STI STI-3030, STI-3038LP Operating Manual
Operating Manual
STI-3030
STI-3038LP
STI-3030
STI-3038LP
Propane
STI-3030 | STI-3038LP Operating Manual
Table of Contents
1.0 Technical Data.............................................1
2.0 Safety Instructions .........................................3
3.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.0 Transportation............................................15
5.0 Starting the Machine ......................................16
6.0 Operation of the Machine...................................18
7.0 Maintenance .............................................19
8.0 Troubleshooting / Diagnostics ..............................22
9.0 STI Reference Guide & Procedures ..........................24
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.
Prep/Master® Warranty
Substrate Technology guarantees that its machines and products are without manufacturing
defects. The warranty period on machines is one (1) year from the date of sale and the variable
speed drive carries a two (2) year warranty from the date of sale. Substrate Technology will replace
any part that is defective at its own cost within the warranty period. This warranty does not cover
wear items or instances of abuse or neglect.
***When transporting P/M machines, it is mandatory to move all pocket weights to the head of the
grinder, or off the machine. Failure to do so will result in damage to the handle frame that is not
covered under warranty.
[updated October 2015]
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Operating Manual STI-3030 | STI-3038LP
1.0 Technical Data
1.1 Rating
1.2 Unit Specifications
1.3 Operative Range and Correct Usage
1.4 Stand-by Power Supply (Generator)
1.5 Advice for Operators of Grinding Machines
1.6 Machine Type Designation
1.1 Rating
Machine: Prep/Master® Grinder
Machine-Type: STI-3030 | STI-3038LP
Manufacturer: Substrate Technology
1384 Bungalow Rd.
Morris IL 60450 USA
+1.815.941.4800
www.substratetechnology.com
1.2 Unit Specifications
STI-3030 Dimensions:
Length 86 in 218 cm
Width 30 in 76 cm
Height 52 in 132 cm
Weight 1,320 lbs. 599 Kg
Connected loads of the electrical system:
Power 30 HP
Electrical Connection 220/230 VAC 1 or 3 Phase 60 Hz
STI-3038LP Dimensions:
Length 86 in 218 cm
380/480 VAC 3 Phase 50-60Hz
depending on ordered unit
Width 30 in 76 cm
Height 48 in 122 cm
Weight 1,084 lbs. 492 Kg
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STI-3030 | STI-3038LP Operating Manual
1.3 Operative Range and Correct Usage
The Prep/Master® STI- 3030 | STI-3038LP is designed to be used on clean, dry or wet
horizontal surfaces without obstacles. The machine cannot 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.
1.4 Stand–by Power Supply (Generator)
If the Prep/Master® STI-3030 is operated using a generator, the generator must be
operated in accordance with the current local electrical directives (this applies in
especially 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.
1.5 Advice for Operators of Grinding Machines
During the operation of the Prep/Master® STI- 3030 | STI-3038LP 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 the persons working near the machine must wear sound–insulating devices.
1.6 Machine Type Designation
Machine Type: Prep/Master® STI-3030 | STI-3038LP
Working Width: 30 in. / 72 cm
Drive: Manual
Grinding Capacity: Variable
Dust Hose Connection: 3 in./76mm x 25 ft./8m
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Operating Manual STI-3030 | STI-3038LP
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.
Electrical Warning
Warning against dangerous voltages.
Electric Only
Indicates that the section information only pertains to the electric model.
Propane Only
Indicates that the section information only pertains to the propane model.
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STI-3030 | STI-3038LP Operating Manual
2.2 Organizational Measures
The Operating Instructions are to be kept near the location where the machine is located
and must be reachable 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.
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!
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Operating Manual STI-3030 | STI-3038LP
2.3 Personnel Selection and Qualification
Only reliable personnel are allowed to work on the machine or operate the machine. Note the
statutory minimum age. Specify clearly the responsibilities of personnel for operation, setting up,
servicing and maintenance work. 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.
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 when the machine is
running!
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STI-3030 | STI-3038LP 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 2.5 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.
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.
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Operating Manual STI-3030 | STI-3038LP
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-3030). / Turn off propane supply at tank and remove key from ignition
(STI-3038LP).
• 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.
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 Instructions
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).
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STI-3030 | STI-3038LP Operating Manual
Please instruct operators and 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.
3.0 General Information
3.1 Operative Range
3.2 Scope of Supply
3.3 Operating Features - STI-3030
3.4 Operating Features - STI-3038LP
3.5 Exploded Diagrams & Part Numbers
3.7 Electric Motor - STI-3030 only
3.8 Cutting Area
3.9 Couplers & Tool Plates / Stone Holders
3.10 Variable Speed Drive - STI-3030 only
3.11 Tool Change
3.12 Care & Maintenance
3.1 Operative Range
The STI Prep/Master® STI-3030 | STI-3038LP 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.
3.2 Scope of Supply
Provided with machine:
• Prep/Master® STI-3030 | STI-3038LP
• Manual (1)
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Operating Manual STI-3030 | STI-3038LP
3.3 Operating Features - STI-3030
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.
Dead Man Key
Dead Man Key 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. Lanyard must be worn by operator for this
safety device to work properly. Pull key out to stop the machine motor.
Manual On/Off Switch
The On/Off switch is used to turn off all power supplied to the grinder.
3.4 Operating Features - STI-3038LP
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.
Rocker Switch
Use the rocker switch to engage or disengage the clutch.
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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