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Struers Magnutom-5000 Instruction Manual

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Manual No.: 16587025-03
Revision B
Date of Release:2023.05.22
Magnutom-5000
Instruction Manual

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Summary of Contents for Struers Magnutom-5000

  • Page 1 Manual No.: 16587025-03 Revision B Date of Release:2023.05.22 Magnutom-5000 Instruction Manual...

  • Page 2: Table Of Contents

    Magnutom-5000 Instruction Manual Table of Contents Page Intended use ................. 3 Safety Precaution Sheet .............. 5 Icons and typography ..............7 User’s Guide ................. 9 Reference Guide ................ 66 Quick Reference............... 121 Pre Installation check list ............122 Declaration of Conformity ............133...

  • Page 3: Intended Use

    Magnutom-5000 Instruction Manual Intended use Magnutom-5000 is intended for automatic cutting of metallic or other solid materials by wet abrasive cutting. The machine is only to be operated by skilled/trained personnel in a professional working environment (e.g. a materialography laboratory).
  • Page 4 Original instructions: The contents of this manual is the property of Struers. Reproduction of any part of this manual without the written permission of Struers is not allowed. All rights reserved. © Struers 2023.

  • Page 5: Safety Precaution Sheet

    13. Use of safety goggles and gloves are recommended when using the flushing hose. 14. Do not work on or around cutting table when the table is repositioned. 15. For maximum safety and lifetime of the machine, use only original Struers consumables.
  • Page 6 The equipment is designed for use with consumables supplied by Struers. If subjected to misuse, improper installation, alteration, neglect, accident or improper repair, Struers will accept no responsibility for damage(s) to the user or the equipment. Dismantling of any part of the equipment, during maintenance, service or repair, should always be performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.).

  • Page 7: Icons And Typography

    Magnutom-5000 Instruction Manual Icons and typography Struers uses the following icons and typographical conventions. A list of the Safety Messages used in this manual can be found in the chapter on in the Reference Guide section of Cautionary Statements the Instruction Manual.

  • Page 8: Typographic Conventions

    Magnutom-5000 Instruction Manual General Messages NOTE: indicates a risk of damage to property, or the need to proceed with special care. HINT: indicates additional information and tips. Colour Inside Logo The 'colour inside' logo on the cover page of this Instruction Manual indicates that it contains colours which are considered to be useful for the correct understanding of its contents.

  • Page 9: User's Guide

    Handling noise (during operation ..........21 Connecting a Recirculation Cooling Unit ........22 Connecting a Coolimat-2000 Recirculation Cooling Unit..22 Connecting other Struers Cooling Systems......22 Connecting Other External Filter Units ........23 Moveable X-Table (option) ............23 Moveable R-Table (option) ............24 2.
  • Page 10 Magnutom 5000 Instruction Manual Main Menu..................31 Changing the Language ............32 Editing Numeric Values ............33 Editing Alphanumeric Values..........34 Editing Cutting Sequences Names ......... 35 Single Cut ..................36 Feed speed ................37 Cut length ................37 Cut-off wheel ................. 38 Wheel Speed .................
  • Page 11 Magnutom 5000 Instruction Manual 3. Maintenance General Cleaning ................54 Daily ..................... 54 AxioWash ..................55 Cleaning the Cutting Chamber ..........56 Maintenance of Cut-off Wheels ............. 57 Storage of Bakelite Bonded Al Cut-off Wheels ....57 Maintenance of Diamond and CBN Cut-off Wheels ....57 Weekly ..................

  • Page 12: Getting Started

    Instruction Manual 1. Getting Started Device Description Magnutom-5000 is an automatic cut-off machine, designed for cutting of large and over-sized workpieces. The machine is designed for wet, abrasive cutting of all stable and non-explosive metals. It is equipped with a re-circulation system for cooling liquid.

  • Page 13: Unpacking And Placing Magnutom

    Magnutom 5000 Instruction Manual Unpacking and Placing WARNING Magnutom When lifting the machine by the built-in truck lifting point, ensure that the boom is properly secured with the locking pins provided. Adjust the positon of the fork following the pictures bellow to prevent a damage of the machine.
  • Page 14 Magnutom 5000 Instruction Manual HINT: Store the packing crate, foam packaging, fittings, transport- and transport beams for future use. Failure to use the original transport safety devices and fittings could cause severe damage to the machine and will void the warranty.

  • Page 15: Getting Acquainted With Magnutom

    Magnutom 5000 Instruction Manual Getting Acquainted with Take a moment to familiarise yourself with the location and names of Magnutom the Magnutom components. Signalling light Safety lock release (optional) Control Panel Side door Emergency stop Front door Water outlet Hold-to-run button Demister (optional) Access door MAIN SWITCH...

  • Page 16: Hold-To-Run Operation

    Magnutom 5000 Instruction Manual To move the cut-off wheel while the protection hood or side door are Hold-to-run operation open, press the Hold-to-run button while operating the joystick. Press Hold-to-run button while operating the joystick. NOTE: Hold-to-run functionality might get corrupted in case of a collision between i.e.

  • Page 17: Power Supply

    Magnutom 5000 Instruction Manual Side views Main Switch Water outlet Access to Electrical 24 V connection for connection box Recirculation Cooling Unit Inspection door Compressed air inlet Quick coupling for water inlet Power Supply ELECTRICAL HAZARD Switch the power off when installing electrical equipment. •...
  • Page 18 Magnutom 5000 Instruction Manual  The other end of the cable can be fitted with an approved plug or hard-wired into the mains, according to the electrical specifications and local regulations. NOTE: Check that the mains voltage corresponds to the voltage stated on the type plate on the side of the machine.

  • Page 19: Compressed Air Connections

    Magnutom 5000 Instruction Manual Compressed Air Connections To connect compressed air:  Connect an 8 mm compressed air hose to the compressed air inlet. NOTE: The air pressure must be between 5.5 bar (80 psi)and 9.9 bar (145 psi) min 40l/min. Magnutom is fitted with a water / oil filter that removes excessive Emptying the Water / Oil Filter amounts of these substances from the compressed air supply.
  • Page 20 Magnutom 5000 Instruction Manual 1. Nut 4. Spindle lock button 2. Flange 3. Spindle lock NOTE: Conventional cut-off wheels based on Al /SiC abrasives should be placed between two cardboard washers, to protect the cut-off wheel and flanges. NOTE: For maximum precision with diamond or CBN cut-off wheels, do not use cardboard washers.

  • Page 21: Connection To An External Exhaust System

    Magnutom 5000 Instruction Manual Connection to an External Struers recommends the use of an exhaust system as workpieces Exhaust System may emit harmful gases when cut. Magnutom is prepared for connection to an exhaust system via a 160 mm (approx. 6.3") fitting on the top of the cabinet.

  • Page 22: Connecting A Recirculation Cooling Unit

    To ensure optimal cooling, Magnutom should be fitted with a Cooling Unit Recirculation Cooling Unit. Struers Coolimat-2000 is designed for use with large cut-off machines such as Magnutom. Coolimat-2000 are available as a Band Filter or a Static Filter unit.

  • Page 23: Connecting Other External Filter Units

    Magnutom 5000 Instruction Manual Connecting Other NOTE: External Filter Units Please contact a qualified electrician to verify that the external filter unit can be used with Magnutom. The electrical diagrams in the Spare Parts section of the manual can be used for identification of the different wires.

  • Page 24: Moveable R-Table (Option)

    Magnutom 5000 Instruction Manual The Rotary-table option is a motor driven, movable table. The table Moveable R-Table (option) can be moved left to right by moving the joystick left or right and can rotate +/-180°, by rotating joystick. The R-table option is required to use the Magnutom’s Cutting sequence functions.

  • Page 25: Operation

    Magnutom 5000 Instruction Manual 2. Operation Using the Controls Control Panel Magnutom-5000, XY table control Magnutom-5000, Rotary table panel. control. panel.
  • Page 26 Magnutom 5000 Instruction Manual Name Function Name Function Menu dependent UNCTION Multifunction knob. multi-function key. Push knob to select See the bottom function. line of the Turn knob to move individual screens. the cursor or to adjust settings. Push knob to store modified settings Starts/ Stops Move up- or...

  • Page 27: Sleep Mode

    Magnutom 5000 Instruction Manual If the Magnutom has not been used for 15 minutes, the backlight is Sleep Mode dimmed and the cutting chamber light is switched off. This is to increase their lifetimes.  Push any Control Panel key to reactivate the backlight and the light.

  • Page 28: Signals

    Magnutom 5000 Instruction Manual Signals The Cutting chamber lights will flash continuesly if Magnutom has Cutting chamber lights been idle for 30 seconds after a cutting process is completed. (The lights will not flash if the operator has interacted with Magnutom) Signalling light (option) Signalling light...
  • Page 29 Magnutom 5000 Instruction Manual Overview of Signals* State “Operating” “Stopped” “Attention” “Emergency” Green light Yellow light Yellow light Red light Operation is in progress. Operation is stopped. Stopping is impending. Operation is stopped. A caution or marginal A caution or marginal A protective device is condition is detected, and condition is detected, and...

  • Page 30: Navigating The Software

    Magnutom 5000 Instruction Manual Navigating the Software Use the TURN/PUSH knob to navigate the software: Push knob to select a menu or item. Turn knob to move the cursor or to adjust settings. Press knob to store modified settings. Press to return to the previous menu, without saving changes.

  • Page 31: Main Menu

    Magnutom 5000 Instruction Manual Additionally, some service information is supplied; the total operation time and the time since the last service of the machine. The display will then change to the last screen shown before Magnutom was switched off. Main Menu During normal operation, immediately after start up, where the splash screen is displayed, the software goes to the screen that was used before the machine was switched off.

  • Page 32: Changing The Language

    Magnutom 5000 Instruction Manual Changing the Language Follow these steps:  Turn the knob to select Configuration.  Push knob to activate the Configuration Menu.  Turn the knob to select User options.  Push knob to activate the Options Menu. ...

  • Page 33: Editing Numeric Values

    Magnutom 5000 Instruction Manual  Push knob to accept the language.  The Configuration menu now appears in the language you have chosen.  Check if there are any other settings that need changing in the Options menu. If not, Push to return to the Configuration menu.

  • Page 34: Editing Alphanumeric Values

    Magnutom 5000 Instruction Manual Editing Alphanumeric Values Follow these steps:  Turn knob to to select the text value to be changed, e.g. Keyboard sound:  Push knob to toggle between the 2 options.  Press to accept the option and return to the previous menu ...

  • Page 35: Editing Cutting Sequences Names

    Magnutom 5000 Instruction Manual Editing Cutting Sequences Up to 20 cutting sequences can be saved in the database. Names Each cutting sequence can contain up to 50 movements. Follow these steps:  Push knob to open the Cutting sequences menu. ...

  • Page 36: Single Cut

    Magnutom 5000 Instruction Manual Single cut can be edited from the editing menu. Single Cut Spindle lock status Cut-off wheel speed Feed speed Cutting mode Cut Length RPM compensation* Cut-off wheel Cut stop position *Only available with X-table and R-table option. Editing the Parameters The cutting parameters can be set both prior to and during cutting.

  • Page 37: Feed Speed

    Magnutom 5000 Instruction Manual  Push knob to select the parameter. A scroll box appears. •  Turn knob to adjust the value of the parameter.  Push knob to save the setting. Feed speed Can be set to values between 0.1 – 10 mm/s, in steps of 0.1 mm (4 – 394 mils, in step of 4 mi).

  • Page 38: Cut-Off Wheel

    When Wheel Selection Mode is set to ‘Intelligent’, the Material guide menu will appear. Select the hardness of your Material in the pop-up menu and Magnutom will suggest the suitable Struers cut-off wheel, and automatically retrieve the recommended rotational speed for that specific wheel.

  • Page 39: Cutting Mode

    Magnutom 5000 Instruction Manual Cutting Mode 4 cutting modes are available: Cutting mode can also be selected in the Cutting mode setup menu when editing the Cut length. Icon Cutting Mode Typical use: Z Vertical cut Vertical cut-length can be set. Cutting of larger samples Y Horizontal cut.

  • Page 40: Cutting Sequence

    Magnutom 5000 Instruction Manual Cutting sequence can be edited from the Cutting sequence editing Cutting Sequence menu. Different Cutting sequences available. Cutting sequence menu Spindle lock status Number of cutting steps Cutting sequence Cutting method number and name locked/unlocked Number of moving Type of Cut-off wheel steps New Cutting Sequence...
  • Page 41 Magnutom 5000 Instruction Manual New Cutting sequence Follow these steps: programing  Push knob to open the editing menu.  Turn knob to select Cutting sequence  Push knob to open selected Cutting sequence  New Cutting sequence screen appears ...

  • Page 42: Cut-Off Wheel

    Material guide menu will appear. Select the hardness of your Material in the pop-up menu and − Magnutom will suggest the suitable Struers cut-off wheel, and automatically retrieve the recommended rotational speed for that specific wheel.  Select the diameter of the cut-off wheel: 432 or 508 mm (17” or 20”).

  • Page 43: Capture Current Position

     Select RPM compensation and Push the knob. RPM compensation By turning on RPM compensation, cutting RPM will be automatically adjusted, to keep optimal cutting parametres. (available only for Struers Cut-off wheels) New Cutting sequence Follow these steps: programing  Turn knob to get to New step ...

  • Page 44: Safe Move

    Safe move movemet. Cut-off wheel will firstly go to top rear position, than table adjust (rotate and move) to requested position. Default value: ON NOTE: Struers always recommend to use Safe move NOTE: Using safe move will not ensure no collision.

  • Page 45: Capture Current Position

    Magnutom 5000 Instruction Manual Select Capture current position to copy current Cut-off wheel and Capture current position table position and save their values. New Cutting step Follow these steps:  Push knob to select Cutting step  Turn knob to adjust parametres...

  • Page 46: Cutting Mode

    Magnutom 5000 Instruction Manual Cutting Mode 4 cutting modes are available: Cutting mode can also be selected in the Cutting mode setup menu when editing the Cut length. Icon Cutting Mode Typical use: Z Vertical cut Vertical cut-length can be set. Cutting of larger samples Y Horizontal cut.

  • Page 47: Cut-Off Wheel

    When Wheel Selection Mode is set to ‘Intelligent’, the Material guide menu will appear. Select the hardness of your Material in the pop-up menu and Magnutom will suggest the suitable Struers cut-off wheel, and automatically retrieve the recommended rotational speed for that specific wheel.
  • Page 48 Magnutom 5000 Instruction Manual New Pause step Follow these steps: Push knob to select Pause step  Push knob to adjust value  Turn knob to adjust the value of the parameter  Push knob to confirm value...

  • Page 49: Clamping The Workpiece

    Magnutom 5000 Instruction Manual  Move the cut-off wheel backwards to the rear of the cutting Clamping the Workpiece chamber for optimum access to the cutting table.  Clamp the workpiece with the clamping device of your choice e.g. a quick clamping device. Place the workpiece between the clamp and the backstop.

  • Page 50: Cutting On Magnutom

    Magnutom 5000 Instruction Manual See the section on in the Reference Guide in the Cutting on Magnutom AutoCut Instruction Manual for advanced use. Starting the Cutting  Position the cut-off wheel by slowly moving it to within 1 - 2 mm AutoCut: Off (0.04 –...

  • Page 51: The Cutting Process Screen

    Magnutom 5000 Instruction Manual The Cutting process screen shows information about the cutting The Cutting Process Screen process including:  Cutting Parameters  Motor Information  Cutting Mode and a Countdown timer Heading Motor load Feed speed Cutting Mode Length of cut Timer Countdown Value selected Actual Feed speed...

  • Page 52: Manual Stop

    Magnutom 5000 Instruction Manual Cutting Mode Cutting mode Timer Countdown An estimate of time remaining for the cutting process. (When AutoStop is selected, a countdown timer will not be displayed.) Magnutom automatically stops cutting when the workpiece is cut Manual Stop through but can be stopped at any time during operation by pressing STOP ...

  • Page 53: Additional Cooling

    Magnutom 5000 Instruction Manual When cutting hollow and/or thin workpieces, two flexible water jets Additional Cooling are provided for workpiece cooling.  Position the cooling jets to the left and right of the cutting area.   Open the valve (position ) to activate the cooling jets.

  • Page 54: Maintenance

    Magnutom’s continued safe operation. The maintenance procedures described in this section must be carried out by skilled or instructed persons. To ensure a longer lifetime for your Magnutom, Struers strongly General Cleaning recommends daily cleaning of the cutting chamber.

  • Page 55: Axiowash

    Magnutom 5000 Instruction Manual The AxioWash cleaning program is an efficient way to automatically AxioWash clean the cutting chamber. The following parameters can be adjusted: time, cut-off wheel movement or X-table movement (with X–table option). Time Can be set to values between 30 sec - 30 min, in steps of 30sec. Default value: 15 minutes Cut-off wheel movement Mode...

  • Page 56: Cleaning The Cutting Chamber

    Magnutom 5000 Instruction Manual  Clean the cutting chamber , especially the cutting table the T- Cleaning the Cutting Chamber slots and the bellows. Clean automatically (using AxioWash) and then manually (using the flushing gun). Automatic cleaning: AxioWash To start the AxioWash function: ...

  • Page 57: Maintenance Of Cut-Off Wheels

     Clean painted surfaces, and the control panel with a soft damp cloth and common household detergents. For heavy duty cleaning, use Struers Cleaner.  Clean the cover with a soft damp cloth and a common household anti-static window cleaning agent.

  • Page 58: Cleaning The Cutting Chamber

    Clamping Device and Vertical Quick Clamping Device at regular intervals. Maintenance of the Clamping Devices is part of the regular yearly Struers Service. Maintenance of Cutting Table The stainless steel bands forming the cutting table should be replaced if they have become worn or damaged. The bands are available as spare parts.

  • Page 59: Yearly

    To maintain the optimum performance of Magnutom, lubricate the Lubricating the Cutting Table cutting table at regular intervals (approx every 100 hours). Part of Struers ServiceGuard Check the service info displayed on the screen at start-up to monitor the actual number of usage hours.

  • Page 60: Testing Safety Devices

    If cutting and recirculation pump start, press STOP contact Struers Service.  Open the door  Use the joystict to move the cutting table. If the cutting table moves, contact Struers Service. Replacement af ter 5 years of the screen is required due to material deterioration.
  • Page 61 Magnutom 5000 Instruction Manual WARNING Do NOT use the machine with defective Safety Devices. Contact Struers Service. WARNING Use a padlock to secure the main switch during repair.

  • Page 62: Cautionary Statements

    Magnutom 5000 Instruction Manual 4. Cautionary Statements WARNING When lifting the machine by the built-in truck lifting point, ensure that the boom is properly secured with the locking pins provided. ELECTRICAL HAZARD • Switch the power off when installing electrical equipment. •...
  • Page 63 Do not clean the roof of the cutting chamber or directly on the doors with the flushing gun. CAUTION Carry out inspection at more regular intervals if Magnutom is used for more than one 7 hour shift a day. WARNING Do NOT use the machine with defective Safety Devices. Contact Struers Service.
  • Page 64 Magnutom 5000 Instruction Manual WARNING Use a padlock to secure the main switch during repair. WARNING In case of fire, alert bystanders, the fire brigade and cut power. Use a powder fire extinguisher. Do not use water. WARNING The PETG screen must be replaced after a lifetime of 5 years. Other Safety critical components are to be replaced as required, depending on the wear on the machine, but must be replaced at after a maximum lifetime of 20 years.

  • Page 65: Disposal

    Magnutom 5000 Instruction Manual 5. Disposal Equipment marked with a WEEE symbol contains electrical and electronic components and must not be disposed of as general waste. Please contact your local authorities for information on the correct method of disposal in accordance with national legislation. NOTE: Swarf must be disposed of according to the current safety regulations for handling and disposal of swarf/ additive in the cooling...

  • Page 66: Reference Guide

    Magnutom 5000 Instruction Manual Reference Guide Table of Contents Page 1. Advanced Operations Configuration Menu............... 68 User Options Menu ............... 68 Changing Operation Mode ............. 70 New Pass Code ................71 Process Options Menu ..............72 Return position:..............72 ExciCut .................. 73 AxioWash time...............
  • Page 67 IEC 61000-3-12 ..............110 EN ISO 13849-1:2015 ............110 8. Spare Parts and Diagrams Safety Related Parts of the Control System (SRP/CS) ....111 Magnutom-5000 YZ ............. 111 Magnutom-5000 XYZ ............112 Magnutom-5000 XYZR ............113 Diagrams ..................114 9. Technical Data ..............

  • Page 68: Advanced Operations

    Magnutom 5000 Instruction Manual 1. Advanced Operations Configuration Menu A number of different settings and parameters can be set or adjusted from the Configuration menu. There are 3 under menus: User options • • Process options • User defined cut-off wheels User Options Menu Default value: To re-set the setting to default value, press the F1 key on the Control Panel.
  • Page 69 Magnutom 5000 Instruction Manual Wheel selection mode Can be set to Intelligent or Manual Default value: Intelligent Manual: the cut-off wheel is selected manually from the selection tree in the Edit method screen Intelligent: a cut-off wheel is automatically suggested based on the material (hardness) selected by user.

  • Page 70: Changing Operation Mode

    Magnutom 5000 Instruction Manual To change the operation mode, go to the Configuration menu and Changing Operation Mode then the User Options menu. Select Operation mode to access the Operation mode menu. Follow these steps:  Push knob to select Pass code Use the ...

  • Page 71: New Pass Code

    Magnutom 5000 Instruction Manual A New pass code can also be selected from the Operation mode New Pass Code menu. NOTE: When a pass code is set the operator has 5 attempts to enter the correct pass code after which the Magnutom will be locked. Re-start Magnutom using the Main Switch then enter the correct Pass Code.

  • Page 72: Process Options Menu

    Magnutom 5000 Instruction Manual Process Options Menu After cutting or after pressing STOP , the return movement of the Return position:  cut-off wheel can be set to three different functions: Mode Result Start Magnutom automatically retracts the cut-off wheel to the original position of the cut-off wheel, at the time you pressed START (default).

  • Page 73: Excicut

    Magnutom 5000 Instruction Manual ExciCut ExciCut cutting action can be set to On or Off. Default value - On Both the amplitude and the frequency of the ExciCut action can be tailored to provide optimal cutting of specific workpieces: ExciCut amplitude Can be set in the range 0.5 –...

  • Page 74: Autocut

    Magnutom 5000 Instruction Manual Can be set to Off, Simple or Program. AutoCut Default value – Off Mode Result The operator moves the cut-off wheel towards the workpiece before START is pressed.  Simple The cut-off wheel will automatically move towards the workpiece at a maximum speed of 5mm/s when START is pressed.

  • Page 75: Setting An Autocut Position

    Magnutom 5000 Instruction Manual Setting an AutoCut Position: Follow these steps - from the Edit method menu:  Press the F1 key The AutoCut pop-up screen will appear (note: AutoCut must be set to Program from the Process options menu) ...

  • Page 76: Water Flow Checking

    Magnutom 5000 Instruction Manual NOTE: AutoCut position is set for the current cutting mode selected. If cutting mode is then changed, the AutoCut position is automatically reset to zero (for safety reasons). When AutoCut position is set to 0.0mm, AutoCut Program will function in the same way as AutoCut Simple.

  • Page 77: Cutting Start Pos. Y

    Magnutom 5000 Instruction Manual Cutting start pos. Y Can be set to Off or between 0 to 385 mm Default value - Off Can be set between 0 to 230 cm or Off Cutting start pos. Z Default value - Off Setting the Cutting start position is useful when cutting workpieces of the same size.

  • Page 78: User Defined Cut-Off Wheels Menu

    Magnutom 5000 Instruction Manual User Defined Cut-off Wheels Up to 10 user cut-off wheels can be defined for use on Magnutom. Menu The parameters for the wheel size, rotational speed and width can be set using the Edit wheel menu. Size Can be set in the range 300 –...

  • Page 79: Maintenance Menu

    NOTE: The Service functions menus are in English only. Using the same names/ terms is useful when communicating with your local Service Technician or Struers Customer Service department. Magnutoms user and process options can be set to default values by Reset configuration selecting Reset configuration.

  • Page 80: Changing The Cut-Off Wheels During Serial Cutting Sequence

    Magnutom 5000 Instruction Manual Changing the Cut-off Wheels When cutting several specimens it may be necessary to change the During Serial Cutting cut-off wheel during a Serial cutting sequence. Sequence  Press STOP to manually interrupt the cutting process.  The cut-off wheel arm goes to the start position.

  • Page 81: Axiocut Cutting Mode

    Magnutom 5000 Instruction Manual AxioCut Cutting Mode AxioCut cutting mode offers cutting of large and very hard materials. The vertical cut length and height of the workpiece can be set as well as the depth of each downwards step (in the example below, set to 5 mm).

  • Page 82: Stop Settings

    Magnutom 5000 Instruction Manual There are two ways to set the stop position: Setting a Cut length or Stop Settings AutoStop. When the AutoStop function is selected, the machine automatically AutoStop stops when the workpiece has been cut through. AutoStop is based on changes in the cutting motor load where a decrease in load indicates that the workpiece has been cut through.

  • Page 83: Positioning Screen

    Magnutom 5000 Instruction Manual The Positioning screen shows the Y and Z positions of the cutting Positioning Screen arm and the X position of the X-table (with x-table option). The screen is displayed for 3 seconds when the joystick has been activated.

  • Page 84: Removing A Relative Zero Position

    Magnutom 5000 Instruction Manual Go to relative zero position  Move the cutting arm to abs.: zero position (0.0 mm). Removing a Relative Zero Position  With the cursor highlighting the rel.: position, press Enter.

  • Page 85: Reference Positions

    Magnutom 5000 Instruction Manual Magnutom will perform a search for reference positions for every 20 Reference Positions start up. To perform an additional reference search:  Switch Magnutom off.  Press the Emergency Stop button then switch Magnutom on (a message will appear to inform that the Emergency Stop is activated).

  • Page 86: Clamping Irregular Workpieces

    This could result in damage to the cut-off wheel or to the sample itself. Use the T-slots to mount the special clamping tools. Struers offers a large selection of Clamping Tools (See Accessories). To achieve faster cutting, position the workpiece so that the wheel will cut the smallest possible cross-section.

  • Page 87: Safety Features

    Magnutom 5000 Instruction Manual The machine’s work zone guards are equipped with a guard Safety Features interlocks to prevent the cut-off wheel from spinning while the guards are open. Furthermore, an interlock locking mechanism prevents opening of the guards before the cut-off wheel has come to a complete stop.

  • Page 88: Optimising Cutting Results

    How can I achieve f aster Position the workpiece so as to cut the cutting? smallest possible cross-section. Use a high Feed Speed. Please ref er to the Selection Guide in the Struers Cut-off Wheels brochure.

  • Page 89: Struers Knowledge

    Minimizing cutting artefacts will help the remaining materialographic process and act as a good base for efficient and high quality preparation. HINT: For further information, see the section on Cutting on the Struers website.

  • Page 90: Accessories

    Magnutom 5000 Instruction Manual 3. Accessories Please refer to the for details of the range Magnutom brochure available. Clamping Tools Please refer to the Struers Clamping Tools brochure for details of the range available.

  • Page 91: Consumables

    The warranty may not cover damaged machine parts (e.g. seals and tubes), where the damage can be directly related to the use of non-Struers consumables. Cut-off Wheels When Wheel selection mode is set to Intelligent, a cut-off wheel is automatically suggested based on the material (hardness) selected by the user.
  • Page 92 Magnutom 5000 Instruction Manual Other Consumables Cutting additives More information can be found on Struers.com . https://www.struers.com/en/Knowledge/Cutting/7-ways-to-optimize...

  • Page 93: Trouble-Shooting

    Remove the excess cooling f luid tank. f rom the tank. Samples or cutting chamber Insuf f icient additive for cooling fluid. Add Struers Additive for cooling fluid corroded. to the cooling fluid, using the correct concentration. Check with a ref ractometer.
  • Page 94 Check that there is enough water in Insuf f icient cooling. the recirculation cooling unit. Check the cooling liquid hoses. The cut-off wheel is too sof t f or the See Consumables section, Cut-of f task. Wheels. Magnutom vibrates (worn bearings). Call a Struers Service Technician.
  • Page 95 Leave the protection hood open, cutting chamber f or too long. when you leave the machine. Insuf f icient additive for cooling fluid. Add Struers cutting f luid additive and water to the recirculation tank in the correct concentration. Check with a ref ractometer.

  • Page 96: Error Messages

    Magnutom 5000 Instruction Manual Error Messages Error messages are divided into two classes, Messages and Errors. Follow instructions. Explanation is included below for relevant screens. Messages are intended to inform the operator of the machine’s Messages progress and advise about minor operational errors. Errors must be rectified before cutting can be continued.
  • Page 97 Magnutom 5000 Instruction Manual Message Explanation Action Try to re-open and close the Saf ety door not properly closed. saf ety door once again and repeat previous operation. Autotuning procedure of Do not switch the machine off f requency inverter and cutting during this procedure.
  • Page 98 Magnutom 5000 Instruction Manual Message Explanation Action The messages appear every Close safety doors and press Enter to start calibration 50th start of the machine. Press ENTER to set cut size The selected cut size is not possible due to the current to the maximum available or position of cut-of f wheel.
  • Page 99 Magnutom 5000 Instruction Manual Message Explanation Action Press ENTER to Multicut is activated but the current position of the X-table is automatically decrease the not enough to make all the cuts. number of cuts or press Esc to return to edit the method.
  • Page 100 Magnutom 5000 Instruction Manual Message Explanation Action The cutting sequence was Either continue f rom of f ered stopped, f ollowed by pressing cut or start new sequence. the start button This pop-up occurs when the Select Continue if you want user starts stops a cutting to continue in stopped sequence via stop button and...
  • Page 101 Magnutom 5000 Instruction Manual Message Explanation Action Pop-up displayed when a Conf irm the dialog and sequence is started without edit/reposition axes to be suf f icient space to make all able to run the sequence. requested moves. If any of axis is conf igured as adjustable the evaluation of sequence feasibility is based on its current position.
  • Page 102 Magnutom 5000 Instruction Manual Message Explanation Action Cutting sequence remembers Continue in sequence if you size of a cut-of f wheel it was are sure collision might not def ined with to detect potential occur. Otherwise abort collisions between bigger cut-off operation.
  • Page 103 If error remains, contact a Struers Service Technician. Water f low is too low at the Press ENTER to abort the beginning of a cutting process. cutting process. Then check the cooling system.
  • Page 104 Struers Service Technician. e.g. detection of workpiece will not f unction. The f orce sensor is disabled in Contact a Struers service #111 the service menu. technician to re-enable the f orce sensor. Magnutom will operate without this sensor but some f eatures, e.g.
  • Page 105 Re-start. A f luctuation may have occurred If error remains, contact a in the mains power supply. Struers Service Technician. Magnutoms OptiFeed f eature Reduce the set f eed speed automatically reduces f eed bef ore re-starting the cutting speed if the load on the motor process.
  • Page 106 Re-start. If error remains, contact a Struers Service Technician. Please make a note of the Reason code and Error status register displayed on Magnutom. Press ENTER to clear this General Z-servo motor error detected during movement.
  • Page 107 Magnutom 5000 Instruction Manual Error Explanation Action Excessive f orce is detected Remove any obstacles f rom during a cutting process. cutting direction then press ENTER to clear the error. This can happen if flange or cut- of f wheel guard collides with a cutting sample.

  • Page 108: Service

    Instruction Manual 6. Service Service Information Struers recommends that a regular service check be carried out yearly (or after every 1,500 hours of use, if this is sooner). Struers offers a range of comprehensive maintenance plans to suit the requirements of our customers. This range of services is called ServiceGuard.
  • Page 109 Magnutom 5000 Instruction Manual The grease cartridge will need to be replaced after 1,500 hours of service. ServiceGuard Replacing the grease cartridge is part of the Struers program.

  • Page 110: Legal And Regulatory

    Pursuant to Part 15.21 of the FCC Rules, any changes or modifications to this product not expressly approved by Struers ApS could cause harmful radio interference and void the user’s authority to operate the equipment.

  • Page 111: Spare Parts And Diagrams

    Control System (SRP/CS) NOTE: Replacement of Safety critical components can only be performed by a Struers engineer or a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.). Safety critical components may only be replaced by components with at least the same safety level.

  • Page 112: Magnutom-5000 Xyz

    Magnutom 5000 Instruction Manual Magnutom-5000 Order number Magnutom-5000 XYZ Cut-off wheel guard 16580508 Front PETG safety glass 16140572 Side PETG safety glass 16140556 Y,Z axis proximity sensor disk 16140981 X proximity sensor disk 16580185 Rz proximity sensor disk 16580322 Solenoid interlock AZM 161...

  • Page 113: Magnutom-5000 Xyzr

    Magnutom 5000 Instruction Manual Magnutom-5000 XYZR Magnutom-5000 XYZR Order number Cut-off wheel guard 16580508 Front PETG safety glass 16140572 Side PETG safety glass 16140556 Y,Z axis proximity sensor disk 16140981 X proximity sensor disk 16580185 Rz proximity sensor disk 16580322...

  • Page 114: Diagrams

    Magnutom 5000 Instruction Manual Diagrams Magnutom-5000 Block diagram ......... 16583050 Magnutom-5000 Water diagram ........16581000 Magnutom-5000 Air diagram ..........16581001 See the following pages. Circuit Diagram. Please refer to the main marking plate on the machine.

  • Page 118: Technical Data

    Magnutom 5000 Instruction Manual 9. Technical Data Subject Specification Cutting capacity (max) Ø 190 mm / 7.4" 190 x 254 mm / 7.4 x 10" and 184 x 400 mm / 7.2 x 15.7“ 114 x 618 mm / 4.5 x 24.3" (values valid for YZ and XYZ) 114 x 533 mm / 4.5 x 21”...

  • Page 119: Mains Cable Specification

    Magnutom 5000 Instruction Manual Subject Specification ENVIRONMENT Noise level Approx. 61 dB(A) running idle, at a distance of 1.0 m / 39.4" from the machine. Compressed air 5.5 – 9.9 bar pressure (Class-3, as specified in ISO 8573-1), min 40l/min ELECTRICAL DATA Specification Cutting Power...

  • Page 120: Cutting Capacity

    Magnutom 5000 Instruction Manual Cutting Capacity The graph shows the projected cutting capacity under the following conditions:  A new cut-off wheel  The workpiece is laid directly on the cutting table  Vertical clamping is used  Using ZY or AxioCut cutting mode The actual cutting capacity depends on the sample material, cut-off wheel and clamping technique.

  • Page 121: Quick Reference

    Magnutom 5000 Instruction Manual Quick Reference  Place the workpiece between the clamp and the back stop on the Clamping the Workpiece right hand cutting table.  Push the clamp towards the workpiece and lock the quick- clamping device with the locking handle. ...

  • Page 122: Installation Requirements

    Manual No.: 16587005 Revision C Date of Release 2021.08.31 Magnutom-5000, Pre-Installation Checklist Read the Installation instructions in the Instruction Manual before installing the machine. Installation Requirements Crane and 2 lifting straps* OR forklift truck (lifting capacity > 3,000  kg / 6,700 lbs) Wrench/ bit: 10 mm Hexagonal ...
  • Page 123 Magnutom-5000, Pre-Installation Checklist Location The machine is designed to be placed on the floor. Make sure that the floor of the working area and the transportation corridor is designed to carry Magnutoms weight. Dimensions Width 180 cm / 70.7" (front door open) 262 cm / 103"...
  • Page 124 Magnutom-5000, Pre-Installation Checklist Right and front Centre of gravity Left and back Distance from floor to: Power connection 30 cm / 11.8” Water inlet 53 cm / 21” Under the machine, Water outlet with opening at the right hand side and...
  • Page 125 Magnutom-5000, Pre-Installation Checklist Recommended space Recommended space at the front: 100 cm / 40”. Front Rear Recommended space behind the machine: 100 cm / 40”. Recommended space at the left: 100 cm / 40” – to open the side Sides door fully Recommended space at the right: 100 cm / 40”...
  • Page 126 Magnutom-5000, Pre-Installation Checklist Lifting Weight: A forklift truck or crane is required to lift Magnutom off the shipment 2,650 kg / 5,850 lbs pallet. Forklift Special requirements for the fork lift Capable of lifting 3,000 kg / 6,700 lbs ...
  • Page 127 Magnutom-5000, Pre-Installation Checklist Magnutom is mounted with removable lifting beams. NOTE: Ensure, that the lifting beams are securely mounted before lifting the machine. NOTE: Remove the lifting beams when the machine is in its final destination. It is not necessary to remove the transport beams.

  • Page 128: Power Supply

    Magnutom-5000, Pre-Installation Checklist Power supply The machine is delivered without a mains cable. A 4-lead or 5-lead cable is required. The cable is connected to the electric connection box at the rear of the machine. Yellow/green Earth (ground) Connections Brown or Black,...

  • Page 129: Safety Specifications

    Magnutom-5000, Pre-Installation Checklist Residual Current Circuit Breaker Electrical Installations with RCCB (RCCB) The equipment must be protected by RCCB type B time delayed, 30 mA (or better). Electrical Installations without RCCB The equipment must be protected by an insulation transformer (double-wound transformer).
  • Page 130 Magnutom-5000, Pre-Installation Checklist Cutting liquid  Required  Option A Recirculation Cooling Unit is required. See Accessories on page for details. Water outlet  Required  Option The machine is supplied with a set of drain pipes. The pipes are fitted to redirect the cooling water into the recirculation cooling unit.

  • Page 131: Accessories And Consumables

    Wheels brochure Required Recirculation Cooling Unit Struers Coolimat-2000 with band filter unit (065261xx) or Coolimat- 2000 static filter (065262xx) are recommended. They are supplied with a 2.5 m / 8.2' water hose and a GEKA connection for easy assembly.

  • Page 132: Declaration Of Conformity

    Based on: 16587901 E Declaration of Conformity Manufacturer Struers ApS • Pederstrupvej 84 • DK-2750 Ballerup • Denmark Name Magnutom-5000 Model Function Cut-off machine Type Cat. no. Magnutom-5000 06586146 06586246 06586346 Accessories equipment 06146914 06146912 Serial no. Module H, according to global approach...
  • Page 133  Pederstrupvej 84 DK-2750 Ballerup Denmark...