Struers Cooli System 1 User manual

Cooli System
Instruction Manual
Original Instructions
Doc. no.: 15767025-02_A_en-us
Date of release: 2022.12.01

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 2022.12.01.
2 Cooli System

Table of Contents
1 About this manual 5
2 Safety 5
2.1 Intended use 5
2.2 Device description 6
2.3 Cooli Systemsafety precautions 6
2.3.1 Read carefully before use 6
2.4 Safety messages 7
2.5 Safety messages in this manual 8
3 Transport and storage 9
3.1 Transport 9
3.2 Long-term storage or shipping 9
4 Installation 10
4.1 Overview - the cooling unit 10
4.2 Unpack the machine 11
4.3 Check the packing list 11
4.4 Cooling system configurations 12
4.5 Lift the machine 13
4.6 Power supply 16
4.6.1 Single-phase supply 16
4.6.2 Connection to the machine 17
4.7 Filters 17
4.7.1 The filter tube 18
4.8 Noise 18
5 Assembling the cooling unit 18
5.1 The tank 19
5.2 The control unit 19
5.3 The recirculation pump 20
5.4 The filter tray 20
5.5 Connection to the machine 21
6 Operate the device 21
6.1 Filling the tank 21
6.2 Control panel functions 22
7 Maintenance and service 22
7.1 General cleaning 23
Cooli System 3

7.2 Daily 23
7.2.1 Filter bag 23
7.2.2 Filter tube 24
7.2.3 Magnetic filter 24
7.2.4 Static filter 24
7.3 Monthly 25
7.3.1 Changing the cooling fluid 25
7.4 Spare parts 25
7.5 Service and repair 26
7.6 Disposal 26
8 Troubleshooting 27
9 Technical data 28
9.1 Technical data 28
9.2 Control unit 29
9.3 Safety Circuit Categories/Performance Level 30
9.4 Noise and vibration levels 30
9.5 Safety Related Parts of the Control System (SRP/CS) 31
9.6 Diagrams 31
9.6.1 Diagrams - Cooli-1 31
9.7 Legal and regulatory information 34
10 Manufacturer 34
Declaration of Incorporation of Partly Completed Machinery 35
4 Cooli System

1 About this manual
Instruction Manuals
Struers equipment must only be used in connection with and as described in the Instruction
Manual supplied with the equipment.
Note
Read the instruction manual carefully before use.
Note
If you wish to view specific information in detail, see the online version of this
manual.
2 Safety
2.1 Intended use
The cooling system is intended for filtration, cooling and recirculation of cutting fluid containing
waste from machining of materials. The system is designed for use with Struers grinding,
mounting and cutting machines.
The machine is for use in a professional working environment (e.g. a materialographic
laboratory).The machine must be operated only by skilled/trained personnel.
The device is designed to be used with Struers consumables specially designed for this purpose
and this type of device.
A signal from the machine it supports is required for the cooling system to function as intended.
Do not use the machine for
the following
Filtration of any type of explosive and/or flammable material, or
materials which are not stable during machining, heating or
pressure. Furthermore, the machine must not be used with
consumables (cutting fluids, filter materials) that are not
compliant with function and materials of the cooling system*.
Pumping of any type of explosive and/or flammable material, or
materials which are not stable during machining, heating or
pressure.
Furthermore, the machine must not be used with consumables
(cutting fluids) that are not compliant with function and
materials of the Cooling System.
Model Cooli System
1 About this manual
Cooli System 5

2.2 Device description
The cooling system is a filtration and recirculation machine for cutting fluid with cutting debris
(typically swarf). It filters and cools down the cutting fluid from a grinding and/or cutting machine.
Cutting fluid is led into the filter, which is placed on a perforated metal plate. The filtered cutting fluid
is collected in a tank underneath the filter unit and is then recirculated to the cutting machine with a
pump which is inserted in the tank.
The cutting fluid with waste is led into a specifically designed filter (XL filter or filter tube) which is
attached to the water inlet. Cutting debris (typically swarf) is collected in the filter.
The XL filter can be re-used. The filter tube is designed for single-use.
Operation is manual, and the operator must monitor the filter and cutting fluid condition. When the
disposable filter is filled, the operator empties or replaces the filter.
The cutting liquid must be filled/topped up, correctly mixed and replaced according to specifications.
The cooling system is controlled via a control cable, which activates and stops the machine it is
connected to. This means that it starts and stops simultaneously with the machine, and is on stand-
by when circulation is not required.
If the Emergency stop is activated on the main machine, the Cooling System also stops.
2.3 Cooli Systemsafety precautions
2.3.1 Read carefully before use
1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.
2. The machine must be installed in compliance with local safety regulations. All functions on the
machine and any connected equipment must be in working order.
3. The operator must read the safety precautions and Instruction Manual, as well as relevant
sections of the manuals for any connected equipment and accessories.
4. Only use original Struers consumables as this ensures maximum safety and prolongs the
machine's lifetime.
5. When working with cooling fluid always observe the safety regulations for handling, mixing,
filling, emptying and disposing of the cooling fluid additive. Never use flammable cooling fluid.
Note that the cooling fluid can be hot and must therefore be handled with care.
6. Always wear protective gloves and safety goggles when you clean and fill up the tank.
7. The recirculation pump must be disconnected from the electrical power supply before it can be
removed from the cooling unit.
8. All safety functions must be intact and in working order. If they are not, they must be replaced or
repaired before the machine can be used.
9. Always use the handle to close the cover.
10. Do not insert your hands through the openings into the water inlet ducts on the cover.
11. Cooling fluid can be slippery - therefore always keep the area around the tank clean.
6 Cooli System
2 Safety

12. If you observe malfunctions or hear unusual noises, switch off the machine and call technical
service.
13. In case of fire, alert bystanders and the fire brigade. Disconnect the electrical power supply.
Use a powder fire extinguisher. Do not use water.
14. Always switch off the electrical power supply and remove the plug or power cable before
dismantling the machine or installing additional components.
15. The machine must be disconnected from the electrical power supply before any service.
16. Struers equipment must only be used in connection with and as described in the Instruction
Manual supplied with the equipment.
17. If the equipment is subjected to misuse, incorrect installation, alteration, neglect, accident or
incorrect repair, Struers will accept no responsibility for damage to the user or the
equipment.
18. Dismantling of any part of the equipment, during service or repair, should always be
performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic,
etc.).
2.4 Safety messages
Struers uses the following signs to indicate potential hazards.
ELECTRICAL HAZARD
This sign indicates an electrical hazard which, if not avoided, will result in death or
serious injury.
DANGER
This sign indicates a hazard with a high level of risk which, if not avoided, will
result in death or serious injury.
WARNING
This sign indicates a hazard with a medium level of risk which, if not avoided,
could result in death or serious injury.
CAUTION
This sign indicates a hazard with a low level of risk which, if not avoided, could
result in minor or moderate injury.
CRUSHING HAZARD
This sign indicates a crushing hazard which, if not avoided, could result in minor,
moderate or serious injury.
HEAT HAZARD
This sign indicates a heat hazard which, if not avoided, can result in minor,
moderate or serious injury.
2 Safety
Cooli System 7

General messages
Note
This sign indicates that there is a risk of damage to property, or a need to proceed
with special care.
Hint
This sign indicates that additional information and hints are available.
2.5 Safety messages in this manual
WARNING
Struers equipment must only be used in connection with and as described in the
Instruction Manual supplied with the equipment.
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
WARNING
Switch off the machine, disconnect the electrical power cable before you dismantle
the machine or install additional components.
ELECTRICAL HAZARD
Switch off the electrical power supply before installing electrical equipment.
The machine must be earthed (grounded).
Make sure that the actual electrical power supply voltage corresponds to the voltage
stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.
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.
CAUTION
If the filter tube is twisted or has folds, stop the machine and reposition the filter tube.
Never use the filter tube when you perform dry-cutting.
Never reuse a filter tube.
8 Cooli System
2 Safety

CAUTION
The cooling unit will be very heavy when it is full.
Place the cooling unit in its final position, or make sure that you can easily push it
into position before filling the tank.
CAUTION
Always wear protective gloves and safety goggles when you clean and fill up the
tank.
CAUTION
Avoid skin contact with the cooling fluid additive.
3 Transport and storage
If, at any time after the installation, you have to move the unit or place it in storage, there is a
number of guidelines we recommend that you follow.
• Package the unit securely before transportation.
Insufficient packaging could cause damage to the unit and will void the warranty. Contact
Struers Service.
• We recommend that you keep all original packaging and fittings for future use.
3.1 Transport
• Clean and dry the filter unit and tank.
• Disconnect the unit from the electrical power supply.
• Disconnect the water inlet and the water outlet.
Transporting the unit to a new location
• Lift the cooling system onto a pallet and move to its new location.
• At the new location, make sure that the facilities required are in place.
3.2 Long-term storage or shipping
Note
We recommend that you keep all original packaging and fittings for future use.
• Disconnect the control unit from the electrical power supply.
• Disconnect the water inlet and the water outlet.
• Clean the machine and all accessories thoroughly.
• Remove the control unit, the pump and the water level gauge. Place the items in a box.
3 Transport and storage
Cooli System 9

• Place the box in the tank.
• Build a case around the machine.
• To keep the machine dry, plastic-wrap the machine and place a bag of desiccant (silica gel) in
the case.
• Place a lid on the case.
At the new location
At the new location, make sure that the facilities required are in place.
4 Installation
4.1 Overview - the cooling unit
50 l tank
Front view
ARecirculation pump
BMagnetic filter
CControl unit
DFilter tray
ETank
100 l tank
Front view
ARecirculation pump
BMagnetic filter
CControl unit
DFilter tray
ETank
10 Cooli System
4 Installation

150 l tank
Front view
ARecirculation pump
BMagnetic filter
CControl unit
DFilter tray
ETank
FWater level gauge
150 l tank
Rear view
ADrain valve
4.2 Unpack the machine
Note
We recommend that you keep all original packaging and fittings for future use.
The equipment is delivered on a pallet and fastened with cable ties.The control unit is packed
separately.
1. Remove the transport case.
2. Remove the plastic wrapping.
3. Lift off the filter unit and pump cover and
remove the waste collection bin and the
water level gauge.
4.3 Check the packing list
Optional accessories may be included in the packing box.
The packing box contains the following items:
4 Installation
Cooli System 11

Pcs. Description
1 Tank
1 Recirculation pump
1 Filter bag (with adapter plate for 100 l and 150 l tanks)
1 Control unit
1 24 V/CAN control cable
2 Power supply cables
1 Cable connection box
1 Instruction Manual set
The tank is available in the following variants:
50 l tank 05766906
100 l tank 05766905
150 l tank (for Cooli System 1) 05766929
150 l tank (for Cooli System 2) 05766931
The pump is available in the following variants:
Small pump 05766116, 05766123, 05766216,
05766122, 05766124
Large pump 05766016, 05766023, 05766022,
05766024
Large pump (long) 05765016, 05765023, 05765022.
05765024
Other components
Filter bag 05766928
XL Filter bag 05766932
Static filter 05766934
Water level gauge 05766911
Lid 05766925
4.4 Cooling system configurations
Your cooling system can be configured in several ways.
Option 1
• 150 l Tank: 05766929
• Large pump, long: 05765016, 05765023, 05765022, or 05765024
• Cooli-1 control unit: 05761116
12 Cooli System
4 Installation

• XL filter bag 05766932
Option 2
• 150 l Tank: 05766931
• Large pump: 05766016, 05766023, 05766022, or 05766024
• Cooli-1 control unit: 05761116
Option 3
• 50 l Tank: 05766906
• Small pump: 05766116, 05766123, 05766216, 05766122, or 05766124
• Cooli-1 control unit: 05761116
• Filter bag 05766928
Option 4
• 100 l Tank: 05766905
• Large pump: 05766016, 05766023, 05766022, or 05766024
• Cooli-1 control unit: 05761116
• XL filter bag 05766932
Option 5
• 50 l Tank: 05766906
• Small pump: 05766116, 05766123, 05766216, 05766122, or 05766124
• Cooli-1 control unit: 05761116
• Connection kit: 05766925
Option 6
• 100 l Tank: 05766905
• Large pump: 05766016, 05766023, 05766022, or 05766024
• Cooli-1 control unit: 05761116
• Connection kit: 05766925
4.5 Lift the machine
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
4 Installation
Cooli System 13

Weight
Cooling unit with 50 l tank: 32 kg/70.5 lbs
Cooling unit 100 l tank: 44 kg/97 lbs
Cooling unit with 150 l tank: 65 kg/143 lbs
Lifting points and center of gravity
50 l tank
Side view
Front view
14 Cooli System
4 Installation

100 l tank
Side view
Front view
150 l tank
Side view
Front view
Procedure
To facilitate easy access for service technicians, allow sufficient space around the machine.
4 Installation
Cooli System 15

1. Lift the tank from the pallet.
2. Place the tank on the floor next to the machine you wish to connect it to.
3. Position the straps under the machine, so that they are on the inner side of the rollers.
4. A lifting bar is recommended to keep the two straps apart below the lifting point.
4.6 Power supply
WARNING
Switch off the machine, disconnect the electrical power cable before you dismantle
the machine or install additional components.
ELECTRICAL HAZARD
The machine must be earthed (grounded).
Switch off the electrical power supply before installing electrical equipment.
Make sure that the actual electrical power supply voltage corresponds to the voltage
stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.
Power socket
The electrical power supply socket must be easy to access.
Note
The equipment is shipped with 2 types of electrical power cables. If the plug supplied
on these cables is not approved in your country, the plug must be replaced with an
approved plug.
4.6.1 Single-phase supply
Single-phase supply
The 2-pin plug (European Schuko) is for use on single-phase
electrical power connections.
The 3-pin plug (North American NEMA) is for use on single-
phase electrical power connections.
The leads must be connected as follows:
Yellow/Green Earth (ground)
Brown or Black Line (live)
Blue or White Neutral
16 Cooli System
4 Installation

4.6.2 Connection to the machine
• Connect the electrical power cable to the machine (C14
IEC 320 connector).
• Connect the cable to the electrical power supply.
Note
To keep water away from the connections (Protection Rating IP44), place the
cable box around the cable connections.
Note
To prevent the cables from trailing on the ground and being damaged, hang them
by the hooks in the cooling unit tank.
4.7 Filters
Filter bag
Insert the water outlet hose from the connected machine into
the hole that has the correct size.
4 Installation
Cooli System 17

4.7.1 The filter tube
1. Insert 5 to 10 cm of the filter tube through the quick-release clamp.
Hint
You can remove the end of the rigid connector pipe while you mount the filter tube.
Use grease or soap to lubricate the sealing ring to make reinsertion easier.
2. Mount the filter tube into the outlet hose or
pipe approx. 5 cm from the end of the pipe.
3. Place the filter tube in a U-shape in the filter
unit.
4. Make sure that there are no folds in the
tube.
Note
The first time you use the cooling system after changing the filter tube, make sure that
the filter tube expands to its full length when it fills with water.
CAUTION
If the filter tube is twisted or has folds, stop the machine and reposition the filter tube.
Never use the filter tube when you perform dry-cutting.
Never reuse a filter tube.
4.8 Noise
For information on the sound pressure level value, see this section: Noise and vibration levels ►30
To lower the noise, try to decrease the force with which the cut-off wheel is pressed against the
workpiece. The processing time may increase.
5 Assembling the cooling unit
Note
Some of the cooling unit components are optional.
18 Cooli System
5 Assembling the cooling unit

5.1 The tank
50 l tank
AControl unit
BRecirculation pump
CFilter tray
DWater level gauge
EMagnetic filter
100 l tank
AControl unit
BRecirculation pump
CFilter tray
DWater level gauge
EMagnetic filter
150 l tank
AControl unit
BRecirculation pump
CFilter tray
5.2 The control unit
Note
The control panel must be mounted facing the cooling unit's handle.
5 Assembling the cooling unit
Cooli System 19

1. To mount the Cooli System control unit, place the bolts
in the holes.
2. Secure the bolts with the supplied nuts.
Connecting the cables to the control unit
1. Connect the cables to the respective sockets on the
rear of the control unit.
Note
The sockets and cables are different from
each other so you cannot connect the
wrong cable to the wrong socket.
Note
Connect the 24 V/CAN to the machine with
which you are using the cooling unit.
The 24 V/CAN cable used is supplied with
the control unit.
5.3 The recirculation pump
• Mount the recirculation pump on the connection for the pump.
Adapter ring
• A small pump: use the adapter ring to decrease the diameter of the connection.
• A large pump: remove the adapter ring to increase the diameter of the connection.
Magnetic filter
• Mount the magnetic filter in the hole. See The tank ►19.
Water level gauge
• Mount the water level indicator in the hole. See The tank ►19.
5.4 The filter tray
• Place the filter tray in the tank.
20 Cooli System
5 Assembling the cooling unit