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ISO 9001 Registered Company
ISOMET 2000 Precision Saw
MA112480-20 03/06/00
Declaration of Conformity
Manufacturer: BUEHLER, Ltd.
Of: 41 Waukegan Road
Lake Bluff, Illinois 60044
Declares the following product: ISOMET 2000
To be in accordance with EC Directive(s);
Safety of Machinery: EMC Directive:
89/392/EEC and 91/368/EEC and 93/44/EEC
according to the following standards:
89/336/EEC and 92/231/EEC according to the
following standards:
EN 292 PART 1 1991
EN 292 PART 2 1991
EN 60204 PART 1 1993
EN 50081-1: 1992
EN 50082-1: 1992
Position: Engineering Manager
Name: Chuck Motley
Signature: Chuck Motley Date: 11/28/95
This Manual is a custom generated document. It includes all revisions
relative to this specific Buehler item as of the date shown below.
MA112480-20 03/06/00
Table of Contents
Warranty ...................................................................................................................................... 2
Unpacking.................................................................................................................................... 2
Assembly ..................................................................................................................................... 2
Installation.................................................................................................................................... 2
Location .......................................................................................................................... 3
Electrical ......................................................................................................................... 3
Blade Installation ............................................................................................................ 3
Cooling and Lubrication.................................................................................................. 4
Operation ..................................................................................................................................... 5
Energizing the Unit ......................................................................................................... 5
Specimen Loading.......................................................................................................... 5
Positioning the Sample................................................................................................... 6
Setting the Load.............................................................................................................. 7
Checking and Adjusting Load......................................................................................... 8
Cutting the Specimen ..................................................................................................... 8
Blade Dressing ............................................................................................................... 10
Pre-Dressing................................................................................................................... 10
Dressing During the Cycle.............................................................................................. 10
Maintenance ................................................................................................................................ 11
General Specification: .................................................................................................... 11
Internal Coolant/Lubricant Recirculating System ........................................................... 11
Cleaning the Unit ............................................................................................................ 11
ISOMET™ 2000 Precision Saw Application Guide........................................................ 33
OPERATION AND MAINTENANCE INSTRUCTIONS
BUEHLER
ISOMET 2000 PRECISION SAW
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Figure 1 ISOMET™ 2000 Precision Saw
Warranty
This unit is guaranteed against defective material and workmanship for
a period of two (2) years from date of receipt by customer. Warranty is
void if inspection shows evidence of abuse, misuse or unauthorized
repair. Warranty covers only replacement of defective materials.
If for any reason, this unit must be returned to our plant for warranty
service, please apply for prior authorization with shipping instructions,
and include the following information: Customer Purchase Order
Number, Buehler Invoice Number, Date, Serial Number, and reason for
return.
Unpacking
Carefully unpack and check contents. If any components are missing
or damaged, save the packing list and material and advise the carrier
and BUEHLER of the discrepancy.
Assembly
The ISOMET™ 2000 Precision Saw is shipped fully assembled. A
Dressing Stick, three Specimen Chucks, two Flanges, one Diamond
Wafering Blade, one bottle of ISOCUT® Plus Cutting Fluid Concentrate,
and an accessory wrench are included. (Accessories available for use
with this unit.)
Installation
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Location
The ISOMET™ 2000 Precision Saw is intended for bench-top
placement. Select a location with convenient access to electrical and
water services.
Electrical
All units operate with a universal requirement range from 85-264V
50/60 Hz AC Input. Appropriate cord for country of use is supplied.
Blade Installation
Flanges support the Wafering and Abrasive Blades. Failure to provide
adequate flange support may result in curved cuts and damaged
blades. Always select the maximum flange diameter commensurate
with the size of the specimen to be cut. (See Accessories and
Supplies.)
1. Remove Thumb Screw and End Cap Bushing from Drive Shaft.
2. Install the Inner Flange on the Drive Shaft.
3. Install the blade against the inner Flange.
4. Slip on the Outer Flange and End Cap Bushing, then hand
tighten Thumb Screw to complete installation.
NOTE Before installation of a Wafering or Abrasive Blade, the End Cap
Bushing, Screw and Flanges should be cleaned in a mild detergent
solution to remove adherent particles from prior cutting. This will
prevent misalignment and damage to the Blade.
Figure 2 Blade Installation
Blade Dressing
New wafering blades, including the original equipment blade, must be
dressed before making sample cuts. Dressing removes the normal
smeared matrix metal and exposes the abrasive grain to assure free
cutting. New wafering blades should be dressed several times and
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older blades dressed as required based on the properties of the
sample material being cut. (See Maintenance: Blade Dressing.)
Cooling and Lubrication
Two different methods of applying coolant/lubricant are provided with
the ISOMET™ 2000 Saw. For most applications the self contained
recirculating system will provide adequate coolant flow. For optimum
cooling at extremely high cutting speeds with hard materials, the
ISOMET™ 2000 Saw can be connected to an external water supply
and drain. A water overflow protects the cutter in the event that the
drain becomes clogged or inadvertently closed. (See Accessories)
NOTE The unit's motor and recirculating system operate only when the cover
is closed. These machines have a water spray deflector built into the
hood, but if the cooling discharge water valve is opened too far, the
directional nozzles may force water between the hood and the top of
the cabinet. This water may well over the lip of the cabinet and run
down the sides of the machine.
Internal Coolant/Lubricant Recirculating System
When using the internal coolant system, fill the coolant tank with the
correct mixture of ISOCUT® PLUS Cutting Fluid Concentrate and
water. The fluid level should be approximately 5.0 cm (2″) deep or 4
liters.
ISOCUT® PLUS Cutting Fluid has been formulated for optimum cooling
and lubrication in medium and high speed cutting applications. It is a
water soluble concentrate which enhances the cooling properties of
water with effective lubrication and anti-corrosive properties.
ISOCUT® PLUS Cutting Fluid promotes clean cutting with diamond
blades or abrasive wheels for faster, superior quality cuts. A flow
control valve is provided at the base of the coolant tubes to prevent
excessive coolant from over-flowing at the hood, etc. (See Accessories
and Supplies for part numbers.)
Internal Pump
The Plumbing Assembly contained in this unit is only used with the
internal coolant/lubricant system. (See Figure 3). When external
coolant is used, the plumbing will be modified. Instructions are supplied
with the Accessory kit.
Check and change the cutting fluid as required.
NOTE When using abrasive cut-off wheels with the ISOMET™ 2000 Saw, the
coolant tank should be cleaned frequently, not exceeding the life of 3
wheels. (See Maintenance Section.)
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Figure 3 Internal Lubrication System
Operation
Energizing the Unit
1. Attach the blade and flanges as described in blade installation
section. Refer to Application Guide for proper blade selection.
2. Plug the unit into an appropriate power source.
NOTE Some types of GFI protection circuitry on the market are very sensitive
and may trip prematurely during machine start-up. If this happens, the
BUEHLER Service Department should be contacted to recommend a
solution.
3. Check the circuit breaker on the rear of the unit. It should be in
the (I) On position. Press the POWER ON Button. The green
LED control light should energize as well as all the LED
displays. The unit is now ready for specimen loading.
Specimen Loading
Several chucks are available to hold specimens of many different sizes
and shapes. (See Accessories and Supplies.) Select the proper chuck
for the particular application and attach to the support arm.
1. Open the hood and press the RAISE Button in the Arm section
on the Control Panel. See Figure 5. Raise the Support Arm all
the way up.
2. Attach the Chuck to the Support Arm with the Thumb Screw.
See Figure 4.
3. Clamp specimen into the Chuck.
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CAUTION Make sure the specimen is secured into chuck and the chuck to
the arm so that the specimen will not slip or rotate during cutting.
Improper clamping or chuck selection may cause blade damage.
Positioning the Sample
To position the specimen for cutting, the Position section of the Control
Panel in Figure 5 is used.
1. Press the RETRACT Button on the control panel until the
Support Arm and sample are clear of the Blade.
NOTE If the sample will not clear the blade, temporarily replace
the sample with a dummy of similar cross-section that can
clear the blade until after step 3 in this section.
2. Press LOWER Button on the control panel until the Support Arm
and sample are in the position shown in Figure 6A. If the
movement of the sample stops prior to reaching the position
shown, loosen the screw at the rear of the support arm and
adjust the arm as shown. Check to be sure there is enough
clearance so specimen can travel .25 (6 mm) past completion of
the cut to allow for overtravel during the automatic stop cycle.
FORCES APPLIED
NO EXTERNAL
Figure 6A Support Arm Adjustment
3. Raise the Support Arm to a level approximately 1 cm above the
blade.
CAUTION Do not allow the Specimen to contact the Blade while adjusting
the position of the arm. Blade damage may result. Also do not
apply any external force (pushing with fingers) to arm. This will
cause damage to the electronics.
4. Press the ADVANCE Button on the Control Panel moving the
Support Arm until the Specimen is even with the outer surface
of the blade. Press the ZERO DISPLAY Button on the Control
Panel, Figure 3. The MILLIMETER LED Display should now
read zero.
5. Adjust the Position until the desired cut specimen thickness is
measured on the MILLIMETER LED Display. The position has a
25.4mm range and is graduated in 0.005mm increments.
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NOTE The Support Arm can be raised/lowered and advanced/retracted with
the cover open or closed.
Figure 4 Specimen Chuck Adjustment
Setting the Load
To set the amount of force to be applied to the sample during the
cutting cycle, the Load section of the Control Panel is used. Refer to
Application Guide for proper load selection.
1. Preset the amount of load to be applied to the blade during the
cutting cycle. This is accomplished by pressing the LOAD
INCREASE or DECREASE Button until the desired load is
indicated on the Load LED Display.
NOTE The Display automatically sets to 100g when the unit is powered up.
The Load can be preset between 100g and 1000g in 10g increments.
NOTE The specimen must be loaded while the arm is in the raised position.
The ISOMET™ 2000 automatically tares the sample weight before a
cycle begins. The taring is done when the arm is in the raised position.
This features allows the saw to accurately apply the force displayed on
the front panel.
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Figure 5 Front Panel
Checking and Adjusting Load
During the cutting cycle, the ISOMET™ 2000 Saw will monitor the load
being applied to the blade. If an overload condition occurs, the system
will automatically decrease the load to maintain optimum cutting
conditions. A Bar Graph on the Control Panel indicates the % of set
load at which the unit is operating. Optimum cutting is attained when
the bar graph reads near or at 100% during the cycle.
To change the set load during operation, press the LOAD DECREASE
or INCREASE Button.
Cutting the Specimen
To cut the Specimen, the Load, Speed, Lubricant and Cycle portions on
the Control Panel are used.
1. Press the Lower Button on the Arm Section of the Panel until
the Specimen is approximately 1 cm above the Blade.
2. Close the cover.
WARNING The ISOMET™ 2000 Saw is designed to operate only with the cover
closed. This prevents manual feeding of sample materials or
dressing sticks into the rotating blade, which could result in
personal injury and/or blade damage. Efforts to defeat safety
interlock could result in personal injury.
3. Set the Blade speed by pressing the SPEED INCREASE or
DECREASE Buttons until the desired RPM is indicated on the
Speed LED Display. The speed can be set between 200 and 5000
RPM in 100 RPM increments. Refer to Application Guide on Page
29 for proper speed selection.
4. Press the LUBRICANT ON Button if the cooling/lubricant system is
being used.
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5. Press the CYCLE RUN Button. The Support Arm will begin to lower
and the Blade will rotate at the selected speed. The preset load will
not be applied for approximately 7 seconds. During this interval, the
sample will approach the blade and a 100g load will be applied in
order to establish a "kerf" cut. The unit will then apply the set load.
The ISOMET™ 2000 Saw is supplied with a 6″ dia. Wafering Blade
as standard equipment and the Support Arm is set at the factory to
accommodate this condition. In normal operation, the Arm auto-
matically advances the specimen into the Wafering Blade until the
cut is completed or until the lower position limit switch within the
cutter is activated, whichever comes first. If the specimen does not
contact the Wafering Blade within seven seconds, the Arm will
automatically return to the start position without cutting the sample.
This could occur if a much smaller Wafering Blade is used or if the
sample is very small and the Specimen Arm is not repositioned.
Figure 6 shows the factory set Arm position (when the arm is
raised to it’s maximum) relative to the various size Wafering
Blades that may be used with the ISOMET™ 2000 Saw. It is
easy to see that there is a considerable distance for the Support
Arm to travel before making contact with a four inch diameter
blade. The support arm should be lowered with the LOWER
button until the specimen is about 1 cm. from the blade before
starting the cut cycle.
If necessary to allow for a variety of operational conditions, the
Support Arm may be repositioned. This is accomplished by
loosening the Mounting Screw that secures the Support Arm to
the shaft. Be careful to prevent the Support Arm from striking
the Wafering Blade. Reposition the Support Arm as described in
Positioning The Sample section on page 6.
NOTE Do not move the specimen arm laterally along the shaft. The arm has
25.4 cm of stroke. Any loss in stroke by repositioning the arm may
result in the arm stalling against the cabinet resulting in loss of
micrometer accuracy.
Figure 6 Support Arm Adjustment
6. During operation, observe the Load Bar Graph. Due to
differences in sample thickness and density/consistency, or as
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the blade surface "loads up" when cutting soft materials, the %
set load may vary as the system adjusts for optimum load
conditions. (See Checking and Adjusting Load.)
NOTE If the bar graph does attain 100%, the removal rate may be too high for
the material being cut. (Example: thin wall tubing. The arm may retract
as if "end of cut". To correct for this type of material, the load or speed
should be reduced.
When the Support Arm reaches the end of the cut, it will return to its
upright position and the blade will stop.
NOTE If, at any time during the cutting mode, the operator lifts the cover or
presses the CYCLE STOP Button, the Support Arm will return to its
upright position and the blade will stop immediately.
7. At the end of operation, press the POWER OFF Button.
The ISOMET™ 2000 Saw will retain the last set of parameters
that were used even when the Power Off Button is pressed or if
the unit is disconnected from the power source.
Blade Dressing
Position the Dressing Stick in the Dressing Chuck shown in Figure 7.
Dressing should always be performed with coolant/lubricant.
WARNING The ISOMET™ 2000 Saw is designed to operate only with the
hood closed. Overriding this safety feature could result in serious
injury or equipment damage.
Pre-Dressing
To Pre-Dress the blade, close the hood and press the dressing
CHUCK RETRACT Button on the Control Panel. Hold this button until
the dressing chuck body retracts clear of the blade. Insert the dressing
stone in the clamp placing the edge of the stone approximately 1/16″
behind the blade. Secure the stone by tightening the thumbscrew.
Close the hood. Press the LUBRICANT ON Button to activate the
coolant. Press and hold the DRESSING CHUCK ADVANCE Button
until the stone begins to advance. As the stone advances toward the
blade the saw blade will automatically turn at 500 rpm for optimum
dressing. Continue advancing the stone until it touches the blade. Now
push the button intermittently advancing the stone slowly into the
blade. Press the DRESSING CHUCK RETRACT Button to return the
chuck back to the starting Pre-Dress position. Repeat as required.
NOTE To terminate the dressing cycle at any time simply stop pressing the
DRESSING CHUCK ADVANCE/RETRACT Buttons for a minimum of
three seconds.
NOTE When using 7″ diameter blades use supplied spacer (111198) to lock
dressing stick into vertical position.
Dressing During the Cycle
The blade can also be dressed during the Cycle-Run by simply
advancing the stone until it touches the blade and intermittently
advance the stone into the blade as required.
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Figure 7 Dressing Chuck and Blade Dressing
Maintenance
General Specification:
1. Sound level is 77dBA maximum.
Internal Coolant/Lubricant Recirculating System
When Coolant/Lubricant is contaminated with abrasive residue or swarf, it
should be discarded and replaced.
1. To drain coolant; turn off unit, lift the hood, remove the blade and
flanges.
NOTE Retract arm to the far left position.
2. DISCONNECT THE POWER CORDS FROM THE CABINET.
3. Remove the Dressing Chuck Bracket and Coolant Assembly, and
Screen.
4. Lift the Coolant Tank at the handle and pull so that the tank slides
horizontally.
5. Thoroughly clean the Coolant Pump, Specimen Screen, Dressing
Chuck and Coolant Tank.
6. Slide the Coolant Tank back into the cabinet.
7. Place the components back into the tank as shown in Figure 8.
Connect the power cords into the correct connectors.
Cleaning the Unit
The ISOMET™ 2000 Precision Saw should be cleaned periodically to
prevent build-up of cutting residue and cutting fluids. Exterior painted
surfaces including the cutting chamber may be cleaned with non-abrasive
household cleaners.
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The protective hood and touch pad control panel should be cleaned using
mild soap and water applied with a soft cloth.
Figure 8 Tank Removal and Cleaning
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Figure 9 Parts Diagram for ISOMET™ 2000 Precision Saw
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Figure 10 Parts Diagram for ISOMET™ 2000 Precision Saw
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Figure 11 Parts Diagram for ISOMET™ 2000 Precision Saw
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Figure 12 Parts Diagram for ISOMET™ 2000 Precision Saw
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Figure 13 Parts Diagram for ISOMET™ 2000 Precision Saw
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Figure 14 Parts Diagram for ISOMET™ 2000 Precision Saw
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