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AbraPlan-30
Instruction Manual
Original Instructions
Doc. no.: 16297025-01_A_en-us
Date of release: 2023.03.29
Copyright
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.
All rights reserved. © Struers ApS 2023.03.29.
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-30safety 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
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-30safety 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. Notethat 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
to
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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