Struers AbraPol-30 Instruction Manual
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Struers AbraPol-30 Instruction Manual

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

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Summary of Contents for Struers AbraPol-30

  • Page 1 AbraPol-30 Instruction Manual Original Instructions Doc. no.: 16307025_B_en Date of release: 2021.06.14...
  • Page 2 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. AbraPol-30...

  • Page 3: Table Of Contents

    2.1 Intended use 2.1.1 AbraPol-30 safety precautions 2.2 Safety messages 2.3 Safety messages in this manual 3 Getting started 3.1 Device description 3.2 AbraPol-30 - overview 4 Transport and storage 4.1 Storage 5 Installation 5.1 Unpacking 5.2 Checking the packing list 5.3 Power supply...
  • Page 4 6.6 The preparation process 6.6.1 The splash guard 6.6.2 Starting the preparation process 6.6.3 Stopping the preparation process 6.6.4 The Spin function 7 Maintenance and service - AbraPol-30 7.1 General cleaning 7.2 Daily 7.2.1 Checking the recirculation tank 7.3 Weekly 7.3.1 Cleaning the bowl...
  • Page 5 7.8 Spare parts 7.9 Service and repair 7.10 Disposal 8 Troubleshooting - AbraPol-30 8.1 Messages and errors - AbraPol-30 8.1.1 Messages 8.1.2 Errors 9 Technical data 9.1 Technical data - AbraPol-30 9.2 Safety Circuit Categories/Performance Level 9.3 Noise and vibration levels 9.4 Safety Related Parts of the Control System (SRP/CS)

  • Page 6: About This Manual

    1   About this manual 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.

  • Page 7: Abrapol-30 Safety Precautions

    Connect the machine to a cold water tap. Make sure that the water connections are leak- proof and that the water outlet is working. Struers recommends that the main water supply is shut off or disconnected if the machine is to be left unattended.

  • Page 8: Safety Messages

    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.

  • Page 9: Safety Messages In This Manual

    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).

  • Page 10: Getting Started

    Getting started 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.

  • Page 11: Abrapol-30 - Overview

    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.

  • Page 12: Transport And Storage

    • 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. AbraPol-30...

  • Page 13: Storage

    • Place the machine and accessories in their original packaging. Installation WARNING Struers equipment must only be used in connection with and as described in the instruction manual supplied with the equipment. Unpacking Note Struers recommends that all original packaging and fittings are kept for future use.

  • Page 14: Power Supply

    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).

  • Page 15: Noise

    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. Vibration For information on the total vibration exposure to hand and arm, see this section: Technical data ►54. AbraPol-30...

  • Page 16: Compressed Air Supply

    For specifications, see Technical data - AbraPol-30 ►54. Struers recommends that the machine is connected to an exhaust system. Connect a 52 mm pipe to the exhaust outlet on the machine. Connect the other end of the pipe to the exhaust system.

  • Page 17: Connecting To The Waste Water Outlet

    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. AbraPol-30...
  • Page 18 Note To prevent corrosion, Struers recommends using a Struers additive in the cooling water. For more information, see the additive container. Line the tank with a clean plastic liner.

  • Page 19: Connecting An External Recirculation Unit (Option)

    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. AbraPol-30...

  • Page 20: Adjusting Disc Cooling And Op-Flushing

    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. Connect the external pump control to the AUX connection on the rear of the machine.A...

  • Page 21: Placing Bottles In The Dosing Unit

    Do not use the machine with non-compatible accessories or consumables. Control panel functions CAUTION Keep clear of rotating parts during operation. When working at machines with rotating parts, take care to prevent clothes and/or hair from being caught by the rotating parts. AbraPol-30...
  • Page 22 Press to toggle when only 2 options are available. • Press the Turn/Push knob to select a function or save a selected setting. Back • Press this button to return to the previous screen or to cancel functions/changes. AbraPol-30...

  • Page 23: The Display

    A short beep, when you press a key, indicates that the selection is confirmed. You can enable or disable the beep: select Configuration. Long beep A long beep, when you press a button, indicates that the key cannot be activated at the moment. You cannot disable this beep. AbraPol-30...

  • Page 24: Navigating In The Display

    Press the button to cancel changes. 6.2.2 Main menu From the Main menu screen you can choose between the following options: • Automatic preparation • Manual preparation You can also access the maintenance and configuration screens. • Maintenance • Configuration AbraPol-30...

  • Page 25: Changing Settings And Text

    Press the Turn/Push knob to toggle between the options. Navigate to select Save & Exit. Press the Turn/Push knob to exit the screen. 6.2.4 Software settings Start-up - the first time SeeNavigating in the display ►24 for instructions on how to navigate in the display. AbraPol-30...

  • Page 26: Configuration

    ►27. – Specimen holder positioning.See Adjusting the specimen holder position ►37 – User defined consumables for setting specific parameters. – Options for general settings. 6.3.1 Operation mode User levels You can select three different user levels as operation mode. AbraPol-30...

  • Page 27: New Pass Code

    Bottle configuration Hint The different suspensions and lubricants used must always be configured so that the correct suspension or lubricant is used during the preparation. To configure the bottles to be used for lubricants and suspensions, do the following: AbraPol-30...

  • Page 28: User Defined Consumables

    • Lubricant configuration User surface configuration From the Configuration menu, select User surface configuration. In the Surface name column you can select an item. You can rename or delete this item. To return to the Configuration menu, press Back AbraPol-30...
  • Page 29 1 DP-Lubricant, water based Select this option if the lubricant contains water. – 2 DP-Lubricant, alcohol based Select this option if the lubricant is water-free and is to be used for preparing water-sensitive materials. To return to the Configuration menu, press Back AbraPol-30...

  • Page 30: Options

    The machine automatically continues to the next step, but pauses when grinding with SiC Paper, which must be changed between the steps. Always The machine automatically continues to the next step. Flushing time after OP 20 - 60 seconds step AbraPol-30...

  • Page 31: Preparation Methods

    Creating a preparation method You can create a preparation method in several ways: • Create a preparation method To create a preparation method, see Creating a preparation method ►32. • Change a preparation method and save it under another name AbraPol-30...

  • Page 32: Creating A Preparation Method

    You can change the settings for each step in a preparation method. Setting Surface type/Surface • Select surface type and surface. Suspension type/Suspension • Select the suspension. Lubricant • Select the lubricant. All-in-one suspensions are set up as lubricants. AbraPol-30...
  • Page 33 Specimen holder: Direction • Select the direction of the specimen holder: • Co-rotation Recommended for the best preparation result and most uniform polishing. • Counter-rotation Recommended for polishing with oxide polishing suspensions to keep the suspension on the polishing cloth. AbraPol-30...

  • Page 34: Changing A Preparation Method

    You can change an existing preparation method. If you wish to change a Struers Metalog Guide methods, you must save the method under another name and in a different group in the User Methods database before you can make any changes.

  • Page 35: Setting Dosing Levels

    Clamping and leveling specimens The specimens must be evenly distributed in the specimen holder. They must be of approximately the same size and weight. The specimen holder must be balanced. If it is not, it will result in excess vibration during grinding. AbraPol-30...

  • Page 36: Inserting Or Removing The Specimen Holder

    At the same time, use the heel of your hand to press and hold down the flange. Support the specimen holder with one hand while you lower it to release it from the coupling. Release the flange and remove the specimen holder. AbraPol-30...

  • Page 37: Adjusting The Specimen Holder Position

    Press F1 again to move the specimen holder up. The preparation process 6.6.1 The splash guard Manual preparation • The splash guard for manual preparation is supplied with the machine. AbraPol-30...

  • Page 38: Starting The Preparation Process

    Starting the preparation process Make sure that the splash ring is in place. If needed, press Back until the Main menu screen is shown. Select Struers methods in the Main menu. Select Automatic preparation. Select the Struers Methods menu. Select the method you wish to use.

  • Page 39: The Spin Function

    7   Maintenance and service - AbraPol-30 The specimen holder returns to its initial position. 6.6.4 The Spin function Only use the spin function to rotate the preparation disc at high speed • to remove water from the surface of the disc.

  • Page 40: General Cleaning

    The serial number and the voltage are stated on the type plate of the machine. General cleaning To ensure a longer lifetime for your machine, Struers strongly recommends regular cleaning. Note Do not use a dry cloth as the surfaces are not scratch resistant.

  • Page 41: Weekly

    7   Maintenance and service - AbraPol-30 Weekly Clean the machine regularly to avoid damage caused by abrasive grains or metal particles. Clean all painted surfaces and the control panel with a soft damp cloth and common household detergents. For heavy duty cleaning, use a heavy duty cleaning agent such as Solopol Classic.

  • Page 42: Monthly

    7   Maintenance and service - AbraPol-30 Cleaning selected tubes One by one, select the bottles you wish to clean. The status in the Select column must be set to Yes Press F1 to start the cleaning process. A pop-up message appears.

  • Page 43: Changing The Cooling Fluid

    7   Maintenance and service - AbraPol-30 7.4.2 Changing the cooling fluid Note The cooling unit fluid contains additive and grinding residue and you must not dispose of it into the waste water drain. Cooling fluid must be disposed of in compliance with local safety regulations.

  • Page 44: Testing Safety Devices

    7   Maintenance and service - AbraPol-30 Replacing the safety cover screen Note The safety cover screen must be replaced immediately if it has been weakened by collision with projectile objects or if there are visible signs of deterioration or damage.

  • Page 45: Safety Cover

    7   Maintenance and service - AbraPol-30 Test 2 Press the emergency stop. Press the Start button. If the machine starts, press the Stop button. Contact Struers Service. 7.5.3 Safety cover The cover has a safety switch system to prevent the operator from coming into contact with the moving parts of the working zone while the cover is open.
  • Page 46 7   Maintenance and service - AbraPol-30 Procedure Carefully separate the tubes at the couplings. Press the two tabs on the pump and remove the pump from the axle. Press the two tabs on the pump and remove the bottom cover of the pump.

  • Page 47: Calibrating The Pumps

    Struers.com. Service and repair Struers recommends that a regular service check be carried out yearly or after every 1500 hours of use. When the machine is started up, the display shows information about total operation time and the machines service information.

  • Page 48: Disposal

    8   Troubleshooting - AbraPol-30 Service check Struers offers a range of comprehensive maintenance plans to suit the requirements of our customers. This range of services is called ServiceGuard. The maintenance plans include equipment inspection, replacement of wear parts, adjustments/calibration for optimal operation, and a final functional test.

  • Page 49: Messages

    8   Troubleshooting - AbraPol-30 8.1.1 Messages Messages provide information about the machine’s status and minor errors. 8.1.2 Errors Errors must be corrected before operation can be continued. Press Enter to acknowledge the error/message. Error message Explanation Action Information Operation mode does not Change operation mode allow editing.
  • Page 50 8   Troubleshooting - AbraPol-30 Error message Explanation Action Question Hint Are you sure you want cannot to delete all preparation undo groups and methods? deletion groups method Press Enter to delete all the groups and methods. Struers methods are not deleted.
  • Page 51 8   Troubleshooting - AbraPol-30 Error message Explanation Action Warning If no beacon is installed, disable the beacon in the Beacon not detected! Options menu. Either check beacon If a beacon is installed: connection or disable it check the connection. in Options menu.
  • Page 52 8   Troubleshooting - AbraPol-30 Error message Explanation Action Error Something has prevented the Check the air supply. specimen mover head tried The mover head did not Make sure that nothing from moving. move correctly. obstructs the movement of the specimen mover - Check the air supply.
  • Page 53 8   Troubleshooting - AbraPol-30 Error message Explanation Action Fatal error The emergency stop button This error can appear if has been activated, but the the emergency stop Emergency stop mode internal monitoring switch is button is released very active, but monitoring not active.

  • Page 54: Technical Data

    9   Technical data Technical data Technical data - AbraPol-30 Subject Specifications Safety standards See the Declaration of Conformity Preparation discs Diameter 300 mm (12”), 350 mm (14”) Speed 40-600 rpm, in steps of 10 Power consumption 2.2 kW (2.9 Hp)
  • Page 55 Minimum cable size at maximum fuse: 3 x AWG12/2.5 mm + PE Residual Current Circuit Type B, 30 mA is required. Breaker (RCCB) Note Always follow local regulations. Software and electronics Display LCD 320 x 240 pixels Controls Touchpad/Turn/Push knob Memory FLASH-ROM/RAM/NV-RAM AbraPol-30...

  • Page 56: Safety Circuit Categories/Performance Level

    Total vibration exposure to upper parts of the body does not exceed 2.5 m/s Safety Related Parts of the Control System (SRP/CS) WARNING Safety critical components must be replaced after a maximum lifetime of 20 years. Contact Struers Service. AbraPol-30...
  • Page 57 SRP/CS (safety-related parts of a control system) are parts that have an influence on safe operation of the machine. Note Replacement of safety critical components must only be performed by a Struers engineer or a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.).

  • Page 58: Diagrams

    9.5.1 Diagrams - AbraPol-30 Title AbraPol-30, Block diagram 16303050 C AbraPol-30, Circuit diagram, 5 pages 16303102 D - Page 1 16303102 D - Page 2 16303102 D - Page 3 16303102 D - Page 4 16303102 D - Page 5...
  • Page 59 +45 44 600 800 telephone: +45 44 600 800 telephone: +45 44 600 800 HQ1 removed X2, Auxilliary X3, Connector for X4, Connector X5, Connector AbraPol-30, Block Diagram AbraPol-30, Block Diagram AbraPol-30, Block Diagram Connector Beacon for LAN for Service Size...
  • Page 60 Denmark (AWG14) Rev. C (2019-11-08) CZO (AWG14) (AWG14) W14 renamed to W30 AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) 3x200-240V / 50-60Hz 3x 35 AT 3x 20 AT (CC)
  • Page 61 Rev. C (2019-11-08) CZO telephone: +45 44 600 800 telephone: +45 44 600 800 telephone: +45 44 600 800 W14 renamed to W30 AbraPol-30, Circuit Diagram (Power to unlock) Rev. D (2020-05-06) CZO - Control Voltage Connector X20 changed to 4-pol Size...
  • Page 62 +45 44 600 800 +45 44 600 800 +45 44 600 800 W14 renamed to W30 AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) Rev. D (2020-05-06) CZO - Inputs and outputs...
  • Page 63 +45 44 600 800 +45 44 600 800 YE = yellow W14 renamed to W30 AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) AbraPol-30, Circuit Diagram (Power to unlock) GN = green Rev. D (2020-05-06) CZO...
  • Page 64 Rev. C (2019-11-08) CZO telephone: +45 44 600 800 telephone: +45 44 600 800 telephone: +45 44 600 800 W14 renamed to W30 AbraPol-30, Circuit diagram (Power to unlock) 24V-S3 Interlock protected 24Vdc Rev. D (2020-05-06) CZO - Safety related circuits...
  • Page 65 Draw. Init Appr. date Appr. Init yyyy-mm-dd yyyy-mm-dd Material: Scale: Format: Tolerance: DS/ISO 2768 - Weight : Description: Rev: Pederstrupvej 84 DK-2750 Ballerup Copenhagen 16302005 Water connect. diagram AbraPol-30 Denmark Phone :+45 44600 800 Fax : +45 44600 804 AbraPol-30...
  • Page 66 9   Technical data 16302002 A l n I l i P t f i o i t t i n t i n : l a : e l o i t e l l AbraPol-30...

  • Page 67: Legal And Regulatory Information

    Residual current circuit breaker • Compressed air supply Accessories and consumables Required accessories and consumables that have been ordered separately. The use of Struers consumables is recommended. • Preparation discs • Specimen holder For information about the available range, see: •...

  • Page 68: Packaging Specifications

    Illumination Make sure that the machine is adequately lit up. A minimum of 300 Lumen is recommended to illuminate the controls and other work areas. Ambient conditions Operating environment Surrounding 5-40°C/40-105°F temperature Humidity Max. 90 % RH non- condensing AbraPol-30...

  • Page 69: Dimensions

    10   Pre-installation checklist 10.4 Dimensions Side view 163 cm/5'4" (without beacon) 193 cm/6' 4" (with beacon) 84 cm/2'9" Front view 163 cm/5' 4" (without beacon) 193 cm/6' 4" (with beacon) 97 cm/ 3'2" AbraPol-30...

  • Page 70: Recommended Space

    • 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. AbraPol-30...

  • Page 71: Long-Term Storage Or Shipping

    10   Pre-installation checklist 10.6.1 Long-term storage or shipping Note Struers recommends that all original packaging and fittings are kept for future use. • Clean the machine and all accessories thoroughly. • Disconnect the unit from the electrical power supply. •...
  • Page 72 Output, main motor 200-240 V: 2.2 kW Max. load 200-240 V: 20 A Voltage/frequency: 3 x 380-480 V/50-60 Hz Power consumption 380-480 V/50-60 Hz: 3 kW Output, main motor 380-480 V/50-60 Hz: 2.2 kW Max. load 380-480 V/50-60 Hz: 11 A AbraPol-30...

  • Page 73: 10.10 Safety Specifications

    Water supply specifications Water pressure 1 to 4 bar/14.5 to 58 psi Water flow min 10 l/min (2.6 gpm) Hose supplied Diameter: ¾”. Length: 2 m/6.5". With standard connector Tube connection ¾" British Standard pipe thread. A recirculation unit is recommended. AbraPol-30...

  • Page 74: 10.12 Compressed Air

    /h) at 0 mm (0") water gauge. An exhaust system is required when working with alcohol- based suspensions or lubricants. 10.14 Recirculation unit (option) The use of a Struers recirculation unit is recommended. The recirculation unit includes • a recirculation pump •...

  • Page 75: 11 Manufacturer

    11   Manufacturer Required Struers recommends adding a Struers anti-corrosion additive to the cooling water. 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.

  • Page 76: Declaration Of Conformity

    Based on: 16307902 A Struers ApS Pederstrupvej 84 DK-2750 Ballerup, Denmark Declaration of Conformity EU / UE / EL / EC / EE / ES / EÚ / AB Manufacturer / Производител / Výrobce / Producent / Hersteller / Κατασκευαστής / Fabricante / Tootja / Valmistaja / Fabricant / Proizvođač / Gyártó / Fabbricante / Gamintojas / Ražotājs / Fabrikant / Producent / Fabricante / Producătorul / Výrobca / Proizvajalec / Tillverkare / 販売...

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