Struers Discotom-10 Instruction Manual
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Struers Discotom-10 Instruction Manual

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Discotom-10
Instruction Manual
Original Instructions
Doc. no.: 16257025_A_en
Date of release: 2023.09.05

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Summary of Contents for Struers Discotom-10

  • Page 1 Discotom-10 Instruction Manual Original Instructions Doc. no.: 16257025_A_en Date of release: 2023.09.05...
  • Page 2 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. Discotom-10...

  • Page 3: Table Of Contents

    Table of Contents 1 About this manual 1.1 Accessories and consumables 2 Safety 2.1 Intended use 2.2 Discotom-10 safety precautions 2.2.1 Read carefully before use 2.3 Safety messages 2.4 Safety messages in this manual 3 Get started 3.1 Device description 3.2 Overview 3.3 Dimensions...
  • Page 4 7.2.5 Clean the flushing gun nozzle 7.3 Weekly 7.3.1 The machine 7.3.2 Cutting chamber 7.3.3 Recirculation unit 7.4 Monthly 7.4.1 Cooling fluid 7.4.2 Lubricate the cutting table 7.4.3 Clamping devices 7.5 Annually 7.5.1 Test the safety devices 7.6 Cutting table 7.7 Cut-off wheels Discotom-10...
  • Page 5 11 Service and repair 11.1 Service information 12 Disposal 13 Troubleshooting 13.1 Machine problems 13.2 Cutting problems 13.3 Error messages 14 Technical data 14.1 Technical data 14.2 Cutting capacity 14.3 Diagrams 14.4 Legal and regulatory information 15 Manufacturer Declaration of Conformity Discotom-10...

  • Page 6: About This Manual

    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.

  • Page 7: Discotom-10 Safety Precautions

    Instructions for Use and, where applicable, Safety Data Sheets for the applied consumables. For maximum safety and lifetime of the machine, use only original Struers consumables. 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.

  • Page 8: Safety Messages

    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.

  • Page 9: Safety Messages In This Manual

    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. ELECTRICAL HAZARD Disconnecting the unit from the electrical power supply must only be done by a qualified technician. Discotom-10...
  • Page 10 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.
  • Page 11 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. Discotom-10...

  • Page 12: Get Started

    Get started Device description Discotom-10 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.

  • Page 13: Overview

    Protective cover E Joystick for table movement J Safety 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. Discotom-10...
  • Page 14 Remember to reactivate the safety lock release before operating the machine. Cutting chamber A Cut-off wheel guard B Cut-off wheel flanges C Safety lock D Y-table E X-table (optional) Note Do not use the emergency stop for operational stop of the machine during normal operation. Discotom-10...
  • Page 15 D USB port for software update Cooling fluid inlet E Power supply cable connection J Flushing gun Main switch • Turn the main switch clockwise to switch on the power. Note The AUX output is turned on during the cutting process. Discotom-10...
  • Page 16 3   Get started 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. Discotom-10...

  • Page 17: Dimensions

    3   Get started Dimensions Side view Discotom-10...
  • Page 18 3   Get started Footprint Discotom-10...

  • Page 19: Control Panel Functions

    Push the knob to store modified settings. Joystick • 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. Discotom-10...

  • Page 20: Transport And Storage

    • 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.

  • Page 21: Transport

    Secure the cutting arm with the transportation support. Move the recirculation cooling unit. Place the lifting straps on the designated lifting points on the machine. Note The crane and the straps must be approved to at least twice the weight of the load. Discotom-10...

  • Page 22: Installation

    Optional accessories may be included in the packing box. The packing box contains the following items: Pcs. Description Discotom-10 Fork spanner for cut-off wheel: 24 mm Triangle key for safety lock release Connector pipe for water outlet Elbow pipe for water outlet...

  • Page 23: Lift The Machine

    Remember to re-activate the safety lock release before operating the machine. Weight Discotom-10 200 kg (441 lbs) Transportation support A transportation support is mounted to support the cutting arm during transport.
  • Page 24 Place the two straps under the machine. Place the straps outside the feet on the machine. Without lifting bar With lifting bar Struers recommends the use of a lifting bar to keep the straps apart below the lifting point. Lift the machine onto the table. Discotom-10...

  • Page 25: Location

    The machine must be placed on a safe and stable table with an adequate working height.The table must be able to carry at least the weight of the machine and the accessories. A workbench designed for Struers table top machines is available as an accessory. Discotom-10...
  • Page 26 Make sure that the work station has adequate lighting. Avoid direct glare (dazzling light sources within the operator's line of vision) and reflected glare (reflections of light sources). A minimum of 300 Lumen is recommended to illuminate the controls and other work areas. Discotom-10...

  • Page 27: Power Supply

    Incorrect voltage can damage the electrical circuit. 5.5.1 Connection to the machine Procedure Open the electrical connection box. Connect the power cable as described below: EU cable UL cable L1: Brown L1: Black L2: Black L2: Red Discotom-10...

  • Page 28: Power Supply Cable - Recommended Specifications

    3 x 460-480 V / 60 Hz 3x AWG16 + PE 3x AWG10 + Electrical data The other end of the cable can be fitted with an approved plug or hard-wired into the power supply according to the electrical specifications and local regulations. Discotom-10...

  • Page 29: External Short Circuit Protection

    Incorrect voltage can damage the electrical circuit. To ensure optimal cooling, you must fit the machine with a recirculation cooling unit. Minimum requirements Pump capacity 125 L/min (33 gal/min) at 1 bar Discotom-10...

  • Page 30: Exhaust (Optional)

    We recommend the use of an exhaust system, as workpieces can emit harmful gases when cut. The exhaust system will also reduce the level of water condensation on the sides of the cover. Minimum capacity:50 m /h (1766 ft /h). Discotom-10...

  • Page 31: Noise

    For information on the total vibration exposure to hand and arm, see this section: Technical data ►88. Manual cutting of workpieces causes vibrations. Take action to lower the vibration where possible; decrease the pressure on the handle or use a vibration-reducing glove. Discotom-10...

  • Page 32: Operate The Device

    Operate the device Change the cut-off wheel. Note The spindle of the Discotom-10 is a left-hand thread. Note To protect the cut-off wheel and flanges, you must place conventional cut-off wheels based on Al2O3 or SiC abrasives between two cardboard washers.

  • Page 33: Position The Cutting Table

    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. Remove the flushing gun from the holder. Point the gun into the flushing chamber. Discotom-10...
  • Page 34 Always place the flushing gun back in its holder when you have finished using it. Do not use the flushing gun to clean the safety guard as this can result in water We recommend that the flushing gun is operated at a pressure of max. 3 bar. Discotom-10...

  • Page 35: Cutting Table

    The display is primarily divided into 2 areas. The position of these areas and the information they contain are explained in the illustration below, which uses the Options menu as an example: Discotom-10...
  • Page 36 When you press a key, a short beep indicates that the command has been accepted, whereas a long beep indicates that the key cannot be activated at the moment. You can switch this sound on or off in Configuration, under Options. Discotom-10...

  • Page 37: Edit Values

    (Enter) will toggle between the 2 options. Turn the knob to increase or decrease the numeric value (or to toggle between the two options). Push the knob to accept the new value. If you press Esc, the changes are reversed to the original value. Discotom-10...

  • Page 38: Software Settings

    Press Esc to accept the option and return to the previous menu, or turn the knob to select and edit other options in the menu. 6.4.5 Software settings When switching the machine on for the first time, the Select language screen will appear. To change the language after this, see Change the language ►40). Discotom-10...
  • Page 39 Select Save & Exit. The Main menu now appears in the language you have chosen. When you start the machine, it will open the last screen that was used before it was switched off. To go to the Main menu, press Esc. Discotom-10...
  • Page 40 6   Operate the device Change the language Open the Configuration menu. Discotom-10...
  • Page 41 6   Operate the device Open the Options menu. Open the Language pop-up menu. Discotom-10...

  • Page 42: Operation Mode

    To change the operation mode: Go to the Options menu, under Configuration. Select Operation mode. Select Pass code. Use the F1 and F2 keys to select digits. Turn the knob to change the digits and push knob to enter the pass code. Discotom-10...

  • Page 43: Change The Cutting Mode And Parameters

    When a pass code is set, you have 5 attempts to enter the correct pass code, after which the machine will be locked. Re-start the machine using the main switch, then enter the correct pass code. 6.4.7 Change the cutting mode and parameters Cutting display The cutting display shows two types of information: Discotom-10...
  • Page 44 The bottom area of the display shows the motor information: – Load %: Motor load. – Temp %: Motor temperature. The values displayed are in relative (%) values. Change the cutting mode The Discotom-10 has two cutting modes: Automatic and Manual. Discotom-10...
  • Page 45 To adjust the values of these parameters: Use the knob to select a cutting parameter. Turn the knob to change the value of the parameter. Push the knob to store the new value. Cut-off wheel To select or change the cut-off wheel: Discotom-10...
  • Page 46 Select the cut-off wheel parameter. Select a wheel category. Select a cut-off wheel from the list. The selected cut-off wheel is now displayed, and the rotational speed of the wheel is inserted. Cutting mode To change the cutting mode: Discotom-10...
  • Page 47 6   Operate the device Select the cutting mode parameter. Push the knob to change the cutting mode. Discotom-10...
  • Page 48 Impact cutting can result in higher wheel wear, but will reduce the risk of overheating the workpiece that otherwise can take place with an inaccurate wheel / material combination. Feed speed To set the feed speed: Select the feed speed parameter. Discotom-10...
  • Page 49 6   Operate the device Use the knob to adjust and accept the settings. MultiCut (Optional) To select the MultiCut mode: Select the MultiCut parameter. Discotom-10...
  • Page 50 Mode 4 The thickness of the cuts are set by moving the joystick then pressing Enter to set the position of the cut MultiCut 1 With the MultiCut 1 mode, you can cut up to 10 samples of equal width. Discotom-10...
  • Page 51 With the MultiCut 2 mode, you can cut up to 10 samples of different widths. Parameters Sample width Sets the width of the samples that will be cut. No of samples Sets the number of samples that will be cut. Discotom-10...
  • Page 52 With the MultiCut 3 mode, you can cut up to 10 samples at different relative distances from the zero, or starting position. The distances are manually entered. To set up the distances: Select Mode3 in the Select MultiCut mode menu. Discotom-10...
  • Page 53 With the MultiCut 4 mode, you can cut at different relative distances from the zero, or starting position. Enter the distances by using the X-table to position the workpiece in front of the cut-off wheel, where you want to cut the sample, and then record this position. To set up the distances: Discotom-10...
  • Page 54 Repeat the steps to insert the cutting positions for all samples. Parameters Cutting position (Relative) This parameter sets the position of the cuts. The values show the relative distance to the zero position. Absolute X pos. Actual absolute position of the X-table Discotom-10...

  • Page 55: Stop Modes

    If the cursor is placed outside the cutting position box, F1 will clear all positions. Hint Press F2 to move the X-table until the sample is in the starter position. 6.4.8 Stop modes To select a stop mode: Select the stop mode parameter. Discotom-10...
  • Page 56 6   Operate the device Select the desired setting. The Discotom-10 has 3 stop modes: – Auto – Relative – Absolute Auto When Auto stop mode is selected, the machine automatically stops when the workpiece has been cut through. We recommend that you use this mode for normal cutting.
  • Page 57 The Y-table is set to stop in a position relative to where cutting starts. After entering the stop position (approximate sample size + wheel wear) the cutting process will stop as soon as the specified position has been reached. The positioning range (table travel) is 0-200 mm. Discotom-10...

  • Page 58: Motor Load And Temperature Display

    The Y-table is set to stop in a fixed position measured from the zero position, where the cutting table is at the very front of the cutting chamber. The positioning range is 0-200 mm. 6.4.9 Motor load and temperature display The motor load and temperature values displayed are relative percentage (%) values. Discotom-10...

  • Page 59: Start The Cutting Process

    Wear suitable gloves to protect fingers from abrasives and warm/sharp specimens. CAUTION Check that the protective cover is in full working condition prior to cutting. CAUTION Laser radiation. Do not stare into beam or expose users of telescopic optics. Class 2M laser product. Discotom-10...
  • Page 60 Press Start. The cut-off wheel starts rotating and the cooling water starts to flow. Pull the cutting handle down and let the cut-off wheel work itself into the workpiece. Increase the force and begin cutting. Reduce the force when the cut-off wheel has almost cut through the workpiece. Discotom-10...

  • Page 61: Stop The Cutting Process

    You can stop the cutting process at any time during the cutting process. Note The cut-off wheel may stop rotating if the speed is set to the lowest level. Do not use this function to stop the cutting process. Press Stop to stop the cut-off wheel. Discotom-10...

  • Page 62: Configuration

    6   Operate the device Configuration 6.5.1 Options Select Configuration in the Main menu. Open the Options menu. Discotom-10...
  • Page 63 The Feed and Stop values in the display panel can be set to be displayed in either mm (default) or inches. Time Set the time to get correct readings from the log files. Date Set the date to get correct readings from the log files. Discotom-10...

  • Page 64: User Defined Cut-Off Wheels

    In this case, you can specify an additional cutting distance to make sure that the workpiece is cut completely. The additional cutting distance can be specified between 0-25 mm. 6.5.2 User defined cut-off wheels To set up a new cut-off wheel: Select New in the User defined cut-off wheels menu. Discotom-10...
  • Page 65 6   Operate the device Insert a name for the cut-off wheel or press F4 to accept the suggestion (UCW: User defined cut-off wheels). Select the newly created cut-off wheel. Discotom-10...

  • Page 66: Reset Functions

    Use a softer cut-off wheel. burning of the specimen? How can I avoid uneven cuts? Reduce the feed speed. How can I avoid burrs? Use a softer cut-off wheel. Causes increased wheel wear. Secure the workpiece on both sides of the cut-off wheel. Discotom-10...

  • Page 67: Maintenance And Service

    The serial number and the voltage are stated on the type plate of the machine. General cleaning Note Do not use acetone, benzol or similar solvents. Note Accumulated dirt and swarf can restrict the movement and cause damage to the cutting table. Discotom-10...

  • Page 68: Recirculation Unit

    CAUTION Avoid skin contact with the cooling fluid additive. Note Clean the cutting chamber thoroughly if you are not going to use the machine for a longer period of time. Note Only use AxioWash for cleaning the cutting chamber. Discotom-10...

  • Page 69: Daily

    Daily 7.2.1 The machine Note Do not use acetone, benzol or similar solvents. Note Avoid spraying cooling fluid or water into the safety lock mechanism. Note Do not use a dry cloth as the surfaces are not scratch resistant. Discotom-10...
  • Page 70 Press the button on the rear of the nozzle and clean the cutting chamber thoroughly. Press Stop to stop flushing. Close the valve. Place the flushing gun in the holder. Note To avoid corrosion, leave the cover open to let the cutting chamber dry completely. Discotom-10...

  • Page 71: Protective Cover

    The flushing gun nozzle can collect swarf, inhibiting the flow of cooling fluid. When necessary: • Unscrew the nozzle head and rinse it under clean water. Weekly 7.3.1 The machine Clean the machine regularly to avoid damaging effects to the machine and the specimens from abrasive grains or metal particles. Discotom-10...

  • Page 72: Cutting Chamber

    • Clean painted surfaces, and the control panel with a soft damp cloth and common household detergents. For heavy duty cleaning, use Struers Cleaner. • Clean the cover with a soft damp cloth and a common household anti-static window cleaning agent.

  • Page 73: Clamping Devices

    7.5.1 Test the safety devices WARNING Do not use the machine with defective safety devices. Contact Struers Service. Note Testing should always be performed by a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.). The safety devices must be tested at least once a year.
  • Page 74 Press Start. If the machine starts the cutting process, press Stop and contact Struers Service. Test 3 Start a cutting process. Press Stop. If it is possible to open the cover while the cut-off wheel still rotates, contact Struers Service. Cover interlock •...

  • Page 75: Cutting Table

    If you have technical questions or when you order spare parts, state the serial number. The serial number is stated on the type plate of the unit. For further information, or to check the availability of spare parts, contact Struers Service. Contact information is available on Struers.com.

  • Page 76: Safety Related Parts Of The Control System (Srp/Cs)

    9   Safety Related Parts of the Control System (SRP/CS) Note Replacement of safety critical components must only be performed by a Struers engineer or a qualified technician (electromechanical, electronic, mechanical, pneumatic, etc.). Note Safety critical components must only be replaced by components with at least the same safety level.

  • Page 77: 10 In-Line Filter

    When the machine is started up, the display shows information about total operation time and the machines service information. After 1500 hours of operation time, the display will show a message reminding the user that a service check should be scheduled. Discotom-10...

  • Page 78: Service Information

    Maintenance menu. Various topics can be selected for information on the condition of the different components. Service information can also be used in cooperation with Struers Service for remote diagnostics of the equipment. This menu contains read-only information; machine settings cannot be changed or modified.

  • Page 79: 12 Disposal

    After the 1,500 hours operation time has been exceeded, the pop-up message will change to alert you that the recommended service interval has been exceeded. Contact Struers Service. 12 Disposal Equipment marked with a WEEE symbol contains electrical and electronic components and must not be disposed of as general waste.

  • Page 80: 13 Troubleshooting

    Filter tube needs to be Change the filter tube. In some often. changed. cases, the In-line filter will require more frequent cleaning. To make this process easier, it can be moved to the quick coupling on the Cooli pump. See In-line filter ►77. Discotom-10...

  • Page 81: Cutting Problems

    Forgotten pass code. Contact Struers Service. It is necessary to revert to the factory settings of the software to regain access to the machine. Note: Stored information and predefined processes will be lost.
  • Page 82 The cut-off wheel is too soft for the Select a harder cut-off wheel. does not cut task. through the Incorrect cut-off wheel. Select and adequate cut-off wheel. workpiece. The cut-off wheel is worn. Replace the cut-off wheel with a new cut-off wheel. Discotom-10...

  • Page 83: Error Messages

    The cutting force is too high. Reduce the force on the cut-off wheel. The bearings are worn. Contact Struers Service. The workpiece The cut-off wheel gets caught in the Support the workpiece and clamp it breaks when workpiece.
  • Page 84 Messages Cause Action Do not touch the joystick during power on. Restart the machine. If the error remains, contact Struers Service. Specify thicker cuts. Press Enter to delete all the methods. Note: This action cannot be reversed. Press Enter to...
  • Page 85 Messages Cause Action Cover lock Restart the handling software machine. error. If the error remains, contact Struers Service. Insufficient water Check the water pressure was level and the detected at filters. process start up. For some installations, the in-line filter will...
  • Page 86 Allow the cutting motor to cool. If the error remains after the next restart, contact Struers Service. The cutting motor Clear any draws too much obstruction away current in idle from the cut-off condition. wheel.
  • Page 87 If the error remains after the next restart, contact The cutting motor Struers Service. is overheated. MultiCut 4: the When you use cutting position set MultiCut 4, you has a lower x-...

  • Page 88: 14 Technical Data

    30 secs shown without without activating activating the the joystick in button, there is an either x- or y- error.Contact direction. Struers Service. Restart the machine. If the error remains, contact Struers Service. 14 Technical data 14.1 Technical data...
  • Page 89 Safety StandardsSafety CE-labeled according to EU standards directives REACH For information about REACH, contact your local Struers office. Operating environment Surrounding temperature 5 - 40 °C (41 - 104 °F) Humidity 35 - 85 % RH non-condensing Power supply 1...
  • Page 90 Power supply 6 Voltage/frequency 3 x 380-415 V (60 Hz) Power inlet 3L + (N) + PE Power S3 70% 3 kW (4 hp) Current, nominal load Current, max. 12 A Ampere rating of the largest 5.6 A motor or load Discotom-10...
  • Page 91 LpA = 79.5 dB(A) (measured pressure level at workstations value). Uncertainty K = 4 dB(A) Measurements made in accordance with EN ISO 11202 Vibration level Declared vibration emission Total vibration exposure to upper parts of the body does not exceed 2.5 m/s Discotom-10...

  • Page 92: Cutting Capacity

    – A new cut-off wheel. – The workpiece is laid directly on the cutting table, with overhang where appropriate. – Vertical clamping is used. Note The actual cutting capacity depends on the specimen material, cut-off wheel and clamping technique. Discotom-10...

  • Page 93: Diagrams

    If you wish to view specific information in detail, see the online version of this manual. Title Discotom-10 Block diagram 16253052 ►94 Water diagram 16151000 ►95 Circuit diagram See the diagram number on the type plate of the equipment, and contact Struers Service via Struers.com. Discotom-10...
  • Page 94 14   Technical data 16253052 Discotom-10...
  • Page 95 14   Technical data 16151000 Discotom-10...

  • Page 96: Legal And Regulatory Information

    Responsibility of the manufacturer The following restrictions should be observed, as violation of the restrictions may cause cancellation of Struers legal obligations. The manufacturer assumes no responsibility for errors in the text and/or illustrations in this manual. The information in this manual is subject to change without notice. The manual may mention accessories or parts not included in the supplied version of the equipment.

  • Page 97: Declaration Of Conformity

    Based on: 16157901 H Declaration of Conformity Manufacturer Struers ApS • Pederstrupvej 84 • DK-2750 Ballerup • Denmark Name Discotom-10 Model Function Cut-off machine Type Cat. no. 06256129, 06256130, 06256135, 06256136, 06256146, 06256147, 06256154, 06256229, 06256230, 06256235, 06256236, 06256246, 06256247, 06256254...
  • Page 98 Tõlked leiate aadressilt Katso käännökset osoitteesta Pour les traductions, voir Za prijevode idite na A fordítások itt érhetők el Per le traduzioni consultare www.struers.com/Library 翻 訳 については、 Vertimai patalpinti Tulkojumus skatīt Voor vertalingen zie For oversettelser se Aby znaleźć tłumaczenia, sprawdź...

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