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Struers AbraPol-30, Instruction Manual

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Struers AbraPol-30 Instruction Manual Download Page 57

Note

SRP/CS (safety-related parts of a control system) are parts that have an influence
on safe operation of the machine.

Note

Replacement of safety critical components must only be performed by a Struers
engineer or a qualified technician (electromechanical, electronic, mechanical,
pneumatic, etc.).
Safety critical components must only be replaced by components with at least the
same safety level.
Contact Struers Service.

Safety
related
part

Manufacturer/Manufactur
er description

Manufacturer
catalogue no.

Electrical
ref.

Struers
catalogue
no.

Emergency
stop button

Schlegel

Latching mushroom head

ES Ø22 type RV

S1

2SA10400

Emergency
stop
contact

Schlegel

Contact block

MTO, 1 NC

S1

2SB10071

Emergency
stop,
Module
holder

Schlegel

Module holder, 3 elements

MHL

S1

2SA41603

Work zone
guard
interlock
with locking
device

Schmersal

Solenoid interlock

AZM 170SK-
11/02ZRK-2197

24 V AC/V DC

YS1

2SS00025

Safety relay

Omron

Safety relay unit

G9SB-3012-A

KS1

2KS10006

Contactor,
cooling
water

Omron

Motor contactor

J7KNG-10-10-24D

K1

2KM71410

Frequency
inverter,
Disc motor

Lenze

Frequency inverter i550

200 V:

i55AE222D1AV10001
S

400 V:

i55AE222F1AV10001
S

A5

2PU52220

2PU54220

9   Technical data

AbraPol-30

57

Summary of Contents for AbraPol-30

Page 1: ...AbraPol 30 Instruction Manual Original Instructions Doc no 16307025_B_en Date of release 2021 06 14...

Page 2: ...contents of this manual are the property of Struers ApS Reproduction of any part of this manual without the written permission of Struers ApS is not allowed All rights reserved Struers ApS 2021 07 22...

Page 3: ...Noise 15 5 5 Vibration 15 5 6 Compressed air supply 16 5 7 Connecting to an exhaust system 16 5 8 Connecting to the water supply 16 5 9 Connecting to the waste water outlet 17 5 10 Connecting the reci...

Page 4: ...or removing the specimen holder 36 6 5 3 Adjusting the specimen holder position 37 6 6 The preparation process 37 6 6 1 The splash guard 37 6 6 2 Starting the preparation process 38 6 6 3 Stopping th...

Page 5: ...Diagrams 58 9 5 1 Diagrams AbraPol 30 58 9 6 Legal and regulatory information 67 10 Pre installation checklist 67 10 1 Installation requirements 67 10 2 Packaging specifications 68 10 3 Location 68 10...

Page 6: ...may contain aggressive solvents which dissolve e g rubber seals The warranty may not cover damaged machine parts e g seals and tubes where the damage can be directly related to the use of consumables...

Page 7: ...ltage corresponds to the voltage stated on the type plate of the machine The machine must be earthed grounded Always follow local regulations Always switch off the electrical power supply and remove t...

Page 8: ...ays be performed by a qualified technician electromechanical electronic mechanical pneumatic etc 2 2 Safety messages Signs used in safety messages Struers uses the following signs to indicate potentia...

Page 9: ...hout Residual Current Circuit Breakers The equipment must be protected by an insulation transformer double wound transformer Contact a qualified electrician to verify the solution Always follow local...

Page 10: ...ith defective safety devices Contact Struers Service 3 Getting started 3 1 Device description AbraPol 30 is a semi automatic or manual machine for materialographic preparation grinding polishing with...

Page 11: ...ends connecting the machine to an exhaust system to remove fumes from the working area If the emergency stop is activated the power to all hazardous moving parts is cut 3 2 AbraPol 30 overview AbraPol...

Page 12: ...panel functions 21 4 Transport and storage If at any time after the installation you have to move the unit or place it in storage there is a number of guidelines we recommend that you follow Package...

Page 13: ...packing tape on the top of the box 2 Remove the loose parts 3 Remove the unit from the box 4 Unscrew the transport brackets that secure the machine to the pallet 5 Use a forklift truck to lift the mac...

Page 14: ...thed grounded Make sure that the actual electrical power supply voltage corresponds to the voltage stated on the type plate of the machine Incorrect voltage can damage the electrical circuit ELECTRICA...

Page 15: ...e can be fitted with an approved plug or hard wired into the power supply according to the electrical specifications and local regulations 5 4 Noise For information on the sound pressure level value s...

Page 16: ...on the machine 2 Connect the air hose to the compressed air supply 3 Secure the connections with hose clamps 5 7 Connecting to an exhaust system For specifications see Technical data AbraPol 30 54 St...

Page 17: ...hose 2 Lead the water outlet hose out of the machine through one of the openings in the sides of the machine 3 Make sure that the hose slopes downward towards the waste water drain throughout its ent...

Page 18: ...move the unit into position without having to wiggle it from side to side The pump must be placed on the left hand side and close to the rear end of the recirculation unit Note To prevent corrosion S...

Page 19: ...ection of the flow is as stated with an arrow on the pump If the direction is incorrect switch two of the phases EU cable switch two of the phases UL cable switch phases L1 and L2 5 Push the unit into...

Page 20: ...time in the software If you need to adjust the rate of disc cooling 1 Loosen the locknut and turn the regulator screw as needed 2 Tighten the locknut Hint If needed use the throttle valves to adjust t...

Page 21: ...nnector to the connector on the bottle cap OP pump Connect the long piece of tube to the connector on the bottle cap 3 Enter the bottle details in the Bottle configuration menu to make them available...

Page 22: ...ation of the disc Spin function Press this button again to stop the rotation Water Activates the water flow Remember to adjust the flow on the water tap Lubricant For manual dosing of lubricant Abrasi...

Page 23: ...splay shows the configuration and the version of the installed software The display is divided into some main areas See this example A Title bar The title bar shows the function you have selected B In...

Page 24: ...ric value or to toggle between two options If there are only two options press the knob to toggle between the two options If there are more than two options a pop up box is shown The Back button Use t...

Page 25: ...ng settings To change a setting select the field for changing the setting 1 Turn the Turn Push knob to go to the field where you wish to change the setting 2 Press the Turn Push knob to enter the fiel...

Page 26: ...the screen that was shown when the machine was switched off is shown just after the start up screen 6 3 Configuration You can set a number of settings and parameters 1 From the Main menu select Config...

Page 27: ...d confirm your selection 6 3 2 New pass code When you access the Operation mode menu you will be prompted to enter a pass code The default pass code is 2750 Changing the pass code You can change the p...

Page 28: ...ected to pump 1 select Suspension 8 Select Type 9 Select the Select suspension type menu 10 Select the correct type and grain size of the suspension you are using 11 Repeat the procedure for all of th...

Page 29: ...configuration You can define up to 10 new user defined lubricants Hint Configure all in one suspensions as lubricants If they are configured as suspensions the dosing level will not be high enough 1...

Page 30: ...ettings in one of the following units Newton m Metric Lbf mils Imperial Select disc size Select the disc size diameter 300 mm 350 mm Date Set the date Time Set the time Operation mode See Operation mo...

Page 31: ...is installed No When a shift valve is not installed Beacon installed Yes When a beacon is installed No When a beacon is not installed 6 4 Preparation methods The software includes 10 Metalog Guide met...

Page 32: ...the preparation method name indicates that there are unsaved changes 4 When you have changed the required settings press F3 New method Step No 2 is shown 5 When you have created and changed the requi...

Page 33: ...isc and the specimen mover is set to 300 rpm we recommend the following Use disc cooling Pre dose sufficiently if you work with new preparation surfaces Use a 200 mm specimen holder on a 350 mm surfac...

Page 34: ...Lock method 3 You will be prompted to confirm that you wish to lock the method 4 The symbol in front of the method name shows that the method is locked If you make changes to this preparation method y...

Page 35: ...is started This lubricates the surface to prevent damage from occurring if the specimens were to run on a dry surface Applicable values depend on the frequency of use and surface types For frequently...

Page 36: ...coupling Use working gloves to protect fingers and hands Inserting the specimen holder 1 Place the specimen holder under the quick coupling and support it with your fingers 2 Press and hold down the f...

Page 37: ...the handle clockwise or counter clockwise to the desired position then release the handle to re engage the torque moment on the screw 5 Tighten the screws again A Handle B Screw Further adjustments Fo...

Page 38: ...utton Recirculation option The recirculation pump starts automatically when the process is started The preparation process The display shows the status of the process as shown in this example The gree...

Page 39: ...n function press and hold the Disc rotation button It rotates at 150 rpm 2 To stop the spin function press the Disc rotation button again At 600 rpm 1 Close the cover of the machine 2 To start the spi...

Page 40: ...ol or similar solvents If the machine is not to be used for a longer period of time Clean the machine and all accessories thoroughly 7 2 Daily Clean all accessible surfaces with a soft damp cloth Reci...

Page 41: ...with the specific equipment Clean the recirculation unit Clean the recirculation unit tank Fill up the recirculation unit tank 7 3 1 Cleaning the bowl To clean the bowl use the bowl cleaning function...

Page 42: ...l change to Clean 7 4 Monthly Recirculation unit See the manual supplied with the specific equipment Clean the recirculation unit Replace the cooling fluid at least once a month Note Replace the cooli...

Page 43: ...size 4 From the Maintenance menu select Empty recirculation tank 5 Press F1 to start the pump 6 The pump stops automatically To stop it manually press Stop 7 Follow the on screen instructions CAUTION...

Page 44: ...placed Recirculation unit See the manual supplied with the specific equipment 7 5 1 Testing safety devices The safety devices must be tested at least once a year WARNING Do not use the machine with de...

Page 45: ...stops rotating The cover also acts as a shield to guard the operator in case of hazardous projectiles such as specimens which are not properly secured Test 3 1 Open the protective cover 2 Press the St...

Page 46: ...o tabs on the pump and remove the bottom cover of the pump Hint If needed use a flat headed screwdriver to press gently on the tabs A Couplings B Silicon tubes C Tabs 4 Remove the three rollers 5 Remo...

Page 47: ...echnical questions or when you order spare parts state serial number and voltage frequency The serial number and the voltage are stated on the type plate of the machine For further information or to c...

Page 48: ...he display is sensitive to temperature changes Change the brightness in the Configuration menu Water is not draining away Drain hose squeezed Straighten the hose Drain hose clogged Clean the hose Drai...

Page 49: ...sed This might affect removal accuracy For the greatest accuracy start a new process When the process is paused a new reference point will be calculated for the remaining removal and this will affect...

Page 50: ...ake a note of the reason code displayed 124 Warning Water for polishing valve bad electrical connection detected Bad wiring in the valve controlling polishing water Re start If the error remains conta...

Page 51: ...ter dripping might occur from the dosing arm Re start If the error remains contact Struers Service 46 Error The head did not move down sufficiently for the calibration to start Calibration aborted Thi...

Page 52: ...If the error remains contact Struers Service Make a note of the error code displayed 103 Error The required air pressure is not obtained Check the air supply Make sure that the air pressure is min 6...

Page 53: ...Re start If the error remains contact Struers Service 61 Fatal error Machine failed during Power On Self Testing Try restarting the machine Contact Struers technical support if the problem persists Re...

Page 54: ...ng temperature 5 40 C 41 104 F Humidity 85 RH non condensing Storage and transport conditions Surrounding temperature 20 60 C 4 140 F Humidity 85 RH non condensing Water supply Water pressure 1 4 bar...

Page 55: ...e size at minimum fuse 3 x AWG12 2 5 mm2 PE Max fuse 35 A Minimum cable size at maximum fuse 3 x AWG12 2 5 mm2 PE 3 x 380 480 V 50 60 Hz Min fuse 15 A Minimum cable size at minimum fuse 3 x AWG12 2 5...

Page 56: ...PL a Emergency stop EN 60204 1 Stop category 0 EN ISO 13849 1 Category 1 Performance Level PL c 9 3 Noise and vibration levels Noise level A weighted sound emission pressure level at workstations LpA...

Page 57: ...ue no Electrical ref Struers catalogue no Emergency stop button Schlegel Latching mushroom head ES 22 type RV S1 2SA10400 Emergency stop contact Schlegel Contact block MTO 1 NC S1 2SB10071 Emergency s...

Page 58: ...V10001 S A4 2PU52075 2PU54075 9 5 Diagrams If you wish to view specific information in detail see the online version of this manual 9 5 1 Diagrams AbraPol 30 Title No AbraPol 30 Block diagram 16303050...

Page 59: ...over Working light 24V S4 1xoutputs 1xoutputs 1xoutputs 1xoutputs sink driver Y7 Release Pressure X5 155 C Thermal protection Belt gearing 5 1 Disc 40 600 RPM CW CCW 3 2 2kW 4 pole M2 AC motor for dis...

Page 60: ...pecimen mover motor BK3 BK2 BK1 YE GN FT1 Plate for electronics XPE3 Plate for electronics IT filter screws MUST be removed 150 C EN 61800 5 1 K1 2 5 3 1 6 4 M2 Disc motor BK34 GNYE11 2 2kW V PE U Mot...

Page 61: ...river BU 33 X14 2 Input KS1 status E STOP status Sink Driver X4 12 11 W7 WH BU 9 BU 13 BU 18 BU 17 BU 16 BU 15 BU 12 BU 14 BU 21 BU 20 BU 19 BU 23 BU 24 Sink Driver X4 8 X4 2 24V 1 GND 24V 1 chain T31...

Page 62: ...D D GND 1 2 7x0 25mm 3 GY 4 YE GN WH BN W11 RD WH GN X4 4xAWG24 shield 9p male BK YE RED YELLOW GREEN 1 2 4 5 3 X16 1 X16 5 4 3 2 1 5 WH BN X3 5 X3 13 24V 1 Sink Driver Beacon Optional Accessory GN YE...

Page 63: ...X42 X41 2 1 2 1 24Vdc YE GN BN WH Motor 24Vdc DP module RD BK RD BK Motor 4x0 25mm 9p male X42 X41 2 1 2 1 24Vdc YE GN BN WH Motor 24Vdc DP module RD BK RD BK Motor 4x0 25mm 9p male X42 X41 2 1 2 1 24...

Page 64: ...e Torque Off 3 4 pole 11 X14 1 X14 2 GND Input Status SIB SIA GS 2 1 A1 A2 X4 12 Sink Driver L1 L2 L3 K1 X20 Recirkulationpump connector L1 L2 L3 L1 L2 L3 24V 1 24V S4 24V S4 24V S2 M2 AC Motor for Po...

Page 65: ...way air actuator driven valve 163000091 Y7 Solenoid Valve 2YM12120 SU2 GY BN W15 Y1 Connection of Tap water valve Y6 YE WH PK GN Water to pistol Disc Cooling Water to OP S SU3 Drain Accessories Tub If...

Page 66: ...4 1 n e p o n r u t 2 1 n e p O 2 P B e r u s s e r p t o l i P A t i n I r p p A e t a d r p p A t i n I w a r D n o i t p i r c s e d n o i s i v e R e t a d a e r C v e R 2 3 1 4 F E D A B C 0 3 l...

Page 67: ...try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment in...

Page 68: ...floor to the following units Emergency stop 107 cm 42 1 Front panel 130 cm 51 2 Display 141 cm 55 5 Cover handle open closed Open 137 cm 53 9 Closed 106 cm 41 7 Illumination Make sure that the machine...

Page 69: ...4 Dimensions Side view A 163 cm 5 4 without beacon 193 cm 6 4 with beacon B 84 cm 2 9 Front view A 163 cm 5 4 without beacon 193 cm 6 4 with beacon B 97 cm 3 2 10 Pre installation checklist AbraPol 30...

Page 70: ...here is enough room behind the machine for access to the compressed air connection 10 6 Transport and storage If at any time after the installation you have to move the unit or place it in storage the...

Page 71: ...e packing crate Remove the transport brackets that secure the machine to the pallet 10 8 Lifting CRUSHING HAZARD Take care of your fingers when handling the machine Wear safety shoes when handling hea...

Page 72: ...size at minimum fuse 3 x AWG12 2 5 mm2 PE Max fuse 35 A Minimum cable size at maximum fuse 3 x AWG12 2 5 mm2 PE Voltage frequency 3 x 380 480 V 50 60 Hz Min fuse 15 A Minimum cable size at minimum fu...

Page 73: ...lation transformer double wound transformer 10 10 Safety specifications Safety Circuit Categories Performance Level Emergency stop EN 60204 1 Stop category 0 EN ISO 13849 1 Category 1 Performance Leve...

Page 74: ...3 Exhaust option Recommended Minimum capacity 50 m3 h 1750 ft3 h at 0 mm 0 water gauge An exhaust system is required when working with alcohol based suspensions or lubricants 10 14 Recirculation unit...

Page 75: ...struers com Responsibility of the manufacturer The following restrictions should be observed as violation of the restrictions may cause cancellation of Struers legal obligations The manufacturer assu...

Page 76: ...lse med f lgende direktiver og standarder de Wir erkl ren dass das genannte Produkt den folgenden Richtlinien und Normen entspricht el es Declaramos que el producto mencionado cumple con las siguiente...

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