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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

Knauf Air Duct Fabrication Manual �

Grooving Machine

Ifoneormorerollersdoesturnbyhand,examinedrivegearstobesurelockingAllenscrewsaretightagainstkeysandthatkeyslotsareinplace(seeFigure2) .Makesurethesprocketsareinlinewhenre-tightening .Toavoidprematurewear,allgearsshouldbeoperatinginthesameplane .

Resurfacing pinch rollersOnearlymodels,thetoppinchrollerinfrontandthetoppinchrollerinbackwerecoatedattheGlassMasterfactorywithanabrasivesubstance(crushednutshellheldinplacebyepoxypaint) .Thishelpedtherollersgriptheairstreamsurfaceoftheductboardandpullitpastthestationaryknives .However,normalusagewearsthegritofftheserollers .Asmoreandmoregritiswornoffandthedriverollersbecomesmoother,theductboardoftenwillnotpassthroughthemachineinastraightline .Theboardwillinvariablybegintosliptotherightorleft,wastingmaterialandneedlesslyaddingtofabricationcost .

Whenthisoccurs,fabricatorsoftenattempttocorrecttheproblembyclosingthegapbetweenthepinchrollers .This is not recom-mended.Closingthepinchrollergapcancauseirreparabledamagetotheductboard;theglassfibersareliterallycrushed,theboardbecomeslimp,andthefoilwrinklesandbeginstocomeloosefromthefiberglass .

Resurfacingthepinchrollersiseasilydoneinthefield .ThisisbestaccomplishedusingrollsofindustrialgradeemeryclothandsprayadhesiveavailablefromGlassMaster .No other roll resurfacing method is recommended.Thecorrectresurfacingprocedureisasfollows:1 . Thoroughlycleanthepinchrolltoberesurfaced .2 . Applysprayadhesiveevenlytothepinchrollerfromoneendto

theother .3 . Unrolltheemeryclothandsecureittooneendofthecleaned

rollerwithapoprivet .4 . Applysprayadhesivetotheundersideoftheemerycloth .When

theadhesiveistacky,windtherollspirallyandevenlyalongtheentirelengthoftheroller,makingsurewrapsofemeryclotharetightlybuttedtogether .Whenyoureachtheotherendoftheroll,securetheemeryclothwithapoprivet .CompleteinstructionsandtechnicalassistanceisavailablefromGlassMasteroryourKnaufRep .

Note: Onlythetopfrontandtopbackrollersshouldbeabrasive-coated,usingemeryclothandsprayadhesivebymeansofthemethodpre-viouslydescribed .Ifthebottompinchrollersorthelevelingrollersarecoated,thiswilldamagethefoilfacingoftheductboard .Alsochangingthespacingbetweenpinchrollersdoesnothingtochangethedepthoftheknifecuts .

Roller Adjustment, Maintenance, and Repair

Fig .2 .KeyslotsandAllenscrew

Figure3 .Resurfacingdriverollerwithemeryclothsothatnogapsoccurbetweenwraps

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Roller Adjustment, Maintenance, and Repair

Fig .4 .Factorypinchrollerspacingmustbemaintained

Pinch roller spacingSpacingbetweenthepinchrollersiscritical .RollerspacingshouldneverbecloseddowntighterthanthespacingsetattheGlassMastermachinefactory .Thosefactoryspacingare: For1"ductboard ⅝" (16mm) For1½"ductboard 15/16" (24mm) For2"ductboard 1¼" (32mm)Withagood,grittysurfaceontheupperdriverollers,theycanbespacedevenfartherapartandstillpulltheductboardstraight

throughthemachinewithoutdamagingit .

Spacing adjustment:Properadjustmentofthedistancebetweenpinchrollerscanbeac-complishedeasily .First,loosenthechainidler(seeninthebottomleftcornerofFigure1) .Itisattachedtotheleftrollerplate .Loosenthetwo9/16"(14mm)boltsholdingtheidler .Theseboltsarelocatedontheinsideoftheleftendbelowthefourbottomrollersandthetoolbar .Important: Loosenthesetwobolts,makerequiredadjust-ments,thenpulloutwardandtightenbothbolts .Onthetopofthemachinethereare¾"(18mm)boltsonthefrontedgesofbothendpanels .IfyourE-215hasfourbolts,fourseparaterollerspacingadjustmentsmustbemade,twoateachendofthemachine .IfyourE-215hastwosuchbolts,bothfrontandrearrollerscanbeadjustedsimultaneously .Rollerspacingshouldbemaintainedatthespecifiedfactoryspacingfortheductboardthick-nessinuse(seepage4)alongtheentirelengthofthemachine .

TheGlassMasterE-215wasdesignedtogrooveductboardupto2"(51mm)thick .Ifboardsthickerthan1"(25mm)aretobegrooved,thechainmechanismwhichdrivesallrollersmustbeadjustedtoprovidemoreslackinthechainastherollersaremovedfartherapart .

1 . Adjustrollersfordesiredductboardthickness .2 . Takeupslackinchainandtightenchainidler .

Fig .5 .Pinchrollerheightadjustmentbolt

Knauf Air Duct Fabrication Manual �

Grooving Machine

Inordertoensureevencutsalongtheentirelengthofthetoolbarsandtopreventrollersfromdevelopingwarpandsag,laterGlassMasterE-215machineshaveTeflon®"Y"bracesaddedtotherolleronwhichthetoolbladesride .

LubricationTheGlassMasterE-215machinetransmissionisfilledatthefactory .Whileanoilinspectionplugislocatedonthemachinetrans-mission,itshouldnotbenecessarytochecktheoillevel .

Lubricatingthedrivechainisnotrecommended;thiscausesglassfiberstosticktothechain,causingprematurewear .

Adjusting the Tool BarTheGlassMasterE-215machineisconstructedwithtwotubularsteeltoolbars .Thecuttingtoolsarepositionedbetween,andreston,thetoolbarsforfabrication .Theverticalpositionofthetoolbarsdirectlyaffectsthedepthofallcuts .Properpositioningofthetoolbarisabsolutelyessential .Toolbarsaremountedonaplatethatcanbemovedupordownoneachendofthemachine .

Roller Adjustment, Maintenance, and Repair

Fig .7 .Toolbarmountingbracketnuts

Fig .6 .Idlerarmadjustmentbolts

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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

Knauf Air Duct Fabrication Manual �

Grooving Machine

TheGlassMasterE-215machinehasbeentooledtocuteithermodifiedshiplaporV-groovecuts .Formodifiedshiplapconfigura-tion,fabricationtools#1,#2,#3,#4,#5,#R1,#8,andSCOorA,B,C,D,E,F,G,andSCOwereshippedwiththemachine .

Tools #1, and #R1 (A, E):Thesetwotoolsaredesignedtocutthefemaleshiplap .Adjustmentisverysimple:Setallthetoolstocutonehalfthethicknessoftheductboard .Loosenthetwoscrewsinthebladeholderandmovethebladeverticallyuntilhalfoftheboardthicknessisremoved(seeFigure10) .Ifmoreorlessthanhalfthethicknessofthefiberglassisremoved,theductsectionwillnotfolduptoformaperfectrectangleorsquare .Verylittleattentionisnormallypaidtothedepthofthiscutinthefield,yetunlessthesebladesareproperlyadjusteditisdifficulttoputtwosectionsofducttogetherandmaintainastraightductrun .

Tools B, C, D (#3, #2, #3)Thesethreetoolsareusedtocutrightandlefthandshiplapssothatfoldingtheductboardcanbeaccomplished .ToolsBandD(#3)areexactlythesame .ToolC(#2)isthereverseofToolsBandD .(#3) .Adjustmentofallthreetoolsisexactlythesame .Groovesformedbythesetoolsmustbecutprecisely .Ifcuttooshallow,theboardscannoteasilybefoldedandthefinishedductsectionwillnotstandwith90°corners .Ifcuttoodeeply,theductwillbewobblyandflimsyandthefoilfacingcanbedamagedorcut .Fineadjustmentisaccomplishedbylooseningthefourscrews,whichholdthetwoseparatebladestothetoolholder,andmovingthemverticallytoachievethepropercut .

Adjustment of Individual Tools

Fig .10 .Properdepthofcutforfemaleshiplap

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

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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 .

Adjustment of Individual Tools

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

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

Fig .12 .Settrailingbladetocutflushwithfactorymoldedshiplap

Knauf Air Duct Fabrication Manual �

Grooving Machine

Aftertheoriginalbladeiswornorbroken,thereplacementbladeisoftenputbackbyplacingscrewsinthewrongholessothatthebladeactuallyrestsbetweenthelevelingrollers .Noamountofadjustmentcanproduceacleanstapleflapifthebladedoesnotmakeconstantfirmcontactwiththecuttingroller .IfbladesaretobeinstalledontheGlassMasterE-215machine,usethetwoinsideholestosetthem .IfbladesaretobeinstalledonGlassMaster300-SM,E-200,orE-410machines,usethetwooutsideholes .

Note: TheGlassMasterE-200requiresdifferentG(#5)andA(#8)blades .The300-SMrequiresanextractingblade .Forinformation,contactGlassMasteroryourKnaufrepresentative .

Loosenthetwoscrewsholdingthebladeandadjustitsothat,whentheholderissetintothetoolbar,thefrontedgeofthetoolholderwillpressdownslightlybeforeitislockedinplace .Theaddedspringwillcausethebladetocleanallthefiberglasswhileleavingthefoilfacingunharmed .

Adjustment of Individual Tools

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

Fig .16 .Oxydizedfinishwillbewornoffproperlypositionedblade

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

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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 .

Adjustment of Individual Tools

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 .

Adjustment of Individual Tools

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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

Knauf Air Duct Fabrication Manual ��

Grooving Machine

Preferred (Reverse) ToolingThisistherecommendedmethodoftoolarrangementintheindus-try .TheA(#8)toolisthereverseoftheG(#5)tool;itispositionedfirstinlineandnevermoves .Itisstationedatthestrongestareaofthetoolbars--wheretheyarefastenedtothebulkheadofthemachine .Thisproducesthestapleflapattheleftsideoftheductboardasitpassesthroughthemachine,formingaconsistentlycleanstapleflaprequiringlesshandlabortoremoveglassfibers .Cut-offismadenexttotheR1tool(whichisthereverseofthe#1,orF,tool)where½"ofthethicknessofthefiberglassremainsadheredtothefoilfacing .Thisresultsinacleanercut-off .ItismucheasiertosettheA(#8)toolproperlyandlockitinplace,neverhavingtomoveit,thanitistoworkwiththeproblemspresentedbytheG(#5)tool .

ThereisanaddedbenefitforoperatorsusingCloseMasterma-chinestocloseandtapethelongitudinalseamsofductsections .IfPreferredtoolingisused,thefactoryfemaleendoftheductsection(theendonwhichthefoilfacingisadheredtothefiberglass)enterstheGlassMastermachinefirst .IftheStandardtoolingset-upisused,themaleendwithitsloosefoilfacingflapenterstheCloseMastermachinefirst,oftenleavingtheoperatorwithapartiallyclosedductmodulebecausetheclosuretapeisnotpickedupimmediately .Forthisreason,reversetoolingmustbeusedforclosingmoduleswiththeCloseMastermachine .Thetoolsmaybe#8,3,2,3,R1orA,B,C,D,E,SCO .

Tooling arrangements

Fig .19 .ReverseToolingArrangement

E

SCO

D

C

B

A

Fig22 .Reversetoolingcut

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Tooling arrangements

Tool arrangements for one-piece duct

Preferred(Reverse)

A 8" B 10" C 8" D 10" E SCO

8 8" 3 10" 2 8" 3 10" R1 SCO

Standard

1 10" 2 8" 3 10" 4 8" 5 SCO

Tool arrangements for two-piece "U" style duct

Preferred(Reverse)

F 10" B 8" C 10" E SCO

Fillercap: A 8" G SCO

1 10" 3 8" 2 10" R1 SCO

Fillercap: 8 8" 5 SCO

Standard

1 8" 2 10" 3 8" R1 SCO

Fillercap: 8 10" 5 SCO

Toolsshouldbearrangedandspacedaccordingtothefollowingchartstoaccomplishthesecuts .Thesedimensionsarecriticalforcorrectfittingfabrication .Theexampleshownwillproducea10"x8"(254mmx203mm)ductmodule .

Knauf Air Duct Fabrication Manual ��

Grooving Machine

Tooling arrangements

Tool arrangements for two-piece "L" style duct (two sections required)

Preferred (Reverse)

A 8" B 10" E SCO A 8" B 10" E SCO

8 8" 3 10" R1 SCO 8 8" 3 10" R1 SCO

Standard

1 10" 2 8" 5 SCO 1 10" 2 8" 5 SCO

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

Tooling arrangements

V-Groove Tooling Set-up ToolarrangementsfortheotherpossibilitiesusingtheV-grooveconcept .

V-Groovetoolingforone-pieceduct

1 10" 90° 8" 90° 10" 90° 8" 5 SCO

V-groovetoolingfortwo-piece"U"styleduct(2pieces)

1 10" 90° 8" 90° 10" R1 SCO 8 8" 5

V-groovetoolingfortwo-piece"L"styleduct(2piecesrequired)

1 10" 90° 8" 5 SCO 1 10" 90° 8" 5 SCO

ReversetoolingcanbeutilizedwitheithershiplaporV-groovecuttingmethods .Allone-piece,two-piece"L",andtwo-piece"U",plusendcaps,canbemadeusingReversetooling .

Fig .24 .V-GrooveToolingArrangement

Knauf Air Duct Fabrication Manual ��

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

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Technical Support (800) 825-4434, ext. 8212

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