ATA SAPHIR 550 Bedienungsanleitung
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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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SAPHIR 550/560
Operating Manual
GmbH
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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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SAPHIR 550/560
Operating Manual
GmbH
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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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SAPHIR 550/560
Operating Manual
GmbH
- 4 - Stand: 03.02.2020
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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SAPHIR 550/560
Operating Manual
GmbH
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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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SAPHIR 550/560
Operating Manual
GmbH
- 6 - Stand: 03.02.2020
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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SAPHIR 550/560
Operating Manual
GmbH
- 7 - Stand: 03.02.2020
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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SAPHIR 550/560
Operating Manual
GmbH
- 8 - Stand: 03.02.2020
2. Operation
2.1 Main menu
1Grinding Parameters (see 2.2)
2Program Administration (see 2.3)
3System Settings (see 2.4)
1 2 3
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Operating Manual
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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!
1
2 4
5
6
3
7
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SAPHIR 550/560
Operating Manual
GmbH
- 10 - Stand: 03.02.2020
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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