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Pace Technologies TERAPRESS TP 7500S Instruction Manual Download Page 45

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  ▲           

I

NSTRUCTION 

M

ANUAL

 

TERAPRESS TP 7500S 

Mounting Press

 

 

Please read this instruction manual carefully and follow all installation, operating and safety guidelines.

 

3601 E. 34th St. Tucson, AZ  85713  USA  Tel. +1

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520

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882

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6598  Fax +1

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520

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882

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6599  email: [email protected]    Web: https://www.metallographic.com

 

 

 

TPS

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0150

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3

 

1.50in bottom ram

 

 

TPS

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0150

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4

 

1.50in sleeve

 

 

TPS

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0200

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1

 

2in top ram

 

 

TPS

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0200

 

2in spacer

 

 

TPS

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0200

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3

 

2in bottom ram

 

 

TPS

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M

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006

 

Ram rod

 

 

Part no.

 

Description

 

Image

 

  

Mechanical components

 

  

41

 

Summary of Contents for TERAPRESS TP 7500S

Page 1: ...ety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com Equipment Type Automated Compression Mounting Press Model TERAPRESS TP 7500S Compression Mounting Press Electrical Requirements 110 220 Volts Frequency 50 60 Hz Manual Revision Date April 24 2022 ...

Page 2: ...A Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com Contents PAGE Warranty i 1 0 Safety Guidelines 1 2 0 Product Description 3 3 0 Unpacking Shipping and Installation 7 4 0 Start Up and Operation 10 5 0 Maintenance 21 6 0 Troubleshooting 22 7 0 Compression Mounting Guide 24 8 0 List of Spare Parts 34 9 0 Electrical and Mechanical Drawings 48 ...

Page 3: ...r including any reference to Buyer s specifications and any description in catalogs circulars and other written material published by PACE Technologies is the sole purpose of identifying such goods and shall not create an express warranty that the goods shall conform to such description THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED THERE ARE NO IMPLIED WARRANTIES ...

Page 4: ...spended during any period of such default and the original warranty period will not be extended beyond its original expiration date despite such suspension of warranty rights 7 MISCELLANEOUS PROVISIONS This agreement has been made in and shall be governed by the laws of the State of Arizona These terms and conditions and the description of the Products on the reverse side hereof or in any proposal...

Page 5: ...ecommended that no extension cords or multiple outlet connectors be used as this may cause the fuse to overheat but not blow during operation Careful attention to this instruction manual and the recommended safety guidelines is essential for the safe operation of the TERAPRESS TP 7500S mounting press Proper operator training is required for operation of the TERAPRESS TP 7500S mounting press Unauth...

Page 6: ...lation can result in hot molten mounting material leaking danger of burning Initial cooling water coming into contact with mold will produce an initial burst of steam To avoid danger of burning secure the drain line and use caution when the TERAPRESS TP 7500S compression mounting press is in use Mold cylinder and ram get very hot during the mounting process Take care before changing danger of burn...

Page 7: ...melt Rapid heating is achieved by a heater that completely surrounds the mold assembly and is precisely controlled via microprocessors Cooling is also accelerated by a water cooling jacket and can be accomplished by cooling for a set amount of time or to a specific temperature This ensures that curing can be achieved for both thermoset and thermoplastic compression mounting resins Depending on you...

Page 8: ...t 220V 10 amp Thermostat range Room temperature to 392ºF 200ºC Hydraulic pressure range Max 6460 psi Timer 0 99 minutes Mold sizes 1 1 25 1 5 and 2 inch 25 30 and 40 mm Weight 102 lbs 46 kg Dimensions WxHxD 31 x 19 x 19 inches 534 x 485 x 485 mm Working temperature 32 100 F 0 40ºC Shipping temperature 32 100 F 0 40ºC Storage temperature 32 100 F 0 40ºC Water supply connection 8 mm quick connect Wa...

Page 9: ...fety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 2 3 Mechanical Schematic Note Installation of the TERAPRESS TP 7500S should be on a flat sturdy surface with easy access to electrical water and drain connections 5 31 inches 19 inches 19 inches ...

Page 10: ...ated into the upper part of the mold cylinder for efficiency Heating is controlled by a thermostat with the heating times being variable up to 15 minutes The cooling cycle begins automatically after the designated hold time at temperature has passed Cooling can be completed one of two ways 1 Cooling to a preset temperature 2 Cooling for a specific amount of time The TERAPRESS TP 7500S compression ...

Page 11: ...534 x 485 x 485 mm Weight Approx 102 lbs 46 kg 3 2 Shipping When moving box lift from bottom The TERAPRESS TP 7500S compression mounting press is constructed of sensitive electronic and mechanical components Do not drop Use caution when unloading to prevent injury 7 3 3 Installation Install unit carefully Improper installation voids warranty The TERAPRESS TP 7500S compression mounting press should...

Page 12: ...le in 220V IT IS ALSO RECOMMENDED THAT NO EXTENSION CORDS OR MULTIPLE OUTLET CONNECTORS BE USED AS THIS MAY CAUSE THE FUSE TO OVERHEAT BUT NOT BLOW DURING OPERATION Coolant drain The coolant drain line requires a 1 4 inch hose CAUTION The mold temperature is very hot and the initial contact of the cooling water turns to steam which exits the drain hose at a very high temperature Coolant supply The...

Page 13: ... com Web https www metallographic com 9 External Coolant Tank As an optional attachment an external recirculating coolant tank can be connected to the back of the TERAPRESS TP 7500S compression mounting press The advantages of using this tank include significant reduction in water usage as well as shorter cooling times due to the heat exchanger built into the tank The reduction in cycle times can ...

Page 14: ...ration Buttons Settings for Current Procedure Returns to the startup screen Opens the settings Moves the ram down and up Main Operation Buttons The TERAPRESS TP 7500S mounting press has been designed for ease of use in producing high quality metallographic mounts using materials such as phenolics diallyl phthalates hard glass filled epoxies and conductive thermosets The TERAPRESS TP 7500S comes wi...

Page 15: ...raphic com 4 3 Loading a Saved Procedure 1 From the home screen touch the Procedure Manager button 2 Find the desired procedure and touch Select The Select button will appear green for the selected procedure 3 Touch the Load Selected button 4 Touch the BACK button to return to the home screen The selected procedure specifications will now appear at the top 5 Touch Start button 6 The system will no...

Page 16: ...lot 3 Touch numerical value for pressure heating temperature and holding time Use keypad to change to desired values 4 Set Cooling Mode to either Temp or Time Then touch either cooling tempera ture or cooling time and use keypad to change to desired values 5 To set cooling rate touch button to toggle between Low and High 6 Touch the field labeled Name to input a name for the custom procedure using...

Page 17: ...e procedure This is helpful for situations such as where heating the mounting compound or sample needs to be done at a slower rate to ensure proper curing or if the sample is brittle and needs to be pressurized before temperature should be applied for structural integrity of the sample To add Soft Start to a procedure select Soft Start next to the desired procedure Empty boxes will now appear unde...

Page 18: ...e Graph This setting allows for toggling between grayscale and color for the time temperature cycle graph Unit Type This sets the default units of the temperature and pressure values Allow Changes to Procedure on Main Screen This allows the user to change parameters of the procedure after it has been loaded PID Sampling Period This sets the frequency of sampling for the PID controller PID Paramete...

Page 19: ...e and remove bayonet closure 10 Raise ram to push out specimen mount DO NOT POSITION HEAD OVER MOLDING CHAMBER AS THE MOUNTS MAY STICK AND BE EJECTED IF NOT COMPLETELY COOLED OR IF THERE IS DAMAGE TO THE MOLD ASSEMBLY If mold does not easily move refer to troubleshooting guidelines Note The TERAPRESS TP 7500S compression mounting press is capable of single and double mounts by adding a spacer on t...

Page 20: ...lammable materials Lower ram and add mounting material It is recommended that a funnel be used to minimize spilling and to keep the top of the mold clean easier installation and removal of upper ram Upper ram and bayonet closure must be lowered into position for bayonet closure to lock properly After properly positioning upper ram and bayonet turn to tighten Caution Improper closure can result in ...

Page 21: ...g to mounting material recommendations see Tables 4 1 to 4 5 on the following pages Set force according to mounting material recommendations see Tables 4 1 to 4 5 on the following pages 1 Select and install required mold assembly 2 Insert sample and add mounting material 3 Select temperature heating time holding time and force 4 Activate mounting operation by pushing start button Upon completion t...

Page 22: ... Web https www metallographic com 4 8 Changing Mold and Ram Assembly 1 Lower ram 2 Unscrew bayonet closure 3 Raise lower ram up and slide off of base to remove 4 Unscrew reverse threaded the upper ram to remove 5 Loosen the four hex screws by the top of mold assembly to remove mold Unscrew bayonet closure Raise lower ram up and slide off of base to remove Unscrew the upper ram to remove Remove by ...

Page 23: ...2 inch mounts Temperature ºC 160 C 320 F 160 C 320 F 160 C 320 F 160 C 320 F Machine gage pressure psi MPa 2150 14 8 2500 17 2 3750 25 9 6250 43 1 Time minutes minimum 8 10 12 12 Grams of powder 10 2 16 0 23 40 8 Parameters 1 inch mounts 1 25 inch mounts 1 5 inch mounts 2 inch mounts Temperature ºC 160 C 320 F 160 C 320 F 160 C 320 F 160 C 320 F Machine gage pressure psi MPa 2150 14 8 2500 17 2 37...

Page 24: ...sample 20 Parameters 1 inch mounts 1 25 inch mounts 1 5 inch mounts 2 inch mounts Temperature ºC 160 C 320 F 160 C 320 F 160 C 320 F 160 C 320 F Machine gage pressure psi MPa 2150 14 8 2500 17 2 3750 25 9 6250 43 1 Time minutes minimum 8 10 12 12 Grams of powder 13 7 21 4 30 8 55 Table 4 5 Acrylic Mounting Powders Parameters 1 inch mounts 1 25 inch mounts 1 5 inch mounts 2 inch mounts Temperature ...

Page 25: ...h Do not use any chemicals or cleaning medium containing abrasive particles 5 3 Cleaning inside cabinet Over time small quantities of mounting residual can build up inside the cabinet It is recommended that once a year the TERAPRAESS TP 7500S mounting press be cleaned with a vacuum cleaner be sure to disconnect the power before opening the panel 5 4 Filter It is recommended that a filter be used o...

Page 26: ...ect main cable Main switch off Turn on main switch Blown fuse Replace fuse 10 amp fast blow Heating temperature is not reached Defective heating element Replace Leaking water solenoid Replace Bayonet closure and upper ram do not fit into mold Mold cylinder is too hot thermal expansion Let system cool Ram or mold cylinder is defective Replace Closure is tilted Reposition closure Ram is dirty Clean ...

Page 27: ...cooling slowly up and disassemble immediately Cooling water flow is weak or none at all Water supply is off Open valve Solenoid is damaged Clean and or replace ON OFF power switch getting too hot Fuse overheating Replace fuse 10 amp fast blow Too many amps being pulled from the incoming power outlet Plug directly into wall outlet Do not use any extension cords or multiple outlet connections Water ...

Page 28: ...ch can provide better specimen edge retention compared to castable mounting resins Compression mounting resins are available in different colors and with various fillers to improve hardness or conductivity Figure 7 1 Several compression mounting characteristics include Convenient means to hold the specimen Provides a standard format to mount multiple specimens Protects edges Provides proper specim...

Page 29: ...tant features include its maximum heating temperature and how intimately the heater and water cooler are connected to the mold assembly The better compression mounting machines have heaters which can reach temperatures of at least 200 C 450 F For faster turn around time water cooling is essential see Figure 7 2 The primary compression mounting resins are listed below along with standard colors Phe...

Page 30: ...in 100X Figure 7 6 Conductive graphite mount 100X 7 1 Compression Mounting Resin Properties There are a variety of compression mounting materials The two main classes of compression mounting materials are thermosets and thermoplastics Thermoset resins require heat and pressure to crosslink the polymer and the reaction is irreversible Thermoplastics on the other hand can theoretically be remelted T...

Page 31: ...the label on top the mount and cover it with a little acrylic powder To label other compression mounting resins add a thin layer of acrylic over the other mounting material and then position the label on this layer Finish off the mount with another layer of acrylic Figure 7 7 Example of labeling mounts using acrylic resin on top of a phenolic base TABLE Ia Compression Mounting Resin Characteristic...

Page 32: ...ar or Powder Granular Specific gravity gm cm3 1 4 0 95 1 75 2 05 1 7 1 9 Colors Black Red Green Clear Black to gray Blue Black Shrinkage compression in in 0 006 N A 0 001 0 003 0 001 0 003 Coefficient of Linear Thermal Expansion in in C 10E 6 50 N A 28 19 Chemical resistance Glycol petro chemicals solvents some acids and bases Alcohol dilute acids alkalis and oxidizers Solvents acids alkalis Solve...

Page 33: ...e available in a variety of colors Figure 7 8 Figure 7 8 Phenolic resins are available in a variety of colors TIP Use different color phenolics to color code jobs specimens types or for different testing dates For example changing the phenolic color each month will show which samples or jobs are getting old TIP If the color dye in the mount bleeds out when rinsing with an alcohol this is an indica...

Page 34: ...are heated to too high a temperature too quickly This causes a liquid layer to form around the unmelted resin giving it the appearance of a cotton ball in the middle of the mount see figure 7 10 To avoid this problem it is recommended to mount at a lower temperature 120 140 C or to utilize a Soft Start feature that preheats the resin and sample to a lower temperature 120 C before the mounting pres...

Page 35: ...thalates Glass filled epoxies and diallyl phthalates compression mounting resins provide a harder mounting support edge next to the specimen see Figure 7 11 These resins are commonly used to support the edges of coatings heat treated samples and other specimens requiring better flatness Figure 7 12 shows the polished interface between a glass filled epoxy and tungsten carbide specimen Note that th...

Page 36: ...alate around the specimen in order to compensate for any grinding loss The rest of the mount can then be supported with a lower cost compression mounting compound such as a phenolic Red phenolics are used frequently for this technique Figure 7 13 Figure 7 13 Glass filled epoxy laminated with phenolic to reduce the cost of the mount 7 1 4 Specialized Compression Mounting Resins With the addition of...

Page 37: ... release compound to mold assembly 4 Raise mold ram to up position 5 Center specimen on ram 6 Lower ram assembly 7 Pour predetermined amount of resin into mold 8 Clean and remove any excess resin from around the mold assembly threads 9 Lock mold assembly cover 10 Slowly raise ram into up position 11 Apply recommended heat and maintain pressure for specified period of time 12 Cool to near room temp...

Page 38: ...82 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 34 8 0 List of Spare Parts Part no Description Image Electrical HR 8 80 250W Heater rod Φ8 80 250W 110V TC 200C C Temperature Controller 200C closed TPS E 003 Thermocouple M8 Pressure reed K type 120MM FAN Fan 120 120 25 24V POW LC Large Current Switch Socket POW 30A SWITCH Socket with lamp 20A FH 20A Fuse ho...

Page 39: ...1 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com FUSE 6 30 15A Fuse Φ6 30 15A TPS E 001 Solid state Rely DC Control AC Da40A TPS E 002 Heat sink PS 24V LRS15024 Power Supply LRS 150 24 TPS H E 001 Pressure Sensor 4 20 mA 0 30MPA 2 lines 24V Part no Description Image Electrical 35 ...

Page 40: ...USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com SRN T 7IN Capacitive touch screen 7in with 485 communication TPS E 010 Cylinder magnetic induction 6 5 8 5 RELAY HF105F 4 024D 1HS Relay HF105F 4 024D 1HS TB T3 Terminal blocks UK2 5B TB RAIL Slide TB T2 Two side fixed block TB DAM BOARD Dam board Part no Description Image Electrical 36 ...

Page 41: ...s 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com WIRE RT 2020 Trunking 20 20 PCB TPS PCB TPS H E 002 Oil tank TPS H E 003 Hydraulic device MOT SVO 750 750W Servo Motor MD 110220 SVO 110 220V Servo Motor Driver TPS T Screen Template Part no Description Image Electrical 37 ...

Page 42: ...cson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com TPS75 T TP 7500S Template Part no Description Image Electrical Part no Description Image Mechanical components TPS M 001 Bottom plate TPS 001 Top cover plate TPS 002 Fixed connect block TPS M 002 Fixed board TPS M 003 Oil cylinder board TPS M 004 Sleeve cap 38 ...

Page 43: ...y guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com TPS 003 Sleeve cap cover TPS M 005 Heat Block TPS 0100 1 1 00in top ram TPS 0100 1 00in spacer TPS 0100 3 1 00in bottom ram TPS 0100 4 1 00in sleeve Part no Description Image Mechanical components 39 ...

Page 44: ...y guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com TPS 0125 1 1 25in top ram TPS 0125 1 25in spacer TPS 0125 3 1 25in bottom ram TPS 0125 4 1 25in sleeve TPS 150 1 1 50in top ram TPS 150 1 50in spacer Part no Description Image Mechanical components 40 ...

Page 45: ...afety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com TPS 0150 3 1 50in bottom ram TPS 0150 4 1 50in sleeve TPS 0200 1 2in top ram TPS 0200 2in spacer TPS 0200 3 2in bottom ram TPS M 006 Ram rod Part no Description Image Mechanical components 41 ...

Page 46: ...th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com TPS F 001 Back plate TPS F 002 Front metal template TPS F 003 Solenoid valve holder TPS F 004 Circuit board fixture TPS F 005 Bottom frame TPS F 006 Protection cover 1 TPS F 007 Protection cover 2 Part no Description Image Sheet Metal Parts 42 ...

Page 47: ...ax 1 520 882 6599 email pace metallographic com Web https www metallographic com P 1 4 YF FF Filter 1 4 Y type brass female P 1 4 F 12BARB Pagoda joint 304 G 1 4 Φ12 HOSE HT High temperature hose 13 21 6MM TUBE T Teflon tube 4 6 SS 6MM FTE 018 Fast twist joint ZG 1 8 Φ6 SS304 TP TH P Choke plug G1 8 SS 8MM Quick connector 1 4 Φ8 SUS SS 6MM YT Y Quick connector 1 4 Φ6 SUS Part no Description Image ...

Page 48: ... 882 6599 email pace metallographic com Web https www metallographic com TPS SOL Solenoid DC24V SS 6MM TJ Fast twist joint 1 4 Φ6 SS FC E Flow control valve 90 degree needle type SS FTC 014 Female Threaded Coupler 1 4 SUS SS 6MM Y Y Quick Connector Φ6 SUS SS 6MM FTE 014 Fast twist elbow 1 4 Φ6 PTC 3 8 E M 8MM Quick connector 3 8 Φ8 90 degree PTC 1 4 M 8MM Quick connector 1 4 Φ8 Part no Description...

Page 49: ...ce metallographic com Web https www metallographic com Part no Description Image Standard Parts TPS P 001 Adjustable exhaust valve 1 4 SS FTCE 014 Female Threaded Coupler 1 4 SUS 1CH9 16 14OG Adjustable elbow hydraulic joint 1CH9 16 14OG 1CM 16 14WD Hydraulic joint 1CM 16 14WD NL 16 JS RL 10 M16 1 5CAP 10 tube NL 16 JS RL 10 10MM PC 10 pipe clamp TPS H IP1 Iron pipe 1 TPS H IP2 Iron pipe 2 TPS H C...

Page 50: ... com Part no Description Image Standard Parts TPS H CG 20402802 Combination gasket 20 4 28 2 TPS H HP 14015 Hydraulic plug M14 1 5 TPS H AC 20015014015 Adapter connector inside 20 1 5 outside 14 1 5 TPS H AC 14015014015 Adapter connector inside 14 1 5 outside 14 1 5 TPS H AC 14015 Adapter connector inside M14 1 5 TPS H FBPJS8 Flanged ball head column SS304 FBPJS8 TPS 004 Bakelite handle M12 100 bl...

Page 51: ...ion operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com Part no Description Image Standard Parts TPS 007 PTFE washer 3in 62 82 2 TPS 008 Rubber feet M8 10 OD 30 H 29 47 TPS C1 SMC cover 1 TPS C2 SMC cover 2 SMC ...

Page 52: ...ction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 9 0 Electrical and Mechanical Drawings 48 9 1 Wiring Diagram ...

Page 53: ...this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 9 2 Heater Wiring Diagram for 110V 49 ...

Page 54: ...this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 9 3 Heater Wiring Diagram for 220V 50 ...

Page 55: ... read this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 9 2 Mechanical Drawings 51 ...

Page 56: ...Press Please read this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 52 ...

Page 57: ...Press Please read this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 53 ...

Page 58: ...Press Please read this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 54 ...

Page 59: ...Press Please read this instruction manual carefully and follow all installation operating and safety guidelines 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web https www metallographic com 55 ...

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