Pace Technologies MEGA-T400 Instruction Manual Download

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NSTRUCTION

ANUAL

MEGA-T400

Abrasive Cutter

3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: [email protected] Web: http://www.metallographic.com

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

Equipment Type:

14 or 16-inch Manual
Abrasive Cut-off Machine

Model:

MEGA-T400

Electrical
Requirements:

208Y 3-phase
(optional 380/415-480V 3-
phase)

Frequency:

50/60 Hz

Motor Horsepower:

7.5 hp (5.5 KW)
(3-phase)

Manual Revision
Date:

January 5, 2017

This instruction manual is
provided with each piece of
delivered equipment.

Summary of Contents for MEGA-T400

Page 1: ...nstruction manual carefully and follow all installation operating and safety guidelines Equipment Type 14 or 16 inch Manual Abrasive Cut off Machine Model MEGA T400 Electrical Requirements 208Y 3 phase optional 380 415 480V 3 phase Frequency 50 60 Hz Motor Horsepower 7 5 hp 5 5 KW 3 phase Manual Revision Date January 5 2017 This instruction manual is provided with each piece of delivered equipment...

Page 2: ...ding 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 OF MECH...

Page 3: ...by Buyer to pay all amounts due and payable to Seller under the work or purchase order or any other agreement between Buyer and Seller Buyer s rights under the warranty shall be suspended 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...

Page 4: ...hic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Contents PAGE Nameplate i Warranty ii 1 0 Product Description 1 2 0 Shipping Unpacking and Installation 5 3 0 Safety Guidelines 10 4 0 Start Up and Operation 11 5 0 Maintenance 16 6 0 Trouble Shooting 17 7 0 List of Spare Parts 18 8 0 Electrical Drawings 43 iii ...

Page 5: ... table feed abrasive cut off machine for cutting materials ranging from soft aluminum metals to hardened tool steels It is ideal for the metallographic laboratory as well as for small industrial or production applications The MEGA T400 is very robust and durable with its cast aluminum alloy and stainless steel construction Featuring a corrosion free T slot table the MEGA T400 is a very versatile f...

Page 6: ...14 inch 350 mm diameter 16 inch 400 mm diameter Wheel arbor 32 mm 1 25 inch diameter Maximum sample diameter 6 inch 150 mm Weight Approx 1200 lbs 545 kg Dimensions WxHxD Hood closed 50 x 64 x 39 inches 1270 x 1630 x 990 mm Hood open 50 x 83 x 39 inches 1270 x 2110 x 990 mm Table dimensions WxD 14 6 x 14 2 inch 370 x 360 mm Cutting chamber Cast aluminum block construction Hood and body Fabricated s...

Page 7: ...2 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines 1 3 Mechanical Schematic Note Installation of the MEGA T400 should be on a flat sturdy surface with easy access to electrical connections 3 ...

Page 8: ...he motor has an inductive brake for faster stopping of the blade Manual feed and table feed cutting The MEGA T400 is an easy to use manual cutter with simple controls Cutting can be accomplished with either a wheel feed or table feed The MEGA T400 also has two removable side port panels for sectioning longer samples 4 High leverage cutting handle Side panel for long sample access Table feed for in...

Page 9: ...delivered in a crate Unpack and check for completeness of parts Measures WxHxD Approx 55 x 48 x 72 Weight Approximately 800 lbs 2 2 Shipping When moving crate lift from bottom To move MEGA T400 use support bars provided with the machine The MEGA T400 is constructed of sensitive electronic and mechanical components Do not drop Caution Heavy equipment Take care to avoid bodily injury 5 Installation ...

Page 10: ...ER TURN SWITCH TO LOCK TO OPEN HOOD AND TO USE CUTTER Connect coolant tank supply drain and electrical connections Electrical connections The standard saw is designed to operate at 208 220V 3 phase 120V 120V 120V ground optional 380 400 480V Verify the direction of rotation of the cut off wheel The wheel should turn from top to bottom as viewed from the front of the machine CAUTION Before installa...

Page 11: ...Pump Tank drain valve External coolant supply Attach 1 2 inch tube between pump and cutter Drain 1 5 inch 38 mm tube Electrical connections Connect six foot electrical power cable to source Note Inspect the operating voltage on the name plate Electrical connection for external coolant supply Power for recirculation system comes from the MEGA M250 Recommended Coolant To minimize corrosion a coolant...

Page 12: ...utton Use only certified cut off wheels from a professional supplier Improper blades selection voids warranty For appropriate blade selection refer to the Abrasive Blade Selection Guidelines Chart in Section 4 3 Disconnect power before opening the main unit Replacement parts should be installed only by qualified personnel Securely clamp the part sample to the working table During cutting consider ...

Page 13: ...h a mobile three chamber counter current coolant tank The first chamber contains a coarse strainer for removing larger debris Replacement of the coolant is accomplished by rolling out the tank and removing the water pump Note Dispose of the old coolant in accordance with federal state and local regulations Coolant pump Pressure line After cutting it is recommended that the cutting chamber be rinse...

Page 14: ... important Emergency stop switch Magnetic Safety switch 10 Test Activate main switch and close hood depress emergency stop switch Proper Response Machine powers down Malfunction Machine does not lose power Corrective measure If system does not power down disconnect power supply cord and call service technician Magnetic safety lock out switch Test Activate main switch and close hood turn cut off wh...

Page 15: ... Emergency Shut off Cuts power to machine Cutting wheel ON Starts the cutting wheel Cutting wheel OFF Stops the cutting wheel inductive brake engages to slow wheel Hood cannot be opened until safety lock releases in approximately 5 seconds after pressing the stop button Coolant ON OFF Operates the coolant pump in Auto or Manual mode Motor amps Continuously monitors the amps that the motor is pulli...

Page 16: ...ographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines 4 3 Wheel and Table Feed Wheel feed chop cut Unlock wheel feed 4 3 1 Wheel feed cutting 4 3 2 Table feed cutting Open wheel spinner Lock wheel into position by turning lever counter clockwise Table feed wheel Unlock wheel by turning lever clockwise 12 ...

Page 17: ...allation operating and safety guidelines 1 Remove blade locking bolt 2 Position new 14 or 16 inch abrasive cut off wheel into position Use only certified abrasive cut off wheels 3 Gently tighten blade locking bolt Note locking bolt is reverse threaded 4 3 Changing abrasive cut off wheels 13 Changing Blade Remove Loosen by turning counter clockwise Tighten Turn clockwise To prevent arbor shaft from...

Page 18: ...sion Additive 128 oz MAXCUT2 1000 128 1 gallon 14 MAXCUT Abrasive Blades 32mm 1 Arbor Pace Product Name Catalog Number Packaging Soft Non ferrous Materials Aluminum Brass Zinc Etc MAX E350 10 Hard Non ferrous Materials MAX C350 10 Soft Steels MAX E350 10 Case Hardened Steels MAX D350 10 Hard Steels MAX D350 10 General Purpose Industrial Blade MAX I350 10 Universal Thin Blade MAX A350 10 16 MAXCUT ...

Page 19: ...ount the initial stress of the samples Fixture examples 4 5 Fixturing sample 17 Fast clamping Left lever Cat No LCL 1000 Right lever Cat No LCR 1000 Note vises have a slot in them so that the face does not rotate UNIVERSAL Clamping vise UNIVERSAL Cat No MG15 01 Clamping height 0 3 5 in 0 90 mm 15 4 4 Manual cutting step by step procedure 1 Connect electrical power and turn on master power switch o...

Page 20: ...uch as the MAXCUT 2 or an oil emulsion cutting fluid such as the MAXCUT OL 1000 It is recommended that the cutting fluid be changed every 50 cuts or weekly for maximum effectiveness 2 Rinse and dry the table and vises after use 3 When the cutter is not in use OPEN the HOOD to prevent humidity and corrosion build up inside the cutting chamber 4 If cutter will not be used for an extended period of t...

Page 21: ...safety switch is in Unlock position for shipping b Hood not closed c Overload relays activated a Turn safety switch to Lock position to operate cutter b Close hood c Restart after resetting Q1 relay Pump motor does not operate a Plug is disconnected b Overload relay activated a Check plug b Restart after resetting Q2 relay Excessive vibration during cutting a Not cutting with enough force b Specim...

Page 22: ...guidelines 7 0 List of Spare Parts Replacement of spare parts is possible with minimal expertise Spare parts for recirculation system are also available upon request 18 Part no Description Images Electrical M4 CB MEGA T400 Full control board replacement M4 QF1 208V MEGA T400 QF1 overload switch motor Schneider GV2 ME21C 17 23A M4 QF1 380V MEGA T400 QF1 overload switch motor Schneider GV2 ME20C 13 ...

Page 23: ...ety guidelines Part no Description Images Electrical M4 QF2 MEGA M250 QF2 overload switch pump Schneider GV2 ME05C 0 63 1A MEG RCMU RCMU timer blade MEG RAMU RAMU timer safety switch LC1D25BDC KM1 DC contactor MEGA T400 Schneider LC1D25BDC LC1D09B7C KM2 AC contactor MEGA T400 Schneider LC1D09B7C LC1D25B7C KM3 AC contactor MEGA T400 Schneider LC1D25B7C M4 MOTOR MEGA T400 Motor 5 5 KW M4 MOTOR S MEG...

Page 24: ...llow all installation operating and safety guidelines Part no Description Images Electrical M4 F1 MEGA T400 F1 fuse 2A M4 F2 MEGA T400 F1 fuse 2A M4 F3 MEGA T400 F1 fuse 30A M4 F4 MEGA T400 F1 fuse 30A M4 F5 MEGA T400 F1 fuse 2A M4 F6 MEGA T400 F1 fuse 2A M2 SAFE T MEGA M250 Safety lock out switch top piece M2 SAFE B MEGA M250 Safety lock out switch bottom piece M2 SAFE K Safety key MEG RL1 RL1 sw...

Page 25: ... com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Electrical T4 E TB 50 Amp terminal block T4 E GTB 50 Amp ground terminal block MEG LITE Light housing M 250B Light blub OSRAM Halogen DC24V 20 Watt M SEAL Wire plastic seal connector MEG PUMP 220 Pump 220 380V MEG PUMP 480 Pump 400 480V 21 ...

Page 26: ...om Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Electrical MEG FPC Female pump connector MEG MPC Male pump connectors MEG AM1 Ammeter set up kit MEG R Rectifier MEG AM2 Amp overload light MEG AM3 Amp overload light controller MEG TC 220 220 380V Transformer MEG TC 480 440 480V Transformer 22 ...

Page 27: ... com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Electrical MEG PS MEGA T400 Main power switch MEG ON On button green MEG LS Light ON Off switch MEG LB Power on light button MEG OFF Off button red MEG W Water ON OFF Switch 23 ...

Page 28: ...graphic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines P150 210 Emergency Stop M4 CABLE MEGA T400 control cable M4 FC MEGA T400 control cable female connector M4 MC MEGA T400 control cable male connector Part no Description Images Electrical 24 ...

Page 29: ...nd follow all installation operating and safety guidelines Part no Description Images Mechanical motor M4 SH MEGA T400 Blade shroud GS T400 M MEGA T400 Motor gas support piston each M4 LL Wheel feed locking mechanism T4 M 001 MEGA T400 wheel feed locking lever T4 M 002 MEGA T400 motor feed handle M4 RH T400 handle rubber handle M4 BELT MEGA T400 Drive Belt M4 MPUL MEGA T400 Motor pulley M4 APUL ME...

Page 30: ...ase read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical motor M4 SHAFT MEGA T400 Arbor shaft M4 AB MEGA T400 arbor shaft bearings 2 set M4 AF MEGA T400 Arbor bolt and blade flange M4 IAF MEGA T400 Arbor bolt and blade flange T4 M 003 Arbor bolt T4 M 004 Blade flange T4 M 005 MEGA T400 Arbor shaft 26 ...

Page 31: ...phic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical motor T4 M 021 Flange stop ring T4 M 028 Wheel fixture T4 M 029 Wheel fixture cover T4 M 030 Lock sliding slot T4 M 031 Lock ring T4 M 032 Lock screw nut 27 ...

Page 32: ... 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical motor T4 M 034 Lock Shaft T4 M 039 Motor table T4 M 035 Small lock pole T4 M 040 Motor shaft holder 28 ...

Page 33: ...tion operating and safety guidelines Part no Description Images Mechanical table M4 TAB MEGA T400 T slot table M4 TRB2 MEGA T400 lot rail bearings set of 4 M4 TAB L MEGA T400 T slot left larger table M4 TAB R MEGA T400 T slot right smaller table T4 P TBP MEGA T400 table bolt plugs M4 SUPPORT T400 table support bar M4 TG MEGA T400 Table feed guide rods pair M4 TRB MEGA T400 table rod bearings set o...

Page 34: ...arefully and follow all installation operating and safety guidelines M4 TRB2 MEGA T400 slot rail bearings set of 4 T4 M 036 Table rail feed slider T4 M 037 Table feed track nut M4 BOOT MEGA T400 Table feed boot M4 TFW MEGA T400 Table feed wheel M4 TFS MEGA T400 Table feed screw rod M4 TFA MEGA T400 screw feed front assembly includes bearings T4 M 007 Ball screw feed side Part no Description Images...

Page 35: ...ase read this instruction manual carefully and follow all installation operating and safety guidelines T4 M 008 Ball screw feed nut T4 M 009 Ball screw feed Part no Description Images Mechanical table Part no Description Images Mechanical tank MEG TANK Recirculating tank MEG TANK C1 Recirculating tank cover with square screen MEG TANK C2 Recirculating tank cover with round screen 31 ...

Page 36: ...ad this instruction manual carefully and follow all installation operating and safety guidelines MEG SCREEN COV1 Tank screen single drain cover MEGA M250 T300 MEG SCREEN COV2 Tank screen double drain cover MEGA T400 MEG SCREEN SQ Coarse screen for MEGA abrasive cutter tanks square MEG SCREEN RD Coarse screen for MEGA abrasive cutter tanks round Part no Description Images Mechanical tank 32 ...

Page 37: ...tp www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical hood GS T400 MEGA T400 gas support spring for hood T4 M 027 Gas spring bracket M4 SW MEGA T400 Side panel M4 FW MEGA T400 front safety glass window T4 M 015 Front cover T4 M 014 Cover 33 ...

Page 38: ...se read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical hood T4 M 006 Back cover T4 P HH Hood handle M4 BT MEGA T400 Rubber skirt for side panel T4 M 016 Hood bracket T4 M 017 Top hood panel T4 M 018 Door roller T4 M 024 Front shield ring T4 M 025 Front splash guard T4 M 026 Front panel roller shaft 34 ...

Page 39: ... Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical base T4 M 038 MEGA T400 base cabinet stand T4 M CASTER MEGA T400 casters M4 FEET MEGA T400 feet 4 set M4 CAB MEGA T400 Cabinet doors M4 CAB H MEGA T400 Cabinet door hinges 2 hing es set M4 MAG Cabinet door magnet T4 M 010 Base casting 35 ...

Page 40: ...om Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines T4 M 011 Control Panel Arm T4 M 012 Control Panel Back Cover T4 M 013 MEGA T400 control panel fabricated box M4 T MEGA T400 template T4 M 019 Electrical box door Part no Description Images Mechanical base 36 ...

Page 41: ... Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines T4 M 020 Electrical box T4 M 022 Foot bracket T4 M 023 Forklift bar Part no Description Images Mechanical base 37 ...

Page 42: ...m Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Plumbing M4 D MEGA T400 drain hose 40 mm 1 5 mm each M4 H MEGA T400 Inlet hose 1 5m MEG RHV Rinse hose and valve MEG RH Rinse hose M2 NOZ Rinse hose nozzle M2 NOZ T Rinse hose nozzle tip M4 COOL MEGA T400 Flexible coolant line from table pair 38 ...

Page 43: ...ating and safety guidelines MEG V Rinse hose shut off valve T4 P SSH MEGA T400 shroud side hose each T4 P TCES MEGA T400 table back coolant feed elbow T4 P TCEL MEGA T400 table front coolant feed elbow T4 P SSH2 MEGA T400 table front feed coolant line T4 P BCOOL MEGA T400 table back feed coolant line T4 P DS Drain screen T4 P LHB Rinse hose barb large T4 P SHB Rinse hose barb small T4 P HBTF Rinse...

Page 44: ...ww metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines G GUN Grease gun G GUN R Grease refill MEG SQ Square MEG TB Tool box MEG 25HW 2 5 mm hex wrench MEG 10HW M10 hex wrench M4 WCH 19 MEGA T400 arbor wrench 19 mm M4 WCH 32 MEGA T400 arbor wrench 32 mm Part no Description Images Tools 40 ...

Page 45: ...elines QC REPAIR Vice repair kit MEGA T400 kit include cam shaft and bar spring and adjustment set screw for one vise LCL 1000 MEGA T400 Left quick clamping vise LCR 1000 MEGA T400 Right quick clamping vise MG15 01 Vertical clamping vise with 75 mm arm 3 inch and shoe for MEGA T400 MIG 01 Vertical clamping vise with 45 mm arm 1 8 inch and shoe for MEGA M250 and MEGA T300 and MEGA T400 MG TB Vertic...

Page 46: ...llographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines MG VW T vertical clamping handle MG H 65 mm 2 6 inch height adapter for either MIG 01 or MG15 01 vertical clamping vises MEG TS T slot nuts 2 set MG 0159 Mechanical stop for cutting repetitive samples Part no Description Images Vice Components 42 ...

Page 47: ...ter 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines ...

Page 48: ...ter 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines ...

Page 49: ...ter 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines ...

Page 50: ...ter 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines ...

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

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

Page 53: ...r 3601 E 34th St Tucson AZ 85713 USA Tel 1 520 882 6598 Fax 1 520 882 6599 email pace metallographic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines 43 ...

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