Pace Technologies MEGA-M300, Instruction Manual

Page 1: ... instruction manual carefully and follow all installation operating and safety guidelines Equipment Type 10 inch Manual Abrasive Cut off Machine Model MEGA M300 Electrical Requirements 208Y Volts 3 phase Frequency 50 60 Hz Motor Horsepower 3 hp 3 phase 2 2 KW Manual Revision Date April 1 2015 Serial Number This instruction manual is provided with each piece of delivered equipment ...

Page 2: ... 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 PURPOSE THIS WA...

Page 3: ... 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 been made in a...

Page 4: ...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 ...

Page 5: ...ut 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 M300 is very robust and durable with its cast aluminum alloy and stainless steel construction Featuring a corrosion free T slot table the MEGA M300 is a very versatile bench top metallographi...

Page 6: ...h diameter Speed 2895 rpm 50 Hz 3400 rpm 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 WxHxD Approx 28 x 30 x 26 710 mm x 750 mm x 650 mm Table dimensions WxD 8 3 x 9 3 212 mm x 232 mm Cabinet Cast aluminum block construction Hood Fabricated steel with Lexan safety glass Working temperature 32 100 F 0 40 C Sh...

Page 7: ...mail 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 M300 should be on a flat sturdy surface with easy access to electrical connections 3 ...

Page 8: ...ines 1 4 Features Powerful motor The MEGA M300 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 M300 is an easy to use manual cutter with simple controls For control and safety the MEGA M300 is equipped with a trigger activated cutting handle The MEGA M300 also has a side port window for longe...

Page 9: ...ranty The MEGA M300 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 motor an...

Page 10: ...and safety guidelines Recirculating tank connections 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 M300 6 Installation conti...

Page 11: ...e 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 that the...

Page 12: ...ank 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 to prevent...

Page 13: ...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 off whee...

Page 14: ...ion 4 1 General The MEGA M300 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 ON OFF ...

Page 15: ...n 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 shaft from t...

Page 16: ...ttp www metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines Abrasive Cutting Fluids Pace Product Name Catalog Number Packaging 10 MAXCUT Abrasive Blades 32mm 1 Arbor Pace Product Name Catalog Number Packaging ABRASIVE Cutting CONSUMABLES SELECTION GUIDELINES CHART 12 ...

Page 17: ...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 electrical power ...

Page 18: ...de cabinet The MEGA M300 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 with a ...

Page 19: ...nterlocking 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 fo...

Page 20: ...y guidelines 7 0 List of Spare Parts 16 Part no Description Image Electrical M2 E CB 001 MEGA M300 Full control board replacement for MEGA M300 M2 QF1 MEGA M300 QF1 overlaod switch motor Schneider GV2 ME14C 6 10A M2 QF2 MEGA M300 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 M300 Schneider LC1D12...

Page 21: ...on operating and safety guidelines Part no Description Image Electrical M2 MOTOR MEGA M300 Motor 2 2 KW M2 E FH 001 Fuse Holder each M2 E F 001 MEGA M300 F1 fuse 2A M2 E F 002 MEGA M300 F2 fuse 2A M2 E F 003 MEGA M300 F3fuse 10A M2 E F 004 MEGA M300 F4 fuse 10A M2 E F 005 MEGA M300 F5 fuse 3A M2 E F 006 MEGA M300 F6 fuse 3A M2 SAFE T MEGA M300 Safety lock out switch top piece M2 SAFE B MEGA M300 S...

Page 22: ... 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 300B Light blub OSRAM Halogen DC24V 20 Watt 18 ...

Page 23: ...m 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 ...

Page 24: ...hic 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 ...

Page 25: ...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 M300 Blade shroud M2 M 013 MEGA M300 Shroud spacer M2 M 020 MEGA M300 Arbor bolt and flange 21 ...

Page 26: ...ead this instruction manual carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical motor M2 M 002 MEGA M300 Arbor M2 M 010 MEGA M300 Motor casting M2 M 011 MEGA M300 Left shaft holder with roller bearing M2 M 012 MEGA M300 Motor shaft base M2 M 001 MEGA M300 Roller Bearing M2 M 015 1 MEGA M300 Motor shaft ring sleeve 1 22 ...

Page 27: ...operating and safety guidelines M2 M 015 2 MEGA M300 Motor shaft ring sleeve 2 M2 M 015 3 MEGA M300 Motor shaft ring sleeve 3 M2 SPRING MEGA M300 motor return spring M2 M 025 MEGA M300 gas support cylinder M2 M 004 MEGA M300 Gas spring bracket Part no Description Image Mechanical motor Part no Description Image Mechanical table M2 M 017 MEGA M300 T slot table base M2 M 018 MEGA M300 table small ra...

Page 28: ...l carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical hood M2 1 001 MEGA M300 Hood cover with both windows M2 M 024 MEGA M300 Hood handle M2 M 014 Safety switch bracket M2 BT MEGA M300 Rubber side port boot M2 M 021 MEGA M300 Side metal cover plate M2 FW MEGA M300 Front window M2 FW F MEGA M300 Front window frame M2 SW MEGA M300 Side window 24...

Page 29: ...e 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 M300 Side window frame M2 M 023 MEGA M300 Motor Feed Handle M2 BT MEGA M300 Rubber side port boot 25 ...

Page 30: ...d 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 M300 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 ...

Page 31: ...truction manual carefully and follow all installation operating and safety guidelines Part no Description Image Mechanical base M2 M 003 MEGA M300 Base Frame M2 M 008 MEGA M300 Casting base M2 M 005 MEGA M300 Left power panel M2 M 006 MEGA M300 Right power panel M2 M 026 MEGA M300 lifting handles M2 M 007 MEGA M300 Handle M2 M 022 MEGA 300 Support feet each M2 T MEGA M300 template 27 ...

Page 32: ...llow all installation operating and safety guidelines Part no Description Image Mechanical plumbing M2 P 001 MEGA M300 Drain hose 40 mm 1 5m M2 P 002 MEGA M300 Inlet hose 1 5m M2 P 003 MEGA M300 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 OB Brass ...

Page 33: ...raphic 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 M300 Blade wheel changing locking rod M2 WCH MEGA M300 Wrenches 30 32 mm 29 ...

Page 34: ...ting and safety guidelines Part no Description Image Tools QC REPAIR Vice repair kit MEGA M300 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 clamping vise a...

Page 35: ...w metallographic com Please read this instruction manual carefully and follow all installation operating and safety guidelines QCR 1000 Right quick clamping vise for MEGA M300 abrasive cutter QCL 1000 Left quick clamping vise for MEGA M300 abrasive cutter MG 0159 Mechanical stop for cutting repetitive samples Part no Description Image Tools 31 ...

Page 36: ...son 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 ...

Page 37: ... 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 ...

Page 38: ... 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 ...

Page 39: ... 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 ...