Struers Discotom-5 User manual

Discotom-5
Instruction Manual
Manual No.: 15117001
Date of Release 01.06.2004

Discotom-5
Instruction Manual
Table of Contents Page
User’s Guide ..............................................................1
Reference Guide.......................................................14
Quick Reference Guide............................................26
A
lways state Serial No and Voltage/frequency if you have technical questions or when ordering spare parts.
You will find the Serial No. and Voltage on the type plate of the machine itself. We may also need the Date
and Article No of the manual. This information is found on the front cover.
The following restrictions should be observed, as violation of the restrictions may cause cancellation of
Struers legal obligations:
Instruction Manuals: Struers Instruction Manual may only be used in connection with Struers equipment
covered by the Instruction Manual.
Service Manuals: Struers Service Manual may only be used by a trained technician authorised by Struers.
The Service Manual may only be used in connection with Struers equipment covered by the Service Manual.
Struers assumes no responsibility for errors in the manual text/illustrations. The information in this manual is
subject to change without notice. The manual may mention accessories or parts not included in the present
version of the equipment.
The contents of this manual are the property of Struers. Reproduction of any part of this manual without the
written permission of Struers is not allowed.
A
ll rights reserved. © Struers 2004.
Struers A/S
Pederstrupvej 84
DK-2750 Ballerup
Denmark
Telephone [phone]
Fax [phone]

Discotom-5
Instruction Manual
Discotom-5
Safety Precaution Sheet
To be read carefully
before use
1. The operator(s) should be fully instructed in the use of the machine and
its cut-off wheels according to the Instruction Manual and the
instructions for the cut-off wheels.
2. The machine must be placed on a safe and stable support table. All
safety functions and guards of the machine must be in working order.
3. Use only intact cut-off wheels. The cut-off wheels must be approved for
min. 50 m/s.
4. Observe the current safety regulations for handling, mixing, filling,
emptying and disposal of the additive for cooling fluid.
5. The workpiece must be securely fixed in the quick-clamping device or
similar. Large or sharp workpieces must be handled in a safe way.
6. The cutting handle should be lowered slowly and carefully, in order to
avoid breaking the cut-off wheel.
7. Struers recommends the use of an exhaust system as the materials
being cut may emit harmful gasses or dust.
8. The rubber curtains on the left hand side make it possible to cut long
workpieces with a height of up to 80mm. Protruding workpieces up to
Ø25mm can be cut.
9. Do not put your hand through the rubber curtain during operation of the
machine.
The equipment is designed for use with consumables supplied by Struers. If subjected to misuse, improper
installation, alteration, neglect, accident or improper repair, Struers will accept no responsibility for
damage(s) to the user or the equipment.
Dismantling of any part of the equipment, during service or repair, should always be performed by a qualified
technician (electromechanical, electronic, mechanical, pneumatic, etc.)

Discotom-5
Instruction Manual
1
User’s Guide
Table of Contents Page
1. Getting Started
Checking the Contents .....................................................................2
Recirculation Cooling Unit...................................................... 2
Unpacking Discotom-5...................................................................... 2
Placing Discotom-5 ........................................................................... 2
Getting Acquainted with Discotom-5............................................... 3
Discotom-5 Rear View ............................................................. 4
Noise Level........................................................................................ 4
Power Supply .................................................................................... 4
Direction of the Cut-off Wheel ................................................ 4
Connecting the Recirculation Cooling Unit..................................... 5
2. Basic Operations
Using the Controls............................................................................ 6
Front Panel Controls of Discotom-5 ....................................... 6
Front Panel Controls ........................................................................ 7
Cooling Valve Positions.................................................................... 8
Cutting Position....................................................................... 8
Cleaning Positions................................................................... 8
Light Diode and Beep Signals.......................................................... 9
Fitting or Changing the Cut-off Wheel..........................................10
Clamping the Workpiece ................................................................ 10
Starting/Stopping the Cutting Process.......................................... 11
Automatic Cutting (AUTO mode)......................................... 11
Manual Cutting ..................................................................... 12
Combining Manual and Auto Operation ....................................... 13
Cleaning .......................................................................................... 13
Flushing the Cutting Chamber............................................. 13

Discotom-5
Instruction Manual
2
1. Getting Started
In the packing box you should find the following parts:
1 Fork spanner (24mm), for changing the cut-off wheel
1 Connector pipe for water outlet
1 Set of Instruction Manuals
1 Cooling water tank with lid
1 Recirculation pump
1 Recirculation sieve
1 Trolley
1 PVC hose ½", 2 m
1 Outlet hose, 2 m
2 Hose clamps
1 Large screw hose clamp
2 Disposable plastic inserts
Remove the screws underneath the pallet to free the Discotom-5.
Discotom-5 should be placed on a table that is able to carry a
weight of min. 125 kg.
Checking the Contents
Recirculation Cooling Unit
Unpacking Discotom-5
Placing Discotom-5

Discotom-5
Instruction Manual
3
Take a moment to familiarise yourself with the location and
names of the Discotom-5 components.
cMain power switch
dInstrument panel
eCut-off wheel locking handle
fCutting handle
gProtection guard, with window
hCutting table
iQuick clamping device and spring
clamp
jCooling valve
kFlush hose inlet
Getting Acquainted
with Discotom-5
,
c
e
(Right side view)

Discotom-5
Instruction Manual
4
cElectrical cable for power supply
dPower connection for recirculation pump
eReset button for recirculation pump
fWater inlet
gWater outlet
hOverflow drain
iExhaust hose
jCut-off wheel locking handle
kUpper back plate
Approx. 67 dB (A) measured at idle running, at a distance of
1.0 m/39.4” from the machine.
First check that the mains voltage corresponds to the voltage
stated on the type plate on the side of the machine.
Discotom-5 is factory mounted with an electric cable. Mount a
plug on the cable:
Black and brown = phase
Yellow/green = earth
Check that when the power is turned on, the cut-off wheel rotates
in the direction indicated by the moulded arrow in the guard of
Discotom-5. If the direction of rotation is incorrect, switch the two
phases.
Discotom-5 Rear View
Noise Level
Power Supply
Direction of the Cut-off Wheel

Discotom-5
Instruction Manual
5
Connect the Recirculation cooling unit as follows:
To connect the electric cable for the recirculation pump, remove
the upper back plate on Dscotom-5 and follow the instructions
on the wiring diagram found on the inside of the back plate.
Check that when the power is turned on, the pump rotates in
the direction indicated by an arrow on the top of the pump. If
not, re-check the connection of the electric cable.
Replace the back plate.
Clamp the inlet hose to the pump and attach the other end to
the water inlet on Discotom-5 f.
Attach the connector pipe to the water outlet g, mount the
large outlet hose and secure with the large hose clamp.
Place the tank on the trolley.
Place a disposable plastic insert in the tank and fold it over the
rim.
Fill the tank with water. The water level should be 8-10 cm
below the upper rim of the tank.
Add Struers Additive according to the instructions.
Fit the tank lid and sieve.
Roll the trolley into place and lead the outlet and overflow
drain hoses g& hinto the cooling water tank. Adjust the
lengths if necessary.
If the recirculation pump is overloaded or blocked, a thermal cut-
out will switch the pump off. This safety cut-out must be reset by
pushing the red button on the back of the Discotom-5 ebefore the
machine can be restarted.
Connecting the Recirculation
Cooling Unit
Reset Button
IMPORTANT
cToo high a level of coolant in the tank might damage the pump. To avoid
this, place the disposable insert so that the pre-punched hole is in front of
the overflow aperture in the tank.
dAlways maintain the correct concentration of Struers Additive in the
cooling water (percentage stated on the Additive container).
Remember to top up with Struers Additive each time you refill with water.

Discotom-5
Instruction Manual
6
2. Basic Operations
Control name Symbol
cMain power switch
dPower indicator light ...........................................Power
eStart key ............................................................s
fStop key .............................................................o
gAuto key .............................................................Auto
hAuto mode indicator light ....................................Auto
iForwards button..................................................v
jBackwards button ...............................................V
kFeed Speed potentiometer .................................
lFeed Speed Reduced indicator light...................
1Load bar .............................................................
2Emergency stop button.......................................
3Emergency stop/overload
indicator light ......................................................o
Using the Controls
Front Panel Controls
of Discotom-5
c

Discotom-5
Instruction Manual
7
Name Key Function Name Key Function
c
MAIN
SWITCH
The main power switch is
located on the right hand
side of Discotom-5. Turn
clockwise to switch on the
power.
i
FORWARDS v Moves cutting table forward.
d
POWER
INDICATOR
Power
Lights when main power is
switched on. j
BACKWARDS V Moves cutting table
backwards.
e
START s Starts the machine. The cut-
off wheel starts rotating and
the cooling water is turned
on.
k
FEED SPEED
Regulates the feed speed of
the cutting table. The speed
can be set from 0.1-2.5
mm/sec.
f
STOP o Stops the machine. The cut-
off wheel stops rotating and
the cooling water is turned
off.
l
FEED SPEED
REDUCED
Lights when the feed speed
has been set too high and is
reduced by the machine.
g
AUTO
Auto
Select or deselect automatic
cutting mode 1
LOAD BAR
Reflects the present motor load status.
h
AUTO
INDICATOR
Auto Lights when automatic
cutting mode selected. 2
EMERGENCY
STOP
Push the red button to stop.
Pull the red button to release.
3
EMERG. STOP
OVERLOAD o
Lights when emergency stop
has been pressed or the
cutting motor is overloaded.
Front Panel Controls

Discotom-5
Instruction Manual
8
In the back of the cutting chamber the flush hose, and a valve for
cooling and cleaning, are located.
During cutting the valve is placed in the vertical position to cool
the cut-off wheel. During cleaning the valve is turned clockwise to
regulate the water flow of the hose.
Cooling Valve Positions
Turn the knob counter-
clockwise to vertical
position to cool the cut-
off wheel.
Turn the knob to regulate
the flow while flushing
the cutting chamber.
Turn the knob clockwise
to vertical position for
flushing the cutting
chamber with maximum
flow.
Cutting Position
Cleaning Positions

Discotom-5
Instruction Manual
9
Discotom-5 is provided with various light diodes indicating the
status of the machine. Beep signals will sound if a key is pressed
when the function cannot be activated.
Status Indication Comments
Green POWER indicator on The main power switch has been
turned on.
White AUTO indicator on AUTO mode is active.
Beep signal You pressed AUTO, START s,
FORWARDS vor BACKWARDS V
while the motor was running.
You pressed START swhile the
protection guard was open.
You pressed START sfor cutting
while cooling valve isn’t in cutting
position.
Turn cooling valve to cutting position.
Red oindicator on The emergency stop has been
pressed.
Release the emergency stop to shut off
the oindicator.
Red oindicator on and 
beep signal
The emergency stop has been
pressed and you tried to press
another key.
Yellow FEED SPEED
REDUCED indicator on
In AUTO mode: the feed speed is
too high.
The machine automatically turns the feed
speed down.
An AUTO cut has finished. Feed
speed reduced.
Turn the feed speed down or press any
key.
Red oand yellow FEED
SPEED REDUCED indicators
on
Cutting in AUTO mode not possible
as the cutting table does not move.
Press any key to stop the indicators.
Material may be too hard for the cut-off
wheel chosen or cutting table may be
jammed. See Trouble Shooting section at
back of manual.
Red oindicator and 1 red
cell on LOAD BAR
Pump motor overloaded. Stop the machine. Push the red button on
the back of the machine to reset the
safety cut-out.
Red oindicator and 2 red
cells on LOAD BAR
Main motor overloaded. Process
halted.
The indicators will disappear when the
motor has cooled down.
Red oindicator, 2 red cells
on LOAD BAR and beep
signal
You tried to press a key before the motor
had cooled down.
Light Diode and Beep Signals

Discotom-5
Instruction Manual
10
Note: The spindle for Discotom-5 is left-hand threaded. If
Discotom-5 has been used for manual cutting, fasten the
cutting handle with the black handle at the right hand side of
the machine before changing the cut-off wheel.
Press and hold down the black locking knob on the right-hand
side of the cut-off wheel, turning the cut-off wheel until the
spindle lock clicks.
Remove the nut with a fork spanner. Remove the flange and
the old cut-off wheel.
Mount the new cut-off wheel.
Mount the flange and the nut. Tighten carefully and release
the locking knob.
Place the workpiece between the quick clamping device and the
spring clamp, and the back stop.
Push the clamps towards the workpiece and lock the quick-
clamping device with the locking handle.
Carefully close the protection guard.
Fitting or Changing the
Cut-off Wheel
IMPORTANT
Conventional cut-off wheels based on Al2O3/SiC abrasives should be placed
between two cardboard washers, to protect the cut-off wheel.
For maximum precision with diamond or CBN cut-off wheels, do not use
cardboard washers.
Clamping the Workpiece
IMPORTANT
The workpiece must be firmly held in the quick-clamping device.

Discotom-5
Instruction Manual
11
When the machine is used in AUTO mode the cut-off wheel is
stationary and the cutting table moves. In MANUAL mode the
cutting table is stationary and the operator moves the cut-off
wheel.
Clamp the workpiece.
Loosen the black handle situated on the right hand side of the
cutting chamber.
Lower the cut-off wheel by drawing the cutting handle
downwards until the cut-off wheel is positioned ready to cut
the workpiece. Fasten the black handle again.
Press vFORWARDS to position the cutting table and the
workpiece just in front of the cut-off wheel.
Close the protection guard.
Set the desired feed speed
Press the AUTO mode key to select AUTO mode.
Press START sto start the machine. The cut-off wheel starts
rotating and the cooling water is turned on. The cutting table
moves forward toward the cut-off wheel at the pre-set feed
speed.
If the machine has been stopped with the STOP okey, the
cutting table will stay in position. To return the cutting table to
its start position press BACKWARDS Vonce. Struers
recommends manually lifting the cut-off wheel away before the
cutting table is moved back. Please note that the protection
guard has to be closed in order to carry out this operation. If
the protection guard has been opened press and hold the
BACKWARDS key Vto move the cutting table to its start
position.
If the cutting table reaches the back of the cutting chamber
during the cutting process, the cut-off wheel automatically
stops and the cutting table returns to its start position.
Note: the cutting table can be positioned with FORWARDS vand
BACKWARDS V.
If the feed speed is set too high, the yellow FEED SPEED
REDUCED indicator ( ) above the feed speed control flashes
and the feed speed is automatically reduced by 10%. Discotom 5
can repeat this reduction up to 5 times.
Once the workpiece has been cut, the operator can reduce the feed
speed using the feed speed control until the overload indicator
stops flashing. Discotom-5 will then be able to cut another similar
workpiece without feed speed reduction.
Starting/Stopping
the Cutting Process
A
utomatic Cutting
(AUTO mode)
Reduced Feed Speed

Discotom-5
Instruction Manual
12
Clamp the workpiece.
Loosen the small black handle on the right side of the cutting
chamber. The cutting handle is now easily moved up and down.
Position the cutting table and the workpiece under the cut-off
wheel with the FORWARDS vand BACKWARDS Vkeys
Close the protection guard.
Make sure that AUTO MODE is de-selected.
Press START sto start the machine. The cut-off wheel starts
rotating and the cooling water is turned on.
Pull down the cutting handle and let the cut-off wheel work
itself into the workpiece. Increase the pressure and begin
cutting.
When the cut-off wheel has almost cut through the workpiece
reduce the pressure.
When the cut-off wheel has cut through the workpiece push the
cutting handle back to its top position.
Press the oSTOP key to stop the machine
Manual Cutting
Remember
When cutting manually, the motor load bar should be used to monitor the
force on the workpiece. Try to keep the motor load in the green or the
beginning of the yellow area.

Discotom-5
Instruction Manual
13
Manual and Automatic cutting mode may be used in combination.
You may start in manual mode and cut into the workpiece. If you
lock this position you can continue in automatic mode, and the
workpiece will move towards the cut-off wheel.
To ensure a longer lifetime for your Discotom-5, Struers strongly
recommends that you clean the cutting chamber with the flush
hose every day.
Press STOP oto stop the cut-off wheel and cooling water.
Open the protection guard and release the workpiece from the
quick-clamping devices.
Pull out the flush hose from the back of the cutting chamber
and point it towards the bottom of the cutting chamber.
Turn the cooling valve to cleaning position (see sketch at left)
and adjust the flow as needed.
Clean the cutting chamber thoroughly.
Note: Do not clean the protection guard with the flush hose;
use a damp cloth instead.
Turn the cooling valve to cooling position.
Leave the protection guard open to let the cutting chamber dry
completely.
Combining Manual and
Auto Operation
Cleaning
Flushing the Cutting Chamber
Cooling Valve
The cooling valve for cooling/cleaning
is located in the back of the cutting
chamber to the left.
Turn the knob
counter-
clockwise to
vertical position
to cool the cut-
off wheel.
Turn the knob
to regulate the
flow while
flushing the
cutting
chamber.
Turn the knob
clockwise to
vertical position
to flush the
cutting chamber
with maximum
flow.
AVOID RUST!
Leave the protection guard open to let the cutting chamber dry completely.

Discotom-5
Instruction Manual
14
Reference Guide
Table of Contents Page
1. Advanced Operations
Adjusting the Back Stop................................................................. 15
Clamping Irregular Workpieces..................................................... 15
Cutting Protruding Workpieces ..................................................... 15
Mounting an Adjustable Stop ........................................................ 15
Connection to an External Exhaust System ................................. 15
Mounting an Adjustable Cutting Table......................................... 16
Optimising the Cutting Results..................................................... 17
Explanation of Safety Factors........................................................ 17
2. Accessories................................................................................18
3. Consumables
Cut-off Wheels................................................................................. 19
Other Consumables ........................................................................ 19
4. Trouble-Shooting......................................................................20
5. Maintenance
Daily Service ................................................................................... 23
Weekly Service................................................................................ 23
Monthly service............................................................................... 23
Replacing the Cooling Water ................................................ 23
Checking the Recirculation Cooling Unit...................................... 24
Maintenance of Cutting Tables......................................................25
Maintenance of Cut-off Wheels...................................................... 25
Storing Bakelite Bonded Al2O3Cut-off Wheels ................... 25
Maintenance of Diamond and CBN Cut-off Wheels ............ 25
Maintenance of Clamping Devices................................................ 25
6. Technical Data ..........................................................................26

Discotom-5
Instruction Manual
15
1. Advanced Operations
Use a 13 mm spanner to loosen the back stop.
Place the workpiece. Adjust the back stop so that the centre of
the workpiece is under the centre of the cut-off wheel:
Tighten the back stop.
If you also need to adjust the clamping devices, loosen them
and position them parallel to the back stop. Tighten the
clamping devices.
Irregular workpieces without plane clamping surfaces must be
clamped using special clamping tools, as the workpieces must not
move during cutting. This could result in damage to the cut-off
wheel or to the workpiece itself. For this purpose a vertical
clamping device with one flat clamping shoe is available. (See
Accessories).
In the cutting chamber there is a hole in the right side allowing
protruding workpieces to be cut. The workpiece can have a dia. of
up to 25 mm (1”).
If you need to repeatedly cut samples of the same length, an
adjustable stop may be mounted. The adjustable stop is mounted
to the right of the cutting table and allows samples of up to 57
mm length to be cut. (See Accessories).
Struers recommends the use of an exhaust as workpieces may
emit harmful gasses or dust when cut.
On the back of Discotom-5 you will find a joint for a 50 mm dia.
exhaust hose.
Mount an exhaust hose from your local exhaust system onto the
joint.
Adjusting the Back Stop
Clamping Irregular Workpieces
Cutting Protruding Workpieces
Mounting an Adjustable Stop
Connection to an External
Exhaust System

Discotom-5
Instruction Manual
16
If you need to cut plane parallel sections, an adjustable table may
be mounted on top of the existing cutting table. The adjustable
table positions the workpiece at a right angle to the cut-off wheel
and is movable up to 60mm. (See Accessories).
Dismount the clamping tools, if mounted.
Move the cutting handle to the top position and the cutting
table to the back in order to create working space.
Move the centre part of the adjustable cutting table to the left
by turning the handle until the holes for the Allen screws are
visible.
Loosely mount two T-nuts underneath the adjustable cutting
table using Allen screws.
Slide the adjustable cutting table onto the cutting table:
-Position the adjustable cutting table on the left-hand side of
the cutting table with the spindle on the left.
-Open the hinged protection guard to let the spindle pass.
-The guide pins and T-nuts on the bottom of the adjustable
cutting table are slid into the third T-slot from the left; this
automatically aligns the adjustable cutting table.
Tighten the Allen screws for the T-nuts.
Mount clamping tools using the T-slots in the adjustable
cutting table.
Mounting an Adjustable
Cutting Table