App. No.: lo! 'II 0 I 1 5'Voltage: ~ 2.0 -2.1{0 160 -r, 0

1990.09

Instruction ManualGebrauchsanweis u ng

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Prestopress-3Safety Precaution Sheet

To be read carefully before use1. The operator(s) should be fully aware 4. Be sure that the top closure is mount-

of the use of the apparatus according ed correctly before applying pressureto the instruction manual. to the press (6.2.7).

2. Be sure that the water tubings/ S. Keep the embedding pressure belowconnections are without leaks. ,the red area of the manometer.

3. The heat must not be switched on I 6. Don't place your head over the cy-unless the heating/cooling unit is cor- linder opening when removing the em-rectly mounted on the press with the bedded specimen.embedding cylinder.

Prestopress-3 is designed for use with compressionmounting resins, supplied by Struers. If subjected tomisuse, improper installation, alteration, neglect,accident or improper repair, Struers will take noresponsibility for damage(s) to the users or themachines.

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m~di~ pr~Q wl~Prestopress-3 1. DESCRIPTION cInstruction Manual 1.1 Application 'e ,~~tfng of

1 2 Desi n he advantage.In technK:a1 enquiries and in orders . gfor spare parts, please state app. No.and voltage (see cover).

2. TECHNICAL DATAAll information and data in this In-struction Manual were valid when itwas printed. The Struers p'licy 3. CONTENTS OF THE PACKAGEbeing, however, to make current im-provements of our products, we re- 3.1 Unpackingserve ourselves the right to modifyour products without notice. Besides,we ask you to note that this Instruc- 4. INST ALL A TIONtK>n Manual concerns apparatus andall a~ssories. Consequently, it may 4.1 Set-uphappen that the Manual mentions 4.2 Connection to waterequipment whid1 is not of relev~ce 4.3 Connection to electricityfor your purpose at the present time.

5. MOUNTING AND REPLACEMENTOF EMBEDDING CYLINDERS

5.1 Mounting of embedding cylinder5.2 Replacement of embedding cylinder

6. OPERA TION6.1 Controls6.2 Mounting6.3 Mounting hints

7. MAINTENANCE7.1 Cleaning of mounting head7.2 Checking oil level7.3 Exchange of oil7.4 Filling up

8. ACCESSORIES

9. CONSUMABLES

10. SPARE PARTS

$true,. TechValhojs AII6176DK-261 0 Rodovre/CopenhagenDenmark

Telephone +45 31 70 80 90Telex 19625Telefax +45 31 41 65 44

StnJer8 Tech/$ . division of StnJers A/S

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1. DESCRIPTION Prestopress-3 is a manual, hydraulic embedding press withelectric heating and water cooling.

1.1 Application Prestopress-3 is designed for hot pressure mounting ofspecimens for microscopic examination. The advantagesof this embedding method are:Excellent adhesion between resin and specimenNo shrinkage between resin and sp~cimenLower costs because of relatively cheap embedding resins.

1.2 Design The mounting unit consists of a heating coil and a coolingcoil, both embedded in the same cabinet. The electricheating coil is controlled by a variable thermostat, and itis protected by a thermal fuse.The embedding cylinder consists of a cylinder, an upperram, and a lower ram.The embedding pressure is obtained by means of a closed,hydraulic system comprising a high-pressure cylinder withreturn spring, a hand-operated piston pump with twogearings, a return valve, and an oil reservoir.

2. TECHNICAL DATA

Base unit Dimensions:Height: 360 mmWidth: 215 mmDepth: 270 mmWeight: approx. 32 kg

Pressure: 0-45 kN

Heating/cooling unit 220 V/1400 W, 50-60 Hz115 V/1100 W, 50-60 HzTemperature: Adjustable between 140 and 180oC(285-356oF)Cooling coil: 4.3 mm dia. copper coil for tap water

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3. CONTENTS OF THE PACKAGE

Base unit 1 base unit1 heating/cooling unit1 13 mm pipe wrench2 hoses for cooling water3 hose clips 13 mm1 Allen key 2.5 mm, for cabinet1 Allen key 6 mm, for oil screw1 fork spanner 13 mm1 fork spanner 22 mm1 measuring spoon for mounting resin1 funnel for mounting resin1 can of Mould Release Powder3 sample cans with Resin 3, 5, and 6

Cylinder set 1 cylinder1 upper ram1 lower ram1 syringe with heat conductive paste(the exchangeable embedding cylinders are available in thesizes 25 mm, 30 mm, 40 mm, 1", 1 1/4", and 1 1/2").

3.1 Unpacking Tilt the transport box backwards and remove the twotransport screws. Then Prestopress-3 can be removed fromthe transport pallet.

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4. INST ALLA TION

4.1 Set-up Prestopress-3 should be placed on a stable base because ofthe weight of the apparatus and the forces to which it isexposed. In order to improve the stability it isrecommended to screw the apparatus to the table withthe transport screws.

4.2 Connection to water 1. Mount one hose on the cooling water inlet of theheating/cooling unit (fig. 2.1). Tighten the connectionwith a hose clamp.

2. Connect the hose to water (hose clamp).3. Mount the other hose on the water outlet (hose clamp)

(fig. 2.2) and lead it to a drain.Make sure that the hoses are without sharp bends orcurves.

The water supply must have a pressure of at least 5 mwater column (0.5 bar).

4.3 Connection Mount a plug on the current cable. Brown or black lead isto electricity the phase, light blue lead is 0 and yellow/green lead is

earth.Note! Check that the mains voltage corresponds with thevoltage stated on the back of the heating/cooling unit.Measure the mains voltage, if in doubt.

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.5. EMBEDDING CYLINDERS

.5.1 Mounting of 1. Raise the piston rod approx. 50 mm from the bottomembedding cylinder position by closing the return valve (fig. 1.3) and

pumping with the handle (fig. 1.1).2. Mount the lower ram on the piston rod and tighten

with the 13 mm and 22 mm fork spanners.3. Move the piston rod to the bottom position by open-

ing the return valve.4. Place the cylinder above the ram and screw it into

the flange. Pull the lock pawl (fig. 2.4) away from the, ., " cylinder and screw the cylinder further in, until the

..- .I lock pawl catches the hole in the cylinder.

5. Mount the upper ram on the bayonet closure.6. Apply a thin layer of heat conductive paste to the

outer side of the cylinder. Make sure that the entiresurface is covered. Surplus paste can be removedwith acetone.

7. Move the heating/cooling unit down over the cylin-der, turning it lightly back and forth to distribute thepaste.

5.2 Replacement of 1. Move the piston rod to the bottom position by open-embedding cylinder ing the return valve (fig. 1.3).

2. Remove the heating/cooling unit.'I' 3. Draw the lock pawl (fig. 2.4) back and unscrew theil cylinder.

4. Close the return valve and move the piston rodapprox. 50 mm up by pumping with the handle.

5. Unscrew the lower ram.6. Tip the upper ram off the top closure. If the ram

sticks: push a screwdriver in between ram and fittingand tip off the ram.

7. Mount the new cylinder set as described under sec-tion 5.1.

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r 6. OPERA TION6.1 Controls

Pump handle (fig. 1.1) The pump handle has two settings:1. With the handle pressed inwards it is set for moving

the ram up and down during the opening procedures.2. With the handle pulled out completely it is set for

establishing the mounting pressure.Manometer (fig. 1.2) Shows the pressure in kN. The pressure must not exceed

45 kN.Return valve (fig. 1.3) To be closed (turned clockwise) for raising the piston rod

and for establishing the embedding pressure.To be opened (turned counter-clockwise) for moving theram of the pressure cylinder back to its lower position.

Switch for heating/ When the switch is pressed the heating is started. The redcooling unit (fig. 1.4) lamp (fig. 1.5) is lit when the heating is on.Thermostat The embedding temperature can be set from 140-1800C

(285-3560F) by means of the thermostat. To obtain highertemperatures, turn the adjusting knob (fig. 2.5) counter-clockwise, for lower temperatures, turn clockwise.

Bayonet closure The bayonet closure is equipped with four green pointsdistributed with 900 intervals. When one of the greenpoints is opposite one of the corresponding green points onthe heating/cooling unit, the bayonet closure is either in aquite closed position or a quite open position. Pressureshould only be established in the cylinder, if the bayonet !closure is in one of these positions, otherwise the cylinder

, and the bayonet closure may be damaged.

6.2 Mounting Mount the cylinder and ram according to section 5.1For guide lines regarding amount of resin, pressure,heating/cooling times and temperature, see section 6.3paragraph 1-4.List of available resins, see section 9.1. Close the return valve (fig. 1.3) and move the lower

ram to its upper position by pumping the handle (fig.1.1). With unloaded pump the inner handle positionfor quick pumping can be used advantageously (seesection 6.1).

2. Apply Mould Release Powder to the lower ram andplace the cleaned specimen on the ram.

3. Move the ram to its lower position by opening thereturn valve.

4. A suitable amount of resin is poured through thefunnel into the embedding cylinder. Embedding data,see section 6.3.

5. Remove any hardened resin from previous embeddingfrom the upper ram and apply Mould Release Powder.

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6. Clean the upper part of the embedding cylinder fromresin dust and mount the top closure (fig. 1.6) withthe upper ram.If the ram does not fit, remove it and check the ramand cylinder for resin residues. The tolerance be-t\veen ram and cylinder is very fine and even smallquantities of residue may be disturbing.

7. Close the top section by turning it 900 clockwise. Thegreen dot on the top closure should be opposite thegreen dot on the heating/cooling unit (ordinary

" bayonet closure, PREBA).!Ii 8. Close the return valve.I,~ 9. Establish pressure in the embedding cylinder byIi pumping the pump handle (in the inner position).!;,

~ 10. Switch on the heat (fig. 1.4)Ii 11. Maintain the pres~ure during the ~r.ocess by pumping:1 the pump handle (In the outer posItIon).). 12. Switch off the heat when the heating process is, finished.

1.i ' 13. Start the cooling by leading water through the!! heating/cooling unit. Maintain the pressure during theII. process.~ :Iii 14. When the cooling is finished, turn off the water andI: relieve the pressure by opening the return valve.

15. Turn the top closure with the upper ram 900 counter-clockwise. The green dot on the top closure should beopposite the green dot on the heating/cooling unit(ordinary bayonet closure, PREBA).

16. Close the return valve and raise specimen and topclosure by pumping the handle.

17. Remove the top closure and the embedded specimen.I

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6.3 Mounting Hints Details on Mounting Resins, see section 9. .

1. Quantity of resin Depending on the size of the specimen, use from 15 to 30ml resin. When using Resin 4 and 5, it will be anadvantage only to use these in the bottom of the cylinderand then fill up with a low cost bakelite resin.

2. Pressure The optimum pressure will vary from 15 kN for 25 mmmounts up to 35 kN for 40 mm mounts.

3. Heating/cooling times The preparation time will primarily depend on thesize and properties of the specimen, but abt. 90% of allspecimens can be embedded with good result, using aheating time of 8 min and a cooling time of 4 min.Resin 3 will need a heating time of 10 min and should becooled as slowly as possible.

4. Distance between The distance between specimen and cylinder wall must bespecimen and at least 3 mm (1/8") to avoid cracks in the resin. This iscylinder wall especially the case for sharp-edged specimens.

5. Small specimens It may be difficult to place small specimens, especially ifthey are thin and long. Such specimens can be stabilizedby means of Struers Mounting Clips which are available ,both of plastic and of metal. !

6. Electrolytic polishing If the specimen is to be electrolytically polished, Resin3 can be used at the bottom, and on top a conductive resin(Resin 1 or 2).

7. Porous specimens Thermoplastic materials (Resin 3) penetrate well into Iiporous specimens. If at the same time a hard surface is ,Irequested, Resin 3 can be mixed with either Resin 4 orResin 5.

chi 8. Pres~ure sensitive Pressure sensit~ve spe.cimens ~hould be embedded in'" specImens thermo-hardenIng reSIns (ResIn 4, 5 and 6). Soften the

resin by pre-heating without pressure for 1-3 minutes.9. Thermoplastic resins When using thermoplastic resins (Resin 3) pre-heating

without pressure should take place for 4-12 min in orderto soften the resin. The longer the pre-heating, the softerthe resin. When pressure is applied afterwards the resinwill disperse better on the specimen and the localpressure peaks are avoided.

10. Clean specimen The specimen must be dry and free from grease. Ifnecessary, use Struers Specipur.

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.Iii 7. MAINTENANCE Apa~t from cleaning a~d change of oil the base unitI t requIres no regular maIntenance.)jl 7.1 Cleaning of.1111 mounting head The embedding cylinders and rams must be kept clean.ii! Prior to each embedding, check to see that no mounting: t resin residue from a previous mount remains on or around

the outside of either the upper or lower ram. If not

properly cleaned, these residues may cause sticking or

i jamming when the rams go up and down.i.1 The cylinder can be cleaned with alcohol or acetone,

i possibly in an ultrasonic cleaning apparatus. Rams which

I have become scratched on the polished surfaces can beI polished with 6 or 3 ~m diamond paste on a final polishing

cloth (DP-Nap).

7.2 Checking oil level 1. Dismantle heating/cooling unit and mounting cylinder

(section 5.2)

2. Unscrew stop for lock pin (fig. 3.16)

3. Pullout lock pin (fig. 4.15)

4. Unscrew spacer ring (fig. 4.14)

A 5. Unscrew the six screws (2 on each side of the pressand the two upper screws on the frontplate) which hold

=:JL the cover, and lift the cover off the press

6. Move the lower ram to its lower position by opening

the return valve (fig. 1.3)

? I ~ 7. If the bellows fall to L = 50 mm or more, with themain ram in bottom position, the oil has to be re-

filled.

For re-fill, please see section 7.4

7.3 Exchange of oil The oil should be exchanged every 3 years.

1. Move the lower ram to its bottom position

2. Empty the oil from the press through the drain screw

which is placed in the right-hand side at the bottom of

the press

3. Press the bellows completely together with the hand

4. Screw the drain screw back in place and fill up with

new oil (section 7.4)

7.4 Filling up 1. Remove the oil screw, (A) on top of the bellows

2. Raise the bellows manually to L = approx. 10 mm

3. Fill up with oil to the upper edge of the hole.

" Remember that the lower ram must be completely inits bottom position!

Oil type Mobil DTE 18 or similar hydraulic oil is recommended.

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8. ACCESSORIESAdvanced bayonet Top closure which makes it possible to have the upper ramclosure in a displaced position.

Codeword: PRENYOrdinary bayonetclosure Codeword: PREBA

Embedding cylinder set diameter 25 mm, codeword PROMIdiameter 30 mm, codeword PROTEdiameter 40 mm, codeword PROIFdiameter 1", codeword PROONdiameter I 1/4", codeword PROQUdiameter 1 1/2", codeword PROHA

Intermediate ram For every cylinder diameter there is an intermediate ramwhich makes it possible to embed two specimens simul-taneously.

i Codeword: PRODO;

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9. CONSUMABLES

Mounting resins Resin 1, electrically conductive acrylic resin with iron(see also next page) powder, thermoplastic, net 1 kg.

Codeword: RESFEResin 2, electrically conductive acrylic resin with copperpowder, thermoplastic, net 1 kg.Codeword: RESCUResin 3, transparent acrylic resin, thermoplastic,net 0.75 kg.Codeword: RESNOAs above, net 3.2 kg.Codeword: RESRE

1 As above, net 7.5 kg.1, Codeword: RESYV

l Resin 4, glass fibre filled resin on basis of diallylphthalate,thermo-hardening, green, net 0.75 kg.Codeword: RESDIAs above, net 3.2 kg.Codeword: RESOFAs above, net 7.5 kg.Codeword: RESTY

if Resin 5, mineral filled epoxy resin, thermo-hardening, net,1 0.75 kg.fl i Codeword: RESIF

Iii As above, net 3.2 kg.iil Codeword: RESME

;I li As above, net 7.5 kg.i Codeword: RESENi

II ! Resin 6, hard bakelite resin with fillings, thermo-hardening,I i: net 0.75 kg.

I! Codeword: RESBAI: 'i As above, net 7.5 kg.ii Codeword: RESUKII:1 Pre-mount, as Resin 6, but as pills, 25 mm/1", net 6.6 kg.'!

ii' Codeword: RESUNIi! As above, but 30 mm/1 1/4", net 6.6 kg.Ii Codeword: RESGII!

! As above, but 40 mm/1 1/2", net 6.6 kg.I Codeword: RESAM

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1'li, Mould Release Agent Prevents the specimens from sticking, net 0,075 kg..I:' Codeword: PREPO!

Heat Conductive Paste Paste for improving the heat transition between theembedding cylinder and the heating/cooling unit, net 0,1 kg. .Codeword: PREPA

Specipur Degreasing liquid. Increases the adhesion of thespecimen to the resin, 1 litre, net 2.1 kg.Codeword: FIXCI

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Fixation Clips Metal clips for retaining small specimens, 9 mm, 100 pcs.Codeword: CLIPSSame as above, but 6 mm, 100 pcs.Codeword: CLIMO

Multiclips Plastic clips for retaining small specimens, 50 pcs.Codeword: CLIPE

Mounting resins Resins 1, 2 and 3 are thermoplastic, and resins 4, 5 and 6are thermosetting.

Resin 1 Electrically conductive resin for mounting of ferrousmetals and aluminium alloys for electrolytic polishing.To provide a non-conductive area around the surface ofthe specimen, a small amount of Resin 3 is poured intothe cylinder first. The back of the specimen is thencleaned with a brush and the conductive resin is added.Use Mould Release Agent. Minimum temperature 110oC.Minimum pressure 20 kN.

Resin 2 Electrically conductive resin for mounting of Cu-alloysand noble metals for electrolytic preparation. Minimumtemperature 110oC. Minimum pressure 20 kN.

Resin 3 Acrylic resin for transparent mounts. Use Mould ReleaseAgent. Minimum temperature 110oC. Minimum pressure20 kN.

Resin 4 Glassfibre-reinforced diallylphtalate resin of extreme ;1hardness ensuring good edge retention. May ),advantageously be used with bakelite resin, in which casea small amount of Resin 4 is applied around the specimensurface, after which the cylinder is filled up with bakeliteresin. ~gul"~i~i~:~e+~!:~~:~?.~dJ ~~o~e~~:~!E.gerymountin~. Minimum temperature 110 C. Minimumpressure 20 kN.

Resin 5 Epoxide resin. Produces better mounts than ordinary"bakelite" mounting materials. Provides good adhesion tothe edge of the specimen, as well as good edge retentionand hardness. May advantageously be used with bakeliteresin, in which case a small amount of Resin 5 is appliedaround the specimen surface, after which the cylinder is 11filled up with bakelite resin. ~~.ul.d Release A~e!);t shouldf n~;d "~ii~~~;..:r~..~~~~.~:iq~' Minimum temperature110 C. Minimum pressure 15 kN.

Resin 6 Hard bakelite resin with fillings. Use Mould ReleaseAgent. Minimum temperature 110oC. Minimum pressure20kN.

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10. SPARE PARTS

Fig. andPOSe No. Description Spare Part No.

3.1 Bottom Plate 441 MP 13.2 Pump Housing 441 MP 23.3 O-ring l8.2x3 mm 441 MP 33.4 Steel Ball, 9.5 mm dia. 386 MP 773.5 Bearing 441 MP 53.6 Gasket and O-ring 441 MP 63.7 Spring Holder 441 MP 73.8 Pump Piston 441 MP 83.9 Spring 441 MP 93.10 Seeger Support Disc, steel,

SS 16x22xl.5 mm 441 MP 103.11 Seeger Ring, steel

l6xl mm dia. 441 MP 113.12 Flange 441 MP 12

,( 3.13 Bearing 441 MP 13,t..., 3.14 Scraper l6x22x3x4 mm 441 MP 14

\\t 3.15 Fork with roll 441 MP 15~~t,

3.16 Stop for locking pawl 441 MP 16\~t

3.17 Valve, non-return 441 ~P 17~t

3.18 Tube from pump housing 441 MP 18~r

.. :' 3.19 T -fitting 441 ~iP 19" "

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3.20 Tube for main cylinder 441 MP 20t,; f:~;1 3.21 Angular Connection, adjustable 441 ~P 21

7j.l~ qf:~ ! ~\!;! 3.22 Tube between T -fittings 441 MP 22 ,J q~1 1,=,,: 3.23 Tube for oil reservoir 441 MP 23 :,1 'if' I ~~" 3.24 Angular Connection with

valve seal 441 MP 24t\ '1 !,A ( \; \~ 2 .3.25 Tube for manometer 441 MP 25

: L:J! i ;:\'3.26 Manometer Connection 441 \iP 26

, ,~-' 3.27 Manometer 377 MP 11

f , ", 3.28 Front Plate 441 MP 28

:1 ~;; ':!,l3.29 Cover 441 MP 29

, ,;;. 4.1 Cylinder Bottom 441 MP 30f1:'

4.2 Cylinder Tube 441 MP 314.3 O-ring 46x2 mm dia. 441 MP 324.4 Piston 441 MP 334.5 Gasket and O-ring 441 MP 344.6 Slide Ring 441 MP 35

I F . d: Ig. anI POSe No. Description Spare Part No.

4.7 Piston Rod 441 ~P 364.8 Spring 441 ~P 374.9 Retaining Ring 441 MP 384.10 Flange 441 MP 394.11 Scraper Ring 386 MP 114.12 Disc 441 MP 40

4.13 Seeger Ring, stainless,65x2.5 mm dia. 441 r-.1P 41

4.14 Connection Ring forPrestopress-2 Cylinder Sets 441 ~iP 42

4.15 Locking Pawl with balland magnet 441 MP 43

4.16 Pointed Screw for piston rod 377 MP 404.17 Lower Ram (state cyl.dia.) 377 MP 724.18 Upper Ram (state cyl.dia.) 377 MP 744.19 Embedding Cylinder

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I Fig. andI i POSe No. Description Spare Part No..0.

6.8 Top for bellow 441 MP 586.9 Oil Filler Screw 441 MP 596.10 Pin for bellows guiding 441 MP 606.11 Spindle 441 MP 616.12 Distance Pipe 441 iP 626.13 Sleeve 441 MP 636.14 Star Handle 441 MP 64

Oil, 1 litre 441 MP 657.1 Heating/cooling element,

(state voltage and frequency) 377 MP 837.2 Holder for melting fuse 359 MP 517.3 Melting Fuse 359 MP 527.4 Spring Ring 386 MP 837.5 Thermostat 386 MP 847.6 Terminals 386 MP 85

7.7 Cable Entry, screwed 386 :\iP 867.8 Plate 386 MP 877.9 Front Plate 386 MP 887.10 Signal Lamp 359 MP 1117.11 ON/OFF Switch 394 MP 407.12 Cabinet, lower 386 MP 917.13 Cabinet, upper 386 MP 927.14 Cabinet, back 386 MP 93

7.15 Insulating Ring 377 MP 917.16 Top Ring 377 MP 92

Embedding Unit,220 V/1400 W, complete 441 MP 66

Embedding Unit,115 V/1100 W, complete 441 MP 67

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