Struers Accutom-100 User manual

Accutom-100
Instruction Manual
Manual No.:
16177025-04
Revision A
Date of release YYYY.MM.DD

Accutom-100
Instruction Manual
1
Table of Contents Page
Intended use ................................................................ 2
Safety Precaution Sheet.............................................. 4
User’s Guide ................................................................ 8
Reference Guide ....................................................... 81
Appendix:................................................................. 109
Accutom-10/-100, Pre-Installation Checklist........... 110
Declaration of Conformity........................................ 118

Accutom-100
Instruction Manual
2
Intended use
For professional, automatic, materialographic cutting or grinding of
materials for further materialographic inspection. Only to be operated
by skilled/trained personnel.
The machine is designed only to be used with Struers consumables
specially designed for this purpose and this type of machine.
The machine is for use in a professional working environment
(e.g. a materialographic laboratory).
Cutting or grinding of materials other than solid materials suitable for
materialographic studies. In particular, the machine must not be used
for any type of explosive and/or flammable material, or materials
which are not stable during machining, heating or pressure.
The machine may not be used with cut-off wheels which are not
compatible with the machine requirements (e.g. toothed cut-off
wheels).
Accutom-100
NOTE:
READ the instruction manual carefully before use.
Keep a copy of the manual in an easy-to-access place for future
reference.
Do not use the machine for:
Models:

Accutom-100
Instruction Manual
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Always state Serial No and Voltage/frequency if you have technical
questions or when ordering spare parts. You will find the Serial No.
and Voltage on the type plate of the machine itself. We may also
need the Date and Article No of the manual. This information is found
on the front cover.
The following restrictions should be observed, as violation of
the restrictions may cause cancellation of Struers legal obligations:
Instruction Manuals: Struers Instruction Manual may only be used
in connection with Struers equipment covered by the Instruction
Manual.
Struers assumes no responsibility for errors in the manual
text/illustrations. The information in this manual is subject to changes
without notice. The manual may mention accessories or parts not
included in the present version of the equipment.
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 2019.
Struers
Pederstrupvej 84
DK 2750 Ballerup
Denmark
Telephone [phone]
Fax [phone]

Accutom-100
Instruction Manual
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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(s) must read the Safety and User’s Guide
sections of this manual and the relevant sections of
the manuals for any connected equipment and accessories.
The operator(s) must read the Instructions for Use and, where
applicable, Safety Data Sheets for the applied consumables.
4. This machine is to be operated and maintained by
skilled/trained personnel only.
5. Use only intact cut-off wheels. Cut-off wheels must be
approved for min. 5,000 rpm.
6. The machine must be placed on a safe and stable table with
an adequate working height able to carry the machine and
supplementary accessories and consumables.
7. Operators should ensure that the actual voltage corresponds to
the voltage on the rear of the machine. The machine must be
earthed. Follow the local regulations. Always turn the power off
and remove the plug or the cable before dismantling
the machine or installing additional components.
8. Consumables: only use consumables specifically developed for
use with this type of materialographic machine.
9. Observe the current safety regulations for handling, mixing,
filling, emptying and disposal of the additive for cooling fluid.
Avoid skin contact with the additive for cooling fluid.
10. Mind the protruding safety catch when the guard is raised.
11. The workpiece must be securely fixed in a clamping device.
12. Use of working gloves is recommended as the specimen may
be both very hot and have sharp edges.
1From Safety Precaution Sheet, Revision B
Safety Precaution Sheet1
Read carefully before use

Accutom-100
Instruction Manual
5
13. Use of safety goggles is recommended when using the flushing
hose. Only use the flushing hose for cleaning inside the cutting
chamber.
14. If you observe malfunctions or hear unusual noises - stop
the machine and call technical service.
15. The machine must be disconnected from the mains prior to any
service. Wait 15 minutes until residual potential on
the capacitors is discharged.
16. Do not cycle mains power more than once every three minutes.
Damage to the drive will result.
17. In case of fire, alert bystanders, the fire brigade and cut power.
Use a powder fire extinguisher. Do not use water.
The equipment should only be used for its intended use and as detailed in
the Instruction Manual.
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.).

Accutom-100
Instruction Manual
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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.
Always consult the Instruction Manual for information on the potential
hazards marked by the icons fixed to the machine.
ELECTRICAL HAZARD
indicates an electrical hazard which, if not avoided, will result in
death or serious injury.
DANGER
indicates a hazard with a high level of risk which, if not
avoided, will result in death or serious injury.
WARNING
indicates a hazard with a medium level of risk which, if not
avoided, could result in death or serious injury .
CAUTION
indicates a hazard with a low level of risk which, if not
avoided, could result in minor or moderate injury .
CRUSHING HAZARD
indicates a crushing hazard which, if not avoided, could result
in minor, moderate or serious injury .
EMERGENCY STOP
Icons and Safety Messages

Accutom-100
Instruction Manual
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NOTE
indicates a risk of damage to property, or the need to proceed with
special care.
HINT
indicates additional information and tips.
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.
Users should therefore print this document using a colour printer.
Bold type
indicates button labels or menu options in
software programs
Italic type
indicates product names, items in software
programs or figure titles
Blue text
indicates a link to another section or webpage
Bullets
indicates a necessary work step
General Messages
Colour Inside Logo
Typographic conventions

Accutom-100
Instruction Manual
8
User’s Guide
Table of Contents Page
1. Getting Started
Device Description .............................................................................11
Checking the Contents of Packing.....................................................12
Unpacking Accutom ...........................................................................12
Placing Accutom ................................................................................13
Recommended workbench dimensions ...................................13
Recommended Space.....................................................13
Getting Acquainted with Accutom......................................................14
Front of Accutom ......................................................................15
Rear of Accutom .......................................................................15
Inside the Chamber.........................................................16
Safety Lock.........................................................................................17
Supplying Power ................................................................................18
Power Socket ..................................................................18
Single-phase Supply .......................................................18
3-phase Supply ...............................................................18
Connection to the Machine .............................................18
Filling the Recirculation Tank with Cooling Fluid...............................19
Water Sensitive Materials ...............................................19
Optimising Cooling ..........................................................20
Flushing Hose ....................................................................................21
Debris Collection ................................................................................22
Noise Level.........................................................................................22
Handling noise (during operation) ............................................22
Mounting a Cut-off Wheel ..................................................................23
Mounting a Cup Wheel.......................................................................25
Mounting a Specimen Holder.............................................................27
Connecting a Vacuum Chuck to the Vacuum System .............27
(Optional accessory) .......................................................27
2. Basic Operation
Front Panel.........................................................................................28
Front Panel Controls ..........................................................................29
Reading the Display ...........................................................................30
Manoeuvring in the Menu Structure .........................................31
Acoustic Signals .......................................................................31
Standby Mode...........................................................................31
Software Settings ...............................................................................32
Zero Positions...........................................................................33
Changing the Language ...........................................................33
Editing Numeric Values ............................................................34
Editing Alphanumeric Values ...................................................35
Main menu..........................................................................................36
Editing a Method ................................................................................37

Accutom-100
Instruction Manual
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Cutting Method Parameters .....................................................38
Cut-off wheel.............................................................................39
MultiCut .....................................................................................40
(Accutom-100 only) .........................................................40
Return position..........................................................................40
Cutting Force Level...................................................................41
Grinding Methods Parameters...........................................................41
Cup wheel ......................................................................42
Positioning Keys.................................................................................43
Setting Relative Zero Position ..................................................43
Moving to Relative Zero Position ....................................44
Starting a Cutting Process .................................................................45
Clamping the Workpiece ..........................................................45
Positioning the Workpiece........................................................45
The Cutting Process Screen..............................................................46
Feed speed......................................................................46
Wheel speed....................................................................46
Length of cut....................................................................46
Motor load ......................................................................47
MultiCut ......................................................................47
Timer Countdown............................................................47
Manual Stop..............................................................................47
Re-starting cutting.....................................................................47
Changing Parameters During Cutting ......................................47
Retracting the Workpiece .........................................................47
OptiFeed ......................................................................47
Starting a Grinding Process...............................................................48
Clamping the Specimen ...........................................................48
Positioning the Specimen.........................................................48
The Grinding Process Screen............................................................49
Feed speed......................................................................49
Wheel speed....................................................................49
Removal ......................................................................49
Motor load ......................................................................50
Timer Countdown............................................................50
Manual Stop..............................................................................50
Re-starting grinding ..................................................................50
Changing Parameters During Grinding....................................50
Retracting the Specimen ..........................................................50
OptiFeed ......................................................................50
3. Advanced Operation
Maintenance Menu.............................................................................51
Service functions Menu ............................................................51
Reset functions Menu...............................................................51
Clean cutting track....................................................................51
Configuration Menu............................................................................52
Options Menu............................................................................52
Changing Operation Mode .......................................................53
New Pass Code ........................................................................54
Creating a User Defined Cut-off Wheel in the Database ..................54

Accutom-100
Instruction Manual
10
Creating a User Defined Cup Wheel in the Database.......................55
Cutting Method Parameters...............................................................56
Holder Rotation.........................................................................57
MultiCut Equal size ...................................................................58
MultiCut Different Sizes ............................................................59
Cutting Force Level:..................................................................60
Optimising the Cutting Results .................................................60
Grinding Method Parameters.............................................................61
Holder Rotation.........................................................................62
Positioning mode ......................................................................62
Grinding Thin Sections.......................................................................64
Preparing the Glass Slides .......................................................64
Grinding the Specimen .............................................................64
Grinding length...................................................................................65
4. Maintenance
General Cleaning ...............................................................................66
Daily Inspection..................................................................................66
Checking the Guard..................................................................66
Checking the Safety Lock.........................................................66
Daily Maintenance..............................................................................67
Machine ......................................................................67
Weekly................................................................................................68
Cleaning the Cutting Chamber.................................................68
Checking the Cooling Fluid Tank .............................................69
Cooling Fluid Nozzles .....................................................69
Tube for Water-free Cooling Fluid ............................................69
Cleaning the Cooling Fluid Tank........................................................70
Yearly .................................................................................................71
Inspection of Guard ..................................................................71
Replacing the Guard .......................................................71
Testing Safety Devices ......................................................................71
Emergency Stop .......................................................................71
Safety lock ................................................................................72
Hold-to-run Button ....................................................................72
Spare Parts ........................................................................................72
Maintenance of Cut-off Wheels and Cup Wheels .............................73
Abrasive Cut-off Wheels...........................................................73
Diamond and CBN Cut-off Wheels ..........................................73
Dressing Diamond and CBN Cut-off Wheels ...........................74
Testing Cut-off Wheels .............................................................74
Changing Cooling Pump Tubes.........................................................75
Spare Parts ........................................................................................76
5. Cautionary Statements .........................................................77
6. Transport and Storage ..........................................................79
7. Disposal ....................................................................................80

Accutom-100
Instruction Manual
11
1. Getting Started
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.
The operator selects and mounts the cut-off wheel / cup wheel and
enters the process parameters.
The operator mounts the workpiece in the clamping tool. Then,
the clamping tool is mounted directly to the cutting arm via a dovetail
connection.
The guard locks when the operator starts the machine. It remains
locked until all movements are stopped, and the cut-off wheel/cup
wheel is in the selected stop position.
The specimens can become hot during the process. It is
recommended to wear gloves when handling the processed
specimens.
It is recommended to connect Accutom-100 to an external exhaust
system to remove fumes from the process.
In case of power-loss during the process, the guard remains locked.
Use the special key to release the lock and open the guard.
The emergency stop cuts the power to all moving parts. The guard
can be opened, when the emergency stop is released.
Device Description

Accutom-100
Instruction Manual
12
In the packing box you will find the following parts:
1
Accutom-100
2
Mains cables
1
Triangle key for safety lock release
1
Support pin
1
Socket spanner, 17mm
1
Tray (with paper)
1
Allen key, 3 mm
1
Brush (for cleaning)
1
Hose for connection to exhaust, 51 mm dia.,2 m
1
Hose clamp, 40-60 mm dia.
1
Flange screw for Cup Wheel
1
Long nozzle screw for cup wheel
1
Instruction Manual set
NOTE:
Always lift Accutom from underneath the machine
A crane and two lifting straps2are required to lift Accutom off
the shipment pallet.
Before lifting Accutom into position:
Remove the screws around the base of the packing crate and lift
the entire upper part of the crate.
Remove the metal brackets securing Accutom to the pallet (a
4 mm Allen key is required to remove the 8 screws that secure
the metal brackets).
Remove the recirculation tank.
Place the two lifting straps under Accutom.
Position the straps under Accutom, so that they are on the inside
of the feet. See drawing.
Use straps which are long enough so that they do not place
stress on the guard (use straps of approx. 3-3½ m in length).
2Crane and straps must be approved for at least twice the weight of
the load.
Checking the Contents of
Packing
Unpacking Accutom

Accutom-100
Instruction Manual
13
A lifting bar is recommended so that the two straps are kept
apart below the lifting point.
Lift Accutom onto the table.
Lift the front of Accutom and carefully move into place.
CRUSHING HAZARD
Take care not to trap fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
HINT:
Store the packing crate, bolts and brackets for use whenever
Accutom is transported/re-located.
Failure to use the original packaging and fittings could cause
severe damage to the machine and will void the warranty.
The machine must be placed on a safe and stable table with
an adequate working height and which is able to carry
the machine and supplementary accessories and consumables.
Ensure that the work station has adequate lighting. Avoid direct
glare (dazzling light sources within the operator's line of vision)
and reflected glare (reflections of light sources).
Height: Recommended 80 cm / 31.5”
Width: min. 70 cm / 27.6”
Depth: min. 80 cm / 31.5”
Check that the Accutom is resting securely with all 4 rubber feet
on the table.
(For greatest accuracy, the machine must be completely level -
tolerance ±1 mm).
The machine must be close to the power supply.
The machine must be operated in a well-ventilated room or
connected to an exhaust system.
To facilitate easy access for servicing, allow sufficient space around
the machine.
Placing Accutom
Recommended workbench
dimensions
Recommended Space

Accutom-100
Instruction Manual
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Take a moment to familiarise yourself with the location and names of
the Accutom components.
MAIN SWITCH
The main switch is located at the rear of Machine.
The EMERGENCY STOP is located on the front of the machine.
Emergency Stop
Push the red button to Activate.
Turn the red button clockwise to Release.
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.
Getting Acquainted with
Accutom

Accutom-100
Instruction Manual
15

Emergency Stop

Flushing Hose

Front Panel (Details in
section 2. Basic Operation

Cutting motor

Hold-to-run button

Guard

Cooling fluid tank

Exhaust

Exhaust

Vacuum connection (plug)

Main switch

Hinges

Mains connection

Cover for recirculation

Service socket
pump
Front of Accutom
Rear of Accutom

Accutom-100
Instruction Manual
16

Specimen holder arm

Cooling nozzles

Vacuum connection

Wheel spindle

Flexible LED light

Tray for cut off specimens
Inside the Chamber

Accutom-100
Instruction Manual
17
NOTE:
The guard on Accutom can only be opened when the machine is
connected to a power supply and the main power switch is on.
To open the guard if the power is not connected:
Remove the Cooling fluid tank.
Use the triangle key (supplied) to de-activate the safety lock.
Turn the key 180°.
Do not use force!
HINT:
Remember to re-activate the safety lock release before operating
Accutom.
Safety Lock
Insert key here

Accutom-100
Instruction Manual
18
ELECTRICAL HAZARD
Switch the power off when installing electrical equipment.
The machine must be earthed (grounded).
Check that the mains voltage corresponds to the voltage stated on
the type plate on the side of the machine.
Incorrect voltage may result in damage to the electrical circuit.
The mains power socket must be easily accessible and located
between 0.6 m - 1.9 m (2½” – 6’) above floor level. (An upper limit of
1.7 m (5’ 6”) is recommended).
Accutom is shipped with 2 types of Mains cables:
The 2-pin (European Schuko) plug is for use on single-phase
connections.
If the plug supplied on this cable is not approved in your country,
then the plug must be replaced with an approved plug. The leads
must be connected as follows:
Yellow/green:
earth (ground)
Brown:
line (live)
Blue:
neutral
The 3-pin (North American NEMA) plug is for use on 3-phase power
connections.
If the plug supplied on this cable is not approved in your country,
then the plug must be replaced with an approved plug. The leads
must be connected as follows:
Green:
earth (ground)
Black:
line (live)
White:
line (live)
Connect the power cable to the Machine. (IEC 320 connector).
Connect to the mains power supply.
Supplying Power
Power Socket
Single-phase Supply
3-phase Supply
Connection to the Machine