Struers AbraPlan-30 User manual

Brand: Struers

Model: AbraPlan-30

Type: User manual

AbraPlan-30

Instruction Manual

Original Instructions

Doc. no.: 16297025-01_A_en-us

Date of release: 2023.03.29

The 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.

2 AbraPlan-30

Table of Contents

1 About this manual 6

1.1 Accessories and consumables 6

2 Safety 6

2.1 Intended use 6

2.2 AbraPlan-30safety precautions 7

2.2.1 Read carefully before use 7

2.3 Safety messages 8

2.4 Safety messages in this manual 9

3 Getting started 10

3.1 Device description 10

3.2 AbraPlan-30 - overview 11

4 Transport and storage 13

4.1 Storage 13

5 Installation 13

5.1 Unpack the machine 13

5.2 Check the packing list 14

5.3 Power supply 14

5.4 Noise 15

5.5 Vibration 15

5.6 Compressed air supply 16

5.7 Connect to an exhaust system 16

5.8 Connecting to the waste water outlet 16

5.9 Connect the recirculation unit 16

5.10 Connecting an external recirculation unit 18

5.11 Connecting to the water supply 19

6 Operate the device 19

6.1 Control panel functions 19

6.2 The display 21

6.2.1 Navigating in the display 22

6.2.2 Main menu 22

6.2.3 Changing settings and text 23

6.2.4 Software settings 23

6.3 Configuration 24

6.3.1 Operation mode 24

AbraPlan-30 3

6.3.2 New pass code 25

6.3.3 Water during grinding 25

6.4 Mounting a grinding stone or diamond grinding disc 26

6.5 Clamp and level the specimens 29

6.6 Inserting or removing the specimen holder 29

6.7 Grinding 30

6.7.1 Grinding setup 30

6.7.2 Starting the grinding process 31

6.7.3 Stopping the grinding process 32

6.8 Dressing 32

6.8.1 Dressing setup of diamond tool 33

7 Maintenance and service 36

7.1 General cleaning 36

7.2 Daily 36

7.2.1 Checking the recirculation tank 36

7.3 Weekly 37

7.3.1 Cleaning the bowl 37

7.4 Monthly 38

7.4.1 Cleaning the recirculation unit 39

7.4.2 Changing the cooling fluid 39

7.5 Annually 40

7.5.1 Test the safety devices 40

7.5.2 Emergency stop 41

7.5.3 Safety cover 41

7.6 Spare parts 42

7.7 Service and repair 42

7.8 Disposal 43

8 Troubleshooting - AbraPlan-30 43

8.1 Messages and errors - AbraPlan-30 44

8.1.1 Messages 45

8.1.2 Errors 45

9 Technical data 49

9.1 Technical data 49

9.2 Safety Circuit Categories/Performance Level 52

9.3 Noise and vibration levels 52

9.4 Safety Related Parts of the Control System (SRP/CS) 53

9.5 Diagrams 54

9.5.1 Diagrams - AbraPlan-30 54

9.6 Legal and regulatory information 58

4 AbraPlan-30

10 Manufacturer 58

Declaration of Conformity 59

AbraPlan-30 5

1 About this manual

CAUTION

Struers equipment must only be used in connection with and as described in the

Instruction Manual supplied with the equipment.

Note

Read the Instruction Manual carefully before use.

Note

If you wish to view specific information in detail, see the online version of this manual.

1.1 Accessories and consumables

Accessories

For information about the available range, see the AbraPlan-30 brochure:

•The Struers Website (http://www.struers.com)

Consumables

The equipment is designed to be used only with Struers consumables specifically designed for this

purpose and this type of machine.

Other products 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 not supplied by Struers.

For information about the available range, see:

•The Struers Consumables Catalogue (via https://www.struers.com)

2 Safety

2.1 Intended use

The machine is for use in a professional working environment (e.g. a materialographic laboratory).

AbraPlan-30 is for professional automatic plane grinding of materials for further materialographic

preparation and inspection.

The device is designed to be used with Struers consumables specially designed for this purpose and

this type of device.

The machine must be operated only by skilled/trained personnel.

6 AbraPlan-30

1 About this manual

Do not use the machine for

the following

Preparation (grinding or polishing) of materials other than solid

materials suitable for materialographic studies.

The machine must not be used for any type of explosive and/or

flammable material, or materials which are not stable during

machining, heating or pressure.

Model AbraPlan-30

2.2 AbraPlan-30safety precautions

2.2.1 Read carefully before use

1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries

and material damage.

2. The machine must be installed in compliance with local safety regulations. All functions on

the machine and any connected equipment must be in working order.

3. The operator must read the safety precautions and Instruction Manual, as well as relevant

sections of the manuals for any connected equipment and accessories. The operator must

read the Instruction Manual and, where applicable, the Safety Data Sheets for the applied

consumables.

4. Do not use the machine for preparing materials that are flammable or unstable as a result of

mechanical processing, pressure or heat during the preparation process (e.g. combustible or

explosive materials).

5. Make sure that the actual electrical power supply voltage corresponds to the voltage stated

on the type plate of the machine. The machine must be earthed (grounded). Always follow

local regulations.

6. This machine must be operated and maintained only by skilled/trained personnel.

7. Struers equipment must only be used in connection with and as described in the Instruction

Manual supplied with the equipment.

8. If the equipment is subjected to misuse, incorrect installation, alteration, neglect, accident or

incorrect repair, Struers will accept no responsibility for damage to the user or the

equipment.

9. Dismantling of any part of the equipment, during service or repair, should always be

performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic,

etc.).

10. The equipment is designed to be used only with Struers consumables specifically designed

for this purpose and this type of machine.

11. Notethat the machine's center of gravity is located in the upper part of the machine.

12. Make sure that the crossbar is fitted to the machine before lifting it.

13. When you lift the machine with a forklift, always lift it from the front.Never lift it from the side

or the rear.

14. Make sure to place the machine on a stable floor that can bear the weight of the machine.

15. Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens.

2 Safety

AbraPlan-30 7

16. If you observe malfunctions or hear unusual noises, switch off the machine and call technical

service.

17. Do not switch the machine on and off more than once every five minutes. Damage to the

electrical components could occur.

18. In case of fire, alert bystanders and the fire brigade.Disconnect the electrical power supply.Use

a powder fire extinguisher.Do not use water.

19. The machine must be disconnected from the electrical power supply before any service.Wait 5

minutes until residual potential on the capacitors is discharged.

20. Make sure that the specimens are securely fixed to the specimen holder before using the

machine. Make sure that you are using the correct screws.

21. Always use working gloves when changing the grinding stone/diamond grinding discs.

2.3 Safety messages

Struers uses the following signs to indicate potential hazards.

ELECTRICAL HAZARD

This sign indicates an electrical hazard which, if not avoided, will result in death or

serious injury.

DANGER

This sign indicates a hazard with a high level of risk which, if not avoided, will result in

death or serious injury.

WARNING

This sign indicates a hazard with a medium level of risk which, if not avoided, could

result in death or serious injury.

CAUTION

This sign indicates a hazard with a low level of risk which, if not avoided, could result

in minor or moderate injury.

CRUSHING HAZARD

This sign indicates a crushing hazard which, if not avoided, could result in minor,

moderate or serious injury.

HEAT HAZARD

This sign indicates a heat hazard which, if not avoided, can result in minor, moderate

or serious injury.

General messages

Note

This sign indicates that there is a risk of damage to property, or a need to proceed

with special care.

8 AbraPlan-30

2 Safety

Hint

This sign indicates that additional information and hints are available.

2.4 Safety messages in this manual

CAUTION

Struers equipment must only be used in connection with and as described in the

Instruction Manual supplied with the equipment.

ELECTRICAL HAZARD

The machine must be earthed (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.

ELECTRICAL HAZARD

For electrical installations with Residual Current Circuit Breakers

For AbraPlan-30 a residual current circuit breaker Type B, 30 mA is required (EN

50178/5.2.11.1).

For electrical installations without 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 regulations.

CAUTION

Prolonged exposure to loud noises may cause permanent damage to a person’s

hearing.

Use hearing protection if the exposure to noise exceeds the levels set by local

regulations.

ELECTRICAL HAZARD

Make sure that the electrical power supply voltage corresponds to the voltage

stated on the type plate of the pump.

Incorrect voltage can damage the electrical circuit.

CAUTION

The cooling unit tank is very heavy when it is full.

ELECTRICAL HAZARD

The pump of the recirculation cooling unit must be earthed (grounded).

Make sure that the electrical power supply voltage corresponds to the voltage

stated on the type plate of the pump.

Incorrect voltage can damage the electrical circuit.

2 Safety

AbraPlan-30 9

ELECTRICAL HAZARD

Ask a qualified electrician to verify that the external cooling unit can be used with the

machine.

CAUTION

The pressure of the cooling fluid supplied to the machine must be max. 2 bar.

CAUTION

Do not use the machine with non-compatible accessories or consumables.

CAUTION

The grinding stone/diamond grinding disc has rough or sharp edges.

Use working gloves to protect fingers and hands.

CAUTION

A specimen holder with specimens can be heavy. Do not release the specimen

holder until it is secured in the coupling.

Use working gloves to protect fingers and hands.

CAUTION

Avoid skin contact with the cooling fluid additive.

WARNING

Do not use the machine with defective safety devices.

Contact Struers Service.

WARNING

Safety critical components must be replaced after a maximum lifetime of 20 years.

Contact Struers Service.

3 Getting started

3.1 Device description

AbraPlan-30 is a semi-automatic machine for high speed materialographic plane grinding with a 356

mm diameter grinding disc.

A recirculation cooling unit must be connected for supplying cooling water to the grinding process.

The operator selects the grinding surface and the preparation parameters. Stone guard and flushing

gun must be in place before the grinding process is started.

10 AbraPlan-30

3 Getting started

The operator starts the process by clamping the specimens in the specimen holder and placing

the specimen holder in the machine. The cover is locked when the operator starts the machine,

and it remains locked until the motors are stopped.

The operator presses the start button on the control panel to start the grinding process.

The machine stops automatically when the process time or the removal process is completed.

The operator cleans the specimens before the next preparation step or inspection.

We recommend 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 AbraPlan-30 - overview

AbraPlan-30

Front view - with safety cover

ASafety cover

BEmergency stop

CCover plate for compartment containing

recirculation cooling unit

Front view - without safety cover

ADisplay

BControl panel

CDresser arm

DMotor - Specimen holder

EQuick coupling - Specimen holder

3 Getting started

AbraPlan-30 11

Side view - left

AConnection for exhaust

BCompressed air inlet

COpening for water outlet hose

Side view - right

AElectrical power switch

BOpening for water outlet hose

CElectrical connection box

Electrical connection box

AAUX connector

BBeacon connection

CService sockets

The grinding chamber

AStone guard

BFlushing/cooling unit (flushing gun and holder)

CDressing arm

Control panel

See Control panel functions ►19.

12 AbraPlan-30

3 Getting started

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 the unit securely before transportation. Insufficient packaging could cause damage

to the unit and will void the warranty. Contact Struers Service.

• We recommend that you use the original packaging and fittings.

4.1 Storage

Note

We recommend that you keep all original packaging and fittings for future use.

Disconnect the unit from the electrical power supply.

• Remove any accessories.

• Clean and dry the unit before storage.

• Place the machine and accessories in their original packaging.

5 Installation

5.1 Unpack the machine

Note

We recommend that you keep all original packaging and fittings for future use.

1. Cut the 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 machine from the pallet. Lift the machine from the front.

6. Place the machine on a plane and horizontal floor.

7. Remove the locking pin from the crossbar and remove the bar. Keep the crossbar for use if

you need to move the machine.

For details about the weight of this machine, see Technical data ►49.

Moving the machine

To move the machine, use a fork-lift truck and a crossbar.

4 Transport and storage

AbraPlan-30 13

5.2 Check the packing list

Optional accessories may be included in the packing box.

The packing box contains the following items:

Pcs. Description

1 AbraPlan-30

1 Outlet hose with straight PVC pipe. Diameter: 50 mm. Length: 2.5 m.

1 Inlet hose

1 Hose for emptying the cooling unit tank

2 Hose clamp. Diameter: 11 mm

2 Hose clamp. Diameter: 40-60 mm

1 Hose for compressed air. Length: 2 m

1 Hose connection for compressed air. Diameter: 8 mm

1 Rubber disc. Diameter: 350 mm

1 Flange

1 Bolt M12 for grinding stone flange

1 Allen key, 8 mm

1 Fork spanner, 24 mm

1 Instruction Manual set

5.3 Power supply

ELECTRICAL HAZARD

The machine must be earthed (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.

ELECTRICAL HAZARD

For electrical installations with Residual Current Circuit Breakers

For AbraPlan-30 a residual current circuit breaker Type B, 30 mA is required (EN

50178/5.2.11.1).

For electrical installations without 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 regulations.

Procedure

For specifications see the section Technical data.

14 AbraPlan-30

5 Installation

1. Open the electrical connection box. A

2. Connect a 4-lead or 5-lead cable as shown.

PE Earth (ground)

N Neutral (not used internally)

L1 Phase

L2 Phase

L3 Phase

EU cable

L1 Brown

L2 Black

L3 Black or Grey

Earth (ground) Yellow/Green

Neutral Blue

UL cable

L1 Black

L2 Red

L3 Orange/Turquoise

Earth (ground) Green (or Yellow/Green)

Neutral White

The other end of the cable 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, see this section: Technical data ►49

CAUTION

Prolonged exposure to loud noises may cause permanent damage to a person’s

hearing.

Use hearing protection if the exposure to noise exceeds the levels set by local

regulations.

5.5 Vibration

For information on the total vibration exposure to hand and arm, see this section: Technical data

►49

5 Installation

AbraPlan-30 15

5.6 Compressed air supply

For specifications, see Technical data ►49.

1. Connect the compressed air hose to the compressed air inlet on the machine.

2. Connect the air hose to the compressed air supply.

3. Secure the connections with hose clamps.

5.7 Connect to an exhaust system

For specifications, see Technical data ►49.

Struers recommends that the machine is connected to an exhaust system.

1. Connect a 52 mm pipe to the exhaust outlet on the machine.

2. Connect the other end of the pipe to the exhaust system.

5.8 Connecting to the waste water outlet

If you are connecting the machine to the waste water drain

1. The machine is delivered with a water outlet 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 entire

length. If needed, shorten the hose.

If you are connecting the machine to a recirculation unit

Usually, the machine is connected to the recirculation tank or to an external recirculation unit.

Recirculation unit: See Connect the recirculation unit ►16

External recirculation unit: See Connecting an external recirculation unit ►18

5.9 Connect the recirculation unit

To ensure optimal cooling, mount a recirculation unit on the machine.

Note

Before you connect the recirculation unit to the machine, you must prepare it for use.

See the Instruction Manual for this unit.

ELECTRICAL HAZARD

Make sure that the electrical power supply voltage corresponds to the voltage stated

on the type plate of the pump.

Incorrect voltage can damage the electrical circuit.

16 AbraPlan-30

5 Installation

Filling the recirculation tank

1. Before you fill the tank, make sure that there

is room under the machine for the

recirculation unit to slide in easily. If this is

not the case, use the adjustable feet to adjust

the height of the machine.

2. Make sure that the recirculation unit is placed

correctly under the machine:

– The wheels of the unit must be in line

with the sides of the compartment so

that you can 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, Struers recommends using a Struers additive in the cooling

water. For more information, see the additive container.

3. Line the tank with a clean plastic liner.

CAUTION

The recirculation tank is very heavy when it is full.

Note

Do not overfill the tank.

Avoid spilling when you move the tank.

4. Fill up the tank with cooling fluid. Make sure

that the water/additive ratio is correct.

5 Installation

AbraPlan-30 17

Connecting the unit to the machine

1. Connect the water inlet hose to the quick

coupling on the recirculation pump.

AElectrical power socket - not shown

BWater inlet hose - to machine

CRecirculation pump

DQuick coupling - on pump

2. Insert the water outlet hose from the machine

into the large hole of the filter unit. If needed,

shorten the hose.

3. Connect the cable from the recirculation pump

to the electrical power socket of the recirculation

unit inside the compartment.

4. Make sure that the direction 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 place in the compartment

under the machine.

5.10 Connecting an external recirculation unit

1. Guide the water outlet hose through the opening on the left or right side of the machine to the

recirculation unit.

2. Connect the water outlet on the pump to the water inlet hose.

ELECTRICAL HAZARD

Make sure that the electrical power supply voltage corresponds to the voltage stated

on the type plate of the pump.

Incorrect voltage can damage the electrical circuit.

CAUTION

The pressure of the cooling fluid supplied to the machine must be max. 2 bar.

18 AbraPlan-30

5 Installation

3. Connect the cable from the external pump to the electrical power

socket of the recirculation unit inside the compartment.

Wiring: For specifications see the section Technical data.

Note

If you are using the AUX connection, contact

Struers Service more information on the

connection and the required flow.

4. Connect the external pump control to the AUX connection on the

rear of the machine. A

5.11 Connecting to the water supply

You can connect the machine to the main water supply. However, this requires a special valve

and flow sensor.

If needed, contact Struers Service for advice.

6 Operate the device

CAUTION

Do not use the machine with non-compatible accessories or consumables.

6.1 Control panel functions

ADisplay

BFunction keys - F1 to F4

C Dress function

DFlush function

E Back function

FTurn/push knob knob

GStart button

HStop button

IEmergency stop button

6 Operate the device

AbraPlan-30 19

Button Function

Function key

• Press this button to activate controls for various purposes. See the bottom line

of the individual screens.

Dress

• Press this button to dress the grinding stone.

Flush

• Press this button to start and stop the flushing gun.

The Turn/push knob knob

• Turn the Turn/push knob knob to move the focus on the screen and change

steps and setting. Press to toggle when only 2 options are available.

• Press the Turn/push knob knob to select a function or save a selected setting.

Back

• Press this button to return to the previous screen or to cancel

functions/changes.

Start

• Starts the preparation process.

Stop

• Stops the preparation process.

20 AbraPlan-30

6 Operate the device

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Struers AbraPlan-30 User manual

Brand: Struers

Model: AbraPlan-30

Type: User manual

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Struers AbraPlan-30 User manual

Struers AbraPlan-30 User manual

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