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Struers Labotom-15 Instruction Manual

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Labotom-15
Manual No.: 16057025
Revision B
Instruction Manual
Date of Release 2018.12.12
Original Instructions
For:
Labotom-15 from Serial no. 60520000

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Summary of Contents for Struers Labotom-15

  • Page 1 Labotom-15 Manual No.: 16057025 Revision B Instruction Manual Date of Release 2018.12.12 Original Instructions For: Labotom-15 from Serial no. 60520000...

  • Page 2: Table Of Contents

    Labotom-15 Instruction Manual Table of Contents Page Intended use .............. 3 Safety Precaution Sheet ..........5 User’s Guide .............. 9 Reference Guide ............40 Quick Reference ............67 Appendix: ..............68 Pre-installation checklist ........... 68 Contents of the Declaration of Conformity ....77...

  • Page 3: Intended Use

    Labotom-15 Instruction Manual Intended use For professional manual wet abrasive cutting of materials for further material inspection and only to be operated by skilled/trained personnel. The machine is intended only to be used with cooling fluids and cut-off wheels developed for this purpose and this type of machine.
  • Page 4 Original instructions. The contents of this manual are the property of Struers. Reproduction of any part of this manual without the written permission of Struers is not allowed. All rights reserved. © Struers 2018.

  • Page 5: Safety Precaution Sheet

    Labotom-15 Instruction Manual Labotom-15 Safety Precaution Sheet 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.
  • 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 service or repair, should always be performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.).
  • Page 7 Labotom-15 Instruction Manual Icons and typography Struers uses the below icons and typographical conventions. A list of the Safety Messages used in this manual can be found in the chapter on Cautionary Statements in the Reference Guide section of the Instruction Manual.
  • Page 8 Labotom-15 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

    Unpacking Labotom-15 ..............12 Lifting Labotom-15 ................13 Placing Labotom-15 ................ 14 Recommended workbench dimensions ........... 14 Getting Acquainted with Labotom-15 ..........15 Front ..................15 Rear view ................16 Inside the Cutting Chamber ............ 17 Supplying Power ................18 Direction of the Cut-off Wheel ..........
  • Page 10 Labotom-15 Instruction Manual Monthly Maintenance ..............31 Replacing the Cooling Fluid ........... 31 Maintenance of Clamping Devices ......... 31 Maintenance of Cutting Tables ..........32 Maintenance of Cut-off Wheels ..........32 Yearly ....................33 Inspection of Cover ..............33 Cleaning the Flush Gun Nozzle ..........34 Testing Safety Devices ..............

  • Page 11: Getting Started

    1. Getting Started Device Description Labotom-15 is a manual cut-off machine. The machine is designed for wet abrasive cutting and it offers safe cutting of all stable, non- explosive metals. For the machine to function, it must run with a cooling and/or recirculation unit.

  • Page 12: Checking The Contents Of The Crate

    1 Elbow pipe 75 mm dia. 1 Set of Instruction Manuals Unpacking Labotom-15  Remove the two transport brackets that secure Labotom-15 to its transport pallet – use a torque bit T30 key to remove the eight coach bolts. HINT: Store the packing crate, foam packaging and fittings for use whenever Labotom is transported/re-located.

  • Page 13: Lifting Labotom-15

    Lifting points. Place straps on the inside of the rubber feet. CAUTION The machine is heavy. Always use crane and straps.  Place the two lifting straps under Labotom-15. Position the back strap on the inner side of the feet. −...

  • Page 14: Placing Labotom-15

     Place the machine on a rigid, stable workbench (optionally, buy a Struers table unit). Labotom-15 has two wheels at the rear to easily adjust the position of the machine.  Check that the machine is level and that all four rubber feet rest on the workbench.

  • Page 15: Getting Acquainted With Labotom-15

     NOTE: The cover on Labotom-15 can only be opened when the machine is connected to a power supply and the main power switch is on.  To open the cover when the power is not connected, lift the front of the Labotom-15 and carefully move it forwards to access the safety lock release.

  • Page 16: Rear View

    Labotom-15 Instruction Manual Rear view         Cooling unit connection Water inlet   Power supply cable Connection for external   connection fume extraction system Wheels Damper   Drain  Flushing gun...

  • Page 17: Inside The Cutting Chamber

     Lamp  MAIN SWITCH The main switch is located on the right-hand side of Labotom-15.  Turn clockwise to switch on the power. EMERGENCY STOP  Push the red button to Activate.  Turn the red button clockwise to Release.

  • Page 18: Supplying Power

    Labotom-15 Instruction Manual NOTE: Do not use the Emergency stop for operational stop of the machine during normal operation. BEFORE releasing (disengaging) the Emergency stop, investigate the reason for activating the Emergency stop and take any necessary corrective action. Supplying Power ELECTRICAL HAZARD The machine must be earthed (grounded).

  • Page 19: Connecting A Recirculation Cooling Unit

    Labotom-15 Instruction Manual Connecting a Recirculation To ensure optimal cooling and lubricating, Labotom-15 must be fitted Cooling Unit with a Struers Cooling Unit. Cooling System 4 is the Cooli configuration designed for use with Labotom-15. NOTE: Before connecting the cooling unit to the Labotom, follow the instructions in the Struers Cooling Unit Instruction Manual to prepare it for use.

  • Page 20: Connection To An External Exhaust System

    Labotom-15 Instruction Manual Connection to an External Struers recommends the use of an exhaust system as workpieces Exhaust System may emit harmful or unpleasant gases when cut. The unit is prepared for connection to an exhaust system via a hole at the rear of the cabinet.

  • Page 21: Clamping Devices

    Clamping Devices There are several types of clamping tools available as accessories (please refer to the for details of the range Labotom-15 brochure available). Clamping devices are ordered separately. NOTE: When fitting clamping tools, always ensure that they cannot come into contact with the cut-off wheel.

  • Page 22: Mounting A Quick Clamping Device And Spring Clamp

    Labotom-15 Instruction Manual  Mount the back stop for the Quick Clamping Device on the left- Mounting a Quick Clamping hand side of the cutting table. The cut-out corner should be on Device and Spring Clamp the right. Do not tighten the screws.

  • Page 23: Noise

    Take action to lower the vibration where possible; decrease the pressure or use a vibration-reducing glove. It is always recommended to clamp with recommended Struers clamping solutions to reduce the source of vibration. CAUTION Risk of hand to arm vibration during manual cutting.

  • Page 24: Basic Operations

    Labotom-15 Instruction Manual 2. Basic Operations This chapter describes the basic operation of Labotom. Information on the advanced functions can be found in the Advanced Operation section of the Instruction Manual. Using the Controls Flush Start Stop Function Starts the water pump.

  • Page 25: Flushing Gun

    Labotom-15 Instruction Manual Labotom-15 comes complete with a flushing system. This enables Flushing Gun the cutting chamber to be rinsed clean of any debris discarded during the cutting process. Flushing is operated through the Control Panel buttons. CAUTION  Avoid skin contact with the additive for cooling fluid.

  • Page 26: Clamping The Workpiece

    Labotom-15 Instruction Manual Clamping the Workpiece Using the Struers Vertical Quick Clamping Device (available as an Accessory).  Clean the cutting table with the flushing gun.  Place the workpiece under the clamp of the Vertical Quick Clamping Device (on the left-hand side of the cutting table).

  • Page 27: Starting/Stopping The Cutting Process

     Wait until the safety lock is released before opening the cover (there is a 4 second delay from pressing STOP). NOTE: The cover on Labotom-15 is equipped with a safety lock. The cutting motor will not start with the cover open. NOTE:...

  • Page 28: Maintenance

    To ensure a longer lifetime for your Labotom-15 Struers strongly recommends daily cleaning of the cutting chamber. Clean the cutting chamber thoroughly if the Labotom-15 is not to be used for a longer period of time. Please refer to the Instruction Manual for the Recirculation Cooling Recirculation Cooling Unit Unit.

  • Page 29: Daily Maintenance

    Labotom-15 Instruction Manual Daily Maintenance  Clean all accessible surfaces with a soft, damp cloth. Machine NOTE: Do not use a dry cloth as the surfaces are not scratch resistant. Grease and oil can be removed with ethanol or isopropanol.

  • Page 30: Weekly Maintenance

    Labotom-15 Instruction Manual Weekly Maintenance The machine should be cleaned regularly to avoid damaging effects to the machine and the specimens from abrasive grains or metal particles.  Clean painted surfaces, and the control panel with a soft, damp cloth and common household detergents.

  • Page 31: Monthly Maintenance

    Labotom-15 Instruction Manual Monthly Maintenance  Replace the cooling fluid in the Recirculation Cooling Unit at Replacing the Cooling Fluid least once a month. CAUTION Avoid skin contact with the additive for cooling fluid. Do not press FLUSH until the flushing gun points into the cutting chamber.

  • Page 32: Maintenance Of Cutting Tables

    Instruction Manual Adjusting the Clamping Column Maintenance of the Clamping Devices is part of the regular yearly Struers Service. For details on adjustments and maintenance, consult Struers. Should the clamping column require a slight adjustment to improve holding of the workpiece:...

  • Page 33: Yearly

    Inspection of the cover and replacement of the screen are part of ServiceGuard, the Struers range of service plans. WARNING To ensure its intended safety, the cover must be replaced every 5 years .

  • Page 34: Cleaning The Flush Gun Nozzle

    If cooling fluid starts to run from the cut-off wheel guard, press STOP  and contact Struers Service.  Activate Emergency stop.  Press FLUSH to activate the water pump. If cooling fluid starts to run, press STOP  and contact Struers Service.

  • Page 35: Spare Parts

    Labotom-15 Instruction Manual WARNING Do NOT use the machine with defective Safety Devices. Contact Struers Service. Spare Parts A list of selected wear parts that may need replacement during the lifetime of the machine can be found in the Spare Parts and in the Reference Guide section of the Instruction Manual.

  • Page 36: Cautionary Statements

    Labotom-15 Instruction Manual 4. Cautionary Statements List of Safety Messages in the Manual CAUTION The machine is heavy. Always use crane and straps. ELECTRICAL HAZARD The machine must be earthed (grounded). Switch the power off when installing electrical equipment. Check that the mains voltage corresponds to the voltage stated on the type plate on the side of the machine.
  • Page 37 ELECTRICAL HAZARD Disconnection of the power supply may only be performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.) WARNING Safety critical components are to be replaced after a maximum lifetime of 20 years. Contact Struers Service for information.

  • Page 38: Transport And Storage

    (silica gel) with the machine, too. At the new location, check that:  The facilities required are in place (power and exhaust).  Check the Pre-Installation Checklist (if it is lost, contact Struers for a copy) ELECTRICAL HAZARD...

  • Page 39: Disposal

    Labotom-15 Instruction Manual 6. Disposal Equipment marked with a WEEE symbol contain 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.

  • Page 40: Reference Guide

    Safety Related Parts of the Control System (SRP/CS) ....53 Spare Parts List ................54 Diagrams ..................55 Labotom-15 Block Diagram 16053051 ........56 Labotom-15 Circuit Diagram 16053101 ........57 Labotom-15, Water diagram 16051002 ........60 7. Legal and Regulatory FCC Notice ..................

  • Page 41: Struers Knowledge

    Labotom-15 Instruction Manual 1. Struers Knowledge Materialographic sectioning is where most microstructure analysis begins. A good understanding of the abrasive cutting process can help to select suitable clamping and cutting methods and thereby ensure the high-quality cut. Minimizing cutting artefacts will help the remaining materialographic process and act as a good base for efficient and high-quality preparation.

  • Page 42: Advanced Operations

    This could result in damage to the cut-off wheel or to the workpiece itself. Use the T-slots to mount the special clamping tools. Struers offers a selection of Clamping Tools (Please refer to the or the Labotom-15 brochure Struers Clamping Tools brochure details of the range available).

  • Page 43: Adjusting The Cutting Handle

    Adjusting the Cutting Handle The cutting handle is factory-mounted in a position which will suit most people when Labotom-15 is placed on a table 800 mm high. However, it is possible to change the position of the cutting handle:  Remove the 4 screws from the back of the hardware box on the rear of Labotom-15.

  • Page 44: Adjusting The Tilting Cutting Unit

    To adjust the friction:  Remove the 4 screws from the back of the hardware box on the rear of Labotom-15. Loosen 2 screws  Loosen the 2 screws on the cutting arm spring.  Hold the cutting arm in position.

  • Page 45: Optimising The Cutting Results

    How can I achieve faster Position the workpiece so as to cut the cutting? smallest possible cross-section. Apply a higher cutting force. Please refer to the Selection Guide in the Struers Cut-off Wheels brochure.

  • Page 46: Accessories And Consumables

    For extending the cutting chamber when cutting long workpieces. To be mounted on the left-hand side of Labotom-15. For workpieces with a maximum size of: 120 mm / 4.7" dia. or 200 x 90 mm / 8" x 3.5". 06056902...

  • Page 47: 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. Please refer to the Selection Guide in the Cut-off Wheels Struers Cut-off Wheels brochure.

  • Page 48: Trouble-Shooting

    If this does not help: Contact Struers Service. Workpieces or cutting chamber Insufficient additive for cooling fluid. Add Struers additive Corrozip to the rusty. cooling water, using the correct concentration. Please follow the instructions in the Recirculation Cooling Unit Instruction Manual.
  • Page 49 The hardness of the cut-off wheel is Please refer to the Selection Guide workpiece. inappropriate for the hardness / in the Struers Cut-off Wheels dimensions of the workpiece. brochure. The force on the cut-off-wheel is too Apply a lower force on the cut-off high.
  • Page 50 The cut-off wheel is too soft for the Please refer to the Selection Guide task. in the Struers Cut-off Wheels brochure. Labotom-15 vibrates (worn Contact Struers Service. bearings). The cut-off wheel does not cut Incorrect choice of cut-off wheel. Please refer to the Selection Guide through the workpiece.
  • Page 51 Leave the cover open when you cutting chamber for too long. leave the machine. Insufficient additive for cooling fluid. Add Struers additive Corrozip to the cooling water in the correct concentration. The additive is not suitable for the Add Struers additive Corrozip to the application.

  • Page 52: Service

    Labotom-15 Instruction Manual 5. Service Struers recommends that a regular service check be carried out after every 1500 hours of use. Struers offers a range of comprehensive maintenance plans to suit the requirements of our customers. This range of services is called ServiceGuard.

  • Page 53: Spare Parts And Diagrams

    Other Control Systems Assembly Protection guard assembly Struers manufact. Struers’ Cat. nos. are listed in the Spare Parts list. NOTE: The PETG screen must be replaced after a lifetime of 5 years. Replacement of Safety critical components can only be performed by a Struers engineer or a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.).

  • Page 54: Spare Parts List

    The following is a list of selected wear parts that may need replacement during the lifetime of the machine. For further information, or to check the availability of other replacement parts, please contact your local Struers Service department. Contact information is available on Struers webpage Spare Part Cat no: El.

  • Page 55: Diagrams

    Labotom-15 Instruction Manual Diagrams Labotom-15 Block Diagram ..........16053051 Labotom-15 Circuit Diagram (3 pages) ........ 16053101 Labotom-15, Water diagram ..........16051002 See the following pages.

  • Page 61: 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 62: Technical Data

    Labotom-15 Instruction Manual 8. Technical Data Subject Specifications Metric/ US/Imperial International Cutting Cutting power constant [S3 60%] 5.5 kW 8.8 HP Cutting power intermittent [S3 15%] 7.5 kW 11.4 HP Rotational speed (running idle) 2350 rpm 2350 rpm 43 m/s...

  • Page 63: Specifications

    3x460-480/60 24 A NOTE: Labotom-15 must be protected with external fuses, please see above for the fuse size required. Noise level: The figures quoted are emission levels and are not necessarily safe working levels. While there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required.
  • Page 64 Labotom-15 Instruction Manual Mains Cable Specification* Voltage / Min. Minimum cable size Max. Minimum cable frequency: Fuse @ Min. fuse Fuse size size size @ Max. fuse 3x200/50 40 A 3x4.0mm² + PE + N 50 A 3x4.0mm² + PE + N...
  • Page 65 Labotom-15 Instruction Manual Cutting Table Dimensions...
  • Page 66 A Vertical Clamping Tool is used. The actual cutting capacity depends on the workpiece material, cut- off wheel and clamping technique. In particular, Labotom-15 is suitable for sectioning rods, tubes and pipes of up to 80 mm. HINT: Certain workpieces can be difficult to clamp adequately and may result in resonance and vibration.

  • Page 67: Quick Reference

    Labotom-15 Instruction Manual Quick Reference Clamping the Workpiece  Place the workpiece in a suitable clamping tool on the left hand side of the cutting table.  Make sure that the workpiece is clamped securely. Starting/Stopping the Cutting  Close the cover.

  • Page 68: Appendix

    PIC No.: 16057037 Revision A Date of Release 2018.12.12 Labotom-15, Pre-Installation Checklist Read the Installation instructions in the Instruction Manual before installing the machine. Installation Requirements − Crane and 2 lifting straps, approved to at least twice the weight of the load −...
  • Page 69 For other tables, check there is enough space under/ at the side of the table for a Recirculation cooling unit. Lifting Weight: 180 kg / 397 lbs A crane, 2 lifting straps and a lifting bar are required to lift Labotom-15 off the shipment pallet. Place the two lifting straps under Labotom-15. ...
  • Page 70 Labotom-15, Pre-Installation Checklist Dimensions Centre of Gravity Lifting Points [LL1] Place lifting straps between front and hind legs as indicated. Use a lifting bar to keep the lifting straps from pressing against the housing. Page 3 of 3...
  • Page 71 Check there is enough room behind the table for the inlet and outlet hoses.  (No extra space is required when using Struers table as the table top has pre- cut holes for the hoses). For connection to an external exhaust system: ...

  • Page 72: Power Supply

    3x220-230V-50Hz 3x220-240V-60Hz 3x380-415V-50Hz 3x460-480V-60Hz External Short Circuit Labotom-15 must be protected with external fuses. Please see the Recommended Protection Mains Cable specification for details on the fuse size required. Type A, 30 mA (or better) is recommended. Residual Current Circuit...
  • Page 73 Labotom-15, Pre-Installation Checklist Safety Specifications Stop Mechanisms Designed to comply with a minimum of EN60204-1, Stop Category 0 Cover EN ISO 13849-1, Performance Level d EN60204-1, Stop Category 0 Emergency stop EN ISO 13849-1, Performance Level c Water Supply  Required ...

  • Page 74: Ambient Conditions

    Recirculation Required cooling unit Struers Cooling System 4 with 100 l tank, large pump, Cooli-1 filter bag and adapter is recommended. The Recirculation Cooling Unit is supplied with a 2.5 m / 8.2' water hose and a GEKA connection for easy assembly.

  • Page 75: Contents Of The Declaration Of Conformity

    Labotom-15 Instruction Manual Contents of the Declaration of Conformity Manufacturer Struers ApS Pederstrupvej 84 DK-2750 Ballerup, Denmark Telephone +45 44 600 800 Herewith declares that Labotom-15 Name: Function: Cut-off machine 06056229, 06056230, 06056235, 06056236, Type: 06056246, 06056254 fulfils all the relevant provisions of the:...
  • Page 76  Pederstrupvej 84 DK-2750 Ballerup Denmark...