Struers Discotom-100 User manual

Discotom-100
Instruction Manual
Original Instructions
Doc. no.: 16157025-03_A_en
Date of release: 2023.09.05

Copyright
The contents of this manual are the property of Struers ApS. Reproduction of any part of this manual without
the written permission of Struers ApS is not allowed.
All rights reserved. © Struers ApS.
2 Discotom-100

Table of Contents
1 About this manual 6
1.1 Accessories and consumables 6
2 Safety 6
2.1 Intended use 6
2.2 Discotom-100safety precautions 7
2.2.1 Read carefully before use 7
2.3 Safety messages 8
2.4 Safety messages in this manual 9
3 Get started 12
3.1 Device description 12
3.2 Overview 13
3.3 Dimensions 17
3.4 Control panel functions 19
4 Transport and storage 20
4.1 Storage 20
4.2 Transport 21
5 Installation 22
5.1 Unpack the machine 22
5.2 Check the packing list 22
5.3 Lift the machine 23
5.4 Location 25
5.5 Power supply 27
5.5.1 Connection to the machine 27
5.5.2 Power supply cable - recommended specifications 28
5.5.3 External short circuit protection 28
5.5.4 Residual Current Circuit Breaker (RCCB) 29
5.6 Recirculation cooling unit 29
5.7 Exhaust (optional) 30
5.8 Noise 31
5.9 Vibration 31
6 Operate the device 32
6.1 Change the cut-off wheel. 32
6.2 Clamp the workpiece 32
6.3 Position the cutting table 33
Discotom-100 3

6.4 Basic operation 33
6.4.1 Flushing gun 33
6.4.2 Cutting table 35
6.4.3 Display 35
6.4.4 Edit values 37
6.4.5 Software settings 38
6.4.6 Operation mode 42
6.4.7 Change the cutting mode and parameters 43
6.4.8 Stop modes 58
6.4.9 Motor load and temperature display 61
6.4.10 Start the cutting process 62
6.4.11 Stop the cutting process 64
6.5 Configuration 65
6.5.1 Options 65
6.5.2 User defined cut-off wheels 67
6.5.3 Reset functions 69
6.6 Optimize cutting results 69
7 Maintenance and service 70
7.1 General cleaning 71
7.1.1 Recirculation unit 71
7.1.2 AxioWash 72
7.2 Daily 73
7.2.1 The machine 73
7.2.2 Protective cover 74
7.2.3 Wheel guard 74
7.2.4 Safety lock 74
7.2.5 Clean the flushing gun nozzle 75
7.3 Weekly 75
7.3.1 The machine 75
7.3.2 Cutting chamber 75
7.3.3 Recirculation unit 75
7.4 Monthly 76
7.4.1 Cooling fluid 76
7.4.2 Lubricate the cutting table 76
7.4.3 Clamping devices 76
7.5 Annually 76
7.5.1 Test the safety devices 76
7.6 Cutting table 78
7.7 Cut-off wheels 78
4 Discotom-100

8 Spare parts 79
9 Safety Related Parts of the Control System (SRP/CS) 79
10 In-line filter 80
11 Service and repair 81
11.1 Service information 81
12 Disposal 82
13 Troubleshooting 83
13.1 Machine problems 83
13.2 Cutting problems 84
13.3 Error messages 86
14 Technical data 91
14.1 Technical data 91
14.2 Cutting capacity 93
14.3 Diagrams 94
14.4 Legal and regulatory information 97
15 Manufacturer 97
Declaration of Conformity 99
Discotom-100 5

1 About this manual
CAUTION
Struers equipment must only be used in connection with and as described in the
Instruction Manual supplied with the equipment.
Note
Read the Instruction Manual carefully before use.
Note
If you wish to view specific information in detail, see the online version of this manual.
1.1 Accessories and consumables
Accessories
For information about the available range, see the Discotom-100 brochure:
•The Struers Website (http://www.struers.com)
Consumables
The equipment is designed to be used only with Struers consumables specifically designed for this
purpose and this type of machine.
Other products may contain aggressive solvents, which dissolve e.g. rubber seals. The warranty may
not cover damaged machine parts (e.g. seals and tubes), where the damage can be directly related
to the use of consumables not supplied by Struers.
For information about the available range, see:
•The Struers Consumables Catalogue (via https://www.struers.com)
2 Safety
2.1 Intended use
For professional semi-automatic or manual wet abrasive cutting of metallic or other solid materials for
further material inspection and only to be operated by skilled/trained personnel. The machine is
intended only to be used with cooling fluids and cut-off wheels developed for this purpose and this
type of machine.
The machine is for use in a professional working environment (e.g. a materialographic laboratory).
6 Discotom-100
1 About this manual

Do not use the machine
for the following
Cutting of materials other than solid materials suitable for
materialographic studies. In particular, the machine must not be
used for cutting of any type of explosive and/or flammable
material, or materials which are not stable during machining,
heating or pressure.
The machine may not be used with cut-off wheels which are not
compatible with the machine requirements (e.g. saw-blade or
toothed cut-off wheels).
Model – Discotom-100 with fixed table
– Discotom-100 with automatic x-table
2.2 Discotom-100safety precautions
2.2.1 Read carefully before use
1. Ignoring this information and mishandling of the equipment can lead to severe bodily injuries
and material damage.
2. The machine must be installed in compliance with local safety regulations.
3. The machine must be placed on a safe and stable support table.
4. When lifting the machine using a forklift, lift from front or rear - never lift the machine from the
side.
5. When lifting the machine using lifting straps, ensure that the straps are crossed and do not
press on the sides of the machine.
6. The operator(s) must read the Safety and Operate the device sections of this manual and the
relevant sections of the manuals for any connected equipment and accessories. The
operator(s) must read the Instructions for Use and, where applicable, Safety Data Sheets for
the applied consumables.
7. For maximum safety and lifetime of the machine, use only original Struers consumables.
8. Use only intact cut-off wheels. The cut-off wheels must be approved for use with rotational
speeds between 1,500 and 3,000 rpm.
9. The machine is not for use with saw-blade type cut-off wheels.
10. Do not use the machine for cutting materials that are flammable or unstable during the
cutting process (e.g. combustible or explosive materials). Do not use the machine for cutting
materials that are not suitable for materialographic cutting.
11. Observe the current safety regulations for handling, mixing, filling, emptying and disposal of
the additive for cooling fluid.
12. Do not use flammable cooling fluid.
13. All safety functions and guards of the machine must be in working order.
14. Modifying or disabling the protective cover may cause serious hazard.
15. The workpiece must be securely fixed in a quick-clamping device or similar. Large or sharp
workpieces must be handled in a safe way.
2 Safety
Discotom-100 7

16. Use of working gloves is recommended as workpieces may be both very hot and produce sharp
edges. Wearing of gloves is also recommended when flushing and cleaning the machine.
17. Use of safety shoes is recommended when handling large or heavy workpieces or moving the
machine.
18. Use of safety goggles is recommended when using the flushing hose.
19. Cooling fluid may become hot.
20. Do not work on or around cutting table when the table is repositioned using the positioning
joystick.
21. The cutting arm should be lowered slowly and carefully, in order to avoid breaking the cut-off
wheel.
22. Laser radiation. Do not stare into beam or expose users of telescopic optics. Class 2M laser
product.
23. Struers recommends the use of an exhaust system as the materials being cut may emit harmful
gasses or dust.
24. The machine emits only moderate noise. However, the cutting process itself may emit noise,
depending on the nature of the workpiece. Use hearing protection if exposure to noise exceeds
levels set by local regulations.
25. If any of the cutting-chamber cover springs are damaged {at the rear of machine), they must be
replaced before the machine is used again.
26. Standard components, like nuts, bolts, springs etc., must be of the same quality and properties
as those provided by Struers.
27. Always use a recirculation cooling unit. Observe the current safety regulations for handling,
mixing, filling, emptying and disposal of the cooling fluid with additives. Only use suitable cooling
fluids that are compatible with the materials and function of the cut-off machine. Use of gloves
and goggles is recommended.
28. In case of fire, alert bystanders, the fire brigade and cut power. Use a powder fire extinguisher.
Do not use water.
29. The machine must be disconnected from the electrical power supply before any service.
30. Prior to any service, disconnect the machine and wait for 10 minutes until the residual potential
on the inverter capacitors is discharged.
31. Do not restart the Discotom-100 or cycle the electrical power supply more than once every three
minutes. This may result in damage to the frequency inverter.
2.3 Safety messages
Struers uses the following signs to indicate potential hazards.
ELECTRICAL HAZARD
This sign indicates an electrical hazard which, if not avoided, will result in death or
serious injury.
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2 Safety

DANGER
This sign indicates a hazard with a high level of risk which, if not avoided, will
result in death or serious injury.
WARNING
This sign indicates a hazard with a medium level of risk which, if not avoided,
could result in death or serious injury.
CAUTION
This sign indicates a hazard with a low level of risk which, if not avoided, could
result in minor or moderate injury.
CRUSHING HAZARD
This sign indicates a crushing hazard which, if not avoided, could result in minor,
moderate or serious injury.
HEAT HAZARD
This sign indicates a heat hazard which, if not avoided, can result in minor,
moderate or serious injury.
Emergency stop
Emergency stop
General messages
Note
This sign indicates that there is a risk of damage to property, or a need to proceed
with special care.
Hint
This sign indicates that additional information and hints are available.
2.4 Safety messages in this manual
Specific safety precautions - residual risks
ELECTRICAL HAZARD
Switch off the electrical power supply before installing electrical equipment.
The machine must be earthed (grounded).
Make sure that the actual electrical power supply voltage corresponds to the
voltage stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.
2 Safety
Discotom-100 9

ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by a
qualified technician.
WARNING
The machine must not be used for any type of explosive and/or flammable material,
or materials which are not stable during machining, heating or pressure.
WARNING
To ensure its intended safety, the PETG screen must be replaced every 5 years. A
label on the screen indicates when it is due to be replaced.
Replacement of the screen is required to remain compliant with the safety
requirements in the European standard EN 16089.
WARNING
Replace the cover screen immediately if it has been weakened by collisions with
projectile objects or if there are visible signs of deterioration or damage.
WARNING
If any of the following checks fail, do not use the machine until problems are resolved.
WARNING
Do not use the machine with defective safety devices.
WARNING
Safety critical components must be replaced after a maximum lifetime of 20 years.
CAUTION
This machine must be operated and maintained only by skilled/trained personnel.
CAUTION
The equipment is designed to be used only with Struers consumables specifically
designed for this purpose and this type of machine.
CAUTION
The protective cover will minimize the risk of ejection but will not eliminate it
completely.
CAUTION
Laser radiation. Do not stare
into beam or expose users of
telescopic optics. Class 2M
laser product.
10 Discotom-100
2 Safety

CAUTION
Prolonged exposure to loud noises may cause permanent damage to a person’s
hearing.
Use hearing protection if the exposure to noise exceeds the levels set by local
regulations.
CAUTION
Risk of hand to arm vibration during manual cutting.
Prolonged exposure to vibration may cause discomfort, joint damage or even
neurological damage.
CAUTION
An inadequately clamped workpiece can be propelled and cause damage.
Make sure that the workpiece is securely fixed in a quick-clamping device or
similar.
CAUTION
Avoid skin contact with the cooling fluid additive.
CAUTION
Wear suitable gloves when handling cooling fluid.
CAUTION
Do not start flushing until the flushing gun points into the cutting chamber.
CAUTION
Only use the flushing gun for cleaning inside the cutting chamber.
CAUTION
Always wear protective gloves and safety goggles when you use the flushing gun.
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
General safety precautions
WARNING
Struers equipment must only be used in connection with and as described in the
Instruction Manual supplied with the equipment.
2 Safety
Discotom-100 11

WARNING
Switch off the machine, disconnect the electrical power cable and wait 5 minutes
before you dismantle the machine or install additional components.
WARNING
In case of fire, alert bystanders, the fire brigade and cut power. Use a powder fire
extinguisher. Do not use water.
3 Get started
3.1 Device description
Discotom-100 is a manual/automatic cut-off machine with a motorized Y-table and optional X-table.
The machine is designed for wet, abrasive cutting of all stable and non-explosive metals.
The machine must be connected to a suitable recirculation system, which supplies cooling fluid to the
workpiece and cut-off wheel during cutting.
The cutting process starts by securing the workpiece to the cutting table with clamping tools. The
operator selects the cutting parameters (e.g. cut-off wheel, RPM, feed and cutting length). The
protective cover locks when the operator starts the machine, and it remains locked for the duration of
the cutting. When the cut-off wheel stops, the lock releases and the workpiece and the specimen can
be removed.
Finally, the category B emergency stop cuts the power to the cut-off wheel. The protective cover can
be opened once the cut-off wheel comes to a standstill.
The machine can be connected to an external exhaust system to remove fumes from the cutting
process.
Note
In case of a power loss during a cutting process, use the special key to open the
power-to-open protective cover.
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3 Get started

3.2 Overview
Front view
ACutting handle
BEmergency stop
CControl panel
DTurn/push knob
EJoystick for table movement
FFlushing gun
GHold-to-run button
HCutting arm
IProtective cover
JSafety lock release
Emergency stop
The emergency stop button is located on the front of the machine.
– Push the red button to activate.
– Turn the red button clockwise to release.
3 Get started
Discotom-100 13

Note
The protective cover can only be opened when the machine is connected to power
and switched ON. If power is lost, follow these steps to deactivate the lock and open
the cover:
1. Insert the triangle key into the safety lock release.
2. Gently, turn the triangle key 180° clockwise to unlock.
3. Remember to reactivate the safety lock release before operating the machine.
Cutting chamber
ACut-off wheel guard
BCut-off wheel flanges
CSafety lock
DY-table
EX-table (optional)
Note
Do not use the emergency stop for operational stop of the machine during normal
operation.
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3 Get started

Note
Before releasing (disengaging) the emergency stop, investigate the reason for
activating the emergency stop and take any necessary corrective action.
Rear view
AAUX Out, 24 VDC, 0.5 A
BCooling unit connection
CService socket
DUSB port for software update
EPower supply cable connection
FMain switch
GExhaust outlet flange
HCooling fluid outlet flange
ICooling fluid inlet
JFlushing gun
Main switch
• Turn the main switch clockwise to switch on the power.
Note
The AUX output is turned on during the cutting process.
3 Get started
Discotom-100 15

Hold-to-run button
• To position the cutting table while the protective cover is open, press the hold-to-run button
while you operate the joystick.
16 Discotom-100
3 Get started

3.3 Dimensions
Side view
3 Get started
Discotom-100 17

Footprint
18 Discotom-100
3 Get started

3.4 Control panel functions
ADisplay
BF1-F4 Menu dependent
multifunction keys. See
the bottom line of the
individual screens.
CTurn/push
knob
Multifunction knob.
• Push the knob to
select a function.
• Turn the knob to
adjust settings.
• Push the knob to
store modified
settings.
DJoystick • Move up-or down to
position the Y-table.
• Move left or right to
position the X-table
(optional)
Flush Starts and stops the pump to flush the cutting
chamber.
AxioWash Starts the AxioWash function.
3 Get started
Discotom-100 19

Line laser Activates and deactivates the line laser for precise
placement of the workpiece.
Cutting arm lock Locks and unlocks the cutting arm.
Escape Moves one step backward in menus.
Start Starts the machine and the recirculation unit and/or
the band filter.
Stop Stops the machine and recirculation unit and/or band
filter.
4 Transport and storage
If, at any time after the installation, you have to move the unit or place it in storage, there is a number
of guidelines we recommend that you follow.
• Package the unit securely before transportation. Insufficient packaging could cause damage to
the unit and will void the warranty. Contact Struers Service.
• We recommend that you use the original packaging and fittings.
4.1 Storage
ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by a
qualified technician.
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
Note
We recommend that you keep all original packaging and fittings for future use.
20 Discotom-100
4 Transport and storage