Pace Technologies PICO 155P Precision Saw User manual

PICO 155P Precision Saw
INSTRUCTION MANUAL
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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:
Precision Wafering Saw for 6-inch blades
(will accept 3,4,5 and 7-inch blades)
Model:
PICO 155P Precision Saw
Electrical Requirements:
110/220 Volts (single-phase)
Frequency:
50/60 Hz
Motor Horsepower:
150 watts
Manual Revision Date:
April 2021

PICO 155P Precision Saw
INSTRUCTION MANUAL
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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.
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.
PACE TECHNOLOGIESMAKES 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 MERCHANTABILITYOR 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 TECHNOLOGIESPRODUCTS. PACE TECHNOLOGIES WILL IN NO
EVENT BE LIABLE FOR INCIDENTALOR CONSEQUENTIALDAMAGES 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.

PICO 155P Precision Saw
INSTRUCTION MANUAL
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Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
ii
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 contemporaneousagreements 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.

PICO 155P Precision Saw
INSTRUCTION MANUAL
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iii
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Contents
P
AGE
Warranty i
1.0 Safety Guidelines 1
2.0 Product Description 3
3.0 Unpacking, Shipping, and Installation 8
4.0 Start-Up and Operation 15
5.0 Maintenance 22
6.0 Troubleshooting 24
7.0 List of Spare Parts 26
8.0 Electrical and Mechanical Drawings 41
9.0 Precision Wafer Sectioning 53

PICO 155P Precision Saw
INSTRUCTION MANUAL
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1
Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
1.0 Safety Guidelines
1.1 Warning Sign
! This sign points to special safety features on the machine.
1.2 Safety Precautions
Careful attention to this instruction manual and the recommended safety guidelines is
essential for the safe operation of the PICO 155P wafering saw.
Proper operator training is required for the safe operation of the PICO 155P wafering saw.
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.
!
Use only certified wafering wheels from a professional supplier. Improper blade
selection voids warranty. (For appropriate blade selection, refer to the Abrasive Blade
Selection Guidelines Chart in Section 9)
!
Disconnect power before opening electrical back panel.
!
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 wafering blade. Use the appropriate clamping
devices to avoid this occurrence.
!
Never start a cut under load.
1.3 Emergency Statement
Always follow proper operational guidelines and avoid bodily contact with coolants and
abrasives. Seek appropriate medical care for cutting injuries.

PICO 155P Precision Saw
INSTRUCTION MANUAL
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Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
Test:
Activate main switch and close hood.
Turn on cut-off wheel. Open the hood
slightly (approx. 1 inch).
Proper
Response:
Cut-off wheel stops.
Malfunction:
Cut-off wheel does not stop.
Corrective
measure:
If cut-off wheel does not power down,
disconnect power supply cord and call
service technician.
1.4 Safety Tests
Emergencystop switch
Emergency stop switch
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.
Safety cut-off switch
Safety cut-off switch
Examine and verify that the PICO 155P wafering saw
safety devices and operating performance are in good
working condition prior to use. The following safety
checks are considered important:
!

PICO 155P Precision Saw
INSTRUCTION MANUAL
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Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
3
2.0 Product Description
2.1 General Description
Magnetic Safety Switch Automatic
Cut-off
Switch
Coolant
Nozzles
Sliding Load Arm
EmergencyStop
Digital speed readout Micrometer
Feed Control
Easy to use
Control Panel
Variable Speed Control
(50-1500 rpm)
Removable
Coolant Tank
The PICO-155P is a precision wafering saw for
sectioning delicate specimens ranging from fish
bones to microelectronic components. It is an
ideal saw for the metallographic laboratory. The
PICO-155P has the ability to cut at speeds
ranging from 50 to 1500 rpm, with loads ranging
from 0 up to 1000 grams.
The PICO 155P is a very robust and durable
precision saw with its cast aluminum alloy and
stainless-steel construction. The PICO-155P
utilizes diamond wafering blades ranging from 3
to 7-inches in diameter. A new feature and benefit
of the PICO-155P is that it uses a pump coolant
system for better lubrication at the cutting surface
as compared to traditional gravity drag lubricant
machines. This is especially important for cutting
with smaller diameter wafering blades.
Capable of using a
wide range of wafering
blade diameters
Blade Dressing
Fixture

PICO 155P Precision Saw
INSTRUCTION MANUAL
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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
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
2.2 Technical Specifications
Electrical specifications:
110V/220V single-phase
Motor power:
150 W - 24V (50/60 Hz)
Cut-off wheels:
3 - 7-inch diameter blades
Wheel arbor:
0.5 inch (12.5 mm) diameter
Speed:
50-1500 rpm
Load:
0-1500 grams
Weight:
Approx. 65 lbs (30 kg)
Dimensions (WxDxH):
Hood closed 14.5” x 18”x 14.5”
(368 mm x 457 mm x 368 mm)
Hood open 14.5”x 23” x 19”
(368 mm x 584 mm x 483 mm)
Micrometer feed:
0-1 inch (0-25 mm)
Working temperature:
32° - 100°F (0 - 40°C)
Shipping temperature:
32° - 100°F (0 - 40°C)
Storage temperature:
32° - 100°F (0 - 40°C)
Coolant tank (included):
1/2 gallon (1.9 liters)

PICO 155P Precision Saw
INSTRUCTION MANUAL
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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.
5
PICO 155P ASSEMBLY DRAWINGS
Housing
Casting
Lid
Cooling System

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6
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
NOTE: Assembling the counter weight rod will add 4.75”(~120mm) in depth.
19.0in
(483mm)
14.5in
(368mm)

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7
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3601 E. 34th St. Tucson, AZ 85713 USA Tel. [phone] Fax [phone] email: [e-mail] Web: http://www.metallographic.com
2.4 Features
Standard
Cutting
set-up
With table top
cutting set-up
Improved Coolant System
The PICO 155P is an upgraded version
of the PICO 155 medium speed wafering
saws. Utilizing a 24V pump and flexible
coolant lines, the PICO 155P allows for
better coolant distribution, even for
smaller diameter wafering blades.
Motor feedback
The PICO 155P is equipped with a 125 W
motor that has a feedback loop for
maintaining the cutting velocity, even
under higher loads and increased drag.
In addition, the circuit board has
overload protection feedback which will
stop the motor if the blade becomes
jammed or pulls too many amps.
Easy to use
The PICO 155P is a user-friendly
precision cutter with simple controls.
Simply align the sample and start the cut.
The variable speed motor can easily be
adjusted by turning the knob on the front
panel. Following completion of the cut,
the motor will stop and activate an
audible buzzer.
Multi-purpose machine
The PICO 155P saw is a very versatile
precision cutter. It can be used as a
standard precision saw or as a tabletop
saw for cutting larger samples such as
printed circuit boards.

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8
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.2
Shipping
When moving cutter, lift by the base.
The PICO 155P is constructed with sensitive
electronic and mechanical components.
DO NOT DROP.
! Caution: Take care to avoid bodily injury.
3.0 Unpacking, Shipping, and Installation
3.1 Unpacking Unit is delivered in a box. Unpack and check for completeness of
parts.
Crate Measures WxHxD: 24”x 36”x 23”
Crate Weight: Approximately105 lbs
3.3 Installation
!Install unit carefully! Improper installation voids warranty.
The PICO 155P should be placed on a flat, stable surface.
Connect the micrometer by pushing the micrometer flush and then snugly
tighten the locking bolt.
CAUTION: DO NOT over tighten as this may damage the micrometer.
Then position the specimen arm and loading bar to the micrometer
shaft so they are both at about the same angle to the shaft.
(Installation continued on next page)

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9
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.3.1 Installation - Coolant Tank
1. Insert stainless-steel tank cover tray
onto coolant tank with the larger
diameter hole located on the back
right side of the tank. Slide tank into
chamber.
2. Slide in the left side of the two-piece
stainless-steel sample tray cover and
then the right-side cover.
3. Clean and insert pump filter through
both the sample tray cover and the
stainless-steel tank cover
Insert stainless-steel tank
cover into tank as shown
Insert LEFT
sample tray
cover
Insert
RIGHT
sample tray
cover
Insert Filter
into coolant
tank

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10
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.3.2 Installation - Micrometer
1. For easier installation, retract
micrometer adjustment arm - do
not force movement beyond limits
as this may damage the
micrometer.
2. Loosen bolts on sample
support
arm and slide smaller diameter side
of micrometer shaft into outer shaft
guide. DO NOT tighten bolts on
sample support arm at this point.
3. Push micrometer into the
outer shaft
guide thus pushing the micrometer
shaft to the right. While holding
micrometer in place, tighten set
screw on outer shaft guide. NOTE:
The hole in the micrometer does not
need to line up with the bolt.
DO NOT over tighten the bolt as this
may damage and pinch the
micrometer.
4. Attach sample fixture to sample
support arm and then align holder
to approximately where the
wafering blade will be installed.
Tighten sample holding arm bolts.
Retract micrometer arm
Slide smaller end of
micrometer shaft into outer
shaft guide
Tighten set screw:
DO NOT OVER
TIGHTEN as this
may damage
micrometer
Install sample
fixture, align
sample support
arm and then
tighten bolts

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11
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.3.3 Installation - Weight and Counter Balance
1. Attach load arm. Then snugly
tighten.
2. Attach counterbalance rod.
3. Attach sliding counterbalance
weight.
4. Attach main sliding weight.
5. Attach additional loading weights if
desired.

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12
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.3.4 Installation - flanges and blade
Arbor size is
1/2-inch diameter
Use largest flange as possible
for more blade support
Follow recommended
guidelines for blade choice
Attach outside flange Attach end cap
and bolt
Note: It is recommended that the blade be dressed
periodically to optimize its effectiveness.
Tighten bolt to secure
wafering blade
Adjust mechanical
cut-off height every
time the flange size is
changed

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13
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.3.5 Installation - dressing fixture
Select proper dressing stick.
Install onto the dressing fixture
and secure with the allen screws.
Slowly feed dressing stick into
wafering blade while running saw at
a slow speed.
Align dressing fixture with lip on
front of casting panel with opening
in cover. Then attach the dressing
fixture to the cover with the allen
screws.
For optimum cutting
performance, it is
recommended that the wafering
blade be periodically dressed.
This will improve/decrease
cutting times as well as extend
the life of the blade.
Note: Even for hard ceramic
materials, dressing is important
as the wafering blades are metal
pressed blades and the metal
from the blade itself can coat or
blind the diamond, thus resulting
in less efficient cutting.
Proper dressing should be
conducted at slow speeds and
low loads (e.g., 300 rpm and low
feed rate).

Please read this instruction manual carefully and follow all installation, operating and safety guidelines.
14
PICO 155P Precision Saw
INSTRUCTION MANUAL
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!
!
3.3.6 Installation
Sample fixture can be positioned
differently with respect to the
blade.
Note: For soft or gummy
materials, it is recommended
that the sample be positioned
on the back side of the blade.
This will reduce the tendency
of the sample to jam the blade.
Machine can run at either 110V or 220V
power.
Connect the electrical plug and activate the
main power switch (note: the hood must be
closed for power to turn on at the front
panel). Verify that the emergency stop
switch is deactivated and the system will be
ready for operation.
Turn emergency
switch clockwise to
release
Power
switch
The safety fuse takes a 3 amp fuse if running
the machine at 110v or a 1.5 amp fuse if
running at 220v.

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15
PICO 155P Precision Saw
INSTRUCTION MANUAL
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4.0 Start-up and Operation
4.1 General
4.2 Control Panel
Digital Speed
Control
Cutting
Wheel (ON)
Variable Speed
Controller
Cutting Wheel
(OFF) Pump (AUTO / MANUAL)
Control
Emergency Shut Off:
Immediately cuts all power to machine.
Cutting wheel ON:
Starts the cutting wheel.
Cutting wheel OFF:
Stops the cutting wheel (inductive brake engages to slow wheel).
Pump Control:
Manually controls pump ON/OFF or automaticallycontrols pump
when cutting (AUTO).
Variable Speed
Controller:
Continuouslyvariable speed between 50-1500 rpm.
The PICO 155P is a low-medium speed precision wafering saw.

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16
PICO 155P Precision Saw
INSTRUCTION MANUAL
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3.
4.3 Changing Wafering Blade
1. Remove blade-locking bolt and remove blade.
2. Position new blade into position.
Use only certified wafering blades. See Table IV
! for recommended blade for your application.
4. Gently tighten blade locking bolt.
To prevent shaft from
turning, use wrench to
hold in place
Changing Blade
Remove: Loosen by
turning counter-
clockwise
Tighten: Turn clockwise
4.4a Zeroing the micrometer
1. Turn micrometer on with left button.
2. Press left button again and hold for several
seconds until “set” starts to blink in the upper right-
hand corner of the screen.
3. Press the right button several times until the
numbers read zero.
4. Press the left button to set the number.
4.4b Changing between microns and inches
To change between microns and inches, turn off
micrometer,and then turn back on with left button.
Depress right button and hold until the scale
changes.
-On / Off
-Hold to
reset
to zero
-To change
between inches
and microns