Struers AbraPol-30 User manual

AbraPol-30
Instruction Manual
Original Instructions
Doc. no.: 16307025_B_en
Date of release: 2021.06.14

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 2021.07.22.
2 AbraPol-30

Table of Contents
1 About this manual 6
1.1 Accessories and consumables 6
2 Safety 6
2.1 Intended use 6
2.1.1 AbraPol-30safety precautions 7
2.2 Safety messages 8
2.3 Safety messages in this manual 9
3 Getting started 10
3.1 Device description 10
3.2 AbraPol-30 - overview 11
4 Transport and storage 12
4.1 Storage 13
5 Installation 13
5.1 Unpacking 13
5.2 Checking the packing list 13
5.3 Power supply 14
5.4 Noise 15
5.5 Vibration 15
5.6 Compressed air supply 16
5.7 Connecting to an exhaust system 16
5.8 Connecting to the water supply 16
5.9 Connecting to the waste water outlet 17
5.10 Connecting the recirculation unit (option) 17
5.11 Connecting an external recirculation unit (option) 19
5.12 Adjusting disc cooling and OP-flushing 20
5.13 The dosing pump units 20
5.13.1 Placing bottles in the dosing unit 21
6 Operating the device 21
6.1 Control panel functions 21
6.2 The display 23
6.2.1 Navigating in the display 24
6.2.2 Main menu 24
6.2.3 Changing settings and text 25
6.2.4 Software settings 25
AbraPol-30 3

6.3 Configuration 26
6.3.1 Operation mode 26
6.3.2 New pass code 27
6.3.3 Bottle configuration 27
6.3.4 User defined consumables 28
6.3.5 Options 30
6.4 Preparation methods 31
6.4.1 Creating a preparation method 32
6.4.2 Settings 32
6.4.3 Changing a preparation method 34
6.4.4 Locking a preparation method 34
6.4.5 Copying a preparation step 34
6.4.6 Deleting a preparation step 34
6.4.7 Setting dosing levels 35
6.5 The specimen holder 35
6.5.1 Clamping and leveling specimens 35
6.5.2 Inserting or removing the specimen holder 36
6.5.3 Adjusting the specimen holder position 37
6.6 The preparation process 37
6.6.1 The splash guard 37
6.6.2 Starting the preparation process 38
6.6.3 Stopping the preparation process 38
6.6.4 The Spin function 39
7 Maintenance and service - AbraPol-30 39
7.1 General cleaning 40
7.2 Daily 40
7.2.1 Checking the recirculation tank 40
7.3 Weekly 41
7.3.1 Cleaning the bowl 41
7.3.2 Cleaning the tubes 41
7.4 Monthly 42
7.4.1 Cleaning the recirculation unit 42
7.4.2 Changing the cooling fluid 43
7.5 Annually 43
7.5.1 Testing safety devices 44
7.5.2 Emergency stop 44
7.5.3 Safety cover 45
7.6 Changing the pump tubes 45
7.7 Calibrating the pumps 47
4 AbraPol-30

7.8 Spare parts 47
7.9 Service and repair 47
7.10 Disposal 48
8 Troubleshooting - AbraPol-30 48
8.1 Messages and errors - AbraPol-30 48
8.1.1 Messages 49
8.1.2 Errors 49
9 Technical data 54
9.1 Technical data - AbraPol-30 54
9.2 Safety Circuit Categories/Performance Level 56
9.3 Noise and vibration levels 56
9.4 Safety Related Parts of the Control System (SRP/CS) 56
9.5 Diagrams 58
9.5.1 Diagrams - AbraPol-30 58
9.6 Legal and regulatory information 67
10 Pre-installation checklist 67
10.1 Installation requirements 67
10.2 Packaging specifications 68
10.3 Location 68
10.4 Dimensions 69
10.5 Recommended space 70
10.6 Transport and storage 70
10.6.1 Long-term storage or shipping 71
10.7 Unpacking 71
10.8 Lifting 71
10.9 Power supply 71
10.10 Safety specifications 73
10.11 Water supply 73
10.12 Compressed air 74
10.13 Exhaust (option) 74
10.14 Recirculation unit (option) 74
11 Manufacturer 75
Declaration of Conformity 76
AbraPol-30 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 brochure for AbraPol-30:
•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
The machine is for use in a professional working environment (e.g. a materialographic laboratory).
AbraPol-30 is for professional semi-automatic or manual materialographic preparation (grinding or
polishing) of materials for further materialographic inspection.
The device is designed to be used with Struers consumables specially designed for this purpose and
this type of device.
The machine must be operated only by skilled/trained personnel.
6 AbraPol-30
1 About this manual

Do not use the machine for
the following
Preparation (grinding or polishing) of materials other than solid
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 AbraPol-30
AbraPol-30 with shift valve
2.1.1 AbraPol-30safety precautions
Read carefully before use
1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.
2. The machine must be installed in compliance with local safety regulations. All functions on
the machine and any connected equipment must be in working order.
3. The operator must read the safety precautions and Instruction Manual, as well as relevant
sections of the manuals for any connected equipment and accessories.
The operator must read the Instruction Manual and, where applicable, the Safety Data
Sheets for the applied consumables.
4. This machine must be operated and maintained only by skilled/trained personnel.
5. The machine must be placed on a safe and stable floor.
6. 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). Always follow
local regulations. Always switch off the electrical power supply and remove the plug or power
cable before dismantling the machine or installing additional components.
7. Connect the machine to a cold water tap. Make sure that the water connections are leak-
proof and that the water outlet is working.
8. Struers recommends that the main water supply is shut off or disconnected if the machine is
to be left unattended.
9. Consumables: only use consumables specifically developed for use with this type of
materialographic machine. Alcohol-based consumables: follow the current safety rules for
handling, mixing, filling, emptying and disposing of alcohol-based liquids.
10. Keep clear of rotating parts during operation. When you perform manual grinding or
polishing, be careful not to touch the disc. Do not try to collect a specimen from the tray while
the disc is rotating.
11. Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens.
12. When working at machines with rotating parts, take care to prevent clothes and/or hair from
being caught by the rotating parts. Appropriate safety clothing must be used.
13. If you observe malfunctions or hear unusual noises, stop the machine and call technical
service.
2 Safety
AbraPol-30 7

14. The machine must be disconnected from the electrical power supply prior to any service. Wait 5
minutes until residual potential on the capacitors is discharged.
15. Do not switch the machine on and off more than once every five minutes. Damage to the
electrical components could occur.
16. In case of fire, alert bystanders and the fire brigade. Disconnect the electrical power supply. Use
a powder fire extinguisher.Do not use water.
17. Struers equipment must only be used in connection with and as described in the instruction
manual supplied with the equipment.
18. The equipment is designed to be used only with Struers consumables specifically designed for
this purpose and this type of machine.
19. 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.
8 AbraPol-30
2 Safety

Hint
This sign indicates that additional information and hints are available.
2.3 Safety messages in this manual
CAUTION
Struers equipment must only be used in connection with and as described in the
instruction manual supplied with the equipment.
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
For electrical installations with Residual Current Circuit Breakers
For AbraPol-30 a residual current circuit breaker Type B, 30 mA is required (EN
50178/5.2.11.1).
For electrical installations without Residual Current Circuit Breakers
The equipment must be protected by an insulation transformer (double-wound
transformer).
Contact a qualified electrician to verify the solution.
Always follow local regulations.
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
Risk of hand to arm vibration during manual preparation.
Prolonged exposure to vibration may cause discomfort, joint damage or even
neurological damage.
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.
CAUTION
The recirculation tank is very heavy when it is full.
2 Safety
AbraPol-30 9

CAUTION
The pressure of the cooling fluid supplied to the machine must be max. 2 bar.
CAUTION
Do not use the machine with non-compatible accessories or consumables.
CAUTION
Keep clear of rotating parts during operation.
CAUTION
When working at machines with rotating parts, take care to prevent clothes and/or
hair from being caught by the rotating parts.
CAUTION
A specimen holder with specimens can be heavy. Do not release the specimen
holder until it is secured in the coupling.
Use working gloves to protect fingers and hands.
CAUTION
Avoid skin contact with the cooling fluid additive.
WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.
3 Getting started
3.1 Device description
AbraPol-30 is a semi-automatic or manual machine for materialographic preparation
(grinding/polishing) with a 300 mm or 350 mm diameter preparation disc.
A recirculation cooling unit (option) can be connected for supplying cooling water to the grinding
process. If preparation with oxide suspensions is needed, and a recirculation cooling unit has been
installed, a shift valve must be included or retrofitted.
The operator selects the grinding/polishing surface, the preparation method, and the cooling
fluid/abrasive suspension that will be applied automatically during the process.
Semi-automatic preparation starts by clamping the specimens in the specimen holder and placing
them in the machine.
10 AbraPol-30
3 Getting started

The operator can select manual preparation for special applications. The operator holds the
specimens during manual preparation. When manual preparation is used, a special splash guard
must be placed before the machine is started.
The operator starts the machine by pressing the Start button on the control panel.
The machine stops automatically. The operator cleans the specimens before the next preparation
step or inspection.
Struers recommends connecting the machine to an exhaust system to remove fumes from the
working area.
If the emergency stop is activated, the power to all hazardous moving parts is cut.
3.2 AbraPol-30 - overview
AbraPol-30
Front view - with safety cover
ASafety cover
BEmergency stop
CCover plate for compartment containing
recirculation unit ((option))
Front view - without safety cover
AHandles for adjusting specimen holder
position
BDisplay
CControl panel
DMotor - Specimen holder
EDosing arm
FQuick coupling - Specimen holder
Side view - left
AConnection for exhaust
BCompressed air inlet
COpening for water outlet hose
3 Getting started
AbraPol-30 11

Side view - right
AElectrical power switch
BCompressed air inlet
CElectrical power connection
Rear view
AWater inlet
BRegulation valve for disc cooling
CRegulation valve for OP flush
AAUX connector
BBeacon connection
CService sockets
Control panel
See Control panel functions ►21.
4 Transport and storage
If, at any time after the installation, you have to move the unit or place it in storage, there is a number
of guidelines we recommend that you follow.
• Package the unit securely before transportation.
Insufficient packaging could cause damage to the unit and will void the warranty. Contact
Struers Service.
• Struers recommends that all original packaging and fittings are kept for future use.
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4 Transport and storage

4.1 Storage
Note
Struers recommends that all original packaging and fittings are kept for future use.
Disconnect the unit from the electrical power supply.
• Remove any accessories.
• Clean and dry the unit before storage.
• Place the machine and accessories in their original packaging.
5 Installation
WARNING
Struers equipment must only be used in connection with and as described in the
instruction manual supplied with the equipment.
5.1 Unpacking
Note
Struers recommends that all original packaging and fittings are kept for future use.
1. Cut the packing tape on the top of the box.
2. Remove the loose parts.
3. Remove the unit from the box.
4. Unscrew the transport brackets that secure the machine to the pallet.
5. Use a forklift truck to lift the machine from the pallet. Lift the machine from the front.
6. Place the machine on a plane and horizontal floor.
7. Remove the locking pin from the crossbar and remove the bar. Keep the crossbar for use if
you need to move the machine.
For details about the weight of this machine, see Technical data - AbraPol-30 ►54
Moving the machine
To move the machine, use a fork-lift truck and a crossbar.
5.2 Checking the packing list
Optional accessories may be included in the packing box.
The packing box contains the following items:
5 Installation
AbraPol-30 13

Pcs. Description
1 AbraPol-30 with shift valve/without shift valve
1 Splash guard for manual preparation
1 Inlet hose Diameter: 19 mm/¾", Length: (2 m)
1 Hose for emptying the cooling unit tank
1 Filter gasket
1 Reduction ring with gasket Diameter: ¾" to ½"
2 Hose clamp. Diameter: 40-60 mm
1 Hose for compressed air. Length: 2 m
1 Hose connection for compressed air. Diameter: ¾"
1 Exhaust hose. Diameter: 50 mm. Length: 2.5 m
1 Fork spanner, 24 mm
1 Instruction Manual set
5.3 Power supply
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
For electrical installations with Residual Current Circuit Breakers
For AbraPol-30 a residual current circuit breaker Type B, 30 mA is required (EN
50178/5.2.11.1).
For electrical installations without Residual Current Circuit Breakers
The equipment must be protected by an insulation transformer (double-wound
transformer).
Contact a qualified electrician to verify the solution.
Always follow local regulations.
Procedure
For specifications see the section Technical data.
14 AbraPol-30
5 Installation

1. Open the electrical connection box.A
2. Connect a 4-lead or 5-lead cable as shown.
PE Earth (ground)
N Neutral (not used internally)
L1 Phase
L2 Phase
L3 Phase
EU cable
L1 Brown
L2 Black
L3 Black or Grey
Earth (ground) Yellow/Green
Neutral Blue
UL cable
L1 Black
L2 Red
L3 Orange/Turquoise
Earth (ground) Green (or Yellow/Green)
Neutral White
The other end of the cable can be fitted with an approved plug or hard-wired into the power supply
according to the electrical specifications and local regulations.
5.4 Noise
For information on the sound pressure level value, see this section: Technical data ►54,
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.
5.5 Vibration
For information on the total vibration exposure to hand and arm, see this section: Technical data
►54.
5 Installation
AbraPol-30 15

CAUTION
Risk of hand to arm vibration during manual preparation.
Prolonged exposure to vibration may cause discomfort, joint damage or even
neurological damage.
Handling vibration during operation
Manual preparation may cause vibrations in hand and arm. To lower the vibration, decrease the
pressure or use a vibration-reducing glove.
• Limit grinding/polishing operations to a maximum of 10 minutes. Wait for 5 minutes before
continuing grinding/polishing.
5.6 Compressed air supply
For specifications, see Technical data - AbraPol-30 ►54
1. Connect the compressed air hose to the compressed air inlet on the machine.
2. Connect the air hose to the compressed air supply.
3. Secure the connections with hose clamps.
5.7 Connecting to an exhaust system
For specifications, see Technical data - AbraPol-30 ►54.
Struers recommends that the machine is connected to an exhaust system.
1. Connect a 52 mm pipe to the exhaust outlet on the machine.
2. Connect the other end of the pipe to the exhaust system.
5.8 Connecting to the water supply
If the machine is used without a recirculation unit, it must be connected directly to the main water
supply in these cases:
• if an OP-pump is mounted
• if disc cooling is required
Water from the main water supply Water from the recirculation unit (option)
Procedure
1. Connect the pressure hose to the water inlet hose on the back of the machine:
16 AbraPol-30
5 Installation

– Insert the filter gasket in the coupling nut with the flat side against the pressure hose.
– Tighten the pressure nut.
2. Connect the other end of the pressure hose to the main water outlet
– Mount the reduction ring with gasket on the cold water outlet if necessary.
– Insert the gasket.
– Tighten the coupling nut.
Adjusting the water flow
• If needed, use the water valve to adjust the water flow
during grinding/polishing.
5.9 Connecting to the waste water outlet
1. The machine is delivered with a water outlet hose.
2. Lead the water outlet hose out of the machine through one of the openings in the sides of the
machine.
3. Make sure that the hose slopes downward towards the waste water drain throughout its
entire length. If needed, shorten the hose.
5.10 Connecting the recirculation unit (option)
To ensure optimal cooling, mount a recirculation unit on the machine.
Note
Before you connect the recirculation unit to the machine, you must prepare it for
use. See the Instruction Manual for this unit.
ELECTRICAL HAZARD
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.
5 Installation
AbraPol-30 17

Filling the recirculation tank
1. Before you fill the tank, make sure that there is
room under the machine for the recirculation
unit to slide in easily. If this is not the case, use
the adjustable feet to adjust the height of the
machine.
2. Make sure that the recirculation unit is placed
correctly under the machine:
– The wheels of the unit must be in line with
the sides of the compartment so that you
can move the unit into position without
having to wiggle it from side to side.
– The pump must be placed on the left hand
side and close to the rear end of the
recirculation unit.
Note
To prevent corrosion, Struers recommends using a Struers additive in the cooling
water. For more information, see the additive container.
3. Line the tank with a clean plastic liner.
CAUTION
The recirculation tank is very heavy when it is full.
Note
Do not overfill the tank.
Avoid spilling when you move the tank.
4. Fill up the tank with cooling fluid. Make sure that
the water/additive ratio is correct.
18 AbraPol-30
5 Installation

Connecting the unit to the machine
1. Connect the water inlet hose to the quick
coupling on the recirculation pump.
AElectrical power socket - not shown
BWater inlet hose - to machine
CRecirculation pump
DQuick coupling - on pump
2. Insert the water outlet hose from the machine
into the large hole of the filter unit. If needed,
shorten the hose.
3. Connect the cable from the recirculation
pump to the electrical power socket of the
recirculation unit inside the compartment.
4. Make sure that the direction of the flow is as
stated with an arrow on the pump. If the
direction is incorrect, switch two of the
phases:
– EU cable: switch two of the phases.
– UL cable: switch phases L1 and L2.
5. Push the unit into place in the compartment
under the machine.
5.11 Connecting an external recirculation unit (option)
1. Guide the water outlet hose through the opening on the left or
right side of the machine to the recirculation unit.
2. Connect the water outlet on the pump to the water inlet hose.
ELECTRICAL HAZARD
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.
5 Installation
AbraPol-30 19

CAUTION
The pressure of the cooling fluid supplied to the machine must be max. 2 bar.
3. Connect the cable from the external pump to the electrical power
socket of the recirculation unit inside the compartment.
Wiring: For specifications see the section Technical data.
Note
If you are using the AUX connection, contact Struers
Service more information on the connection and the
required flow.
4. Connect the external pump control to the AUX connection on the
rear of the machine.A
5.12 Adjusting disc cooling and OP-flushing
You can set the level of disc cooling and flushing time in the software
If you need to adjust the rate of disc cooling:
1. Loosen the locknut and turn the regulator screw as needed.
2. Tighten the locknut.
Hint
If needed, use the throttle valves to adjust the maximum water flow for disc cooling
and flushing after OP.
The level of disc cooling and flushing time is set in the software. See Options ►30.
5.13 The dosing pump units
You can configure up to 6 pumps:
ADP-pumps
Up to 6 pumps, positions 1 to 6 (shown in
the red box)
BOP-pumps
Up to 2 pumps, positions 5 and 6 (shown in
the green box)
Mounting the dosing pump units
1. Remove the cover plates.
2. Insert the pump units in the correct position in the bottle units and push until they are firmly
secured.
3. Secure the units with the attached screws.
20 AbraPol-30
5 Installation