Metkon FORCIPOL Series Guía del administrador

metkon.com

OPERATION & INSTRUCTION MANUAL

MODULAR GRINDING AND POLISHING SYSTEM

EC Declaration of Conformity

Manufacturer : Metkon Instruments Inc.

Address : Demirtas Dumlupinar Organize Sanayi Bolgesi

Ali Osman Sonmez Cd. No: 14 Bursa / TURKEY

Model No : FORCIPOL 102/202

Herewith declares that;

Metallographic Grinding & Polishing Machine

is in conformity with the provisions of the Machinery Directive (directive 2006/42/EEC), as amended, and with national

implementing legislation;

is in conformity with the provisions of the Low Voltage Directive (directive 2014/35/EU), as amended, and with national

implementing legislation;

is in conformity with the provisions of the EMC Directive (directive 2014/30/EU), as amended, and with national

implementing legislation;

And furthermore declares that

the following (parts/clauses of) standards have been applied

EN ISO 12100:2010, TS EN 60204-1, TS EN IEC 61000-6-2, TS EN 61000-6-4

Authorized Person: ERCIN SENAY

Position: Manager of Research and Development Department

Year: 2019

Bursa / Turkey

3 
 
 
Index 
 
DESCRIPTION ............................................................................................................................ 6 
Design .....................................................................................................................................................................................6 
Technical Data ........................................................................................................................................................................7 
Warranty .................................................................................................................................................................................8 
Safety Precautions ..................................................................................................................................................................8 
INSTALLATION & SET UP........................................................................................................... 9 
Unpacking & Checking Contents of Package ...........................................................................................................................9 
Step by Step Unpacking...........................................................................................................................................................9 
Installation and Set-Up ...........................................................................................................................................................9 
Electrical Installation ........................................................................................................................................................................ 10 
Water & Cable Connections................................................................................................................................................................ 11 
Assembling FORCIMAT 52/102 Automatic Head.................................................................................................................................12 
Air Connection...................................................................................................................................................................................13 
Assembling Sample Holders.............................................................................................................................................................. 14 
Adjusting the Height of FORCIMAT 52/102 Head............................................................................................................................... 14 
Fixing and Releasing the Automatic Head ..........................................................................................................................................15 
LEVOMAT Specimen Loading Fixture................................................................................................................................................ 16 
DOSIMAT Peristaltic Fluid Dispenser..................................................................................................................................................17 
Installation of DOSIMAT 12/52/102 ....................................................................................................................................................17 
To Make DOSIMAT Ready for Operation............................................................................................................................................ 18 
Cleaning DOSIMAT Hoses...................................................................................................................................................................19 
Platen Installation..............................................................................................................................................................................19 
Using Different Diameter Discs ..........................................................................................................................................................19 
Optional Recirculating Cooling System (ENVIRO) ...............................................................................................................................19 
Noise Level ........................................................................................................................................................................................19 
CONTROL PANEL (FORCIPOL Control Unit)............................................................................. 20 
Control Button Functions ......................................................................................................................................................20 
CONTROL PANEL (FORCIMAT 52) ........................................................................................... 20 
Control Button Functions ......................................................................................................................................................20 
CONTROL PANEL (DOSIMAT 12)...............................................................................................21 
Control Button Functions ...................................................................................................................................................... 21 
CONTROL PANEL (DOSIMAT 52) ..............................................................................................21 
Control Button Functions ...................................................................................................................................................... 21 
CONTROL PANEL (DOSIMAT 102) ........................................................................................... 22 
TOUCH SCREEN CONTROL PANEL (FORCIMAT 102) ............................................................... 22 
Control Button Functions ......................................................................................................................................................22 
Password List........................................................................................................................................................................23 
Operation Parameter Ranges ................................................................................................................................................23 
OPERATION (FORCIPOL Control Unit)..................................................................................... 24 

4 
 
 
Setting Parameters ................................................................................................................. 24 
Setting Disc Speed ............................................................................................................................................................................ 24 
Setting Disc Turning Direction .......................................................................................................................................................... 24 
Setting Operation Time ..................................................................................................................................................................... 24 
Cooling Water ................................................................................................................................................................................... 24 
Cooling Water Activation Modes....................................................................................................................................................... 24 
Disc Cleaning and Drying Function ................................................................................................................................................... 24 
Changing Parameters of Disc Cleaning and Drying Function............................................................................................................. 24 
Start and Stop ................................................................................................................................................................................... 24 
OPERATION (FORCIMAT 52).................................................................................................... 25 
Setting Parameters ................................................................................................................. 25 
Setting Disc Speed ............................................................................................................................................................................ 25 
Setting Head Speed........................................................................................................................................................................... 25 
Opposite Rotation Direction.............................................................................................................................................................. 25 
Setting Operation Time ..................................................................................................................................................................... 25 
Cooling Water ................................................................................................................................................................................... 25 
Cooling Water Activation Modes....................................................................................................................................................... 25 
Disc Cleaning and Drying Function ................................................................................................................................................... 25 
Changing Parameters of Disc Cleaning and Drying Function............................................................................................................. 25 
Manual Operation............................................................................................................................................................................. 26 
Pistons Up/Down.............................................................................................................................................................................. 26 
Start and Stop ................................................................................................................................................................................... 26 
OPERATION (DOSIMAT 12) ...................................................................................................... 26 
Setting Parameters ................................................................................................................. 26 
Setting Dosing Period ....................................................................................................................................................................... 26 
Setting Dosing Time.......................................................................................................................................................................... 26 
Purge .......................................................................................................................................................................................... 26 
Retratch .......................................................................................................................................................................................... 26 
Turning off/on the DOSIMAT 12 ........................................................................................................................................................ 26 
OPERATION (DOSIMAT 52)...................................................................................................... 27 
Setting Parameters ................................................................................................................. 27 
Selecting / Deselecting the Bottles ................................................................................................................................................... 27 
Setting Dosing Period and Dosing Time............................................................................................................................................. 27 
Purge .......................................................................................................................................................................................... 27 
Retratch .......................................................................................................................................................................................... 27 
Turning off/on the DOSIMAT 52........................................................................................................................................................ 27 
OPERATION (FORCIMAT 102).................................................................................................. 28 
Mounting of Sample Holder.................................................................................................... 28 
Switch on the Equipment ....................................................................................................... 28 
Manual Operation .................................................................................................................................................................29 
Individual / Central Force Operation .....................................................................................................................................29 
Generating a New Program ................................................................................................................................................... 31 
Saving/Loading Program .......................................................................................................................................................32 

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Saving Program................................................................................................................................................................................. 32 
Loading Program .............................................................................................................................................................................. 32 
SERVICE AND MAINTENANCE ................................................................................................. 33 
Maintenance .........................................................................................................................................................................33 
Daily Maintenance............................................................................................................................................................................ 33 
Weekly Maintenance ........................................................................................................................................................................ 33 
Monthly Maintenance....................................................................................................................................................................... 34 
Yearly Maintenance.......................................................................................................................................................................... 34 
Troubleshooting....................................................................................................................................................................35 
ACCESSORIES AND CONSUMABLES........................................................................................ 36 
Sample Holders and Accessories...........................................................................................................................................36 
Consumables.........................................................................................................................................................................39 
SiC Grinding Papers .......................................................................................................................................................................... 39 
MAGNETO Diamond Grinding Discs................................................................................................................................................... 43 
MAGNETO-S Silicon Carbide Grinding Discs...................................................................................................................................... 45 
Polishing Cloths................................................................................................................................................................................46 
Diamond Products ............................................................................................................................................................................48 
Alumina & Colloidal Silica Products...................................................................................................................................................49 
TECHNICAL DOCUMENTATION ............................................................................................... 50 
Pneumatic Wiring Diagram (FORCIMAT 52)...........................................................................................................................50 
Pneumatic Wiring Diagram (FORCIMAT 102).........................................................................................................................50 
Customer Service .................................................................................................................................................................. 51 
 
 

DESCRIPTION

Design

All materials testing laboratories in the industry, research or

educational field have a demand for sample preparation.

Whether your requirements call for individual components or

basic sample preparation, FORCIPOL family of instruments

will meet your needs. FORCIPOL Series of instruments are

available as Single wheel (FORCIPOL 102) and Dual wheel

(FORCIPOL 202) Units.

Both single and double wheel versions are suitable with

Ø200, Ø250 and Ø300 mm wheels. The working wheel is

clockwise and counterclockwise wheel rotation possibility.

The state of the art frequency converter allows smooth speed

variation (50-600 rpm) of the grinding wheel with soft start

and soft stop. This allows the setting of the optimum speed

for each individual preparation process. It is perfect choice for

laboratories preparing a wide range of different materials

from very small to very large.

FORCIPOL instruments are designed to modular configuration

for manual, semi-automatic and programmable automatic

equipment. When only manual preparation is required,

FORCIPOL Control Unit can be fitted on the FORCIPOL grinder

/ polisher. If automatic operation is required in the future, one

of the FORCIMAT automatic heads can be installed at any

time.

When the number of specimens to be prepared increases,

FORCIPOL instruments can be fitted with one of FORCIMAT

automatic heads (FORCIMAT 52 or FORCIMAT 102) for

automation. FORCIMAT automatic heads provide high rate

sample preparation and frees the operator from the grinding

and polishing procedures. FORCIMAT series of Automatic

Heads are available as two types:

FORCIMAT 52 and FORCIMAT 102

Technical Data

Model

Order No

FORCIPOL 102

36 21-200/250/300

FORCIPOL 202

36 22-200/250/300

Number of Wheels

Wheel Diameter

Ø200/250/300 mm

Base Motor Power

1 HP

Wheel Speed

50-600 RPM

Wheel Rotation Direction

CW/CCW

Dimensions, WxDxH, (cm)

45 x 74 x 34

87 x 74 x 34

Weight, kgs

Model

Order No

FORCIPOL Control Unit

30 11

FORCIMAT 52

30 12

FORCIMAT 102

30 14

Operation

Manual

Semi Automatic

Programmable

Automatic

Application of Force

Individual

Individual + Central

Control Panel

Touch Pad Controls

7" HMI Touch Screen

Program Memory

Last Parameters

Retained in Memory

Last Parameters

Retained in Memory

30 Programs

Head Motor Power

100 W

Sample Holder Rotation Direction

Sample Holder Speed

50-150 RPM

Individual Force

5-60 N

Central Force

30-500 N

Grinding Depth Measurement

Optional

(10 µm Accuracy)

Disc Cleaning & Drying Feature

Yes

Smart Water Saving Feature

Yes

Compatible Instruments

FORCIPOL 102/202

Compressed Air Requirement

6 Bars

Dimensions, WxDxH, (cm)

20 x 20x 39

(above FORCIPOL disc)

26 x 46 x 54

(above FORCIPOL disc)

26 x 46 x 54

(above FORCIPOL disc)

Weight, kgs

Model

Order No

DOSIMAT 12

40 06

DOSIMAT 52

40 07

DOSIMAT 102

40 08

Number of Pumps (Bottles)

Control Panel

Touch Pad Controls

Controllable from LCD

Screen of FORCIMAT 102

Program Memory

Last Parameters

Retained in Memory

Last Parameters

Retained in Memory

30 Programs

Pre-Dosing Function

Yes

Compatible Instruments

FORCIMAT 52/102

FORCIMAT 52

FORCIMAT 102

Dimensions, WxDxH, (cm)

14 x 21x 16

20 x 74 x 30

Weight, kgs

Warranty

The FORCIPOL Series of instruments are guaranteed against

defective material or workmanship defects for a period of 12

months from the date of receipt by the customer or latest 18

months after the shipping date. The warranty is not valid if

inspection shows evidence of misuse or unauthorized repair.

Warranty covers only replacement of defective materials. If

this unit need to be returned to our factory for service, please

contact your distributor for authorization and include the

following details: Serial Number of the unit, Invoice number

and date. Transport costs belong to the customer.

NOTE

The equipment is designed to be used with

METKON accessories and consumables. In case of

misuse of equipment, improper installation,

alteration, use of different source parts, improper

repair, METKON will accept NO responsibility for any

damages to the operator or the equipment. Disassembling of

any part should always be performed by a qualified

technician

Safety Precautions

Read the below instructions carefully before use.

Place the machine on a sturdy and safe platform.

The equipment must be installed in compliance with

local safety regulations.

Only use approved METKON accessories and

consumables to achieve maximum safety and lifetime.

Follow the instructions and safety regulations when

lifting and carrying the equipment.

Be sure that the water connections are assembled

properly without any water leakage.

Be sure that the water outlet hose is safely assembled to

the outlet connection.

Make sure that the grinding and polishing discs are

correctly assembled and the pins on the faceplate are

engaged with the grinding disc.

While grinding manually, be careful not to touch the

grinding disc and do not put your hand close to head.

Do not try to collect a specimen from the working area

while the disc is turning.

Disconnect the electrical connection before servicing the

equipment.

Do not put your hand under the sample holder while

moving the head up and down.

Follow the periodically maintenance.

NOTE

METKON Instruments Inc. can make any changes

without notice on the equipment, accessories,

consumables and miscellaneous products.

Consequently; visual or written information on

the instruction manuals, technical materials, catalogues,

website, product videos and other marketing materials may

show inconsistencies and may be different from the product.

INSTALLATION & SET UP

Unpacking & Checking Contents of Package

Carefully unpack and check contents of the package. If any

components are missing or damaged, save the packing list

and materials and advise your distributor and the carrier of

the discrepancy.

Carefully unpack and check that the following items have

been received:

Power Cable, 1.8 mt, 1 piece

Drain Hose, 1.5 mt, 1 piece

Water Inlet Hose, 1.5 mt, 1 piece

Pneumatic Fitting, 8 mm to ¼”, 1 piece

Brass adapter, ¼”to ½”, 1 piece

Hose Clamp, Ø22 to Ø36 mm, 1 piece

Air Hose, 1.5 mt, 1 piece (If FORCIMAT 52/102 is ordered)

Hex Key, 1.5 mt, 1 piece (If FORCIMAT 52/102 is ordered)

WARNING

Please consider the weight of equipment and

be sure that there are enough people (at least

2) or lifting equipment to lift safely for

transportation. It is recommended to wear

safety shoes during transportation.

ATTENTION

FORCIPOL 102/202 is bolted to a wood base for

protection during shipping. Remove the bolt

securing the unit to the wood base.

Step by Step Unpacking

Carefully remove the outer stretch wrap, cut the strips

and remove the cover.

Place the upper box on the ground.

Open that box and remove the consumables.

Open the other box and remove the equipment from the

box by holding wooden base at the bottom. Be careful

not to damage ABS cover when lifting. Please consider

weight of equipment when lifting it. Lift the equipment

by considering the center of gravity.

Equipment is fixed on the wooden base with bolts.

Carefully remove these bolts.

Carefully remove the protective bubble wrap. Be carefull

not to damage equipment while using a knife.

Installation and Set-Up

CAUTION

Follow approved procedures and take all

necessary preventive safety measures when

lifting and installing this equipment. Improper

lifting can result equipment damage.

FORCIPOL 102/202 is available as bench top.

FORCIPOL 102/202 should be placed on a sturdy and safe

platform. Please be sure that the platform is large enough

and can stand its weight.

In order to work with equipment comfortably, it is

recommended to leave at least 30 cm space from all side

of the equipment.

You can see the dimensions and weight of FORCIPOL

102/202 together with FORCIPOL Control Unit as below:

FORCIPOL 102 + FORCIPOL Control Unit

Dimensions

45 cm

74 cm

39 cm

Weight

Approx. 55 kgs

FORCIPOL 202 + FORCIPOL Control Unit

Dimensions

87 cm

74 cm

39 cm

Weight

Approx. 60 kgs

Electrical Installation

Before making electrical connections, check that the voltage

and frequency stated on the specification plate correspond to

the local voltage and frequency. Check that the values for

mono-phase voltage if it is compatible with the intended

electrical supply before installation.

ATTENTION

Connect the unit to the grounded mains

voltage.

WARNING

Electrical Shock Hazard. A qualified electrical

technician should perform all hard wiring and

electrical maintenance.

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