Pace Technologies MEGA-T400S User manual

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Equipment Type: 400 mm (~16-inch)
Manual Abrasive Cut-off Machine
Model: MEGA-T400S
Electrical
Requirements:
480 Volts (3-phase)
Frequency: 50/60 Hz
Motor Horsepower: Variable speed Servo Motor:
12 KW (16 hp) @480V, 3-phase
Manual Revision Date: March 16, 2023
This instruction manual is
provided with each piece of
delivered equipment.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
ii
WARRANTY
Terms and Conditions applying to all PACE Technologies Products
1. LIMITED WARRANTY AND DISCLAIMER:
PACE Technologies Products are warranted for two years 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 MERCHANTABILITY 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

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
iii
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.
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. All disputes
arising under or relating to the purchase of the equipment shall be brought and resolved solely and exclusively
in the State of Arizona, Pima County . 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., 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.
8. RESTOCKING FEE:
All Returns are subject to a restocking charge equal to 15% (fifteen percent) of the Invoice, unless the Goods
are proved to be non-conformed by PACE Technologies.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
iv

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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 12
5.0 Maintenance 18
6.0 Trouble Shooting 19
7.0 Cutting Basics 21
8.0 Electrical and Mechanical Drawings 24
v

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.0 Product Description
The MEGA-T400S 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-T400S is very robust and durable
with its cast aluminum alloy and stainless steel
construction. Featuring a corrosion-free T-slot
table, the MEGA-T400S is a very versatile
wheel/table feed floor model metallographic
cutter.
1
Control
Screen
Manual
wheel feed
Cutting
chamber
Table wheel
feed
Blade Height
Locking
Screw
Safety
Lock-out
Emergency
Stop
Control
knobs
Powerful motor
The MEGA-T400S is equipped with a powerful
belt driven servo motor. In addition, the motor
has an inductive brake for a quicker response of
halting the blade (approx. 2-3 seconds).
Manual feed and table feed cutting
The MEGA-T400S is an easy-to-use manual
cutter with simple controls. Cutting can be
accomplished with either a wheel feed or table
feed.
The MEGA-T400S features a removable side
port panel for sectioning longer samples.
Base cabinet
stand
Rinse Valve

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
2
T-slot table
LED light inside
Removable side
port for longer
feed through
samples
Pass through side panels for
long sample access Safety lock-out
for protecting
user against
moving blade
When current setting
is exceeded, a red
flashing light appears
inside.
1. When closing the hood, press down the hood to ensure that
the safety switch is engaged.
2. After the cut has finished, if the hood lock does not release
DO NOT FORCE OPEN, try pushing down on the hood to
release the safety pin.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Easy to use
vises.
3
Coolant applied through
the shroud directly to the
blade.
Flexible coolant
hose for application to
cutting area (optional).

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.2 Technical Specifications
4
EU Directives: Machinery directive 2006/42/EC
RoHS Directive 2011/65/EU
Electrical specifications: 480V, 3-phase
Motor power: Constant torque variable speed
Servo Motor:
-14.4 KW (19.2 hp) 480V
Speed (rpm): Variable 1000-3000 rpm
Adjustable cutting load: 2-15 amps (max. 20 amps)
Electronic motor brake:Stops in ~3-5 seconds
Cut-off wheels: 16 inch mm (~400 mm) diameter
Wheel arbor: 32 mm (~1.25 inch) diameter
Maximum sample diameter: 6-inch (150 mm) diameter
3 x 6-inches (75 x 150 mm) (HxD)
Wheel feed: Manual
Table feed: Manual
Vertical movement: 5 inch (125 mm)
Weight: Approx. 880 lbs (400 kg)
Dimensions (WxDxH): Hood Closed: 48 x 51 x 63 inch
(1220 cm x 1300 cm x 1600 cm)
Hood Open: 48 x 51 x 66 inch
(1220 cm x 1300 cm x 1665 cm)
Table dimensions (WxD): 11 x 18.25 inch t-slot
(280 x 470 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):
14 gallons (53 liters)

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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-T400S should be on a flat sturdy surface, with easy access to
electrical connections.
5
MEGA-T400S hood open dimensions
MEGA-T400S hood closed dimensions

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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. 51x51x75 inches
Weight: Approx. 1000 pounds
2.2 Shipping When moving crate, lift from bottom. To move MEGA-T400S use
support bars provided with the machine.
The MEGA-T400S contains sensitive electronic and mechanical
components. Do not drop.
! CAUTION: Heavy equipment. Take care to avoid bodily injury.
6
(Installation continued on next page)
Casters set
for moving
cutter
Casters set
for stationary
support
Machine includes support bars to lift machine and move
with the aid of a forklift. The casters are adjusted so the
saw can be rolled into place easier. After fixing the
position, retract the wheels on the caster.
Once the cutter is in place, remove the forklift support
bars so the tank will move inside the cabinet.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
2.3 Installation
(Installation continued on next page)
7
!
Install unit carefully! Improper installation voids warranty.
!
The MEGA-T400S should be placed on a flat stable surface.
Connect the electrical connections
to a 3-phase power line. The motor driver
max amp draw is 20 amps. However,
the operating power is set to 15 amps.
!
Electrical Connections - The standard saw is designed to operate at 208-220V 3-phase
(120V-120V-120V-ground) (optional 380V)
Verify voltage on nameplate
!
Connect pump connector, supply line from cutter to the pump and insert the drain hose into
the basket filter
!
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. If not reverse any two of the 3-phase power wires.
Main
Power
switch
Main
Power
Not
used
Coolant
supply
line to
cutter
Electrical
connector
for pump

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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
valve
External coolant supply: Attach 3/4 inch tube between pump and cutter.
Drain: 1.5-inch (38 mm) tube.
Electrical connections: Connect 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-T400S,
Recommended Coolant: To help minimize corrosion apply a coolant with a anti-corrosion
additive or an oil emulsion coolant is recommended. Note:
Recommended that the coolant be changed every 50 cuts or once a
week, whichever occurs first.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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-T400S 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
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-T400S.
Proper operator training is required for the safe operation of the MEGA-T400S. 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.
!
Before operating, cutting chamber hood must be closed. After cutting, the safety latch will not
open for approximately 2-8 seconds after pressing the emergency or red 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.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Recirculation Tank
The MEGA-T400S is equipped with a
coarse filter to remove large particulate
and broken blades
NOTE: Dispose of the old coolant in
ordnance with federal, state and
local regulations.
Electrical
connection
Pressure
line
After use, water off the cutting
chamber to prevent debris and
corrosion build- up.
Water
valve
Rinse line
10
Drain
line
Coarse
strainer
NOTE: Leave hood open
to dry after cleaning.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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-T400S safety
devices and operating performance are in good working
condition before use. The following safety checks are
considered significant:
Emergency stop switch
Magnetic Safety switch
11
Test: Activate the main switch and the close
hood; depress emergency stop switch.
Proper
Response:
Machine powers down and motor
stops in 5-10 seconds
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 the main switch and close the
hood; turn cut-off wheel ON then OFF;
Try to open the hood.
Proper
Response:
The hood does not open for approxi-
mately 3-5 seconds.
Malfunction: If hood opens immediately.
Corrective
measure:
If the cut-off wheel does not power
down, disconnect the power supply cord
and call a service technician.
Emergency stop switch
HOOD (Closing / Opening)
1. When closing the hood, press down on the hood to ensure
that the safety switch is engaged.
2. If the hood lock does not unlock DO NOT FORCE OPEN, or
try pushing down on the hood to release the safety pin.

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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-T400S is a manual wheel and manual table feed cutter.
12
4.2 Control Panel
Coolant
ON/AUTO/OFF
Cutting
wheel (ON)
Light
ON/OFF
Cutting
wheel (OFF)
Touch screen
control
Information
Screen
Note: When first powering up the MEGA-T400S the initialization time for the saw is
approximately 15 seconds.
The servo motor is also designed to increase speed slowly and typical takes 4-5
seconds to reach full speed.
Cutting wheel ON: Starts the cutting wheel.
Cutting wheel OFF: Stops the cutting wheel (inductive brake engages to slowing
wheel). The hood will not open until safety lock releases in
approximately 5-8 seconds after pressing the stop button.
Coolant ON/AUTO/OFF: Operates the coolant pump in Auto or Manual mode. Must be
selected before starting the motor.
Light ON/OFF: Turns inside chamber light On or Off.
Discontinued use if safety lock fail
!

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Start up screen - Press control panel knob to
progress to information screen
START UP SCREEN
INFORMATION READY SCREEN
OPERATING SCREEN
Information screen - set speed and force
(amps) by selecting parameter on the touch
screen and adjusting the parameter in the sub-
screen. Repeat for other parameter.
Set
Speed
Actual
Operating
Speed
Cutting
force
(amps)
Setting
Percentage
or fraction
of amps to
set amount
13

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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
14
Wheel lock

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MEGA-T400S
Abrasive Cutter
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://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 350 mm abrasive cut-off wheel into position.
3. Use only certified abrasive cut-off wheels.
4. Gently tighten blade locking bolt (Note: locking bolt is reverse
threaded).
4.4 Changing abrasive cut-off wheels
15
!
Changing Blade
Remove: Loosen by
turning clockwise
Tighten: Turn counter-
clockwise
To prevent
shaft from
turning, push
in the locking
rod to hold in