ATA SAPHIR 550 User manual

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SAPHIR 550/560
Operating Manual
GmbH
- 1 - Stand: 03.02.2020
Introduction
This operating manual contains important instructions descriptions and tips for operation and safety. It is the basis for
safe economic and problem-free work.
Personnel must be instructed by an authorized person before the machine is commissioned.
Safety First
comes first!
Whoever works with or on the machine transports or sets up the machine commissions or decommissions the
machine maintains or cleans the machine is obligated to read and observe these safety instructions guidelines
and precautions.
This will prevent injuries to persons and damage to the machine material and environment. Furthermore any
claim in accordance with EU machine guideline 2006/42/EU is nullified if the machine is used improperly.
This operating manual is a component part of the delivered device.
Made in Germany

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Table of Contents
Introduction ............................................................................................................................................... 1
Table of Contents ....................................................................................................................................... 2
Guarantee ................................................................................................................................................ 4
Intended Use ............................................................................................................................................. 4
Explanation of the safety symbols and “notice signs used in the manual .................................................... 5
1. Product Description ..................................................................................................................... 6
1.1 Machine ..................................................................................................................................... 6
1.2 Changing the working wheel ....................................................................................................... 6
1.3 Additional options ...................................................................................................................... 7
1.3.1 Dosing system ............................................................................................................................. 7
1.3.2 Sedimentation container ............................................................................................................... 7
1.3.3 Abrasion measurement ................................................................................................................ 7
1.4 Reference path ............................................................................................................................ 7
2. Operation ................................................................................................................................... 8
2.1 Main menu ................................................................................................................................. 8
2.2 Grinding parameters ................................................................................................................... 9
2.2.1 Entering values .......................................................................................................................... 10
2.2.2 Program steps ........................................................................................................................... 11
2.2.2.1 Copying a program step ............................................................................................................ 11
2.2.3 Start / Stop / Pause keys ........................................................................................................... 12
2.2.4 Station selection ........................................................................................................................ 12
2.2.5 Manual mode and automatic mode ............................................................................................ 13
2.2.5.1 Automatic mode ........................................................................................................................ 13
2.2.5.2 Manual mode ............................................................................................................................ 14
2.2.6 Process parameters .................................................................................................................... 15
2.2.6.1 Single/Central pressure ............................................................................................................. 15
2.2.6.2 Grinding with time/abrasion ...................................................................................................... 15
2.2.6.3 Water ....................................................................................................................................... 16
2.2.6.4 Direction of rotation for sample holder ........................................................................................ 16
2.2.6.5 Manually bringing out the pistons ............................................................................................... 16
2.2.6.6 Manual rotating of the sampleholder ........................................................................................... 16
2.2.6.7 Working wheel cooling .............................................................................................................. 16
2.2.6.8 Progress indicator ...................................................................................................................... 17
2.2.7 Movement control ...................................................................................................................... 17
2.2.7.1 Head movement ........................................................................................................................ 17
2.2.7.2 Memorizing a position ............................................................................................................... 18
2.2.7.3 Inserting/loosening the sample holder ......................................................................................... 18
2.2.8 Dosing ...................................................................................................................................... 19
2.2.8.1 Manual post-dosing ................................................................................................................... 19
2.2.8.2 Settings for the dosing unit ......................................................................................................... 20
2.3 Program administration ............................................................................................................ 21
2.3.1 Load program ........................................................................................................................... 21
2.3.2 Program functions- save / delete / protect against overwriting ..................................................... 21
2.3.3 Saving onto a USB flash drive .................................................................................................... 22
2.4 System Settings ......................................................................................................................... 23
2.4.1 Pre/Post-pressure ...................................................................................................................... 23
2.4.2 Additional settings ..................................................................................................................... 24
2.4.3 Calibration (single pressure) ....................................................................................................... 25
2.4.4 Setting Limits (Work area) .......................................................................................................... 26
3. Maintenance and Care .............................................................................................................. 27
3.1 Maintenance ............................................................................................................................. 27
3.2 Care ......................................................................................................................................... 27
4. Malfunctions and Measures ....................................................................................................... 28
4.1 Malfunctions, causes and their eradication ................................................................................. 28

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4.2
Malfunction messages on the display ......................................................................................... 29
4.3 Dismantling instructions for the housing ..................................................................................... 30
4.4 Replacing the housing ............................................................................................................... 30
5. General Safety Instructions ........................................................................................................ 31
5.1 Basic safety measures ............................................................................................................... 31
5.1.1 Ensure that information is available............................................................................................. 31
5.1.2 Before starting ........................................................................................................................... 31
5.1.3 After finishing work ................................................................................................................... 32
5.2 Safety - service, maintenance and care ...................................................................................... 32
5.2.1 Safety test ................................................................................................................................. 33
5.3 Safety when working on electrical equipment ............................................................................ 33
5.4 Repeated inspection .................................................................................................................. 34
5.5 Environmental protection ........................................................................................................... 35
5.6 Noise emissions ........................................................................................................................ 36
5.7 Changes to the machine ............................................................................................................ 36
5.8 Operating personnel requirements............................................................................................. 36
5.9 Safety when transporting, setting up, commissioning and decommissioning ................................ 36
6. Transport and Setup .................................................................................................................. 37
6.1 Transport .................................................................................................................................. 37
6.2 Delivery condition ..................................................................................................................... 37
6.3 Technical prerequisites .............................................................................................................. 37
6.4 Setting up and connecting the device ......................................................................................... 38
7. Commissioning and Function Testing .......................................................................................... 39
8. Additional Information .............................................................................................................. 39
8.1 Accessories and Consumables ................................................................................................... 39
8.2 Acceptance protocol .................................................................................................................. 39
8.3 Spare parts list.......................................................................................................................... 39
9. Appendix ................................................................................................................................. 40
9.1 Declaration of conformity .......................................................................................................... 40
9.2 Technical data .......................................................................................................................... 40
9.3 Arrangement plan..................................................................................................................... 40
9.4 ATM service and contact............................................................................................................ 40

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Guarantee
The manufacturer assumes neither liability nor guarantee if:
»the instructions contained in the transport installation and operating manual are not observed
»the machine including additional fixtures is operated improperly and is not properly maintained and
repaired
»any technical or functional modifications have been made that are not authorized by the manufacturer.
Intended Use
The Saphir 550 / 560 is an electronically controlled grinding and polishing machine that is designed exclusively to
execute grinding and polishing work of embedded or non-embedded samples automatically or manually.
This applies as well for all options available for the machine.
If the Saphir 550 / 560 is not used for the purpose listed here then no safe operation of the machine can be ensured.
This applies as improper use.
The owner/operator of the machine not the manufacturer is liable for all personal injuries and property damage that
occur from improper use!
The grinding and polishing machine is configured for:
mechanical preparation of many metallic and non-metallic materials.
use of all ATM grinding and polishing cloths / papers and foils up to ∅ 300 mm.
ATM GmbH makes no warranty of success if other media are used.
Intended use also includes the reading of this operating manual as well as compliance with all instructions contained
therein – particularly the safety instructions.

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Explanation of the safety symbols and “notice signs used in the manual
The following safety symbols are used in this manual. Primarily these symbols serve to alert the reader to the safety
instructions accompanying the symbol.
This symbol indicates that hazards to life and health exist.
This symbol indicates that it is forbidden to interfere in the machine when it is running.
This symbol indicates that hazards exist for machine material or environment.
This symbol identifies explanations that contribute to better understanding of the machine processes
and is “notice” sign for important information.
This symbol identifies situations that require notification of the authorized service organization.

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1. Product Description
1.1 Machine
The Saphir 550 / 560 is a grinding machine for manual grinding and polishing of a wide range of workpieces and
materials. With its very low amount of maintenance and high technological niveau operating costs are kept to a
minimum.
This Saphir 550 / 560 is fitted with a robust drive motor which drives the main shaft via ribbed v-belt.
The Saphir 550.3 / 560.3 is equipped with a grinding & polishing head Rubin 520.3.
The Saphir 550 and 560 differ from each other in the number of working wheels. The Saphir 550 has 1 working
wheel the Saphir 560 has 2.
1.2 Changing the working wheel
»Pull the mounted working wheel upwards and then away.
»Set the new working wheel onto the carrier wheel and rotate it until the carrier pins click into place.
»Finally press the working wheel with light pressure onto the carrier wheel.
Basic unit
Automatic head

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1.3 Additional options
1.3.1 Dosing system
The microprocessor-controlled dosing system is integrated into the unit.
This dosing facility for the application of diamond suspensions and lubricant is fitted with:
»programmable dosing interval
»settable dosing time (pump time)
»3 separate units 1 x lubricant 4 x suspension and 1 x end-polishing suspension
»exact droplet dosing (uncontrolled dripping is avoided through return suction of residual liquid)
The dosing system is programmed via the control and offers a uniform and automated working sequence of the
polishing process through the 6 ports for suspension vessels i.e. lubricant. (please note here the all-round product
pallet of diamond suspensions from ATM)
1.3.2 Sedimentation container
The movable Aluminium sedimentation container for the settling of grinding abrasion consists of a two-chamber
system with overflow. An inlet sieve is hooked into the first chamber to collect larger grinding residues.
1.3.3 Abrasion measurement
Abrasion measurement enables you to grind-away the workpiece sample by a preselected amount.
Upon reaching the desired dimension the grinding sequence is ended automatically.
Here we differentiate between grinding acc. to time and grinding acc. to abrasion.
1.4 Reference path
After switching on the machine it first runs through a reference path. This involves taking the head all the way to the
top position. If there is no successful reference path then the machine cannot be used.
4 x suspension
Lubricant
End-polishing suspension

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2. Operation
2.1 Main menu
1Grinding Parameters (see 2.2)
2Program Administration (see 2.3)
3System Settings (see 2.4)
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2.2 Grinding parameters
Graphic operator interface (Automatic mode activated)
1Function field Program steps (see 2.2.2)
2Function field Process parameters (see 2.2.6)
3Progress indicator (see 2.2.6.8)
4Function field Movement control (see 2.2.7)
5Function field Dosing (see 2.2.8)
6Station display/selection (see 2.2.4)
7Start-key (see 2.2.3)
Manipulation is performed by explicit pressure on the monitor with a finger or a suitable object.
At the bottom of the monitor there is the status display. This gives useful information and tips.
Deactivated keys are to be recognized by their grey background. When a key is activated then the background
illuminates in the appropriate function colour.
Attention: Sharp or pointed objects can damage the monitor screen!
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2.2.1 Entering values
Should one of the fields which contains a value be pressed then a numbered mask appears and a new value can be
entered. If directly after opening the mask a number key is pressed then the old value is automatically overwritten.
1Value field
2Rapid select keys
3Number keys
4Esc key (process is aborted old values remain)
5Correction key
6Enter key (new value is overwritten)
On the left-hand side are the rapid select keys. A new selection is directly accepted and implemented (e.g. the new
rpm is directly overwritten in the course of a process without the Enter key having to be pressed).
Entries outside the permitted range are not accepted and are intercepted.
Values for time can be entered in different ways.
Entry examples:
1 Minute: 1:00 or 1:
15 Seconds: 15
2 Minutes 5 Seconds 2:05 or 2:5 or 125 (entries of more than 60 seconds are automatically re-
calculated)
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2.2.2 Program steps
1Program steps
2Copy program step (see 2.2.2.1
3Memo field
A program can consist of a number of steps which can be reworked one after the other in automatic mode. Upon
starting the process the activated step at the moment will be implemented (recognisable by the blue background).
Once a step has finished the head travels upwards automatically and the next step is activated (assuming it is
programmed).
A step is programmed when a program duration not equal to 00:00 min is entered.
A programmed step can be recognized by the black digit in the key.
For every step short memos relating to the process can be entered into the memo field.
»After canceling a program step the head does not travel upwards automatically.
»The upwards movement can be aborted by pressing one Y movement key (see 2.2.7.1).
2.2.2.1 Copying a program step
Use this function to copy one single program step into another.
Procedure:
1. Select step to be copied (activate)
2. Press the key ”Copy“ (8)
3. Select step into which the parameter is to be copied(if no selection is made within 5 seconds then the
function is aborted)
4. Acknowledge safety query
3
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2.2.3 Start / Stop / Pause keys
Depending on whichever whether automatic or manual mode is activated (see 2.2.5) other keys are shown:
Start key in Automatic mode Start key in manual mode
Press once on the Start key to start the process. It changes now to the Stop key which can be then pressed to abort the
process.
Pause/Stop key in Automatic mode Stop key in manual process
The Start button is only displayed when the station is also activated (see 2.2.4 Station select).
Both stations stopped, both stations stopped,
right is selected and can be started left is selected and can be started
The Stop button is always displayed so that the currently running station can always be stopped directly.
ight station is selected and can be started
left station is started and can be stopped
2.2.4 Station selection
Possibilities for selection vary according to machine and its accessories.
In the case of a machine with 2 stations it is possible to switch between stations.
For machines with only 1 station the key acts as display (whether automatic mode or manual mode is activated).
Station display Saphir 550 (only 1 station) Station select Saphir 560 (2 stations)

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The orange-illuminated station is selected => in the process parameters (see 2.2.6) the appropriate
parameters are displayed related to that particular station.
The Start key is concerned with this selected station here.
Automatic mode activated:
Manual mode activated:
Right wheel automatic mode activated
Left wheel manual mode possible
For machines with more than 1 station when 1 station is running it is possible to switch over to and also work with
the other station.
2.2.5 Manual mode and automatic mode
2.2.5.1 Automatic mode
In order to work in automatic mode the head is to be positioned above the working wheel.
All settable parameters in automatic mode are shown.
To start the automatic process the head must be taken downwards enough direction working wheel.
It is possible to initiate a pause inside the course of the process by pressing the Pause key.
The sample holder and samples can be removed temporarily for inspection.
The process can now be resumed (press the Pause key again)
or aborted (pressure on the Stop key).
Automatic process started Automatic process paused
on right working wheel on right working wheel

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2.2.5.2 Manual mode
Manual mode is activated when the head is positioned next to the wheel.
All settable parameters in manual mode are shown.
(Fig. may vary)
Press the Start key once to start the working wheel with the preset speed.
Press the button again and the wheel stops.
As long as the dosing tubes are still to be found above the working wheel dosing can also be used in manual mode.

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2.2.6 Process parameters
1Program duration
2Single/Central pressure (see 2.2.6.1)
3Downward pressure
4Grinding to abrasion (only possible in central pressure) (see 2.2.6.2)
5Desired abrasion
6rpm working wheel
7Rotational direction sample holder (see 2.2.6.4)
8rpm sample holder
9System settings (see 2.4)
10 Bring out pistons manually (see 2.2.6.5)
11 Manual rotating of the sampleholder (see 2.2.6.6)
12 Water (see 2.2.6.3)
13 Working wheel cooling (see 2.2.6.7)
14 Machine illumination
2.2.6.1 Single/Central pressure
Single pressure:
Central pressure:
If this mode is switched over then the sample holder head must also be correctly set because the force for downward
pressure has to be re-calculated accordingly.
2.2.6.2 Grinding with time/abrasion
If grinding with abrasion is deactivated then the process is grinding/polishing with time. The sequence runs so long
until the preset time has ended.
If grinding with abrasion is activated then the automatic process runs only so long until the preset abrasion is
reached or the preset time has ended. This way it can be assured that a grinding sequence does not run unendlessly.
The time should be set so far that the preset abrasion is also reached at the same time.
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2.2.6.3 Water
Water can be preselected here. If the preselection is activated then water will be switched on as long as the working
wheel is running (automatic or manual mode).
The preselection of water deactivates the preselection for diamond suspensions i.e. lubricants (see 2.2.8).
To switch off the water manually (e.g. for cleaning) press & hold the key for 1 second.
A short press switches it off again.
2.2.6.4 Direction of rotation for sample holder
Rotate with:
Rotate against:
2.2.6.5 Manually bringing out the pistons
The pistons can be brought out manually (e.g. for cleaning).
Press & hold this key for more than 1 second => pistons are brought out.
Press & hold the key for longer than 2 seconds and the pistons stay out until the key is pressed again momentarily.
2.2.6.6 Manual rotating of the sampleholder
The insertion of samples into the sampleholder in the single pressure can be facilitated with this function which rotates
the sampleholder. So the already loaded samples can be rotated back and the remaining free spaces can be rotated
forward. After pressing the button the hood goes down and the sample holder rotates slowly. As soon as the button is
released the movement stops again.
2.2.6.7 Working wheel cooling
The working wheel can as with the water be preselected and will remain so as long as the working wheel runs.
In Economy mode it is switched on for 2 seconds every 2 seconds.
Economy deactivated:
Economy activated:
Economy mode (Eco):

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2.2.6.8 Progress indicator
This indicator at the bottom of the screen shows the progress in an automatic process or sequence.
The left-hand side shows the already elapsed time i.e. for grinding of abrasion; this is the amount of abrasion which
has already been removed.
1Already elapsed time/removed abrasion
2Remaining time
2.2.7 Movement control
1Save height position
2Save side position
3Release sample holder
4Head upwards
5Head downwards
6Loosen brake (swing head left/swing head right)
2.2.7.1 Head movement
Use the 2 middle keys to move the head either upwards or downwards.
The head can only be moved downwards when it is directly above the working wheel; otherwise the head would press
down onto and damage the housing.
Press the large key on the right-hand side to loosen a brake so that the head can be swung to the left or to the right
by hand. Release pressure on the key and the brake comes back into effect.
If a position is memorized in the X- direction then the brake stays loosened even after removing pressure from the
key. This enables you to swing the head with 2 hands.
If the head is to be found in the area of the working wheel then the brake will begin to grip when it is swung too far
to one side or the other. This makes sure that the sample holder does not travel too far and hit the bowl.
»As the brake has a certain amount of technically-related delay in loosening the head should only
be moved by hand with moderate speed.
»If the movement is too fast then the brake position can be exceeded.
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2.2.7.2 Memorizing a position
For each program step it is possible to memorize a side-related (X) and a height-related(Y) position.
This reference position can be called up again after loading of a program/program step.
To memorize the current reached position press key (for sideways position) i.e. key (for height
position). Background colour of the key changes to green (Position memorized).
To travel to the reference position move the head in the respective direction. It will stop automatically at the
memorized position.
Black arrows indicate the direction towards the reference position.
Reference position reached:
Reference position futher right:
To delete a position press & hold the key for 1 second.
2.2.7.3 Inserting/loosening the sample holder
To insert/loosen the sample holder press key take the weight of the sample holder and acknowledge the
safety query. The sample holder is then loosened and can be removed.
Background colour of the key changes to green:
Now you can insert a sample holder. Then press the sample holder into its seating and press the key once more.

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2.2.8 Dosing
1Select diamond suspension
2Select end polishing suspension
3Interval time for suspension
4Suspension progress indicator/manual post-dosing
5Setting the dosing units
6Select lubricant
7Interval time for lubricant
8Lubricant progress indicator/manual post-dosing
During a process a dosing sequence for the preselected pump is activated after completion of the interval time.
A dosing sequence consists of a forward pumping phase and a reverse-pumping phase (protection against dripping).
Lengths of pumping phases are adjustable in the dosing settings (see 2.2.8.2).
There can only be 1 suspension pump activated at any one time.
Selection of a diamond suspension or lubricant rejects the selection of water (see 2.2.6.3).
2.2.8.1 Manual post-dosing
The progress indicator dictates the duration until the next dosing.
For manual post-dosing press onto the progress indicator for the desired pump.
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2.2.8.2 Settings for the dosing unit
1Pumping duration of the diamond suspension pump i.e. lubricant pump during an interval
2Reverse pumping duration of the diamond suspension pump i.e. lubricant pump at the end of a
pumping phase (protection against dripping)
3Pre-dosing duration of the end-polishing suspension at the stat of a program step
4Pumping duration of the end-polishing suspension during an interval
5Rinsing duration of the end-polishing suspension system at the end of a pumping phase (with
water)
6Rinsing duration of the end-polishing suspension system at the end of a program step (with water)
7Manual activation of the suspension pump (for filling/cleaning)
8Manual activation for rinsing of the end-polishing suspension system (with water)
9Quit i.e. leave
10 Manual activation of the lubricant pump (for filling/cleaning)
11 Switch-over pump to suction for diamond suspension and lubricant
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