PICO 175 Precision Saw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INSTRUCTION 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Web: http://www.metallographic.com VERSION 1.0 WARNINGS Please read the instructions carefully before turning on the machine. Supplying the wrong voltage will cause severe damage to the electrical system. Do not disassemble.
Contents 1. Technical Specifications... 4 2. PICO 175 Overview... 5 3. Tools and Accessories... 8 4. Touch-Screen Overview and Functions... 9 4.1 Main Operation Buttons and Indicators... 9 4.2 Save New Procedure... 11 4.3 Open Saved Procedure... 11 4.4 Manual Cut Screen... 12 4.4.1 Navigation Controls... 12 4.4.2 Operation Settings... 13 4.4.3 Cutter Load and RPM Gauges... 13 4.5 Auto Settings 1 Screen... 13 4.5.1 Navigation Controls (See 4.4.1, page 12)... 14 4.5.2 Cutter Settings... 14 4.5.3 Sample Feed Settings... 14 4.5.4 Slicing Settings... 14 4.6 Auto Settings 2 Screen... 16 4.6.1 Units... 16 4.6.2 Blade Dimensions... 16 4.6.3 Travel Range in the X and Y Direction... 17 4.6.4 Sample Holder Final Position... 17 4.6.5 Auto Feed Mode Settings... 18 4.6.6 Pulse Mode Settings... 19 4.7 Dashboard Monitor Screen... 20 4.7.1 Travel Distance (See 4.4.1, page 12)... 20 4.7.2 Load and Blade RPM Gauges (See 4.4.3, page 13)... 20 4.7.3 Procedure Overview... 20 5. Making a Cut... 21 6. Cutting Mode Examples... 26 2
6.1 Manual Cutting Mode Example... 26 6.2 Normal Cutting Mode Example... 26 6.3 Auto Feed Cutting Mode Example... 26 6.4 Pulse Cutting Mode Example... 27 6.5 Slicing Mode Example... 28 7. Troubleshooting... 29 8. Range of Parameters... 30 3
1. Technical Specifications Electrical Specifications: Motor Power: Cut-Off Wheels: Wheel Arbor: Wheel Arbor RPM: Sample Holder Speed: Sample Holder RPM: Load: Weight: 110V/220V Single Phase 750 W 12V (50/60 Hz) 6 8 inch Diameter Blades 0.5 inch (12.5 mm) diameter 50 5000 rpm 0 0.12 inch/sec (0 3 mm/sec) 0 500 rpm 0 20 N Approx. 160 lbs. (73 kg) Dimensions (W x D x H): Hood Closed: 25 x 22.4 x 17.8 (635 mm x 569 mm x 452 mm) Hood Open: 25 x 23 x 29 (635 mm x 584 mm x 737 mm) Sample Feed Range: X-Direction: 0 2.6 in (0 66mm) Y-Direction: 0 3.4 in (0 86mm) 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): 3/4 gallon (2.8 liters) 4
2. PICO 175 Overview Touch-Screen Monitor Dressing Fixture Rubber Mat Extractor Fan Emergency Stop Button Acrylic Cover Recommended Procedures Settings Front Side View Left Side Access Panel Power Switch Left Side View 5
Back Side View Splash Guard Extractor Case Drain Valve Right Side Access Panel Coolant Tank Drip Pan Right Side View 6
LED Light Coolant Lines Safety Magnet Lock Saw Blade Positioning Unit / Dove Tail Adapter Clamp Sample Trap Tray Cutting Chamber (Dressing Fixture not included in picture) Dressing Stick Holder Dressing Stick Dressing Fixture 7
3. Tools and Accessories 32 mm Diameter Vise (P150-707) 40 mm Diameter Vise (P150-708) Universal Holder (P150-702) Larger Single Saddle with Lip (P150-702b) Double Parallel Vise for Long Specimens (P150-703) Vise for Irregular Shaped Specimens (P150-706) Vise for Adhering Specimens (P150-709) Teardrop Holder (P150-710) Fastener Vise for Longitudinal Sectioning (P150-711) Dovetail Adapter (P175-DT) 75 mm Arbor Flanges (P150-712) 50 mm Arbor Flanges (P150-306) Tools (P175-Tools) 12V LED Light Bulb (P175-LED-12V) Power Cord (CORD-110/220V) 8
4. Touch-Screen Overview and Functions 4.1 Main Operation Buttons and Indicators Operation Indicators Screen Navigation Buttons Main Operation Buttons 9
Screen Navigation Buttons and Operation Indicators Operation status indicator of Cutter System (left icon) and Safety Switch (right icon). Length Unit indicator. Go to Manual Cut screen. Go to Auto Settings 1 screen. Go to Auto Settings 2 screen. Go to Dashboard Monitor screen. Main Operation Buttons Open the Open Procedure window. Open the Save Procedure window. Save X and Y Coordinates as new Reference Point. Sample Holder Axis Rotation On/Off button. Extractor Fan and Cooling Pump On/Off button. LED Light On/Off button. Blade Rotation On/Off button. Start/Pause/Resume Automated Procedure. Stop Automated Procedure. Reset Sample Holder to Origin. 10
4.2 Save New Procedure Press the button to open the Save Procedure window and select the procedure file number where you want to save your new procedure. Press the X button to close the window. (NOTE: All the parameters, except the Reference Point, will be saved.) Procedure Files 4.3 Open Saved Procedure Press the button to open the Open Procedure window and select the procedure file number that you want to open. Press the X button to close the window. Procedure Files 11
4.4 Manual Cut Screen 4.4.1 Navigation Controls Distance from the Origin in the X-Direction Distance from the Origin in the Y-Direction Distance from the Reference Point in the X-Direction Maximum Travel Speed Input Window Decrease Travel Speed Button Distance from the Reference Point in the Y-Direction Increase Travel Speed Button Navigation Control Buttons X and Y Coordinate System Maximum Travel Speed Percentage Display Bar 12
4.4.2 Operation Settings Cutter Motor RPM Input Window Positioning Unit RPM Input Window 4.4.3 Cutter Load and RPM Gauges Ideal Load Area Low RPM Area Underload Area High RPM Area Gauge Needle Gauge Needle Overload Area 4.5 Auto Settings 1 Screen 13
4.5.1 Navigation Controls (See 4.4.1, page 12) 4.5.2 Cutter Settings Cutter Motor RPM Input Window Cutter Motor Maximum Load Input Window 4.5.3 Sample Feed Settings Sample Feed Rate in the Y-direction Input Window Feeding Distance in the Y-direction Input Window Sample Holder RPM Input Window Auto Feed On/Off Button Pulse Feed On/Off Button 4.5.4 Slicing Settings Number of Slices Input Window Slice Width Input Window Variable Width On/Off Button Got to Variable Width Edit Screen 14
Variable Width Slices Window Press the button to open the Variable Width Slices window. (NOTE: The number of variable width input windows available depends on the number entered in the No. of Slices input window.) Tap on any available input window to open the numeric keypad and enter the desired width. Press Accept, Cancel, or X to close the Variable Width Slices window. First s Slide Width Input Window Unavailable Input Window 15
4.6 Auto Settings 2 Screen 4.6.1 Units Millimeter Unit Button Inch Unit Button 4.6.2 Blade Dimensions Blade Thickness Input Window Blade Diameter Input Window 16
4.6.3 Travel Range in the X and Y Direction X-Axis Maximum Travel Distance Input window Y-Axis Maximum Travel Distance Input window 4.6.4 Sample Holder Final Position Select the final position of the sample holder by tapping on one of the three options available. See the Final Position Diagram below. (NOTE: The final position is better suited for sectioning procedures.) Origin Reference Point Final X-distance traveled and Y-Reference Point Final Position Diagram 17
4.6.5 Auto Feed Mode Settings (NOTE: The Auto Feed Mode Settings are only implemented when the Auto Feed mode is engaged.) Trigger Time Input Window Underload Input Window Overload Input Window Rate of Change Input Window Trigger Time: is the time that the needle in the Load Gauge (page 13) must remain in either the Underload or Overload region in order for the Feed Rate to increase or decrease, respectively, by the Rate of Change percentage. Overload: is the MAX Load percentage (page 14) that will mark the beginning of the overload region in the Load Gauge, shown in red color. Underload: is the MAX Load percentage that will mark the end of the underload region, starting from 0N, in the Load Gauge, shown in blue color. Rate of Change: is the Feed Rate percentage that will be added to or subtracted from the feed rate after the Trigger Time has passed. 18
4.6.6 Pulse Mode Settings The Pulse Mode Settings are implemented when the Pulse Cutting mode is engaged. Pulse Mode Cutting Time Input Window Pulse Mode Return Speed Input Window Pulse Mode Cooling Time Input Window Cutting Time: is the time that the sample will move towards the cutting blade (in the y- direction) right after the needle in the Load Gauge has reached the Ideal (green) region. Cooling Time: is the time that the sample holder will remain still once the needle in the Load Gauge has reached the Underload (blue) region after moving away (in the y-direction) from the cutting blade. Return Speed: is the speed at which the sample holder will move away from the cutting blade in the y-direction. 19
4.7 Dashboard Monitor Screen 4.7.1 Travel Distance (See 4.4.1, page 12) 4.7.2 Load and Blade RPM Gauges (See 4.4.3, page 13) 4.7.3 Procedure Overview The Procedure Overview section displays a summary of the Sample Feed Settings and Slicing Settings. Sample Feeding Rate in the Y-Direction Feeding Distance in the Y-Direction Number of Slices Slice Width Display Sample Feeding Mode 20
The Procedure Progress Bar displays the progress of a procedure based on the distance traveled. 5. Making a Cut Step 1: Pull out the coolant tank, add 3/4 gallons (2650 ml) of coolant, and put the tank back in. (NOTE: Make sure that the suction hose inside the coolant tank is not kinked.) Step 2: Plug in the power cord to the machine and turn it on. (NOTE: Make sure to disengage the emergency stop button.) 21
Step 3: Choose the appropriate vise to hold your sample and mount it in. Step 4: Install the vise and sample on the sample holder adapter first, then mount it on the end of the sample holder shaft. (NOTE: If necessary, rotate the sample holder in order to install the vise properly.) Step 5: Install the blade, on the arbor shaft. Use the open end wrench to tighten the nut and the rod to hold the arbor shaft in place. (NOTE: The shaft and bolt are reversed threaded.) 22
Step 6: Enter the desired parameter settings. (NOTE: Use the list of Procedure Recommendation Settings if your material type is listed there.) Step 7: Using the Navigation Control buttons, move your sample close enough to the edge of the cutting blade and press the button to save the location as your new reference point. (NOTE: Every automated procedure will start from the reference point.) Step 8: Measure the diameter/depth of your sample, add an estimated distance from the front end of your sample to the edge of the blade, and enter the final value in the Depth input window. 23
Step 9: Measure the thickness of the cutting blade and enter it in the Thickness input window. The thickness of the blade is most critical when slicing, since the computer uses the thickness value to calculate the distance the sample has to move in the x-direction in order to make the next cut. Step 10: Make sure to enter the diameter of the blade in the Diameter input window. The computer will use the diameter value to calculate the torque required to make a cut. Step 11: Position the coolant lines so that the coolant is applied to the point of contact between your sample and the cutting blade. 24
Step 12: Close the acrylic hood. (NOTE: The cutting blade will not start spinning until the magnetic safety switch has made full contact with the magnet on the hood and the safety switch status icon on the screen has turned green. Step 13: Turn on the LED light for better visibility. Step 14: Start cutting. WARNING! Blade might emanate coolant mist at high RPM. DO NOT inhale vapors. IMPORTANT: It is highly recommended to drain the extractor case every once in a while, to prevent possible overflow from extracted oil mist. To do so, simply turn the drain valve counterclockwise until fluid starts flowing, if any. Once all the fluid has been drained, turn the drain valve clockwise all the way to close it. Drain Valve Closed Drain Valve Open 25
6. Cutting Mode Examples At this point, we are assuming that the sample and blade have already been installed, coolant has been added to the coolant tank, and all the operation indicators are green. Notice that the sample holder has been positioned and saved at X = 50.000, Y = 38.000. Now, look at the values entered in the screens below. The next cutting examples will be based on these values. 6.1 Manual Cutting Mode Example This is the simplest mode of cutting. Just press the button to turn on the saw, press the button to turn on the coolant pump together with the extractor fan, and use the controls to feed your sample into the cutting blade. 6.2 Normal Cutting Mode Example This is an automated cutting mode that does not use any of the Auto Feed Mode nor Pulse Mode Settings. Therefore, be careful not to overload the saw. 6.3 Auto Feed Cutting Mode Example The Auto Feed cutting mode implements the Auto Feed Mode Settings. Notice in the Load gauges below that the underload area covers 0N to 6N (30% of 20N) and the overload area covers 16N (80% of 20N) to 20N. Press the button, followed by the button. 26
1) If the needle in the Load gauge reaches the overload area (red color) and remains there for more than 1 second (Trigger Time), the sample will start moving away from the cutting blade in the y-direction until the needle in the Load Gauge is no longer in the overload area. 2) Once the sample starts moving back towards the cutting blade, the Feed Rate will have decreased to 0.7 mm/sec, which is 30% (Rate of Change) less than the initial Feed Rate (1.000 mm/s). 3) If the needle reaches the overload area again, the Feed Rate will continue to decrease until the needle remains in the ideal area (green color) during the cut. The opposite will happen when the needle reaches the underload area (blue color) and remains there for more than 1 second. The Feed Rate will continue to increase by 30% every second until the needle reaches the ideal area. 4) Once the sample has reached the desired depth, it will move back to the origin before the end of the procedure. 6.4 Pulse Cutting Mode Example The Pulse Cutting mode is recommended when cutting hard materials and it is likely to overload the saw motor. Only the Pulse Mode Settings will influence this cutting mode, which consists of moving the sample back and forward in order to prevent the saw motor from overloading. Press the button, followed by the button. 1) The sample will start moving towards the cutting blade in the y-direction. 2) As soon as the needle in the Load Gauge reaches the ideal area (green color), the program will start counting up to 3 seconds (Cutting Time) before it starts moving away from the cutting blade at 2 mm/sec (Return Speed). 27
3) Once the needle in the Load Gauge reaches the underload area (blue color), the sample will remain there for 5 seconds (Cooling Time) before it starts moving back towards the cutting blade again. 4) Once the sample has reached the desired depth, it will move back to the origin before the end of the procedure. 6.5 Slicing Mode Example For this particular example, we are going to change a few settings. Notice that we are now cutting 3 slices of 1 mm width each. If you want to cut the slices at different widths, press the button to go to the Variable Width Slices screen. Also notice that the reference point was moved further away from the blade in order to cut several slices. Also notice that the final position of the sample is at. (NOTE: Slicing is compatible with the Auto Feed and Pulse Mode Settings. To start slicing, choose a cutting mode and press the button. Once the total number of slices have been cut, the sample holder will remain X units away from the origin and will move back to Y-reference point. 28
7. Troubleshooting Problem Probable Cause Solution C status icon turned red. Loose connector/wire in the saw system. Make sure all connectors/wires are properly connected. X and/or Y coordinates are not accurate. Travel system motors continued functioning after reaching the range limit. Return sample holder to the origin using the button. Unable to save new reference point. The function was stopped or canceled before the sample holder reached the origin. Return the sample holder to the origin using the button. Coolant flow hesitation Coolant filter is covered with debris. Coolant filter is not fully submerged. Remove coolant filter and rinse it. If necessary, remove coolant solution with debris and pour in fresh coolant solution. Properly submerge the coolant filter. If necessary, pour in more coolant solution. 29
8. Range of Parameters Parameter Minimum Value Maximum Value Blade RPM 50 5000 MAX Load (N) 5.0 20.0 Feed Rate (mm/sec or inch/sec) CAUTION: Do not move faster than 0.12 inch/sec 0.001 3.000 Sample Holder RPM 0 500 No. of Slices 0 99 Depth (mm or in) 0.01 86.00 Width (mm or in) 0.001 66.000 Thickness (mm or in) 0.010 15.000 Diameter 1.0 205.0 Travel Speed (mm/sec or inch/sec) CAUTION: Do not move faster than 0.12 inch/sec 0.001 3.000 Max X (mm or in) 0.01 66.00 Max Y (mm or in) 0.01 86.00 Trigger Time (sec) 0.1 5.0 Overload (MAX Load %) 0 100 Underload (MAX Load %) 0 100 Rate of Change (Feed Rate %) 0.1 100.0 Cutting Time (sec) 0.1 100.0 Cooling Time (sec) 0.5 100.0 Return Speed (mm/sec or inch/sec) CAUTION: Do not move faster than 0.12 inch/sec 0.001 3.000 30