Chennai Metco BAINCUT MEDIUM User manual

BAINCUT MEDIUM
Instruction Manual
Metallography
Abrasive Cutting Machine
Chennai Metco

Intended usage
The Baincut Medium is used for cutting of components to obtain the surface of interest with least
metallurgical damage for subsequent metallographic preparation. With the right choice of cutting
parameters and right cutting wheels, excellent quality can be obtained.

Baincut Medium Page 3
Contents
1. Machine Parts ---------------------------------------------------------------------------- 4
2. Safety -------------------------------------------------------------------------------------- 5
3. Transport ----------------------------------------------------------------------------------- 15
4. System Features and Principles of Operation ---------------------------------------- 19
5. Machine Layout ---------------------------------------------------------------------------------- 21
6. Installation ---------------------------------------------------------------------------------- 26
7. Operation --------------------------------------------------------------------------------- 28
8. Maintenance and Inspection --------------------------------------------------------------- 29
9. Troubleshoot -------------------------------------------------------------------------------- 30
10. Dismantling ------------------------------------------------------------------------------- 33
11. Technical Specification ---------------------------------------------------------------------- 34
12. Electrical Circuit ---------------------------------------------------------------------- 35
13. Warranty certificate ---------------------------------------------------------------------- 36
14. Contact us ---------------------------------------------------------------------------------- 37

Baincut Medium
1.
MACHINE PARTS
Take a Moment to
1.Cutting Handle
4.Main Power switch
MACHINE PARTS
Take a Moment to
familiarize
yourself with the location and names
Of the Baincut - M components.
1.Cutting Handle
, 2.FRP Cover, 3.User Panel,
4.Main Power switch
, 5.Coolant tank, 6.Leg Bush
Page 4
yourself with the location and names

Baincut Medium Page 5
2. SAFETY
2.1 Proper Use
2.1.1 Principle
The Baincut cutting machines is state of the art and designed in accordance with recognized technical
research and experience and safety regulation. Failure or neglect to properly install, operate and
maintain the machine/system may be risk of serious or fatal injury to users or third parties or result in
unnecessary damage of the system or other equipment.
2.1.2 Permissible Operation
The machine/system is a technical working appliance, designed exclusively to section materials for
metallurgical purpose. The machine/system is a technical means of achieving, exclusively, low volume
cutting of materials. Any other usage is regarded as improper. Any liability on the part of the supplier
for damages resulting from an improper machine usage is excluded. The risk has to be borne entirely by
the user. The following are the example of the machine/system misuse:
 Using for production purpose.
 Using on other industry or application.
 Using other than recommended lubrication oil on the machine.
 Untrained and unaccomplished this instruction manual personnel operated this machine/system
Proper usage also includes compliance with operating, servicing and maintenance requirement
specified by the manufacturer.
2.1.3 Safe Operation
The machine must only be used in a technically error – free condition and according to proper operating
practice in a safety and risk conscious manner while observing and heeding all caution or danger tags
attached to the machine or included in this manual
Malfunction that can impair safety must be remedied immediately.
2.2 Level of hazard
This symbol is used to call attention to hazards or unsafe practices which could result in an injury or
property damage. The signal words, defined below, indicate the level of the hazards. The message after the
signal word provides information for preventing or avoiding the hazards. While reading your manual pay
close attention to areas labeled the signal words.

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2.3 Safety information
Read and understand all the instruction and safety information in this manual. Everyone who works on or
around this equipment including, but not limited to, operator, maintenance personnel, and supervisory
personnel must read and understand the information in this chapter prior to commencing work on or around
this equipment. Failure to conform to the information in this chapter could lead to property damage or
serious personal injury including possible loss of body parts or death. This chapter only describes proper
safety procedures to follow when working with this equipment. Please refer to the instruction manuals
delivered together with the installation of your equipment.
Please ensure that all work described in this manual is carried out in a good environment / workshop using
proper tools and equipment.
2.4 Protection for Installation, Operation and Maintenance Personnel
In addition to the safety information included in this section, always observe all specific safety information
included with the instructions in balance of this manual. As manufactured this equipment has been equipped
with safety devices which correspond to current technology standard in accordance with the prescribed
applications of this equipment. However, residual risks remain to which attention is drawn individually
within this machine manual.
Instruction obligation: The operating company must verify that:
 Personnel have the necessary technical, equipment-specific, and safety knowledge or that is
achieved by means of relevant training before the equipment is installed, operated, or
maintained.
 Personnel have the necessary competence to be able to work on accordance with the regulations
and instruction.
Indicates an imminently hazardous situation
that, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation that,
if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous that, if not
avoided, might result in minor or moderate
injury. It can also indicate possible loss of
materials or damage to the equipment.

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 Before initial startup, personnel have to read and understand all instructions contained within the
supplied documentation.
Equipment obligation: The operating company is required to equip personnel with the necessary protective
clothing as follow:
 Safety shoes.
 Safety goggles
2.5 Protection for Third parties
The operating company must also make persons who are not charged with the operating or maintenance of
the equipment aware of the dangers.
2.6 Common Sense safety
Accidents frequently occur due to carelessness or lack of knowledge. To avoid potential problems, review
the information in the section before attempting to install, setup, operate, or maintain this equipment. Think
safety at all the times. Do not let familiarity with the equipment lead to unsafe short cuts. The following
common sense safety practices must be observed at all times.
1. Follow all procedures and precautions in the manual carefully and completely.
2. Only attempt repair or adjustments for which proper training has been completed.
3. Always observe all safety warnings and notices on the machine and in the manual.
4. Do not remove or otherwise alter any guards or panel unless the machine is completely shut
down and has been made inoperable. Be sure to replace these items before restarting the
machine.
5. Never operate the equipment without guards and safety mechanisms in place and functional.
6. Do not allow foreign object to fall into machine.
7. Always use the proper tools for performance of any operation on the machine. Whenever
feasible, use voltage-isolated tools.
8. Do not touch any parts of the machine which may have become hot during operation.
9. Do not wear neck ties, jewelry, loose clothing, and long hair.
10. Wear or use gloves, goggles, safety shields, ear protection, and other employer recommended
safety equipment. Wear protective clothing to prevent burns.
11. Disconnect power and lock out all switches before attempting to adjust or manipulate any
moving parts or mechanism on the equipment.
12. Be aware that there are high voltages in this device when power is connected. Power must be
disconnected when the device is being repaired. However, because there are certain checks and
adjustment that can be made only with any power connected, it is imperative that only trained
personnel, aware of the safety hazards involved and familiar with this type of work and
necessary safety precautions, be permitted to perform this work.
13. Maintain good housekeeping practices to prevent slips, falls, cuts, burns, and other possible
accidents. Keep the area all necessary items properly organized.
14. Even though the plant may be equipped with automatic sprinklers or other means of the fire
protection, portable fire extinguishers should be available to the machine operator. To be
effective, portable extinguishers must be reliable, the proper type for each class of fire that may

Baincut Medium
occur in the area, in
sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged as require
operable by are personnel who are trained to use them effectively and promptly.
15.
During refilling the lubrication oil, preventive skin protection by use of skin
recommended. Goggles recommended during refilling for eye protection
during this occurrence to prevent slippage due to oil leaked
2.7 Hazard Warning Label
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
potentially present during operation and maintenance activities.
Hazard warning labels are in appropriate sizes and colors that ca
symbols that show hazard types, in addition to descriptions of warning contents.
2.7.1
Types of Hazards Warning Label
The following safety warning labels appear on the system.
Personnel are requested to confirm the location
of, read and thoroughly understand contents of
all of hazard warning labels applied to this
machine prior to work.
“Warning of Dangerous Electric Voltage”
“Earth (Ground) Protective Conductor Terminal “
“Disconnect the power before open”
sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged as require
operable by are personnel who are trained to use them effectively and promptly.
During refilling the lubrication oil, preventive skin protection by use of skin
recommended. Goggles recommended during refilling for eye protection
during this occurrence to prevent slippage due to oil leaked
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
potentially present during operation and maintenance activities.
Hazard warning labels are in appropriate sizes and colors that ca
tch attention of personnel’s eyes and have
symbols that show hazard types, in addition to descriptions of warning contents.
Types of Hazards Warning Label
The following safety warning labels appear on the system.
Personnel are requested to confirm the location
of, read and thoroughly understand contents of
all of hazard warning labels applied to this
machine prior to work.
“Warning of Dangerous Electric Voltage”
“Earth (Ground) Protective Conductor Terminal “
“Disconnect the power before open”
Page 8
sufficient quantity to protect against the exposure in the area, located where
they are readily accessible for immediate use, and maintained in perfect operating condition.
They must be inspected frequently, checked against tampering, recharged as require
d, and
operable by are personnel who are trained to use them effectively and promptly.
During refilling the lubrication oil, preventive skin protection by use of skin
-protecting agents is
recommended. Goggles recommended during refilling for eye protection
. Safety shoe suggested
Hazard warning labels are applied on the machine where potential hazards are potential hazards are
tch attention of personnel’s eyes and have
symbols that show hazard types, in addition to descriptions of warning contents.
Personnel are requested to confirm the location
of, read and thoroughly understand contents of

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2.7.2 Location of Hazard Warning Label
 Electric system inside the Electrical Control Panels contains highly hazardous high voltage
sections (Figure 1). Lock – out the Main Switch before maintenance, to prevent electric shock
accidents due to contact with high voltage section.
 Turn off the system Main Switch before maintenance, to prevent electric shock accidents due to
contact with such high voltage section.
Figure 1 : Danger Electric Voltage Symbol
Figure 2 has the following points with caution symbol to prevent accidents.
 Don’t open the door immediately after cutting
 Never use the machine while the door is open
 Don’t apply excessive force while cutting
 Remove the lever rod after changing the wheel
Users are
NOT
allowed to change the location of hazard
warning labels. Make sure to apply new labels upon
replacement of the peeled off or worn out labels

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Figure 2
Figure 3 depicts the terminal connection which is to be grounded.
Figure 3 showing the ground terminals at the rear of the Baincut Medium machine

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2.8 Safety devices
2.8.1 Main Switch
Figure 4 showing the Main Switch
The system is provided with a main power switch to interruption of power supply. The system must be
switched off via the Main Switch is secured by means of a padlock if the following works are carried
out:
 Cleaning
 Maintenance
 Repair
The Main switch (arrow on Figure 3) is located on the rear side of the Electrical Control Panel.
 Position 1 : system switched on
 Position 2: system switched off
2.8.2 Emergency Stop button
Figure 5 showing Emergency Buttons

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In an emergency, the system may immediately be brought to a halt by pressing the Emergency Stop
Button.
The Emergency Stop Button (figure 4) is located on the rear side of the Electrical Control Panel.
Before releasing Emergency Stop Button, verify that the danger has been eliminated.
2.9
Lock out/Tag out
2.9.1 Main Switch Lock out/ Tag out
The purpose of lockout is to prevent unexpected startup and release of accumulated energy in order to protect
any personnel during maintenance and inspection process. The other purpose of tag out is to securely prevent
anyone other than permitted personnel from turning operation handle of main energy isolating device to ON, by
applying tags (which indicate the energy isolating device and the equipment may not be operated until the tag
out device is removed) to locked out main energy isolating device. Only persons authorized and certified to
perform Lockout / Tag out (LOTO) procedures may do so. LOTO procedures are typically associated with
maintenance tasks. In Main Power Switch area we perform Lockout / Tag out are shown below.
Anyone who carries out servicing of this machine is
requested to recognize the importance of lockout and learn
every lockout procedures described in this section before
any service.
If the system is still op
erating, carry out the shut down
procedure and ensure the system is completely stopped
before lockout.
When more than one person performs service
at the
same time, appoint a "supervisor" who supervises all the
persons.
Supervisor is requested to be aware of working status
all the time, and to carry out the lockout procedure.

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The step for LOGO of main switch are as follows:
i. Turn the Main Switch to OFF (anti- clockwise) to shut down the power as illustrated below:
ii. Apply padlock to the Main Switch
iii. Apply tag (nameplate) to the lock Main Switch to warn caution against everyone other than
maintainers in charge from starting up power unexpectedly.
2.10 Disposing Individual Component
Reusable raw material and problem material.
Environmental pollution.
 Protect the environment by correctly disposing
of a recycling raw materials and problem
materials
Turn main switch in anti
-
clockwise to turn off the
electrical supply to machine
OFF
Position
Secured position
Figure 5

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 Machine frame and all mechanical machine components are made of steel, light metal and plastics.
These materials are recyclable.
 Take non-reusable difficult waste, lubricant and batteries, to the appropriate waste disposal point.
 Seal any used parts possibly exposed to toxic or corrosive material prior, in inside of vinyl bags. Apply
certain marking to all of the disposal bags to identify possible contamination.
 Drained lubrication oil from oil reservoir during maintenance job occurred must collect in the proper
way and dispose to the correct waste point.
Be careful wh
ile handling waste fluid, which
may corrode
skin and clothing upon contact.

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3. Transport
3.1 Unpacking and Inspection
Inspect equipment and shipping crate immediately upon receipt. Check the packing slip carefully and make sure
all the materials have been received as indicated on the packing ticket. If any damage apparent, you should both
report it to the trucking delivery person and contact the transportation company immediately. When submitting
a claim for shipping damage, request that the carrier inspect the shipping container and equipment.
3.2 Unpacking Location Environment /Cautions
Do not unpack in a location where any of the following conditions apply.
• Unbalanced
• Location with direct humidity (including rain and fog) intrusion
• Location with possible acute temperature change
• Location with strong vibration; also, do not place any product on such location
• Dusty
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or
property damage. The signal words, defined below, indicate the level of the hazards. The message after the
signal word provides information for preventing or avoiding the hazards.
While reading your manual, please pay close attention to areas labeled the signal words.
3.3 Transporting Machine with Box/Crate
Interrupt the unpacking procedure and contact the
responsible forwarder once any obvious abnormality such
as abnormal noise/odor is found during unpacking.
Risk of falling transport items.
Risk of death or severe crushing of limbs
 Lift truck or forklift according to the total weight to be transported
 Fork length min. 1250 mm fork spacing about 1000 mm
 Position the forklift at the corresponding marked places of the crate
 Do not stand under transport item during transport

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Equipment and tools to be used:
 Forklift (figure 1)
 Lift truck (figure 2)
The forklift or lift truck employed must fulfill the following minimum requirements:
• Carrying capacity according to the total weight (machine/system and transport packing), see shipping papers.
• Length of the forks should be at least 1250 mm
• Distance between forks should be at least 1000 mm
i. Insert the fork carefully so that the centre of gravity of the box lies in the middle of the forks
ii. Lift it to a safe level so that the box can be moved to the required place
3.4 Unload Distribution Box
Lifting equipment must be level
with floor
during lifting occurrence
Risk of falling items.
Risk of death or severe crushing of limbs
 Lift truck or forklift according to the total weight to be
transported
 Fork length min . 920 mm fork spacing about 820 mm
 Do not stand under the transport item during transport
 Proper size of pallet shall be use or transportation
Lifting equipment must be level with floor
during lifting occurrence

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Equipment and tools to be used:
 Forklift
 Lift truck
 Pallet Jack (figure )
The forklift or lift truck employed must fulfill the following minimum requirements:
• Carrying capacity according to the total weight (machine/system and transport packing), see shipping papers.
• Length of the forks should be at least 920 mm
• Distance between forks should be about 820 mm
Note: The centre of gravity of Distribution Box is not in the center and depends on the outfitting of the unit.
i. Place the Distribution Box into proper size of empty pallet.
ii. Place the fork lift insertion position on the pallet.
iii. Lift the pallet and transport to the installation site.
iv. Place Distribution Box according to installation plan.
3.5 Unload the Baincut Cutting Machines
Risk of falling transport items.
Risk of death or severe crushing of limbs
 Lift truck or forklift according to the total weight to be transported
 Fork length min . 1250 mm fork spacing about 1000 mm
 Position the forklift at the corresponding marked places of the crate
 Do not stand under transport item during transport

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Equipment and tools to be used:
 Forklift
 Lift stand
i. Insert two lifting stand into the bottom four side of the Cutting Machine
ii. Place the fork arm into hollow section of lifting stand
iii. Lift the machine approx. 10 m and check the centre of gravity
iv. Transport the machine to the installation plan
v. Unload the fork lift to place the cutting machine on the floor
3.6 Relocating the Cutting Machine
3.6.1 Preparing for repositioning
 Turn off the Main Switch of Electrical Control Panel and remove attachment of the main power
supply to system.
 Remove the connecting pipe between Oil Tank and Distribution Box.
 Secure all the parts on the Cutting machine
3.6.2 Repositioning of unit
 Repeat the step on Section 2.4
Lifting equipment must be level with floor
during lifting occurrence

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4. System Features and Principles of Operation
4.1 Introduction
The Baincut Cutting Machine is exclusively designed for sectioning the materials for metallographic
analysis. The machine offers that, the cutting techniques can be programmed through a Programmable Logic
Unit (PLC) for sectioning difficult to cut materials and sections efficiently. For this reason, the user can
increase the quality of the surface finish obtained during cutting. The cutting machines offer manual cutting
mode also to increase the versatility of the cutting process.
A user friendly Liquid Crystal Display (LCD) touch screen panel is provided on this system. Not much
of parameters required to determine before operation. User can choose the pre – existing recipes’ for the best
outputs.
4.2 Machine Description
Baincut cutting machines are exclusively designed for the metallurgical sample cutting. The machine
consists of a motor that rotates along with an abrasive or precision wheel to cut the sample using abrasive
action.
One of the advantages of the machine is the programmable cutting modes that facilitate cutting of large
samples or difficult – to – cut samples efficiently. The automated movement offers precision and reproducibility
while the manual cutting mode offers the user friendly cutting action thus providing versatile range of cutting
options. The advanced touch screen option allows the user to enter and store the cutting parameters for easy
storage and retrieval of cutting data.
4.3 System Content
The Baincut Machines consists of the following assemblies
 Electrical Control Panel assembly
 Coolant assembly
 Mechanical Assembly
4.3.1 Electrical Control Assembly
The Electrical Control Panel consists of PLC, LCD display, Relays,3-phase AC contactors, switches and
etc. The function of control panel is used to program the cutting cycle. The electrical assembly consists of cycle
start, cycle stop, and coolant on and off. In automated machines the electrical assembly is also used to control
the servo motors for automated movement. The safety feature in electrical assembly includes the cutting cycle
starts only when the door is closed. The coolant on/off is used to flush the machine with coolant to clean it after
use.

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4.3.2 Coolant Assembly
The coolant tank assembly includes the items of motors, pumps, exhaust valves, tank etc. Main function
of the coolant assembly is to store the coolant in a safe environment and circulate the coolant to remove the
swarf and debris during and after cutting operation.
4.3.3Mechanical Assembly
The mechanical assembly consists of the Base and Stand with motor with the spindle or belt drive, T – slot
table for longitudinal movement, shafts, lead screw to and guide rods to assist the motion along the 3 axes. The
mechanical assembly ensures vibration and chatter free cutting operation.
4.4Working principle of the Baincut Cutting Machines
Initially the system electric motor and coolant pump operate continuously after the electricity connected
and the Main Switch is activated on the Electrical Control panel. Once the parameters have been set and the
cycle start button is switched on, the coolant motor pumps the coolant from the coolant tank to the valves near
the abrasive wheel. The Motor starts rotating and so the coolant spreads through the periphery of the rotating
abrasive wheel. According to the cutting parameters the wheel and table moves through guide rod assembly
cutting the work piece. Once the work piece is cut and the Cycle Stop button is pushed off the motor stops and
the coolant flow also stops.