate.4.
Replace with new coupler.5.
Replace bolts through new coupler and into tool plate* tighten with impact wrench.6.
Place tool plate assembly onto drive plate with bolts* tighten with impact wrench. 7.
* When replacing bolts, be sure to hand start bolts BEFORE using impact wrench to tighten
down. This minimizes the risk of stripping the threads by tightening an unseated bolt.
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Operating Manual STI-2807 | STI-2817LP
7.5 Service Schedule: STI-2817LP
OPERATION INTERVAL
Daily
Check & add engine oil
Check for loose or lost fasteners
Check for oil leakage
Inspect fuel hose and connections
Clean Engine dust filter
Inspect pad driver
Change Engine Oil
Change engine oil filter
Check & clean primary air filter
Check secondary air filter
Inspect battery and battery connections
Replace Engine primary air filter
Replace Engine Pre-filter
Inspect, clean, & re-gap spark plugs,
Replace if necessary
Check & adjust valve clearance *
Retorque heads *
Clean & lap valve seating surface *
Check engine emissions
Check oil level in front gearboxes
Inspect drive belt
Replace drive belt As Required
* Contact a Certified Technician
First 8
Hrs.
•
•
•
•
•
•
Every
50 Hrs.
Every
100 Hrs.
Every
200 Hrs.
••
••
•
•
•
•
•
•
Every
300 Hrs.
•
•
•
Every
400 Hrs.
Every
500 Hrs.
•
•
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STI-2807 | STI-2817LP Operating Manual
8.0 Troubleshooting / Diagnostics
8.1 Diagnosis of Failures
8.2 Diagnosis of Electrical Failure
8.1 Diagnosis of Failures
Prior to any repair work on the machine or drives, the machine must be secured
against unintentional start-up. Put the machine in its Safety-off position.
Failure Possible Reasons for the
Failure
Unusual Vibrations Uneven or loose surface
being ground
Loose or damaged tooling Inspect tooling to make sure
Unusual Noise Uneven or loose surface
being ground
Loose or damaged tooling Inspect tooling to make sure
Shroud is dragging on the
floor
Corrective Actions
Verify suitability of substrate
being ground.
that all connecting hardware is
tight and tool is firmly seated to
holder.
Verify suitability of substrate
being ground.
that all connecting hardware is
tight and tool is firmly seated to
holder.
Adjust shroud and tighten to no
more than ¼ inch above floor
Reduced performance or
no performance
Dust being produced Shroud is out of adjustment Adjust shroud and tighten to no
28
Diamond tooling is worn or
damaged
Dust hose is clogged Inspect dust hose and ports
Dust collector malfunction Verify dust collector is operating
Inspect diamond tooling for
remaining abrasive. If depleted,
replace with new tooling.
more than 2 mm above floor.
for debris that may be clogging
hose.
properly
Operating Manual STI-2807 | STI-2817LP
8.2 Diagnosis of Electrical Failure
Prior to any repair work on the machine or drives, the machine must be secured
against unintentional start-up. Put the machine in its Safety-off position.
Work on electrical equipment or operating materials may only be undertaken by
a skilled electrician or by trained persons under the guidance and supervision
of a skilled electrician in accordance with the electrical engineering regulations.
Failure Possible Reasons for the
Failure
Motor does not start up Missing Phase/ Battery
Failure
Faulty Switch or relays Get diagnosis and replacement
Emergency Stop / Kill Switch Unlock the Emergency Stop /
Motor stops during
operation
Current power is too high /
Low or no fuel
Supply circuit breaker is
disengaged.
Motor is damaged. Inspect motor.
Call your local dealer if you can’t solve the problem.
Corrective Actions
Check power supply or battery
power
by a skilled electrician
Kill Switch button
Disconnect plug / check fuel
supply
Reset circuit breaker or replace
fuse.
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STI-2807 | STI-2817LP Operating Manual
9.0 STI Reference Guide & Procedures
9.1 Introduction
9.2 Why a Diamond Cuts
9.3 Why a Diamond Doesn't Cut
9.4 Heat & Diamonds
9.5 Super-Abrasive Applications
9.6 Acceptable Cost per Square Foot
9.7 Stone Plug Holders vs. Tool Plates
9.8 Segment Attachment
9.9 Recommended Weight Configurations
9.10 Recommended Speed Settings
9.11 Importance of Concrete Densifiers
9.12 Choosing the Right Diamond Tool for the Application
9.13 Diamond Tooling Offered by STI
9.14 Common Applications and Recommended Procedures
9.1 Introduction
Now that you own the most versatile and reliable surface preparation and polishing machine
on the market, you need to understand the way it gets the job done. Diamond tooling
provided by Substrate Technology has been designed and tested for use with the Prep/
Master® line of machinery exclusively. We have assembled a system that takes the guess
work out of the industry that is Concrete Surface Preparation and Polishing. These products
are proprietary, original creations that are made to work consistently so that you have
success on your first and every concrete grinding or polishing project thereafter.
9.2 Why a Diamond Cuts
A diamond’s ability to cut is directly influenced by weight, speed, and diamond size. As any
one of those factors are reduced or increased the remaining two need to be modified to
accommodate that change without affecting performance. Diamond tooling cuts by using the
aggressive characteristics of synthetic or natural diamonds. As the diamond chip is moved
across the work surface, its inherent strength causes a scratch in the material equal to the
amount which the diamond chip is protruding from the matrix.
The matrix that holds the diamond is very important to the diamond chip’s ability to cut as
well as be retained so that the diamond can be held in place for as long as possible to keep
lifespan at an acceptable level. During the grinding process, the matrix holds the diamond
by eroding away only at the leading edge of the diamond as a function of abrasion, but the
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Operating Manual STI-2807 | STI-2817LP
matrix attached to the trailing edge of the diamond stays intact and provides support to the
diamond as it is pushed through the work-piece.
As the diamond chip wears down from abrasion so does the matrix that is supporting it until
the matrix support is reduced so much that the remaining diamond chip falls out of the matrix.
After a diamond chip falls out, the wearing of matrix repeats to expose a new diamond chip
and the process continues until no matrix or diamond remains.
9.3 Why a Diamond Doesn’t Cut
The easiest way to explain why a diamond doesn’t cut is to say that a given material is
harder than what the diamond was created to grind. The reason why the design is flawed for
a specific material hardness is not so easy to explain.
Possible Causes:
Diamond make-up, that is the individual diamond chip’s mechanical makeup, may be 1.
the culprit in a material being too hard to cut. The diamond chip design may not allow
the diamond to fracture fast enough to maintain an aggressive edge when working on a
hard material.
The concentration of diamond chips in a given tool may be too great or too little; the 2.
more diamond chips touching the floor the less the pressure on each chip and viceversa.
The matrix strength may be too strong to release the diamonds at a consistent rate to 3.
always allow a fresh diamond chip to become exposed to the work-piece.
The speed at which the diamond tool is being moved across the surface may be too 4.
fast or too slow for its design thereby causing excess heat.
The weight may be more or less than what the diamond tool was designed to handle 5.
and without the proper amount of pressure the diamond tool is being run outside of its
designed operating limits.
The diamond chip size may be too small or large for the given work-piece and its 6.
inherent hardness characteristics.
Whatever the reason the diamond tool is failing, correcting the problem is usually as easy as
adding water to the equation; because heat, in most cases, inhibits the cutting ability of the
diamond tool.
9.4 Heat and Diamonds
Heat plays a crucial role in the life and cutting characteristics of any diamond tool because
just like a metal cutting tool there is an optimal temperature at which it is designed to operate.
When a diamond is moved across a surface, heat is being produced by the friction caused by
the tool movement and therefore it is impossible to prevent some heat being created.
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STI-2807 | STI-2817LP Operating Manual
With regard to acceptable heat levels, diamond tools are designed to dissipate heat by
transferring heat at a given rate so the cutting ability or lifespan is not compromised. The
diamond tool transfers heat into the metal that holds the diamonds and matrix and eventually
into the tool holder.
The diamond tool also transfers heat as a function of cutting the concrete or stone into
small chips that then carry the resultant heat with them away from the diamond tool (i.e.
Chip Clearance). When one or both of these temperature regulators are not performing in
the way they were designed, the diamond tool stops cutting or keeps cutting but lifespan is
reduced drastically. The best indicator that a diamond tool is operating outside its required
temperature range is when the diamond tool cannot be held in a bare hand.
9.5 Super-Abrasive Applications
When a diamond tool is used on a surface that is softer than that which it was created to cut,
the productivity will be high but so will the diamond cost per square foot.
Examples of super-abrasive applications – thin-set mortar, cementitious, or gypsum based
underlayment, epoxy coatings containing silica, soft concrete (carbonized or rain slab) and
soft natural stone such as limestone.
9.6 Acceptable Cost per Square Foot
Diamond tooling should be costing the equipment owner between $.03 & $.05 per square
foot for each type of diamond tool being used. So if there is a project that requires 4 polishing
steps, the diamond cost should be $.12 - $.20 per square foot ($.03 - $.05 per square foot/per
diamond type x 4 total types) overall. This is a general guideline, but it is important to always
strive for tool choices that yield close to this amount to keep cost at an acceptable level.
9.7 Stone Plug Holders vs. Tool Plates
The two ways to hold diamond tooling on the Prep/Master® is to either use a 2-inch stone
plug holder or an aluminum tool plate; both have their advantages and disadvantages.
The 2-inch stone plug holder offers convenience in diamond tool change because removing
tools only requires a hammer and replacing the tool only requires hand pressure to twist the
tool in. Another advantage, due to the creation of the E/Z plug, the 2-inch stone plug holder
can accommodate a variety of tools for prep and polishing.
One disadvantage is that stone holders can wear out where the 2-inch plug and the 8.5º
taper interface. When the taper in the stone holder wears, the diamond stones sit at a
different height based on that wear which will cause the diamonds stones to make an uneven
cut across an otherwise flat surface; this condition can lead to premature wear of diamond
tooling as well as a floor not being cut flat. Another disadvantage of the 2-inch stone holder,
it’s easy to mix matched sets of diamonds. When used diamonds are mixed, the tool life is
reduced and the likelihood of different tool heights being used is increased since it is difficult
to match used diamonds exactly; this also causes an uneven cut.
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Operating Manual STI-2807 | STI-2817LP
The aluminum tool plate offers a flat cut when new or used because the tooling is mounted
using hardware on a flat tool plate holder. The tools are mounted using hardware that does
not allow any discrepancy in height when mounted properly. Another advantage, when
multiple tool plates are purchased, the operator can keep the tool plates assembled with
each diamond type when not in use so that the diamond tools will be kept in matched sets
until they are depleted; this accomplishes both a flat cut as well as maximum diamond
lifespan. The disadvantage of the tool plate is that an impact wrench and sockets are
required to change tooling; the time it takes to change tools on a tool plate versus a 2-inch
stone plug holder is approximately 5 times as long.
To sum up the difference between the two holder types: Convenient tool change at the
expense of a flat cut if stone holders are not replaced after 100,000 square feet (10,000 m
9.8 Segment Attachment
When attaching the diamond segment to the tool plate ensure that the hardware is tight
to keep tool from loosening. Also make sure that the tool plate, as well as the diamond
segment, is clean where they meet to ensure the flattest possible cut. If the surfaces have
build up, the diamond tool will cut at an angle that will essentially be gouging the surface of
the concrete rather than grinding across it.
2
).
9.9 Recommended Weight Configurations
The Prep/Master® machines come with the necessary amount of weights needed to perform
all the processes it has been designed for. It is important to realize, however, that the full set
of weights will not be used for all applications. So when polishing concrete, for instance, the
machine may only need half the available weights on the head to provide the polish that is
desired on that particular slab; weight will also affect the life of the polishing tools being used.
It is important to note this because when performing any process with the Prep/Master® the
operator must establish what amount of weight is needed to yield the best possible product;
in the shortest amount of time and with the least expense in diamond tooling cost.
9.10 Recommended Speed Settings
Any given tool has a safe operating range with regard to speed. As a rule, no tool is to be run
at less than 30 Hz or more than 90 Hz. To determine the best speed, it is best to start slow
(+/-45Hz) and monitor the tools performance. For all tools listed in this guide, appropriate
speeds follow each product description.
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STI-2807 | STI-2817LP Operating Manual
9.11 Importance of Concrete Densifiers
Whether an unsealed concrete surface is polished or unpolished, that surface will deteriorate
if a densifier is not used. Concrete densifiers offer protection to a concrete floor by a chemical
process in which the densifier reacts with the Calcium Hydroxide (Free Lime) present in all
cured concrete.
During hydration, the process by which cement dries, the compound Calcium Hydroxide is
formed. This compound is a weak by-product of hydration and contributes nothing to the
abrasion resistance or overall strength of the concrete. This weak material can be very easily
abraded from the surface of the concrete which leads to small voids as the particles are
pulled out.
Over time, these voids collapse which make them larger and lead to dulling of the concrete
surface or in extreme cases de-lamination. The chemical densifier fills the voids with crystal
growth created by its reaction with the Calcium Hydroxide and essentially ‘glues’ the cement
particles together.
The result is a surface that exhibits increased abrasion resistance which prevents dusting,
de-lamination or loss of shine if polished. We think it’s important to mention densifiers
here, because if a densifier is omitted from a polishing process, that surface will NOT be
permanent.
9.12 Choosing the Right Diamond Tool for the Application
Using the correct diamond tooling for a specific application is the most important part of
ensuring productivity and an acceptable cost per square foot (lifespan) for the specific tool.
With that said, predicting which tool to use is probably the most difficult thing to do because
concrete surfaces are so variable from one pour to the next and depending on the surface
strength or the strength and composition of topical materials (thin-set, patch, adhesive, etc.)
the variation from one material to the next can cause the diamond tooling to be affected in
any number of ways.
Thin-Set covered concrete: 10S Diamond – 16 Grit•
Patch covered concrete: 10S Diamond – 16 or 30 Grit depending on hardness•
Adhesive covered concrete: 3SEG – 16/20 or 30/40 Grit•
Epoxy Coatings (un-sanded): 3SEG – 16/20 or 30/40•
Sanded Epoxy Coatings: 10S Diamond – 16 or 30 Grit depending on finish desired•
Hard Concrete: 10S Diamond – 30 Grit with the use of water•
Note: There are many different conditions that will be encountered when preparing a
concrete slab, the above is a general list of those conditions. There is no substitute for
experience and observation when it comes to determining exactly which diamond design will
work in a given application.
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Operating Manual STI-2807 | STI-2817LP
9.13 Diamond Tooling Offered by STI
Substrate Technology offers diamond tooling for any phase of the grinding or polishing
process. Below is a list of those tools and their applications:
Concrete Applications:
Metal Bonded Tooling
3SEG Diamond1.
The 3SEG diamond is a 3”, metal bonded diamond used for the aggressive removal of •
fresh or thick adhesives, epoxy and any other flexible material that requires an aggressive
edge to thoroughly remove the coating.
Grits – 16/20, 30/40, 50/60 & 80/100•
Life – 30,000 SF / 3,000 m•
Speed – 50 Hz / 2,700 RPM•
10S Diamond2.
The 10S diamond is a 3 inch, metal bonded diamond used for the aggressive removal •
of dry or thin adhesive, sanded epoxy coatings, thin-set, floor patch, concrete surface
correction (spalling) and scratch removal prior to polishing.
2
Grits – 16, 30, 70, 120, 220 & 400•
Life – 30,000 SF / 3,000 m•
2
Speed – 45 Hz / 2,400 RPM•
Resin Bonded Tooling
3TERZ Pad1.
The Terrazzo polishing pads were made to cut, well, terrazzo. However, after some •
experimenting, we found that the Terrazzo pads also work well for cutting concrete;
whether new or old. The great thing about the Terrazzo pads is that they cut like crazy, but
leave a super-fine scratch pattern.
New, Unsealed Concrete
Terrazzo pads are a first cut tool for new, hard-troweled concrete. They are to be run wet •
to ensure even scratch pattern and consistent removal of the cream layer of concrete.
When used properly, the result should be consistent exposure of the fine sand particles
that reside beneath the paper thin layer of the hard troweled surface.
Grits – 50 & 100•
Life – 8,000 SF / 800 m•
Speed – 50 Hz / 2,700 RPM•
2
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STI-2807 | STI-2817LP Operating Manual
Existing Concrete
Terrazzo pads cannot be used to remove coatings or imperfections; they are a tool for •
scratch removal or as a first cut tool on smooth surfaces. An existing concrete slab that is
coated or damaged must first be cleaned with the appropriate tooling to a minimum 70 grit
scratch in the surface of the concrete before the Terrazzo pad can be utilized.
Grits – 50 & 100•
Life – 6,000 SF / 600 m•
Speed – 50 Hz / 2,700 RPM•
FL-07 Pad2.
For use after Terrazzo Pad 100 grit after surface has been cleaned and allowed to dry. •
The grit system procedure is 3*, 4*, 5, 6, 7, 8, & LUX. These pads are used in the order of
numbers from lowest (#3) to highest (#8) and the LUX pad is a final buffing step.
Life of FL-07 Pads – 8,000 SF / 800 m•
Speed – 50 Hz / 2,700 RPM•
* Note: #3 and #4 are pads that can be omitted from the process if the 100 Terrazzo pad
is used prior to beginning the FL-07 process. If 100 Terrazzo pad does not precede FL-07
process, then the floor must be ground to a minimum 120 grit metal finish.
2
2
REZ/MET Pad3.
For use after minimum 70 grit grinding application•
Grits – 35, 50 & 100•
Life – 5,000 SF / 500 m•
2
Speed – 45 Hz / 2,700 RPM•
Premium Plus Pad4.
For use after 100 Terrazzo pad 100 grit after surface has been cleaned and allowed to dry.•
Grits – 35, 50, 100, 200, 400, 800, 1500, & 3000•
Life – 4,000 SF / 400 m•
2
Speed – 60 Hz / 3,200 RPM•
Special Application Tooling
Carbide Scrapers1.
This tool is used when excessively thick or fresh adhesive needs to be removed. The •
process is done wet to allow the slicing of the material from the surface.
Speed – 40 Hz / 2,100 RPM•
PCD Wolverine2.
This tool is used for the aggressive removal of thick (<2MM) materials. The profile left by •
the PCD is very rough and usually needs to be followed with a metal bond diamond to
smooth the surface to an acceptable profile.
Speed – 40 Hz / 2,100 RPM•
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Operating Manual STI-2807 | STI-2817LP
9.14 Common Applications and Recommended Procedures
Thin-set**, sanded epoxy or patch** removal:•
10S Diamond 16 Grit*•
Adhesive, flexible coatings and non sanded epoxy:•
3SEG Diamond 16/20 Grit*•
*Because of the aggressive scratch left by the 16 or 16/20 grits, a follow up with 30 grit may
be necessary before topical sealers or VCT can be applied. This prevents telegraphing of the
scratches through the finished product(s).
** When performing patch removal it is important to remember that regardless of the patching
material or underlayment being removed there is some percentage of sand present in the
material. This is important to remember because sand, whether coarse or fine, is very
abrasive to the diamond tooling being used. See ‘Choosing the Right Diamond Tool for the
Application’ It’s also worth noting that in most cases underlayment is a relatively soft material
that places more drag on the motor than a grinding or polishing process. So varying the
placement of the weights on the head or handle may be necessary depending on material
softness and desired productivity. Another indicator of an overload is the display of an
overload or lo-volt fault displayed on the variable speed drive display. See ‘Recommended
Weight Configurations’
Concrete Polishing with preparation/removal:
10S Diamond 30 Grit•
10S Diamond 70 Grit•
3TERZ Pad 100 Grit (wet)•
FL-07 Pad #5•
Densifier Application•
FL-07 Pad #6•
FL-07 Pad #7•
FL-07 Pad #8•
Densifier Application•
FL-07 Pad #LUX•
Concrete Polishing of new, unsealed, hard-troweled concrete:
3TERZ Pad 100 Grit (wet)•
Premium Plus Pad 200•
Densifier Application•
Premium Plus Pad 400•
Premium Plus Pad 800•
Densifier Application•
Premium Plus Pad 1500•
37
Substrate Technology, Inc.
1384 Bungalow Rd.
Morris, IL 60450 USA
(815) 941-4800
(815) 941-4600 Fax
www.substratetechnology.com
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