STORCH 573300 ProCut top Polystyrene Cutter User Manual

STORCH 573300 ProCut top Polystyrene Cutter

Scope of delivery

ProCut top insulating panel cutter with corner cutter, integrated transformer, bevel, 3 x spare wires pre-assembled, 1 x spare fuse, plastic case

Technical specifications

• Cutting length 105 cm
• Cutting depth at 90° 30 cm
• Cutting depth at 45° 21 cm
• Weight of device (without freestanding support) 17.5 kg
• Weight of device (with freestanding support) 21.2 kg
• Weight of device with case 34.8 kg
• Case dimensions L 148 cm x W 35 cm x H 63 cm
• Cutting mode Thermal
• Fuse 1 x 10 A
• Cable length 3 metres
• Power supply 230 V / 50 Hz
• Transformer IP 54, splash-proof
  All information is without guarantee! Subject to technical modifications and errors!

Organisation / Personnel

Operators

• Before starting to use the device the operator must have read and understood the operating manual.
• Only authorised and trained operators must have access to the device in order to operate it.
• The operating manual must be available to the operator at all times.
• The operator must not be under the influence of alcohol, drugs or medication.
• Children, performance-impaired persons, and pregnant women are not allowed to operate the device.

Preface

• Reading this instruction manual is the basis for operating the ProCut top foam board cutter.
• This device is a development of STORCH and is produced in Germany. The methods and procedures used for manu-facturing and monitoring purposes correspond to state of the art technology.
• The device possesses a voltage range which can pose an electrical hazard to humans and animals. It should only be unscrewed and / or disassembled by authorised personnel. Similarly, maintenance and repair work should only be con-ducted by electrical specialists and authorised service cen-tres. The buyer / user operates the device at their own risk and under their own responsibility.

Before starting to use the device this instruc-tion manual must be read carefully and in full. If there is anything you do not understand, con-tact us immediately. Do not operate the device if you are in any doubt. By starting to use the device, you confirm that you have read and understood the manual and assume the responsibility for its operation.

Area of application
This device is intended exclusively for cutting rigid polysty-rene foam (styrofoam).

Operation

• The device is to be operated by an instructed person who is familiar with the device. Use of suitable work clothing and protective gloves is recommended. (Also refer to the section entitled “Safety precautions”).
• If the device is going to be used indoors, it should only be operated in areas that are adequately ventilated.
• The device operates with low voltage and it should only be used with the connected special transformer.
• The device should only be operated with the original cut-ting wire (d = 0.7 mm). If work is going to be interrupted for more than 3 minutes, switch off the device.

Cleaning and maintenance

Before starting to use the device all nuts and bolts must be checked and re- tightened if nec-essary. Wire guide rollers and pullout elements are to be cleaned and checked with regard to their ease of movement. If it is heavily contaminated (incrustation), the cutting wire must be replaced.

Safety precautions

Protect the device from moisture. Outdoor operation in the rain is prohibited. Only use dry utensils when cleaning; do not use any cleaning agents that contain solvents.

• Fumes are generated during the cutting process. These fumes contain extremely small amounts of styrene that are far below the permitted limit values.

• The wire gets very hot. If it comes into contact with the skin, it will inevitably result in burns. Use of protective gloves is recommended.

• The wire is subjected to mechanical tension (spring force). If the hot wire ruptures, it can generate sparks. The use of protective goggles is therefore recommended.

• Never connect the device directly to the main power supply (230 V). Operation is only per-mitted with the transformer. If the connecting cable (or plug) is damaged, it must be replaced immediately. Repairs to electrical components should only be conducted by an electrician or a STORCH service centre!

• Only use special STORCH replacement cut-ting wire, art. no. 57 33 01 (d = 0.7 mm). The use of other wires can damage the device and the transformer and result in other subsequent damage.

• When connected to the power supply the trans-former generates heat, even when the device is switched off.
  Make sure that this heat can be emitted freely and that it does not affect any heat-sensitive objects, otherwise these could be turned into a potential source of danger.

• The device should only be used if it can be op-erated safely.

• When assembling to a framework the device must be additionally secured against falling. After installing the device at the place of de-ployment, make sure that it is stable.

• If an installed device is left unattended, it should be pro-tected against external influences.

• The operator of the device is responsible for making sure that any sources of danger and potential tripping hazards in the vicinity of the device are eliminated (e.g. excessively long tension belts, unsecured power cables, packaging, etc.).

Faults, troubleshooting

A regular and careful cleaning and maintenance schedule is required to ensure trouble-free operation.
The transformer must always be disconnected from the mains during troubleshooting measures. Remove the mains plug!

If the wire does not heat up, check the 230 V power sup-ply. Check or replace the two transformer fuses (art. no. 57 00 04). If this does not resolve the malfunction, contact the STORCH service department or one of the STORCH service cen-tres in your area. Do not attempt to repair the transformer yourself and do not replace it with a type not approved by STORCH.Other malfunctions that require the device to be repaired may only be performed by qualified STORCH personnel or one of the authorised STORCH Service Stations.

Guarantee, warranty, liability

We guarantee the flawless operation of the device under the condition that it is duly operated and maintained. The warranty expires 1 year after the date of purchase (billing date). It is restricted to material and manufacturing de- fects. Additional claims and replacement of wear and tear parts (e.g. cutting wire) are excluded.Any variations from the intended use will result in expira- tion of the warranty. The device must be deployed and operated in accordance with the conditions specified in this manual. We shall not assume any liability or warranty for damages resulting from non-compliance or improper handling.

Device description / ProCut top front view

Device description / ProCut top rear view

Device description – Setup / initial operation of ProCut top:
Transport position
The device is transported and delivered in a plastic case: Open the case and remove the device.

Do not use the cutting bow to lift the device (Pos. 13, Fig. 3) from the case. Fold out the carrying handle (Pos. 27, Fig. 3) and use it to lift the device. Set up the device in the same way as you remove it from the case, on the rubber feet located on the long side (Pos. 28, Fig. 3).

Device description – Setup / initial operation of ProCut top:
Base/Freestanding support

• Open the fastening clamp for the base (Pos. 24, Fig. 3) and separate this from the device. Set up the base as shown in Fig. 4 and lock the safety latch (30).
• Lift the ProCut top by the carrying handle (Pos. 27, fig. 3) and the base plate (Pos. 1, Fig. 1) and centre it with the mount for the base (Pos. 23, Abb. 5) on the support for the ProCut top (Pos. 29, Fig. 4).
• The transformer with cable reel (Pos. 26. Fig. 2) then leans against the support for the transformer with cable reel (Pos. 29a, Fig. 4).
• Then fasten the device on the support using the fastening clamp for the base (Pos. 24, Fig. 5). The is used in freestanding state in this position.
• If you want to use the device on scaffolding, there are 2 different positioning variants:
• Variant 1:
  Make sure the device is in a stable position to prevent it falling over. Open the safety latch (Pos. 30, Fig. 4) on the base/the freestanding support (Fig.

4. and fold in the base. Now place the on the scaffolding planks and lean it against the wall of the house with the lean-to buffers (Pos. 20, Fig. 2).

• Variant 2:
  The ProCut top can be suspended on the backrest of the scaffolding using the mount for the base/freestanding sup-port (Pos. 23, Fig. 5). Always secure the device with the fastening clamp for the base/freestanding support (Pos. 24, Fig. 5)!

• To fold up the cutting bow (Pos. 13, Fig. 1) undo the locking lever for the cutting bow (Pos. 36, Fig. 10) on the upper and lower sides of the cutting bow and swivel the cutting bow to the left up to the stop; then retighten both locking levers for the cutting bow. The cutting bow is now at a 90° angle to the base plate.
• Now release the fastening pin (Pos. 25, Fig. 2) on the left bearing rail (Pos. 15, Fig. 1), the locking screw for the bearing rail (Pos. 7a, Fig. 6) and the corner slider for the right bearing rail (Pos. 7, Fig. 6) for the right bearing rail (Pos. 8, Fig. 1) and fold this down so that both are extended horizontally at 90° to the left and right of the cutting wire.
• Now insert the mains plug into the socket (230 V). The device is now operational and can be activated via the On/Off switch (Pos. 12, Fig. 1) (press the rocker switch to the left = basic device operation; press the rocker switch to the right = corner cutting operation; press the rocker switch to the middle = off).
  Caution: The cutting wire heats up within just a few seconds. Touching the wire when switched on will inevitably cause burns. Wearing protective gloves is recommended.

ProCut top cutting variants:

Straight cut (horizontal and vertical)
Lay the insulating panel on the right bearing rail (Pos. 8, Fig. 1). If you are processing very thick panels, fold out the panel support (Pos. 6, Fig. 1). Pull out the cutting bow (Pos. 13, Fig. 1), slide the insulating panel to the left until you have the required dimension (read this off on the measuring scale of the bearing rails, Pos. 8 + 15, Fig. 1) and guide the cutting wire through the insulating panel. For repeat cuts fix the slider for repeat cuts (Pos. 16, Fig. 1) on the left bearing rail (Pos. 15, Fig. 1): The board can be laid vertically or horizontally on the bearing rail (Pos. 8, Fig. 1).

Mitre cut
Use the sliding bevel to measure the mitre angle (Fig. A) and transfer this to the horizontal insulating panel: mark between x and y (Fig. B).

Then fold out the mitre tool (Pos. 4, Fig. 1). Release the locking levers (Pos. 36, Fig. 10) – top and bottom – from the cutting bow (Pos. 13, Fig. 1). Stand the marked panel on the right bearing rail (Pos. 8, Fig. 1), swivel the cutting bow to the right until the angles of the cutting bow (13) and the mitre tool (4) line up with the mark on the insulating panel.
Lock the locking levers (Pos. 36, Fig. 10) at the top and bottom, slide the locking element for mitre cuts (Pos. 11, Fig. 10) up to the stop on the cutting bow and fasten in place. The mitre setting remains in effect for repeat cuts; cuts can be reproduced without requiring any further adjustment.

Bevel cut

Transfer the top and bottom dimensions of the roof pitch to the insulating panel:

Pull out the cutting bow and position the panel on the right bearing rail (Pos. 8, Fig. 1). Release the corner slider for the right bearing rail (Pos. 7, Fig. 6) and locking screw for the right bearing rail (Pos. 7a, Fig. 6). Lift the support (8) with the insulating panel until the wire of the cutting bow lines up with the mark on the insulating panel. Tighten the locking screw for the bearing rail (7a) and the corner slider for the right bearing rail (Pos. 7). The bevel setting stays set for repeat cuts.
If the angle to be set for the bevel cut is known, this can be preset by using the angle scale for bevel cuts (Pos. 17, Fig. 1).

Mitre/bevel cut
This cut is executed in the same way as a mitre cut and bevel cut. The panel can also be mitred when executing the bevel cut.

Section cut-out, rebate / double rebate cut
Pull out the cutting bow (Pos. 13, Fig. 1) to the desired depth and adjust the depth stop on the cutting bow (Pos. 14, Fig. 1) to the required dimension. Note: Subtract the dimension to be cut out from the panel thickness, and position the depth stop on the pivot point mark at the calcu-lated dimension. Lay the insulating panel on the right bearing rail (Pos. 8, Fig. 1) and guide the cutting bow (13) through the panel at the desired cutting point up to the depth stop. Slide the insulating panel to the side until you have the required width, then pull the cutting bow back out of the panel. If you will be making several depth cuts of the same width, use the fold-out slider for reproducible rip cutting (Pos. 16, Fig. 1).For a rebate cut adjust to the required depth, push the cutting bow (13) to the stop, lay the board on the bearing rails (8); then slide the board to the left to the mark, and pull the bow back out of the board. For a double rebate cut, repeat the action described above to create a 2nd rebate dimension.

Replacing the cutting wire on the ProCut top’s cutting bow:

Caution: Use only prefabricated cutting wires (Art. no. 57 33 01) from the device’s scope of supply. Before replacing the wire, switch off the device, disconnect the plug from the power supply, and let the wire cool down for a couple of minutes. Make sure that the wire runs in the groove on the guide pulley and the attachment pin.

Device description – Assembly / initial operation of the corner cutter:
The corner cutter (Pos. 2, Fig. 7) is mounted on the rear of the base plate (Pos. 1, Fig. 7) and remains in this position when not in use.
To commission the corner cutter, remove the fixing strap (Pos. 31, Fig. 7) and swivel the corner cutter in the direction of the arrow until it is parallel to the cutting bow.

Caution: Make sure that the guide slide on the corner cutter (Pos. 32, Fig. 7) is inserted into the opening provided for it on the guide rail (Pos. 5, Fig. 7)!
Then pull the corner cutter down slightly until it latches. The corner is now ready for use.

Commissioning and function corner cutter: working position
The corner cutter is switched on at the on/off switch (Pos. 12, Fig. 1) (rocker to the right). The corner cutter is used to make L-shaped cuts on openings in the facade (e.g., windows/doors), rafter cut-outs with mitres and cut-outs for polystyrene anchors. To allow this to happen, the cutting wire on the corner cutter is pushed into the desired position.

Cutting variants
L-shaped cut (window/door opening)

•  Measure the required cut-out on the object and transfer this to the insulating panel.
•  Push the corner slider for right bearing rail and corner cutter (Pos. 7, Fig. 6) to the height of the horizontal cut-out. The corner cutter cuts into the panel to precisely this depth.
• Lay the insulating panel on the bearing rail (8).
• Press the trigger to enable the corner cutter (Pos. 35, Fig. 9) and guide it downwards. Line up the insulating panel with the mark for the vertical cut precisely below the wire of the corner cutter, and cut into the panel with the wire until the corner cutter is stopped by the depth stop.
• The wire is horizontal while you are doing this.

Note:
If you need to fit a window bench in a window opening, you need to adjust for a slight drop in the horizontal cut. See the “Rafter cut-out” section for details.

• Then remove the insulating panel to the left using your left hand.
• Push the corner cutter upward without applying force un-til it lightly latches.

Rafter cut (with bevel)

•  First transfer the angle dimension for the roof angle with an insulating panel (see mitre cuts) to the cutting wire of the corner cutter.
• To do so place the pre-cut insulating panel (mitre cut) on the bearing rails and move the corner cutter up to the angle. To transfer the angle, use the mitre tool on the corner cutter (Pos. 3, Fig. 8). The taken can also be trans-ferred directly to the mitre tool on the corner cutter (Pos. 3, Fig. 8) using the sliding bevel.
• Then transfer the angle to the cutting wire: push the corner cutter back to the original posi-tion. Release the screw for the corner slider (Pos. 33, Fig. 8) and the wire tensioning slider (Pos. 34., Fig. 8), orient the wire diagonally so that it is parallel to the insulating panel and the mitre tool.
• Then tighten the screw for the corner slider (33) again.
• Tension the wire using the wire tensioning slider (34), then pull this up until the wire is sufficiently tensioned and lock the slider again.
• Measure the depth and width of the required rafter cut-out on the object and transfer this to the insulating panel.
• Lock the depth stop with the corner slider for the right bearing rail and the corner cutter (Pos. 7, Fig. 6).
• Press the trigger (35) to enable the corner cutter, then move the corner cutter downwards with its wire and position the insulating panel directly on the left mark for the rafter width where you want the wire to start cutting.
• Cut into the insulating panel with the corner cutter until it stops at the depth stop.
• Then remove the insulating panel to the left using your left hand.
• When you reach the right mark for the rafter width push the corner cutter upward without applying force until it latches.
• If you will be making several rafter cuts of the same width, use the fold-out slider for re-producible rip cutting (Pos. 16, Fig. 1).

Cut-outs (complete)

• Mark all the dimensions on the insulating panel.
• Position the insulating panel on the bearing rail (8).
• Guide the corner cutter (2) down to the point marked for cutting into the panel.
• Slide the insulating panel from left to right until you have reached the desired length for the cut-out.
• Push the corner cutter back up again until you have reached the desired height for the cut-out.
• Now slide the insulating panel from the right to the left until you have reached the desi-red length for the cut-out.
• Now guide the corner cutter back to the starting point.

Replacing the cutting wire on the corner cutter:

Caution: Use only prefabricated cutting wires (Art. no. 57 33 02) from the device’s scope of supply. Before replacing the wire, switch off the device, disconnect the plug from the power supply, and let the wire cool down for a couple of minutes.
Make sure that the wire runs in the groove on the guide pulley and the attachment pin.

Removal and storing in the transport case
Fold in the base and slot it into the recesses for the device mount (23) on the rear of the ProCut top. Fix the base in place with the fastening clamp – as shown.

Warranty

A legal warranty period of twelve months from the date of purchase/date of invoice applies to our tools for commercial customers.

Claims
If you wish to claim under our warranty or guarantee, please return the complete machine and your invoice to our logi-stics centre in Berka, postage paid, or send it to one of our authorised service centres. We request that you contact us beforehand by calling our free STORCH service hotline on 0800 7 86 72 47.

Warranty entitlement
Claims can only be accepted for material defects or manufacturing errors, and only assuming proper use of the appli-ance. Wear parts are not covered by warranty claims. All claims shall become void in the event of installation of third party components, improper handling and storage, as well as in the event of obvious disregard of the operating instruc-tions.

Performing repairs
All repairs must be conducted on our premises or by an authorised STORCH service centre.

Disposal

End-of-life devices must not be disposed of as domestic waste. Please take them to a suitable collection point or hand over the end-of-life device to your specialist dealer.

EC Declaration of Conformity

References

• STORCH Malerwerkzeuge & Profigeräte GmbH

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