Safety Precaution Sheet To be read carefully before use - Logitech Ltd

Equipment Manual
for the
Operation and Maintenance of the
WG2 Polishing System
Ref: BE-01-9-5

!
NB Logitech Ltd. assert it’s right under the
Copyright, Designs and Patents Act 1988
to be identified as the author of this work.
c Logitech Limited. All rights reserved.
Safety Precaution Sheet
Logitech Lapping and Polishing Machines
To be read carefully before use
1. The operator should be fully aware of the use of the machine
according to the Operation Manual.
2. The machine must be placed in an adequate working position,
providing stable support and adequate ventilation. All functions on
the machine and any connected equipment must be in working
order.
3. Be sure that the supply voltage corresponds to the voltage stated
on the back of the machine. The machine must be earthed.
4. Establish efficient exhaust from the working area if consumables
containing alcohol, for example, are being used.
5. Make sure that the lapping or polishing plate is correctly mounted,
the driving pins engaged with the holes in the turntable.
6. Before loading or unloading the specimen holder, ensure that the
plate has completely stopped rotating.
7. Keep clear of the rotating plate and spec imen holder during
operation. Make sure that any screws for clamping of specimens in
holders protrude as little as possible.
8. Before loading or unloading the abrasive cylinder, ensure that the
abrasive drive has completely stopped.
9. Observe the current safety regulations for handling, emptying and
disposal of the waste materials and fluids.
10. Always turn off the power and remove the plug or cable before
opening the machine or working on any terminal connections.
The apparatus/machine is designed for use with consumables supplied
by Logitech. If subjected to misuse, improper installation, alteration,
neglect, accident or improper repair, Logitech will take no responsibility
for damage(s) to the user or the equipment.
Dismantling of any part of the apparatus/machine, in case of service or
repair, should always be performed by a qualified technician
(electromechanical, electronic, mechanical, pneumatic, etc.).

21
13
34
16
18
17
29
22
33
31
20
1. Fulcrum Pillar
2. Star Clamp
3. Washer
4. Clamp Nut
5. Drive Motor
6. Vertical Column
7. Gearbox
8. Gearbox Fixing Screw
9. Lock-up Pin
10. Hinge Pin
11. Hinge Pin Retaining Screw
12. Gears
15
19
14
30
Figure 1
4
35
28
32
KEY
27
12
13. Overarm
14. Ultrasonic Level
15. Weights
16. Carousel
17. Latch Pin
18. Latch
19. Sample Holder
20. Sample Slide
21. Polishing Plate Base
22. Drive Plate
23. Fine Adjustment Knob
24. Adjusting Lever
26
24
23
25
11
10
9
8
7
6
5
4
3
2
1
25. Plate Cover
26. Roller Arm
27. Cap Screw
28. Locating Pins
29. Drive Rod Points
30. Rollers
31. Drive Rod Clearance
32. Drive Rod Number
33. Double Load Facility
34. Drive Rod
35. Motor to Gearbox Fixing Screw

1. INTRODUCTION
This manual is intended to assist the user in the operation of the WG2 Polishing Head when fitted to the
Logitech PM5 Precision Lapping and Polishing Machine. It covers unpacking, assembly and fine setting
of the polishing head. Operation and processes are suggested, and maintenance and repair are
covered. A wiring diagram is included. Operation of the PM5 machine is described in a separate
instruction manual. It is emphasised that the WG2 system is extremely versatile. There are many
potential applications for which this equipment is suitable. However, in this manual, the bias is towards
adjustments and processes for rock/ore polishing technology.
When using the manual it is necessary to refer to the two foldout diagrams (Figs 1 & 2) which can be
found adjacent to the front and back covers. The bracketed numbers and arrows which appear in the
text refer to parts of the WG2 polishing system. The number is the item number (see legend) and the
arrow indicates the appropriate diagram.
e.g. (< 21) refers to item 21 - Polishing Plate Base, on the left hand foldout diagram (Figure 1)
(38 >) refers to item 38 - Slurry Scraper, on the right hand foldout diagram (Figure 6)
(< 2 >) refers to item 2 - Star Clamp, shown on both diagrams
The WG2 polishing head consists of a carousel (< 16) driven through a series of gears within the
overarm (< 13) by a motor (< 5) mounted in the vertical column (< 6 >). The whole assembly is mounted
on the roller arm (< 26 >). Samples are retained, either directly or indirectly using sample holders, by six
drive rods (< 34) on the carousel. The rods can have weights (< 15) placed to increase the load. During
operation samples are moved across the rotating polishing surface by the rotation and reciprocation of
the carousel. Each sample will rotate randomly about the drive rod point.
Due to continuous development, the WG2 details may occasionally differ from those described in this
manual.
BE-01-9-5 Page: 4

2. INITIAL ASSEMBLY AND ADJUSTMENTS
2.1 Unpacking
The WG2 polishing head should be carefully removed from its packing case and examined for damage
which could have occurred during transit. Remove the polythene wrapping and again examine the unit.
Advise Logitech or the relevant agent and the carrier immediately if damage is apparent.
Clean the unit with tissue and mild solvent (e.g. alcohol or acetone) to remove possible sources of
contamination which may adversely affect the polishing process.
2.2 Polishing Plate Location
The polishing plate (21) is positioned on the drive plate (< 22) which is driven from the motor via the
gearbox of the PM5 machine. The plates are equipped with three locating/drive pins on the underside.
Holding the polishing plate by its edge, place the drive pins centrally in the annular groove of the drive
plate. Manually rotate the plate in this groove until the drive pins are located in the holes and allow the
plate to drop gently into place.
If not already in place, fit a plate cover to the polishing plate. This will allow fitting of the WG2 unit and
approximate positioning of the Head height.
2.3 Fitting of WG2 Polishing Head to PM5
Fit the WG2 support arm assembly over the right-hand support pillar, and clamp into an approximate
position using the star clamp (< 2 >). Hinge up the overarm (< 13) and lock into position with the springloaded
lock-up pin.
Connect the plug to the socket on the WG2 control panel (39 >).
To set the precise position of the polishing head it is first necessary to mount a polishing plate on the
PM5 machine, if this has not already been done (see 2.2 above).
2.4 Precise Setting of WG2 Polishing Head Height
The correct height setting for the polishing head is dictated by the distance from the tip of the drive rod
point when the rod is in the down position to the polishing surface (< 31). The drive rod clearance should
be approximately 1.5 mm. However, there is a certain amount of play when the drive rods are in the
down position, and this should only be used as a guideline.
Lift the overarm slightly and withdraw the spring-loaded lock-up pin.
Allow the carousel to fall slowly as controlled by the hydraulic damper (37 >).
As the carousel nears its final position, support and gently rotate it to ensure that the gear teeth engage
properly.
NOTE: If the carousel gears do not engage properly, do not force the carousel as this may damage the
gear arrangement. Lift the carousel and repeat the previous step.
BE-01-9-5 Page: 5

Select the drive rod nearest the front of the PM5 machine. Release it from the latch, and lower it into the
fully down position. Take care that the rod point does not contact the plate cover.
Observe the distance between the rod point and the plate cover. Lift the drive rod back into the lockedup
position.
Should an adjustment be necessary, slacken the star clamp (< 2 >) and adjust the arm position either
up or down as appropriate.
Re-tighten the star clamp and lower the drive rod to check its height above the plate cover
(approximately 1.0 mm). Readjust as necessary.
Finally, with plate cover removed, check that all drive rod points are approximately 1.5 mm above the
polishing disc when in the fully lowered position and with the star clamp fully tight.
Return the rods to the locked up position and replace the plate cover.
2.5 Positioning of WG2 Polishing Head in relation to Polishing Plate
As the PM5 machine plate always rotates in an anti-clockwise direction, the polishing head must be
positioned to the front of the polishing plate. This is to ensure that the forces imparted to the carousel
by the specimens running on the polishing plate are counteracted by the rollers (< 30 >) on the roller
arm.
In general the head position should be set so that when the Eccentric Sweep is in operation, the
specimens travel as near to the edge of the plate as reasonably possible without falling off and also
traverse the centre of the plate. This provides maximum use of the plate surface. Also, rotation of the
specimens is assisted when they traverse the plate centre.
Slacken the star clamp and position the polishing head a little towards the front of the polishing plate.
Re-tighten the clamp.
Switch on the PM5 machine in polishing mode and set the Eccentric Sweep amplitude to a relatively low
range. Run the plate slowly. Increase the sweep amplitude, by way of the LCD screens "Set Outer Limit"
and "Set Inner Limit" on the Process Data Display on the machine control panel. Assess the amount of
reciprocation of the polishing head, which should be approximately 25mm, and the outer position
reached during this process. Adjust the sweep amplitude as necessary until the required value is
reached.
To set the position of the WG2 Head in relation to the polishing plate, press the machine "STOP" key
when the roller arm has reached the outermost point of its sweep movement.
Slacken the star clamp and gently rotate the complete polishing head about the roller arm pillar until the
outermost drive rod point is approximately 12 mm from the periphery of the plate. Re-tighten the star
clamp, ensuring that the Head height remains approximately the same (re-check as in 2.4 above).
Start the PM5 machine and plate running and observe the Eccentric Sweep. Fine adjustment can be
made using the fine adjustment knob (< 23 >).
Place the slurry scraper (38 >) on its right hand support pillar and position it against the plate. The "L"shaped
catcher should lightly touch both the periphery and the underside of the plate. Excessive
pressure will only wear the scraper block unduly without improving performance.
BE-01-9-5 Page: 6

2.6 WG2 Controls
(See Figure 2 ) The WG2 control panel (39 >) is mounted on the upper part of the PM5 machine casing
and draws power for the WG2 head from a supply unit located within the machine body.
D
WG2
M aterials Tech nol ogi sts & Eng in eers
A - Power socket for WG2 polishing head.
B - Control knob for direction of carousel rotation.
Figure 2
C - Speed control for carousel. Speed continuously variable from zero to a maximum nominal speed of
35 r.p.m.
D - Jog button to rotate carousel for sample loading and unloading when PM5 machine is switched off.
Speed and direction are set by other controls.
JO G
0
B
A
C
BE-01-9-5 Page: 7

3. PREPARATIONS FOR POLISHING
3.1 Polishing Surfaces and Abrasives
The WG2 polishing system can accommodate the full range of Logitech 30 cm diameter lapping and
polishing plates. These include surfaces of cast iron, polyurethane and soft metal for which conditioning
and flatness gauging accessories are normally required. Many different lapping and polishing abrasives
are available for use in various diverse circumstances.
However, this manual is mainly concerned with standard polishing of rock sections, ores and similar
materials. For this type of work, certainly at the initial stages of process development, it is most generally
appropriate to use plate bases fitted with self adhesive synthetic polishing pads and diamond abrasive
polishing agents. Subsequent sections are confined mainly to use of the WG2 polishing system under
such ‘standard’ circumstances.
3.2 Fixing a Polishing Pad to a Plain Plate Base
Thoroughly clean the surface of the plain plate base with a mild solvent.
With clean, dry hands remove the polishing pad from its protective covering.
Partially remove the backing paper to expose approximately 25% of the adhesive surface. Do not allow
this surface to become contaminated.
Press the exposed part of the pad firmly onto the plate, taking great care not to trap air bubbles. A
pad of clean tissue is suitable for this purpose.
Slowly remove the remaining backing paper whilst pressing and smoothing the pad evenly onto the
plate base.
Note that if there are any air bubbles trapped a new pad will be required as pads cannot be peeled off
and re-used.
Using a sharp blade, trim off any excess pad from the periphery of the plate.
To prevent contamination, immediately cover the polishing surface with the appropriate clean plate
cover (< 25).
3.3 Care of Polishing Surface
It is strongly advised that each polishing surface is dedicated to one particular abrasive size or type. The
plate cover should always be fitted except when samples are being polished. Before fitting a cover,
thoroughly clean the inside with tissue and solvent to reduce the possibility of contamination. Fitting and
removal of plate bases should only be carried out with a plate cover in position. It is the responsibility of
the operator to avoid contamination from specimens, other plates, atmosphere etc.
3.4 Application of Abrasive
Diamond can be applied to the polishing surface in a number of different ways. An aerosol spray mixture
may be used or soluble diamond compound and lubricating fluid may be applied separately by hand.
BE-01-9-5 Page: 8

The WG2 polishing system is primarily designed for use with diamond or other slurry being continuously
drip fed to the polishing surface by way of an Abrasive Autofeed Cylinder, as this has proved to be the
most convenient and economical method. Operation and Maintenance of this cylinder is fully described
in Logitech Equipment Manuals Ref. No. BE-01-2 or BE-01-47.
3.5 Sample Retention and Drive
Samples are held beneath the loaded drive rods and moved by the reciprocating and rotating action of
the carousel. The drive rod - specimen connection may be by direct contact in the case of certain types
of unmounted sample, such as ore blocks embedded in resin. For standard rock sections on glass slides
it is convenient to use precision machined sample holders.
3.5.1 Unmounted Samples
The arrangement for unmounted samples is shown in Figure 3 below:
RESIN
The height : surface area ratio should be kept to a minimum to prevent any tendency for the sample to
dig into the polishing pad
3.5.2 Sample Holders
SAMPLE
7mm
DRIVE ROD
120° OR STANDARD 7mm DRILL POINT AS SUPPLIED DRIVE ROD LOCATION
TOO HIGH
Figure 3
RESIN
SAMPLE
Sample holders are available in different geometries and in general are suitable for samples of any
shape. Their limitation is that the samples held by them must be of a standard size as the sample
holders have side plates which fit over the outside of the sample. For standard samples, such as slide
mounts, they are extremely convenient to use.
Supplied as standard with the WG2 polishing system are three holders for 51 x 76 mm glass slides and
six holders for 28 x 48 mm or 26 x 46 glass slides.
To adapt the sample holders to accept either 28 x 48 mm or 26 x 46 mm slides, the side plates can be
removed and re-positioned as in Figure 4.
BE-01-9-5 Page: 9

Chuckfaces may be lapped to renew flatness when necessary
3.6 Loading of Samples
26 x 46 mm 28 x 48 mm
FRONT RETAINING PLATES OMITTED FOR CLARITY- DRAWINGS NOT TO SCALE
Figure 4
The six drive rods can each be loaded using the loading weights. Each weight is 450g nominal and a
maximum load of 1.8 kg can be put on each drive rod. The system is supplied with three loading weights
for each drive rod for normal use although four weights can be accommodated.
Care should be taken to avoid overloading samples on high friction plates.
Where high polishing pressures are required, and for samples with large surface areas (e.g. 51 x 76 mm
slides), it is possible to increase the load on three of the drive rods by using the double load facility
(< 33) on rods 2,4 and 6. This allows the load from one drive rod to be added to the next adjacent drive
rod via the double load bar, thus giving a maximum sample load of 3.6 kg.
BE-01-9-5 Page: 10

4. STANDARD OPERATING PROCEDURES
The following is an outline of standard procedures used for the preparation of polished samples of rock
and ores in thin section or resin block form. Individual applications may require these procedures to be
modified for complete optimisation. A specific set of operating conditions currently used by Logitech for
production of 30 micron polished rock sections is described in section 4.4.
4.1 Samples
The sample should be thoroughly examined to assess its suitability for polishing. Look for pits, plucks,
scratching, taper or any other defect which would render it unsuitable for further processing. Measure
the thickness if appropriate.
Record findings.
Mark the sample for identification during processing.
Immediately prior to polishing, the sample should be thoroughly cleaned to remove any possible source
of contamination. Whenever possible the sample should be immersed in an ultrasonic cleaner
containing Iso-Propyl Alcohol or other appropriate cleaning agent for at least ten minutes. If an
ultrasonic cleaner is not available, thoroughly clean with a tissue and solvent.
4.2 Standard Polishing Procedure
Set all controls on the WG2 polishing head and the PM5 machine to zero.
Remove all loading weights and lock-up the drive rods.
Locate a plate base fitted with a suitable polishing pad on the driver plate. Leave the plate cover in place.
Check the height, position and reciprocation setting of the polishing head and adjust if necessary as
described in section 2.
Clean and fit a slurry chute and tube to the PM5 by way of the screw on the upper casing (beside the
cradle for the Abrasive Autofeed Cylinder) and press the slurry tube into the holder (36 >) on the roller
arm.
Adjust the position of the holder to distribute the slurry over the part of the plate track which will
principally be covered by the samples to be polished. When the carousel is set to rotate contra-lap it will
spread the slurry across the plate to the centre. Conversely if the carousel rotates with the plate the
slurry is spread from the centre.
Place an Abrasive Autofeed Cylinder on the rollers of the cradle in the machine upper casing and check
for free rotation between the roller flange guides.
NOTE: Cylinders and slurry chutes should be dedicated to one particular size of abrasive only and
suitably labelled for identification.
Remove the plate cover and start the PM5 machine with the abrasive feed system running and the
polishing plate rotating at a moderate speed. Adjust the flow to approximately one drop every ten
seconds. If the plate surface is new or dry, wet it thoroughly with abrasive around the periphery by an
initial fast feed of slurry and then reduce to one drop every ten seconds. Stop the machine when the
plate periphery is evenly wetted and set the plate speed back to zero.
BE-01-9-5 Page: 11

If the slide holders are used, first clean them thoroughly (an ultrasonic cleaner is suitable), then apply
one drop of polishing fluid to the chuckface. Press the slide firmly into place thereby spreading the fluid.
The slide will then be firmly retained by surface tension.
Place the sample on the polishing surface below an accessible evenly-numbered drive rod (< 32). Drive
rods 2,4 and 6 have the double load bar fitted. Samples must be located under these rods before
locating or loading samples under the corresponding drive rods 1, 3 or 5.
Lower the drive rod into the hole in the backside of the sample and place one weight on the rod.
If the double load facility is required, lower the adjacent odd-numbered drive rod into the down position
so that it rests on the double load bar and place one weight on the rod. Otherwise place a sample on
the polishing surface below the odd-numbered drive rod and locate and load as before.
Set an arbitrary direction on the WG2 carousel direction control and set the carousel speed control to a
low speed. Use the jog button to turn the carousel until another pair of drive rods are accessible and
load as before.
NOTE: The full capacity of the carousel does not have to be used. A single sample may be polished on
its own if so desired.
Before starting to polish, apply a drop of polishing fluid to each drive rod locating hole. This provides
lubrication and assists rotation of the sample about the drive rod point.
Start the PM5 machine with abrasive feed system (the carousel will also start) and increase plate
rotation speed smoothly to the chosen value (normally full speed).
Set the WG2 carousel rotation direction to contra-lap or with-lap as desired and set the rotation speed
to the chosen value (normally contra-lap, full speed).
Check that the samples are moving and rotating freely about the drive rod points and across the plate.
"SET" the PM5 machine timer for the desired polishing time. The "SET" function may be by-passed if
long polishing times are anticipated, and the machine will run continuously.
Stop the machine and add further loading weights, as the polishing action becomes smoother. Restart
the machine.
When the elapsed time on the PM5 control panel reaches that programmed-in by the operator, the
machine will stop automatically. Remove the samples for cleaning and examination and replace the
plate cover.
4.3 Further Stages of Processing
Should the samples require further polishing using a finer abrasive then certain parts of the system must
be exchanged and the samples and sample holders require to be thoroughly cleaned to remove all
traces of the larger abrasives. In general, other parts of the polishing head and PM5 machine such as
the carousel and weights and the machine deck should be cleaned to ensure that there is no
contamination.
Lift off the Abrasive Feed Cylinder and store.
Lift off the corresponding slurry chute and tube and store cleanly.
Fit the plate cover to the plate base and remove the assembly to a clean storage area.
BE-01-9-5 Page: 12

Clean the WG2 polishing head with tissue and mild solvent and wipe the PM5 machine with tissues
damped with soapy water. Do not use solvents to clean the PM5 deck.
Fit the appropriate plate base, pad and plate cover assembly.
Fit the appropriate slurry chute and pipe.
Position the appropriate autofeed cylinder on the rollers.
Clean specimens and holders.
Continue with the next stage of polishing using the general procedures previously described.
4.4 Logitech Standard Process for Production of 30 micron Polished Rock/
Ore Sections
In conjunction with the standard operation discussed previously, the following is the process used by
Logitech to prepare standard 30 micron rock and ore polished sections.
Starting Conditions:
Samples are machine lapped with 600 grit silicon carbide/water slurry to 40 micron thick using the
standard Logitech machine system technology. Also, other samples such as impregnated materials
(e.g. soils) which have been produced using an alumina/oil based slurry are suitable. [If materials in a
sample tend to exhibit high relief, a finer alumina/oil slurry may be required or the starting thickness of
the samples may be increased.]
STAGE 1:
Time : 2 hours
Polishing Surface : Logitech Pellon PSU polishing cloth on a plain plate base
Abrasive : 3 micron diamond powder in suspension of polishing fluid
Concentration : 2 gm per fill of abrasive cylinder (1.5 litres)
Rate Of Feed : 6 drops per minute from the end of the slurry feed tube
Carousel Rotation : Full speed (35 r.p.m. nominal)
Carousel Direction : Contra-lap
Plate Speed : Full speed (70 r.p.m. nominal)
Sample Load Per sq. cm : Typically 100-200g
ie. 2 weights per 28 x 48 mm slide 4 weights (by double load) per 51 x 76 mm slide
STAGE 2:
As STAGE 1 except abrasive is 1 micron diamond powder.
NOTE: The Logitech standard process stops at 1 micron. Users may elect to use further stages with
0.25 micron diamond or other abrasive/lap combinations for their own sample requirements.
BE-01-9-5 Page: 13

5. USE OF OTHER LOGITECH ACCESSORIES
An important feature of the versatility of the WG2 polishing system is its ability to accommodate all other
Logitech sample holding fixtures and lapping and polishing plates for a wide range of alternative
processes.
In general all lapping and polishing plates may be used in conjunction with the polishing head whenever
the specimen geometry is suitable for this type of drive rod control.
All other jigs and conditioning accessories may be used on the lapping plate provided that the WG2
overarm and carousel is either locked up or removed entirely from the vertical column. (The latter option
is simple to do and is usually more convenient - see 5.1 below.)
5.1 Removal of WG2 Overarm and Carousel
With the carousel in the down position, remove all the loading weights.
Remove the hydraulic damper (37 >) by unscrewing the two knurled thumb nuts which retain it to the
overarm and vertical column.
Note, for later replacement, that the sliding piston is uppermost.
Loosen the screw (< 11) which retains the hinge pin (< 10).
Support the overarm and carousel and withdraw the hinge pin.
Whilst holding out the overarm lock-up pin (< 9), lift the overarm and carousel away from the vertical
column and roller arm.
Reassemble the WG2 polishing head by reversal of the above procedure.
BE-01-9-5 Page: 14

6. MAINTENANCE
Little routine maintenance should be required during normal use other than some occasional light oiling
of all external moving parts. Note that excessive oiling will only collect dirt.
6.1 Cleaning
Regular cleaning is advised to ensure smooth working and to prevent contamination. Cleaning can be
carried out with a tissue moistened in solvent. If desired, the carousel can be immersed in an ultrasonic
cleaner up to the level marked on Fig 1 (< 14).
It is for the user to decide, according to the requirements of the work in hand, the level of cleanliness
which must be attained. However, scrupulous cleanliness will result in a consistently higher standard of
polished sample and is recommended.
6.2 Drive Rod Points
Provided they are cleaned beforehand and lubricated with polishing fluid during use, the drive rod points
(< 29) will last a considerable length of time.
Should they eventually wear down to a level that prevents free rotation of the samples they can easily
be replaced. Using the lever provided, unscrew the worn point and screw in the new. Do not overtighten.
6.3 Drive Motor
After considerable use, wear on the carbon brushes may become sufficient to warrant their
replacement. This will be evident by a lack of power and an increase in noise level. Replacing brushes
is not recommended and Logitech therefore offers a motor exchange scheme.
6.3.1 Drive Motor Replacement: Drive Motor Removal
Remove the overarm and carousel assembly.
Remove the polishing and driver plates.
Remove the vertical column and roller arm from the adjusting lever (< 24 >) by unscrewing the nut (< 4)
and washer (< 3). A special spanner is provided for this purpose. Carefully lower the roller arm away
from the adjusting lever.
Remove the six cap screws (< 27) which fix the vertical column to the roller arm.
Remove the three screws (< 35) which retain the motor to the gearbox.
Gently withdraw the motor from the gearbox.
Remove the plug from the power lead by unscrewing the cap and unsoldering the connections. Draw
the lead through the grommet on the side of the motor housing. Remove the motor.
Retain the plug for wiring to the replacement motor.
BE-01-9-5 Page: 15

6.3.2 Drive Motor Replacement: Fitting Replacement Motor
Carefully unpack the replacement motor and examine it for any damage.
Note the position of the first engaging gear within the gearbox. Carefully replace the motor with the
power lead at a suitable orientation and replace the three screws almost tight.
Gently push the motor sideways so that the motor pinion has maximum engagement with the first
engaging gear in the gearbox and tighten the three screws fully.
Pass the power lead through the grommet and reconnect the plug.
Run the motor and readjust the gear engagement, if necessary, to minimise the noise.
Replace the six cap screws which fix the vertical column to the roller arm. Do not tighten fully.
NOTE: It is essential that the vertical column is fixed to the roller arm with the carousel properly
supported by the rollers. To do this, replace the overarm and carousel on the vertical column and adjust
the position of the vertical column on the roller arm so that the carousel runs correctly against the rollers,
before tightening the cap screws fully. Remove the overarm and carousel.
Replace the roller arm and vertical column on the adjusting lever with the washer and nut.
Replace the overarm and carousel.
BE-01-9-5 Page: 16

40
19
Figure 6 - Plan view of PM5 machine with WG2 Head
MAIN DR IVE
30
1 Pillar
2 Star Clamp
6 Vertical Column
19 Sample Holder
23 Fine Adjustment Knob
24 Adjusting Lever
26 Roller Arm
ZE RO
TI ME EL APS ED
HR S
MINS
PR ES ET TIME
SET
+ -
PLATE S PEE D
RP M
STA RT
ST OP
REMOTE
SH UT OFF
ON
OF F
PO W ER
37
ABRASIVE AUTOFEED PRO CESS DATA
ON
CYL
OF F
EM PT Y
KEY
HELP
26 23
30 Rollers
36 Slurry Tube Holder
37 Hydraulic Damper
38 Slurry Scraper
39 WG2 Control Panel
40 Slurry Tube
39
36
38
2
1
6

TRANSFORME R
2EL C-457
Br PuGy
Be Y O
Y Be O R
Br PuGy
Be
Y W W Be
240V
INP UT
Br PuGy
Be
Y Be Y Be
110V
INPUT
R Bk
R Bk
NOTE
CHANGE FUSE F5 ON
US ER INTE RF AC E
BOARD T O 6.3A
Bk
R
Bk
O
Bk
18V T O
S TE PPER
CONTROLLER
36V T O
WG MOTOR
Bk
CONTROLLER
O
Bk
O
36V T O
REVERS ING UNI T
CONTROLLER O
DC POWER IN
Pu
Pk
Br
O
24/0.2
LINK FOR
WG OPTION
Pk
Gy
66 65 64 63 62 61 56 55 54 53 52 51
RAMP RAMP
UP
DOWN
10V
SPRINT ELECTRIC
MIN
I /P
MIN MAX
SPEEDSP EE D ST AB
400LV MOT OR
C ONTR OLL ER
COM
RUN
1
2
3
4
IR
COMP
OFF
OFF
OFF
ON
60V
30V
T ACH
COM
A
+
A-
F-
F
+
N
L
MAX
CURR
1 2 3 4 5 6 7 8 9 10 11 12 13
G R W Y Pk Pu Pk Bk O
7/0.2
PLAT E
DRIVE
SYSTEM INTERF ACE BOARD
BASE CASTING
PL AT E
SPEE D
INITIAL
TRIMMER
S ETTINGS
ENSURE LINK
IS I N 30V
POSI TI ON
CHE CK
SWITCH
SETTINGS
24/0.2
24/0.2
16/0.2
Pk Gy Y Be Pk Bk O
28
27 26 25 24
ZS
-24V
R
F
COM
N
LV R EVE RS ING
UNI T
23 22 21
110
240
RUN
D8
D8
A IN
-
A OUT
+
A
+
IN
A
-
OUT
36 37
Pk
38
31 32 33 34 35
Pk Y Gy Pu Bk
AC POWER
OUT
SP RI NT EL EC TR IC
RUN
4R7 7WAT T
WIREWOUND
(RS.155-857)
7/0.2
24/ 0.2
12-WAY
CONNECTORS
INSIDE BAS E
Bk
Bk
Gy
1 1 1 1
Gy
W
2 2
2 2
W
R
3 3
3 3
R
G
4 4
4 4
G
Y
5 5
5 5
Y
Be
6 6
6 6
Be
Pk
7 7
7 7
Pk
Br
8
9
8
9
8
9
8
9
Br
O
O
10 10
10 10
11 11 11 11
G/ Y
12 12
12 12
G/Y
12-WAY CONNECTOR
AT SANDWI CH PLATE
WG
MOT OR
1 3 2
3-WAY POWER
CONNECTOR BETWEEN
ABRASIVE CASI NG
AND WG MOTOR
1
3 2
Bk G/Y Gy
24/0.2
10K
POTE NTIOM ET ER
R W G
ABRASI VE CASING
16/0.2
GND Ground
L Live
E Earth
N Neutral
Be Blue
Bk Black
Br Brown
G Green
Y Yellow
G/Y Green and Yellow
Gy Grey
Pk Pink
W White
R Red
Sc Screen
I/P Input
LCD Liquid Crystal Display
PSM Programmable Sample Monitor
WIRING DIAGRAM - WG2 POLISHING HEAD
F ORWARD/
RE VER SE
SWITCH
Y
Be Pk
7/ 0.2
Br
JOG
BUTTON
O
7/0.2
BE-01-9-5 Page: 18