FEMTO 1100 Polishing Head - Metallographic products for

Transcription

FEMTO 1100 Polishing Head
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INSTRUCTION MANUAL
3601 E. 34th St. Tucson, AZ 85713 USA Tel. +1 520-882-6598 Fax +1 520-882-6599 email: [email protected]
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.
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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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.
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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
5
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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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.
8
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INSTRUCTION MANUAL
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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)
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).
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
4.5 MANUAL NANO-FEMTO Polishing Mode
polishing cloths.
the back.
panel to MANUAL
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.
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
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INSTRUCTION MANUAL
4.5 SEMI-AUTO NANO-FEMTO Polishing Mode
polishing cloths.
the back.
panel to AUTO
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.
system.
5. Press the START/STOP button on the NANO
controller to stop the polishing operation.
Preset
Speeds
Start/Stop
NANO
manually
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
25
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INSTRUCTION MANUAL
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
26
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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.
28
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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
30
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INSTRUCTION MANUAL
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
31
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INSTRUCTION MANUAL
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
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
32
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INSTRUCTION MANUAL
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
33
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INSTRUCTION MANUAL
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
CERMESH metal mesh cloth
Individual Head / Wheel
Force (lbs) speed
Time
60-75 lbs
200 rpm / 200 rpm
Until plane
TEXPAN polishing pad
SIAMAT
colloidal silica
75-100 lbs
200 rpm / 200 rpm
5 minutes
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)
34
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INSTRUCTION MANUAL
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
35
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INSTRUCTION MANUAL
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.
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INSTRUCTION MANUAL
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
36
37
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INSTRUCTION MANUAL
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
38
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INSTRUCTION MANUAL
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
39
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INSTRUCTION MANUAL
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.
40
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INSTRUCTION MANUAL
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
41
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INSTRUCTION MANUAL
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.
42
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INSTRUCTION MANUAL
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
43
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INSTRUCTION MANUAL
Part no.
Description
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
44
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INSTRUCTION MANUAL
Part no.
Description
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)
45
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INSTRUCTION MANUAL
Part no.
Description
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
46
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INSTRUCTION MANUAL
Part no.
Description
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
47
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INSTRUCTION MANUAL
Part no.
Description
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
48
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INSTRUCTION MANUAL
Part no.
Description
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
49
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INSTRUCTION MANUAL
Part no.
Description
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
50
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INSTRUCTION MANUAL
Part no.
Description
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)
51
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INSTRUCTION MANUAL
Part no.
Description
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
SR-40mm
SR-50mm
52
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INSTRUCTION MANUAL
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
53
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INSTRUCTION MANUAL
Part no.
Description
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
54
-------------------------------------------------- ▲
INSTRUCTION MANUAL
Part no.
Description
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
55
-------------------------------------------------- ▲
INSTRUCTION MANUAL
Part no.
Description
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
56
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INSTRUCTION MANUAL
Part no.
Description
Images
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
57
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INSTRUCTION MANUAL
Part no.
Description
Images
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
PTM-225-005
PTM-225-006
PTM-125-007
8 and 10-inch polisher cover
PTM-225-007
12 and 14-inch polisher cover
PTM-225-007H
Cover handle
58
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INSTRUCTION MANUAL
Part no.
Description
Images
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
59
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INSTRUCTION MANUAL
Part no.
Description
Images
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
60
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INSTRUCTION MANUAL
Part no.
Description
Images
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
61
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INSTRUCTION MANUAL
Part no.
Description
Images
N12-BP
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
62
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INSTRUCTION MANUAL
Part no.
Description
Images
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
63
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INSTRUCTION MANUAL
Part no.
Description
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)
64
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INSTRUCTION MANUAL
Part no.
Description
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
65
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INSTRUCTION MANUAL
9.0 Schematics (FEMTO mechanical)
66
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INSTRUCTION MANUAL
9.1 Schematics (FEMTO electrical)
67
-------------------------------------------------- ▲
INSTRUCTION MANUAL
9.2 Schematics (NANO case assembly)
68
-------------------------------------------------- ▲
INSTRUCTION MANUAL
9.2 Schematics (NANO case assembly)
69
-------------------------------------------------- ▲
INSTRUCTION MANUAL
9.2 Schematics (NANO internal mechanical assembly)
70
-------------------------------------------------- ▲
INSTRUCTION MANUAL
9.2 Schematics (NANO internal mechanical assembly)
71
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INSTRUCTION MANUAL
9.3 NANO Electrical Schematic
72
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INSTRUCTION MANUAL
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
2. Go into Program “nS” (Password:0253) → Enter → input “2” → Enter
3. Go into Program “Sr” (Password:0253) → Enter → input “1.4” → Enter
FOR 110V
FOR 220V
73
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INSTRUCTION MANUAL
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
74
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INSTRUCTION MANUAL
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
Go into Program “U” (Password:0253) → Enter → input “1001” →Enter → input “2042” → Enter
→ input “3050” →Enter→ input “4255” →Display “OVER” →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.
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:
75
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INSTRUCTION MANUAL
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
76

FEMTO 1100 Polishing Head - Metallographic products for

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