Struers LaboPol-20 User manual

LaboPol-20
Instruction Manual
Original Instructions
Doc. no.: 16327025-02_A_en-us
Date of release: 2023.03.02

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 2023.03.02.
2 LaboPol-20

Table of Contents
1 About this manual 6
2 Safety 6
2.1 Intended use 6
2.2 LaboPol-20safety precautions 7
2.2.1 Read carefully before use 7
2.3 Safety messages 8
2.4 Safety messages in this manual 9
3 Getting started 10
3.1 Device description 10
3.2 LaboPol-20 - Front view 11
3.2.1 Control panel/Specimen mover 12
3.3 LaboPol-20 - Rear view 12
3.4 Struers knowledge 13
3.5 Accessories and consumables 13
4 Transport and storage 13
4.1 Transport 13
4.2 Long-term storage or shipping 14
5 Installation 15
5.1 Unpack the machine 15
5.2 Check the packing list 15
5.3 Lift the machine 15
5.4 Location 16
5.5 Power supply 17
5.5.1 Single-phase supply 17
5.5.2 2-phase supply 17
5.5.3 Connection to the machine 18
5.6 Water supply and water outlet 18
5.6.1 Connecting to the water supply 18
5.6.2 Connecting to the waste water outlet 18
5.7 Installing the preparation disc 19
5.7.1 Preparation disc types 19
5.8 Noise 19
5.9 Vibration 19
LaboPol-20 3

6 LaboUI 20
6.1 Installation 20
6.1.1 Unpack the machine 20
6.1.2 Check the packing list 20
6.1.3 Installation - LaboUI 21
6.2 Operate the device 21
6.2.1 Control panel functions 21
6.2.2 Water tap 22
6.2.3 The spin function 23
6.2.4 The splash guard 23
6.2.5 Manual preparation 23
6.2.6 Starting and stopping the machine 24
7 LaboForce-50 25
7.1 Installation 26
7.1.1 Unpack the machine 26
7.1.2 Check the packing list 26
7.1.3 Installation - LaboForce-50 27
7.1.4 Adjusting the specimen mover 28
7.2 Operate the device 30
7.2.1 Control panel functions 30
7.2.2 Water tap 31
7.2.3 The spin function 32
7.2.4 The splash guard 32
7.2.5 Inserting a specimen 32
7.2.6 Adjusting the force 33
7.2.7 Manual preparation 33
7.2.8 Starting and stopping the machine 34
7.2.9 Removing the specimens 36
7.2.10 Changing the specimen mover plate 36
8 LaboDoser-10 36
8.1 Unpack the machine 37
8.2 Check the packing list 38
8.3 Installation 38
8.4 Operating LaboDoser-10 39
8.5 Changing lubricant/suspension 39
9 Maintenance and service 40
9.1 General cleaning 40
9.2 Daily 40
9.3 Weekly 40
4 LaboPol-20

9.4 Monthly 41
9.4.1 LaboForce-50 - pressure feet 41
9.5 Annually 41
9.5.1 Test the safety devices 41
9.5.2 Emergency stop 42
9.6 Spare parts 42
9.7 Service and repair 43
9.8 Disposal 43
10 Troubleshooting 44
10.1 Troubleshooting - LaboPol-20 44
10.2 LaboForce-50 44
11 Technical data 45
11.1 Technical data 45
11.2 Safety Circuit Categories/Performance Level 46
11.3 Noise and vibration levels 47
11.4 Technical data - equipment units 47
11.5 Safety Related Parts of the Control System (SRP/CS) 47
11.6 Diagrams 48
11.6.1 Diagrams - LaboPol-20 48
11.6.2 Diagrams - equipment units 51
11.7 Legal and regulatory information 51
12 Manufacturer 51
Declaration of Conformity 53
LaboPol-20 5

1 About this manual
CAUTION
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
The machine is for use in a professional working environment (e.g. a materialographic laboratory).
The equipment is designed to be used only with Struers consumables specifically designed for this
purpose and this type of machine.
The machine is for professional manual or semi-automatic materialographic preparation (grinding or
polishing) of materials for further materialographic inspection.
The machine must be operated only by skilled/trained personnel.
Manual preparation LaboPol-20 is intended to be used in combination with:
• LaboUI
Semi-automatic preparation LaboPol-20 is intended to be used in combination with:
• LaboForce-50
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 LaboPol-20
6 LaboPol-20
1 About this manual

2.2 LaboPol-20safety precautions
2.2.1 Read carefully before use
In combination with: LaboUI, LaboForce-50.
Ignoring this information and mishandling of the equipment can lead to severe bodily injuries and
material damage.
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 machine must be placed on a safe and stable table with an adequate working height.
The table must be able to carry at least the weight of the machine and the accessories.
3. Connect the machine to a cold water tap. Make sure that the water connections are leak-
proof and that the water outlet is working.
4. 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.
5. Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens.
6. 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.
7. 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.
8. Risk of hand to arm vibration during manual preparation.Prolonged exposure to vibration
may cause discomfort, joint damage or even neurological damage.
9. The machine must be disconnected from the electrical power supply before any service.
Wait 5 minutes until residual potential on the capacitors is discharged.
10. 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.
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.
3. This machine must be operated and maintained only by skilled/trained personnel.
4. The machine must always be used with the splash guard in place.
5. 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.
2 Safety
LaboPol-20 7

6. Struers recommends that the main water supply is shut off or disconnected if the machine is to
be left unattended.
7. 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.
8. If you observe malfunctions or hear unusual noises, switch off the machine and call technical
service.
9. Do not switch the machine on and off more than once every five minutes. Damage to the
electrical components could occur.
10. In case of fire, alert bystanders and the fire brigade. Disconnect the electrical power supply. Use
a powder fire extinguisher. Do not use water.
11. Struers equipment must only be used in connection with and as described in the Instruction
Manual supplied with the equipment.
12. The equipment is designed to be used only with Struers consumables specifically designed for
this purpose and this type of machine.
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.).
2.3 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.
CRUSHING HAZARD
This sign indicates a crushing hazard which, if not avoided, could result in minor,
moderate or serious injury.
8 LaboPol-20
2 Safety

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
Struers equipment must only be used in connection with and as described in the
Instruction Manual supplied with the equipment.
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
WARNING
Switch off the machine, disconnect the electrical power cable and wait 5 minutes
before you dismantle the machine or install additional components.
ELECTRICAL HAZARD
Switch off the electrical power supply before installing electrical equipment.
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.
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.
CAUTION
Keep clear of rotating parts during operation.
2 Safety
LaboPol-20 9

CAUTION
When working at machines with rotating parts, take care to prevent clothes and/or
hair from being caught by the rotating parts.
CAUTION
For manual preparation use the switch on the side of the specimen mover head to
disable rotation of LaboForce-50.
CAUTION
Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens.
CAUTION
When you perform manual grinding or polishing, be careful not to touch the disc.
CAUTION
Do not try to collect a specimen from the tray while the disc is rotating.
CAUTION
When the disc is rotating, make sure your hands are kept completely clear of its
periphery and out of the splash bowl.
WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.
WARNING
Before you release the emergency stop, investigate the reason for activating the
emergency stop and take any necessary corrective action.
WARNING
Safety critical components must be replaced after a maximum lifetime of 20 years.
Contact Struers Service.
3 Getting started
3.1 Device description
LaboPol-20 is for materialographic preparation (grinding/polishing) using a preparation disc of 200
mm in diameter.
LaboPol-20 is for manual preparation when used with LaboUI.
10 LaboPol-20
3 Getting started

LaboPol-20 is for semi-automatic preparation when used with LaboForce-50.
The operator selects the grinding/polishing surface and the cooling fluid/abrasive suspension to be
applied.
Cooling water is applied when the operator opens the water tap. Other fluids are applied manually
or by a separate dosing unit.
With LaboUI the operator holds the specimens during the preparation.
With LaboForce-50 the operator places the specimens in the specimen mover plate.
The operator sets the rotation speed of the preparation disc before starting the process.
The machine must always be used with the splash guard in place.
The splash guard for manual preparation is supplied with the machine.
The splash guard for other types of preparation must be ordered separately.
The operator starts the machine by pressing the Start button on the control panel.
The operator stops the machine by pressing stop on the control panel.
The operator cleans the specimens before the next preparation step or inspection.
We recommend that an exhaust system is applied when alcohol-based suspension or lubricants
are used.
If the emergency stop is activated, the power to all moving parts is cut.
3.2 LaboPol-20 - Front view
AConnection for control
panel
BSplash guard for
manual preparation
(both discs)
CPreparation disc
location (both discs)
DEmergency stop
EWater tap
FStorage pad
Emergency stop
If LaboForce-50 is mounted on the machine, activating the emergency stop on the
machine will also stop LaboForce-50.
3 Getting started
LaboPol-20 11

Note
Do not use the emergency stop for operational stop of the machine during normal
operation.
Before you release the emergency stop, investigate the reason for activating the
emergency stop and take any necessary corrective action.
• To activate the emergency stop, press the red emergency stop button.
• To release the emergency stop, turn the red emergency stop button clockwise.
3.2.1 Control panel/Specimen mover
The machine can be mounted with one of the following units. See the specific sections for installation
instructions.
LaboUI
• See Control panel functions ►21.
LaboForce-50
• See Control panel functions ►30.
3.3 LaboPol-20 - Rear view
AMain switch
BFuses
CElectrical power socket
DWater inlet from main
water supply
EWaste water outlet
FType plate
12 LaboPol-20
3 Getting started

3.4 Struers knowledge
Mechanical preparation is the most common method of preparing materialographic specimens for
microscopic examination.
The specific requirement of the prepared surface is determined by the particular type of analysis
or examination.
Specimens can be prepared to the perfect finish, the true structure, or the preparation can be
stopped when the surface is acceptable for a specific examination.
Hint
For further information, see the section on Grinding and Polishing on the Struers
website.
3.5 Accessories and consumables
Accessories
For information about the available range, see:
•The LaboSystem brochure (https://www.struers.com/Products/Grinding-and-
Polishing/Grinding-and-polishing-equipment/LaboSystem)
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 (via https://www.struers.com)
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.
• We recommend that you use the original packaging and fittings.
4.1 Transport
• Disconnect the unit from the electrical power supply.
• Disconnect the water inlet and the water outlet.
• Remove the splash guard, the preparation disc and the bowl liner.
4 Transport and storage
LaboPol-20 13

• Lift the machine by gripping the base of the
machine from beneath, from both the left
side and the right side.
– Alternatively, use a crane and two lifting
straps to lift the machine.
– Position the straps under the machine,
so that they are on the outer side of the
feet.
• Lift the machine onto a stable surface.
4.2 Long-term storage or shipping
Note
We recommend that you keep all original packaging and fittings for future use.
• Clean the machine and all accessories thoroughly.
• Disconnect the unit from the electrical power supply.
• Disconnect the water inlet and the water outlet.
• Remove the splash guard, the preparation disc and the bowl liner.
• Remove the control panel or specimen mover.
• Remove any accessories.
• Lift the machine by gripping the base of the machine from beneath, from both the left side and
the right side.
• Place the machine and accessories in their original packaging.
• Secure the boxes on a pallet with straps.
At the new location
At the new location, make sure that the facilities required are in place.
14 LaboPol-20
4 Transport and storage

5 Installation
5.1 Unpack the machine
Note
We recommend that you keep all original packaging and fittings 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.
5.2 Check the packing list
Optional accessories may be included in the packing box.
The packing box contains the following items:
Pcs. Description
1 LaboPol-20
2 Electrical power supply cables
1 Disposable bowl liner, clear plastic
1 Splash guard for manual preparation
1 Water inlet hose. Diameter: 19 mm/¾". Length: 2 m/6.6'
1 Filter gasket
1 Reduction ring with gasket, ¾" to ½"
1 Water outlet hose. Diameter: 32 mm/1.6". Length: 1.5 m/4.9'
1 Elbow pipe for water outlet
1 Hose clamp
1 Allen key with cross handle, 6x150 mm/0.23x6"
2 Caps for use after mounting LaboUI, or LaboForce-50
1 Instruction Manual set
5.3 Lift the machine
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
Note
Do not lift the machine by the light gray top part or by the water tap.
Always lift the machine from beneath.
5 Installation
LaboPol-20 15

Weight
LaboPol-20 22 kg (49 lbs)
1. Lift the machine by gripping the base of the
machine from beneath, from both the left
side and the right side.
– Alternatively, use a crane and two lifting
straps to lift the machine.
– Position the straps under the machine,
so that they are on the outer side of the
feet.
2. Lift the machine onto the table.
3. The machine must rest securely with all 4
feet on the table.
5.4 Location
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
• The machine must be placed close to the electrical power supply, main water supply and waste
water drain.
• To facilitate easy access for service technicians, allow sufficient space around the machine.
• Place the machine on a rigid, stable workbench with a horizontal surface and an adequate
height.
• The machine must rest securely with all 4 feet on the table.
• To level the machine, turn the adjustable rubber feet.
16 LaboPol-20
5 Installation

5.5 Power supply
WARNING
Switch off the machine, disconnect the electrical power cable and wait 5 minutes
before you dismantle the machine or install additional components.
ELECTRICAL HAZARD
Switch off the electrical power supply before installing electrical equipment.
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.
Note
An autotransformer is required in countries with a 110 V electrical power supply.
Power socket
The electrical power supply socket must be easy to access. The electrical power supply socket
must be located at a height ranging from 0.6 m to 1.9 m (2½” to 6’) above floor level. Not higher
than 1.7 m (5’ 6”) is recommended.
Note
The equipment is shipped with 2 types of electrical power cables. If the plug
supplied on these cables is not approved in your country, the plug must be
replaced with an approved plug.
5.5.1 Single-phase supply
Single-phase supply
The 2-pin plug (European Schuko) is for use on single-phase
electrical power connections.
The leads must be connected as follows:
Yellow/Green Earth (ground)
Brown Line (live)
Blue Neutral
5.5.2 2-phase supply
The 3-pin plug (North American NEMA) is for use on 2-phase
electrical power connections.
The leads must be connected as follows:
5 Installation
LaboPol-20 17

Green Earth (ground)
Black Line (live)
White Line (live)
5.5.3 Connection to the machine
• Connect the electrical power cable to the machine (C14
IEC 320 connector).
• Connect the cable to the electrical power supply.
5.6 Water supply and water outlet
Water for wet grinding is supplied from the main water supply.
5.6.1 Connecting to the water supply
Note
The cold-water supply must have a head pressure in the range:1-9.9 bar (14.5-143
psi)
Hint
New water pipe installations:
Leave the water to run for a few minutes to flush any debris from the pipe before
connecting the machine to the water supply.
Connecting the water inlet hose
Connect the 90°-angle end of the water inlet hose to the water inlet on the back of the machine:
1. Insert the filter gasket in the coupling nut with the flat side against the water inlet hose.
2. Tighten the coupling nut firmly.
Connect the straight end of the water inlet hose to the water supply tap for cold water:
1. If needed, connect the reduction piece with gasket to the water supply tap.
2. Tighten the coupling nut firmly.
5.6.2 Connecting to the waste water outlet
1. Connect the elbow pipe to the waste water outlet pipe.
2. Connect the waste water outlet hose to the elbow pipe. If needed, lubricate with grease or soap
to make it easier to insert the pipe in the hose. Use a hose clamp to fasten the hose to the pipe.
3. Lead the other end of the waste water hose to the waste water drain.If needed, shorten the
hose.
Note
Make sure that the hose slopes downward towards the waste water drain throughout
its entire length.
Make sure that there are no sharp bends in the waste water hose.
18 LaboPol-20
5 Installation

5.7 Installing the preparation disc
Note
Make sure that the cavity on the underside of the preparation disc and the cone on
the machine are clean.
Make sure that the bowl liner is clean and that the drain is positioned correctly.
Procedure
1. Place the preparation disc carefully on the driving pin.
2. Rotate it slowly until it is safely engaged.
5.7.1 Preparation disc types
The machine can be used with the following disc types:
Preparation disc types Preparation surface
MD-Disc For MD consumable.
Wet grinding disc For SiC Paper.
Aluminum disc For adhesive-backed consumable.
5.8 Noise
For information on the sound pressure level value, see this section: Technical data ►45
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.
How to handle noise during operation
Different materials have different noise characteristics.
Manual preparation To lower the noise, try to decrease the force with which the
specimen is pressed against the preparation surface. The
processing time may increase.
Semi-automatic preparation To lower the noise, decrease the rotational speed and/or the
force with which the specimens are pressed against the
preparation surface. The processing time may increase.
5.9 Vibration
For information on the total vibration exposure to hand and arm, see this section: Technical data
►45.
5 Installation
LaboPol-20 19

CAUTION
Risk of hand to arm vibration during manual preparation.
Prolonged exposure to vibration may cause discomfort, joint damage or even
neurological damage.
How to handle 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.
6 LaboUI
Front view
AControl panel
BDisc speed control
CControl panel column
6.1 Installation
6.1.1 Unpack the machine
Note
We recommend that you keep all original packaging and fittings 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.
6.1.2 Check the packing list
Optional accessories may be included in the packing box.
The packing box contains the following items:
20 LaboPol-20
6 LaboUI