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NSTRUCTION

ANUAL

MEGA-M250b

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.

Recirculating tank connections

(Installation continued on next page)

Drain into
screen

Pump

Tank
drain

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 with a anti-corrosion additive or an oil
emulsion coolant is recommended. Note: It is recommended that the
coolant be changed every 50 cuts or every week, whichever occurs
first.

Содержание MEGA-M250b

Страница 1: ...ad this instruction manual carefully and follow all installation operating and safety guidelines Equipment Type 10 inch Manual Abrasive Cut off Machine Model MEGA M250b Electrical Requirements 208Y Volts 3 phase Frequency 50 60 Hz Motor Horsepower 3 hp 3 phase 2 2 KW Manual Revision Date January 5 2017 Serial Number This instruction manual is provided with each piece of delivered equipment ...

Страница 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...

Страница 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...

Страница 4: ...phic 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 7 4 0 Start Up and Operation 10 5 0 Maintenance 14 6 0 Trouble Shooting 15 7 0 List of Spare Parts 16 8 0 Electrical Drawings 32 iii ...

Страница 5: ...brasive 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 M250 is very robust and durable with its cast aluminum alloy and stainless steel construction Featuring a corrosion free T slot table the MEGA M250 is a very versatile bench top meta...

Страница 6: ...208 380V 60 Hz 2895 rpm at 440 480V 50 Hz 3475 rpm at 440 480V 60 Hz Maximum sample diameter 3 inch 75 mm Short sample size 2 4 inch x 5 3 inch 60 mm x 135 mm Weight Approx 280 lbs 126 kg Dimensions WxDxH Hood Closed 28 x 29 x 24 inches 710 x 740 x 610 mm Hood Open 28 x 35 x 31 inches 710 x 890 x 790 mm Table dimensions WxD 8 25 x 8 9 inch 210 mm x 230 mm Cabinet Cast aluminum block construction H...

Страница 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 M250 should be on a flat sturdy surface with easy access to electrical connections 3 ...

Страница 8: ...ty guidelines 1 4 Features Powerful motor The MEGA M250 is equipped with a powerful direct drive motor In addition the motor has an inductive brake for faster stopping of the blade Manual wheel cutting The MEGA M250 is an easy to use manual cutter with simple controls For control and safety the MEGA M250 is equipped with a trigger activated cutting handle The MEGA M250 also has a side port window ...

Страница 9: ...voids warranty The MEGA M250 should be placed on a flat stable surface TO OPEN HOOD CUTTER IS SHIPPED WITH THE LOCKOUT SWITCH TURNED TO UNLOCK AFTER CONNECTING POWER TURN SWITCH TO LOCK TO OPEN HOOD AND TO USE CUTTER Connect coolant tank supply drain and electrical connections Electrical connections The saw is designed to operate at 208 220V 3 phase can be converted to 380V 3 phase by rewiring the...

Страница 10: ...een Pump Tank drain 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 w...

Страница 11: ...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 ...

Страница 12: ...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 Water pump Electrical connection Pressure line Pump valve closed After cutting it is recommended that the cutting chamber be rinsed t...

Страница 13: ...sidered important Emergency stop switch Magnetic Safety switch 9 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 ...

Страница 14: ...d Operation 4 1 General The MEGA M250 is a manual wheel feed cutter 10 4 2 Control Panel Emergency Shut off Coolant ON OFF 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...

Страница 15: ...tallation operating and safety guidelines 1 Remove blade locking bolt reverse threaded 2 Position new 10 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 11 Changing Blade Remove Loosen by turning clockwise Tighten Turn counter clockwise To prevent shaf...

Страница 16: ... Abrasive Cutting Fluid 128 oz MAXCUT 1000 128 1 gallon MAXCUT 2 Cutting Fluid with Anticorrosion Additive 32 oz MAXCUT2 1000 32 32 oz MAXCUT 2 Cutting Fluid with Anticorrosion Additive 128 oz MAXCUT2 1000 128 1 gallon 10 MAXCUT Abrasive Blades 32mm 1 Arbor Pace Product Name Catalog Number Packaging Soft Non ferrous Materials Aluminum Brass Zinc Etc MAX E250 10 Hard Non ferrous Materials MAX C250 ...

Страница 17: ...Fixture examples 4 5 Fixturing sample 17 Fast clamping Clamping diameter 3 inches 76 mm Left lever Cat No QCL 1000 Right lever Cat No QCR 1000 Note vises have a slot in them so that the face does not rotate UNIVERSAL Clamping vise UNIVERSAL Cat No MIG 01 Clamping height 45 mm arm Height adapter 65 mm attachment for MIG 01 Cat No MG H 13 4 4 Manual cutting step by step procedure 1 Connect electrica...

Страница 18: ...such 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 ...

Страница 19: ... a Check plug b Restart after resetting Q2 relay Excessive vibration during cutting a Not cutting with enough force b Specimen locked too far back on cutting table c Incorrect blade selection a Increase cutting force b Move specimen forward c Use correct blade Corrosion of table of vises a Improper cleaning and drying b Incorrect or old cutting fluid c Cutting chamber has become a humidity corrosi...

Страница 20: ...nd safety guidelines 7 0 List of Spare Parts 16 Part no Description Image Electrical M2 E CB 001 MEGA M250 Full control board replacement for MEGA M250 M2 QF1 MEGA M250 QF1 overlaod switch motor Schneider GV2 ME14C 6 10A M2 QF2 MEGA M250 QF2 overload switch pump Schneider GV2 ME05C 0 63 1A MEG RCMU RCMU timer blade MEG RAMU RAMU timer safety switch LC1D12B7C KM1 KM3 AC contactor MEGA M250 Schneide...

Страница 21: ...nstallation operating and safety guidelines Part no Description Image Electrical M2 MOTOR MEGA M250 Motor 2 2 KW M2 E FH 001 Fuse Holder each M2 E F 001 MEGA M250 F1 fuse 2A M2 E F 002 MEGA M250 F2 fuse 2A M2 E F 003 MEGA M250 F3fuse 10A M2 E F 004 MEGA M250 F4 fuse 10A M2 E F 005 MEGA M250 F5 fuse 3A M2 E F 006 MEGA M250 F6 fuse 3A M2 SAFE T MEGA M250 Safety lock out switch top piece M2 SAFE B ME...

Страница 22: ... http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Electrical M2 SAFE K Safety key MEG RL1 RL1 switch 24 V RELAY B 24V relay base GTB Ground terminal block TB Terminal block MEG LITE Light housing M 250B Light blub OSRAM Halogen DC24V 20 Watt 18 ...

Страница 23: ...aphic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Electrical M SEAL Wire plastic seal connector MEG PUMP 220 Pump 220 380V MEG PUMP 480 Pump 400 480V MEG FPC Female pump connector MEG MPC Male pump connectors MEG AM1 Ammeter set up kit MEG R Rectifier MEG AM2 Amp overload light 19 ...

Страница 24: ...allographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Electrical MEG AM3 Amp overload light controller MEG TC 220 220 380V Transformer MEG TC 480 440 480V Transformer MEG PS Main power switch MEG ON On button green MEG LS Light ON Off switch MEG LB Power on light button 20 ...

Страница 25: ...hic com Please read this instruction manual carefully and follow all installation operating and safety guidelines MEG OFF Off button red MEG W Water ON OFF Switch P150 210 Emergency Stop Part no Description Image Electrical Part no Description Image Mechanical motor M2 M 016 MEGA M250 Blade shroud M2 M 013 MEGA M250 Shroud spacer M2 M 020 MEGA M250 Arbor bolt and flange 21 ...

Страница 26: ...Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical motor M2 M 002 MEGA M250 Arbor M2 M 010 MEGA M250 Motor casting M2 M 011 MEGA M250 Left shaft holder with roller bearing M2 M 012 MEGA M250 Motor shaft base M2 M 001 MEGA M250 Roller Bearing M2 M 015 1 MEGA M250 Motor shaft ring sleeve 1 22 ...

Страница 27: ...llation operating and safety guidelines M2 M 015 2 MEGA M250 Motor shaft ring sleeve 2 M2 M 015 3 MEGA M250 Motor shaft ring sleeve 3 M2 SPRING MEGA M250 motor return spring M2 M 025 MEGA M250 gas support cylinder M2 M 004 MEGA M250 Gas spring bracket Part no Description Image Mechanical motor Part no Description Image Mechanical table M2 M 017 MEGA M250 T slot table base M2 M 018 MEGA M250 table ...

Страница 28: ...ion manual carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical hood M2 1 001 MEGA M250 Hood cover with both windows M2 M 024 MEGA M250 Hood handle M2 M 014 Safety switch bracket M2 BT MEGA M250 Rubber side port boot M2 M 021 MEGA M250 Side metal cover plate M2 FW MEGA M250 Front window M2 FW F MEGA M250 Front window frame M2 SW MEGA M250 Side ...

Страница 29: ...mail 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 Image Mechanical hood M2 SW F MEGA M250 Side window frame M2 M 023 MEGA M250 Motor Feed Handle M2 BT MEGA M250 Rubber side port boot 25 ...

Страница 30: ...ating and safety guidelines Part no Description Image Mechanical tank MEG TANK Recirculating tank MEG TANK C1 Recirculating tank cover with square screen MEG TANK C2 Recirculating tank cover with round screen 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 SC...

Страница 31: ... this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical base M2 M 003 MEGA M250 Base Frame M2 M 008 MEGA M250 Casting base M2 M 005 MEGA M250 Left power panel M2 M 006 MEGA M250 Right power panel M2 M 026 MEGA M250 lifting handles M2 M 007 MEGA M250 Handle M2 M 022 MEGA 250 Support feet each M2 T MEGA M250 template 27 ...

Страница 32: ...ly and follow all installation operating and safety guidelines Part no Description Image Mechanical plumbing M2 P 001 MEGA M250 Drain hose 40 mm 1 5m M2 P 002 MEGA M250 Inlet hose 1 5m M2 P 003 MEGA M250 Flexible coolant line pair MEG RHV Rinse hose and valve MEG RH Rinse hose M2 NOZ Rinse hose nozzle M2 NOZ T Rinse hose nozzle tip M2 CFV Rinse hose shut off valve MEG IB Brass inlet hose barb MEG ...

Страница 33: ...metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Tools 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 M2 ROD MEGA M250 Blade wheel changing locking rod M2 WCH MEGA M250 Wrenches 30 32 mm 29 ...

Страница 34: ...on operating and safety guidelines Part no Description Image Tools QC REPAIR Vice repair kit MEGA M250 kit include cam shaft and bar spring and adjustment set screw for one vise MIG 01 Vertical clamping vise with 45 mm arm 1 8 inch and shoe MG H 65 mm 2 6 inch height adapter for either MIG 01 or MG15 01 vertical clamping vises MG TB Vertical clamping vise t slot bolt and nut MG VW Vertical clampin...

Страница 35: ...b http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines QCR 1000 Right quick clamping vise for MEGA M250 abrasive cutter QCL 1000 Left quick clamping vise for MEGA M250 abrasive cutter MG 0159 Mechanical stop for cutting repetitive samples Part no Description Image Tools 31 ...

Страница 36: ...th 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 32 8 0 Electrical Drawings ...

Страница 37: ...er 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 33 ...

Страница 38: ...er 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 34 ...

Страница 39: ...er 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 35 ...

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