Metkon MOBIPREP

Operation & Instruction Manual

Portable Grinding/Polishing & Electrolytic Etching

EC Declaration of Conformity

Manufacturer: Metkon Instruments Inc.

Address: Demirtas Dumlupinar Organize Sanayi Bolgesi, Ali Osman Sonmez Cd. No: 14 Bursa / TURKEY

Model No: MOBIPREP

Herewith declares that the Portable Grinding/Polishing & Electrolytic Etching Machine confirms compliance with European Community Directives related to electromagnetic compatibility (89/336/EEC) and CE marking (93/68/EEC) as of 18.09.1998.

This declaration applies to all identical copies of the product. Relevant harmonized European standards have been applied for electromagnetic compatibility assessment.

Date: 2017

Description

The MOBIPREP is a battery-powered portable Grinder / Polisher and etcher designed for metallographic sample preparation in the field or in a laboratory. It features maintenance-free batteries for operation without stationary mains power. The system consists of a control unit and a precision hand-guided grinding-polishing device with a high-performance micro motor. The hand-guided device can be used with either 45° or 90° angle or straight grinding-polishing pieces.

The ON/OFF switch is located on the hand-guide and provides tactile feedback with an audible tone from the control unit when operated. All accessories are supplied with a hardcase protection and carrying bag. The MOBIPREP can also be used for electrolytic etching with the included etching pen, allowing for the etching of alloyed steels with weak electrolytes, even in field conditions.

Technical Data

Model	MOBIPREP 90 01
Voltages	36V or 100-240V / 50-60 Hz
Speed	0 - 25,000 rpm
2 LED Indicator	On / Low Battery
Operation Modes	E - Etching-1 (E1) EP - Etching-2 or Polishing-1 (E2 or P1) EPG - Etching-3 or Polishing-2 or Grinding-1 (E3 or P2 or G1) PG - Polishing-2 or Grinding-2 (P2 or G2) G3 - Grinding-3 G4 - Grinding-4
Disc Diameter	30 mm
Reduction Gear	3.9:1
Dimensions, WxDxH	104 x 54 x 160 mm
Weight	1 kg

Warranty

The MOBIPREP is guaranteed against defective material or workmanship for 12 months from the date of receipt by the customer, or a maximum of 18 months after the shipping date. The warranty is void if inspection reveals misuse or unauthorized repair. Warranty covers only replacement of defective parts. For service, contact your distributor with the unit's serial number, invoice number, and date. Transport costs are the customer's responsibility.

NOTE: The equipment is designed for use with METKON accessories and consumables. METKON is not responsible for damages resulting from misuse, improper installation, alteration, use of non-METKON parts, or improper repair. Disassembly should only be performed by a qualified technician.

NOTE: METKON Instruments Inc. reserves the right to make changes to equipment, accessories, consumables, and products without notice. Information in manuals, technical materials, and marketing may differ from the actual product.

Safety Precautions

Operators must be fully instructed in the use of the equipment, accessories, and consumables according to this manual.
Material Safety Data Sheets for Metkon consumables are available at www.metkon.com under the E-Metkon section.
Ensure the MOBIPREP is placed firmly on a stable support.
Always store the MOBIPREP, micro motor, accessories, and consumables in their carrier and protection bag.
Do not touch electrical cables or parts with wet hands. ⚠️
When disconnecting from power, always pull the plug, not the cable.
Immediately disconnect from power if water or any liquid penetrates the unit. ⚠️
Do not insert metallic, flammable, or other objects into the MOBIPREP or its sockets.
Disconnect from power after charging.
Only connect supplied devices to MOBIPREP sockets.
Do not open the control unit or attempt to change internal parts.
Do not touch the micro motor while it is rotating.
When installing accessories, tighten the collet chuck correctly and recheck before use. Do not overtighten, as this can damage the spindle.
Avoid applying excessive force, which can cause tool slippage, damage, injury, loss of concentricity, or precision.
Clean the collet chuck and spindle before replacing grinding tools. Metal chips or particles can damage the collet chuck or spindle.
Stop operation immediately if abnormal rotation or vibrations occur. Consult the "TROUBLESHOOTING" section.
If the motor and attachment generate heat from continuous use, reduce motor speed or stop the motor until it cools down.
Always inspect the equipment and accessories for damage before and after operation.
Do not disassemble, modify, or attempt to repair the MOBIPREP. Service must be performed by METKON or an authorized service center.
In case of any malfunction, contact your supplier or the manufacturer.

Installation & Set Up

Unpacking & Checking Contents of Package

Carefully unpack and check all contents. If any components are missing or damaged, save the packing list and materials and notify your distributor and the carrier.

Ensure the following items have been received:

MOBIPREP
High Torque Brushless DC Motor
5 pcs. Grinding & Polishing Carrier
4 pcs. Storage box for consumables
90° Angle Attachment
Protection and Transport Case

WARNING: The MOBIPREP weighs 1 kg. Ensure it is secured to prevent it from tipping over. Carefully remove outer packing material and refer to packing documents for a complete list of supplied items.

Installation and Set-Up

CAUTION: Follow approved procedures and safety measures when lifting and installing this equipment. Improper lifting can cause damage.

Electrical Installation

The MOBIPREP is a portable, battery-powered unit. Before connecting the charger, verify that the voltage and frequency on the specification plate match your local supply. Ensure the single-phase voltage is compatible with your electrical supply.

ATTENTION: Connect the unit to a grounded mains voltage supply.

WARNING: Electrical Shock Hazard. All hard wiring and electrical maintenance should be performed by a qualified electrical technician.

Disconnect the power supply before making any electrical adjustments.
Verify that the supply voltage and frequency are correct by checking the machine's identification plate.

Voltage / Frequency	Operational Power Range	Fuse Rating
230 V, 50/60 Hz, 1 ph.	200 - 250 V	5A (C Type)
115 V, 50/60 Hz, 1 ph.	100 - 125 V	5A (C Type)

Dimensions and weight of MOBIPREP:

	W	D	H
Dimensions	104 mm	54 mm	160 mm
Weight	Approx. 1 kg

Operation

Charging the Battery

To charge the built-in batteries:

Connect the battery charger to the charging socket (#5).
The Battery Indicator will light green when fully charged, and red when charging is needed.

WARNING: Fully charged batteries self-discharge in 4-6 months. Complete discharge can reduce battery lifetime. Charge batteries at regular intervals.

Connection of the Attachments to the Brushless DC Motor

CAUTION: Ensure hands and all interlocking parts of attachments and motor are clean before connecting to prevent contaminants from entering the motor or attachment.

Reduction Gear (Reducer) Connection

Align the threads on the motor's front end with the reducer's rear end and turn the reducer clockwise.
If the drive shaft does not engage the drive dog, turn it approximately 2 turns. DO NOT FORCE.
If engagement is difficult, turn the reducer back a few threads, rotate the reducer by hand to engage the drive shaft and drive dog, then screw them together using the provided pin wrench.

[Diagram description: Shows aligning threads, tightening, and turning the reduction gear.]

90° and 45° Angle Attachment Connection

The 45° angle attachment is an optional accessory.

Align the thread on the motor's front end with the angle attachment's rear end and turn clockwise.
If the drive shaft does not engage the drive dog, turn it approximately 2 turns. DO NOT FORCE.
If engagement is difficult, loosen the angle attachment, rotate its shaft by hand, and re-try to ensure full engagement of the drive shaft and drive dog.
Once fully engaged, secure the motor and angle attachment using the provided pin wrench.

[Diagram description: Shows connecting the angle attachment to the motor.]

Straight Quick Release Piece Connection (Optional)

Align the threads on the motor's front end with the attachment's rear end and turn clockwise.
If the drive shaft does not engage the drive dog, turn it approximately 2 turns. DO NOT FORCE.
If engagement is difficult, turn the attachment back a few threads, rotate it by hand to engage the drive shaft and drive dog, then screw them together using the provided wrench.

[Diagram description: Shows connecting the straight quick release piece to the motor.]

Changing the Grinding and Polishing Carriers on Angle Attachment

Attach the collet wrench to the attachment head. Apply light pressure and place the wrench on the collet chuck.
Turn counterclockwise slowly. The collet wrench will engage within 90° of rotation.
Continue turning until the rod on the angle attachment can be removed.
When mounting new carriers, turn the wrench clockwise to tighten firmly.

[Diagram description: Shows using the collet wrench to loosen and tighten the collet chuck for changing carriers.]

Changing the Grinding and Polishing Carriers on Straight Quick Release Piece (Optional)

Turn the lock spindle towards the arrow to release the rod and remove by hand.
Mount the grinding & polishing carriers firmly and lock the spindle to the "CLOSE" position.
If the collet chuck is difficult to remove, use the provided wrench.
For high torque cutting tools or when closing the collet chuck, if the chuck or tools cannot be removed by hand, use the provided wrench. Open the lock spindle (lever) and turn the wrench counterclockwise to release the collet chuck or cutting tools.

[Diagram description: Shows releasing the spindle, changing carriers, and using the wrench to loosen the collet chuck.]

Grinding and Polishing Operation

Connect the hand-guided device to socket #4.
Select the Grinding Mode (G) using adjustment knob #3.
Place SiC grinding paper (ø30 mm, 80-1200 grit) on the carrier.
Select the Polishing Mode (P1 or P2) using adjustment knob #3 (P1 for pre-polishing, P2 for fine polishing).
Place the polishing cloth on the carrier.
Apply diamond pastes to the cloth (grain sizes: 9μ, 6μ, 3μ, 1μ, 0.25μ).
Use sufficient diamond lubricant between the sample and cloth for lubrication, friction reduction, and cooling. The cloth should be moist, not wet.
Switch the hand-guided device ON/OFF using the control button on the micro motor.
Apply light pressure during grinding and polishing.
Clean the prepared spot with water or alcohol (ethanol) between steps.

[Diagram description: Shows the grinding/polishing setup with the hand-guided device.]

Etching (Optional)

Electrolytic etching can be used after grinding and polishing as an alternative to chemical etching.

Connect the Etching Pen to Socket #4.
Clamp the anode (red wire) of the Etching Pen to the sample or workpiece using the clamp or magnetic anode.
Select the Etching Mode (E1 or E2) using adjustment knob #3.
Remove the pen cap, insert a cotton-wool applicator, and fill the Etching Pen with the relevant electrolyte using the syringe. The applicator should be soaked with the electrolyte.
Wipe the etching pen on the prepared spot until the desired etching is achieved (the surface will become darker).
After etching, clean the area with water or alcohol (ethanol) to stop the process.
Avoid over-etching when using a portable microscope. For replica examination, over-etching may be necessary.
When not in use, replace the cap on the Etching Pen.

[Diagram description: Shows using the etching pen on a sample.]

Recommended Electrolytes

Materials	Electrolyte	Etching Mode	(Replacing Chemical Etching with...)
Carbon steels	Special Salt Solutions (e.g. 5% NaCl solution)	E2	(Nital)
Aluminum Alloys	10% oxalic acid	E1	(10% NaCl solution)
Austenitic stainless steels	Nital (3% HNO3 in ethanol) + water (50:50) or 3% aqueous HNO3	E2	(V2A-steel formulation)
High-alloyed steels (ferritic / martensitic)	Nital (3% HNO3 in ethanol) + water (50:50) or 3% aqueous HNO3	E2	(concentrated acid formulations)

Replica

The replica material is cellulose acetate, 35 microns thick, soluble in acetone.

Cut a piece of replica material to cover the area to be replicated.
Apply one or two drops of acetone to the specimen surface.
Place the replica film immediately onto the surface, allowing surface tension to pull it down without pressure.
Let the film dry for about 10 minutes until it can be easily separated from the surface.
Remove the film and place it between two cover glass slides for microscopic examination.

Service and Maintenance

Maintenance

Clean the MOBIPREP with a soft, slightly damp cloth.
Clean grinding & polishing carriers and accessories before attaching them to the micro motor to prevent dust and particle contamination.

Troubleshooting

ERROR	DESCRIPTION	ACTION
Overheating during rotation	Excessive force is applied during operation	Lower the force applied.
Abnormal vibration or noise during rotation	The grinding & polishing carrier is bent.	Replace the grinding & polishing carrier.
Cutting Tool Slippage	Collet chuck is not correctly installed.	Check and clean the collet chuck. Reinstall the collet chuck and re-tighten.
High Run Out	Collet chuck is worn.	Replace the Collet chuck.

Accessories and Consumables

Accessories

Order No	Accessories for MOBIPREP
90 10	Etching-Pen for electrolytic etching
90 11	Angle piece 90°, with 3-mm collet on
90 12	Angle piece 45°, with 3-mm collet on
90 13	Straight quick release piece, with 3-mm collet on
90 14	Grinding and polishing carriers (5 pieces)
90 15	Shoulder bag for Mobiprep, synthetic leather

Consumables

In-situ/Field metallography is used for microstructure analysis on large parts that cannot be easily transported or where destructive preparation is permissible (e.g., storage tanks, piping systems, power plants). In-situ Metallography allows for quick on-site evaluation of components, offering numerous advantages.

Paper Grinding Discs, Self-Adhesive Back (1 Pack 250 Pcs.)

Order No	CODE	Description
90 20	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 80 Grit
90 21	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 120 Grit
90 22	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 320 Grit
90 23	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 500 Grit
90 24	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 800 Grit
90 25	DEMPAX-P	SiC-grinding papers, self-adhesive, 250 pieces (ø 30 mm), 1200 Grit

Polishing Cloth Self-Adhesive (1 Pack 50 pcs.)

Order No	CODE	Description
90 26	PORTO	Polishing Cloth (30 mm) for 0.25, 1, 3 microns (50 pcs.)
90 27	RADO	Polishing Cloth (30 mm) for 6, 9 microns (50 pcs.)

Diamond Pastes, Monocrystalline

Order No	CODE	Description
39-301-M	DIAPAT-M	Diamond Paste, 0.25 µm, 10gr. syringe
39-311-M	DIAPAT-M	Diamond Paste, 1 µm, 10gr. syringe
39-321-M	DIAPAT-M	Diamond Paste, 3 µm, 10gr. syringe
39-331-M	DIAPAT-M	Diamond Paste, 6 µm, 10gr. syringe
39-341-M	DIAPAT-M	Diamond Paste, 9 µm, 10gr. syringe

Diamond Lubricant

Order No	CODE	Description
39-502	DIAPAT	Diamond Lubricant, Water-based, 1 lt bottle

Replica Set & Etching Consumables

Order No	CODE	Description
90 28		Cotton rolls (100 pcs) for electrolytic etching
90 40	REPLI	Replica foil 35 microns thick, to be used with acetone
90 41		Microscope slide glasses

Technical Documentation

Customer Service

Metkon Instruments Inc. offers factory-trained assembly personnel for customer service. Please contact the following address:

Head Quarter
Metkon Instruments Inc.
Demirtas Dumlupinar Organize Sanayi Sitesi
Ali Osman Sonmez Cad. No: 14 Bursa/TURKEY
Tel: +90 (224) 261 1840
Fax: +90 (224) 261 1844
E-Mail: metkonsales@metkon.com
Web: www.metkon.com