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NSTRUCTION

ANUAL

MEGA-T300 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.

Contents

AGE

Nameplate

Warranty

1.0 Product Description

2.0 Shipping, Unpacking and Installation

3.0 Safety Guidelines

4.0 Start

Up and Operation

5.0 Maintenance

6.0 Trouble Shooting

7.0 List of Spare Parts

8.0 Electrical Drawings

iii

Содержание MEGA-T300

Страница 1: ...nstruction manual carefully and follow all installation operating and safety guidelines Equipment Type 300 mm 12 inch Manual Abrasive Cut off Machine Model MEGA T300 Electrical Requirements 208Y 380 Volts 3 phase Optional 480V 3 phase Frequency 50 60 Hz Motor Horsepower 5 5 hp 4 KW 3 phase Manual Revision Date April 21 2014 This instruction manual is provided with each piece of delivered equipment...

Страница 2: ...cations 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 MECHANTABILITY OR FITNESS FOR PARTICULAR ...

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: ...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 6 3 0 Safety Guidelines 9 4 0 Start Up and Operation 16 5 0 Maintenance 17 6 0 Trouble Shooting 18 7 0 List of Spare Parts 19 8 0 Electrical Drawings 41 iii ...

Страница 5: ... 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 T300 is very robust and durable with its cast aluminum alloy and stainless steel construction Featuring a corrosion free T slot table the MEGA T300 is a very versatile table feed bench top model metallogra...

Страница 6: ...8 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 Coolant applied directly to the blade Flexible coolant hose for application to cutting area Easy to use vises 2 ...

Страница 7: ... diameter Maximum sample diameter 4 inch 100 mm Weight Approx 350 lbs 160 kg Dimensions WxHxD Approx 36 x 34 x 26 hood closed 90 cm x 86 cm x 65 cm Approx 36 x 34 x 32 hood open 90 cm x 86 cm x 82 cm Table dimensions WxD 12 x 9 300 mm x 230 mm Cutting chamber Cast aluminum block construction Hood and body Fabricated steel with shock resistant plastic window Working temperature 32 100 F 0 40 C Ship...

Страница 8: ...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 T300 should be on a flat sturdy surface with easy access to electrical connections 4 ...

Страница 9: ... In addition the motor has an inductive brake for faster stopping of the blade Manual feed and table feed cutting The MEGA T300 is an easy to use manual cutter with simple controls Cutting can be accomplished with either a wheel feed or table feed The MEGA T300 also has a removable side port panel for sectioning longer samples 5 East to grip cutting handle Side panel for long sample access Table f...

Страница 10: ...s 2 0 Unpacking Shipping and Installation 2 1 Unpacking Unit is delivered in a crate Unpack and check for completeness of parts Measures WxHxD Approx 36 x 36 x 36 Weight Approximately 375 lbs 2 2 Shipping When moving crate lift from bottom To move MEGA T300 use support bars provided with the machine The MEGA T300 is constructed of sensitive electronic and mechanical components Do not drop Caution ...

Страница 11: ... 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 voltage on nameplate 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 installation or when t...

Страница 12: ...erating and safety guidelines Recirculating tank connections External coolant supply Attach 3 4 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 T300 8 Installati...

Страница 13: ...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 4 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 14: ...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 Water pump Electrical connection Pressure line After cutting it is recommended that the cutting chamber be rinsed to ...

Страница 15: ... important Emergency stop switch Magnetic Safety switch 11 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...

Страница 16: ...n 4 1 General The MEGA T300 is a manual wheel and manual table feed cutter 12 4 2 Control Panel Coolant ON OFF 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 m...

Страница 17: ...w metallographic 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 by turning lever counter clockwise 4 3 1 Wheel feed cutting 4 3 2 Table feed cutting Open wheel spinner Table feed wheel Lock wheel by turning lever clockwise 13 Wheel lock ...

Страница 18: ...llation operating and safety guidelines 1 Remove blade locking bolt reverse threaded 2 Position new 300 mm 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 4 Changing abrasive cut off wheels 14 Changing Blade Remove Loosen by turning clockwise Tighten Turn counter clockwise To prevent shaft f...

Страница 19: ...32 oz MAXCUT 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 300 mm 12 MAXCUT Abrasive Blades 32mm 1 Arbor Pace Product Name Catalog Number Packaging Soft Non ferrous Materials Aluminum Brass Zinc Etc MAX E300 10 Hard Non ferrous ...

Страница 20: ...e initial stress on the samples Fixture examples 4 6 Fixturing sample 17 Fast clamping Left lever Cat No QCL 1100 Right lever Cat No QCR 1100 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 16 4 5 Manual cutting step by step procedure 1 Connect electrical power and turn on master power switch on the s...

Страница 21: ...ng outside cabinet The MEGA T300 requires very minimal maintenance However to increase the life of the saw it is suggested that the cutting chamber be rinsed after cutting It is also recommended that the hood be left open in order to minimize corrosion inside of the chamber due to high humidity from the cutting operation and cutting fluid The cabinet and front shield should be cleaned occasionally...

Страница 22: ...e a Interlocking 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 enou...

Страница 23: ...rts Replacement of spare parts is possible with minimal expertise Spare parts for recirculation system are also available upon request 19 Part no Description Images Electrical M3 CB MEGA T300 Full control board replacement for MEGA T300 GV2ME20C QF1 overload switch Schneider GV2 ME20C 13 18A GV2ME14C MEGA T300 QF1 overload switch 380V and 480V motor Schneider GV2 ME14C 6 10A GV2ME05C MEGA M250 QF2...

Страница 24: ...erating and safety guidelines Part no Description Images Electrical LC1D18B7C KM1 KM3 AC contactor MEGA T300 Schneider LC1D12B7C LC1D18B7C KM2 AC contactor MEGA T300 Schneider LC1D09B7C M3 F H Fuse Holder each M3 F1 MEGA T300 F1 fuse 2A M3 F2 MEGA T300 F1 fuse 2A M3 F3 MEGA T300 F1 fuse 20A M3 F4 MEGA T300 F1 fuse 20A M3 F5 MEGA T300 F1 fuse 2A M3 F6 MEGA T300 F1 fuse 2A M3 MOTOR MEGA T300 Motor 4...

Страница 25: ...www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Electrical M2 SAFE B MEGA M250 Safety lock out switch bottom piece 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 21 ...

Страница 26: ...Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Electrical 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 MEG FPC Female pump connector MEG MPC Male pump connectors MEG AM1 Ammeter set up kit MEG R Rectifier 22 ...

Страница 27: ...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 Electrical MEG AM2 Amp overload light MEG AM3 Amp overload light controller MEG TC 220 220 380V Transformer MEG TC 480 440 480V Transformer MEG PS Main power switch 23 ...

Страница 28: ...aphic com Web http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines 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 P150 210 Emergency Stop Part no Description Images Electrical 24 ...

Страница 29: ...llographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical motor M3 SH MEGA T300 Blade shroud T3 M 001 Arbor bolt T3 M 002 Arbor inside flange T3 M 003 Arbor blade outside flange T3 M 004 1 Flange lock housing T3 M 004 2 Flange lock nut T3 M 004 3 Flange lock shaft 25 ...

Страница 30: ...llographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines T3 M 003 Motor table base T3 M 005 Motor table lock slot T3 M 006 Motor base adjustment guide T3 M 007 Motor base adjustment block T3 M 008 Motor extension shaft T3 M 009 Motor extension shaft housing Part no Description Images Mechanical motor 26 ...

Страница 31: ...tp www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical motor T3 M 010 Motor shaft T3 M 011 Motor shaft screw holder GS T300 MEGA T300 400 Newton gas cylinder pistons for hood T3 M 0012 Motor feed handle T3 M 004 MEGA T300 blade locking rod 27 ...

Страница 32: ...s instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical table M3 TG MEGA T300 Table feed guide rods pair M3 BOOT MEGA T300 Table feed boot M3 TFW MEGA T300 Table feed wheel T3 M 013 MEGA T300 Table feed screw T3 M 014 MEGA T300 T slot table T3 M 015 MEGA T300 wheel feed locking lever T3 M 016 Table feed rail guide plate 28 ...

Страница 33: ...l installation operating and safety guidelines Part no Description Images Mechanical table T3 M 017 Table feed back screw cover T3 M 018 Table feed rail guide block T3 M 019 Table feed sliding rail guide T3 M 020 Screw feed casting base outside cover wheel T3 M 021 Screw feed casting base inside cover T3 M 054 Screw feed drive outside guide for table T3 M 022 Screw feed drive inside guide for tabl...

Страница 34: ... read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical table T3 M 024 Screw feed wheel base cover 1 T3 M 025 Table feed support bar large T3 M 026 Table feed support bar small Part no Description Images Mechanical tank MEG TANK Recirculating tank MEG TANK C1 Recirculating tank cover with square screen 30 ...

Страница 35: ...ad this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical table MEG TANK C2 Recirculating tank cover with round screen MEG SCREEN COV1 Tank screen single drain cover MEGA M250 T300 MEG SCREEN SQ Coarse screen for MEGA abrasive cutter tanks square MEG SCREEN RD Coarse screen for MEGA abrasive cutter tanks round 31 ...

Страница 36: ... read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical base M3 FEET MEGA T300 support feet 4 set T3 M 028 MEGA T300 lifting handles 2 set T3 M 027 MEGA T300 casting base Part no Description Images Mechanical Hood T3 M 029 MEGA T300 Control panel fabricated cover T3 M 033 MEGA T300 Cutting chamber hood 32 ...

Страница 37: ...allographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical Hood T3 M 045 MEGA T300 Right hood T3 M 030 Splash panel T3 M 031 Water shield T3 M 032 M Side panel metal T3 M 032 P Side panel plastic M3 BT MEGA T300 rubber boot or side access M3 T MEGA T300 template 33 ...

Страница 38: ... www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical Hood T3 M 034 Cooling sheet top panel T3 M 052 Electrical panel base plate T3 M 053 Electrical panel support box T3 M 035 Back sheet T3 M 036 Cooling back panel T3 M 037 Side cooling vent 34 ...

Страница 39: ...www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical Hood T3 M 038 Hood handle T3 M 039 Left front panel T3 M 040 Lock shaft T3 M 041 Lock shaft block T3 M 043 Lock shaft ring T3 M 044 M8 gas spring back holder T3 M 046 Right hood sheet cover 35 ...

Страница 40: ...tp www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Mechanical Hood T3 M 047 Rubber shield holder M3 FW MEGA T300 front safety window T3 M 048 Safety glass frame T3 M 049 Small water shield T3 M 050 Water nozzle bracket T3 M 051 Water split block 36 ...

Страница 41: ...ase read this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Images Plumbing M3 D MEGA T300 Drain hose 40 mm 1 5m M3 H MEGA T300 Coolant line 20 mm 1 5 meter M3 COOL MEGA T300 Flexible coolant line pair Part No M3 COOL MEG RHV Rinse hose and valve MEG RH Rinse hose M2 NOZ Rinse hose nozzle M2 NOZ T Rinse hose nozzle tip 37 ...

Страница 42: ...eb http www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines MEG V Rinse hose shut off valve MEG IB Brass inlet hose barb MEG OB Brass drain hose barb Part no Description Images Plumbing Part no Description Images Tools G GUN Grease gun G GUN R Grease refill MEG SQ Square 38 ...

Страница 43: ...rating and safety guidelines MEG TB Tool box MEG 25HW 2 5 mm hex wrench MEG 10HW M10 hex wrench M3 WCH MEGA T300 Wrenches 30 32 mm Part no Description Images Tools Part no Description Images Vice Components QC REPAIR Vice repair kit MEGA T400 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 15 01 Vertical c...

Страница 44: ...g and safety guidelines 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 clamping vise adjustment t wrench MEG TS T slot nuts 2 set QCR 1100 Right quick clamping vise for MEGA T300 abrasive cutter QCL 1100 Left quick clamping vise for MEGA T300 abrasive cutter MG 0159 Mechanical stop for cutting ...

Страница 45: ...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 41 8 0 Electrical Drawing ...

Страница 46: ...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 42 ...

Страница 47: ...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 ...

Страница 48: ...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 44 ...

Страница 49: ...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 45 ...

Страница 50: ...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 46 ...

Страница 51: ...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 47 ...

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