Buehler SimpliMet 3000 User manual

MA201435_13.1 6/25/2012
www.buehler.com
SimpliMet™3000
Automatic Mounting Press

ii
MA201435_13.1 [Original Instructions] 6/25/2012
Buehler Worldwide Mission Statement
We are Buehler, the science behind materials preparation and analysis and the premier company in our
field, since 1936. Our global mission is to deliver outstanding value and delight our customers by
providing innovative, quality, on-time products and services.
To fulfill our mission, we will continue to:
Listen to and understand our customers to exceed their expectations.
Apply engineering and technical support to provide innovative solutions to our customers.
Achieve profitable growth.
Foster an environment of creativity, respect, teamwork, open communication and ethical behavior.
Provide the training and tools which allow all of us to achieve our mission.
Continually improve our performance in all aspects of the business.
About Buehler
For over 70 years, Buehler has been a leading manufacturer of scientific instruments and supplies for use
in materials analysis. Buehler products are used throughout the world in manufacturing facilities, quality
laboratories and universities to analyze all types materials, including:
Ferrous and Non-ferrous metals
Thermal spray coatings
Printed Circuit Boards
Fasteners
Ceramics
Composites
Semiconductors
Rocks
Glasses
Plastics
Companies use Buehler products to improve the material within their product, monitor production or
incoming purchased material, do failure analysis and perform basic materials research. Buehler products
fall into three categories:
Sample preparation equipment for cutting, grinding and polishing specimen material (usually cross
sectioning) prior to microstructural inspection.
Metallographic consumables for the sample preparation equipment including; cutoff wheels, saw
blades, mounting compounds, grinding papers, polishing cloths and polishing suspensions.
Inspection and testing equipment including microscopes, image analyzers, video equipment and
hardness testers.

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MA201435_13.1 [Original Instructions] 6/25/2012
EC –DECLARATION OF CONFORMITY
Name of Manufacturer and contact information:
41 Waukegan Road
Lake Bluff, Illinois 60044 USA
1-800-BUEHLER / www.buehler.com
Contact information of Buehler’s authorized
representative within the Community:
ITW Test & Measurement GmbH
In der Steele 2
D-40599 Düsseldorf, Germany
(49) (211) 974 100 / www.buehler-met.de
Juergen Vossbruch
Machine Name and Description:
Name: SimpliMet™3000 Automatic Mounting Press
Catalog Number: 20-1435
Description: Automatic mounting press with electro-
hydraulic operation & touch panel control system
Machine Serial Number:
Month Code –NST –Number of units built. (Every unit
assembled is registered in our database.)
Buehler declares this product to be in compliance with EC Directive(s):
2006/42/EC according to the following standards:
EN ISO 12100-1: 2010
EN 60204-1: 2006
89/336/EEC amended by 92/31/EEC and 93/68/EEC
according to the following standards:
EN 55081-1: 1995
EN 55082-1: 1995
EN 61000-4-4 / EN 61000-4-5 / EN 61000-6-2 / EN 50140
Quality Management System:
(ISO 9001:2008)
Registered firm: Underwriters Laboratories, Inc.
QMS Cert. # 10001679
1130 W. Lake Cook Road / Suite 340
Buffalo Grove, IL 60089 / USA
This machine is CE-marked:
Lake Bluff, Illinois, USA
Prepared by:
Kate Watling, Technical Communicator
THIS MANUAL IS A CUSTOM GENERATED DOCUMENT. IT INCLUDES ALL REVISIONS RELATIVE TO THIS
SPECIFIC BUEHLER ITEM AS OF THE DATE SHOWN BELOW.
The items covered in this communication including all attachments may be subject to the export laws of the United States of
America, including without limitation the Export Administration Regulations and the Office of Foreign Asset Control Regulations. The
export, re-export or diversion of these items in contravention of these or other applicable regulations is strictly prohibited.
This information contained in this communication is intended only for the use of the individual or entity to which it is addressed and
may contain information that is privileged, confidential and exempt from disclosure under applicable law.
© 2010 –2012 Buehler, a division of Illinois Tool Works Inc. All rights reserved.

Table of Contents
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MA201435_13.1 [Original Instructions] 6/25/2012
SimpliMet 3000 Automatic Mounting Press..................................................................................................1
Warranty........................................................................................................................................................1
Specifications................................................................................................................................................1
Safety Information.........................................................................................................................................2
Machine Use and Care...........................................................................................................................2
Safety Terms ..........................................................................................................................................3
Unpacking .....................................................................................................................................................3
Installation.....................................................................................................................................................5
Water Connections.................................................................................................................................5
Drain Connections............................................................................................................................6
Vent Valve........................................................................................................................................7
Electrical Installation...............................................................................................................................7
Power Switch ...................................................................................................................................7
Mold Assembly..............................................................................................................................................8
Using the Mold Cylinder .......................................................................................................................12
Operation.....................................................................................................................................................13
Front Control Panel ..............................................................................................................................13
Parameters Fields.................................................................................................................................14
L1 Screen .............................................................................................................................................16
L2 Screen .............................................................................................................................................17
Method Screen .....................................................................................................................................18
Making a Mold.............................................................................................................................................19
Setting Parameters ........................................................................................................................19
Saving a Method ............................................................................................................................19
Loading a Method ..........................................................................................................................20
Preparing the RAM.........................................................................................................................20
Starting a Cycle..............................................................................................................................20
Additional Features...............................................................................................................................21
Mold Cylinder Pre-Warming...........................................................................................................21
Mold Closure Sensor......................................................................................................................21
HEATING and COOLING...............................................................................................................21
Auto RAM Up / Down.....................................................................................................................21
Maintenance................................................................................................................................................22
Monthly.................................................................................................................................................22
Periodically ...........................................................................................................................................22
SimpliMet 3000 Diagnostic Screen.......................................................................................................23
Trouble Shooting Chart...............................................................................................................................24
SimpliMet 3000 Recommended Parameters..............................................................................................25
Trouble Shooting when using Thermosetting Resins .................................................................................26
Buehler Environmental Policy.....................................................................................................................27
SimpliMet 3000 Accessory Mold Assemblies .............................................................................................28

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MA201435_13.1 [Original Instructions] 6/25/2012
SimpliMet 3000 Automatic Mounting Press
The SimpliMet 3000 is a state of the art mounting press with automatic mold sensing. It is easy to use
and has full programmability, increasing productivity and sample consistency. The automatic mold
sensing detects the mold size and loads the appropriate parameters, eliminating the need to look up
tables.
Select from four Buehler pre-programmed, mold size specific methods or program up to 25 user-defined
methods. The SimpliMet 3000 is for use with all thermosetting and thermoplastic resins including
ProbMet™, KonductoMet™, PhenoCure™, EpoMet™F & G (epoxies) and TransOptic™.
Warranty
This unit is guaranteed against defective materials and poor workmanship for a period of 24 months or
2000 hours of normal use (whichever comes first), from the date of receipt by the customer. The warranty
is void if inspection shows evidence of abuse, misuse, unsafe use or unauthorized repair. This warranty
covers all Buehler costs associated with the replacement of defective materials (e.g., parts and labor).
If for any reason this unit must be returned to Buehler for warranty service, please contact Buehler
Service at www.Buehler.com or 1-800-283-4537 for prior authorization and shipping instructions.
(If outside the USA or Canada contact your local Buehler Representative.) Please have the following
information available when contacting Buehler:
Customer Purchase Order Number
Buehler Invoice Number and Date
Serial Number
Reason(s) for return
Specifications
20-1435 SimpliMet 3000 Automatic Mounting Press
Dimensions
16” W x 20 ½” D x 22 7/8” H (405 mm x 520 mm x 580 mm)
Electrical
85 –264 VAC, 50-60 Hz, 1 Phase
1500 Watt on 220V mains
1500 Watt on 115V mains
1200 Watt on 100V mains
Control Voltage
24 VDC
Decibels
70 db: No Pressure, raising and lowering ram
Molding Pressure
1200 –4400 psi ( 80 –300 bar) in 100 psi (5 bar) increments
Molding Temperature
150° C –180° C
Mold Diameters
1” ( 25 mm), 1 ¼” (30 mm), 1 ½” (40 mm), 2” (50 mm)
Heating Time
0 –20 minutes in 10 second increments
Cooling Time
0 –30 minutes in 10 second increments
Weight
73 lbs (33 kg)

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MA201435_13.1 [Original Instructions] 6/25/2012
Safety Information
For safe installation and operation of this equipment, carefully read and understand the contents of this
manual. Improper operation, handling, or maintenance can result in equipment damage and personal
injury.
The SimpliMet 3000 is designed for use in dry, indoor laboratory and workshop environments away from
strong electromagnetic fields and with normal temperature ranges (41° F to 104° F / 5° C to 40° C) and
non-condensing humidity ranges (30-90%).
Machine Use and Care
All operators should be trained in the use of the SimpliMet 3000.If training is needed contact
Buehler at 800.BUEHLER (800.283.4537) or your local Buehler Sales Representative.
Always use safety glasses. Flying debris and liquids can cause severe eye injury.
Dress properly. Do not wear loose clothing or jewelry and contain long hair. They can be caught
in moving parts and can result in severe personal injury.
Protective equipment should be worn to handle specimens, which may be sharp or hot.
Do not operate machine in explosive atmospheres, such as in the presence of flammable
liquids, gases, or dust. Sparks may ignite the dust or fumes.
Maintain the SimpliMet 3000 care. Properly maintained machines are less likely to bind and are
easier to control. Any alteration or modification is a misuse and may result in a dangerous
situation.
Only qualified repair personnel must perform machine service. Service or maintenance
performed by unqualified personnel could result in a risk of injury.
Replace damaged or defective parts immediately and use only identical replacement parts.
Use of unauthorized parts or failure to follow maintenance instructions may create a risk of
electrical shock or injury.
Check for misalignment or binding of moving parts, breakage of parts, and any other
condition that may affect the machine operation. If damaged, have the machine serviced
before using. Poorly maintained machines cause many accidents.
Do not abuse the power cord. Never use the cord to cart the machine or pull the plug from
an outlet. Keep the cord away from heat, oil, sharp edges, or moving parts. Replace
damage cords immediately. Damaged cords increase the risk of electrical shock.
Use of extension cords is not recommended for Buehler machines and equipment.

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MA201435_13.1 [Original Instructions] 6/25/2012
Safety Terms
DANGER
!
WARNING
!
CAUTION
!
NOTICE
Unpacking
The SimpliMet 3000 has been carefully packaged to protect it during transit from the factory to your
location. Carefully unpack and check the contents. If any components are missing or damaged, save the
packing list and materials and advise the carrier and Buehler of the discrepancy.
Carefully unpack and check that the following items have been received:
Accessory Kit #206
Scrapper Tool
Scoop
Sample
EpoMet Molding Compound
Sample
PhenoCure Resin Powder
Sample
Release Agent
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury
CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
NOTICE indicates practices not related to personal injury.

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MA201435_13.1 [Original Instructions] 6/25/2012
SimpliMet 3000 Components
Brush
Power Cord
Cylinder Lock Label
Water Filter
Bayonet Handle
Water Filter
Hose Connections
Hose Clamp
(for drain hose)
Water Hose –1 ft
Insulator Disc
(for upper ram
assembly)
Water Hose –3ft
4 mm Ball Point
Hex Wrench
8 Setscrews
(for mold assembly)
6 mm Hex
T- Wrench
WARNING
!
Equipment Damage. The SimpliMet 3000 weighs approximately 73 lbs (33 kg) and two persons are
required to safely lift the unit from the shipping carton. Follow local safety practices to lift the
SimpliMet 3000 unit from the shipping carton. Improper lifting can result in machine damage.
Personal Injury. Improper lifting of the SimpliMet 3000 can result in personal injury.
The SimpliMet 3000 is bolted to a wood base for protection during shipping. Open areas are provided at
the corners of the base for ease of lifting. Lift the SimpliMet 3000 out of the carton and position it on a
table so it overhangs on the edge. Remove the bolts securing the SimpliMet 3000 to the wood base.

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MA201435_13.1 [Original Instructions] 6/25/2012
Installation
Select a location for your SimpliMet 3000 that provides an adequate working space, a power source,
water connections, and a drain. Placement of the SimpliMet 3000 should be on a sturdy, level bench.
Buehler Tech-Met™tables are highly recommended.
Install the following in the order shown:
1. Plumbing, including water and drain connections
2. Electrical
Water Connections
CAUTION
!
Equipment Damage. The water supply hose and drain hose must be connected and
checked for any leaks before any electrical connections are made.
When connecting water to the SimpliMet 3000, observe local water regulations and use a Buehler
connection kit if using a pressure reliever and a non-return valve from the water source. Use of
the Buehler 49-2105 Water Filtration Kit is highly recommended.
The recommended cooling water flow rate is a minimum of 0.5 gallons/min (2 liters/min) with a
water pressure between 45 –75 psi (3 –5 bar). The maximum working pressure is 125 psi
(8 –6 bar).
Water supply parameters that are different will not affect the operation of the SimpliMet 3000 but
different coolant times may be needed.
Cooling water is supplied through the SimpliMet 3000 by connecting one end of the supplied
water hose to the water outlet fitting located on the back of the unit.
Figure 1 Water Filter (49-2105)
1. Connect one end of the supplied .25-inch (6.35 mm) water hose to the water outlet fitting
located on the back of the SimpliMet 3000.
2. Cut approximately 6-8 inches (180 mm) of hose and add a Water Filtration Kit (49-2105) and
fittings.
3. Connect the other end of the water hose (with filter and fittings) to an external water source
equipped with a separate shut-off valve.

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MA201435_13.1 [Original Instructions] 6/25/2012
Figure 1 SimpliMet 3000 Rear Connections
Drain Connections
1. Position the drain hose to a drain, sink, or other available catch container.
Secure drain hose with clamp if necessary.
NOTICE
Do not leave the drain hose exposed. A short burst of steam will exit the drain hose at the
beginning of a cooling cycle.
The main water supply must be shut off at night or when the machine is left unattended.
If for any reason the SimpliMet 3000 has to be moved, close the vent valve before moving
and open before operating
Drain Hose
Water Hose
Vent Valve

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MA201435_13.1 [Original Instructions] 6/25/2012
Vent Valve
CAUTION
!
Before operating the SimpliMet 3000, the vent valve on the back of the machine must be
opened. A tag will be attached to the vent valve with the following warning: Before
operating, open outer vent valve fully.
1. Fully rotate the knurl knob counter-clockwise to open the vent valve,
The knurl knob is the outer most nut on the vent valve and is easily adjusted with the
fingers.
2. Once installation is complete, check for leaks at the maximum water pressure.
Electrical Installation
Electrical Shock Hazard. Only a qualified electrical technician should perform electrical
installation and maintenance.
Electrical Shock Hazard. Do not change the power plug in any way. Buehler machines are
equipped with a polarized plug (one blade is wider than the other) and a ground pin.
Polarized plugs reduce the risk of electrical shock. This plug will fit in a polarized outlet
only one way.
Disconnect the power supply before making any electrical adjustments.
Capacitors inside the machine may retain a charge even if the machine is
disconnected from the power supply.
The Specification Plate is located on the back of the SimpliMet 3000. Check that Specification
Plate values for voltage, current, and power consumption are compatible with the intended
electrical supply before installation.
Installation of the SimpliMet 3000 must comply with local electrical standards or codes of practice.
The SimpliMet 3000 can be plugged into an outlet rated for the voltage and frequency listed on
the Specification Plate.
Power Switch
The main power switch is located on the back, right side of the machine. Move the main power
switch to the ON position to activate power to the SimpliMet 3000.
The SimpliMet 3000 main power switch also serves as a circuit breaker. If case of an electrical
malfunction, move the switch to the OFF position. To restore power, move the switch to the ON
position.

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MA201435_13.1 [Original Instructions] 6/25/2012
Mold Assembly
The SimpliMet 3000 Automatic Mounting Press is shipped fully assembled except for the Mold Assembly.
Due to various available mold sets, Mold Assemblies are supplied as separate order items.
CAUTION
!
Personal Injury. Due to high temperatures when using this machine, always use caution when
handling molds and working in the mold area. The Mold Cylinder Closure will be warm to the
touch.
1. Connect the SimpliMet 3000 to an electrical supply.
2. Move the power switch to the ON position. The front panel will light up.
3. Install the Upper Ram and insulation parts (see Figure 2).
Insert the Spindle Assembly (knob and threaded rod) through the top of the press.
Place a spacer/ insulator disc on the Spindle Assembly.
Screw Upper Ram to the Spindle Assembly.
The Upper Ram Assembly does not need to be very tight.
Figure 2 Upper Ram Assembly
Figure 3 Supplied Wrenches
4 mm Ball Point Hex Wrench
(P/N: R10497)
6 mm Hex T-Wrench
(P/N: 1430S099)
Spindle Assembly
Upper Ram
Spacer
Insulator Disc

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MA201435_13.1 [Original Instructions] 6/25/2012
4. Using the supplied 6 mm hex wrench, turn the Mold Cylinder Clamp Screw clockwise (unlock
position) until strong resistance is felt, approximately three to four rotations (see Figure 4). This will
open the Mold Closure to fit the Mold Assembly.
Figure 4 Mold Cylinder Clamp Screw
5. Remove the shipping tube.
6. Insert the Mold Cylinder Insulator Ring into the Mold Closure. Align the holes of the Insulator Ring
with the screws (see Figure 5).
Figure 5 Mold Cylinder Insulator Ring
7. Insert the Mold Assembly until it sits level with the top of the Mold Closure (see Figure 6).
Figure 6 Mold Assembly in the Mold Closure
8. Install the eight setscrews (P/N: R10496). Do not tighten.
The Cylinder Lock Label (P/N 1430S119)
is supplied in the Accessory Kit and is
optional for customer use.

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MA201435_13.1 [Original Instructions] 6/25/2012
9. Raise the Ram Rod and install the Lower Ram (see Figure 7).
Figure 7 Lower RAM Assembly
10. Lower the Ram Assembly about halfway down the Mold Cylinder to aid in centering the mold.
11. Place and hold the Upper Ram inside the Mold. This will help in centering the mold
(see Figure 8).
Figure 8 Upper Ram on the Ram Assembly
12. Using the supplied wrench, turn the Mold Cylinder Clamp Screw counter-clockwise until loose. The
Mold Assembly will be secured in the Mold Cylinder.
Figure 9 Mold Cylinder Clamp Screw

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MA201435_13.1 [Original Instructions] 6/25/2012
13. Alternately tighten the eight setscrews on the sides of the Mold Closure (see Figure 6).
This will maintain the mold in the center of the Mold Cylinder.
14. Back off each setscrews ½ turn once snug against the Mold Assembly.
CAUTION
!
Equipment Damage. Over tightening the eight setscrews may cause misalignment of the mold and
make it difficult to remove the Upper Ram from the Mold Cylinder after a molding cycle.
15. Release the Upper Ram. Center the Mold Assembly in the Mold Cylinder.
Figure 10 details an off-centered Ram Assembly caused by over-tightening of the setscrews.
Figure 10 Off-centered Ram Assembly
16. Raise and lower the Ram Assembly to verify smooth operation.
Before making a mold, check that the Upper Ram easily locks and disengages from the Mold
Cylinder. Lower the Upper Ram into the Mold Cylinder and turn the bayonet cap handles
clockwise to lock the Upper Ram into the Mold Cylinder.
17. The SimpliMet 3000 is now ready for operation.
CAUTION
!
To avoid unexpected and extended heating and cooling times and poor mounts, check that the
Mold Cylinder Clamp Screw is loose. This indicates the Mold Assembly is clamped and secure.
Too close to the Mold
Closure, no gap.
Too far from the Mold
closure, too much gap.

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MA201435_13.1 [Original Instructions] 6/25/2012
Using the Mold Cylinder
Before making a mount, clamp the mold cylinder so it cannot rotate.
Before installing or replacing a mold cylinder use the MANUAL COOL function. This will lower
the mold cylinder to a safe handling temperature.
Clean the molding powder flash from the upper and lower RAM after completing each
molding cycle.
Apply Release Agent after every fifth or sixth mold to prevent build up of molding powder on
the inside of the mold cylinder and the outside faces of the upper and lower RAM.

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MA201435_13.1 [Original Instructions] 6/25/2012
Operation
SimpliMet 3000 is used to mount specimens with a variety of compression mounting resins. The mold
cylinders are designed for single or duplex mounting.
Front Control Panel
When power is activated to the SimpliMet 3000 front control panel will light up and display the
default parameters.
Figure 11 SimpliMet 3000 Front Control Panel
ON
Power On The Power On button will activate the SimpliMet 3000.
OFF
Power Off The Power Off button will deactivate the SimpliMet 3000.
Increase The Increase button will incrementally increase (raise) a parameter’s
value.
Decrease The Decrease button will incrementally decrease (lower) a
parameter’s value.
Parameter Scroll The Parameter Scroll button scrolls through the parameter
fields, displaying three parameter fields at a time.

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MA201435_13.1 [Original Instructions] 6/25/2012
Parameters Fields
There are multiple parameter fields available. Use the Parameter Scroll button to scroll
through the LCD screen to display the different parameters.
HEAT
TIME
1:00min
COOL
TIME
3:00min
PRESSURE
4200psi
Figure 12 Parameter Fields 1
HEAT TIME Displays the amount of time the specimen will be heated. Use the Increase
or Decrease buttons to select a time between 0 to 20 minutes, in 10-second
increments.
COOL TIME Displays the amount of time a specimen will be cooled. Use the Increase or
Decrease buttons to select a time between 0 to 30 minutes, in 10-second
increments.
PRESSURE Displays the amount of pressure applied to the specimen. Use the Increase
or Decrease buttons to select between 1200 psi to 4400 psi (80 bar –300
bar), in 100 psi (5 bar) increments.
TEMP-
ERATURE
300F
PRELOAD
PRESSURE
OFF
MOLD
SIZE
1.25IN
Figure 13 Parameter Fields 2
TEMPERATURE Displays the temperature selected. Use the Increase or Decrease buttons to
select a temperature variable between 120F (50C) and 360F (180C), in
20F (10C) increments.
PRELOAD PRESSURE Displays the minimum pressure applied at the beginning of a cycle
before full pressure is applied. Use the Increase or Decrease buttons to
select OFF or a range of psi between 0 psi to 400 psi (0 bar –30 bar), in
50 psi (5 bar) increments.
MOLD SIZE Displays the mold size selected for the specimen. The automatic mold
sensor will automatically display the mold size. There are eight mold sizes
available.
1 in 25 mm
1.25 in 30 mm
1.50 in 40 mm
2.00 in 50 mm

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MA201435_13.1 [Original Instructions] 6/25/2012
UNITS
IMPERIAL
LANGUAGE
ENGLISH
METHOD
LOADED
PHENOLIC
Figure 14 Parameter Fields 3
UNITSDisplays the measurement units used. Use the Increase or Decrease buttons to change the units to Imperial or Metric.
LANGUAGE Displays the language. Use the Increase or Decrease buttons to select a
different language of choice.
English Chinese
French Korean
German Japanese
Portuguese
METHOD LOADEDDisplays the selected method applied to a cycle. Use the Increase or
Decrease buttons to select between four pre-programmed Buehler methods
or 25 user-defined methods. If no method is desired, select NONE.
Four Buehler Pre-Programmed Methods:
PHENOLIC
EPOMET
TRANSOPTIC
DIALLYL PH

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MA201435_13.1 [Original Instructions] 6/25/2012
L1 Screen
HEAT
TIME
1:00min
COOL
TIME
3:00min
PRESSURE
4200psi
MANUAL
COOL
OFF
THERMO-
PLASTIC
OFF
RAM
MOVE
ON
CYCLE
START L1
Figure 15 L1 Screen parameters
CYCLE START Press the CYCLE START button to activate a cycle when the bayonet is
closed.
If the CYCLE START button is pressed in the middle of a cycle, the cycle
will stop.
RAM MOVE Press the RAM MOVE button to activate the movement of the RAM.
MANUAL COOL Press the MANUAL COOL button to active cooling when not in a cycle.
THERMOPLASTIC Press the THERMOPLASTIC button to activate the thermoplastic mode.
Note: Thermoplastic molds require a special heating and cooling cycle
to prevent cloudiness.
Level 1 Press the L1 button to scroll to the L2 screen for a different set of
command functions.