TenuPol-5
Polishing unit
Instruction Manual
Original Instructions

Doc. no.: 14087025-01_A_en-us
Date of release: 2023.03.31

CopyrightThe 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 2023.03.31.

2

TenuPol-5

Table of Contents
1 About this manual
1.1 Accessories and consumables
2 Safety55

2.1 Intended use

5

2.2 TenuPol-5 safety precautions

6

2.2.1 Read carefully before use

6

2.3 Safety messages

7

2.4 Safety messages in this manual

8

2.5 Working with electrolytes

112.5.1 Perchloric acid12

3 Getting started

16

3.1 Device description

16

3.2 Overview - TenuPol-5

17

3.2.1 Control panel functions
4 Transport and storage

17
18

4.1 Transport

18

4.2 Storage

18

5 Installation18

5.1 Unpack the machine18

5.2 Check the packing list

19

5.3 Location

20

5.4 Power supply

20

5.4.1 Voltage

20

5.5 Connecting the polishing unit

21

5.6 Preparing the unit for operation

21

5.6.1 Setting up the polishing unit

22

5.6.2 Filling the container with electrolyte

22

5.6.3 Mounting the jet holders

23

6 Maintenance and service

23

6.1 Manual functions

24

6.1.1 Changing electrolyte

24

6.1.2 Cleaning

26

6.1.3 Operating the pump manually27

6.2 Daily

TenuPol-5

5

27

3

6.2.1 Cleaning

28

6.2.2 Control unit30

6.3 Monthly
6.3.1 Calibrating the pump
6.4 Annually
6.4.1 Test the safety devices

30
31
32

6.5 Spare parts32

6.6 Disposal

32

6.7 Service and repair

33

7 Troubleshooting

33

8 Technical data

34

8.1 Technical data - TenuPol-5

34

8.2 Noise and vibration levels

34

8.3 Safety Circuit Categories/Performance Level

34

8.4 Safety Related Parts of the Control System (SRP/CS)

35

8.5 Diagrams

35

8.5.1 Diagrams - TenuPol-5

35

8.6 Legal and regulatory information

39

9 Manufacturer
Declaration of Conformity

4

30

39
41

TenuPol-5

1 About this manual

1

About this manual
CAUTION
Struers equipment must only be used in connection with and as described in theInstruction 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 thismanual.

1.1

Accessories and consumables
Accessories
For information about the available range, see the TenuPol-5 brochure:•

The Struers Website (http://www.struers.com)

Consumables
The equipment is designed to be used only with Struers consumables specifically designed forthis purpose and this type of machine.
Other products may contain aggressive solvents, which dissolve e.g. rubber seals. The warranty
may not cover damaged machine parts (e.g. seals and tubes), where the damage can be directly
related to the use of consumables not supplied by Struers.
For information about the available range, see:•

The Struers Consumables Catalogue (via https://www.struers.com)

2

Safety2.1

Intended use
The unit is intended to be used in combination with:•

TenuPol-5 Control unit

The machine is for use in a professional working environment (e.g. a materialographic
laboratory).
TenuPol-5 is designed to perform automatic electrolytic thinning of specimens.

TenuPol-55

2 Safety
The equipment is intended for use in quality control applications, where the surface can be preparedfor further materialographic inspection with a transmitted electron microscope (TEM).
The equipment is designed for preparation of conductive materials suitable for electrolytic etching.
In order for the equipment to operate correctly and safety, it must be used with Struers accessories
and consumables specially designed for this purpose and this type of device.
When in use, the machine equipment must not be touched, moved or tampered with.
The operator must be fully instructed in how to handle and use electrolytes with this machine.
The machine must be operated only by skilled/trained personnel.
The machine must be connected to a cooling unit in order to function as intended.
The polishing unit must be placed on an even surface.
The polishing unit must be placed in a well ventilated area, preferably a fume cabinet.

Control unit
See the Instruction Manual for this unit.

Do not use the machine forthe following

Preparation of materials other than materials suitable formaterialographic studies.
The machine must not be used for any type of explosive and/or
flammable material, or materials which are not stable duringmachining, heating or pressure.
Do not use the machine without sufficient ventilation.
The machine must not be used with consumables or a
combination of electrolytes and accessories which are notcompatible for use with this equipment.

Model

TenuPol-5

2.2

TenuPol-5 safety precautions

2.2.1

Read carefully before use

61.

Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.

2.

The machine must be installed in compliance with local safety regulations. All functions on themachine and any connected equipment must be in working order.The machine must be earthed(grounded).

3.

The operator must read the safety precautions and Instruction Manual, as well as relevant
sections of the manuals for any connected equipment and accessories.

4.

The operator must be fully instructed in how to handle and use electrolytes with this machine.

5.

Follow all safety requirements for handling, mixing, emptying and disposing of electrolytes.

TenuPol-5

2 Safety
6.

The machine must be placed in a well-ventilated location.If needed, you can also place it in afume cabinet.

7.

The machine must be placed on a safe and stable table with an adequate working height.

8.

The device is designed to be used with Struers consumables specially designed for thispurpose and this type of device.

9.

The machine is designed to be used with electrolytes recommended by Struers.Electrolytes
that are not recommended by Struers can be dangerous to the operator or harm themachine.

10. Danger of chemical burns. Follow all safety requirements for handling, mixing, emptying anddisposing of electrolytes.
11. Many electrolytes contain alcohol or other flammable solvents. Always follow all safety
precautions when working with these types of electrolyte.
12. Never try to open the polishing unit while it is running.
13. Do not use the pump without having electrolyte or water in the electrolyte container.
14. Struers recommends that the cooling water supply is shut off or disconnected if the machineis to be left unattended.
15. Always use goggles, gloves and other recommended protective clothing.
16. Accessories: Only use accessories specifically developed for use with this type of machine.
17. If you observe malfunctions or hear unusual noises, switch off the machine and call technicalservice.
18. Always switch off the electrical power supply and remove the plug or power cable before
dismantling the machine or installing additional components.
19. Make sure that the actual electrical power supply voltage corresponds to the voltage statedon the type plate of the machine.
20. The machine must be disconnected from the electrical power supply before any service.Wait
5 minutes until residual potential on the capacitors is discharged.
21. Struers equipment must only be used in connection with and as described in the Instruction
Manual supplied with the equipment.
22. If the equipment is subjected to misuse, incorrect installation, alteration, neglect, accident orincorrect repair, Struers will accept no responsibility for damage to the user or theequipment.
23. 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 orserious injury.

TenuPol-5

7

2 Safety
DANGER
This sign indicates a hazard with a high level of risk which, if not avoided, will result indeath 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 resultin minor or moderate injury.
CRUSHING HAZARD
This sign indicates a crushing hazard which, if not avoided, could result in minor,
moderate or serious injury.
HEAT HAZARD
This sign indicates a heat hazard which, if not avoided, can result in minor, moderateor serious injury.

General messages
NoteThis sign indicates that there is a risk of damage to property, or a need to proceedwith 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 theInstruction Manual supplied with the equipment.
WARNING
Follow all safety requirements for handling, mixing, emptying and disposing ofelectrolytes.
WARNING
Danger of chemical burns.
Follow all safety requirements for handling, mixing, emptying and disposing ofelectrolytes.

8

TenuPol-5

2 Safety
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you
start working with it.
CAUTION
Many electrolytes contain alcohol or other flammable solvents. Always follow allsafety precautions when working with these types of electrolyte.
CAUTION
The operator must be fully instructed in how to handle and use electrolytes withthis machine.
CAUTION
The machine is designed to be used with electrolytes recommended by
Struers. Electrolytes that are not recommended by Struers can be dangerous tothe operator or harm the machine.

CAUTION
Fire and explosion hazards•
60% perchloric acid is a very corrosive and oxidizing product. Heating it cancause an explosion, and contact with combustible materials can cause fire.
•Fire fighting must be carried out from a protected location. Use extinguishingmedia as specified in the Safety Data Sheet.

CAUTION
All persons involved in mixing, using, storing, transporting and disposing ofelectrolytes must be trained in how to handle perchloric acid when carrying out
these tasks.
•
Do not inhale any vapor from the solution or its components.
•

Avoid skin contact.

WARNING
Always wear a full-face shield or splash goggles, rubber gloves and a laboratory
coat or coveralls when you are working with perchloric acid.
WARNING
Make sure that you are mixing the solvent in a chemical-fume hood designed forperchloric acid use.
WARNING
Do not use combustible or carbonaceous containers, reaction vessels, spill pans,storage shelves or similar materials when you work with perchloric acid.

TenuPol-5

92 Safety
CAUTION
Do not produce anhydrous perchloric acid, either from its salts or from aqueous
solutions, e.g. by heating with high boiling acids or dehydrating agents such as
sulfuric acid or phosphorous pentoxide. In addition to spontaneous explosion, theanhydrous acid explodes instantaneously on contact with oxidizable organic
materials.
CAUTION
Limit the use or storage of perchloric acid to quantities less than 500 g per fume hood.

CAUTION
Never turn the polishing unit upside down, particularly if there is electrolyte in thepump.
CRUSHING HAZARD
Take care of your fingers when handling the machine.

ELECTRICAL HAZARD
The machine must be earthed (grounded).
Switch off the electrical power supply before installing electrical equipment.
Make sure that the actual electrical power supply voltage corresponds to the voltage
stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.

ELECTRICAL HAZARD
For electrical installations with Residual Current Circuit Breakers
For this machine a residual current circuit breaker Type B, 30 mA (or better) is
recommended 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-woundtransformer).
Contact a qualified electrician to verify the solution.
Always follow local regulations.
CAUTION
Prolonged exposure to loud noises may cause permanent damage to a person’shearing.
Use hearing protection if the exposure to noise exceeds the levels set by local
regulations.
CAUTION
Do not use the machine with non-compatible accessories or consumables.

10

TenuPol-5

2 Safety
CAUTION
Always use goggles or a protective shield, and chemical-resistant gloves.

WARNING
Do not touch, move or tamper with the unit during use.

WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.
WARNING
Safety critical components must be replaced after a maximum lifetime of 20 years.
Contact Struers Service.
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.

2.5

Working with electrolytes
WARNING
Danger of chemical burns.
Follow all safety requirements for handling, mixing, emptying and disposing ofelectrolytes.
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you
start working with it.
CAUTION
Many electrolytes contain alcohol or other flammable solvents. Always follow allsafety precautions when working with these types of electrolyte.
CAUTION
The operator must be fully instructed in how to handle and use electrolytes withthis machine.
CAUTION
The machine is designed to be used with electrolytes recommended by
Struers. Electrolytes that are not recommended by Struers can be dangerous tothe operator or harm the machine.

TenuPol-5

11

2 Safety
CAUTION
Many electrolytes contain alcohol or other flammable solvents. Make sure that all
safety precautions are followed for these types of electrolytes.

Availability
Struers electrolytes are not marketed in the USA. If needed, the chemical compounds for theelectrolyte must be purchased independently.
Contact your Struers representative for further information.

After use
Do not let the electrolyte dry or crystallize inside the machine or on the polished material.

DisposalSee Disposal ►32.

2.5.1

Perchloric acid
CAUTION
Always request and read the Safety Data Sheet for each electrolyte before you startworking with it.
To find the Safety Data Sheet for the components in question, see: www.struers.com.

CAUTION
Fire and explosion hazards•
60% perchloric acid is a very corrosive and oxidizing product. Heating it cancause an explosion, and contact with combustible materials can cause fire.
•Fire fighting must be carried out from a protected location. Use extinguishingmedia as specified in the Safety Data Sheet.

Training
CAUTION
All persons involved in mixing, using, storing, transporting and disposing ofelectrolytes must be trained in how to handle perchloric acid when carrying out thesetasks.
•Do not inhale any vapor from the solution or its components.
•

Avoid skin contact.

Mixing perchloric acid into the electrolyte solution
If you are working with Struers electrolytes marked with the prefix A, you must mix a certain amountof perchloric acid into the electrolyte solution.

12

TenuPol-5

2 Safety
WARNING
Always wear a full-face shield or splash goggles, rubber gloves and a laboratory
coat or coveralls when you are working with perchloric acid.
WARNING
Make sure that you are mixing the solvent in a chemical-fume hood designed forperchloric acid use.
WARNING
Do not use combustible or carbonaceous containers, reaction vessels, spill pans,storage shelves or similar materials when you work with perchloric acid.
WARNINGFor information about electrolytes, see the Safety Data Sheet for the specificproduct.

Procedure
CAUTION
The components must be used in the correct quantity as specified below.

Electrolyte A2
1.

Mix ethanol, butoxyethanol and water.

2.

Immediately before use, add A2 II - perchloric acid to the A2 I mixture.

Formula

A2 I

A2 II

90 ml distilled water

78 ml perchloric acid

730 ml ethanol
100 ml butoxyethanol
Chemicals

TenuPol-5

All chemicals are chemically pure, preferably analytical grade. Per centis, where no other is stated, weight per cent.
Butoxyethanol

Ethylene glycol monobutyl ether,CH3-(CH2)2-CH2-O-CH2-CH2OH

Ethanol 96% vol

CH3-CH2OH

Perchloric acid

60%, HClO4

Distilled water

H 2O

13

2 Safety

Electrolyte A2
Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.

Electrolyte A3
1.

Mix ethanol and butoxyethanol.

2.

Immediately before use, add A3 II - perchloric acid to the A3 I mixture.

Formula

A3 I

A3 II

600 ml methanol

60 ml perchloric acid

360 ml butoxyethanol
Chemicals

All chemicals are chemically pure, preferably analytical grade. Per cent is,where no other is stated, weight per cent.
Butoxyethanol

Ethylene glycol monobutyl ether,CH3-(CH2)2-CH2-O-CH2-CH2OH

Methanol

100% vol., CH3OH

Perchloric acid

60%, HClO4

Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.

14

TenuPol-5

2 Safety

Electrolyte D2
1.

Mix the phosphoric acid in the distilled water2.

Add ethanol, propanol and urea.

FormulaD2
500 ml distilled water
250 ml phosphoric acid

250 ml ethanol
50 ml propanol
5 g urea
Chemicals

All chemicals are chemically pure, preferably analytical grade. Per centis, where no other is stated, weight per cent.
Ethanol

96% vol., CH3-CH2OH

Phosphoric acid

Ortho phosphoric acid 85%,
(HO)3PO

Propanol2-propanol 100%, CH3-CH2CH2OH

Urea

CO(NH2)2

Distilled water

H 2O

Health and Safety
Before mixing, read the MSDS thoroughly for the specific components.
The user must follow the instructions for proper work procedure according to the instruction
manual supplied with the equipment.
Note
The product must be disposed of according to local regulations for dangerous
goods.

Storing perchloric acid or solution
CAUTION
Do not produce anhydrous perchloric acid, either from its salts or from aqueous
solutions, e.g. by heating with high boiling acids or dehydrating agents such as
sulfuric acid or phosphorous pentoxide. In addition to spontaneous explosion, theanhydrous acid explodes instantaneously on contact with oxidizable organic
materials.
CAUTION
Limit the use or storage of perchloric acid to quantities less than 500 g per fume
hood.

3.

TenuPol-5

Never let perchloric acid crystallize on bottle necks, caps or anywhere else.

15

3 Getting started
4.

Store the chemical in a secure, cool, and well-ventilated area with a metal, glass or ceramic spillcatch pan.

5.

Store the chemical away from other chemicals or combustible or organic materials.

6.

Never let solutions dry out.

For more information, see the Safety Data Sheet for the product.

3

Getting started

3.1

Device description
The equipment is used for materialographic preparation which enables further examination ofmaterials for quality control purposes. It is designed for fast preparation of specimens suitable fortransmission electron microscopy (TEM).
Electrolytical thinning can be performed on most metallic material surfaces. The electrochemical
process is possible on electrically conductive materials by the action of electrolyte and electricity.
During the process, a high, local current, which is applied to the area of the specimen covered withelectrolytes, will have an etching effect on the surface. This process makes the surface suitable forfurther materialographic analysis.
The equipment consists of a control unit and a polishing unit.
The polishing unit must be placed in a well ventilated area, preferably a fume cabinet, to prevent
inhalation of hazardous vapors.
The operator fills and empties the electrolyte container in the polishing unit.
Before starting the process, the operator places a specimen/sample/workpiece in the specimen
holder/sample holder. The operator selects a suitable method, accessory, and electrolyte. There are
200 predefined polishing/thinning methods for pre-thinning and final thinning.
The operator makes sure that a suitable combination of electrolytes and polishing parameters is
selected for the material. The operator makes sure that the correct electrolyte is in the polishing unit.
The operator starts the process. A scanning function automatically determines the correct polishingvoltage for the thinning process. Small layers of material are removed from both sides of thespecimen in the electrolytic etching/thinning process. During the process, current and electrolyte
temperature are shown on the screen.
The voltage and current are monitored and adjusted automatically. In case of excess heat and/or
excess power consumption the unit switches off automatically.
The polishing/thinning process stops automatically when a hole appears in the specimen.
After use, the electrolyte container must be emptied and cleaned with water. The electrolyte must be
stored in a safe location in a closed container suitable for the purpose. Cleaning is carried out by
using the electrolyte container filled with water.

16

TenuPol-5

3 Getting started
Note
Proper maintenance is required to achieve the maximum up-time and operating
lifetime of the machine.
Note
The device is designed to be used with Struers consumables specially designed
for this purpose and this type of device.

3.2

Overview - TenuPol-5
A Control unit
B Polishing unit

Polishing unit
Front view - Polishing unit
A
B
C
D
E
F
G
H

Electrolyte container, insulated
Base plate
Pump
Opening for thermometer
Protective coverSpecimen holder
Polishing cell
Jet holder

Control unit
See the manual supplied with the specific equipment.

3.2.1

Control panel functions
There is no control panel on the TenuPol-5 polishing unit.
The unit is controlled from the TenuPol-5 control unit. See the manual supplied with the specificequipment.

TenuPol-517

4 Transport and storage

4

Transport and storageIf, at any time after the installation, you have to move the unit or place it in storage, there is a numberof guidelines we recommend that you follow.

4.1

4.2

•

Package the unit securely before transportation. Insufficient packaging could cause damage tothe unit and will void the warranty. Contact Struers Service.

•

We recommend that you use the original packaging and fittings.

Transport
1.

Clean the polishing unit thoroughly. See Cleaning ►28.

2.

Disconnect the electrical power supply.

3.

Disconnect the polishing unit from the water supply or the cooling unit (option).

4.

Move the unit to its new position.

StorageNote
We recommend that you keep all original packaging and fittings for future use.

•

Disconnect the unit from the electrical power supply.

•

Disconnect the unit from the water supply.

•

Remove any accessories.

•

Clean and dry the unit before storage. See Daily ►27.

•

Place the machine and accessories in their original packaging.

•

Place a bag of desiccant (silica gel) in the box.

•

For details on storage temperature and humidity, see Technical data - TenuPol-5 ►34.

Control unit
See the Instruction Manual for this unit.

5

Installation

5.1

Unpack the machineNote
We recommend that you keep all original packaging and fittings for future use.

18

TenuPol-55 Installation
The equipment is delivered in two boxes.
•

Control unit•

Polishing unit

Polishing unit
1.

Cut the packing tape on the top of the box.

2.

Remove the loose parts.

3.

Remove the unit from the box.

Control unit
See the Instruction Manual for this unit.

Moving the machine
See Transport ►18.

5.2

Check the packing list
The equipment is delivered in two boxes.
•

Control unit•

Polishing unit

Optional accessories may be included in the packing box.

Polishing unit
The packing box contains the following items:
Pcs.

Description

1

Polishing unit

1

Supply and communications cable for connection to the control unit

1

Thermometer pocket

1

Specimen holder. For specimens with a diameter of Ø3 mm

1

Jet holder. Inside diameter: Ø1 mm. Set of 2 pieces

1

Protective cover1

Electrolyte container, insulated, PVC

1Electrolyte container, uninsulated, PVC

2

Tube for cooling coil. Diameter: 8 mm. Length: 1 m

1

Jet holder. With ascending tube for calibration

1

Return tube for calibration

1

Instruction Manual set

TenuPol-5195 Installation
Control unit
See the Instruction Manual for this unit.

5.3

Location
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
WARNING
The polishing unit must be placed in a well ventilated area, preferably a fume cabinet.
Do not touch, move or tamper with the unit during use.
•

The polishing unit must be placed in a well ventilated area, preferably a fume cabinet.

•

Place the unit on a rigid, stable workbench with a horizontal surface and an adequate height.
The workbench must be resistant to chemicals.

•

Place the unit close to the water supply or to a separate cooling unit.

•

The length of the supply and communications cable connecting the two units is 2 m (6.5 ft), sothat the units can be placed in separate locations.

Control unit
See the Instruction Manual for this unit.

5.4

Power supply
CAUTION
The machine must be earthed (grounded).
Switch off the electrical power supply before installing electrical equipment.
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.
Control unit
See the Instruction Manual for this unit.

5.4.1

Voltage
CAUTION
The machine must be earthed (grounded).
Switch off the electrical power supply before installing electrical equipment.
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
In countries with a 100 - 120 V electrical power supply, you must change the setting– 115 V: 100-120 V/50/60 Hz– 230 V: 200-240 V/50/60 HzFactory setting

20

TenuPol-55 Installation
How to change the voltage

5.5

1.

Use a small, flat-tip screwdriver toopen the cover of the fusecompartment at the back of thecontrol unit.

2.

Take the fuse out of the fusecompartment.

3.

Turn the fuse into the required
position.

4.

Push it back into the fusecompartment.

5.

Close the cover of the fusecompartment.

A Fuse compartment

Connecting the polishing unit
WARNING
The polishing unit must be placed in a well ventilated area, preferably a fumecabinet.
Do not touch, move or tamper with the unit during use.
1.

Connect the cable from the polishing unit to the adapter supplied with the control unit.

2.

Connect the adapter cable to the back of the control unit.

3.

Tighten the retaining ring to secure the plug.

Calibrating the pump
The first time the machine is switched on, it is recommended that you adjust the pump. See
Calibrating the pump ►30.

5.6

Preparing the unit for operation
WARNING
The polishing unit must be placed in a well ventilated area, preferably a fumecabinet.
Do not touch, move or tamper with the unit during use.

TenuPol-5215 Installation

5.6.1

Setting up the polishing unit
1.

Place the base plate with pump and cooling coil on theinsulated container.

2.

Insert the thermometer, A, in the hole between thepolishing cell and the pump motor.
CAUTION
Always use the thermometer during
preparation.

3.

Connect one of the tubes supplied with the polishingunit to the cooling coil and to the water supply.

4.

Connect the other tube to the other side of the cooling coil and lead it to the drain.

5.

If the unit is connected to an external cooling unit (option), use suitable, insulated tubes toconnect the cooling unit and the cooling coil.
Note
See the Instruction Manual for this unit.

Hint
If it is not possible to cool the electrolyte with cooling water or an external cooling unit,
place the uninsulated container in an ice bath for cooling.

5.6.2

Filling the container with electrolyte
CAUTION
Always observe the current safety regulations regarding handling and disposal ofelectrolytes.
The operator must be fully instructed in how to handle and use electrolytes with thismachine.
WARNING
Always handle electrolytes in well ventilated areas.
Always use safety gloves, goggles and a funnel when you handle electrolytes.
For instructions on handling electrolytes, see Working with electrolytes ►11.

22

1.

Remove the base plate with the pump and cooling coilfrom the electrolyte container.

2.

Fill the electrolyte container to the mark withelectrolyte (approximately 1 l).

3.

Place the base plate on the electrolyte container.

TenuPol-5

6 Maintenance and service

5.6.3

6

Mounting the jet holders
1.

Place one jet holder in the polishing chamber andslide the sleeve into the groove until the holder fits
tightly against the back wall of the chamber.

2.

Mount the other jet in the same way at the otherside of the chamber.

3.

Connect the two mini jack plugs in thecorresponding sockets in the jet holders.

4.

Place the protective cover over the polishingchamber.

Maintenance and service
Proper maintenance is required to achieve the maximum up-time and operating lifetime of themachine. Maintenance is important in ensuring continued safe operation of your machine.
The maintenance procedures described in this section must be carried out by skilled or trained
personnel.

TenuPol-523

6 Maintenance and service
Safety Related Parts of the Control System (SRP/CS)
For specific safety related parts, see the section "Safety Related Parts of the Control System(SRP/CS)" in the section "Technical data" in this manual.

Technical questions and spare parts
If you have technical questions or when you order spare parts, state serial number andvoltage/frequency. The serial number and the voltage are stated on the type plate of the machine.

6.1

Manual functions
A number of manual functions are available in the software.

1.

From the Main menu screen, select the Manual funct. screen.

From the Manual Functions screen you can choose between the following options:

6.1.1

•

Change electrolyte. See Changing electrolyte ►24.

•

Cleaning. See Cleaning ►28.

•

Pump. See Operating the pump manually ►27.

Changing electrolyte
When you change from a method that uses one type of electrolyte to a method that uses a different
type of electrolyte, you must change the electrolyte. You will be prompted to change the electrolyte
and clean the system. If needed, you can start this function manually.

24

TenuPol-5

6 Maintenance and service
CAUTION
Always use goggles or a protective shield, and chemical-resistant gloves.

WARNING
Do not touch, move or tamper with the unit during use.

1.

From the Main menu screen, select the Manual funct. screen.

2.

From the Manual Functions screen, select the Change electrolyte screen.

3.

Press Enter to continue.

4.

Follow the on-screen instructions. The on-screen instructions are listed
below.

5.

Press Enter to continue through the sequence of steps.

You can cancel the process at any time. To do so, press Escape.

6.

The following messages appear.
[ Remove Electrolyte:]

1. Lift the polishing unit.
2. Place it in the container with water
3. Remove the present elec.

[ Cleaning... ]The system is being cleaned now.
Please wait 54s[ Cleaning done ]1. Lift the polishing table.
2. Use alcohol to remove water.
3. Clean off the remaining alcohol.

TenuPol-525

6 Maintenance and service[ Remove water ]Remove the water.

[ Select new Electrolyte ]
A2
A3
A8
...
10% oxalic
USER 1

6.1.2

Cleaning
When you have finished using the machine, you must clean the system.
CAUTION
Always use goggles or a protective shield, and chemical-resistant gloves.

WARNING
Do not touch, move or tamper with the unit during use.

1.

From the Main menu screen, select the Manual funct. screen.

2.

From the Manual Functions screen, select the Cleaning screen.

3.

Press Enter to continue.

4.

Follow the on-screen instructions.The on-screen instructions are listed below.

5.

Press Enter to continue through the sequence of steps.

You can cancel the process at any time. To do so, press Escape.

26

TenuPol-5

6 Maintenance and service
6.

The following messages appear.
[ Remove Electrolyte:]

1. Lift the polishing unit.
2. Place it in the container with water
3. Remove the present elec.

[ Cleaning... ]The system is being cleaned now.
Please wait 54s[ Cleaning done ]1. Lift the polishing table.
2. Use alcohol to remove water.
3. Clean off the remaining alcohol.

[ Remove water ]Remove the water.

6.1.3

Operating the pump manually
You can activate the pump and adjust the flow rate manually.

6.2

1.

From the Main menu screen, select the Manual funct. screen.

2.

From the Manual Functions screen, select the Pump screen.

3.

Press Enter.

4.

Adjust the flow rate.

5.

Press Enter or Escape to stop the pump.

Daily
Clean the machine every day after you finish working, as any electrolyte residue in the polishingcell can affect subsequent preparations.

TenuPol-527

6 Maintenance and service
Polishing unit
Rinse the polishing cell and pump thoroughly with water before you fill any new electrolyte and at theend of each working day.
WARNING
Never use acetone or similar solvents.

CAUTION
Never turn the polishing unit upside down, particularly if there is electrolyte in the
pump.
Note
Never leave the machine filled with electrolyte for longer periods of time, as this cancause the submerged parts to corrode.
Note
Make sure that the motor housing never comes in contact with the electrolyte.

Note
If you have been working with copper or copper alloys, some copper can havedeposited on the cathodes. Remove it using a few drops of nitric acid before rinsing.

6.2.1

1.

From the Main menu screen, select the Manual funct. screen.

2.

From the Manual funct. screen, select the Pump screen. See Operating thepump manually ►27.

3.

Start the pump and set the flow rate to 50.
–

Make sure that the flow from the jets is equal and that there are noblockages.

–

If you detect any blockage or leak, stop the pump and clean the jets
thoroughly before restarting the pump.

–

Repeat until the flow from the jets is satisfactory.

–

Stop the pump.

4.

Place a specimen holder in the polishing chamber.

5.

Follow the instructions for cleaning: See Cleaning ►28.

6.

When the cleaning program is finished, clean all accessible surfaces with adamp cloth, including the inside of the electrolyte container.

7.

Wash all the used specimen holders thoroughly.

Cleaning
When you have finished using the machine, you must clean the system.

28

TenuPol-5

6 Maintenance and service
CAUTION
Always use goggles or a protective shield, and chemical-resistant gloves.

WARNING
Do not touch, move or tamper with the unit during use.

1.

From the Main menu screen, select the Manual funct. screen.

2.

From the Manual Functions screen, select the Cleaning screen.

3.

Press Enter to continue.

4.

Follow the on-screen instructions.The on-screen instructions are listed
below.

5.

Press Enter to continue through the sequence of steps.

You can cancel the process at any time. To do so, press Escape.

6.

The following messages appear.
[ Remove Electrolyte:]

1. Lift the polishing unit.
2. Place it in the container with water
3. Remove the present elec.

[ Cleaning... ]The system is being cleaned now.
Please wait 54s[ Cleaning done ]1. Lift the polishing table.
2. Use alcohol to remove water.
3. Clean off the remaining alcohol.

[ Remove water ]Remove the water.

TenuPol-529

6 Maintenance and service

6.2.2

6.3

Control unit•

Avoid spilling electrolyte on the cabinet or on the front plate of the control unit.

•

Clean the front plate with a damp cloth after use.

Monthly
Recirculation unit
See the Instruction Manual for this unit.
Note
Replace the cooling fluid immediately if you notice that it is infected by algae orbacteria.

6.3.1

Calibrating the pump
The first time the machine is switched on
The pump must be adjusted before it is used for the first time.
To start the pump adjustment procedure, carry out the following:
1.

The first time you switch on the machine, the following message isshown:The pump must be adjusted.

1.

Insert the calibration holder in the polishing cell.

2.

Place the black tube in the thermometer hole.

3.

Connect the calibration holder.

4.

Select Adjust with tube.

5.

To continue with the pump adjustment procedure, see Carrying out theadjustment ►31 in this section.

Subsequent use
If the results are not correct, or if you cannot reproduce the results, adjust the pump.
This function calibrates the pump of the polishing unit and ensures that the flow rate settings in theStruers methods are correct.

30

1.

Insert the calibration holder in the polishing cell.

2.

Place the black tube in the thermometer hole.

3.

Connect the calibration holder.

4.

From the Main menu screen, select the Configuration screen.

5.

Press F4 - Adj. Pump.

6.

To continue with the pump adjustment procedure, see Carrying out theadjustment ►31 in this section.

TenuPol-5

6 Maintenance and service
Carrying out the adjustment
The following message is shown:
Insert container
Please insert a container filled with 1.5 litre water.
Add a drop of detergent.
7.

Fill the container with 1.5 liters of water.

8.

Add one drop of detergent to release the surface tension of thewater.

9.

Press Enter to continue.
The following message is shown:
Insert tubes
Insert jet holder with ascending tube, return tube andspecimen holder with specimen.

10. Do as instructed.
11. Press Enter to continue.

12. Select Maximum pump flow.
13. Press Enter to start the pump.

14. Adjust the water level to the upper mark. The maximum setting
should be approx. 120.
15. Press Enter to save the value.

16. Select Minimum pump flow.
17. Adjust the water level to the lower mark. The minimum setting
should be approx. 75.
18. Press Enter to save the value.

19. When you have completed the adjustment, press Escape.

6.4

Annually
The safety devices must be tested at least once a year.

TenuPol-531

6 Maintenance and service

6.4.1

Test the safety devices
WARNING
Do not use the machine with defective safety devices. Contact Struers Service.

Protective cover
The safety devices must be tested at least once a year.
WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.

Procedure

6.5

1.

To inspect the protective cover and the work zone interlock, remove theprotective cover including the work zone interlock.

2.

Press Start.

3.

Make sure that polishing does not start.

Spare parts
Technical questions and spare parts
If you have technical questions or when you order spare parts, state the serial number. The serial
number is stated on the type plate of the unit.
For further information, or to check the availability of spare parts, contact Struers Service. Contact
information is available on Struers.com.
Note
Replacement of safety critical components must only be performed by a Struers
engineer or a qualified technician (electromechanical, electronic, mechanical,
pneumatic, etc.).
Note
Safety critical components must only be replaced by components with at least thesame safety level.

6.6

Disposal
Equipment marked with a WEEE symbol contains electrical and electronic
components and must not be disposed of as general waste.
Contact your local authorities for information on the correct method of disposal inaccordance with national legislation.
For disposal of consumables and recirculation fluid, follow local regulations.

32

TenuPol-5

7 Troubleshooting
Electrolytes
Contact your local authorities for information on the correct method of disposal in accordance withnational legislation.

6.7

Service and repair
We recommend that a regular service check be carried out yearly or after every 1500 hours ofuse.
When the machine is started up, the display shows information about total operation time and themachines service information.
After 1500 hours of operation time, the display will show a message reminding the user that aservice check should be scheduled.
Note
Service must only be performed by a qualified technician (electromechanical,
electronic, mechanical, pneumatic, etc.).
Contact Struers Service.

7

Troubleshooting
Control unit
Error

Cause

ActionThe supply voltage is too low.

The power supply voltage is
too low compared to thevoltage stated on the back of
the control unit.

If needed, change the voltage
setting. See Voltage ►20.

No electrical connection.

There is no connection to thepolishing unit.

Make sure that the polishingunit is connected to the backof the control unit.

Too little electrolyte in theelectrolyte container.

Increase the amount ofelectrolyte in the container up
to a maximum of 1.5 l.

Temperature is above max.
limit.

The electrolyte temperature is
above the preset limit.

Connect the device to tap
water or an external cooling
unit and wait until thetemperature is below thespecified limit.

The device is switched on but
the display is blank.

The backlight of the display
has been turned off.

Press any button to reactivate
the backlight.

See also TenuPol-5 Control unit, Optimizing the results.

TenuPol-533

8 Technical data

8

Technical data

8.1

Technical data - TenuPol-5
Subject

Specifications

Software and electronics

Supplied from TenuPol-5 Control unit. See the Instruction
Manual for this unit.

Power supply

Supplied from TenuPol-5 Control unit. See the Instruction
Manual for this unit.

Output: Voltage/Current

Polishing

Safety standards

See the Declaration of Conformity

Dimensions and weight

Width

270 mm (10.6")

Depth

180 mm (7.1")

Height

276 mm (10.9")

Weight3.8 kg (8.4 lbs)

Surrounding temperature

5-40°C (41-104°F)

Humidity

0-95 % RH non-condensing

Surrounding temperature-25-55°C (13-113°F)

Humidity

0-95 % RH non-condensing

Operating environment

Storage and transportconditions

8.2

0-100 V (0.1 V steps)/2.5 A

Noise and vibration levels
Noise level

A-weighted soundemission pressurelevel at workstations

LpA = 55.4 dB(A) (measured value)
Uncertainty K = 4 dB
Measurements made in accordance with EN
ISO 11202

Vibration level

8.3

N/A

Safety Circuit Categories/Performance Level
Safety Circuit Categories/Performance Level
Work zone interlock

EN 60204-1, Stop category 0
EN ISO 13849-1, Category 1
PL c

34

TenuPol-5

8 Technical data

8.4

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.
Note
SRP/CS (safety-related parts of a control system) are parts that have an influenceon 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.).
Safety critical components must only be replaced by components with at least thesame safety level.
Contact Struers Service.

8.5

Safetyrelatedpart

Manufacturer/Manufacturer
description

Manufacturer
catalog no.

Electricalref.

Struers
catalog no.

Interlockswitchcircuit Polishingunit

Schmersal

BNS33-11Z-2M

SS1

2SS00140

Interlockswitchcircuit Polishingunit

Schmersal

BPS33

SS1

2SS00141Interlockswitchcircuit Polishingunit

Finder

62.32.9.024.4800

K1

2KL46680

Coded-magnet sensor

Coded-magnet (actuator) for
sensorPower relay

Diagrams
If you wish to view specific information in detail, see the online version of this manual.

8.5.1

Diagrams - TenuPol-5
Control unit
See the Instruction Manual for this unit.

TenuPol-535

8 Technical data
Polishing unit

36

Title

No.

TenuPol-5, Block diagram

15393051 A

TenuPol-5, Connection adapter

15393508 B

TenuPol-5

TenuPol-5= SAMPLE

COOLINGWATER
OUTLET

WATER
INLET

NTC
RT1

Temperature
sensor

ELECTROLYTE

IRreceiver

PUMP

Moveable Guard

IRtransmitter

SS1

DC-MOTOR
M1

Safety Switch

Coded magnet

X4

2

X3

2

D/C

M

TRANSMITTER CATHODE

TRANSMITTER ANODE+ ANODE (SAMPLE)- CATHODE' s

XS1 (12-poles)

LED-backlight

240x128 DOTS

X3

2

K1
Relay

LC-DISPLAY
A3

Opto interface- Celltemp.
- polish /thinning

W4

XS2

12x0,75

W8RECIEVER EMITTER

12

X213-polesX10

Circuit for:

12x0,5W5RECIEVER COLLECTOR

STRAP

2x0,5

CN1

X1

- Transmitter- Reciever- Pump motor- Heatsink temp.
- Transformer
temp.

Circuit for:

X3

6

X4

20

X7

uP-BOARD
A1

W2-25VDC+/-15V

85 AND
170 Vdc+/-15V, +5V

Powersupply

FUSE 1AT+1AT

X3

X2

X2

X5

2

Monday, July 22, 2019

Rev.A: FTH 2019-07-22
Derived from 15393050-B
Relay and protection guard introduced
PC-connection removed

V-25 uPX1

FUSE 1AT

FUSE 1AT

FUSE 2,5AT

X2

X2

X6

POWERBOARD
A2

3

A2

CAGE Code

TenuPol-5
Block diagram

Scale

2X115V

4

FTH / FTHDW G NO

TRAFO
T1

3x1,5

3 x 5 MATRIXKEYBOARD
SB1

24V

20V

60/120V

20V+20V+t

STRUERS A/SVALHOEJSALLE 176
DK-2610 ROEDOVRE
DENMARK
PHONE:+45 3670 3500

8

2

2

Size

2

4

CAP.
C1

volt.sel.
115/230V

fuse+

filter+Switch+QS1W1

MAINSUPPLY IN

Sheet

1

of

15393051
1A

Rev

8 Technical data

15393051 A

37

38

A

B

C

D

2

A

B

Rev.B: FTH2019-07-29
Wire colors in cable changed

BK10

BK10

1

M

5

Towards Control Unit

Connector Male 12-poles

BK = BLACK
BN = BROWN
RD = RED
OG = ORANGE
YE = YELLOWGN = GREEN
BU = BLUE
VT = VIOLETGY = GREY
WH = WHITE
PK = PINKGD = GOLD
TQ = TURQUOISE
SR = SILVER
GNYE = GREEN AND
YELLOW

3

Thursday, August 01, 2019

FILE NAME.: 5393508-.DSN
PAGE1.SCH

Scale

A4

Strap

EmitterCollector

Cathode

Anode

-

+

+

-

Towards Polishing Unit

2

Connection
Detection

IR ReceiverIR Transmitter

Pump Motor

Anode

CathodeInterlocked
Safety Switch
on guard

1

Sheet15393508
SLN / SLNDWG NO

1

1

of

1

TENUPOL-5
CONNECTION-ADAPTER<Cage Code>CAGE Code

WIRING DIAGRAM:

Size

NC

Connector Female 13-poles

12

11

10

9

8

7

4

6

2

3

13

5

1

X2

2

STRUERS ApSPederstrupvej 84
DK-2750 Ballerup
DENMARK
PHONE: + 45 44 600 800

E

BK9

BK9

12

F

BK12

BK8

BK8

6

C

BK12

BK7

BK7

3

D

5

BK4

BK4

4

L

BK11

BK6

BK6

11

BK11

BK2

BK2

10

K

7

BK3

BK3

9

J

G

BK5

BK5

COLOR CODES:

3

812 x 0,75

W8

H

4

4
BK1

5

BK1

X1

B

Rev

A

C

8 Technical data
15393508 B

TenuPol-5

9 Manufacturer

8.6

Legal and regulatory information
FCC noticeThis equipment has been tested and found to comply with the limits for a Class B digital device,pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and canradiate radio frequency energy and, if not installed and used in accordance with the instructions,
may cause harmful interference to radio communications. However, there is no guarantee thatinterference will not occur in a particular installation. If this equipment does cause harmfulinterference to radio or television reception, which can be determined by turning the equipment off
and on, the user is encouraged to try to correct the interference by one or more of the following
measures:

9•

Reorient or relocate the receiving antenna.

•

Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver isconnected.

Manufacturer
Struers ApS
Pederstrupvej 84
DK-2750 Ballerup, Denmark
Telephone: +45 44 600 800
Fax: +45 44 600 801
www.struers.com

Responsibility of the manufacturer
The following restrictions should be observed, as violation of the restrictions may cause
cancellation of Struers legal obligations.
The manufacturer assumes no responsibility for errors in the text and/or illustrations in thismanual. The information in this manual is subject to change without notice. The manual may
mention accessories or parts not included in the supplied version of the equipment.
The manufacturer is to be considered responsible for effects on safety, reliability, andperformance of the equipment only if the equipment is used, serviced, and maintained inaccordance with the instructions for use.

TenuPol-5

39

Based on: 14087902 B

Declaration of Conformity
Manufacturer

Struers ApS • Pederstrupvej 84 • DK-2750 Ballerup • Denmark

Name

TenuPol-5 Polishing unit

Model

N/A

Function

Polishing unit for TenuPol-5, Electrochemical thinning

Type

408

Cat. no.

04086002 TenuPol-5 Polishing unit in combination with
05396233 TenuPol-5Control unit

Serial no.

EU

Module H, according to global approach
We declare that the product mentioned is in conformity with the following legislation, directives and standards:
2006/42/EC

EN ISO 12100:2010, EN ISO 13849-1:2015, EN ISO 13849-2:2012

2011/65/EU

EN IEC 63000:2018

2014/30/EU

EN 61000-3-2:2014, EN 61000-3-3:2013, EN 61000-6-1:2007, EN 61000-6-3:2007,
EN 61000-6-3-A1:2011, EN 61000-6-3-A1-AC:2012

Additional
standards

NFPA 70, NFPA 79, FCC 47 CFR Part 15 Subpart B

Authorized to compile technical file/
Authorized signatory

Date: [Release date]en

For translations seebgЗа преводи вижте

csPřeklady vizda

Se oversættelser pådeÜbersetzungen finden Sie unterelΓια μεταφράσεις, ανατρέξτε στη διεύθυνση

esPara ver las traducciones consulteetTõlked leiate aadressiltfiKatso käännökset osoitteesta

fr

Pour les traductions, voir

hr

Za prijevode idite nahu

A fordítások itt érhetők elit

Per le traduzioni consultareja

翻 訳 については、

ltVertimai patalpintilv

Tulkojumus skatītnlVoor vertalingen zie

noFor oversettelser sepl

Aby znaleźć tłumaczenia, sprawdź

pt

Consulte as traduções disponíveis emroPentru traduceri, consultați

seFör översättningar besökskPreklady sú dostupné na stránkesl

Za prevode si oglejtetrÇeviriler için bkz

zh

翻译见

www.struers.com/Library