Dace Technologies MEGA-T300b User manual

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Equipment Type: 300 mm (~12-inch) Manual Abrasive Cut-off
Machine
Model: MEGA-T300b
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: January 5, 2017 This instruction manual is
provided with each piece of
delivered equipment.

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
WARRANTY
Terms and Conditions applying to all PACE Technologies Products
1. LIMITED WARRANTY AND DISCLAIMER:
PACE Technologies Products are warranted for one year from the purchase date to be free from defects in
material and workmanship under correct use, normal operating conditions, and proper application. PACE
Technologies obligation under this warranty shall be limited to the repair or exchange, at PACE Technologies
option, of any PACE Technologies Product or part which proves to be defective as provided herein. PACE
Technologies reserves the right to either inspect the product at Buyer’s location or require it to be returned to
the factory for inspection. Buyer is responsible for freight to and from factory on all warranty claims. The
above warranty does not extend to goods damaged or subjected to accident, abuse or misuse after release from
PACE Technologies warehouse, nor goods altered or repaired by anyone other than specifically authorized
PACE Technologies representatives. PACE Technologies shall not in any way be responsible for the
consequences of any alteration, modification or misuse unless previously approved in writing by an officer of
PACE Technologies. Note: Corrosion is considered a maintenance issue and not a warranty issue.
PACE TECHNOLOGIES MAKES NO EXPRESS WARRANTIES OTHER THAN THOSE WHICH ARE
SPECIFICALLY DESCRIBED HEREIN. Any description of the goods sold hereunder, including 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 MECHANTABILITY OR FITNESS FOR
PARTICULAR PURPOSE. THIS WARRANTY STATES PACE TECHNOLOGIES ENTIRE AND
EXCLUSIVE LIABILITY AND BUYER’S EXCLUSIVE REMEDY FOR ANY CLAIM FOR DAMAGES
IN CONNECTIONS WITH PACE TECHNOLOGIES PRODUCTS. PACE TECHNOLOGIES WILL IN NO
EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, NOR
FOR ANY SUM IN EXCESS OF THE PURCHASE PRICE.
2. LIABILITY CAP:
PACE Technologies maximum aggregate liability for loss and damage arising under, resulting from or in
connection with the supply or use of the Equipment and Consumables provided under this purchase, or from
the performance or breach of any obligation (s) imposed hereunder, whether such liability arises from any one
or more claims or actions for breach of contract, tort, (including negligence), delayed completion, warranty,
indemnity, strict liability or otherwise, unless otherwise limited by the terms hereof, shall be limited to one
hundred percent (100%) of the purchase price.
3. DELIVERY:
Customer assumes and shall bear the risk of all loss or damage to the Products from every cause whatsoever,
whether or not insured, and title to such Products shall pass to Customer upon PACE Technologies delivery of
the Products to the common carrier of Pace Technologies choice, or the carrier specified in writing by
Customer, for shipment to Customer. Any claims for breakage, loss, delay, or damage shall be made to the
carrier by the Customer and Pace Technologies will render customer reasonable assistance in prosecuting
such claims.
ii

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
4. ACCEPTANCE:
Customer shall inspect the Products promptly upon receipt of delivery. Unless customer objects in writing
within thirty (30) business days thereafter, customer shall be deemed to have accepted the Products. All claims
for damages, errors, or shortage in Products delivered shall be made by Customer in writing within such five
(5) business day period. Failure to make any claim timely shall constitute acceptance of the Products.
5. PAYMENT:
Customer agrees to provide timely payment for the Products in accordance with the terms of payment set forth
on the reverse side hereof or in any proposal submitted herewith. If any payment is not paid on or before its
due date, Customer shall pay interest on such late payment from the due date until paid at the lesser of 12% per
annum or the maximum rate allowed by law.
6. DEFAULT:
If Buyer is in default (including, but not limited to, the failure 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 been made in and shall be governed by the laws of the State of Arizona. These terms and
conditions and the description of the Products on the reverse side hereof or in any proposal submitted herewith
constitute the entire agreement and understanding of the parties with respect to this sale and supersede all prior
and contemporaneous agreements or understandings, inducements or representations, expressed or implied,
written or oral, between the parties with respect hereto. Any term or provision of this Agreement may be
amended, and any observance of any term of this Agreement may be waived, only by a writing signed by the
party to be bounds. The waiver by a party of any breach shall not be deemed to constitute a waiver of any
other breach. Should suit be brought on this Agreement, the prevailing party shall be entitled to recover its
reasonable attorneys’ fees and other costs of suit including costs and attorneys’ fees incurred on appeal or in
collection of any judgment.
iii

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.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 20
8.0 Electrical and Mechanical Drawings 42
iii

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.0 Product Description The MEGA-T300 is a manual wheel feed
or table feed abrasive 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-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 metallographic cutter.
1.1 General Description
1
Control
panel
Manual
wheel
feed
Cutting
chamber
Table wheel
feed
T-slot table
Safety
Lock-out
Safety
Lock-out
Emergency
Stop
Blade
change
locking peg

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] 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

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.2 Technical Specifications
Electrical specifications: 208Y (phase-phase or 120/120/120 to ground), 380V, 400,
480V 3-phase optional)
Motor power: 4.5 hp (3 kW) - 3-phase to ground
Speed (rpm): 2910 rpm at 208-380V/50 Hz
3492 rpm at 208-380V/60 Hz
2910 rpm at 440-480V/50 Hz
3492 rpm at 440-480V/60 Hz
Cut-off wheels: 300 mm (~12-inch) diameter
Wheel arbor: 32 mm (~1.25 inch) diameter
Maximum sample diameter: 4-inch (100 mm)
Weight: Approx. 350 lbs (160 kg)
Dimensions (WxDxH): Hood Closed: 36 x 34 x 26-inches
(914 x 864 x 660 mm)
Hood Open: 36 x 34 x 32-inches
(914 x 864 x 813 mm)
Table dimensions (WxD): 12 x 9-inch
(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)
Shipping temperature: 32° - 100°F (0 - 40°C)
Storage temperature: 32° - 100°F (0 - 40°C)
Recirculation system (included): 16 gallons (60 liters)
3
EU Directives: Machinery directive 2006/42/EC
Low Voltage Directive 2006/95/EC
Electromagnetic Compatibility directive 2004/108/EC
EU Harmonized Standards: EN ISO 1200:2010
EN 61010-1:2010
EN 61326-1:2006

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] 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

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.4 Features
Powerful motor
The MEGA-T300 is equipped with a
powerful belt drive motor. 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 feed for
increasing
cutting
capacity Safety lock-out
for protecting
user against
moving blade
Blade locking
lever
Viewing
window
Easy to
use
control
panel
Emergency
stop button

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
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: Heavy equipment. Take care to avoid bodily injury.
6
(Installation continued on next page)

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
2.3 Installation
!
Install unit carefully! Improper installation voids warranty.
!
The MEGA-T300 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 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 there
is no power to the machine, the
hood cannot be opened with the
interlocking safety device in the
LOCK position. To open the
hood without power hook-up,
turn the interlocking device with
key to the UNLOCK position
(used for service and shipping).
Main Power switch
(Installation continued on next page)
7
Turn to Lock
position to operate
Shipped in the
Unlock

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Recirculating tank connections
8
(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.

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3.0 Safety Guidelines
3.1 Warning Sign
!This sign points to special safety features on the machine.
The MEGA-T300 abrasive cutter has been designed for cutting metallographic specimens.
DO NOT CUT oversize samples. Always follow proper operational guidelines and avoid
contact with moving parts, lubricants and abrasives. Seek appropriate medical care for
cutting injuries.
3.3 Emergency Statement
!
Before operating, cutting chamber hood must be closed. After cutting, the safety latch
will not open for approximately 5 seconds after pressing the stop (red) button.
!
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 that the
part may pinch and cause jamming of the cut-off wheel. Use the appropriate clamping
devices to avoid this occurrence.
!Never start a cut under load.
!Make sure that the cut-off blade is rotating down and into the sample.
3.2 Safety Precautions
9
Careful attention to this instruction manual and the recommended safety guidelines is
essential for the safe operation of the MEGA-T300.
Proper operator training is required for the safe operation of the MEGA-T300. Any
unauthorized mechanical and electrical change, as well as improper operation, voids all
warranty claims. All service issues need to be reported to the manufacturer / supplier.

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Recirculation tank
The MEGA-T300 is equipped with a mobile
three-chamber 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 prevent debris and
corrosion build-up.
Water flow
regulating valve
Rinse line
10
Drain
line
Three Chamber tank
with counter-current
flow Coarse
strainer
Tank
drain

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3.4 Safety Tests
!
Examine and verify that the MEGA-T300 safety devices
and operating performance are in good working
condition prior to use. The following safety checks are
considered 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 wheel ON then OFF;
Try to open the hood.
Proper
Response:
Hood does not open for approximately 5
seconds.
Malfunction: Hood opens immediately.
Corrective
measure:
If cut-off wheel does not power down,
disconnect power supply cord and call
service technician.
Emergency stop switch

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
4.0 Start-up and Operation
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 mode.
Light ON/OFF: Turns inside chamber light On or Off.
Ammeter: Number of amps being pulled by the motor.
Amp overload signal
light:
Red light turns on if too many amps are being pulled by the
motor. This is a warning light to indicate that the cutting
force needs to be reduced.
Cutting
wheel (ON)
Light
ON/OFF
Cutting
wheel (OFF)
Power
Light
Amp overload
signal light
Ammeter

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.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

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, 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 from
turning, push
in locking rod
to hold in place

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Abrasive Cung Fluids
Pace Product Name Catalog Number Packaging
MAXCUT™ Abrasive Cung Fluid (32 oz) MAXCUT 1000-32 32 oz
MAXCUT™ Abrasive Cung Fluid (128 oz) MAXCUT 1000-128 1 gallon
MAXCUT™ 2 Cung Fluid with Ancorrosion Addive (32 oz) MAXCUT2 1000-32 32 oz
MAXCUT™ 2 Cung Fluid with Ancorrosion Addive (128 oz) MAXCUT2 1000-128 1 gallon
300 mm (~12 MAXCUT™ Abrasive Blades 32mm (~1¼) Arbor
Pace Product Name Catalog Number Packaging
So Non-ferrous Materials (Aluminum, Brass, Zinc, Etc.) MAX-E300 10
Hard Non-ferrous Materials MAX-C300 10
So Steels MAX-E300 10
Case Hardened Steels MAX-D300 10
Hard Steels MAX-D300 10
General Purpose Industrial Blade MAX-I300 10
ABRASIVE Cutting CONSUMABLES SELECTION GUIDELINES CHART
15

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MEGA-T300b
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
For proper clamping, use the appropriate clamping vises to securely hold the sample in
place. It is recommended that both sides of the part be clamped to avoid pinching of the
blade (possibly breaking the blade) and to minimize burning of the workpiece during
cutting.
For proper fixturing, take into account the 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 side panel
before opening the hood.
2. Position fixtures and sample near to cut-off wheel.
3. Close hood.
4. Turn on coolant and cutter motor.
5. Hand feed the cutting wheel or table feed into the sample.
6. Turn off cutter and allow blade to completely stop before opening cover.
Note magnet safety switch has an approximately 5 second delay. Cutter
hood cannot be opened until safety switch is deactivated.