Struers MoviPol-5 User manual

MoviPol-5
Instruction Manual
Original Instructions
Doc. no.: 15967025_A_en
Date of release: 2022.01.10

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 2022.01.27.
2 MoviPol-5

Table of Contents
1 About this manual 6
2 Safety 6
2.1 Intended use 6
2.1.1 MoviPol-5safety precautions 7
2.2 Safety messages 8
2.3 Safety messages in this manual 9
2.4 Symbols on the device 11
2.5 Working with electrolytes 11
2.5.1 Perchloric acid 12
3 Getting started 16
3.1 Device description 16
3.2 MoviPol-5 - overview 17
3.3 Accessories and consumables 18
4 Transport and storage 19
4.1 Transport 19
4.2 Air transport 19
4.3 Transport - the shoulder strap 20
4.4 Storage 20
5 Installation 21
5.1 Unpacking 21
5.2 Checking the packing list 21
5.3 Placing the machine 21
5.4 Power supply 22
5.4.1 Connecting the battery charger 22
5.4.2 Inserting the battery pack 23
5.4.3 Charging the battery 24
5.5 Connecting the anode 25
5.6 Fitting the polishing chamber 25
5.7 Connecting an external etching kit (option) 25
5.8 Noise 25
6 Operating the device 26
6.1 Control panel 26
6.2 Preparing the device for operation 27
6.3 Switching on the machine 27
MoviPol-5 3

6.4 Display 27
6.4.1 Main menu 28
6.4.2 Changing settings and text 29
6.5 Working with electrolytes 30
6.5.1 Filling the electrolyte cartridge 31
6.5.2 Inserting the electrolyte cartridge 32
6.5.3 The electrolyte usage counter 34
6.5.4 Replacing the electrolyte cartridge 34
6.6 Methods 35
6.6.1 Creating a method 37
6.7 Starting the polishing/etching process 37
6.8 Stopping the polishing/etching process 38
6.9 Emptying electrolyte from the holder 39
6.10 External etching (option) 39
7 Configuration 40
7.1 Electrolyte configuration 41
7.2 User options 43
7.3 Process options 44
8 Troubleshooting 44
8.1 Troubleshooting - Mechanical problems 44
8.2 Troubleshooting - Polishing problems 45
9 Maintenance and service - MoviPol-5 46
9.1 Before each use 46
9.2 Battery pack 46
9.3 General cleaning 46
9.4 Daily 47
9.4.1 The pump system and polishing pistol holder 47
9.5 Weekly 47
9.6 The polishing chamber 48
9.7 Spare parts 48
9.8 Service information 48
9.9 Service and repair 48
9.10 Disposal 49
10 Technical data 49
10.1 Technical data - MoviPol-5 49
10.2 Noise and vibration levels 50
10.3 Diagrams 51
10.3.1 Diagrams - MoviPol-5 51
10.4 Legal and regulatory information 56
4 MoviPol-5

11 Manufacturer 56
Declaration of Conformity 57
MoviPol-5 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.
2 Safety
2.1 Intended use
MoviPol-5 is a transportable polishing unit for on-site non-destructive electrolytic sample preparation
and etching.
The equipment is designed for preparation of conductive materials, suitable for electrolytic polishing
and etching. To operate correctly and safely, MoviPol-5 must be used with Struers purpose-designed
consumables and accessories.
MoviPol-5 is only to be operated by adult/skilled/trained personnel in a professional working
environment (e.g. a materialography laboratory). Maintenance and cleaning must be carried out on a
regular schedule and according to instructions provided in this manual.
MoviPol-5 must always be operated in a well-ventilated area.
Do not use the machine for
the following
Preparation of materials other than materials suitable for
materialographic studies.
Preparation of any type of explosive and/or flammable material, or
materials which are not stable during machining, heating or
pressure.
Preparation using consumables or a combination of electrolytes
and accessories which are not compatible for use with this
equipment.
Model MoviPol-5
6 MoviPol-5
1 About this manual

2.1.1 MoviPol-5safety precautions
Read carefully before use
Specific safety precautions - residual risks
1. The operator must read the Instruction Manual and, where applicable, the Safety Data
Sheets for the applied consumables.
2. The operator must be fully instructed in how to handle and use electrolytes with this machine.
3. The equipment must only be used in non-wet conditions.
4. Do not carry out preparation on unstable materials.
5. Make sure that the carrying handle and the shoulder strap are intact.Replace them if
damaged.If you are using the shoulder strap to carry the machine, make sure that the buckle
is safely fastened.
6. Make sure that your working space is well-ventilated.Polishing and etching can result in the
production of fumes.
7. Always use goggles or a protective shield, and chemical-resistant gloves.
8. Danger of chemical burns.Follow all safety requirements for handling, mixing, emptying and
disposing of electrolytes.
General safety precautions
1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.
2. Struers equipment must only be used in connection with and as described in the instruction
manual supplied with the equipment.
3. Accessories: Only use accessories specifically developed for use with this type of machine.
4. The device is designed to be used with Struers consumables specially designed for this
purpose and this type of device.
5. Consumables: only use consumables specifically developed for use with this type of
materialographic machine.
6. Make sure that the actual electrical power supply voltage corresponds to the voltage stated
on the type plate of the machine.
7. Make sure that power is disconnected before opening the cabinet or carrying out any service
or maintenance tasks.
8. Do not operate the machine if there are visible cracks or damage to the unit.
9. The machine must be emptied of any remaining electrolyte, and it must be firmly secured
during transportation.
10. Never leave the machine unattended when it is filled with electrolyte.
11. Place the polishing pistol in its holder when not in use. Wipe any electrolyte residue off the
machine.
12. Always observe the maximum polishing voltage allowed at the current work site.
2 Safety
MoviPol-5 7

13. 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.
14. Dismantling of any part of the equipment, during service or repair, should always be performed
by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.).
2.2 Safety messages
Signs used in 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.
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.
8 MoviPol-5
2 Safety

2.3 Safety messages in this manual
WARNING
Danger of chemical burns.
Follow all safety requirements for handling, mixing, emptying and disposing of
electrolytes.
WARNING
Always wear a full-face shield or splash goggles, rubber gloves and a laboratory
coat or coveralls when you are working with perchloric acid.
WARNING
Make sure that you are mixing the solvent in a chemical-fume hood designed for
perchloric acid use.
WARNING
Do not use combustible or carbonaceous containers, reaction vessels, spill pans,
storage shelves or similar materials when you work with perchloric acid.
WARNING
Always remove the battery before transport.
WARNING
Always remove the battery before storage.
WARNING
During transportation the device must not contain electrolyte and must not be
turned upside down. During use, the equipment must not be tilted.
WARNING
Do not fill the electrolyte above the maximum level.
WARNING
Do not operate the machine if there are visible cracks or damage to the unit.
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you
start working with it.
CAUTION
Many electrolytes contain alcohol or other flammable solvents. Always follow all
safety precautions when working with these types of electrolyte.
2 Safety
MoviPol-5 9

CAUTION
The operator must be fully instructed in how to handle and use electrolytes with this
machine.
CAUTION
The machine is designed to be used with electrolytes recommended by
Struers.Electrolytes that are not recommended by Struers can be dangerous to the
operator or harm the machine.
CAUTION
Fire and explosion hazards
• 60% perchloric acid is a very corrosive and oxidizing product. Heating it can
cause an explosion, and contact with combustible materials can cause fire.
• Fire fighting must be carried out from a protected location. Use extinguishing
media as specified in the Safety Data Sheet.
CAUTION
Make sure that there is adequate ventilation when you are using the equipment with
perchloric acid, particularly if the equipment is carried or hung by the shoulder strap.
CAUTION
All persons involved in mixing, using, storing, transporting and disposing of
electrolytes must be trained in how to handle perchloric acid when carrying out these
tasks.
• Do not inhale any vapor from the solution or its components.
• Avoid skin contact.
CAUTION
Do not produce anhydrous perchloric acid, either from its salts or from aqueous
solutions, e.g. by heating with high boiling acids or dehydrating agents such as
sulfuric acid or phosphorous pentoxide. In addition to spontaneous explosion, the
anhydrous acid explodes instantaneously on contact with oxidizable organic
materials.
CAUTION
Limit the use or storage of perchloric acid to quantities less than 500 g per fume hood.
CAUTION
Struers equipment must only be used in connection with and as described in the
instruction manual supplied with the equipment.
CAUTION
Always connect the battery charger to the battery pack before you connect the
battery charger to the electrical power supply.
10 MoviPol-5
2 Safety

CAUTION
Do not use the machine with non-compatible accessories, battery or
consumables.
CAUTION
Funnel, gloves, ventilation as well as all other prescribed equipment must be used
during filling/emptying of electrolytes.
CAUTION
Do not start the pump until you hold the polishing pistol securely against the
surface.
CAUTION
Before you carry or transport the machine to another location, make sure that you
empty the holder of any remaining electrolyte.
CAUTION
Make sure that the actual electrical power supply voltage corresponds to the
voltage stated on the type plate of the battery pack.
Incorrect voltage can damage the electrical circuit.
2.4 Symbols on the device
AWear safety goggles
2.5 Working with electrolytes
When you are working with electrolytes, make sure that you observe all necessary safety
precautions.
WARNING
Danger of chemical burns.
Follow all safety requirements for handling, mixing, emptying and disposing of
electrolytes.
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you
start working with it.
CAUTION
Many electrolytes contain alcohol or other flammable solvents. Always follow all
safety precautions when working with these types of electrolyte.
2 Safety
MoviPol-5 11

CAUTION
The operator must be fully instructed in how to handle and use electrolytes with this
machine.
CAUTION
The machine is designed to be used with electrolytes recommended by Struers.
Electrolytes that are not recommended by Struers can be dangerous to the operator
or harm the machine.
Working with perchloric acid
See Perchloric acid ►12.
Availability
Struers electrolytes are not marketed in the USA. If needed, the chemical compounds for the
electrolyte must be purchased independently.
Contact your Struers representative for further information.
After use
Do not let the electrolyte dry or crystallize inside the machine or on the polished material.
Make sure that you rinse cleaning cloths used to wipe any drips or spills with water to prevent
electrolyte from drying out.
Disposal
SeeDisposal ►49.
2.5.1 Perchloric acid
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you start
working with it.
If you are working with Struers electrolytes marked with the prefix A, you must mix a certain amount
of perchloric acid into the electrolyte solution.
To find the Safety Data Sheet for the components in question, see: www.struers.com.
CAUTION
Fire and explosion hazards
• 60% perchloric acid is a very corrosive and oxidizing product. Heating it can
cause an explosion, and contact with combustible materials can cause fire.
• Fire fighting must be carried out from a protected location. Use extinguishing
media as specified in the Safety Data Sheet.
12 MoviPol-5
2 Safety

CAUTION
Make sure that there is adequate ventilation when you are using the equipment
with perchloric acid, particularly if the equipment is carried or hung by the shoulder
strap.
Training
CAUTION
All persons involved in mixing, using, storing, transporting and disposing of
electrolytes must be trained in how to handle perchloric acid when carrying out
these tasks.
• Do not inhale any vapor from the solution or its components.
• Avoid skin contact.
Mixing perchloric acid into the electrolyte solution
If you are working with Struers electrolytes marked with the prefix A, you must mix a certain
amount of perchloric acid into the electrolyte solution.
WARNING
Always wear a full-face shield or splash goggles, rubber gloves and a laboratory
coat or coveralls when you are working with perchloric acid.
WARNING
Make sure that you are mixing the solvent in a chemical-fume hood designed for
perchloric acid use.
WARNING
Do not use combustible or carbonaceous containers, reaction vessels, spill pans,
storage shelves or similar materials when you work with perchloric acid.
WARNING
For information about electrolytes, see the Safety Data Sheet for the specific
product.
Procedure
CAUTION
The components must be used in the correct quantity as specified below.
2 Safety
MoviPol-5 13

ElectrolyteA2
1. Mix ethanol, butoxyethanol and water.
2. Immediately before use, add A2 II - perchloric acid to the A2 I mixture.
Formula A2 I A2 II
90 ml distilled water
730 ml ethanol
100 ml butoxyethanol
78 ml perchloric acid
Chemicals All chemicals are chemically pure, preferably analytical grade. Per cent is,
where no other is stated, weight per cent.
Butoxyethanol Ethylene glycol monobutyl ether,
CH3-(CH2)2-CH2-O-CH2-CH2OH
Ethanol 96% vol CH3-CH2OH
Perchloric acid 60%, HClO4
Distilled water H2O
Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.
ElectrolyteA3
1. Mix ethanol and butoxyethanol.
2. Immediately before use, add A3 II - perchloric acid to the A3 I mixture.
Formula A3 I A3 II
600 ml methanol 60 ml perchloric acid
360 ml butoxyethanol
Chemicals All chemicals are chemically pure, preferably analytical grade. Per cent is,
where no other is stated, weight per cent.
Butoxyethanol Ethylene glycol monobutyl ether,
CH3-(CH2)2-CH2-O-CH2-CH2OH
Methanol 100% vol., CH3OH
Perchloric acid 60%, HClO4
14 MoviPol-5
2 Safety

ElectrolyteA3
Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.
ElectrolyteD2
1. Mix the phosphoric acid in the distilled water
2. Add ethanol, propanol and urea.
Formula D2
500 ml distilled water
250 ml phosphoric acid
250 ml ethanol
50 ml propanol
5 g urea
Chemicals All chemicals are chemically pure, preferably analytical grade. Per cent
is, where no other is stated, weight per cent.
Ethanol 96% vol., CH3-CH2OH
Phosphoric acid Ortho phosphoric acid 85%,
(HO)3PO
Propanol 2-propanol 100%, CH3-CH2-
CH2OH
Urea CO(NH2)2
Distilled water H2O
Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.
2 Safety
MoviPol-5 15

Storing perchloric acid or solution
CAUTION
Do not produce anhydrous perchloric acid, either from its salts or from aqueous
solutions, e.g. by heating with high boiling acids or dehydrating agents such as
sulfuric acid or phosphorous pentoxide. In addition to spontaneous explosion, the
anhydrous acid explodes instantaneously on contact with oxidizable organic
materials.
CAUTION
Limit the use or storage of perchloric acid to quantities less than 500 g per fume hood.
3. Never let perchloric acid crystallize on bottle necks, caps or anywhere else.
4. Store the chemical in a secure, cool, and well-ventilated area with a metal, glass or ceramic spill
catch pan.
5. Store the chemical away from other chemicals or combustible or organic materials.
6. Never let solutions dry out.
For more information, see the Safety Data Sheet for the product.
Disposal
SeeDisposal ►49.
3 Getting started
3.1 Device description
MoviPol-5 is used for on-site materialographic preparation and enables examination and quality
inspection of metallographic materials.
Electrolytical polishing/etching can be performed on most metallic material surfaces. It is an
electrochemical process, which can be performed on electrically conductive materials by applying an
electrolyte and electricity to the test area.
Before starting the process, the user must wear protective goggles and gloves.
During the process, a high, local current, when applied to an area of the material covered by the
electrolyte, will have a polishing/etching effect on the targeted surface. This makes the surface
suitable for further materialographic analysis. The process is non-destructive and does not introduce
deformation to the micro-structure of the workpiece.
MoviPol-5 is portable. It is packed in a case, which is suitable for transport by one person. The
equipment has a replaceable, rechargeable battery. Electrolytes are contained in an electrolyte
cartridge, which is filled/emptied by the operator.
The process starts with the operator identifying a relevant surface area and the type of material that
needs inspection. A suitable method, accessory and electrolyte are identified. Before operation the
operator places the equipment on a plane surface or, if carrying, keeps it level.
16 MoviPol-5
3 Getting started

The area must be well ventilated to prevent inhalation in case of hazardous fumes.
Before the operator inserts the electrolyte cartridge, an electrolyte, which is suitable for the
material that is to be prepared, must be selected. Once the electrolyte cartridge is inserted, the
equipment must stay in the same location or be kept still and level if carried.
The operator starts the machine and guides the polishing pistol to the area of interest. During the
electrolytical polishing/etching process, small layers of material can now be removed, and the
uneven material surface can be reduced to a plane area for further analysis.
In case of excess heat and/or power consumption, the equipment switches off automatically.
After use, the electrolyte cartridge must be removed, and the equipment must be cleaned with
water. Cleaning can be carried out using an electrolyte container filled with water. The equipment
can then be placed in the carrying case, protected and ready for transport.
Maintenance and cleaning must be carried out as described in the instruction manual.
The machine is designed only to be used with suitable consumables and accessories (e.g.
electrolytes).
3.2 MoviPol-5 - overview
MoviPol-5
ABattery pack with
connection for battery
charger
BAnode socket marked
Anode
CShoulder strap
DDisplay
EControl panel
FPolishing pistol
GConduit for storing the
hose
HCarrying handle
Polishing pistol
APolishing chamber. The
cathode is in the base
of the polishing
chamber
BLight
C Start/Stop button
3 Getting started
MoviPol-5 17

Electrolyte cartridge compartment
AElectrolyte cartridge
BDoor
Control panel
ADisplay
BControl buttons
See alsoControl panel ►26.
3.3 Accessories and consumables
Consumables
The use of Struers consumables is recommended.
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)
Accessories
For information about the available range, see:
•Brochure for non-destructive preparation (http://www.struers.com/Library#brochures)
18 MoviPol-5
3 Getting started

4 Transport and storage
4.1 Transport
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.
• Struers recommends that all original packaging and fittings are kept for future use.
WARNING
Always remove the battery before transport.
• Clean and dry the unit before transport and storage.
• Before transportation, make sure that the polishing pistol is placed in its holder and the hose
is wound around the conduit.
• During transportation the unit must not contain electrolyte. See Daily ►47.
Air transport
See Air transport ►19
Battery charger
See the Instruction Manual for this unit.
Battery Pack
Operating environment 0 to 45°C/32 to 113°F
Transport and storage -20 to +55°C/°F
See the Instruction Manual for this unit.
For more detailed information, see the section Technical data.
4.2 Air transport
Note
Contact your transportation provider for information on local carriage restrictions.
See the IATA website for further information.
• Clean and dry the unit before transport and storage.
4 Transport and storage
MoviPol-5 19

Lithium batteries
WARNING
Always remove the battery before transport.
Note
Contact your transportation provider for information on local carriage restrictions.
There are restrictions on the carriage of lithium batteries.
The battery has a Watt-hour rating of 98.28 Wh. The battery is classed as a small battery.
4.3 Transport - the shoulder strap
Attaching the shoulder strap
If you wish to use the shoulder strap for hanging or carrying the unit:
1. Attach the shoulder strap to the unit.
2. Use the loops and buckle to secure the shoulder strap in place.
Note
Before each use, make sure that the carrying handle, the shoulder strap and the
buckle are not damaged, and that the buckle is correctly fastened. Replace any
damaged parts.
4.4 Storage
Note
Struers recommends that all original packaging and fittings are kept for future use.
WARNING
Always remove the battery before storage.
• Remove any accessories.
• Clean and dry the unit before storage.
• Place the machine and accessories in their original packaging.
• For more detailed information, see the section Technical data.
Battery Pack
See the Instruction Manual for this unit.
20 MoviPol-5
4 Transport and storage