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Struers Accutom-100 Instruction Manual

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Accutom-100
Instruction Manual
Original Instructions
Doc. no.: 16177025-06_A_en
Date of release: 2023.11.01

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Summary of Contents for Struers Accutom-100

  • Page 1 Accutom-100 Instruction Manual Original Instructions Doc. no.: 16177025-06_A_en Date of release: 2023.11.01...
  • Page 2 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. Accutom-100...
  • Page 3 Table of Contents 1 About this manual 1.1 Accessories and consumables 2 Safety 2.1 Intended use 2.2 Accutom-100 safety precautions 2.2.1 Read carefully before use 2.3 Safety messages 2.4 Safety messages in this manual 3 Get started 3.1 Device description 3.2 Overview 3.3 Emergency stop...
  • Page 4 7.1 The Service menu 8 Configuration menu 8.1 Options menu 8.2 User defined cut-off wheels 8.3 User defined cup wheels 9 Maintenance and service 9.1 General cleaning 9.2 Cut-off wheels and cup wheels 9.3 Change the coolant pump tubes 9.4 Daily Accutom-100...
  • Page 5 9.9 Service and repair 9.10 Disposal 10 Troubleshooting 10.1 Machine problems 10.2 Cutting problems 10.3 Error messages - Accutom-100 11 Technical data 11.1 Technical data 11.2 Technical data - equipment units 11.3 Safety Related Parts of the Control System (SRP/CS) 11.4 Diagrams...
  • Page 6 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.
  • Page 7 The machine must not be used with cut-off wheels which are not compatible with the machine requirements (e.g. toothed cut-off wheels). Model Accutom-100 Accutom-100 safety precautions 2.2.1  Read carefully before use Ignoring this information and mishandling of the equipment can lead to severe bodily injuries and material damage.
  • Page 8 20. The equipment is designed to be used only with Struers consumables specifically designed for this purpose and this type of machine. 21. Struers equipment must only be used in connection with and as described in the Instruction Manual supplied with the equipment.
  • Page 9 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.
  • Page 10 Take care of your fingers when handling the machine. Wear safety shoes when handling heavy machinery. CAUTION Struers equipment must only be used in connection with and as described in the Instruction Manual supplied with the equipment. CAUTION Mind the protruding safety catch when the safety guard is raised.
  • Page 11 Get started Device description Accutom-100 is an automatic cut-off machine for cutting and grinding of the majority of solid and stable (non-explosive) materials. It has Y-movement of the cut-off wheel, a motorized X-arm and a built-in recirculation cooling unit. The cut-off wheel and X-arm can only be moved either when the guard is closed or holding the hold-to-run button when using the positioning keys.
  • Page 12 D Guard B Front panel E Hold-to-run button C Coolant tank Emergency stop The emergency stop button is located on the front of the machine. • Push the red button to activate. • Turn the red button clockwise to release. Accutom-100...
  • Page 13 3   Get started Rear view A Exhaust flange E Type plate B Hinges F Service socket C Pump cover G Power socket D Vacuum connection (plug) H Main switch Accutom-100...
  • Page 14 3   Get started Cutting chamber A Flexible LED light F Exhaust B Coolant nozzles G Flushing hose C Wheel spindle H Cutting motor D Specimen holder arm Tray for cut off specimens E Vacuum connection Accutom-100...
  • Page 15 You can only open the guard on the machine when the machine is connected to the power supply and the main power switch is on. To open the guard if the power is not connected Use the triangle key supplied to deactivate the safety lock. Remove the coolant tank. Accutom-100...
  • Page 16 • 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.
  • Page 17 Use screwdrivers/bits: TX30, PH2 and H4 Procedure Remove the coolant tank. Position the straps under the machine, so that they are on the inside of the feet. Make sure that the tension on the lifting straps is distributed evenly. Accutom-100...
  • Page 18 At the new location, make sure that the facilities required are in place. Installation Unpack the machine CRUSHING HAZARD Take care of your fingers when handling the machine. Wear safety shoes when handling heavy machinery. Note We recommend that you keep all original packaging and fittings for future use. Accutom-100...
  • Page 19 Check the packing list Optional accessories may be included in the packing box. The packing box contains the following items: Pcs. Description Accutom-100 Electrical power supply cables Triangle key for safety lock release Support pin Socket spanner. 17 mm (0.7") Tray (with paper) Allen key, 3 mm (0,12")
  • Page 20 Do not lift the machine by the light gray top part. Always lift the machine from beneath. Weight Accutom-100 68 kg (150 lbs) • Use a crane and two lifting straps to lift the machine. The lifting straps must be approved for lifting at least twice the weight of the load.
  • Page 21 (reflections of light sources). A minimum of 300 Lumen is recommended to illuminate the controls and other work areas. Ambient conditions Operating environment Surrounding temperature Operation: 5-40°C (40-105°F) Storage: 0-60°C (32-140°F) Humidity Operation: 35-85% RH non- condensing Storage: 0-90% RH non- condensing Accutom-100...
  • Page 22 9.1 A Current, largest load 1.45 A 5.5.1 Single-phase supply Single-phase supply The 2-pin plug (European Schuko) is for use on single-phase electrical power connections. The leads must be connected as follows: Yellow/Green Earth (ground) Brown Line (live) Blue Neutral Accutom-100...
  • Page 23 The coolant then returns to the tank located under the cutting chamber. CAUTION Read the Safety Data Sheet for the coolant additive before use. CAUTION Avoid skin contact with the coolant additive. Always wear protective gloves and safety goggles. Accutom-100...
  • Page 24 The standard tube only lasts for a few hours, if it is used for water-free coolant. If you use water-free coolant, replace the standard tube in the coolant pump with a tube for water-free coolant. To replace the tube in the coolant pump, see Change the coolant pump tubes ►75. Accutom-100...
  • Page 25 A blocked drain can result in water overflow and insufficient cooling if the level of coolant in the tank is too low. Mount a cut-off wheel Procedure CAUTION Mind the protruding safety catch when the safety guard is raised. Accutom-100...
  • Page 26 Before you mount the cut-off wheel, test the cut-off wheel for damages. See Cut-off wheels and cup wheels ►73. Mount the cut-off wheel and hold it flat against the inner flange. Remount the outer flange with the machined surface facing towards the inner flange. Mount the flange screw. Accutom-100...
  • Page 27 Mount a cup wheel Change the wheel flange set A cup wheel flange set is required when grinding on Accutom-100. Remove the standard flange set by pulling it away from the wheel spindle and replace it with the cup wheel flange set.
  • Page 28 Use the 17 mm socket spanner to gently fasten the flange screw. Tighten the screw with a force of maximum 5 N·m (4 lbf·ft). Coolant nozzle The right coolant nozzle is not required during the grinding process. To stop the flow of coolant from the right nozzle: Accutom-100...
  • Page 29 Minimum capacity: 30 m /h (1,060 ft /h) at 0 mm (0") water gauge. Exhaust connection The machine is delivered with an exhaust hose. – Length: 1.5 m (4.9'). – Diameter: 50 mm (2"). Accutom-100...
  • Page 30 Fit a hose nipple onto the longer piece of the vacuum hose (1 m / 3') and connect to a vacuum pump. Hint You can shorten the hose to minimize the distance from the machine to the vacuum pump. Connect the other end of the hose to the vacuum inlet on the rear of the machine. Accutom-100...
  • Page 31 Use hearing protection if the exposure to noise exceeds the levels set by local regulations. Handling noise during operation Different materials have different noise characteristics. • To lower the noise, decrease the rotational speed and/or the force with which the workpiece is pressed against the cut-off wheel. The processing time may increase. Accutom-100...
  • Page 32 6   Basic operation Basic operation Control panel A F1 G Turn/push knob B Esc H Start C Flush Stop D Rotate holder J Backward and forward positioning keys E Fast positioning keys F Left and right positioning keys Accutom-100...
  • Page 33 The direction of the rotation changes each time you press the key. Fast positioning keys These keys open the Positioning menu or move the specimen holder in the X- direction in steps of 100 μm. Keep the key pressed to increase the speed. Accutom-100...
  • Page 34 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 display Note The screens shown in this manual may differ from the actual screens in the software. Accutom-100...
  • Page 35 The display is divided into three main areas: A Title bar The title bar shows the function you have selected. These fields show information about the selected function. In some B Information fields fields you can select and change the value. C F1 function Menu-dependent function. Accutom-100...
  • Page 36 Select the language you want to use. If needed, you can change the language from the Options menu. See Options menu ►65. Start-up - daily operation When you switch on the machine, the screen that was shown when the machine was switched off is shown just after the start-up screen. Accutom-100...
  • Page 37 6   Basic operation Reference positions The reference positions are calibrated at each start-up, or if the reference positions have been lost. Main menu From the Main menu screen you can choose between the following options: Cutting methods Grinding methods Maintenance Configuration Accutom-100...
  • Page 38 Press the hold-to run button and the positioning keys to move the specimen holder arm or the cut-off wheel / cup wheel while the guard is open. The positioning screen disappears after 5 seconds or when you press Esc. Accutom-100...
  • Page 39 To move the workpiece to X relative zero position: Close the guard. Select X = 0 and press Enter. To move the cut-off wheel to Y relative zero position: Close the guard. Select Y = 0 and press Enter. Accutom-100...
  • Page 40 You can lock methods to prevent making changes. Locked Unlocked Hint If you make changes, the original method will be overwritten. To keep the original method, make a copy of the method and rename it. 6.7.2 Settings From the Main menu screen, select Cutting methods. Accutom-100...
  • Page 41 6   Basic operation Select a cutting method. Change increment / Parameters Settings Default description Struers cut-off wheels Cut-off wheel User defined cut-off wheels Single cut Cut up to 20 slices of MultiCut 1 MultiCut equal thickness Cut up to 20 slices of...
  • Page 42 (0.0002 - 0.1 (0.0002 in/s) (0.004 in/s) in/s) Recommended Rotational 300 - 5000 rpm 50 rpm setting for the speed cut-off wheel 1 - 110 mm 0.1 mm 30 mm Cutting length (0.04 - 4.3") (0.004") (1.2") Cutting force Medium High Accutom-100...
  • Page 43 The changes are saved automatically. You can reset the method to the default values. See The Maintenance menu ►64. 6.7.3 Material guide To access the Material guide: Select a cutting method. Highlight the cut-off wheel parameter. Press F1. A pop-up menu will appear. Select a material from the list. Select the diameter. Accutom-100...
  • Page 44 > 800 and hard ceramics 0.005 - Medium 2700 0.25 Extremely hard 0.005 - B0C15 > 500 Medium 5000 ferrous metals 0.25 Hard and very hard 50A15 500 - 800 Medium 0.05 - 0.30 1000 - 5000 ferrous metals Accutom-100...
  • Page 45 Oscillation is useful when cutting very hard materials as it will reduce the heat buildup. Oscillation is also used for fragile materials as there is a better distribution of the force used to cut through the workpiece. Settings – Off: The holder does not rotate. Accutom-100...
  • Page 46 – Rotate: The workpiece rotates around its center. – Oscillate: The holder oscillates around its center. For a demonstration of the movement: Press F1 to start Oscillation and check for correct alignment. Press F1 again to stop the movement. Accutom-100...
  • Page 47 Select this parameter if you need to make an initial cut, before you start cutting the samples. This cuts a scrap sample, which Initial cut you will not use. For example, if the workpiece has an uneven edge that makes it unsuitable as a first sample. Accutom-100...
  • Page 48 6   Basic operation Parameters The nominal thickness values for all Struers cut-off wheels are already saved within the wheel definitions. When you select a cut-off wheel, that particular wheel thickness Drift correction will automatically be used. For user defined wheels, you must enter the thickness manually.
  • Page 49 For example, if the workpiece has an uneven edge that makes it unsuitable as a first sample. The nominal thickness values for all Struers cut-off wheels are already saved within the wheel definitions. When you select a cut-off wheel, that particular wheel thickness Drift correction will automatically be used.
  • Page 50 When cutting with rotation or oscillation, the workpiece and the specimen holder must be clamped so that they rotate evenly around the center of the workpiece. This way the fastest cutting is obtained as the cut-off wheel will be cutting most of the time and the possibility of damaging the cut-off wheel is limited. Accutom-100...
  • Page 51 A blocked drain can result in water overflow and too little water in the tank . Close the guard. Press Start. Note Check that there is a steady flow of coolant from the nozzles. Accutom-100...
  • Page 52 If, for example, the motor load is too great, you can reduce the feed speed. Select the parameter you want to change. Press Enter and change the value. Press Enter to confirm the change or press Esc to cancel. Accutom-100...
  • Page 53 You can lock methods to prevent making changes. Locked Unlocked Hint If you make changes, the original method will be overwritten. To keep the original method, make a copy of the method and rename it. 6.9.2 Settings From the Main menu screen, select Grinding methods. Accutom-100...
  • Page 54 6   Basic operation Select a grinding method. Change increment / Parameters Settings Default description Struers cup wheels Cup wheel User defined cup wheels 1 - 110 mm 0.1 mm Grinding length 10 mm (0.4") (0.04 - 4.3") (0.004") Accutom-100...
  • Page 55 The changes are saved automatically. You can reset the method to the default values. See The Maintenance menu ►64. 6.9.3 Material guide Use the following table as a guide to select the cup wheel and grinding parameters according to the specimen material. Accutom-100...
  • Page 56 Oscillation is also used for fragile materials as there is a better distribution of the force used during grinding. – Off: The holder does not rotate. – Oscillate: The holder oscillates around its center. For a demonstration of the movement: Accutom-100...
  • Page 57 Move the specimen as close to the cup wheel as possible, without touching each other using the right fast-positioning key while pressing the hold-to-run button. Press the right positioning key while holding the hold-to-run button to move the specimen slowly against the cup wheel, just until there is just contact between specimen and wheel. Accutom-100...
  • Page 58 Y-direction. Press Start. After completing the grinding process, the machine will stop precisely at the predefined position. 6.10 Start the grinding process Clamp the specimen • Clamp the specimen in the specimen holder. Accutom-100...
  • Page 59 A blocked drain can result in water overflow and too little water in the tank . Close the guard. Press Start. Note Check that there is a steady flow of coolant from the nozzles. Accutom-100...
  • Page 60 If, for example, the motor load is too great, you can reduce the feed speed. Select the parameter you want to change. Press Enter and change the value. Press Enter to confirm the change or press Esc to cancel. Accutom-100...
  • Page 61 Grind the specimen Glue the specimen on a pre-ground glass slide. Measure the total thickness of the glass and the specimen. Insert the glass slide with specimen in the specimen holder. Press F1 to view the calculator and enter the values. Accutom-100...
  • Page 62 Set the removal mode to Relative, set the stop position as the thickness of the specimen: 0. 500 mm (0.02"). To avoid over grinding, grind to the required thickness in steps. For instance, if you need to remove 180 μm of material: Remove 150 μm of material. Inspected and remeasured the specimen. Accutom-100...
  • Page 63 Do not start flushing before the flushing hose is pointing into the cutting chamber. Procedure CAUTION Mind the protruding safety catch when the safety guard is raised. A Flushing hose B Hold-to-run button Remove the hose from the coolant nozzles. Accutom-100...
  • Page 64 The Service menu Service information is read-only information. The machine settings cannot be changed. Service information can be used in cooperation with Struers Service for remote diagnostics of the equipment. Accutom-100...
  • Page 65 Information on total operation time and servicing of the machine is displayed on the screen at start-up. Configuration menu Options menu From the Options menu you can set up general parameters. From the Main menu select Configuration. Select Options. Accutom-100...
  • Page 66 This prevents the accumulation of lost axis steps. The accuracy of the axis position is then driven by the accuracy of the reference sensor. Hint We recommend that you use the „ref X" or "ref YX" option for better grinding/cutting accuracy. Accutom-100...
  • Page 67 Change the operation mode Select Operation mode. Select Pass code. Use the F1 key and the knob to enter the current pass code. Hint The default pass code is: 2750. Push the knob. Select Operation mode. Select an operation mode. Accutom-100...
  • Page 68 Restart the machine using the main switch, then enter the correct pass code. Note Remember to make a note of the new pass code, since you cannot change the settings without the pass code. User defined cut-off wheels Procedure From the Configuration screen, select User defined cut-off wheels. Accutom-100...
  • Page 69 Press F1 and select Rename. Use the knob and the Backward and Forward keys to enter a name for the new cut-off wheel (Press F1 to toggle between upper and lower-case letters). If needed, press Esc to cancel the changes. Accutom-100...
  • Page 70 8   Configuration menu Select the wheel and enter the settings. User defined cup wheels Procedure From the Configuration screen, select User defined cup wheels. Accutom-100...
  • Page 71 Press F1 and select Rename. Use the knob and the Backward and Forward positioning keys to enter a name for the new cup wheel (Press F1 to toggle between upper and lower-case letters). If needed, press Esc to cancel the changes. Accutom-100...
  • Page 72 To ensure a longer lifetime for your machine, we strongly recommends regular cleaning. Note Clean the cutting chamber daily and if the machine is not to be used for a period of time. Note Do not use a dry cloth as the surfaces are not scratch resistant. Accutom-100...
  • Page 73 The wheel may also bend and cause a skew cut. A combination of both factors may result in damage to the cut-off wheel. To dress the cut-off wheel, use the aluminum oxide dressing stick supplied with the cut-off wheel. Accutom-100...
  • Page 74 With a pencil (not metal), gently tap the cut-off wheel around the edge. The cut-off wheel passes the test if it gives a clear metallic tone when tapped. If the cut-off wheel sounds dull or muted, it is cracked and unsafe to use and must be replaced. Accutom-100...
  • Page 75 9   Maintenance and service Change the coolant pump tubes Procedure Remove the four screws on the protection plate on the rear of the machine. Remove the three screws on the cover of the cooling pump. Accutom-100...
  • Page 76 Lubricate the tube along its length with the supplied silicone grease. This will help the rollers in the pump to turn smoothly. Press the tube into position around the pump axle. Mount the tube correctly in the pump Correct Accutom-100...
  • Page 77 Checking the guard safety lock Note Check the interlock tongue regularly to make sure that it is not is not damaged and that it fits perfectly in the locking mechanism. • Make sure that the interlock tongue slides easily into the locking mechanism. Accutom-100...
  • Page 78 • Clean all accessible surfaces with a soft damp cloth and common household detergents. • For heavy duty cleaning, use Struers Cleaner. • Clean the safety guard with a soft damp cloth and a common, household anti-static window cleaning agent.
  • Page 79 • Check the coolant level after 8 hours of use or at least every week. If needed, refill the tank. • Replace the coolant if it appears to be contaminated (build-up of cutting debris). • Add coolant additive. Accutom-100...
  • Page 80 Avoid skin contact with the coolant additive. Wear suitable gloves and safety goggles when handling cooling fluid. Coolant can contain swarf (cutting and grinding debris or other particles. CAUTION Do not start flushing until the flushing gun points into the cutting chamber. Accutom-100...
  • Page 81 Do not overfill the tank. Note Flush the recirculation cooling system with clean water if the machine is not to be used over longer periods of time. This will prevent any dried residue of cutting material from damaging the inside of the pump. Accutom-100...
  • Page 82 9.7.1 The guard WARNING Do not use the machine with defective safety devices. Contact Struers Service. WARNING To ensure its intended safety, the guard must be replaced every 3 years. A label on the guard indicates when it is due to be replaced.
  • Page 83 Emergency stop WARNING Do not use the machine with defective safety devices. Contact Struers Service. Test 1 Start a cutting process: Press the Start button. The machine starts operating. Press the emergency stop. If operation does not stop, press the Stop button.
  • Page 84 If you have technical 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 check the availability of spare parts, contact Struers Service. Contact information is available on Struers.com.
  • Page 85 Note Service must only be performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.). Contact Struers Service. Service check We offer a range of comprehensive maintenance plans to suit the requirements of our customers. This range of services is called ServiceGuard.
  • Page 86 The following are examples of combinations which can result in exothermic reactions if a large amount of swarf is produced during cutting or grinding on the same machine, and when favorable conditions are present: • Aluminum and copper. • Zinc and copper. Accutom-100...
  • Page 87 Inadequate cooling. Check the positioning of the coolant nozzles. If needed, clean the nozzles. Make sure that there is sufficient water in the coolant tank. Check the concentration of additive in the coolant. Accutom-100...
  • Page 88 The feed speed is set too Reduce the feed speed. high. The force level is set too high. Reduce the force level. The cut-off wheel bends on Make an initial cut at a lower contact with the workpiece. feed speed. Accutom-100...
  • Page 89 The specimen has been left in Remove the specimen directly the cutting chamber for too after cutting. Leave the cutting long. chamber guard open when you leave the machine. Insufficient additive for Check the concentration of coolant. additive in the coolant. Accutom-100...
  • Page 90 Delete one or more of the methods – this will free The database maximum space to store new methods. storage capacity has been Note: it is not possible to delete Struers reached. methods. Auto: the machine will cut to the max. available length.
  • Page 91 Y direction: 110 mm (precision 0.1 mm) Specimen holder arm X-movement Rotation Oscillation Automatic rotation of specimen holder (before cutting) Positioning speed X = 10 mm/s. Positioning range X direction: 60 Positioning length X direction: 60 mm (precision 0.005 mm) Accutom-100...
  • Page 92 LED back light Safety standards CE-labeled according to EU directives REACH For information about REACH, contact your local Struers office. Operating environment Surrounding temperature 5 - 40 °C (41-104 °F) Humidity < 85 % RH non-condensing Power supply...
  • Page 93 Height, guard closed 44 cm (17.3”), guard closed Height, guard open 91 cm (35.8"), guard open Weight 68 kg (150 lbs) 11.2 Technical data - equipment units For technical data covering the individual units of equipment, see the specific equipment manual. Accutom-100...
  • Page 94 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.).
  • Page 95 1241.6931.1120000 Metal line switches Lock relay Finder 38.51.0.024.0060 Relay interface modules Note Struers catalogue numbers are listed in Spare parts ►84. 11.4 Diagrams Note If you wish to view specific information in detail, see the online version of this manual.
  • Page 96 11   Technical data 16173051 Accutom-100...
  • Page 97 11   Technical data 16171004 Accutom-100...
  • Page 98 11   Technical data 16171003 Accutom-100...
  • Page 99 Responsibility of the manufacturer The following restrictions should be observed, as violation of the restrictions may cause cancellation of Struers legal obligations. The manufacturer assumes no responsibility for errors in the text and/or illustrations in this manual. The information in this manual is subject to change without notice. The manual may mention accessories or parts not included in the supplied version of the equipment.
  • Page 101 Based on: 16177901 G Declaration of Conformity Manufacturer Struers ApS • Pederstrupvej 84 • DK-2750 Ballerup • Denmark Name Accutom-100 Model Function Precision cut-off machine/Grinding machine Type Cat. no. 06176227 Serial no. Module H, according to global approach We declare that the product mentioned is in conformity with the following legislation, directives and standards:...
  • Page 102 Tõlked leiate aadressilt Katso käännökset osoitteesta Pour les traductions, voir Za prijevode idite na A fordítások itt érhetők el Per le traduzioni consultare www.struers.com/Library 翻 訳 については、 Vertimai patalpinti Tulkojumus skatīt Voor vertalingen zie For oversettelser se Aby znaleźć tłumaczenia, sprawdź...