Abrapol-2
Contents
1. zi X6 4 52 EH p lt iv Biz d s 39R E o 7 8 v M S DOWN PELO i EP aud t5 Y mA Ss eot j lee f PAO 7 30mA yu E A oe 22 0 5 E 5 Lh SE Out ye ai fe FLIP en V TE ss o Kh 3 6 H PB START PA2 o 4 4 RLS lt 53 3 EMERG E e E N C 5 HP 5 T m i 30 mA uns vios AB MI 7 STAND ma 303 257 po tema vs 29 Zn 8 GREEN 96 7 3 i BR Te 298 12 5 STOP ac P 8110 W 3 3031 8102 woe 29 D Ph i 1 155 Ro3 107 COMM B PAS 20 5 e INPUTS 2 GREEN MEAS Se 6 eu 8 i DOSER 5 26 UNIT pie PRO x pon n E KZ p i few E SPARE Par lt 16 15 2K amp m RU Moon Kos R19 Joes2. 21004326 1 2 3 Mcex2 4 MC6 x 20 8 1 5 16 IK 11 10 WN 5 12 3 20 Pneumatic Parts Fig 20 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 1 ere retener ree 368M P 330 2 Throttle sound absorber 422M P024 3 Manotmeter en re i 14229027 4 Solenoid valve eene 260M P012 6 Quick exhaust 14222900 Filter reduction valve unit SMC 375MP 199 Filter glass for 375MP 199 381MP 435 8 Reduction valve 2Y R00003 9 Non reurmvalve enn 260M 127 10 Non return hbrotlevalve eene 260M P128 Abrapol 2 Spare Parts and Diagrams 21 Pneumatic Diagram Pos and Description Spare Part No Fig 21 Drawing 14220236 22 Contactor Box Fig 22 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 1 Thermo relay F1 200 240 381M P234 Thermo relay 1 380 480 394M P 0508 2 Thermo relay F2 200 240 394M P049C Thermo relay F2 380 480V 381M P234 3 Mains noisefilter
3. 4 1 1 rE CA d Si 1 e 8 5 170 PA 5 220 PA 98 x 240 D 8 x 310 8 x 240 125 PA 98 x 315 ss 0202218 PA 8 300 Pneumatik monteringstegn 14220 231K Motor protection fuse setting Motor schutz Einstellung R lage du fusible prot geant le moteur mos n os ETT LI 0 5 2 0 4 0 4 0 4 0 4 Matr Overfi beh M lforhold ikke ang tol efter 05 150 2768 e 2002 415 opdaterst Projektionsmetode Dato Sign 18 11 98 7 ers de Tegn 170889 BMJ B F2 A alle verdier endr undt 500 50 Kontr 1 70889 v H 040196 BAN Indstilling af termosikring Erst 200V 50 60tilf 090392 2 14221045C
4. 3 PAV AD Ob cm 3 Checking the Contents of Packing of Accessories 3 Recirculation Cooling conet ent 3 Dosing Unit erri ttr rta nde Rx niet 3 Solenoid 3 Drip Vo dfe ro sass 3 leg 4 Abrapol 2 4 Getting Acquainted with 2 5 Front of Ee KEE 5 fOe 6 Direction of Rotation EE 6 Supplying Compressed Air 6 Mounting a Recirculation Cooling Unit Accessory 6 Mounting Solenoid Valve 7 Mounting a Dosing Unit 550 7 Mounting a Drip Lubricator 7 Mounting Microstop 7 2 Operation IJ sing Ehe hs ies heiratete ta tend 8 Buttons Adjusting Knobs 8 Front Panel e 9 2486 9 E Ee 11 Programming a Preparation 5 11 When Grinding with Water 11 When Grinding pol
5. 19 Lubricant Nozzles 19 Manual Lubrication 19 LUD Gatton Chart aieo eer rene 20 4 Machine Adjustments Adjustment of counter pressure 21 Adjustment of 5 21 Adjustment of brake action in bottom position of vertical movement 5 eio Gata oes 21 Adjustment of 21 5 Trouble shooting 22 Oe Technical Data 24 15 16 Abrapol 2 Instruction Manual 1 Accessories and Consumables Specification Code Cooling unit Additive Bottle with 1 litre additive for cooling fluid Recirculating cooling unit complete 3 phased TRECI ADDUN Dosing unit Dosing unit for 2 lubricants and 3 suspensions complete DOTWO Water valve Magnet valve for control of tap water supply complete Connection Kit for Multidoser ABVEN material Serial no gt 260 1383 MULAT Drip lubricator Holder for one lubricant bottle with valve for ON OFF ABPYR mechanical regulation of quantity Microstop For stopping the process after removal of the required ABKRO Grinding polishing disc Wet grinding disc aluminium for 9305 mm SiC paper DP polishing disc aluminium ROTAL 300 mm 12 Petrodisc M 290 mm 8 for 200 mm specimen holder 0230 mm 9 for 160 mm speci
6. 3 x 480V 60Hz max 3 6 1 6 6 0 2 Maximum consumption approx 20 550W 0 75 hp at disc rotation 150 rpm 1100W 1 5 hp at disc rotation 300 150 W 0 2 hp Disc 150 rpm or 300 rpm Specimen holder 150 rpm 50 700 N From 0 05 to 99 55 min at 0 05 min intervals Height 1420 mm Length 850 mm Depth 510 mm Weight 250 kg The noise level of the machine is 55 dB A measured at idle running at a distance of 1 m 39 4 from the machine 204 60204 1 VDE 0113 110 W 64 l min 1 water column pressure at 0 1 atm Height 410 mm Length 400 mm Depth 500 mm Weight about 7 2 kg 44 Abra 00 Pr EN tm Date of Release 18 02 1999 Revised 09 06 2000 5 pare Parts and Diagrams Abrapol 2 Spare Parts and Diagrams Always state Serial No and Voltage frequency if you have technical questions or when ordering spare parts The following restrictions should be observed as violation of the restrictions may cause cancellation of Struers legal obligations Instruction Manuals Struers Instruction Manual may only be used in connection with Struers equipment covered by the Instruction Manual Service Manuals Struers Service Manual may only be used by a trained technician authorised by Struers The Service Manual may only be used in connection with Struers equipment covered by the Service Manual Struers assumes no responsibility for errors in the manual text
7. 8108 ef 2 gel E EN 2 ve SEES YA pe 2 quin 1 42 ve F oreen Cr 3 s FE Die VE lm if GREEN cue SV Gn PL REL E 18 4 5 m R LURNI aga 1 22 6 p um WOREEN benUr 1 Pen 041763 vta8 9v 144007 122 KEN SUPERELEX 25 PUA bl Y3 Y4 Y5 Y6 Y7 185 170 Nr i begge ender PU 3 bl 200 PU 3 bl T EE RO Suspensionen 222 PU 3 bk PRSE ep m PU 3 bk 1 gu 15 qued Y Solenoid Valves gt 600 Magnet Ventile P Pumps Pumpen blue Air lt blau Luft E 5 m a bk black Liquid 8 5 schwarz Fl ssigkeit Slo Elo Elo zim Zim zio zio wje uie ikke ang ruheder ikke ang tolerancer brapol 2 tilbeh r Dosersystem GB D Navn Bre 22 232 222223 STRUERS 5 LUB 1 LUB 2 SUSP 1 SUSP2 SUSP 3 i type Erst Pneumatic Diagram 203 Pneumatik Diagramm 14220536 A eneen HUSK Skive under lag 60 e Omnifit 100M Just til 6bar 5 8 1 8 1 56 g ge t
8. No suspension escapes the nozzles The nozzles are blocked The suspensions do not have the right viscosity Clean the nozzles You are using suspensions not manufactured by Struers Change to the original Struers suspensions The suspensions are too old Change the suspensions The suspension bottles have not been shaken for a long time Shake the bottles Centre of specimen not polished after previous grinding on Petrodisc M or diamond grinding disc The polishing suddenly takes more time The specimens go too far beyond the outer edge of the grinding disc The polishing cloth is filled up with removed material The suspension ability has deteriorated and the diamonds sink to the bottom Adjust the position of the specimen holder disc in proportion to the grinding disc Change polishing cloth Shake the suspension bottle The supply of coolant is inadequate 22 The cooling pump rotates the wrong way Change two phases in the electric connection of the pump There is no water in the tank Fill up with water and additive Abrapol 2 Instruction Manual Error Cause Action The grinding paper is torn up by Excessive grinding pressure contact with the specimens Reduce the pressure with the The specimens are not at the same level reduction valve fig 1 7 Use Struers levelling apparatus Soft and brittle specimens
9. OEAH 2 2 02 15 44315 14315 4315 310 5 24505 ia QY ZOEAH 9 q 9 IX 54915 14315 U3IVA 14505 pen NO NO OLEAH 60EAH LOEAH 0 706 P EOEd PZOEd PIOEd OX LA 9A SA 7A EA AA OA sa 913 Ten 1913 20 87i7NI S gek 9 t x EOEA NVOS 5 o So 5 LOEA DAN 7064 00 EE io 2 N 20 4 OAT poe ee 4 NH 1069 o z om DEER E A UA BRB Sa SEN o 8 dp 6 j 5 5 q 4 Nanay Ox 2222 s Ed oot o 00 o9 00 o 7 N 9 ILONV I 0 1 10 1 Mie Ka LOEVH 915 335 20 QU S za zo mE 7 YOLOSNNOD om ash un on un 08 HOLIMS Se HMM AN 9x sx 7 amp zx Aer XISLVW 031 VEA Nae SEE Sane Rep A g SOEA LOEA 3051 n n 1 7 9 E 7 T 9 amp 4 6 at Si 9t 72 52 92 ei ZOEX 0 ev ov t8 ig SA 9A 015 Oy 42 dee SE Peaga rg I LS 215 5 VIVG S 95 S3NI1NV2S SINN NYNLIJY
10. Abrapol 2 dna Instruction Manual Abrapol 2 Instruction Manual Table of Contents Page SOR Ded emere ehe cede Reference Guide 15 Always state Serial No and Voltage frequency if you have technical questions or when ordering spare parts You will find the Serial No and Voltage on the type plate of the machine itself We may also need the Date and Article No of the manual This information is found on the front cover The following restrictions should be observed as violation of the restrictions may cause cancellation of Struers legal obligations Instruction Manuals Struers Instruction Manual may only be used in connection with Struers equipment covered by the Instruction Manual Service Manuals Struers Service Manual may only be used by a trained technician authorised by Struers The Service Manual may only be used in connection with Struers equipment covered by the Service Manual Struers assumes no responsibility for errors in the manual text illustrations The information in this manual is subject to changes without notice The manual may mention accessories or parts not included in the present version of the equipment The contents of this manual is the property of Struers Reproduction of any part of this manual without the written permission of Struers is not allowed All rights reserved Struers 2002 Struers A S Valhejs All 176 DK 2610 Redo
11. Press Create in MODE Remove the plastic suspension supply tube from suspension nozzle 3 Manually activate ABRASIVE for 5 seconds with a beaker under the nozzle Refill tube Repeat procedure for SUSP 2 and SUSP 1 Check if the supply of coolant in the tank is sufficient and not too contaminated Must be performed every week or before breaks longer than 24 hours The cleaning should be carried out in the following order 1 2 e Take a bottle of lukewarm water Replace the 1um suspension bottle with the water bottle If lum suspension is not used choose the finest diamond suspension used This should correspond to SUSP 3 Press Create in the MODE Press key for step no 1in CHOICE Press SUSP 3in DATA Press SUSP in Manual Control and hold a beaker under the nozzle to avoid water splashing on the cloth Press for 5 10 seconds Move the bottle with water from suspension to Zum suspension Press SUSP 2 corresponding to suspension Repeat point 6 Repeat point 7 for suspension SUSP 1 Abrapol 2 Instruction Manual Yearly V belts Check regularly and at least once a year that the V belts are tight Adjust if necessary General Cleaning The machine and the recirculating cooling system should be kept as clean as possible order to avoid contamination of the specimens Cooling Tank Every time water is changed the cooling tank should be cleaned carefully to remove all grindin
12. 394M P045 4 5 Thermo relay 3 F 4 200 240 381M P233 Thermo relay 3 F 4 380 480V 375M P 263B 6 Transformer T1 state voltage 394M P043 EN Fk jme 25 00149 8 FuseF12 25 RFU 14000 9 F seF 11 LO AT 10 pcs 422M P027 10 Auxiliary switch for seras 381M P237 11 Contactor K1 K2 i a eres 376MP110 23 Circuit Boards Fig 23 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 1 Display Board ores eee 422M POLO 2 CPU 422M POM PROMP latest version 422M P040 3 Interface Power Supply BOB do 422M P012 4 3 pole cabled plug for solenoid valve 422 029 5 9 pole cabled plug for solenoid 422M P030 Fuse F5 2 5 422MP031 Fuse PCB F6 1 6 422 032 Mains switch 013 472 Haupt 52 schaiter rm eae ee Supply conductor and machine curent protection Sicherungen f r Hauptkabel und e 20 Not supplied by Struers Nicht von Struers geliefert gn wh bk bk black schwarz bn browns braun ye gn yellow green gelb gr n Noise filter St rftter __ 21 bk
13. Editing a Preparation Method Mounting a Preparation Disc 12 Name of Cloth Recommended Dosing Levels Lubricant Suspensions DP Plan 3 5 Abrapol 2 Instruction Manual The table gives examples of recommended dosing levels for 7 different polishing cloths with different resilience Remember that these examples are Struers recommendations and therefore adjustments may be needed according to the requirements of the specimens to be prepared DP Pan DP Dur 02 OO DP Dac 6 DP Plus 8 DP Mol 8 5 DP Nap 8 5 m Set the machineto CREATE mode Press the key the preparation step which should be edited Enter the required changes by means of the Data Keys W Placethe program card for the material to be prepared on the two pins on the front plate so that is covers the Choice Program The keys can be activated through the card and a light diode shows when a key is selected m Press AUTO mode Press CLEAR to cancel existing step sequence Select a preparation method by pressing the relevant PREPARATION STEP KEYS in the correct sequence The light diode for the first selected step turns green and the following steps turn red indicating that the step to be activated when the machine is started is the step with the green light The programmed data for this step can now be read on the data keys Set the AUTO mode Press CLEAR to delete any existing sequ
14. SE tegnet CAD Trafo deit i 2 t 90 HSB ee 16 8 98 BM ee ee FS F1t 5 eg Malforhold fikke ang tol efter 05 150 2768 L Loss sign th freg 110498 BRY SY 52 5 kd o wor gt gt e gn X11 8 X12 30 4 38 X13 Q t D THO m Lo Sern 2 ex 2 i 5 J E lt 1111 11111 1 1 1111 1 io N lt we 5 o 1 SQ T3 eg wg 3x18 Interface Board w8 10 T Y S4 AIR M S Up Down Down a 5 5 7 UJ ae Valid es S9 d do D x10 tekst ou Tora 29 49 BOIS 27 C spot tri o skip TA gt M lestok Overtiadebehandi E 2 Matr E S STRUERS me BOS TIE I TES Of EK ee t3 gt p B X pateant 201285 5214 nr 02687659 Primary Supply Primary Supply Prim r Versorgung Prim r Versorgung 100V AC 110 115V AC 115V 0 100V I F 0 63A 100V II Primary Supply Primary Supply Prim r Versorgung Versorgung 200V 215 220V AC 115V 115V I F 0 33A I 200V II 215 220V Primary Supply Prim
15. as indicated with a light diode Start the flow of water independently of a preparation step by pressing the key WATER amp in Manual Functions If lubricant and suspension are selected in the Data Program water cannot be selected To be able to give manual dosing of lubricant and suspension you should first choose the type of lubricant and suspension you want to use in the data field and also set the dosing level Y ou can now press the key LUBRICANT and the key SUSPENSION af in Manual Functions The dosing will be at maximum for as long as the key is pressed Stop the disc and water by pressing the key STOP or by pressing the key DISC D and the key WATER Abrapol 2 Instruction Manual Reference Guide Table of Contents Page 1 Accessories and Consumables 16 2 Struers Metalog Guide 17 3 Maintenance M 18 SUSPENSION 165 rene 18 Cleaning of nozzles 18 Week ya A AERE CARY INR EA NUR cane 18 ee M 18 Extended Cleaning of Nozzles and Tubes 18 19 19 General Cleaning npo tre e rc n aer n t 19 Cooling oer 19 Painted Surfaces 19 AIF ue E E
16. for Abra armi ue entire 12600312 27 Flexible water nozzle complete 42M P003 Abrapol 2 Spare Parts and Diagrams Fig 19 Drawing 000 900 19A Abrapol 2 Fig 19A Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No Bearing unit complete but without turntable V belt pulley and bearing flange 260M P 065 Turntable w quad ring and 4xM 8 screw holes 300mm 14590010 Axial bearing 2100 2135 x 25 260M P017 Shell ALBIDA LX 381MP415 Bearing ern rre 260M P 197 Roller bearing upper 6007 260M P018 V belt pulley please state frequency 260M P 068 Roller bearing lower 6007RS 260M P018 Bush for V belt 260M P069 Seeger ring 1 62 X 2 tuere innen 260M P019 Seeger ring U 35 x 1 5 etre 260M P067 Bearing protection 260M P 183 V ring ase ep eene ret 260MP 184 Thrust collar set of 4 315MP 059 QUGSQ ETDQ inr nate end te ern in nte 21Q04450 Ee Lu Le BEE 21Q04441
17. illustrations The information in this manual is subject to changes without notice The manual may mention accessories or parts not included in the present version of the equipment The contents of this manual is the property of Struers Reproduction of any part of this manual without the written permission of Struers is not allowed All rights reserved Struers 2000 Struers A S Valhejs All 176 DK 2610 Redovre Copenhagen Denmark Telephone 45 36 70 35 00 Telefax 45 38 27 27 01 Abrapol 2 Spare Parts and Diagrams 1 Spare parts and Diagrams Table of contents Drawing Front Controls Placing the program card Inserting the specimen holder Main switch Non return valve Connection of recirculating pump Valve for mains water Dosing unit 10 Dosing unit connection 11 Drip lubricator 12 Microstop 13 Contents of packing case 14 Recirculating Cooling Unit 15 Valve for mains water 16 Dosing unit 17 Drip lubricator 18 Microstop 19 Abrapol 2 20 Pneumatic parts 21 Pneumatic diagram 22 Contactor box 23 Circuit boards Photos and drawings Diagrams 24 Circuit diagram for mains voltage 14221007G 25 Wiring Diagram Contactor Box 14221012H Control Voltage Wiring Diagram 14221034D 26 Connecting Diagram Supply Voltage 100 230V 14221013A 27 Control Voltage Circuit Diagram 142
18. screw adjusts the braking action of the up down unit when it returns to its initial top position Normal adjustment of the down speed brake action is approx 1 8 turn from the home position Adjustment is very delicate because the braking action should not prevent the specimen holder from contact with the grinding disc when working at a low process pressure This may cause problems particularly with thin specimens therefore specimens should always protrude approx 2 5 mm from the specimen holder After loosening the two screws fig 19 10 the position of the quick coupling on the shaft can be vertically adjusted Mounting the quick coupling too close to the shaft end may transmit the grinding pressure to the specimen holder through the two lock balls This would damage the specimen holder stud and make removal of the specimen holder difficult Incorrect mounting can be noticed either by measuring or by the fact that the lock slots of the specimen holder studs have become smooth from wear 21 Error Cause Abrapol 2 Instruction Manual 5 Trouble shooting Action Display shows ES The emergency stop button has been activated Emergency Stop Release the emergency stop button by pulling the button One of the motors has been overloaded Wait till ES disappears from the display Reduce the grinding and polishing pressure If ES immediately appears again a phase is missing or the motor is defective
19. to adjust the flow on the water tap LUBRI CANT KD SUSPEN SION 42 MICRO STOP CLEAR AUTO LUBRI CANT 21 SUSPEN SION Key Auto _ gt Function Activates the dosing of lubricant Choose between bottle 1 2 Activates the dosing of suspension Choose between bottle 1 3 Activates Microstop The present preparation sequence is deleted when AUTO is activated When transferring a preparation method or if you want to clear a sequence AUTO mode should be activated Activates the dosing of the selected lubricant Activates the dosing of the selected suspension Program Cards Programming a Preparation Step When Grinding with Water When Grinding Polishing with Lubricant Abrapol 2 Instruction Manual The program cards supplied with the machine are used for filling in data about the preparation method of a given material Data about the single preparation step should be stated on the back of the card and data about the material to be prepared as well as information about the preparation disc and force should be stated on the front of the card The card should be placed on the front panel so that it covers the Choice functions 8 different preparation steps can be programmed individually in regard of time speed of disc water type and dosing of lubricant and suspension These 8 steps can be combined in a number of different ways so that different materials can b
20. 21033D 28 Circuit Diagram Keyboard Display Board 14221052 29 Circuit Diagram In out Supply Board 14221062B 30 Pneumatic Doser 14220536A 31 Pneumatic Mounting Diagram 14220231K 32 Thermal relay 14221045C The drawings are not to scale Some of the drawings may contain position numbers not used in connection with this manual Abrapol 2 Spare Parts and Diagrams 1 Front Pos and Description Spare Part No Fig 1 Abrapol 2 Spare Parts and Diagrams 2 Controls Pos and Description Spare Part No Fig 2 3 Placing the Program Card Fig 3 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No WES SUI 394M P040 2 Front plate with touch pad keyboard 14220087 Program set 2 xo tumens 422M P040 3 Pin for program tens 422 041 d rrt rne een ti om ren 383M P020 5 Flex tube 422M P003 Abrapol 2 Spare Parts and Diagrams 4 Inserting the Specimen Holder Fig 4 Spare Parts and Diagrams Abrapol 2 5 Main Switch Fig 5 Abrapol 2 Spare Parts and Diagrams 6 Non return valve Pos and Description Spare Part No
21. Fig 6 1 Non return valve 3 4 for TRECI 260M P082 Connection of Recirculating Pump Abrapol 2 Spare Parts and Diagrams Spare Parts and Diagrams Abrapol 2 8 Valve for mains water Fig 8 Spare Parts and Diagrams Abrapol 2 9 Dosing Uni Fig 9 2 Abrapol 2 Spare Parts and Diagrams 10 Dosing Unit Connection Fig 10 Abrapol 2 Spare Parts and Diagrams 11 Drip lubricator Fig 11 Spare Parts and Diagrams Abrapol 2 12 Microstop Fig 12 2 55 2 Abrapol 2 Spare Parts and Diagrams 13 Contents of Packing Case Pos and Description Spare Part No Fig 13 3 Water hose 1 2 1 RNU 29316 D 2 Qoo DP disc or MD disc to be ordered separately Abrapol 2 Spare Parts and Diagrams 14 Recirculating Cooling Unit Fig 14 Fig 14 15 Valve for Mains Water Fig 15 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 1 ABVEN Solenoid valve complete 5OHz 04226902 1 ABVEN Solenoid valve complete 60Hz 04226903 5a Solenoid 50H KEE 375M P192 5a Solenoid TEE 375MP193 5b Solenoid valve for water 50 2 422M P 004A 5b Solenoid valve for water 422M P 004B 6 3
22. G RE 16 6 25uH k 50 2 19 bk3 bk2 bk F1 fos je 9 9 9 95 97 3 Varistor S10V 510 550 k6 bk Al ye gn Connections for Struers recirc pump 3x U 0 13 kW Anschluss f r Struers Rezirkulationspumpe 3x 0 13 kW bk3 15 2 bkt 3xU 0 15 0 18 Sample mover motor Probenhaiter Motor 510 510 550 F9 Mr bk3 bk2 bk3 bk2 96 16 95 97 95 97 0 DN Voltage 35V Control Netz Voltage K3 spannung Steuer 24V spannung T1 3 Varistor 510 S10K550 F10 See Fuse setting Table F1 F4 Sehe Sicherungstabelle All wirings 19 Polishing disc motor Polierscheibe Motor D dere den See Fuse Controt Vollage 1 13 Abrapol 2 STRUERS 45 mas Circuit Diagram for Mains Voltage Schaltplan f r Netzspannung 465 a6 Lean 57 id gt ble ER pias 4 gt F 20A 5 12 97 81 a el 8 Ei E 3 220 500 See connecting diagram Sehe Verbindungs schaltplan Connections for Struers Rec Pump 12 Beie BD Noise Filter Control voltage trafo 100 230V Steuerspannungstrafo BK BK6 380 500V 5 Lus 2204 v Ti rd7 v X2 tif 23 9 96BMJ E Fig 1 6 gt 2 5 8
23. Specimen holder lowered too fast especially if the specimens project more than 6 mm over the edge Use adhesive grinding paper or dummy specimen over the whole surface of the grinding paper The speed of the downward movement is controlled by a throttle valve fig 20 8 Adjust the speed by turning the screw at the top of the valve clockwise for decreasing and counter clockwise for increasing the speed Incorrect adjustment of the shock reduction device in the compressed air cylinder Display shows NO AIR Missing or incomplete air supply Display defective Defect in the circuit of the display or Adjust the screw on the cylinder Access through the lower hole in the side plate behind the bottles if doser unit is mounted Normal setting 1 8 rotation from the starting point Check that air hoses are tight and properly clamped Replace the display defect in the CPU circuit 23 Abrapol 2 Voltage frequency Internal fuse Entry pressure Main motor Specimen holder motor Rotational speed Vertical working pressure Timer intervals Dimensions and Weight Noise L evel Safety standard Recirculating Cooling Unit M otor Pump Dimensions and Weight Standard 24 Abrapol 2 Instruction Manual 6 Technical Data 3 x 200V 50 60Hz max 6 8A 3 x 220V 50 60Hz max 2A 3 x 380V 50Hz max 3 8 3 x 415V 50Hz max 3 6A x 440V 60Hz 3 5
24. T B 7 6 B 2 X10 2 X10 3 5 8 5 SIGN FOR CBE LIEU 5 W2 rda rd37 m 0120 7 5 1 226 NO 13 3 X7 13 une 5 TE RL enl R4 UMS 7 12 5112 U122 RL2 Zus 1 gt 3 7 10 amp 0 5 01245 5 L 5 7 9 e U125 RLS 2 A 3 X6 4 E89 Y d 37 5 EE ip rdt NEP dep m L M 2 W5 ye gn From ei E E a Contactor z Be Le a HS ZA ESA nd W 7 7 444 ut rda2 l wg rds 3 START B EMERG STOP 2 9 STAND BY M S STOP W103rd2 W103 Spare Parts and Diagrams Abrapol 2 5031 22228 ve 0035 2 1 E E 94315 74315 QW OEA ELEAH dp 84315 74315 NO NO ELEAH Zx3 L0 AH 6 6 6 6 19 14315 64315 E dY GY ZIEAH _ LX3i 90 3 1 19 Ld3is 4 151 00 NO NO ZLEAH SOEAH 8 4315 24315 5519 D I WA SLEAH LEAH 70EAH Be E Pros EX 94315 24516 4316 041 tdSns dissi NO SIEAH NO HEAH
25. aration can be read on the display When the time has elapsed the preparation disc will automa tically stop and the specimen holder will return to its initial position The light diode for the next preparation step in the se quence turns green The machine is now ready for the next step A preparation step can be stopped at any time during the process by pressing the key STOP in Manual Functions 13 Setting Microstop Manual Functions When Grinding with Water When Grinding Polishing with Lubricant 14 Abrapol 2 Instruction Manual Press the key MICROSTOP in the Data field Press both start buttons The specimen holder is activated independently of the disc and moves downwards without being rotated Turn the micrometer screw clockwise until STOP is read on the display Press the key STOP The specimen holder moves upwards toits initial position Turn the micrometer screw counter clockwise corresponding tothe required removal IMPORTANT When Microstop is activated the machine does not automatically proceed to the next step Press the key STOP and the next step will switch from red to green Manual operations are possible as the disc can run independently of the specimen holder The manual functions are found on the lower right corner of the front panel indicated with 2 Start the disc separately by pressing the key DISC O The disc will operate according to the pre set speed 150 rpm or 300 rpm
26. bottom position of vertical movement Adjustment of quick coupling Abrapol 2 Instruction Manual 4 Machine Adjustments The Adjustments listed below are only required after repairs or service Counter pressure is the pressure on the primary side of the compressed air cylinder which counterbalances the weight of the up down unit The counter pressure returns the unit to its initial top position It is adjusted by a reduction valve fig 20b 8 The correct pressure is 2 7 bar when using air to eliminate hysteresis Measure with a precision manometer The Down speed is adjusted by an adjustable throttle valve fig 10 4 normal position of the valve being approx 1 3 4 turn from home position To obtain faster travel turn the valve approx 1 4 turn Screwing the valve beyond the latter position may cause problems in the form of excessive initial grinding pressure for approx 1 4 1 sec involving a risk of the specimen tearing the grinding paper or polishing cloth When specimens are protruding more than 6 mm from the sample holder disc the brake See below does not work and in this case the throttle valve fig 10 4 is closed 1 2 to 1 turn to reduce the down speed The brake incorporated in the compressed air cylinder comes into operation 5 10 mm above the polishing disc depending on how far specimens protrude from the specimen holder Access to the adjusting screw is gained through two holes at the left side plate The upper
27. box contact plug ind 422M P005 Fig 15 Abrapol 2 Spare Parts and Diagrams 16 Dosing Unit Pos and Description Spare Part No Fig 16 1 Bottle 1L cap with 376M P084 Cap plate for lubricant bottle 1000 375MP 028 2 9 pole box ind contact plug 422M P008 3 Water rri tee idera dann 435MP017 4 Lubricant pump 375M P025 5 Box without valves 422M P006 Solenoid 375M P187 O ring 810 82 1 78 10 130M P057 Air tube 05 03 2 2m 375M P178 6 Suspension bottle 250 375M P027 Non return valve for cap 422M P018 Cap plate for suspension bottle 250 422 017 13 DP Suspension nozzle complete 375MP031 14 Lubricant nozzle 375M P032 15 Nozzle holder plate 422M P013 Nozzle DOW Gents 422M P014 Lubricant pump Cormmplete 375MP025 Throttle gauge for air tubing suspension noz
28. e prepared without having to repeat the programming Set the machineto CREATE mode Press the PREPARATION STEP KEY 1to8 Set the time by pressing the key TIME UP or TIME DOWN The preset time be read on the display W Set the speed of disc to either 150 rpm or 300 rpm by pressing the key SPEED respectively on the left side of the key to select 150 rpm and on the right side to select 300 rpm NB The speed of disc will automatically be pre set to 150 rpm when an unprogrammed preparation step key is pressed Select water supply by pressing the key WATER Select the type of lubricant needed for the step by pressing one of the two LUBRICANT keys Lub 1 or Lub 2 gt When one of the lubricant keys has been activated the display left shows level 0 Set the dosing level 0 10 by pressing the selected lubricant key again Each time you press the dosing level increases see table below for Recommended Dosing Levels Select the suspension needed for the step by pressing one of the three SUSPENSION keys Susp 1 f Susp 2 or Susp 3 When one of the suspension keys has been activated the display right shows level 0 Set the dosing level 0 10 by pressing the selected suspension key Each time you press the dosing level increases see table below for Recommended Dosing Levels 11 Recommended Dosing Levels Editing a Preparation Step Transferring a Preparation Method
29. ence W Select a new sequence with the PREPARATION STEP KEYS Placethe disc on the turntable and move it until the three pins engage with the holes in the turntable Inserting the Specimen Holder Adjusting the Specimen Holder Position Adjusting the Force Starting the Preparation Process When grinding with Water When Grinding Polishing with Lubricant Stopping the Preparation Process Abrapol 2 Instruction Manual Place the specimen holder under the quick coupling Press and hold the black flange of the column down with your thumbs while guiding the pressure tap of the specimen holder into the coupling Release the black flange Turn the specimen holder until the three pins engage with the corresponding holes The position of the specimen holder has to be adjusted correctly in relation to the preparation disc to get the best possible preparation results Loosen the two handles placed on each side of the specimen holder motor The specimen holder motor can now be moved manually to the sides The eccentricity can be read on the scale placed on the specimen holder motor When the correct position is found fasten the handles again Turn the adjusting knob to set the required force Start the preparation step by pressing the two start buttons simultaneously until specimen holder starts rotating Regulate the water flow on the tap Adjust the dosing valve of the drip lubricator The remaining time of prep
30. g waste Cleaning will be easier if Struers plastic inserts are used Remember to add Additive for Cooling Fluid IMPORTANT Do not use benzine or petroleum for cleaning when the additive is used Painted Surfaces Painted surfaces and keyboard should be cleaned with a moist cloth and common household detergents IMPORTANT Never use alcohol acetone or similar solvents Air Filter The air filter should cleaned regularly and water the glass vessel around the filter let out This is carried out by pressing the button at the bottom of the vessel Access through hole the rear plate fig 10 3 Lubricant Nozzles The lubricant nozzles can be blocked by impurities in the lubricant Removethe nozzle and try to blow it clean with compressed air blow from the point and inward If this does not help the nozzle has to be cleaned with a very fine needle under microscope Manual Lubrication Before the nozzle is remounted the whole system should be washed out by activating the M anual lubricant key 19 Abrapol 2 Instruction Manual Lubrication Chart Point of Lubrication Lubricant Interval Quick coupling Oil 200 h Surfaces of columns Oil 200h of up and down unit Grinding disc bearing Grease 2 000 h Gear of gear motor Grease 10 000 h or 2 years Grease eg Shell Albida Grease LX 20 Adjustment of Counter pressure Adjustment of Down speed Adjustment of brake action in
31. ishing with Lubricant 11 Recommended Dosing 5 12 Editing a Preparation 12 Transferring a Preparation Method 12 Editing a Preparation Method 12 Mounting a Preparation 12 Inserting the Specimen 13 Adjusting the Specimen Holder 13 the ge cT 13 Starting the Preparation Process 13 When grinding with water 13 When Grinding polishing with Lubricant 13 Abrapol 2 Instruction Manual Stopping the Preparation Process 13 Setting MICFOSEOD ees facets itte tira oe CORE eta 14 Manual aeo 14 When Grinding with Water 14 When Grinding polishing with Lubricant 14 Checking the Contents of Packing Abrapol 2 Checking the Contents of Packing of Accessories Recirculation Cooling Unit Dosing Unit DOTWO Solenoid Valve Drip Lubrica
32. men holder Specimen holders For many sizes and shapes of specimens Ask for sepa 0230 mm 9 DETOT 250 mm 10 DEDIF 9300 mm 12 DEDAL MD polishing disc aluminium 0200 mm 8 DEMLA 0250 mm 10 DEMIF DEMAL PETIL PETHA rate list Table unit for Abraplan or Abrapol 2 With cabinet and trolley for recirculating cooling unit 1 set of tubes for cooling unit LABAB Storage unit For accessories and consumables The unit consists of 2 chapters one with 8 drawers including a drawer with inserts for specimen holders and another one with 8 shelves LABCO Insert for specimen holders Fits into the specimen holder drawer of the LABCO storage unit LABOA Remember Struers offers a comprehensive range of consumables for rinding and polishing Please ask for separate leaflets Metalog Guide Abrapol 2 Instruction Manual 2 Struers Metalog Guide Struers Metalog Guide you will find a detailed description of grinding polishing methods for automated mechanical specimen preparation Struers Metalog Guide offers preparation methods for the most common materials based on a simple analysis of two key properties hardness and ductility Finding the right method is easy including choice of consumables Always consult Struers Metalog Guide for the correct preparation method for the actual specimens Struers Metalog Guide contains 6 useful chapte
33. mes of the Abrapol 2 components Base unit Specimen holder Specimen holder motor Quick clamping device Quick coupling flange Handle for adjusting specimen holder position Nozzle block Cooling water Soen e Front panel Main Switch left hand side of cabinet Standby Double start buttons Emergency stop Force selector Display Supplying Power Direction of Rotation Supplying Compressed Air Mounting a Recirculation Cooling Unit Accessory Abrapol 2 Instruction Manual IMPORTANT Check that the mains voltage corresponds to the voltage stated on the type plate on the side of the machine Mount a plug on the electric cable and connect it as follows Y ellow green earth Black brown phase Check that the preparation disc rotates counter clockwise If not change the two phases Connect the compressed air supply with the inlet the rear side of the machine by means of the air hose and the hose connection delivered with the machine Fasten the air hose with hose clamp The pressure supply should be 6 bar and should be supplied either from a central compressor portable compressor with compressed air reservoir or compressed air bottle A capacity of 20 l min at atmospheric pressure is sufficient Placethe recirculation cooling unit on either side of the machine where you find it the most convenient Mount the non return valve the pump of
34. pension nozzle 422 016 Cap plate for suspension bottle 422M P017 BEEN Y Xa Jw ME ES NSSENN 17 Drip Lubricator Fig 17 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No l 21 cero tr ones 158M P016 2 ValV needle 158MP010 3 WMalveQoutlet toner rnnt eet 158MP 005 4 Solenoid rere 376M P044 5 Nozzle with fittings reet 422M P019 8 Lubricator etnies 158 014 9 Ce vlt et 158M P015 O ring CR CHE e nuce nete nee 249M P032 10 3 pole box ind contact plug 422M P005 11 Solenoid Housing ortos 14229048 18 Microstop Fig 18 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 4 3 pole box ind contact plug 422M P005 BEE 260 202 13 Micrometer 5 260M P206 19 Abrapol 2 Fig 19 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No 1 V belt pulley state frequency 260M P 068 Bushing for V Belt pulley 260 68 260M P 069 2 Nipple and connecting 260M P168 3 Emergency stop swi
35. position until the emer SWITCH the machine GENCY gency button is released by STOP pulling the button 2 On Off switch for daily use 15 For setting the required force The pre set force can be read on STAND FORCE the manometer BY SELECTOR 13 Starts the preparation process For reading the pre set time of Press the double start button grinding polishing simultaneously until the DOUBLE DISPLAY START specimen holder starts rotating Instruction Manual Abrapol 2 Front Pand Keys Name Key Data 150 300 Disc rpm SPEED Ga Abrapol 2 Instruction Manual 9 WATER CHOICE 9 STEP KEYS MODE 15 Create CREATE de Function Sets the speed of disc Choose between 150 rom and 300 rpm Increases or decreases Y the preparation time Activates the water flow Remember to adjust the flow on the water tap 8 keys for programming the individual preparation steps With these keys a complete pre paration method can be trans fered to the machine memory To program a preparation step CREATE mode should be activated MANUAL FUNCTIONS gt D DISC STOP WATER 10 disc starts rotating independently of the specimen holder The machine is stopped at any time during the preparation process By restart the machine will start from the point where the preparation was interrupted Activates the water supply Remember
36. r Versorgung 230V AC 115V 115V 100V OV 115 2 Ed 211 717 _ Connecting Diagram Supp Volt 100 230 Verbind schaltpl Versorg sp 100 230v 4221201 3A 4503499 gt 01 24 12 88 A T1 INTERFACE BOARD P 24V X6 11 OUTPUT A1 X244 150 RPM rdi N 5 Ao DISC MOTOR K X6 10 rdi A2 1 413 2 13 W5 rd 13 PORT k2 N 1 SAMPLE MOVER 91 2 K 1 rats 25 ws rats MOTOR 2 X6 8 24V0 RECIRKPUMP 191 AA 01016216 ws cate 24 8 5 14 DI 2 el WATER s lo cus eo 3 VALVE Bega i 1215 8 AIR 951 R UP DOWN D X6 5 Word 2 wi01rd2 7 d y X102 MATRIX FOR OUTPUT LUB UNIT LUB 1 14 7 s Y 13 2 X6 3 LUB 1 a Lou H 2 Z xa x X6 2 PORT med o rdf s Ha DOSER UNITI SUSP 1 Xr P MRS ua B et 85 fT S esc 13 2 13 6 7 18 6 SUSP 2 E EI 13 2 24 13 7 X747 P SUSP 3 i 5 rd36 1 w rd zk wn rate 5 5 7 16 T Bg RLO 0119 NS 3 ZB comms W7 rdi INPU
37. rs Metalogram a quick and safe guide to the right preparation method M etalog Methods a complete catalogue of preparation methods based on Struers vast store of materialographic experience and employing Struers range of consumables Preparation Philosophy the basics of modern specimen preparation seen from a professional point of view M etalog Process the materialographic preparation process from start to finish logically explained M etalog Master a combined trouble shooting guide and supply of in depth information on the processes of mechanical preparation including an expert system for the solving of preparation problems Consumables Specification quick access to the relevant consu mables for the chosen preparation methods A complete guide to materialographic specimen preparation Contact your local dealer for a free copy of Metalog Guide 17 Daily Suspension nozzles Cleaning of nozzles alone Weekly Coolant Extended Cleaning of Nozzles and Tubes 18 Abrapol 2 Instruction Manual 3 Maintenance Shake the DP suspensions lightly every morning Blow the nozzles free from suspension every night Should be carried out whenever the machine is not operated for more than 4 6 hours as Take a bottle of lukewarm water Replace the 1um suspension bottle with the water bottle If lum suspension is not used choose the finest diamond suspension used This should correspond to SUSP 3
38. tch element 381MP440 4 Drain 260 185 5 Emergency stop push button without switch element 381M P439 7 Cap for 260M POO4 260M P005 8 Push button Start esst 260M P004 9 Splash enr ne 260M P143 Lid for 260MP 143 eo rtr eet ad 260M P144 10 Quick release coupling complete 260 027 11 Damper coupling complete 260M P080 Damper coupling with lower flanger 12600330 12 Hand 260MP155 14 Specimen holder motor state voltage and frequency 260M P 085 15 Sltding e eror ert nir rre 422M P021 16 Dial Fail era 422M P022 17 een ne 422M P023 18 MTCFOSWIECI etn recent nene 260M P009 19 Double acting compressed air cylinder 260MP 102 20 V belt pulley for main motor 260 071 21 Bushing for 260MP071 260M P072 22 Driving belt 50 HZ rei 260M P073 22 Driving belt 60 Hz 2 PCS ce e 260M P083 23 Main motor state voltage and frequency 260M P070 24 Hose complete 422M P003 25 Water Cock iuc mit m nia con nens 383M P020 26 Column
39. the recirculation cooling unit m Mount the inlet hose from the machine on the non return valve Connect the electric cable from the pump to the machine Mount the outlet hose on the underside of the tank m Mount the drain angle on the other end of the outlet hose by means of the hose fitting and lead it down intothe hole of the recirculation cooling unit Check that there is a steady fall on the whole course of the outlet hose Placea plastic the tank and fill with water and additive Abrapol 2 Instruction Manual Mounting a Solenoid Valve If no recirculation cooling unit is mounted on Abrapol 2 Accessory solenoid valve must be mounted instead Fasten the solenoid valve the rear side of the machine by means of two screws with washers W Connect the electric cable to the machine Cut theinlet hose at a distance of 100 mm from the machine and connect the part still fixed on the machine to the inlet of the valve and connect one end of the cut off part to the outlet of the valve and the other end to the water tap Mounting a Dosing Unit m Mount the dosing box the left side of Abrapol 2 by means Accessory of screws Loosen the nozzle plate and screw the nozzle holder firmly on the front plate of the machine Fasten the nozzle plate again W Connect the compressed air hose on the rear side of the machine W Connect the plug on the rear side of the machine and fasten the cable with the n
40. tor Abrapol 2 Instruction Manual Installation the packing box you should find the following parts HA NH N H H N H H B NNR PR RPP yerr Abrapol 2 complete with inlet hose cable Splash ring Lid Non return valve for recirculating Cooling Unit Outlet hose Fitting for outlet hose Hose clamps for outlet hose Hose for compressed air Hose connection for compressed air Hose clamps for compressed air Hexagon key 2 5 mm Program Cards Instruction M anual Recirculation Cooling Unit Drain angle Funnel Plastic bags Bottle holder plate Nylon Strap Screws M5x10 Screw M4x8 Washers M5 Washer M4 Lubricants Suspensions Solenoid valve with mounting plate Clamp for inlet hose Washers Screws M5x10 Lubricant bottle Mounting plate with valves and bottle holder Screws M5x10 Washers M5 Microstop Placing Abrapol 2 Abrapol 2 Instruction Manual Microswitch with mounting box Screw M 5x10 Screws M 5x16 Washers M 5 Cable damp Washer MAI Screw M 4x8 Hexagon key 4 mm Micrometer screw Instruction Manual kA DI DRM Abrapol 2 should be placed on a plane and horizontal floor The machine must be placed close to the power supply water mains and water outlet facilities Getting Acquainted with Abrapol 2 Front of Abrapol 2 Abrapol 2 Instruction Manual Take moment to familiarise yourself with the location and na
41. vre Copenhagen Denmark Telephone 45 36 70 35 00 Fax 445 38 27 27 01 Abrapol 2 Instruction Manual Abrapol 2 Safety Precaution Sheet To be read carefully before use 1 operator should be fully aware of the use of the machine according to the instruction manual 2 The machine must be placed in an adequate working position 3 Be sure that the actual voltage corresponds to the voltage stated on the side of the machine The machine must be earthed 4 sure that the water connections are without leaks The main water supply should be turned off if you leave the machine unattended 5 Make sure that the specimens in the specimen holder are securely fixed 6 Keep clear of the preparation disc when operating 7 f you observe malfunctions or hear unusual noises stop the machine and call technical service The equipment is designed for use with consumables supplied by Struers If subjected to misuse improper installation alteration neglect accident or improper repair Struers will accept no responsibility for damage s to the user or the equipment Dismantling of any part of the equipment during service or repair should always be performed by a qualified technician electromechanical electronic mechanical pneumatic Abrapol 2 Instruction Manual User s Guide Table of Contents Page 1 Installation Checking the Contents of
42. ylon strap screw and washer Place the bottle support under the bottle box Placethe bottles fill them and connect them with the tubing Lubricant 1 blue lubricant Lubricant 2 lubricant Suspension 1 DP Suspension highest grain size Suspension 2 DP Suspension medium grain size Suspension 3 DP Suspension lowest grain size IMPORTANT Only use Struers suspension in the dosing unit Mounting a Drip Lubricator W Fasten the mounting plate the arm for the specimen Accessory holder motor by means of the two screws with washers Connect the plug to the machine Fill the bottle with lubricant and place it in the lubricator Mounting Microstop W Fasten the microswitch to the left side of the machine by Accessory means of screws Connect the plug to the rear side of the machine and fasten the cable with the cable clamp the screw and washer Clamp the micrometer screw in the holder and mount the holder to the arm for the specimen holder motor by means of screws and washers Using the Controls Buttons Adjusting Knobs Abrapol 2 Instruction Manual 2 Operation See section Getting aquainted with Abrapol 2 for location of buttons Key Function Name Key Function Buttons Adjusting Knobs See Drawing of Abrapol 2 aD Turns on off the main power of Interrupts all functions The the machine The main switch is specimen holder remains in MAIN located on the left hand side of EMER lower
43. zle 422M P016 16 Nozzle holder cover eege em 422M P009 16 Dosing Unit Fig 16 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No A 1 Lubricant nozzle 375M 5 2 O ring 3 x 1 for lubricant nozzle head 375M P036 3 Lubricant nozzle screw 375MP038 AIB 4 O ring 24 48 x 1 78 for nozzle screw 375MP037 5 Guide ball for 00226 375M P270 6 O ring 216 x 2 for nozzle 422M P015 B 1 DP Suspension nozzle 375M P034 3 DP Suspension nozzle screw 375M P039 7 AA ka 7 2 Oe 2 d 22 Fig 16a Fig 16b Lubricant Nozzle DP Suspension Nozzle 16C Dosing Unit 16C 16 4 Abrapol 2 Spare Parts and Diagrams Pos and Description Spare Part No Lubricant pump 375MP025 1 Diaphtagtm ern he noe 7 52 2 a 375M P053 ce 375 20 SG Wee 375M P022 5 Banjo connection cre tr Renta tees 375M P023 6 Check valve non return valve 375MP024 Sie Ee Le 375M P187 alle c 422M P007 Throttle gauge for air tubing sus
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