FEMTO 1100 Polishing Head - Metallographic products for
Transcription
FEMTO 1100 Polishing Head - Metallographic products for
FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Equipment Type: Semi-automated polishing head Model: FEMTO 1100 Electrical Requirements: 110 / 220 Volts (single-phase) Frequency: 50/60 Hz Motor Horsepower: 120W Manual Revision Date: January 20, 2015 Web: http://www.metallographic.com Please read this instruction manual carefully and follow all installation, operating and safety guidelines. FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 Contents PAGE Warranty ii 1.0 Product Description 1 2.0 Unpacking, Shipping and Installation 4 3.0 Safety Guidelines 13 4.0 Start-Up and Operation 15 5.0 Maintenance 36 6.0 Trouble Shooting 37 7.0 Metallographic Consumables 38 8.0 Spare Parts 43 9.0 Schematics 66 Please read this instruction manual carefully and follow all installation, operating and safety guidelines. i FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 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. 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. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. ii FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 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. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. iii FEMTO 1100 Polishing Head INSTRUCTION MANUAL -------------------------------------------------- ▲ 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 1.0 Product Description 1.1 General Description Pressure Gage Variable speed display Manual Start/Stop Dispenser Reservoir Variable speed knob Pressure Adjustment Auto / manual mode toggle Dispenser ON/OFF Pistons UP/DOWN Dispenser controller Water Supply Head release lever / switch Dispenser feed Specimen Pressure pistons Emergency switch Speed display Timer display Water solenoid switch Auto start button The FEMTO 1100 is a variable speed polishing head (0-200 rpm) for use with the NANO 1000T or NANO 2000T grinding/ polishing machine for semi-automated metallographic specimen preparation. The FEMTO 1100 can also run either automatically with the NANO polishing base or in a manual mode independently control from the NANO polisher. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 1 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 1.2 Technical Specifications Electrical specifications: 110 / 220V single-phase (50/60 Hz) Number of specimens: 1-6 samples (1-inch to 1.5-inch diameter. 1-3 samples 2-inch diameter (holder and rings sold separately) Force application: Individual piston Motor power: 120 W Polishing head speed: 0 to 200 rpm variable speed Weight: Approx. 55 lbs (25 kg) Dimensions (WxHxD): Approx. 13” x 18” x 18” (330 mm x 450 mm x 450 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) Hook ups: Air - clean filter air with lubricator (recommended) Electrical - 110V or 220V, 50/60 Hz) 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 Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 2 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 1.3 Mechanical Schematic Note: Installation of the FEMTO 1100 / NANO polishing base should be on a flat sturdy surface, with easy access to drain, water and electrical connections. 1.4 Features and Benefits The FEMTO 1100 is equipped with a 120 W variable 0-200 rpm speed motor. The drive mechanism is connected to the motor via a maintenance-free anti-slip polychain. The FEMTO 1100 also has a lubricant dispenser in addition to a high flow water valve for hands free wet grinding with abrasive papers and lubrication for polishing. In addition, the FEMTO 1100 can be operated either automatically or independently with the NANO polishing base. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 3 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.0 Unpacking, Shipping and Installation 2.1 Unpacking Unit is delivered in a box. Unpack and check for completeness of parts. Measures WxHxD: 20” x 30” x 37” (with NANO 1000). Weight: 2.2 Shipping Varies, depending upon model (approximately 55 lbs—FEMTO head). When moving box, lift from bottom. ! Caution: Heavy sensitive electronic equipment. Take care to avoid bodily injury and damage to the unit. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 4 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation ! Install unit carefully! Improper installation voids warranty. The FEMTO 1100 / NANO polishing base should be placed on a flat stable surface. Requires air, water supply, drain and electrical connections. After mounting on NANO polishing base (water, drain, electrical) and connection to a air and electrical supply, the system is ready for operation by activating the main power switches on both the NANO polisher and FEMTO head for Automatic operation. NANO interface cable Head release switch Head release lever FEMTO post Dispenser Interface cable Post locking collar Dispenser Positioning adjustment Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 5 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3.1 Post Connection Post positioning Bottom side post location on NANO polisher Post slot Post connection: Brass Plate Groove Remove the plastic cover plate from underneath the NANO polisher. Loosen and swing the brass holding plate for the post so that you can see the post alignment notch. The post notch must fit into the groove in the brass plate. Remove plastic cover from the top of the NANO polisher and lower the FEMTO post into the hole. (note it is recommended to tighten the FEMTO post locking lever first). Work the post down as far as possible. The post notch should extend below the NANO casting base. If the post does not go down all the way align the post with the brass plate and insert bolt/flat washer and locking washer and tighten so that the post is fully down. Replace brass plate and NANO plastic cover. IMPT: Securing the post is very important and must be done by tightening the bolt/ washer/locker washer from underneath the NANO polisher Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 6 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation (continued) 2.3.2 Specimen Holder Attachment Specimen holder adjustment screws Center pistons inside ring Specimen holder: The specimen holder is attached to the FEMTO drive shaft via two hex screws that tight on the two flat sides of the shaft. The specimen holder needs to be adjusted so that the pistons are approximately centered in the holder holes. This is adjustment is done by loosening the flange between the holder and shaft coupler and rotating the holder into the correct position. Retighten screws and nuts. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 7 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation (continued) 2.3.3 Height Adjustment for FEMTO Head /Specimen Holder Step 1: To lift head, rotate lever to engage piston to lift head Step 2: Lower head onto a cardboard spacer Specimen holder height adjustment: The specimen holder height needs to be adjusted to prevent the pistons from being ground during the operation of the machine. Step 1: Connect air and lift up head. Step 2: Place the working wheel with the highest profile abrasive/polishing pad on the wheel. Using a single wall box as a spacer, place the cardboard on top of the working wheel/abrasive combination. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 8 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation (continued) 2.3.3 Height Adjustment for FEMTO Head /Specimen Holder Step 3: Loosen and lower post holding collar Step 4: Rotate lever to disengage button Specimen holder height adjustment: Step 3: Loosen holding ring collar on the FEMTO post and slide down out of the way. Step 4. Rotate release lever slightly to lower the head. Step 5. Slide the holding ring collar up to the bottom of the FEMTO head and tighten. Step 6. Lift head by rotating release lever to engage button on bottom of FEMTO head. Remove cardboard and lower head. In the FEMTO manual mode, lower pistons with the down toggle switch. Verify that the bottom of the piston is not rubbing against the abrasive surface. (Note it is better to operate the specimen holder as close to the working abrasive wheel as possible in order to get flatter specimens Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 9 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation (continued) 2.3.3 Height Adjustment for FEMTO Head /Specimen Holder Specimen holder height adjustment: Step 7. In the FEMTO manual mode, lower pistons with the down toggle switch. Verify that the bottom of the piston is not rubbing against the abrasive surface. (Note it is better to operate the specimen holder as close to the working abrasive wheel as possible in order to get flatter specimens Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 10 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com 2.3 Installation (continued) Web: http://www.metallographic.com FEMTO 1100 HEAD External air supply 2.3.4 Backside connections Communication cables to NANO polishing base 110 V / 220 V switch Electrical supply Power switch External air supply: It is recommended that the air supply be clean, filtered and lubricated to extend the life and performance of the systems. Electrical connection: Connect electrical power cable and communications cable. Note: Inspect the operating voltage on the name plate. FEMTO connections NANO 2000 POLISHER Electrical connection 110V or 220V External water supply Water drain Connect drain for best direction to drain with fittings Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 11 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 2.3 Installation (continued) 2.3.5 Lubricator Connection Lubricator set-up (screw in reservoir) Fasten lubricator to FEMTO base casting Connect communication cable to FEMTO base Connect supply hose to dispenser Position dispensing tube by sliding along rail. To lock into place tighten screws located under the holder Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 12 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 3.0 Safety Guidelines 3.1 Warning Sign ! This sign points to special safety features on the machine. 3.2 Safety Precautions ! Careful attention to this instruction manual and the recommended safety guidelines is essential for the safe operation of the FEMTO 1100. ! Proper operator training is required for operation of the FEMTO 1100. 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. ! ! ! ! ! ! Operate unit as specified in this manual. Disconnect power before opening unit. Do not leave any specimen or other parts on the working wheel. Ensure that the air slots on polishing head are not obstructed. When unit is not in use turn off water and air. Keep hands clear of the specimen holder when the machine is running. Do not place or position hands under specimen holder when it is in the raised position or when lowering the head. 3.3 Emergency Statement The FEMTO 1100 power head has been designed for polishing metallographic specimens up to 2-inch diameter. Always follow proper operational guidelines and avoid contact with moving parts, lubricants and abrasives. Seek appropriate medical care for cutting injuries. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 13 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 3.4 Safety Test ! The emergency stop switch on the NANO polisher controls the operation of the FEMTO 1100 power head when operated in the AUTO mode. Test the emergency stop switch by running the FEMTO 1100 head in the AUTO mode through the NANO polisher. The following safety check is considered important: Emergency stop switch Emergency stop switch Test: Activate main switch. Start NANO 1000/ FEMTO 1100 machine in AUTO mode. Depress emergency stop switch. Proper Response: NANO 1000 and FEMTO 1100 head stops. Malfunction: NANO 1000 or FEMTO 1100 polisher does not lose power. Corrective measure: If system does not power down, disconnect power supply cord and call service technician. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 14 FEMTO 1100 Polishing Head INSTRUCTION MANUAL -------------------------------------------------- ▲ 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 4.0 Start-up and Operation 4.1 General The FEMTO 1100 is an semi-automated grinding/ polishing accessory for the NANO polisher. Wheel speed indicator 4.2 FEMTO 1100 Control Panel Pressure Gage Auto-mode for timed grinding/ polishing Pressure Adjustment Manual mode polishing Pistons up/down Motor Speed Controller Start/Stop (manual mode) Start / stop buttons: Start/stop the FEMTO head in the manual mode. Note the Start/ Stop button on the NANO polisher controls the Automatic polishing operation. Auto/ manual toggle: Manual mode operates FEMTO independent of NANO polisher. Auto mode operates FEMTO in conjunction with NANO polisher. Pistons Up/Down: The UP/DOWN toggle controls the pistons in the manual mode. Motor controller knob: The FEMTO head has a variable speed motor (0-200 rpm). Wheel speed indicator: Displays the motor speed (0-200 rpm) Pressure adjustment: Controls the pressure applied to the pistons. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 8 15 FEMTO 1100 Polishing Head INSTRUCTION MANUAL -------------------------------------------------- ▲ 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com 4.2 FEMTO 1100 Control Panel (applied force vs. pressure gage) The NANO 2000 is a hand grinding/ polishing machine. By adding the FEMTO power head, semi-automated polishing can be accomplished. Applied Force per sample Applied Force per sample (lbs) 4.3 NANO Polisher Control Panel 12 11 10 9 8 7 6 5 4 3 2 1 0 30 40 50 60 70 80 90 100 Pressure gage reading (PSI) Water switch Programming mode Auto-mode for timed grinding/ polishing Preset speeds (Low, medium, high) Web: http://www.metallographic.com Wheel direction Speed control Run/Stop Emergency stop button: Emergency stop switch cuts power to the motor immediately. Wheel direction: Clockwise rotation or counter clockwise rotation. Run / stop buttons: Start/stop the polishing wheel in both manual and auto mode. Water switch: Activates the water solenoid for the rinse bowl and rinse spout. Preset speeds: Allows for faster speed control, SPL - low speed, SPM - medium speed, SPH - high speed (factory setting approx. 100, 200, 300 rpm. Auto-mode: Allows for running pre-programmed speeds and times (factory setting approx. 200 rpm, FWD, 30 seconds). Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 16 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.4 AUTO Polishing Mode 1. Install working wheel and attach grinding papers / polishing cloths. Position the specimen holder so that the sample tracks over the entire diameter of the grinding papers in order to break the grinding papers uniformly. Note positioning is not as significant for polishing pads. 2. Switch on the FEMTO and NANO machines at the back. Set the toggle switch on the FEMTO control panel to AUTO Adjust polishing force Adjust head speed Set to Auto mode Set an approximate pressure and head speed on the FEMTO head. 3. Set the base speed, time and direction on the NANO controller (see next page for instructions) 4. Position flexible water spout over working wheel. During sample preparation adjust water flow by turning water control knob as required. Note: Initial operation of water valve may contain air in the lines. Turn water on slowly to purge air from system. 4. Turn on AUTO mode so light is lit. To start operation press START/STOP button to begin. 5. Adjust speed of the polishing head and applied pressure Set to Auto mode Starts Auto polishing mode TIP: It is recommended that the FEMTO head speed match or exceed the NANO base speed, running in the same direction. This provides flatter specimen samples, especially for coarse grinding. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 17 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.4.1 Programmable Mode 1 The programming mode can be used to pre-set the . polishing speed, direction and time for automated polishing. It can also be used to change the fast speed buttons. 2 To change the speed of the wheel: . Press the PRG button and use the up and down keys to SP1 and press ENTER. Use the up and down < key to change the speed. Press ENTER to save. 3 To program a grinding/ polishing time: . Press the PRG button and use the up and down keys to t1 and press ENTER. Use the up and down < key to change the time (enter in seconds - displayed min-sec) 4 To operate the pre-programmed conditions: . PRESS the AUTO button and then start the program with the RUN/STOP button. The pre-programmed conditions will be executed. Fast speed buttons To change the speed setting for the fast speed buttons use the following procedure: Press the PRG button and use the up and down keys to SL (slow speed) and press ENTER. Use the up and down < key to change the speed. Use Sn for changing the medium speed and SH for the fast speed. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 18 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.5 MANUAL NANO-FEMTO Polishing Mode 1. Install working wheel and attach grinding papers / polishing cloths. 2. Switch on the FEMTO and NANO machines at the back. Set the toggle switch on the FEMTO control panel to MANUAL Set an approximate pressure and head speed on the FEMTO head. Load samples and toggle the Pistons to the DOWN position. Adjust polishing force Toggle to lower pistons Adjust head speed Press green Start/Stop button to start the FEMTO head (NANO polisher will not start automatically in this mode, it must be started separately). Set to Manual Start/Stop FEMTO head Adjust the FEMTO speed and force. 3. Start the NANO head by using preset speeds (SPL, SPM, SPH) and pressing START/STOP button. Note speed can be adjusted with up and down arrow keys. 4. Position flexible water spout over working wheel. During sample preparation adjust water flow by turning water control knob as required. Note: Initial operation of water valve may contain air in the lines. Turn water on slowly to purge air from system. 5. Both the NANO and FEMTO heads need to be stopped by pressing the green button on the FEMTO head and the START/STOP button on the NANO controller. Preset Speeds Start/Stop NANO manually Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 19 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.5 SEMI-AUTO NANO-FEMTO Polishing Mode 1. Install working wheel and attach grinding papers / polishing cloths. 2. Switch on the FEMTO and NANO machines at the back. Set the toggle switch on the FEMTO control panel to AUTO Set an approximate pressure and head speed on the FEMTO head. Load samples. 3. Start the NANO head by using preset speeds (SPL, SPM, SPH) and pressing START/STOP button. Note speed can be adjusted with up and down arrow keys. Adjust polishing force Adjust head speed Set to Auto mode Adjust the FEMTO speed and force. The FEMTO head and NANO polisher will start automatically in this mode, however, it will run until the START/STOP button is pressed. 4. Position flexible water spout over working wheel. During sample preparation adjust water flow by turning water control knob as required. Note: Initial operation of water valve may contain air in the lines. Turn water on slowly to purge air from system. 5. Press the START/STOP button on the NANO controller to stop the polishing operation. Preset Speeds Start/Stop NANO manually Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 20 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.7 MANUAL Hand Polishing Mode (NANO ONLY) To use the NANO polishing without the FEMTO head, turn off the power to the FEMTO head using the main power switch on the back of the FEMTO head. Swing the FEMTO head out of the way. 4.7.1 Grinding / polishing by hand 1. Install working wheel and attach grinding papers / polishing cloths. 2. Switch on the machine in the back and set the mode, speed, and time (if required). 3. Position flexible water spout over working wheel. During sample preparation adjust water flow by turning water control knob as required. Note: Initial operation of water valve may contain air in the lines. Turn water on slowly to purge air from system. 4. Press START/STOP start and stop the machine in the manual mode. 4.7.2 Direction and speed controller (manual) 1. To change direction of the wheel: -Press FWD (clockwise) or REV (counter clockwise), LED will light 2. To change the speed of the wheel: Select low, medium or high speed fast buttons and use up and down arrows to fine tune speed if required Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 21 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.8.1 Manual Mode - Programming 1 The programming mode can be used to pre-set . the polishing speed, direction and time for automated polishing. It can also be used to change the fast speed buttons. 2 To change the speed of the wheel: . Press the PRG button and use the up and down keys to SP1 and press ENTER. Use the up and down < key to change the speed. 3 To program a grinding/ polishing time: . Press the PRG button and use the up and down keys to ST1 and press ENTER. Use the up and down < key to change the time (seconds). 4 To operate the pre-programmed conditions: . PRESS the AUTO button and then start the program with the RUN/STOP button. The preprogrammed conditions will be executed. Preset Speeds Start/Stop NANO manually To change the speed setting for the fast speed buttons use the following procedure: Press the PRG button and use the up and down keys to SL (slow speed) and press ENTER. Use the up and down < key to change the speed. Use SN for changing the medium speed and SH for the fast speed. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 22 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.9 Positioning and Loading FEMTO holder 1 For grinding with abrasive papers, the specimen holder . for the FEMTO head should be positioned so that the specimen tracks over the entire radius of the grinding paper. Since grinding papers break down relatively fast, it is recommended that the hardest part of the mount (typically the specimen) track over the entire radius in order to uniformly break down the grinding papers. If the specimen does not break down the grinding papers uniformly then the softer outside part of the mount will grind more. The result is after polishing there will be a portion of the mount which is not fully polished. This portion of the mount will appear as a crescent shaped moon and can cause issues when examining the edge of the specimen. Position holder so that the specimen in the mount tracks over then entire radius of the grinding paper. TIP: If you have small samples, mount them toward the outside edge of the mount for better tracking 2 Individual specimen holders do not hold the specimen . in the holder. When the head is lifted, the specimens will remain on the working wheel. In such a case they will need to be reloaded after changing the abrasive. TIP: By placing a rubber O-ring around the top of the mount it can be lifted when the head is raised and held in place. Note you most likely will not be able to do this if you use the splash guards. O-rings to hold specimens in place when head is lifted Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 23 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.10 Metallographic Specimen Preparation Basics TIP: To optimize individual polishing machines, the specimen mounts need to be square. It is recommended that the specimen be mounted in either a compression mounting press or with a rubber mold for castable mounting. 2-piece molds produce tapered mounts Rubber molds produce square mounts DO NOT USE TAPERED 2-PIECE MOLDING CUPS USE A BELT GRINDER FOR COARSE GRINDING!!! Square grinding attachment TIP: Individual polishing machines DO NOT require coarse planar grinding. In fact, extremely coarse grinding with 60 grit down to 180 grit is not recommended. If coarse grinding is required, it is recommended that the PENTA 7500 belt grinder, with its square grinding attachment be used. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 24 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.10 Metallographic Specimen Preparation Basics A typical metallographic specimen preparation consists of the following basic steps: Preparation Stage Purpose Initial documentation: To document the initial condition of the sample, To map the sample surface, To highlight the area of interest. Sectioning / cutting: To reduce the size of large samples and to sample the specimens close to the area of interest. Rough, or planar grinding (refer to Section 4.9.1): To obtain a planar surface, To remove sectioning damage, To approach the area of interest. Rough polishing (refer to Section 4.9.2): Ideally to remove all the subsurface damage and microstructural damage produced during cutting and rough grinding (Superficial scratches may still be present after this step). Final polishing (refer to Section 4.9.1):: Generally, more for cosmetic purposes than for removing microstructural damage. In most cases, this stage should be minimized to avoid over polishing and distorting the microstructural features. Etching: To enhance microstructural features such as grain boundaries, grain size, phase differences, etc. Examination: A variety of examination techniques are used in metallography, including: optical microscopy, electron microscopy and hardness testing. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 25 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.10.1 Rough / Planar Grinding Rough or planar grinding, is required to produce flat specimens and to reduce the damage created by sectioning. The planar grinding step is accomplished by decreasing the abrasive grit particle size sequentially to obtain surface finishes that are ready for polishing. Care must be taken to avoid being too abrasive in this step, and actually creating greater specimen damage than produced during cutting. This is especially true for very brittle materials such as ceramics and silicon. The machine parameters which affect the preparation of metallographic specimens include: grinding / polishing pressure, grinding direction, and the relative velocity distribution between the specimen and the polishing wheel. Grinding Speed For automated polishing the relative speed between the polishing head and the polishing wheel has a significant effect on the flatness of the mount, especially for grinding with coarse abrasives. As an example, the following two conditions show the effect of running with the head and base speed in the contra direction as well as running the head and base speeds in the same direction at the same speed. High relative velocity difference (contra) between the polishing head and polishing base Low relative velocity difference (complementary) between the polishing head and polishing base Based on the relative velocity distributions for grinding / polishing the best condition for maintaining a uniform velocity across the specimen as it rotates around the polishing wheel is to run them in the same direction at the same speed. In addition, changing the offset as well as the combination speed Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 26 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 can control the aggressiveness of the grinding/ polishing operation. It is also very important for polishing machines which use individual force pistons for applying the polishing force to run the power head and base at closely matching speeds and in the complementary direction. If these machines are run with significantly different speeds or direction the mount will have a tendency to grind with a wedge and therefore it will not be square. Grinding Pressure Grinding / polishing pressure is dependent upon the applied force (pounds or Newton's) and the area of the specimen and mounting material. Pressure is defined as the Force/Area (psi, N/m 2 or Pa). For specimens significantly harder than the mounting compound, pressure is better defined as the force divided by the specimen surface area. Thus, for larger hard specimens, higher grinding / polishing pressures increase stock removal rates. However, higher pressure also increases the amount of surface and subsurface damage produced in the specimen. Note regarding SiC grinding papers: as the abrasive grains dull and cut rates decrease, increasing grinding pressures can extend the life of the SiC paper. Higher grinding / polishing pressures can also generate additional frictional heat which may be beneficial for the chemical mechanical polishing (CMP) of ceramics, minerals and composites. Likewise for extremely friable specimens (such as nodular cast iron), higher pressures and lower relative velocity distributions can aid in retaining inclusions and secondary phases. Grinding Direction The orientation of the specimen can have a significant impact on the preparation results, especially for specimens with coatings. In general, when grinding and polishing materials with coatings, the brittle component should be kept in compression. In other words, for brittle coatings, the direction of the abrasive should be through the coating and into the substrate. Conversely, for brittle substrates with ductile coatings, the direction of the abrasive should be through the brittle substrate and into the ductile coating. Manual Preparation In order to ensure that the previous rough grinding damage is removed when grinding by hand, the specimen should be rotated 90 degrees and continually ground until all of the scratches from the previous grinding direction are removed. When necessary, the abrasive paper should be replaced with a newer paper to maintain cutting rates. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 27 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.10.2 Rough Polishing The purpose of the rough polishing step is to remove the damage produced during cutting and planar grinding. Proper rough polishing will maintain specimen flatness and retain all inclusions or secondary phases. By eliminating the previous damage and maintaining the microstructural integrity of the specimen at this step, a minimal amount of time is required to remove the cosmetic damage at the final polishing step. Rough polishing is accomplished primarily with diamond abrasives ranging from 9 micron to 1 micron. Polycrystalline diamond -- because of its multiple and small cutting edges -- produces high cut rates with minimal surface damage. Therefore, polycrystalline diamond abrasives are recommended for metallographic rough polishing on low-napped polishing cloths. Rough Polishing Guidelines Material Recommendations Metals (ferrous, non-ferrous, tool steels, superalloys, etc.) Rough polishing typically requires two polishing steps, e.g., a 6micron diamond followed by a 1-micron diamond on low-napped polishing cloths. Ceramics and ceramic matrix composites (CMC) Low-nap polishing pads using polycrystalline diamond, alternating with colloidal silica. This provides a chemical mechanical polishing (CMP) effect which results in a damage-free surface Polymer matrix composites (PMC) Diamond-lapping films are recommended. Biomaterials Low-napped polishing pads with polycrystalline diamond, alternating with colloidal silica. Alternatively, diamond-lapping films may work well. Microelectronic specimens Diamond-lapping films are recommended. Plastics and polymers 800 and 1200 grit SiC abrasive paper are recommended. Plasma spray materials Diamond-lapping films or low-napped polishing pads with alternating diamond and colloidal silica abrasives. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 28 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.10.3 Final Polishing The purpose of final polishing is to remove only the cosmetic surface damage. It should not be used to remove any damage remaining from cutting and planar grinding. If the damage from these steps is not completely removed, the rough polishing step should be repeated or continued. Final Polishing Guidelines Material Recommendation Metals (ferrous, nonferrous, tool steels, superalloys, etc.) High-napped polishing pads with a nanometer alumina polishing abrasive. The polishing times should nominally be less than 30 seconds. Ceramics and ceramic matrix composites (CMC) Low-napped polishing pads using 1-um polycrystalline diamond, alternating with colloidal silica or colloidal silica alone. Polymer matrix composites Fine abrasive diamond-lapping films, followed by a very light polish (PMC) on a high-napped polishing pad. Biomaterials Low-napped polishing pads with polycrystalline diamond, alternating with colloidal silica. Microelectronic specimens Diamond-lapping films followed by a very light polish on a high-napped polishing pad. Plastics and polymers Light polish with alumina on a high-napped polishing pad. Plasma spray materials Diamond-lapping films followed by a very light and short alumina or colloidal silica polish on a high-napped polishing pad. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 29 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.11 Selected Polishing Procedures 4.11.1 1095 Carbon Steel (Pearlite and Martensite Phases) Preparation of high carbon steels is fairly straight-forward. Depending upon the heat treatment, the grinding and polishing times may increase for the harder martensite phase. Abrasive/surface Lubricant Individual Force (lbs) Head / Wheel speed Time PDGD-125M Diamond Grinding Disk water 60-75 lbs 200 rpm /200 rpm Until plane SIRIUS Composite grinding disk 9 um DIAMAT Diamond 60-75 lbs 200 rpm /200 rpm 3 minutes ORION Composite grinding disk 3 um DIAMAT diamond 200 rpm /200 rpm 3 minutes 1 um DIAMAT diamond on ATLANTIS pad DIALUBE Extender 200 rpm /200 rpm 2 minutes 100 rpm /100 rpm 1 minute 0.05 um Nanometer alumina on MICROPAD or TRICOTE pad 1095 Steel, Furnace-Cooled, etched with 2% nital, 400X B.F. Microstructure: Pearlite structure 60-75 lbs 60-75 lbs 60-75 lbs 1095 Steel, Water-Quenched, etched with picric acid, 1000X B.F. Miicrostructure: Martensite structure Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 30 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.11.2 Stainless Steel Stainless steels have high concentrations of chromium (>12%) and are generally relatively soft as compared to heat-treated steels. This makes stainless steel more susceptible to smearing. Preparation is relatively straight-forward. Abrasive/surface Lubricant Individual Force (lbs) Head / Wheel speed Time 320 grit SiC paper 400 grit SiC paper 600 grit SiC paper 800 grit SiC paper 1200 grit SiC paper water 60-75 lbs 200 rpm /200 rpm Until plane 1 minute 1 minute 1 minute 1 minute 1 um DIAMAT diamond on TEXPAN pad SIAMAT colloidal silica 60-75 lbs 200 rpm /200 rpm 2 minutes 60-75 lbs 100 rpm /100 rpm 1 minute 0.05 um Nanometer alumina on NAPPAD pad 431 Stainless Steel microstructure Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 31 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.11.3 Aluminum and Aluminum Alloys Aluminum and aluminum alloys are difficult to prepare because they are soft and contain oxide particles which can become dislodged and scratch the surface. The key to polishing aluminum is to use very fine polishing abrasives (fine aggregates). Abrasive/surface P220 grit ALO paper P500 grit ALO paper P1200 grit ALO paper 1 um DIAMAT diamond on ATLANTIS pad 0.05 um Nanometer alumina on NAPPAD pad Lubricant Individual Force (lbs) Water 60-75 lbs DIALUBE Purple Extender Head / Wheel speed Time 200 rpm / 200 rpm Until plane 1 minute 1 minute 60-75 lbs 200 rpm / 200 rpm 2 minutes 60-75 lbs 100 rpm / 100 rpm 1 minute Aluminum - Silicon Alloy microstructure, Kallings etchant Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 32 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.11.4 Cast Iron Cast irons are difficult materials to prepare properly because the graphite nodules (or graphite flakes) are easily pulled out during preparation. By minimizing the sectioning damage and by starting with a modest-grit-size SiC paper, retaining these difficult particles can be accomplished. Abrasive/surface Individual Force (lbs) Head / Wheel speed Time 60-75 lbs 200 rpm / 200 rpm Until plane 1 minute 1 minute 1 minute 1 minute 1 um DIAMAT diamond on DIALUBE Purple 60-75 lbs GOLDPAD pad Extender 200 rpm / 200 rpm 3 minutes 0.05 um Nanometer alumina on TRICOTE pad 100 rpm / 100 rpm 1 minte 320 grit SiC paper 400 grit SiC paper 600 grit SiC paper 800 grit SiC paper 1200 grit SiC paper Lubricant water Nodular Cast Iron microstructure, Etchant 2% nital, Mag. 100X 60-75 lbs Graphite Cast Iron microstructure, Etchant 2% nital, Mag. 500X Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 33 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 4.11.5 Alumina Ceramic The preparation of hard / brittle / porous ceramic materials is not especially difficult when a few simple preparation tricks are known for this class of materials. First, to minimize grain pull-out (which may be falsely characterized as porosity), sectioning damage must be minimized. This is accomplished by sectioning with the appropriate diamond wafering blade and using the finest practical abrasive for initial grinding. Planar grinding is best achieved with the use of the smallest diamond abrasive possible on a metal mesh cloth. Note that there is a trade-off between planar grinding time (abrasive size) and induced damage. In some cases for ceramics, it is better to take more time and minimize damage at planar grinding in order to reduce overall polishing times. The use of SIAMAT™ colloidal silica also provides a chemical mechanical polishing (CMP) action, which is the most effective means for eliminating both surface and subsurface damage. The combination of SIAMAT™ colloidal silica with a DIAMAT™ polycrystalline diamond also produces excellent surface finishes. Abrasive/surface Lubricant 30 um DIAMAT diamond on CERMESH metal mesh cloth Individual Head / Wheel Force (lbs) speed Time 60-75 lbs 200 rpm / 200 rpm Until plane 6 um DIAMAT diamond on TEXPAN polishing pad SIAMAT colloidal silica 75-100 lbs 200 rpm / 200 rpm 5 minutes 1 um DIAMAT diamond on GOLDPAD polishing pad SIAMAT colloidal silica 75-100 lbs 200 rpm / 200 rpm 5 minutes 75-100 lbs 100 rpm / 100 rpm 5 minutes SIAMAT Colloidal silica on TEXPAN pad 85% Alumina microstructure, 500X (note the sharp edges - edge retention) 99+% Alumina microstructure, 5000X (thermally etched) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 34 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 Educational Etchant and Procedure Database CD Etchant Database - OVER 2200 ETCHANTS Search Fields Material or metal type Specific alloys Etchant name Micro vs. Macro etchant Keyword MSDS for Etchant Chemicals Preparation Guidelines Preparation Basics Preparation Trouble Shooting Etchant Database Preparation Guidelines Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 35 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 5.0 Maintenance 5.1 Introduction The FEMTO 1100 requires very minimal maintenance. However, to increase the life of the polisher, it is suggested that the unit be rinsed after use. 5.2 Cleaning outside cabinet The cabinet should be cleaned occasionally with a moistened cloth. Do not use any chemicals or cleaning abrasives. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 36 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 6.0 Trouble Shooting More extensive trouble shooting, repair guides, video’s, parts list are provided online at www.metallographic.com or http://www.metallographic.com/PACE-service/FEMTO-1100-service.html Problem Cause Solution No power or function a. Unit is disconnected from main a. Verify electrical source and electrical power supply connection. b. Main power switch is off b. Turn on main power switch. c. Blown fuse c. Replace fuse No air supply a. Air regulator blocked a. Clean air connections Specimens not polished evenly across sample A. Specimen not breaking down grinding paper uniformly A. Position specimen holder so that specimen tracks over the entire radius of the grinding paper. B. Match head and base speed B. Relative velocity of base and head does not match. Error Message E1 Pry open fuse holder with small flat head screwdriver a. Motor power surge. a. Turn polisher off and wait until LED discharges. Turn unit back on, if problem persist contact PACE service department Replace fuse Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 36 37 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 7.0 Metallographic Consumables 7.1 SiC Abrasive Paper, Surface Roughness 60-grit SiC 2-dimensional line profile 3-D optical contour mapping 240-grit SiC 400-grit SiC 600-grit SiC 1200-grit SiC Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 38 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 7.2 Composite Grinding Plates Composite grinding disks are an alternative to intermediate grinding and polishing. PACE Technologies composite disk vary slightly from other competitive products in that they are pre-charged with diamond. This allows the disks to cut faster and longer. Two disks types are available, the ORION composite polishing disk is pre-charged with 3 micron diamond, whereas the SIRIUS composite disk is pre-charged with 9 micron diamond. The SIRIUS composites grinding disks offer an alternative to grinding with 320-600 grit SiC papers, and the ORION composite disk offer an excellent alternative to rough polishing with 3-6 micron diamond. Composite grinding disks using diamond suspensions. Composite grinding disks close-up Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 39 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 7.3 Polishing Pads Metal Mesh Cloth. This is a wire mesh material useful for coarse and intermediate lapping / polishing. The texture of this wire allows for the abrasive to become semi-fixed, thus offering the advantage of increased stock removal, while minimizing damage. POLYPAD™ Polishing Pad. This cloth is a synthetic polyester polishing pad which has a similar action to a nylon pad, except that it is much more durable. It is used in the intermediate polishing steps. TEXPAN Polishing Pad. This is the most commonly used polishing cloth material for the intermediate polishing steps. TEXPAN™ Polishing pad is a lownapped cloth. Black CHEM™ 2 Polishing Pad. This porometric polymer pad has the consistency similar to a rubber type of pad. Black CHEM™ 2 pad has a low nap but behaves as an intermediate polishing pad with a performance between low-napped and high-napped pads. GOLDPAD Polishing Cloth. This is a woven lownapped polishing pad used mostly for intermediate diamond polishing for ceramics and metals and polymers. ATLANTIS Polishing Cloth. This polishing pad is a laminated polishing cloth having a resilient foam backing. The foam backing allows the polishing to conform better to the specimen surface. MICROPAD™ and MICROPAD™ 2 Polishing Cloth. This is the most commonly used high-napped final polishing cloth for metals and polymers. Its high nap provides a very soft and gentle polishing action. NAPPAD™ Polishing Pad. This is another high-napped final polishing pad useful for most metals and polymers. It has a higher nap than MICROPAD™, providing the most gentle polishing action of all the cloths. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 40 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 7.4 Polycrystalline Diamond Abrasives Polycrystalline diamond is a synthetic diamond which provides better surface finishes and higher removal rates than monocrystalline diamond. The following are the advantages of a polycrystalline diamond over a monocrystalline diamond: Higher removal rates (self-sharpening abrasive) Very uniform surface finish More uniform particle size distribution Harder / tougher particles Blocky - shaped particles Hexagonal (equally hard in all directions) microcrystallites Extremely rough surface (more cutting points) Surface area is 300% greater than with a monocrystalline diamond No abrasion-resistant directionality (abrasion independent of particle orientation) Diamond Size (um) Color code 0.10 Charcoal 0.25 Gray 0.50 White 1.0 Blue 3.0 Green 6.0 Yellow 9.0 Red 15 Brown 30 Orange 45 Purple Monocrystalline blocky - diamond Polycrystalline multi-faceted diamond Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 41 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 7.5 Final Polishing Abrasives Final polishing abrasives include fine diamond, alumina and colloidal silica. For successful microstructural preparation, the polishing abrasive / cloth combination must be appropriately matched to the specimen hardness, fracture toughness and corrosion properties of the specimen. Ccolloidal Silica Colloidal silica is a relatively soft abrasive with high chemical activity. It is an ideal chemical mechanical polishing (CMP) abrasive. The chemical activity of colloidal silica results from the electrochemical balance (zeta potential) required to keep very fine particles from aggregating. This chemical balance also produces a surface phenomenon which makes the specimen surface more chemically active. This produces a surface layer which can be mechanically removed by the colloidal silica particles themselves, or by the mechanical scrubbing of the surface with the polishing pad. For ceramics, the combination of fine polycrystalline diamond and colloidal silica improves surface finishes and increases polishing rates. Nanometer Alumina Nanometer alumina is a polycrystalline colloidal alumina processed by a proprietary seeded gell process. Polycrystalline alumina offers two significant improvements over conventional alumina calcining processes: 1. Tighter, more controlled particle size distributions 2. Harder alpha alumina particles The tighter, more controlled particle size distribution is a result of less particle aggregation which produces significantly less scratching in soft metals, such as aluminum, tin, lead, copper and soft steels. Nanometer alumina is available in an acidic (pH 4) or basic (pH 10) range. Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 42 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 8.0 Spare Parts Part no. Description Image Electrical FM-001 Front Panel PC board Controller FM-001-C PC board communication cable FM-002 FEMTO 1100 speed control board FM-48V FEMTO 1100 48V power supply FM-100 Power distribution box P150-217 Speed sensor Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 43 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Electrical FM-006 FEMTO 1100 Motor and gear box (125 W) FM-013 FEMTO 1100 Power cable to NANO base (Female to Female) FM-014 FEMTO 1100 Communication cable NANO 1000 (short) FM-015 FEMTO 1100 Communication cable NANO 2000 (long) FAN-24V 24 V Fan TP1-E-FC Fan cover plate Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 44 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Electrical 24RELAY 24 volt relay switch RELAY-B 24 volt relay switch base FEMTO-R Rectifier PS-001 TP-7000/ TP-7001 ON/OFF power switch FUSE-6A 6 amp fast blowing fuse (3/pkg) Part no. Description Image Mechanical Parts FM-025 Polychain belt (OP-355M) FM-16 FEMTO Dispenser unit (gravity feed) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 45 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Mechanical Parts LUB-1000 FEMTO Dispenser bottle FM-PUMP FEMTO 1100 Dispenser unit with pump FM-TUBE FEMTO 1100 pump dispenser tubing FM-018 FEMTO Dispenser stainless steel tube FM-017 FEMTO Dispenser distribution block FM-M-031 Sliding guide for lubrication dispenser block Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 46 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Mechanical Parts FM-007 FEMTO 1100 FRP cover FM-010 FEMTO 1000 Locking lever FM-010-H FEMTO 1100 Lifting Handle FM-011 FEMTO 1000 Height adjustment collar FM-012 FEMTO post-accuator FM-MAPL FEMTO 1100 aluminum plate FM-1100T FEMTO 1100 Template Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 47 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Mechanical Parts FM-M-020 Air-cylinder-bracket FM-M-021 Air-Distributor-bracket FM-M-023-2 Arbor-holder FM-M-024 Base FM-M-025 Base flange FM-M-026 Main-shaft-plastic-ring Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 48 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Mechanical Parts FM-M-028 Collar adapter FM-M-029 Head gear FM-M-030 Motor gear FM-M-023-1 Motor mounting block FM-M-032 Small cylinder holder FM-M-PRH Piston rod housing FM-M-HTCP Housing top cover plate Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 49 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Pneumatic Parts FM-003 FEMTO 1100 Piston cylinders (each) FM-004 FEMTO 1100 Rubber boot (each) FM-005 FEMTO 1100 stainless steel pressure shoe (plate) FM-021 Pressure control valve FM-009 Pressure release valve for lifting head AR-001 Air regulator AP-002 Pressure guage Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 50 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Pneumatic Parts AH-6MM 6 mm air hose (2 meters) AH-6MM 6 mm diameter air hose connector TP-AIR Air hose connector (2-sided) AIR-0100 Air filter lubricator Specimen Holders FM-008 FEMTO 1100 Coupler SH-1100 Specimen holder for 1-6 samples (2540 mm and 1-1.5-inch specimen rings) SH-1200 Specimen holder for 1-3 samples (50 mm and 2-inch specimen rings) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 51 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Image Specimen Holders SR-0100 1-inch specimen rings (6/set) SR-0125 1.25-inch specimen rings (6/set) SR-0150 1.5-inch specimen rings (6/set) SR-0200 2-inch specimen rings (3/set) SR-25mm 25 mm specimen rings (6/set) SR-30mm 30 mm specimen rings (6/set) SR-40mm 40 mm specimen rings (6/set) SR-50mm 50 mm specimen rings (3/set) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 52 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 8.0 Spare Parts Part no. Description Images Electrical (NANO) N1-007b NANO 1000T and 2000T Motor (750 W - 1 hp) N1-007c NANO 1200T Motor (1.5 hp) N1-008b NANO 1000T/2000T PC board / frequency convertor (new machine using 24V transformer) N1-008c NANO 1200T PC board / frequency convertor (new machine using 24V transformer) N1-008T PC board (top only) for 1 rpm increments Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 53 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Electrical (NANO) N1-012b Transformer (24V) N1-013 Emergency Stop N1-015b Front Panel (with time display) with PC board N1-015c Front panel connection cable (with time display) FUSE-C Controller T6.3A fuse - (each) FUSE-NA 10 amp fuse for NANO Polishers (3/ package) PS-001 On/Off switch 24RELAY 24 volt relay switch Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 54 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Electrical (NANO) RELAY-B 24 volt relay switch base NANO-R Rectifier N1-009b Solenoid Valve (24 V) CORD-110V 110V power cord CORD-220R 220V round time power cord CORD-220F 220V three prop flat connector Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 55 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) PW-800 NANO 1000-2000 8-inch working wheel PW-1000 NANO 1000-2000 10-inch working wheel PW-1200 NANO 1200 12-inch working wheel PW-1400 NANO 1200 14-inch working wheel N1-001 NANO 1000 Single Wheel FRP cover N2-001 NANO 2000 Double Wheel FRP cover N12-001 NANO 1200 FRP cover N1-002 NANO 1000-2000 Polishing Table Support Platen Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 56 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N12-002 NANO 1200 Polishing Table Support Platen N1-002PEG Table support PEG's without o-rings (3/set) N1-002-O-Ring Table support PEG O-ring (3/pkg) N1-003S NANO 1000T/2000T Spindle assembly N1-025 FEMTO 1100 post collar (mounts on the NANO 1000-2000 polisher) N1-003P NANO 1000-2000 Pulley wheel for spindle wheel N1-006 NANO 1000-2000 Pulley for motor Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 57 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N1-005 NANO 1000T Single Wheel Belt N2-005 NANO 2000T Double Wheel Belt N12-005 NANO 1200T Single Wheel Belt PTM-125-005 8-inch plain backed paper ring PTM-125-006 10-inch plain backed paper ring PTM-225-005 12-inch plain backed paper ring PTM-225-006 14-inch plain backed paper ring PTM-125-007 8 and 10-inch polisher cover PTM-225-007 12 and 14-inch polisher cover PTM-225-007H Cover handle Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 58 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) PTM-125-001 8 and 10-inch splash guard PTM-125-207 12 and 14-inch splash guard FT-004 Feet (4/pkg) N1-T NANO 1000T Template N2-T NANO 2000T Template N12-T NANO 1200T Template N1-M-001 NANO 1000 Casting Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 59 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N2-M-001 NANO 2000 casting N12-M-001 N1200 casting N1-M-002 Plastic cover N1-M-003 Femto slot holder N1-M-004 NANO 1000 Bottom cover N2-P-BC NANO 2000 Bottom cover Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 60 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N12-BOT NANO 1200 plastic bottom cover N1-M-008 NANO 1000T Motor holder N2-M-003 NANO 2000T Motor holder N12-M-003 NANO 1200 Motor holder N1-014b NANO 1000 rear panel N2-M-002 NANO 2000 rear panel Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 61 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N12-BP NANO 1200 rear panel N1-M-007 Front Panel for NANO 1000T/1200T/2000T Polisher (each) N1-M-005 Solenoid bracket N1-M-006 Water adapter bracket N1-M-009 Water hose clamp Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 62 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Mechanical Components (NANO) N12-M-002 NANO 1200 Spindle N12-M-004 NANO 1200 Wheel pulley N12-M-CR NANO 1200 copper ring N12-M-005 NANO 1200 Spindle shaft N12-M-SSA NANO 1200 Spindle shaft adapter N12-M-RSH NANO 1200 roller shaft housing Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 63 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Plumbing Components (NANO) W-6M 6 mm diameter water supply hose connector W-E-8MM Elbow 8mm quick water connector W-S-8MM 8mm water split quick connector P-Drain Drain hose ( ~2 meters) P-Inlet Water inlet hose (~2 meters) N-P-CFA Copper female adapter N1-010 Drain connector set (elbow, nipple, hose barb) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 64 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: pace@metallographic.com Part no. Description Web: http://www.metallographic.com Images Plumbing Components (NANO) N2-009 NANO 2000 Drain T-fitting D-REDUCER Drain Reducer D-ELBOW Drain elbow D-NIPPLE Drain-nipple D-BARB Drain hose barb P-RINSE Rinse bowl water sprayer P-ADAPTER Rinse bowl water connector PVL Water value (right side) - single unit and right side double PVR Water value (left side) - double unit only Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 65 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.0 Schematics (FEMTO mechanical) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 66 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.1 Schematics (FEMTO electrical) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 67 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.2 Schematics (NANO case assembly) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 68 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.2 Schematics (NANO case assembly) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 69 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.2 Schematics (NANO internal mechanical assembly) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 70 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.2 Schematics (NANO internal mechanical assembly) Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 71 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 9.3 NANO Electrical Schematic Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 72 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 NANO 1000T/2000T and 1200T with 20 rpm increments (1 and 1.5 hp motor) Note: Do not start or run the motor before the correct input voltage is programmed; RESET DEFAULT BEFORE REPROGRAMMING Go to dF → Enter → -def → Enter Steps to set converter input voltage and frequency response: Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2020” → Enter → input “3030” →Enter→ input “4170” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1030” →Enter → input “2170” → Enter → input “3050” →Enter→ input “4255” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1050” →Enter → input “2225” → Enter → input “3120” →Enter→ input “4255” →Display “OVER” →Enter 2. Go into Program “nS” (Password:0253) → Enter → input “2” → Enter 3. Go into Program “Sr” (Password:0253) → Enter → input “1.4” → Enter Steps to set converter input voltage and frequency response: FOR 110V Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2025” → Enter → input “3050” →Enter→ input “4255” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1050” →Enter → input “2255” → Enter → input “3120” →Enter→ input “4255” →Display “OVER” →Enter FOR 220V Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2025” → Enter → input “3050” →Enter→ input “4225” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1050” →Enter → input “2225” → Enter → input “3120” →Enter→ input “4225” →Display “OVER” →Enter 2. Go into Program “nS” (Password:0253) → Enter → input “2” → Enter 3. Go into Program “Sr” (Password:0253) → Enter → input “1.4” → Enter Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 73 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 NANO 1000T/2000T and 1200T with 20 rpm increments (1 and 1.5 hp motor) Programming Step Value Description SR 1.4 Belt ratio - DO NOT CHANGE (Enter PW 0253 to access) SP1 SPEED Disc Speed - VARIABLE T1 TIME Runtime for SP1 SP2 to SP8 200 Multiple step disk speed - DO NOT CHANGE T2 to T8 0 Runtime for multiple steps - DO NOT CHANGE CN 1 Number of cycles – DO NOT CHANGE SL 100 Disc speed for SPL - preset to 100 rpm SN 200 Disc speed for SPM - preset to 200 rpm SH 300 Disc speed for SPH - preset to 300 rpm DF Defaults—DO NOT CHANGE U SET 110/220V—DO NOT CHANGE ST 65 CT Shutoff motor temperature - DO NOT CHANGE Current motor temperature - DO NOT CHANGE CD1 0 Controlled by RUN/STOP button - DO NOT CHANGE CD2 10 Display speed - DO NOT CHANGE Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 74 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 NANO 1000T/2000T and 1200T with 1 rpm increments (1 and 1.5 hp motor) Note: Do not start or run the motor before the correct input voltage is programmed; RESET DEFAULT BEFORE REPROGRAMMING Go to dF → Enter → -def → Enter Steps to set converter input voltage and frequency response: Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2042” → Enter → input “3050” →Enter→ input “4255” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1050” →Enter → input “2225” → Enter → input “3120” →Enter→ input “4255” →Display “OVER” →Enter 2. Go into Program “nS” (Password:0253) → Enter → input “2” → Enter 3. Go into Program “Sr” (Password:0253) → Enter → input “1.4” → Enter NOTE: If any of the numbers are entered incorrectly in the above sequence, the process requires that the default be reset and the program the sequence entered again until it is exactly correct. THIS IS VERY CRITICAL OTHER WISE AN E01 ERROR CAN OCCUR. Steps to set converter input voltage and frequency response: The above settings are for maximum torque which will result is a slight vibration between 240280 rpm, to reduce the vibration at the slight loose of torque rest these parameters: Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2040” → Enter → input “3011” →Enter→ input “4050” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1011” →Enter → input “2050” → Enter → input “3014” →Enter→ input “4050” →Display “OVER” →Enter Go into Program “U” (Password:0253) → Enter → input “1014” →Enter → input “2050” → Enter → input “3050” →Enter→ input “4225” →Display “OVER” →Enter 2. Go into Program “nS” (Password:0253) → Enter → input “2” → Enter 3. Go into Program “Sr” (Password:0253) → Enter → input “1.4” → Enter Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 75 FEMTO 1100 Polishing Head -------------------------------------------------- ▲ INSTRUCTION MANUAL 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 NANO 1000T/2000T and 1200T with 1 rpm increments (1 and 1.5 hp motor) Programming Step Value Description SP1 SPEED Disc Speed - VARIABLE T1 TIME Runtime for SP1 SP2 to SP8 200 Multiple step disk speed - DO NOT CHANGE T2 to T8 0 Runtime for multiple steps - DO NOT CHANGE Cn 1 Number of cycles – DO NOT CHANGE SL 100 Disc speed for SPL - preset to 100 rpm SN 200 Disc speed for SPM - preset to 200 rpm SH 300 Disc speed for SPH - preset to 300 rpm DF Defaults—DO NOT CHANGE U SET 110/220V—DO NOT CHANGE ST 65 CT Shutoff motor temperature - DO NOT CHANGE Current motor temperature - DO NOT CHANGE CD1 0 Controlled by RUN/STOP button - DO NOT CHANGE 0: Front board control 1: External control of board CD2 10 Display speed - DO NOT CHANGE 10: Displays speed (rpm) 11: Displays frequency (Hz) CD3 Motor control method – DO NOT CHANGE CD4 1000 Max. speed (rpm) CD5 100 Min. speed (rpm) (do not go below 100 rpm) CD6 15 Carrier wave value – DO NOT CHANGE Please read this instruction manual carefully and follow all installation, operating and safety guidelines. 76