OPERATING and INSTRUCTIONS MANUAL

METACUT 350
MANUAL ABRASIVE CUTTER
 INDEX
A. DESCRIPTION
1. Design ........................................................................................................................ 4
2. Technical Data ............................................................................................................ 5
3. Warranty ................................................................................................................... 5

B. INSTALLATION and SET-UP

1. Unpacking & Checking Contents of Packing .............................................................. 6

1.1. Step by Step Unpacking ........................................................................................ 7
2. Installation and Set-Up .............................................................................................. 7
2.1. Electrical Installation ............................................................................................ 8
2.2. Cooling Unit ......................................................................................................... 8
2.3. Leveling the Position of the Equipment ................................................................ 9
2.4. Mounting Clamping Devices................................................................................. 11
2.5. Safety ................................................................................................................... 11
2.6. Cut-off Wheel Rotation Direction ......................................................................... 12

C. CONTROL PANEL

1. Control Button Functions ........................................................................................... 12

D. OPERATION

1. Mounting of Abrasive Wheel ..................................................................................... 13

2. Loading & Unloading Specimen ................................................................................. 13
3. Specimen Clamping and Positioning .......................................................................... 14
4. Cutting Operation ..................................................................................................... 15

3.1. Manual Chop Cutting ............................................................................................ 15

E. SERVICE AND MAINTANENCE

1. MAINTANENCE .......................................................................................................... 15

1.1 Daily Maintenance ............................................................................................... 16

1.2 Weekly Maintenance ........................................................................................... 16
1.3 Monthly Maintenance ......................................................................................... 17

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F. ACCESSORIES and CONSUMABLES

1. Clamping Devices and Accessories ............................................................................. 17

2. Consumables .............................................................................................................. 19

G. TECHNICAL DOCUMENTATION

1. Recommended Spare Part List ................................................................................... 20

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 A. DESCRIPTION
_______

1. Design

Specimen integrity begins with high quality cutting. Perfectly cut surfaces reduce the number of
subsequent preparation stages and shorten the total sample preparation time to the minimum.

METACUT 350 is a universal wet cut-off machine for cutting metallic, ceramic and mineral samples
up to a diameter of 120/140 mm solid stock. The side access port makes it possible to accomodate extra
long samples.

The electronic brake system which is included as a standard item brings the cutter to a full stop
just in seconds after it has been switched off.

Cutting power is provided by a 7.5 HP (5.5 KW) motor driving a 350/400 mm cutting wheel. Power
transmission from the motor shaft to the wheel shaft is via special belts. The motor and the power
transmission system is mounted on a steel frame. The bottom part of the instrument is a large heavy
duty alloy base casting on which the cutting mechanisms and the clamping systems are mounted. The
complete system is enclosed with a steel sheet protective hood with a large transparent window to
observe the cutting process. A moisture proof low voltage lamp provides optimum lighting.

METACUT 350 is delivered with an integrated base cabinet.

Fig.1 METACUT 350

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 2. Technical Data

METACUT 350
Cutting Capacity, ø (mm) 130
Cutting Capacity, # (mm) 75x240
Wheel Diameter, (mm) 350
Chop Cutting yes
Cutting Power, (HP) 5,5 - 7,9 kW

Wheel Speed, rpm 2200

T-Slot table dimension, mm (WxD) 406x360

T-Slot Dimensions 12
Stroke Z-axis -
Cooling Unit, (lt) 80
Model Type With cabinet
Lighting LED
Size, WxDxH, (cm) 115x90x152
Weight, (kgs) 410

3. Warranty

The METACUT 350 is guaranteed against defective material or workmanship 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. Should this unit need to be returned to our
factory for service 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: DISABLING SAFETY SWITCH ON THE METACUT 350 WILL VOID WARRANTY.

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B. INSTALLATION & SET UP
_______

1. 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:
 Nozzle, Ø12 mm. (2 Pcs.)
 Hose Clips
 Allen Key, 3 mm.
 Allen Key, 8mm
 Grease and Lubricating Pump
 Return Hose
 30 - 32 mm A/F wrench
 Segment Pack 13mm (10 pieces)
 Water Tank ( 80 lt.)
 Water Pump
 20 pcs. (2 Pack) Abrasive cut-off wheels with dia. Ø 350 mm.
 5 lt. of Metcool Cooling Fluid

WARNING! The METACUT 350 weighs 410 kgs and be sure that there are enough people to
safely lift the unit from the shipping carton. Follow the steps on 1.1 which the unpacking
procedure is described step by step with photos.

The METACUT 350 is shipped completely assembled. The dimensions of METACUT 350;

METACUT 350
Dimensions

W D H

115 cm 90 cm 152 cm

Weight approx 410 kgs.

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 1.1. Step by Step Unpacking

Carefully remove outer packing material. Refer to the packing documents for a list of items supplied.

Water Tank and transportation foot The METACUT 350 is bolted to wooden case for safety
are located inside the cabinet. transport. Disassamble the bolts as shown above

Position the transportation foot under the
cabinet and carefully carry with a fork lift.
To avoid cutting motor movement during
transportation the cutting shaft is attached
to the vise assemblies or directly to the T-
table with red stabilizer. Disassemble the
stabilizer before operating.

2. 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.

Locate the METACUT 350 with convenient access to a 3-phase power source. Be sure to allow a
minimum space of 30 cm at the rear of the machine.

ATTENTION! The safety switch is set to the “UNLOCK” position to lock the hood closed for
transportation. Should the motor not work after pressing the “START” button and the display
functions seem normal, set the safety switch to the “LOCK” position to allow the motor to run.

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 2.1. 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 three-phase voltage, is
compatible with the intended electrical supply before installation.

a. Connect the mains cable of the METACUT 350 to an appropriate electrical outlet. (Fig.2)
b. Check the safety interlock switch is in the correct position (refer to section2.5)
c. Raise the hood and remove the bolt and flange from the hub and disassemble the stabilizer
before operating.
d. Close the Hood. Turn the instrument on from the main switch which is on the right hand side of
the instrument.
e. See D.3. Cutting Operation for operation.
f. Press “START” and “STOP” buttons and observe from the window that the cutting wheel shaft
rotates clockwise when looked at from the left.
g. If the shaft rotation is incorrect, then see B.2.6. Cut-Off Wheel Rotation Direction.

The METACUT 350 requires a 3-phase electrical supply and Earth/Ground. A neutral (N) conductor is not
required.

WARNING! Electrical Shock Hazard. A qualified electrical technician should perform all hard
wiring and electrical maintenance.

 Disconnect the power supply before making any electrical adjustments.

 Make sure that the supply voltage and frequency is correct. Check the values from the machine
identification plate located at the rear of the machine

Voltage / Frequency Operational Power Range Fuse Rating

230 V, 50/60 Hz. 3 ph. 210 - 250 V 32 A

400 V, 50/60 Hz. 3 ph. 380 - 420 V 25 A

2.2. Cooling Unit

The recirculating cooling system is a standard part of the METACUT 350. The cutting surface is cooled
by two spray nozzles whose water jets hit both the cutting wheel and the specimen. This provides an
efficient cooling of the sample and prevents the overheating of the surface structure.

Coolant is lost during the cutting process because of evaporation or left in the cutting chamber or
components. To have the best cutting performance and corrosion protection, rechange the coolant in
a certain time period. ( max. 3 months)

1. Fit the thin hose between the outlet of the pump and the inlet of the METACUT 350 by using
hose clips. (Fig.2)

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2. Connect the return hose between the outlet of the METACUT 350 and the inlet hole of the lid.
(Fig.2)
3. Ensure that both hoses follow smoothly falling curves to prevent sediment
accumulating.(Fig.2)
4. Connect the pump motor with cable from the the METACUT 350 properly. The pump should
rotate in the direction indicated by the arrow.
5. Fill the tank with clean water until the water level comes to 5 cm below the top. Add METKON
Metcool soluble oil. Do not add excessive oil. Do not exceed 3 % oil in water otherwise the
color of the paint of the aluminum base might get faded.

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 2.3. Leveling the position of the equipment

Fig.3 Fig.4

 Put a spirit level on the T-slotted table in x-direction.(Fig.3)

 Check if the bulb is between the lines. If yes, it means the unit is balanced.(Fig.4)

Fig.5

 If the bulb is not between the lines; adjust the height by turning the bolts of the base
chocks.(Fig.5)

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 2.4. Mounting Clamping Devices

When assembling the rear jaw of a clamping device, make sure it is positioned perpendicular to the
cutting wheel (Fig.6). You can check it with a set square. Otherwise the cut side of the specimen will not
be square to the sample axis.

If you are using two clamping devices, the jaws at the both sides will need to be set to the same
alignment.

Fig.6

2.5. Safety

METACUT 350 machines conform to the highest standards of safety regulations. The cutting motor can
not be started unless the hood is closed. Opening the hood during cutting operation is not possible. The
hood can be opened by the operator only after the cutting motor had stopped. The electronic brake
system brings the cutting motor to a stand still in a few seconds.

The safety switch is delivered on UNLOCK position for safety transportation. If you START the
equipment in this situation all the functions (light, table movement, and pump) will work
except cutting motor. SET THE SAFETY SWITCH TO “LOCK” POSITION TO ALLOW MACHINE
OPERATION.

Fig.7 Safety Switch

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 2.6. Cut-Off Wheel Rotation Direction

The cutting wheel shaft has to rotate clockwise when looked at from left of the equipment. Do not
operate the equipment if the cut-off wheel is rotating in the wrong direction.

If the cut-off wheel rotates in the wrong direction follow the steps below.

 Disconnect all electrical power

 Interchange two of the phase supply leads in the plug.
 Reconnect the electrical power and recheck.

C. CONTROL PANEL
_______

Fig.8 METACUT 350 Control Panel

1. Control Button Functions

The Start button activates the cutting motor.

The Stop button deactivates the cutting motor.

Activate / Deactivate light Activate / Deactivate Pump

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 D. OPERATION
_______

1. Mounting of Abrasive Wheel

Place the wheel exchange unit on the wheel shaft from the left end and loosen the bolt with a wrench
by turning it clockwise. Remove the bolt and the flange. (Fig.6) Remove the abrasive wheel carefully.

Mount the new wheel onto the arbor by placing cardboard disc on either side of the wheel to prevent
damage. Then refit flange and bolt, tightening the bolt slightly with the wrench. Remove the wheel
exchange unit. (Fig.9)

For a final check, spin the wheel by hand to see if it has been installed correctly and confirm that the
wheel remains in a vertical alignment as it rotates.

Fig.9 Spindle locking and Mounting of Abrasive Wheel

IMPORTANT:
DO NOT LEAVE THE WHEEL EXCHANGE UNIT ON THE WHEEL SHAFT. INJURY OR DAMAGE
MAY HAPPEN IF MOTOR IS STARTED ACCIDENTALLY.

2. Loading & Unloading of Specimen

In order to load the specimen into the grinding chamber, the lid must be raised first. Be sure to use
both hands for safety reasons. Raise the lid until both plastic rollers rest on the notches on both sides of
the cabinet as shown in Fig.10. After the specimen is loaded and clamped, lower the lid carefully. Use
both hands as shown in Fig.11.
Be sure that the upper part of the Safety Switch (B.2.5.) on the lid has interlocked to the bottom part
after which you can start grinding operation.

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 Fig.10 Fig.11

3. Specimen Clamping and Positioning

It is very important to ensure that the object to be cut is fixed firmly in the clamping device. The
METACUT 350 is equipped with a left – hand cam activated quick acting clamping device and a right –
hand spring type clamping vise (or other optional vises) mounted on two T-slotted tables capable of
handling any kind of object to be cut.

It is possible to detach the complete device so that very large parts can be clamped directly on the T-slot
vice bed. It is also possible to replace the vices on the outer slots of the vice bed, if required.

Fig.12 Vise Assembly

1. Release the clamping lever and open the vices completely.

2. Place the sample and push clamping jaws against the sample rigidly.
3. Push clamping lever so that the sample is held firmly.

When clamping the object to be cut, it should be positioned so as to obtain equal support on both sides
of the cut.

DO NOT apply excessive force when pushing the clamping levers as this can damage the cams. Use

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moderate hand pressure.
 4. Cutting Operation

If there is any vibration or shattering during chop cutting;

1. Please check that you are using the correct wheel for the specimen type that you are
cutting.
2. If the sample is situated directly under the wheel, please move the sample a little bit to
the front (towards yourself).

4.1. MANUAL CHOP CUTTING

a. When clamping the object to be cut, it should be positioned so as to obtain equal support
on both sides of the cut.
b. Be sure that the sample is clamped and cannot move.
c. Turn the instrument on from the main switch which is on the right hand side of the
instrument. The white lamp on the front panel will be on.
d. Close the hood. Equipment will not operate unless the hood is completely closed.
e. Turn on Light and Pump
f. Press START Button.
g. Slowly feed the cutting wheel to the sample by cutting arm at the right side of the
equipment.

 Excessive force is not required when cutting and should not be applied. Motor over load
and circuit trip may occur.

h. Press the STOP button. The wheel break will be applied and the hood lock will release once
the wheel has completely stopped.
i. Turn off the Pump.
j. At the end of the cutting process, return the lever to its starting position and turn off the
machine

E. SERVICE and MAINTENANCE

_______

1. MAINTENANCE

Clean all swarf from the cutting area with a clamp cloth. The wash down hose can be utilized by
closing the valve at the back of the cutting wheel, and opening the valve of the wash down hose. The
pump is then started with the hood raised.

When the cutter is not in use for a long time, keep the hood raised so that the unit dries.

The quick clamping device should be greased with water-resistant automotive grease at intervals of two
to four weeks depending on usage. DO NOT USE grease containing graphite or molybdenum disulfide
which may harm the vice.
Whenever re-adjustment of the vices is necessary after long term use, use the adjustment screw
situated below the clamping shaft.

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The stainless sieve inside the cooling water tank must be cleaned every week depending on the amount
of specimens being cut.

Lubrication ; The T-slotted cutting table must be lubricated as follows.

1. The two shafts on which the table is sliding must be lubricated with thin oil weekly for smooth
operation.
2. The thread screw driving the table should be lubricated with thin oil weekly, through the nozzle at the
front of the table.

1.1. Daily Maintanence

 At the end of the working day, please clean the cutting chamber by using the cleaning hose (Fig.13). After
cleaning it is recommended to dry the clamping devices, T-slotted table and the cutting chamber.
 Leave the hood open when you are finished with cleaning.
 If the hand lever is too soft and / or there is vibration or chatter during cutting, than the rocker shaft
pillow block needs adjustment. Tighten the screw on the right hand pillow block as shown in Fig.14.

Fig.13 Fig.14

1.2. Weekly Maintenance

 Open the lid of the cooling water tank. Remove the filter out and clean it with water.(Fig.15 and Fig
16).
 If the cooling fluid level is low, please add fluid up to the top level of the separators.

Figure 15 Figure 16
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 1.3. Monthly Maintenance

 Check the clamping force of the clamping devices. When insufficient, readjust the clamping force, by using
the setscrew as shown in Fig.17

 The clamping vises need monthly lubrication with a, water-resistant automotive grease. (Never use grease
containing Molybdenum Disulphide or graphite, which can impair the clamping ability of the Vise.) (Fig.18)

 Remove the cooling fluid tank. Drain the cutting fluid completely, and clean out all the swarf and fine
particles. Prepare a new cutting fluid suspension, at a ratio of 97 % water + 3 % Metcool cutting fluid, and
fill to the top of the separators.

Fig.17 Fig.18

F. ACCESSORIES and CONSUMABLES

_______

1. Clamping Devices and Accessories

Many sample preparation applications require the sectioning of a specimen from a small or irregularly
shaped sample or component part. A small size or irregular shaped sample can create positioning and
clamping difficulties for the operator. To overcome these difficulties, METKON offers a number of
special clamping devices for use with our METACUT 350 abrasive cutters. METKON cut-off machines are
equipped with stainless T - slot clamping tables. All clamping devices are made of stainless steel and can
be attached to the cutters T - slot beds in seconds, for fast and positive clamping of parts having virtually
any configuration. Please see below, the clamping devices and accessories table, as well as clamping
device drawings.

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 Clamping Devices for METACUT 400:
GR 0029 Vise Assembly, Right, MTC 350
GR 0030 Vise Assembly, Left, MTC 350
GR 0031 Prism Jaw Block Set for round specimens
GR 0032 Rubber coated jaw block set for sensitive specimens
GR 0154 Vise Assembly, Spring Loaded, MTC 350
MBU 1031 Quick clamping Device with clamping shoe, 115
15 02
mm.
15 04 MK 10 22 Height Block, 70 mm
YM 1058-00 Longitudinal V-Shoe
YM 1059-00 Traverse V-Shoe
GR 0150 Adjustable Mechanical Stop
GR 0033 Chain spanner set with anchor block
GR 1230-00 Angular cutting fixture for cutting upto 45 degrees angle
complete with its vise

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 2. Consumables

Abrasive cut-off wheels

The most commonly used abrasives for the cutting of different materials are SiC and Al2 O3. Silicon
carbide is suitable for non-ferrous metals, whereas Aluminum oxide is preferred for ferrous metals. Hard
wheels are used for cutting soft materials while soft wheels are recommended for cutting harder
materials.

CUT-OFF WHEELS (10 PER PACK.)

Treno Series Abrasive Cut-off Wheels

19-060 TRENO-NF Ø 350 mm, for Non-Ferrous Steels

19-062 TRENO-M Ø 350 mm, for Medium Hard Steels > 23-55 HRC <
19-063 TRENO-S Ø 350 mm, for Hard Steels > 50-60 HRC <

19-072 TRENO-M Ø 400 mm, for Medium Hard Steels > 23-55 HRC <
19-073 TRENO-S Ø 400 mm, for Hard Steels > 50-60 HRC <

Diamond Cutting Discs

Metal bonded wheels are used for cutting brittle materials, such as ceramics or minerals, while resin
bonded wheels are used for more ductile materials, such as sintered carbides or composites containing
predominantly hard phases. Several factors are important for choosing the appropriate wafering blade.
These include:
High & low concentration metal bond diamond wheels. Diamond size (fine or medium), blade diameter
and blade thickness. The diamond concentration is important because it directly affects the load which
is applied during cutting. For example, brittle materials such as ceramics require higher effective loads
to section, whereas ductile materials such as metals require more cutting points. The result is that low
concentration blades are recommended for sectioning hard brittle materials such as ceramics and high
concentration blades are recommended for ductile materials containing a large fraction of metal or
plastic.

ORDER NO DESCRIPTION
Diamond Cut-off Wheels (1pc) for METACUT 350
19-300 DIMOS ø 300 Diamond Cut-off wheels (Metal Bonded)
19-301 DIMOS ø 300 Diamond Cut-off wheels (Resin Bonded)
19-400 DIMOS ø 400 Diamond Cut-off wheels (Metal Bonded)
19-401 DIMOS ø 400 Diamond Cut-off wheels (Resin Bonded)

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G. TECHNICAL DOCUMENTATION

1. Recommended Spare Part List

Order Code Description

YM 0112-01 MOTOR CONTACTOR SWITCH
YM 0114-00 SWITCH XB5-AD21
YM 0115-00 EMERGENCY STOP XB4-BS8445
YM 0120-02 TRANSFORMER, CONTROL, CUTTING
YM 0134-00 Button XB7-EA35, Green
YM 0434-00 SAFETY SWITCH, XCSE7311
YM 0549-00 Key Switch, XCS Z03, Safety device
YM 0598-00 Switch 3LF0 111-5AC04 20A, Main
YM 0616-01 MOTOR PROTECTOR SWITCH, HMMS-32K / 14S
YM 2168-00 ATS-01N 112 FT SOFT STARTER
YM 2320-02 TRANSFORMER BRAKE
YM 2331-01 LABEL, METACUT 350 (300 MIC.)
YM 0008-00 MOTOR 112M2C 220/380/415/440V
YM 0251-00 Bearing 6205 2RSR
YM 0401-01 BEARING, NA4906
YM 0803-01 WHEEL SPINDLE, MTC 350
YM 0806-02 PULLEY, CUTTING WHEEL BELT, MTC 350
YM 0808-00 FLANGE, CUTTING WHEEL, INNER
YM 0809-01 FLANGE, CUTTING WHEEL, OUTER, MTC 350
YM 0811-02 PULLEY, MOTOR RC
YM 0842-01 Belt 610PJ17
YM 2185-02 BEARING COVER, MTC-350
YM 2358-00 LEVER, MTC M-350
YM 2371-00 Housing UCP 206
YM 0042-00 BUSHING, BRASS HOUSING MTC 250
YM 1236-01 LAMP 12V / 20W SRC 400 / MTC 350
YM 1045-00 Gas spring 10X19 1808 360-130 200N
YM 1906-00 Roller C106
YM 2568-00 CEILING LAMP, 12V 50W
YM 0257-00 Pump motor BP220 380V, Recirculation
YM 2378-00 GAS SPRING 1808-365-150 300N

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