Buehler ISOMET 2000 User manual

Brand: Buehler

Model: ISOMET 2000

Type: User manual

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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Buehler ISOMET 2000 User manual

Brand: Buehler

Model: ISOMET 2000

Type: User manual

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Buehler ISOMET 2000 User manual

Buehler ISOMET 2000 User manual

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