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Glass Master Grooving Machine Adjustments Manual

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

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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


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

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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


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 .


Fig .7 .Toolbarmountingbracketnuts

Fig .6 .Idlerarmadjustmentbolts

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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


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 .


Fig .10 .Properdepthofcutforfemaleshiplap

Fig .11 .AdjustmentscrewsontoolsB,C,D(#3,#2,#3also#4)

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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 .


Fig .13 .PropercutdepthusingtoolsB,C,D(#3,#2,#3also#4)

Fig .14 .ToolsG(#5)andA(#8)mustpressfirmlyonthecuttingroller .

Fig .12 .Settrailingbladetocutflushwithfactorymoldedshiplap


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 .


Fig .15 .Properreplacementbladeposition,ToolsG(#5)andA(#8)

Fig .16 .Oxydizedfinishwillbewornoffproperlypositionedblade

SM-300,GM-12E-115,E-215

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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 .


Fig .17 .ProperV-groovecutwhenusing90°blades .Aperfectcutisseenabove .Notethatthereremainsapproximately⅛"(3mm)offiberglassinthebottomofthegroove .

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 .


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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


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 .


Fig .19 .ReverseToolingArrangement

E

SCO

D

C

B

A

Fig22 .Reversetoolingcut

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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 .


Grooving Machine


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

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V-Groove ToolingAllofthepossibletoolingarrangementsformodifiedshiplapcanbeaccomplishedutilizingtheV-grooveconceptwiththeexceptionoffour-pieceduct .ThetwomajorproblemswiththeV-grooveconceptarethatfittingsaremoredifficulttofabricate(somearenotpossible)andthefinishedductsystemhaslessstructuralintegritythanwiththemodifiedshiplapmethod .ThemachineshowninFigure24issetuptofabricatean8"x10"(203mmx254mm)one-pieceductsection .


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


Grooving Machine

Parts Replacement

Fig .23 .Newtoolwithslottedscrewholes,heavygaugemetal

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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

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.

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