Struers Xmatic User manual

Xmatic
Instruction Manual
Original Instructions
Doc. no.: 16897025_A_en
Date of release: 2022.07.08

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 2022.10.06.
2 Xmatic

Table of Contents
1 About this manual 6
1.1 Accessories and consumables 6
2 Safety 6
2.1 Intended use 6
2.2 Safety functions 7
2.2.1 Xmaticsafety precautions 8
2.3 Safety messages 9
2.4 Safety messages in this manual 10
3 Getting started 12
3.1 Device description 12
3.2 Overview 14
3.3 The display 16
4 Installation 17
4.1 Unpacking 17
4.2 Lifting 18
4.3 Checking the packing list 22
4.4 Power supply 23
4.5 Noise 25
4.6 Vibration 25
4.7 Compressed air supply 26
4.8 Connecting to the water inlet and outlet 26
4.9 Connecting to an exhaust system 28
4.10 Installing a beacon on the machine 29
4.11 Connecting the recirculation unit 30
4.11.1 Filling the recirculation tank 30
4.11.2 Connecting the recirculation unit to the machine 31
4.12 Adjusting disc cooling and OP-flushing 32
4.13 Mounting the MD-Disc 33
5 Transport and storage 34
5.1 Storage 34
5.2 Transport 34
6 Start-up - the first time 36
6.1 Mounting the grinding stone or diamond grinding disc 36
6.2 MD surfaces 38
Xmatic 3

6.3 Bottle rack 40
6.3.1 Placing bottles in the bottle rack module 40
6.3.2 Soap and alcohol 41
7 Configuration 41
7.1 Preparation 42
7.1.1 Manual dressing 44
7.2 Machine settings 45
7.3 Cleaning templates 47
7.3.1 Creating cleaning templates 48
8 Operating the device 49
8.1 Clamping and leveling specimens 50
8.2 Placing and removing the specimen holder in/from the vertical conveyor 50
8.3 Methods 52
8.3.1 Struers methods 52
8.3.2 Custom methods 53
8.4 The preparation process 56
8.4.1 Consumables 57
8.4.2 Starting the preparation process 57
9 Maintenance and service - Xmatic 58
9.1 General cleaning 58
9.2 When necessary 58
9.2.1 Air filter 58
9.2.2 Cleaning the MD-Disc 59
9.2.3 Cleaning the grinding stone station 61
9.2.4 Cleaning the tubes 62
9.2.5 Replacing the stone dresser and the MD dressers 65
9.2.6 Cleaning the touch screen 65
9.2.7 Cleaning the MD elevator mirrors 66
9.2.8 Emptying the alcohol separator bottle - (Optional) 66
9.2.9 MD dressers 68
9.3 Daily 68
9.3.1 MD grinding surfaces 68
9.4 Weekly 69
9.4.1 The machine 69
9.4.2 High pressure cleaning station 72
9.4.3 Ultrasonic cleaning station - (Optional) 73
9.5 Monthly 74
9.5.1 Recirculation unit 74
9.6 Annually 75
4 Xmatic

9.6.1 Main safety cover 76
9.6.2 Testing safety devices 76
9.7 Spare parts 78
9.8 Service and repair 78
9.9 Disposal 78
9.9.1 Environmental considerations 78
10 Troubleshooting - Xmatic 79
10.1 Accessing the work zone in case of power failure 79
11 Technical data 81
11.1 Technical data 81
11.2 Safety Related Parts of the Control System (SRP/CS) 86
11.3 Diagrams 87
11.3.1 Diagrams - Xmatic 88
11.4 Legal and regulatory information 92
12 Manufacturer 92
Declaration of Conformity 93
Xmatic 5

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.
1.1 Accessories and consumables
Accessories
For information about the available range, see: The Struers Website (http://www.struers.com).
Consumables
The equipment is designed to be used only with Struers consumables specifically designed for this
purpose and this type of machine.
Other products may contain aggressive solvents, which dissolve e.g. rubber seals. The warranty may
not cover damaged machine parts (e.g. seals and tubes), where the damage can be directly related
to the use of consumables not supplied by Struers.
For information about the available range, see:
•The Struers Consumables Catalogue (http://www.struers.com/Library)
2 Safety
2.1 Intended use
For professional automatic materialographic grinding and polishing of materials for further
materialographic preparation. The machine is only to be operated by skilled/trained personnel. The
machine is designed 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).
6 Xmatic
1 About this manual

Do not use the machine for
the following
Preparation of materials other than materials suitable for
materialographic studies. 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.
Model Xmatic with high-pressure cleaning
Xmatic with high-pressure cleaning and ultra-sonic cleaning
2.2 Safety functions
The machine is equipped with the following safety devices:
• Emergency stops
Stops all hazardous movements
• Plane grinding guard interlock (abrasive guard)
Prevents the stone/disc from turning when the lid is open
• Limited speed function, plane grinding station
Stops the motor if the rotational speed is exceeded
• Limited speed function, specimen mover head
Stops the motor if the rotational speed is exceeded
• Main safety cover interlock, hazardous movements
Prevents any movement in the work zone when the main safety cover is open
• Main safety cover interlock, water and ethanol
Prevents water and ethanol from being dosed when the main safety cover is open
• Main safety cover interlock with locking function
Prevents access to any moving part in case of after-run or loss of power
• MD elevator door interlock
Prevents the elevator from moving when the door is open
• MD elevator door interlock with locking function
Prevents access to the MD elevator in case of after-run or loss of power
• Vertical conveyor doors interlock
Prevents movements in the vertical conveyor when the door is open
• Recirculation unit doors interlocks
Prevents the pumps from operating when the door is open
• Exhaust supervision system
Prevents the use of ethanol in case there is no exhaust system mounted
2 Safety
Xmatic 7

Emergency stops
AEmergency stops
Accessing the preparation area during preparation
Once the machine has completed the preparation, you must wait approximately 3 minutes before you
can open the main safety cover.
2.2.1 Xmaticsafety precautions
Read carefully before use
Specific safety precautions - residual risks
1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.
2. Make sure that the actual electrical power supply voltage corresponds to the voltage stated on
the type plate of the machine.The machine must be earthed (grounded).
3. Switch off the machine, disconnect the electrical power cable before you dismantle the machine
or install additional components.
4. Connect the machine to a cold water tap. Make sure that the water connections are leak-proof
and that the water outlet is working.Cut off the water supply if the machine is not going to be
used for a long period of time.
5. Make sure that the emergency stop is in working order.
8 Xmatic
2 Safety

6. When using specimen holders, make sure that all specimens are securely clamped and
properly balanced before you start the preparation process.
7. Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens.
8. The equipment is designed to be used only with Struers consumables specifically designed
for this purpose and this type of machine.
General safety precautions
1. 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.
2. The operator must read the safety precautions and Instruction Manual, as well as relevant
sections of the manuals for any connected equipment and accessories.
The operator must read the Instruction Manual and, where applicable, the Safety Data
Sheets for the applied consumables.
3. Struers equipment must only be used in connection with and as described in the Instruction
Manual supplied with the equipment.
4. Dismantling of any part of the equipment, during service or repair, should always be
performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic,
etc.).
5. If you observe malfunctions or hear unusual noises, switch off the machine and call technical
service.
6. 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.
2.3 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.
2 Safety
Xmatic 9

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.
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.
2.4 Safety messages in this manual
WARNING
If there are visible signs of deterioration or damage to the main safety cover, it must
be replaced immediately.
Contact Struers Service.
WARNING
Safety critical components must be replaced after a maximum lifetime of 20 years.
Contact Struers Service.
WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.
WARNING
In case of fire, alert bystanders and the fire brigade. Turn off the power. Use a powder
fire extinguisher. Do not use water.
ELECTRICAL HAZARD
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.
ELECTRICAL HAZARD
The equipment is protected by a safety insulation transformer.
Make sure that the adequate ik_min level is present.
Contact a qualified electrician to verify the solution.
Always follow local regulations.
10 Xmatic
2 Safety

ELECTRICAL HAZARD
Disconnect 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.
ELECTRICAL HAZARD
The pump of the recirculation cooling unit must be earthed (grounded).
Make sure that the electrical power supply voltage corresponds to the voltage
stated on the type plate of the pump.
Incorrect voltage can damage the electrical circuit.
ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by a
qualified technician.
CAUTION
Struers equipment must only be used in connection with and as described in the
Instruction Manual supplied with the equipment.
CAUTION
Do not use the machine if it is damaged.
CAUTION
The safety devices must be tested at least once a year.
CAUTION
Testing should always be performed by a qualified technician (electromechanical,
electronic, mechanical, pneumatic, etc.).
CAUTION
Prolonged exposure to loud noises may cause permanent damage to a person’s
hearing.
Use hearing protection if the exposure to noise exceeds the levels set by local
regulations.
CAUTION
Do not use the machine with non-compatible accessories or consumables.
CAUTION
Wear suitable gloves to protect fingers from abrasives and warm/sharp
specimens.
CAUTION
Make sure that the machine is level.
2 Safety
Xmatic 11

CAUTION
The machine must not operate when it is resting on its wheels.
CAUTION
Avoid skin contact with the cooling fluid additive.
CAUTION
The recirculation tank is very heavy when it is full.
CAUTION
The pressure of the cooling fluid supplied to the machine must be max. 2 bar.
3 Getting started
3.1 Device description
The machine is an automatic machine for materialographic grinding, polishing and cleaning.
The operator selects the preparation parameters, the grinding/polishing surfaces, and
suspension/lubricant to be used for the method. There are standard preparation and cleaning
methods on the machine, and customized methods can be added.
The operator starts the process by placing a specimen holder in a drawer on the vertical conveyor.
Up to 8 specimen holders can be placed in the vertical conveyor.
When a specimen holder is placed in the vertical conveyor, the machine automatically detects the
specimen holder and indicates it on the graphical user interface (GUI). The surface area of the
specimens to be prepared can automatically be identified by the machine to determine parameters:
force, water flow and correct dosing levels of suspension/lubricant.
The operator selects between different grinding/polishing methods and/or cleaning methods for each
individual specimen holder.
The operator presses “start” to initiate the process based on the methods selected for each specimen
holder. The vertical conveyor delivers the specimen holder to the pick-up point from where the mover
head picks it up. Depending on the selected method, the mover head brings the specimen holder
through each of the process steps.
A typical method includes a high removal plane grinding step, followed by a cleaning step in the
ultrasonic chamber, or the high-pressure cleaning chamber. Afterwards, a series of grinding and or
polishing steps are carried out on the MD grinding/polishing station. In the MD station, the machine
can automatically exchange the MD surfaces and position the doser arm over the MD surface.
During a step on the MD station the machine automatically doses the selected consumables or
water. Between each step on the MD station the specimen holder is typically cleaned and dried.
12 Xmatic
3 Getting started

After the last process step, the mover head delivers the specimen holder back to the pick-up point
from where the vertical conveyor brings it back to the drawer. The drawer opens automatically to
indicate that the specimens in the specimen holder are ready for inspection.
The machine is able to automatically process all the specimen holders in the vertical conveyor
without operator intervention.
The machine recognizes all Struers consumables present in the machine. This allows the
machine to prompt the operator about missing or low consumable levels for the selected
methods.
The main safety cover of the machine locks when the operator starts the machine, and it remains
locked until all hazardous movements are stopped. It is not possible for the machine to run a
process while the main safety cover is open.
Cleaning
Cleaning is done via high-pressure cleaning and/or ultrasonic cleaning depending on the selected
cleaning method. These types of cleaning are carried out in two separates chambers. Alcohol can
be applied during cleaning and drying of water-sensitive materials, and it is a part of the high-
pressure cleaning process. Concentrated soap can also be applied during the high-pressure
cleaning process.
MD elevator
MD surfaces will automatically be exchanged depending on the selected method. Up to 8 different
grinding/polishing surfaces can be placed in the MD elevator.
The operator can access the MD elevator while the machine is preparing a specimen holder, but
not while it is changing a grinding/polishing surface.
Bottle rack
Several suspensions and lubricant including oxide polishing suspension can be chosen
depending on the method. The bottle rack can fit up to 7 bottles of consumables and 1 for alcohol
and 1 for concentrated soap. The consumable bottles are connected to the machine via a
connector dedicated for each individual bottle position.
The operator can change a suspension/lubricant bottle while the machine is preparing a
specimen holder, however not if it is using the suspension/lubricant in question.
If a bottle is removed and a new is inserted, the GUI will ask if it is necessary to automatically
flush, and the tube can be inserted in the flush function before it is attached to the new bottle.
The machine is equipped with 2 emergency stops. If one of the emergency stops is activated, all
hazardous moving parts are stopped.
Models
Xmatic with high-pressure cleaning
Xmatic with high-pressure cleaning and ultrasonic cleaning
3 Getting started
Xmatic 13

3.2 Overview
Front view
AGrinding station
BMain safety cover
CUltrasonic cleaning station (Optional)
DHigh pressure cleaning station
EMD grinding and polishing
FMD elevator
GEmergency stop
HMain switch
IBottle rack
JElectrical compartment
KRecirculation unit compartment
LRecirculation unit
MDisplay
NPick-up point
OVertical conveyor
14 Xmatic
3 Getting started

Side view
Right side
Main switch.
Left side
AWater flow regulators and water
supply
BWater inlet
CWater outlet
DEthernet connection
ECompressed air
FExternal control signal
GExhaust
Rear view - Power supply
3 Getting started
Xmatic 15

3.3 The display
The display is a touch screen, where you tap on buttons, icons and specific areas to access a screen
or activate a function.
All programming and operation is carried out on the touch screen.
The software is launched when you switch on the machine.
Overview
ASpecimen holders ribbon
BMain menu
CUser modes
DConsumables ribbon
EMD surface ribbon
16 Xmatic
3 Getting started

Detailed view
AThis item indicates that there is a specimen holder in the drawer, and it shows how many
specimens it contains.
BThis item shows the name of the selected method.
CThis item shows the time it takes to run the selected method.
DThis item shows the number of steps included in the method.
ETap this item to access the Step selection and Edit method submenus.
FTap the Run button when you are ready to run the selected method. You can also use this
button to pause the process while it is running.
Note
A green Run button indicates that all the consumables needed for the
selected method are in place.
A red Run button indicates that some of the consumables you need to run the
method are not in place. Solve the problem before you proceed.
GTap this item to open the drop-down list indicating all the steps for the selected method.
HThe MD surface ribbon shows which MD surfaces are available in the machine.
ITap the Pause button whenever you need to pause the process.
JThe consumables ribbon shows which consumables are available in the machine.
KThis item shows the type of user that is logged into the machine.
4 Installation
4.1 Unpacking
The packing box
1. Open and remove the sides and the top of the packing box.
4 Installation
Xmatic 17

The transport brackets
• Unscrew the transport brackets that secure the machine to the pallet.
Note
Struers recommends that all original packaging and fittings are kept for future use.
4.2 Lifting
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
18 Xmatic
4 Installation

Weight
Machine 960 kg (2116 lbs)
The weight of the specimen holders and consumables used.
Center of gravity
Front view Side view
A884 mm (35")
B817 mm (32")
A329 mm (13")
Lifting the machine from the pallet
1. Lift the machine from the pallet using a forklift to access the adjustable feet.
2. Loosen the adjustable feet before moving the machine from the pallet. Make sure that the
feet are positioned higher than the wheels.
4 Installation
Xmatic 19

Removing the counterweight screws on the rear side of the machine
– Use a 5 mm Allen key to remove the counterweight screws.
Moving the machine using a forklift
1. Place the forks so that the center of gravity is placed between the forks. Lift the machine from
the front.
2. Move the machine into its final position.
3. Lower the machine so that the wheels touch the floor.
20 Xmatic
4 Installation