Pace Technologies TERAPRESS TP-7100S User manual

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Equipment Type: Automated Compression Mounting Press
Model: TERAPRESS TP-7100S Compression Mounting Press
Electrical Requirements: 110/220 Volts
Frequency: 50/60 Hz
Manual Revision Date: April 24, 2022

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Contents
PAGE
Warranty i
1.0 Safety Guidelines 1
2.0 Product Description 3
3.0 Unpacking, Shipping, and Installation 7
4.0 Start-Up and Operation 10
5.0 Maintenance 22
6.0 Troubleshooting 23
7.0 Compression Mounting Guide 25
8.0 List of Spare Parts 35
9.0 Electrical and Mechanical Drawings 49

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
i
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 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.

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
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., 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.
ii

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
1.0 Safety Guidelines
1.1 Warning Sign
!This sign points to special safety features on the machine.
1.2 Safety Precautions
1
(Safety Precautions continued on next page)
!
Supplying incorrect voltage will cause severe damage to the electrical system.
Verify the operating voltage listed on the serial plate on back of machine
(indicated in section 3.3).
!
It is recommended that no extension cords or multiple outlet connectors be
used as this may cause the fuse to overheat but not blow during operation.
!
Careful attention to this instruction manual and the recommended safety
guidelines is essential for the safe operation of the TERAPRESS TP-7100S
mounting press.
!
Proper operator training is required for operation of the TERAPRESS TP-
7100S mounting press. Unauthorized mechanical and electrical changes, as
well as improper operation, voids all warranty claims. All service issues need
to be reported to the manufacturer / supplier.

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
The TERAPRESS TP 7100S mounting press has been designed for mounting non-flammable
metallographic specimens up to 2-inch diameter. Always follow proper operational guidelines
and avoid contact with moving parts and hot assemblies. Seek appropriate medical care for
injuries.
1.3 Emergency Statement
2
!
Caution: DO NOT POSITION HEAD OR OTHER BODY PARTS OVER THE
MOLD WHEN RAISING THE RAM TO REMOVE THE SPECIMEN MOUNT
!During operation, the closure and upper parts of the heating and cooling block
can get very hot. For safety, do not touch the closure unit. Use protective
gloves if required.
!
Always completely screw tighten the bayonet cover and back off a fraction so it
is not too tight. Improper installation can result in hot molten mounting material
leaking (danger of burning).
!
Initial cooling water coming into contact with mold will produce an initial burst
of steam. To avoid danger of burning, secure the drain line and use caution
when the TERAPRESS TP 7100S compression mounting press is in use.
!
Mold cylinder and ram get very hot during the mounting process. Take care
before changing (danger of burning).
!
Mounting samples must be chemically compatible with the mounting material.
Do not mount flammable samples.
!
Before opening the unit, disconnect main power plug. Replacement parts
should be installed only by qualified personnel.
!
Follow proper operating instructions (Section 4.0) and obtain proper training
before operation.
!Do not leave press unattended during operation.
!Turn off external water supply when press is not in operation.
1.2 Safety Precautions (continued)

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Interchangeable molds
2.0 Product Description
2.1 General Description
Touch screen
control panel
3
Bayonet holder
The TERAPRESS TP 7100S compression mounting press is designed for ease-of-use and reliability.
It utilizes air pressure to maintain a constant force on the specimen, thus eliminating the requirement
to continually monitor and increase the force as the resin begins to melt.
Rapid heating is achieved by a heater that completely surrounds the mold assembly and is precisely
controlled via microprocessors. Cooling is also accelerated by a water-cooling jacket, and can be
accomplished by cooling for a set amount of time or to a specific temperature. This ensures that
curing can be achieved for both thermoset and thermoplastic compression mounting resins.
Depending on your needs, the TP 7100S is sold with either interchangeable or fixed mold
assemblies. Interchangeable molds allow the user to quickly swap mold sizes from 1 to 2 inch
mounts. Fixed molds offer superior heat retention resulting in shorter cycle times and are best for
labs that work with the same mold size the majority of the time.
With the use of a spacer, the TERAPRESS TP 7100S can produce two mounts simultaneously. This
can substantially increase the productivity of your metallographic laboratory.

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
2.2 Technical Specifications
4
Electrical specifications: 110 or 220 Volts (set at factory)
Heater specifications: 1000 Watts (110V / 15 amp)
2000 Watts (110V / 20 amp)
2000 Watts (220V / 10 amp)
Thermostat range: Room temperature to 392ºF
(200ºC)
Incoming pressure range: Max. 120 psi
Timer: 0 - 99 minutes
Mold sizes: 1, 1.25, 1.5 and 2-inch
25, 30, 40 and 50-mm
Weight: 68 lbs (31 kg)
Dimensions (WxHxD): 31 x 19 x 19-inches
(534 x 485 x 485mm)
Working temperature: 32° - 100°F (0 - 40ºC)
Shipping temperature: 32° - 100°F (0 - 40ºC)
Storage temperature: 32° - 100°F (0 - 40ºC)
Water supply connection: 8 mm quick connect
Water drain connection: 1/4 inch heater hose
Air supply connection: 6 mm quick connect
Fuse: 10 amp fast blow
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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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
2.3 Mechanical Schematic
Note: Installation of the
TERAPRESS TP 7100S
should be on a flat sturdy
surface, with easy access to
electrical, water, air, and drain
connections
5
19 inches
19 inches
31 inches

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
2.4 Features
Mounting Force
The TERAPRESS TP 7100S applies force through a robust pneumatic system. Pressure is
precisely controlled via microprocessors.
Heating / cooling system efficiency
The heating elements and water-cooling jacket have been integrated into the upper part of the mold
cylinder for efficiency. Heating is controlled by a thermostat, with the heating times being variable
up to 30 minutes.
The cooling cycle begins automatically after the designated hold time at temperature has passed.
Cooling can be completed one of two ways:
1. Cooling to a preset temperature
2. Cooling for a specific amount of time
The TERAPRESS TP 7100S compression mounting press offers the user an abundance of control
for both the heating and cooling cycle allowing the TP 7100S the ability to mount any mounting
compound or sample composition.
6
Cooling Temperature (if
Mode is set to Temp)
Cooling Rate: Low or
High
Cooling Time (if Mode
is set to Time)
Cooling Mode: Temp
or Time
Current Temperature Cooling Time Passed

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
3.0 Unpacking, Shipping and Installation
3.1 Unpacking Unit is delivered in a box. Unpack and check for completeness of
parts.
Measures WxHxD: 31 x 19 x 19-inches (534 x 485 x 485mm)
Weight: Approx. 68 lbs (31 kg)
3.2 Shipping When moving box, lift from bottom.
The TERAPRESS TP 7100S compression mounting press is
constructed of sensitive electronic and mechanical components.
Do not drop.
! Use caution when unloading to prevent injury.
7
3.3 Installation
!
Install unit carefully! Improper installation voids warranty.
The TERAPRESS TP 7100S compression mounting press should be placed on a flat
stable surface. Connect to air supply, water supply, drain and electrical connections.
After water, air, drain and electrical connections are completed, the system is ready for
operation by activating the main power switch.
Installation continued on next page

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
Backside connections
Electrical connection: Verify the operating voltage which is printed on the name plate. The
standard voltage is 110V; however, the system is also available in
220V.
Coolant drain: The coolant drain line requires a 1/4-inch hose. CAUTION: The mold
temperature is very hot and the initial contact of the cooling water
turns to steam, which exits the drain hose at a very high temperature.
Coolant supply: The coolant supply line requires an 8 mm hose. It is recommended
that the water supply be turned off when the unit is not in use. Inlet
water should be clean and contamination-free to extend the life and
cooling performance of the system.
Air supply: Air supply line requires a 6 mm pressure hose. Clean dry air is
recommended (a filter lubricator is recommended)
Solenoid regulator: To adjust cooling times, adjust this regulator to open the auxiliary
solenoid.
8
Air supply
Serial name
plate
Main power switch
Electrical connection
Drain Water supply
Solenoid regulator

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
External Coolant Tank
As an optional attachment, an external recirculating coolant tank can be connected to the back of
the TERAPRESS TP 7100S compression mounting press. The advantages of using this tank
include significant reduction in water usage as well as shorter cooling times due to the heat
exchanger built into the tank. The reduction in cycle times can be very advantageous to high
throughput metallographic labs.
9

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
4.0 Start-up and Operation
The TERAPRESS TP 7100S mounting press has been designed for ease-of-use in producing high
quality metallographic mounts using materials such as phenolics, diallyl phthalates, hard glass-filled
epoxies, and conductive thermosets.
The TERAPRESS TP 7100S comes with preloaded procedures to make initial startup as fast as
possible. Custom procedures can also be created and saved for maximum versatility. Section 4.2
gives an overview of all relevant functions on the main screen, and sections 4.3-4.4 describe how to
load procedures as well as how to create custom ones. Section 4.7 gives a general procedure for
compression mounting along with recommended mounting guidelines.
4.1 General
4.2 Touch Screen Overview and Functions
Current Procedure
Begins mounting cycle with
currently displayed parameters.
Opens the Procedure Manager
for editing and loading various
procedures.
Begins cooling manually. This
turns on the water pump.
Temperature/Time
Graph
Main Operation Buttons
Settings for Current
Procedure
Returns to the startup
screen.
Opens the settings.
Moves the ram down
and up.
Main Operation Buttons
10

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
4.3 Loading a Saved Procedure
1. From the home screen, touch the Procedure Manager button.
2. Find the desired procedure and touch Select. The Select button will appear green
for the selected procedure.
3. Touch the Load Selected button.
4. Touch the BACK button to return to the home screen. The selected procedure
specifications will now appear at the top.
5. Touch Start button.
6. The system will now begin mounting the sample to the specifications of the loaded
procedure.
23
4
1
5
11

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
4.4 Creating and Loading Custom Procedures
1. From the home screen, touch the Procedure Manager button.
2. Touch Select on an empty slot.
3. Touch numerical value for pressure, heating temperature, and holding time.
Use keypad to change to desired values.
4. Set Cooling Mode to either Temp or Time. Then touch either cooling tempera-
ture or cooling time and use keypad to change to desired values.
5. To set cooling rate, touch button to toggle between Low and High.
6. Touch the field labeled Name to input a name for the custom procedure using
onscreen keyboard.
7. Touch Save button to save procedure to specified slot.
8. To load a custom procedure, touch Select on desired procedure, then touch
Load Selected, and then touch BACK to return to home screen.
2
3
4
5
7
6
8
8
12

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
4.5 Soft Start Function
Soft Start is a new feature to the TERAPRESS line of mounting presses. It allows the user to
prep the mounting press to a specific temperature and pressure before continuing with the
remainder of the procedure. This is helpful for situations such as where heating the mounting
compound or sample needs to be done at a slower rate to ensure proper curing, or if the
sample is brittle and needs to be pressurized before temperature should be applied for
structural integrity of the sample.
To add Soft Start to a procedure, select Soft Start next to the desired procedure. Empty
boxes will now appear under Pressure, Heating, and Holding, and can be set using the same
method as described in section 4.4. For the example above, Custom 2 will now complete the
following procedure:
1. Heat to 120C while under 10 MPa of pressure.
2. Hold for 2 minutes.
3. Heat to 140C while under 30 MPa of pressure.
4. Hold for 1 minute.
5. Cool to 45C.
13

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
4.6 Settings Menu
Mold Size: This sets the size of the installed mold. Available options in inches are 1.00, 1.5, 1.25, and
2.00. In millimeters, the options are 25, 40, and 40.
Default Procedure List: This setting determines which procedures list will appear as default when
Procedure Manager is selected from the home screen when the machine first starts up.
Colors on Cycle Graph?: This setting allows for toggling between grayscale and color for the time/
temperature cycle graph.
Unit Type: This sets the default units of the temperature and pressure values.
Allow Changes to Procedure on Main Screen?: This allows the user to change parameters of the
procedure after it has been loaded.
PID Sampling Period: This sets the frequency of sampling for the PID controller.
PID Parameters: This setting allows for fine tuning of the PID controller loop.
Password Protection: This allows the user to set a password that must be input before allowing
access to procedures.
Load Procedure on Startup?: This allows the user to set a default procedure to be loaded on startup
for maximum convenience.
Push-up Pressure: This sets the pressure of the ram as it drives up. This setting is important for
situations such as when a mold is stuck to the side walls.
14

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TERAPRESS TP-7100S
Mounting Press
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: https://www.metallographic.com
PID Controller Loop
• The term PID stands for proportional integral derivative and it is one
kind of device used to control different process variables like pressure,
flow, temperature, and speed in industrial applications. In this control-
ler, a control loop feedback device is used to regulate all the process
variables.
• P-Controller
 Proportional, or P-controller gives an output that is
proportional to the current error. It compares the de-
sired or set point value with the actual or feedback
process value.
• I-Controller
 Integral, or I-controller integrates the “steady-state”
error, or expected margin of error between the desired
or set point value with the actual or feedback process
value. Increasing the I value decreases the feedback
system response time while decreasing the I value
increases the feedback system response time.
• D-Controller
 Derivative, or D-controller anticipates the future be-
havior of the margin of error based on the rate of
change of the error with respect to time. It acts as a
damper on the control system to reduce feedback sys-
tem over-response. Increasing this value will decrease
the sensitivity of the feedback response and decreas-
ing, will increase the response.
• The default values for these controllers are:
P=3.0
I =0.1
D=5.0
15