Discotom-100
Instruction Manual
Original Instructions

Doc. no.: 16157025-04_A_en
Date of release: 2023.12.18

CopyrightThe 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
1.1 Accessories and consumables
2 Safety

666

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

21

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 machine27

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 Noise31

5.9 Vibration

31

6 Operate the device

32

Discotom-100

6.1 Change the cut-off wheel.

32

6.2 Clamp the workpiece

32

6.3 Position the cutting table333

6.4 Basic operation
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 parameters43

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 Daily73

7.2.1 The machine73

7.2.2 Protective cover74

7.2.3 Wheel guard

74

7.2.4 Safety lock74

7.2.5 Clean the flushing gun nozzle

75

7.3 Weekly

75

7.3.1 The machine75

7.3.2 Cutting chamber

75

7.3.3 Recirculation unit75

7.4 Monthly

76

7.4.1 Cooling fluid76

7.4.2 Lubricate the cutting table

76

7.4.3 Clamping devices

76

7.5 Annually
7.5.1 Test the safety devices

4

33

76
76

7.6 Cutting table78

7.7 Cut-off wheels

78

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
14.1 Technical data

91

14.2 Cutting capacity

93

14.3 Diagrams

94

14.4 Legal and regulatory information

97

15 Manufacturer
Declaration of Conformity

Discotom-100

91

97
99

5

1 About this manual

1

About this manual
CAUTION
Struers equipment must only be used in connection with and as described in theInstruction Manual supplied with the equipment.
Note
Read the Instruction Manual carefully before use.

Note
If you want 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 thispurpose 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 Website (http://www.struers.com).

2

Safety2.1

Intended use
For professional semi-automatic or manual wet abrasive cutting of metallic or other solid materials forfurther material inspection and only to be operated by skilled/trained personnel. The machine isintended only to be used with cooling fluids and cut-off wheels developed for this purpose and thistype of machine.
The machine is for use in a professional working environment (e.g. a materialographic laboratory).

6

Discotom-100

2 Safety
Do not use the machinefor the following

Cutting of materials other than solid materials suitable formaterialographic studies. In particular, the machine must not be
used for cutting of any type of explosive and/or flammablematerial, or materials which are not stable during machining,heating or pressure.
The machine may not be used with cut-off wheels which are notcompatible 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 notpress on the sides of the machine.

6.

The operator(s) must read the Safety and Operate the device sections of this manual and therelevant 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 forthe 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.

Discotom-100

7

2 Safety
16. Use of working gloves is recommended as workpieces may be both very hot and produce sharpedges. 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 themachine.
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 threeminutes. 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 orserious injury.

8

Discotom-100

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
NoteThis sign indicates that there is a risk of damage to property, or a need to proceedwith 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 thevoltage stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.

Discotom-100

92 Safety
ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by aqualified 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.
WARNINGTo 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 withprojectile 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 specificallydesigned for this purpose and this type of machine.
CAUTION
The protective cover will minimize the risk of ejection but will not eliminate itcompletely.
CAUTION
Laser radiation. Do not stare
into beam or expose users oftelescopic optics. Class 2M
laser product.

10

Discotom-100

2 Safety
CAUTION
Prolonged exposure to loud noises may cause permanent damage to a person’shearing.
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 evenneurological 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 orsimilar.
CAUTION
Avoid skin contact with the coolant additive.

CAUTION
Wear suitable gloves and safety goggles 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 theInstruction Manual supplied with the equipment.

Discotom-100

11

3 Get started
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 theworkpiece 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 canbe removed.
Finally, the category B emergency stop cuts the power to the cut-off wheel. The protective cover canbe 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.

12

Discotom-100

3 Get started

3.2

Overview
Front view

A Cutting handle

F Flushing gun

B Emergency stop

G Hold-to-run button

C Control panel

H Cutting arm

D Turn/push knob

I

E Joystick for table movement

J Safety lock release

Protective cover

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-100

13

3 Get started
Note
The protective cover can only be opened when the machine is connected to powerand 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

A Cut-off wheel guard

D Y-table

B Cut-off wheel flanges

E X-table (optional)

C Safety lock key
Note
Do not use the emergency stop for operational stop of the machine during normal
operation.
Note
Before releasing (disengaging) the emergency stop, investigate the reason for
activating the emergency stop and take any necessary corrective action.

14

Discotom-100

3 Get started

Rear view

A AUX Out, 24 VDC, 0.5 A

F Main switch

B Cooling unit connection

G Exhaust outlet flange

C Service socket

H Cooling fluid outlet flange

D USB port for software update

I

E Power supply cable connection

J Flushing gun

Cooling fluid inlet

Main switch•

Turn the main switch clockwise to switch on the power.
Note
The AUX output is turned on during the cutting process.

Discotom-100

15

3 Get started
Hold-to-run button•

16

To position the cutting table while the protective cover is open, press the hold-to-run button
while you operate the joystick.

Discotom-100

3 Get started

3.3

Dimensions
Side view

Discotom-100

17

3 Get started
Footprint

18

Discotom-100

3 Get started

3.4

Control panel functions
A

DisplayB

F1-F4

Menu dependent
multifunction keys. See
the bottom line of theindividual screens.

C

Turn/pushknob

Multifunction knob.

D

Discotom-100

Joystick•Push the knob toselect a function.

•

Turn the knob toadjust settings.

•

Push the knob tostore modified
settings.

•

Move up-or down toposition the Y-table.

•

Move left or right toposition the X-table(optional)

19

4 Transport and storage

4

Flush

Starts and stops the pump to flush the cutting chamber.

AxioWashStarts the AxioWash function.

Line laser

Activates and deactivates the line laser for precise
placement of the workpiece.

Cutting arm lock

Locks and unlocks the cutting arm.

EscapeMoves one step backward in menus.

Start

Starts the machine and the recirculation unit and/or theband filter.

Stop

Stops the machine and recirculation unit and/or band
filter.

Transport and storageIf, at any time after the installation, you have to move the unit or place it in storage, there is a numberof guidelines we recommend that you follow.

20

Discotom-100

4 Transport and storage

4.1•

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.

Storage
ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by aqualified 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.

4.2

1.

Disconnect the unit from the electrical power supply, the recirculation unit and the exhaustsystem.

2.

Remove any accessories.

3.

Clean and dry the unit before storage.

4.

Place the machine on the blocks on the pallet.

5.

Secure the machine using the transport brackets.

6.

Build the crate.

7.

Place the machine and accessories in their original packaging. To keep the machine dry,
plastic-wrap the machine and place a bag of desiccant (silica gel) with the machine.

Transport
ELECTRICAL HAZARD
Disconnecting the unit from the electrical power supply must only be done by aqualified 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.

To transport the machine safely, follow these instructions.

Discotom-100

21

5 Installation
Preparing for transport
1.

Disconnect the unit from the electrical power supply, the recirculation unit and the exhaustsystem disconnect

2.

Remove any accessories.

3.

Secure the cutting arm with the transportation support.

4.

Move the recirculation cooling unit.

5.

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.

5

Installation

5.1

Unpack the machine
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.

1.

Carefully open and remove the sides and the top of the packing crate.Remove the transport
brackets that secure the machine to the pallet.

2.

Remove the bolts from all the transport brackets that secure the machine to the transport pallet.

3.

Remove the brackets.

Transportation support
A transportation support is mounted to support the cutting arm during transport.
•

5.2

Remove the transportation support before moving the cutting table.

Check the packing list
Optional accessories may be included in the packing box.
The packing box contains the following items:

22

Discotom-100

5 Installation

5.3

Pcs.

Description

1

Discotom-100

1

Fork spanner for cut-off wheel: 24 mm

1

Triangle key for safety lock release1

Connector pipe for water outlet

1

Elbow pipe for water outlet

1

Outlet hose for connection to external cooling unit: 2 m

1

Filter tube connection kit

1

Hose clamp: 70-90 mm

1

Grease gun

1

Instruction Manual set

Lift the machine
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
Note
The straps must be approved for at least twice the weight of the machine.
The straps must be long enough so that they do not place stress on the cover ofthe machine.
Note
The machine's cover can only be opened when the machine is connected to a
power supply and the main power switch is on.
To open the cover when the power is not connected, insert the triangle key
through the access hole at the front to release the safety lock.
Remember to re-activate the safety lock release before operating the machine.
WeightDiscotom-100

204 kg (450 lbs)

Transportation support
A transportation support is mounted to support the cutting arm during transport.
•

Remove the transportation support before moving the cutting table.

Using a crane
You need a crane and two lifting straps to lift the machine off the shipment pallet.
Before lifting the machine into its final position, do as follows:

Discotom-100

23

5 Installation
1.

Remove the screws on the base of the packaging create and remove the top part of the crate.

2.

Remove the metal brackets securing the machine to the pallet using a Torx bit T30 key.

3.

Place the two straps under the machine.

4.

Place the straps outside the feet on the machine.

Without lifting bar

24

With lifting bar

5.

Struers recommends the use of a lifting bar to keep the straps apart below the lifting point.

6.

Lift the machine onto the table.

7.

Lift the front of the machine and carefully move into place using the rollers.

Discotom-100

5 Installation
Using a forklift
You can use a forklift to lift the machine off the pallet.
Before lifting the machine into its final position, do as follows:
1.

Remove the screws on the base of the packaging create and remove the top part of thecrate.

2.

Remove the metal brackets securing the machine to the pallet using a Torx bit T30 key.

3.

Lift the machine from the pallet using a forklift truck.

4.

Position the forks so that the center of mass is between the forks.

5.

Lift the machine onto the table.

6.

Lift the front of the machine and carefully move into place using the rollers.
Note
We recommend that you keep all original packaging and fittings for future use.

5.4

Location
CRUSHING HAZARD
Take care of your fingers when handling the machine.
Wear safety shoes when handling heavy machinery.
Make sure that the following facilities are available:–

Power supply

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 workbenchdesigned for Struers table top machines is available as an accessory.

Discotom-100

25

5 Installation

Recommended workbench dimensions

X:

92 cm (36.2")

Y:

90 cm (35.4")

Z:

80 cm (31.5")•

The machine must be placed close to the electrical power supply, main water supply and waste
water drain.

•

The machine must be placed in a well-ventilated room or connected to an exhaust system.

•

The machine must rest securely with all 4 feet on the table.

•

The machine must be completely level.

•

Make sure that there is enough room behind the machine for the inlet and outlet hoses.

•

Make sure that there is enough room behind the machine to fully open the cover.

•

Make sure that there is enough room to access the main switch.

•

Make sure that there is enough room around the machine for service access.

•

Make sure that there is enough room in front of the machine: 100 cm (40").

Exhaust system (option)•

Make sure there is at least 17 cm (7") of space for the hose.

Extension tunnel (option)•

Make sure that there is at least 1 m (40") to the left of the machine for access to the extension
tunnel.

Illumination•

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.

26

Discotom-100

5 Installation

Ambient conditions
Operating environment

Surrounding temperature

Operation: 5-40°C/40-105°F
Storage: 0-60°C/32-140°F

Humidity

Operation: 35-85% RH noncondensing
Storage: 0-90% RH noncondensing

5.5Power supply
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 thevoltage stated on the type plate of the machine.
Incorrect voltage can damage the electrical circuit.

5.5.1

Connection to the machine
Procedure

1.

Open the electrical connection box.

2.

Connect the power cable as described below:

EU cable

UL cable

L1: Brown

L1: Black

L2: Black

L2: RedDiscotom-100

27

5 Installation

EU cable

UL cable

L3: Black/Grey

L3: Orange/Turquoise

Earth (ground): Yellow/Green

Earth (ground): Green (or Yellow/Green)

Neutral: Blue - Not used

Neutral: White - Not used

The other end of the cable can be fitted with an approved plug or hard-wired into the mains,according to the electrical specifications and local regulations.

5.5.2

Power supply cable - recommended specifications
Local standards can override the recommendations for the main electrical power supply
cable. Always contact a qualified electrician to verify which option is suitable for the local installation
setup.

Voltage/frequency

Min.
fuse
size

3 x 200-240 V

30

3 x 380-480 V

15

Max.
fuse
size

Minimum cable size at
maximum fuse

3x AWG12 / 2.5 mm² +PE

50

3x AWG10 / 4 mm² + PE

3x AWG14 / 1.5 mm² +PE

50

3x AWG10 / 4 mm² + PEMinimum cable size at
minimum fuse

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.
Note
The machine must always be protected by external fuses.See the electrical table fordetails on the fuse size required.

5.5.3

Voltage/frequency

Nominal load

Max. load

3 x 200-240V

16 A

30 A

3 x 380-480V

8A

15 A

External short circuit protection
Note
The machine must always be protected by external fuses.See the electrical table fordetails on the fuse size required.

28

Discotom-100

5 Installation

5.5.4

Residual Current Circuit Breaker (RCCB)
Note
Local standards can override the recommendations for the main electrical power
supply cable. Always contact a qualified electrician to verify which option issuitable for the local installation setup.
Requirements for electrical installations
With Residual Current Circuit Breakers(RCCB) - Required

5.6

Type B time delayed, 30 mA (EN50178/5.2.11.1)

Recirculation cooling unit
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 thevoltage stated on the type plate of the machine.
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

Note
Before connecting the cooling unit to the machine, follow the instructions in thecooling unit Instruction Manual to prepare it for use.
Hint
For intensive use, and for materials generating a lot of swarf, we recommend thatyou use a recirculation unit with band filter.
To connect the machine to a recirculation cooling unit:
1.

Discotom-100

Plug the communication cable of the cooling control unit into the machine's control socket.

29

5 Installation

2.

Connect the water inlet hose to the pump using the quick coupling.

3.

Connect the other end of the hose to the machine's water inlet.

Filter tube kit
Follow the instructions supplied with the filter tube kit.
During the first cutting operation:•

Check that the filter tube expands along its full length as it fills with water.
Note
If the filter tube is twisted or it has folds, stop cutting and reposition the tube.
Do not use cooling systems without suitable filters as it can cause clogging and overflow.
Do not use filter tubes without a suitable cooling fluid.

•

5.7

Connect the cooling unit to the main power supply.

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 m3/h (1766 ft3/h).
To connect the machine to an exhaust system:

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Mount an exhaust hose from your local exhaust system onto the flange (50 mm (2")
diameter).
Note
Without an exhaust system, damp air produced by the cutting process can escapefrom the cutting chamber, and penetrate other areas of the cabinet. This candamage the components and shorten the lifetime of the machine.

5.8

Noise
For information on the sound pressure level value, see this section: Technical data ►91.
Different materials have different noise characteristics. Decreasing the rotational speed and/or
the force with which the cut-off wheel is pressed against the workpiece, will lower the noise.
Processing time may increase.
CAUTION
Prolonged exposure to loud noises may cause permanent damage to a person’shearing.
Use hearing protection if the exposure to noise exceeds the levels set by local
regulations.

5.9

Vibration
For information on the total vibration exposure to hand and arm, see this section: Technical data
►91.
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.

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CAUTION
Risk of hand to arm vibration during manual cutting.
Prolonged exposure to vibration may cause discomfort, joint damage or evenneurological damage.

6

Operate the device

6.1

Change the cut-off wheel.
Note
The spindle of the Discotom-100 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.
For maximum precision with diamond or CBN cut-off wheels, do not use cardboard
washers.

6.2

1.

Use the cutting handle to move the cut-off wheel into the top position and activate the cutting
arm brake.

2.

Press and hold down the spindle locking knob on the right-hand side of the cut-off wheel, turning
the cut-off wheel until the spindle lock engages.

3.

Remove the nut with a fork spanner.

4.

Remove the flange, cardboard washers and the old cut-off wheel.

5.

Mount the new cut-off wheel.

6.

Mount the flange and the nut.

7.

Tighten carefully and release the locking knob.

8.

Release the cutting arm brake.

Clamp the workpiece
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.
Clamp the workpiece with the clamping device of your choice. For example, a quick clamping device.
1.

Place the workpiece between the clamp and the back stop.

2.

Push the clamp towards the workpiece and lock the clamp on the quick-clamping device.

Generally, we recommend that you clamp the workpiece as far back on the cutting table as possible.

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How to clamp irregular workpieces
You must use special clamping tools to clamp irregular workpieces without flat clamping surfaces.
Incorrectly clamped workpieces can move during cutting and damage the cut-off wheel or to theworkpiece.

6.3•

Use the T-slots to mount the special clamping tools.

•

For faster cutting, position the workpiece so that the cut-off wheel cuts the smallest possible
cross-section.

Position the cutting table
Before you start cutting, position the table with the joystick.

How to cut long workpieces
To cut workpieces the exceed the width of the cutting chamber in the left-hand side:
1.

Remove a plate in the cover and replace it with an extension tunnel.

2.

Place the workpiece in the extension tunnel and clamp securely.

6.4

Basic operation

6.4.1

Flushing gun
CAUTION
Avoid skin contact with the coolant additive.

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.

1.

Remove the flushing gun from the holder.

2.

Point the gun into the flushing chamber.

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3.

Open the valve on the flushing gun.

4.

To avoid splashing water while cleaning, use the valve located just before the flushing gun toreduce the maximum water pressure.

5.

Press Flush to start the water pump.

6.

Press the rear of the nozzle and clean the cutting chamber.

7.

Press Stop to stop flushing.

8.

Close the valve and place the flushing gun back in the holder.

9.

Leave the safety guard open to allow the cutting chamber to dry and to avoid corrosion.
Note
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.

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Hint
For instructions on how to use the flushing gun to clean the machine, see Cutting
chamber ►75.

6.4.2

Cutting table
Y-tableThe Y-table is a motor driven, movable table which is used when cutting automatically. Use thejoystick to move the table backwards and forwards. See: Control panel functions ►19.
Note
When you switch the machine on, a pop-up alerts you that the cutting table will
move to the front reference position. Press Enter to continue.

6.4.3

Display
The display on the front panel provides different levels of status information. For example, whenthe machine is switched on using the main power switch, the display informs you about thephysical configuration of the machine and the version of software that is installed:

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:

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A Heading: this indicates where you are in the software’s hierarchy. An icon will indicate whether
the handle is locked or unlocked:
LockedUnlocked

B Information fields: these will be either numerical values or text fields, providing information
associated with the process shown in the heading. The highlighted text shows the cursor position.
To select items in this menu:
1.

Turn the knob to select a menu, a method group or a parameter.

2.

Push the knob to open or activate the selection.

3.

Press Esc to return to the Main menu.

Acoustic Signals
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.

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6.4.4

Edit values
Edit numeric values

1.

Turn the knob to select the value you want to change.

2.

Push the knob to edit the value. A scroll box appears around the value.
Note
If there are only two options, the pop-up box is not displayed. Pushing the knob
(Enter) will toggle between the 2 options.

3.

Turn the knob to increase or decrease the numeric value (or to toggle between the two
options).

4.

Push the knob to accept the new value. If you press Esc, the changes are reversed to theoriginal value.

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Edit alphanumeric values

1.

Turn the knob to select the text value you want to change.

2.

Push the knob to toggle between the 2 options.
Note
If there are more than two options, a pop-up box is displayed. Turn the knob to selectthe correct option.

3.

6.4.5

Press Esc to accept the option and return to the previous menu, or turn the knob to select andedit other options in the menu.

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).

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Select the language you prefer.

You will now be prompted to set the time.

•

Use the knob to adjust and accept the settings.

You will now be prompted to set the date.

1.

Use the knob to adjust and accept the settings.

2.

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.

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Change the language

1.

40Open the Configuration menu.

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2.

Open the Options menu.

3.

Open the Language pop-up menu.

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4.

6.4.6

Select the language you prefer.

Operation mode
There are 3 different user levels:
Production: Methods can be selected and viewed but no editing is possible.
Development: Methods can be selected, viewed and edited.
Configuration: Methods can be selected, viewed and edited and all functions in Configuration areaccessible.

Change the operation mode
To change the operation mode:

42

1.

Go to the Options menu, under Configuration.

2.

Select Operation mode.

3.

Select Pass code.

4.

Use the F1 and F2 keys to select digits.

5.

Turn the knob to change the digits and push knob to enter the pass code.

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6.

Select Configuration.

7.

Select the desired operation mode.

New pass code
To set a new pass code:

1.

Select New pass code.

2.

Enter the new pass code.
Note
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:

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A Cutting parameters
B Motor information
Cutting parameters
In Automatic Cutting mode, the upper area of the display shows information about the cutting
parameters:–

Feed speed–

Stop position

The cutting parameters can be set both before and during cutting.
The set value is displayed to the left of the bar graph. The actual value (during cutting) is displayed
inside the bar graph.

Motor information
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-100 has two cutting modes: Automatic and Manual.

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Select the mode you want to use in the Main menu.

Change the cutting parameters
In automatic cutting mode, the machine applies the selected cutting parameter values for:–Wheel type–

Wheel speed–

Cutting mode–

Feed speed–

MultiCut (with automatic x-table only)–

Stop mode

To adjust the values of these parameters:
1.

Use the knob to select a cutting parameter.

2.

Turn the knob to change the value of the parameter.

3.

Push the knob to store the new value.

Cut-off wheel
To select or change the cut-off wheel:

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46

1.

Select the cut-off wheel parameter.

2.

Select a wheel category.

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3.

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.

Intelligent speed adjustment
To use the intelligent predefined rpm adjustment:

1.

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Press F1 in the Select cut-off wheel menu to enable the intelligent adjustment.

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6 Operate the device48

2.

Select a cut-off wheel to adjust the rpm.

3.

Select the Vickers hardness of the material you want to cut. The rpm setting for the cut-off wheel
is changed accordingly.

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4.

Push the knob to store the value.

Wheel speed
To change the cut-off wheel speed:

1.

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Select the speed parameter.

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Use the knob to adjust the wheel speed (1500 - 3000 rpm).

Cutting mode
To change the cutting mode:

1.

50

Select the cutting mode parameter.

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2.

Push the knob to change the cutting mode.

Direct cutting

Direct cut is the normal and most economic cutting mode and can beused for most cutting operations.

Impact cutting

Impact cutting can be used when it is not possible to find the correct
cut-off wheel for a specific material, and the abraded material clogs thewheel, or the wheel is not wearing enough.
Impact cutting will frequently accelerate the cutting table and thus movethe workpiece at higher speed against the cut-off wheel. This will break
down the wheel and release fresh and sharp abrasive grains that canwork properly.
Impact cutting can result in higher wheel wear, but will reduce the riskof overheating the workpiece that otherwise can take place with aninaccurate wheel / material combination.

Feed speed
To set the feed speed:

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1.

Select the feed speed parameter.

2.

Use the knob to adjust and accept the settings.

MultiCut (Optional)
To select the MultiCut mode:

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1.

Select the MultiCut parameter.

2.

Select the desired setting.

Discotom-100

Single cut

OffMode 1

Cut up to 10 slices of equal thickness

Mode 2

Cut up to 10 slices of varying thickness53

6 Operate the device
Mode 3Cut up to 10 slices of varying thickness counted from a common 0position

Mode 4

The thickness of the cuts are set by moving the joystick thenpressing 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.

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.

Initial cut

Select this parameter if you need to make an initial cut, before you
start cutting the samples. This cuts a scrap sample, which you will
not use. For example, if the workpiece has an uneven edge thatmakes it unsuitable as a first sample.

Req. X-displacement

This parameter is automatically calculated, and it displays therequired movement of the x-table to cut the samples, based on theparameter settings.

MultiCut 2
With the MultiCut 2 mode, you can cut up to 10 samples of different widths.

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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.

Initial cut

Select this parameter if you need to make an initial cut, before
you start cutting the samples. This cuts a scrap sample, which
you will not use. For example, if the workpiece has an unevenedge that makes it unsuitable as a first sample.

Req. X-displacement

This parameter is automatically calculated, and it displays therequired movement of the x-table to cut the samples, based on
the parameter settings.

Hint
Press F1 to clear all sample values and return the menu to its default.

MultiCut 3
With the MultiCut 3 mode, you can cut up to 10 samples at different relative distances from thezero, or starting position.
The distances are manually entered.
To set up the distances:

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1.

Select Mode3 in the Select MultiCut mode menu.

2.

Select the cutting positions.

Parameters

56

Cutting position (Relative)

This parameter sets the position of the cuts. The values show the
relative distance to the zero position.

Cut at zero pos.

Select this parameter to make an initial cut at zero position.
Otherwise, the machine will start cutting at position 1.

No of samples

Sets the number of samples that will be cut.

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Hint
Press F1 to clear the highlighted value in this menu.
If the cursor is placed outside the cutting position box, F1 will clear all positions.

Req. X-displacement

This parameter is automatically calculated, and it displays therequired movement of the x-table to cut the samples, based on
the parameter settings.

MultiCut 4With 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:1.

Position the workpiece relatively close to the cut-off wheel and clamp it.

2.

Use the joystick to move the X-table to the position where the first cut is to be made.

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3.

Push the knob to insert the current position as the cutting position.

4.

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

X-table start pos.

Here you can fine-tune the start position, if the work piece isslightly misaligned during clamping.
When you change the value of this parameter, all other positions
are corrected accordingly.

No of samples

Sets the number of samples that will be cut.

Hint
Press F1 to clear the highlighted value in this menu.
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:

1.

58

Select the stop mode parameter.

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Select the desired setting.

The Discotom-100 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.
Note
We do not recommend that you use Auto stop when cutting tubes, or otherworkpieces which are not very dense or rigid. Use either Relative or Absolute
stop instead.
The automatic stop function is based on monitoring the electrical current used by the cut-off wheel
motor. For the automatic stop to function properly, two criteria have to be met:•

The current used at the start of a cutting operation has to exceed a minimum value. If it does
not, the automatic stop will not be enabled.

•

The current used during the cutting operation has to remain above a minimum value. When it
falls beneath this value, cutting will stop.

In some samples, for example tubes, the current can fall beneath the minimum value when thewall of the tube has been cut through, and the center (hollow part) of the tube is reached during
the cutting operation. If this happens, cutting will stop even though the sample has not been fully
cut through.

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When you start the cutting process, the bar indicating the travel of the cutting table is gray, until the
motor current exceeds the required value. The bar then changes to green to signal that the Automode is enabled.

When the motor current then falls below the specified minimum value, the bar colour changes back togray and the cutting stops.
If only a very small cross section is left at the end, cutting can stop before the workpiece is completely
cut through. Here it is possible to specify an additional cutting distance in Configuration / Options tomake sure that the workpiece is cut completely through. This is especially useful when using
MultiCut.

Relative
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.

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If you set the relative stop position to a value exceeding the possible table travel, the value
displayed is reduced automatically to the maximum possible when you press Enter. Moving the Ytable towards the front of the cutting chamber increases the amount of travel and thisautomatically updates the relative stop data.

Absolute
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.

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Manual cutting mode
The Load % and Temp % displays indicate how much force is being applied to the workpiece andhow hot the motor is. As more force is applied, motor load is increased resulting in a higher
temperature.
A heavy force applied for an extended period of time can result in the motor’s temperature becoming
greater than the safe working limit. The machine will then automatically stop cutting to prevent
damage to the motor.
Applying heavy force for a long period of time may also shorten the life of the cut-off wheel.

Automatic cutting mode
The feed speed is automatically reduced on overload by the OptiFeed feature.

OptiFeed
This feature protects the machine from damage due to continuous overloading of the motor.
If the feed speed is set too high and the motor is overloaded:

6.4.10•The feed speed is reduced by 20%.

•

If the motor load is still too high, the feed speed is again reduced by 20%.

•

This is done up to 4 times until the feed speed is only 20% of the preset value.

•

If the motor is still overloaded, the cutting process is stopped.

•

If the motor is running with normal load again, the feed speed is gradually increased, in steps of
10% of the original feed speed, until the preset feed speed is reached without the motor being
overloaded.

Start the cutting process
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.
HEAT HAZARD
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 oftelescopic optics. Class 2M
laser product.

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Automatic cutting

The cut-off wheel is stationary, and the cutting table moves.

Manual cutting

The cutting table is stationary, and the operator moves the cut-off
wheel.

Automatic cutting
1.

Clamp the workpiece.

2.

Release the cutting arm brake.

3.

Lower the cut-off wheel by pulling the cutting handle downwards until the cut-off wheel ispositioned ready to cut the workpiece.

4.

Activate the cutting arm brake.

5.

To align workpiece and cutting wheel, press the Hold-to-run button and use the joystick toposition the cutting table.

6.

Close the cover of the machine.

7.

Select a method in the Automatic cutting methods menu.

8.

Press Start. The cut-off wheel starts rotating and the cooling water starts to flow. The cutting
table moves towards the cut-off wheel at the preset feed speed.

9.

When the workpiece is cut through or the set stop position has been reached, the cut-off
wheel stops automatically. Depending on the return position setting, the cutting table will
return to where the cutting started (Start) or it will stay where it is (Stay).
Hint
During cutting, you can move the sample away from the cut-off wheel by pressing
the Y-table joystick downwards.

Manual cutting
1.

Clamp the workpiece.

2.

Release the cutting arm brake.

3.

To align the workpiece and cutting wheel, press the Hold-to-run button and use the joystick
to position the cutting table.
Hint
Place the workpiece slightly in front of the center of the cut-off wheel.

4.

Close the cover of the machine.

5.

Select a method in the Manual cutting methods menu.

6.

Press Start. The cut-off wheel starts rotating and the cooling water starts to flow.

7.

Pull the cutting handle down and let the cut-off wheel work itself into the workpiece. Increase
the force and begin cutting.

8.

Reduce the force when the cut-off wheel has almost cut through the workpiece.

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9.

When the cut-off wheel has cut through the workpiece, push the cutting handle back to its top
position.

10. Press Stop to stop the machine.
Note
When cutting manually, use the motor load information to monitor the force on theworkpiece.

Combine manual and automatic operation
To combine the manual and automatic cutting modes:
1.

Cut into the workpiece using the Manual cutting method.

2.

Press Stop to stop the machine.

3.

Activate the cutting arm brake to secure the arm in this position, select an Automatic cutting
method and continue in automatic mode. The workpiece will move towards the cut-off wheel.
Note
Check that there is a steady flow of cooling fluid from the nozzles.

6.4.11

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.

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6.5

Configuration

6.5.1

Options1.

Select Configuration in the Main menu.

2.

Open the Options menu.

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Parameters66

Display brightness

The contrast settings of the display can be adjusted to suit individual
preferences (range 0-100).

Language

The language can be set to English (default), German, French,
Spanish, Japanese, Chinese, Italian, Russian or Korean.

Keyboard soundThe keyboard sound can be set to On or Off. Default: On.

Units

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.

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Parameters
Operation mode

There are 3 different operation modes, which provide different levelsof access to parameters:

Return position–

Configuration: Full functionality, access to all parameters.

–

Development: Limited access to parameters in the
Options menu.

–

Production: No access to parameters except for Display
brightness, Keyboard sound, and Additional cutting
distance.

After cutting or after pressing Stop, the return movement of the cutoff wheel can be set to two different modes:–

Start: The Y-table automatically retracts to the original
position when you press Start.

–

Stay: The Y-table will not move after cutting.

Note
Use the Stay function for Bakelite bonded diamond or CBN cut-off wheels, as
retraction can destroy the rim of the cut-off wheel.

Additional cutting
distance

When you use the Auto stop, cutting is stopped when the motor
current is decreasing below a certain level.
When cutting small workpieces with a small cross section, Auto stop
will stop the cutting process too early due to a very low motor current.
In this case, you can specify an additional cutting distance to makesure 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:
1.

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Select New in the User defined cut-off wheels menu.

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682.

Insert a name for the cut-off wheel or press F4 to accept the suggestion (UCW: User defined
cut-off wheels).

3.

Select the newly created cut-off wheel.

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6.5.3

4.

Use the knob to adjust and accept the settings.

5.

Press Esc to save the changes.

Reset functions
To reset certain functions to factory settings, go to Reset functions from the Maintenance menu:

Reset methods
Select to delete all cutting methods at once.
Note
This action cannot be reversed.

Reset configuration

6.6

1.

Select Reset configuration to set all configuration parameters back to their default settings.

2.

Turn the machine off, then on again and reconfigure the settings.

Optimize cutting results
Question

How can I avoid discolorationor burning of the specimen?

AnswerComments

Reduce the rotational speed.

Causes increased wheel wear.

If reduced rotational speed
fails to solve problem,change to a softer cut-off
wheel.
Reduce the rotational speed.

Causes increased wheel wear.

How can I avoid uneven cuts?
Reduce the feed speed.

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7 Maintenance and service

Question

AnswerComments

How can I avoid smearing?

Reduce the rotational speed.

Causes increased wheel wear.

Use a softer cut-off wheel.

Causes increased wheel wear.

How can I avoid burrs?

Secure the workpiece on
both sides of the cut-off
wheel.

How can I prevent the cut-off
wheel from wearing out tooquickly?

Increase the rotational
speed.

Can cause specimen
discoloration and uneven cuts.

Use a harder cut-off wheel.
Place the cut-off wheel as
low as possible.

How can I cut faster?

How can I avoid machine
vibrations?

7

Place the workpiece in aposition that allows the cutoff wheel to cut the smallest
possible cross-section.
Increase the feed speed.

Can cause specimen
discoloration and uneven cuts.

For minor vibrations,increase the feed speed insteps of 0.1 m/s

Can cause specimen
discoloration and uneven cuts.

For major vibrations,
Can cause specimen
increase the rotational speed
discoloration and uneven cuts.
by 500 rpm.

Maintenance and service
Proper maintenance is required to achieve the maximum up-time and operating lifetime of themachine. Maintenance is important in ensuring continued safe operation of your machine.
The maintenance procedures described in this section must be carried out by skilled or trained
personnel.

Safety Related Parts of the Control System (SRP/CS)
For specific safety related parts, see the section "Safety Related Parts of the Control System(SRP/CS)" in the section "Technical data" in this manual.

Technical questions and spare parts
If you have technical questions or when you order spare parts, state serial number andvoltage/frequency. The serial number and the voltage are stated on the type plate of the machine.

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7.1

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.
Note
Do not use a dry cloth as the surfaces are not scratch resistant.

•

Clean the machine and all accessories thoroughly.

If the machine is not to be used for a longer period of time
To ensure a longer lifetime for your machine, we strongly recommends regular cleaning.

7.1.1

Recirculation unit
1.

Clean the recirculation tank and the connected tubes thoroughly.

2.

If you use a soap solution to clean the bowl or the recirculation tank, rinse with clean water
before filling the recirculation tank.
Note
If the cooling fluid is contaminated by algae or bacteria, replace the cooling fluid
immediately.

3.

If the recirculation water has been infected with bacteria or algae, clean the tank and tubes
with a suitable antibacterial disinfectant.

4.

Clean the static filter: Remove it and rinse it with water.

Change the recirculation water
CAUTION
Avoid skin contact with the coolant additive.

Note
The recirculation water contains additive and grinding residue and you must notdispose of it into the waste water drain.
Recirculation water must be disposed of in compliance with local safety
regulations.

Discotom-100

71

7 Maintenance and service

7.1.2

AxioWash
CAUTION
Avoid skin contact with the coolant additive.

Note
Clean the cutting chamber thoroughly if you are not going to use the machine for alonger period of time.
Note
Only use AxioWash for cleaning the cutting chamber.

Note
You do not need to remove the cut-off wheel or the clamping tools while using
AxioWash.
The AxioWashAxioWash cleaning program is an efficient way to automatically clean the cutting
chamber. You can set values between 1-30 min, in steps of 30 seconds. Default value: 3 minutes.
To start the AxioWash function:

72

1.

Remove the workpiece and tools from the cutting chamber.

2.

Close the adjustable cleaning nozzles.

3.

Close the cover.

4.

Press the AxioWash key on the Control Panel.

5.

Press F1 to start cleaning. The AxioWash program will run for the preset time.

Discotom-100

7 Maintenance and service

7.2

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.

Hint
Grease and oil can be removed with ethanol or isopropanol.

•

Clean all accessible surfaces with a soft, damp cloth.

•

Clean the cutting chamber both automatically (using AxioWash) and then manually (using
the flushing gun).

Automatic cleaning: AxioWash
See AxioWash ►72

Manual cleaning
CAUTION
Avoid skin contact with the coolant additive.

CAUTION
Do not start flushing until the flushing gun points into the cutting chamber.
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.

CAUTION
Using the flushing gun to clean the inside of the protective cover can cause
spillage of cooling fluid on the floor.
When AxioWash is finished:1.

Discotom-100

Take the flushing gun and point it towards the bottom of the cutting chamber.

73

7 Maintenance and service
2.

Open the valve on the flushing gun.

3.

Press Flush to start the water pump.

4.

Press the button on the rear of the nozzle and clean the cutting chamber thoroughly.

5.

Press Stop to stop flushing.

6.

Close the valve.

7.

Place the flushing gun in the holder.
Note
To avoid corrosion, leave the cover open to let the cutting chamber dry completely.

7.2.2

Protective cover
WARNINGTo 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 withprojectile 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.

CAUTION
The protective cover will minimize the risk of ejection but will not eliminate itcompletely.
The protective cover consists of a metal frame and a composite material (PETG) screen that protects
the operator. In the event of damage, the screen will be weakened and offer less protection.
•

7.2.3

Visually inspect the cover and the screen for signs of deterioration, wear or damage (forexample: dents, cracks, damage to the edge sealing).

Wheel guard
Visually inspect that the cut-off wheel guard is intact.

7.2.4

Safety lock
The interlock tongue must be checked regularly for damage and perfect fitting.
•74

Check the interlock tongue for correct function. It must slide unobstructed into the locking
mechanism.

Discotom-100

7 Maintenance and service

7.2.5

Clean the flushing gun nozzle
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.

7.3

Weekly7.3.1

The machine
Clean the machine regularly to avoid damaging effects to the machine and the specimens fromabrasive grains or metal particles.
•

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.

•Do not use harsh or abrasive cleaning agents.
Note
Make sure that no detergent or cleaning agent is flushed into the cooling unit tank,as this will cause excess foaming.

7.3.2

Cutting chamber
Clean the cutting table
1.

Remove the clamping device(s).

2.

Thoroughly clean the clamping device(s).

3.

Store the clamping device(s) in a dry place or replace on the cutting table after cleaning.

Clean the cutting chamber thoroughly

7.3.3

1.

Move the cutting table forwards and backwards to access the whole of the cutting chamber.

2.

Clean along the length of the guide shafts with the flushing gun and a brush to remove
accumulated swarf.

3.

Clean under the cutting table with the flushing gun and a brush to remove accumulated
swarf.

4.

Wipe the gutter on the inside of the cutting-chamber cover and remove accumulated swarf.

Recirculation unit•

Check the level of the cooling water after 8 hours of use or at least every week.

•

Check, and if necessary, clean the filters.

Discotom-100

75

7 Maintenance and service

7.4

Monthly

7.4.1

Cooling fluid
CAUTION
Wear suitable gloves and safety goggles when handling cooling fluid.

Replace the coolant at least once a month.

7.4.2

Lubricate the cutting table
Lubricate the cutting table at regular intervals (approximately every 100 hours) to maintain optimum
performance of the machine.
1.

Move the cutting table to its position using the hold-to-run button and the joystick.

2.

Place the grease gun on the grease nipples in front of the spindle for the cutting table and push
twice to grease the guide shafts.

A grease gun with grease for lubricating the table spindle is supplied with the machine. When all thegrease has been used, refill the grease gun.

7.4.3

Clamping devices
We recommended that you thoroughly clean and lubricate the quick clamping device and verticalquick clamping device at regular intervals.

7.5

Annually

7.5.1

Test the safety devices
WARNING
Do not use the machine with defective safety devices.
Contact Struers Service.

76

Discotom-100

7 Maintenance and 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.
The cover has a safety switch system to prevent the cut-off wheel from starting while the cover is
open.
Cutting table and arm movements are blocked if the protective cover is open. You can use thehold-to-run button to move the position of the cutting table. A locking mechanism prevents theoperator from opening the cover until the cut-off wheel stops spinning.

Emergency stop
Test 1
1.

Start a cutting process.

2.

Activate the emergency stop. If the machine does not stop the cutting process, press Stopand contact Struers Service.

Test 2
1.

Activate the emergency stop.

2.

Press Start. If the machine starts the cutting process, press Stop and contact Struers
Service.

Protective cover
Test 1
1.

Start a cutting process.

2.

Try to open the protective cover – do not use force. If the cover opens, press Stop andcontact Struers Service.

Test 2
1.

Open the cover.

2.

Press Start. If the machine starts the cutting process, press Stop and contact Struers
Service.

Test 3
1.

Start a cutting process.

2.

Press Stop. If it is possible to open the cover while the cut-off wheel still rotates, contact
Struers Service.

Cover interlock•

Discotom-100

Check the safety-catch for correct function. The safety-catch must slide unobstructed into
the locking mechanism. If it does not, call Struers Service.

77

7 Maintenance and service

Fluid system
Test 1
1.

Open the cover.

2.

Start the water pump and activate the flushing gun. If cooling fluid starts to run from the cut-off
wheel guard, press Stop and contact Struers Service.

Test 2
1.

Activate the emergency stop.

2.

Start the water pump by releasing the flushing gun. If cooling fluid starts to run, press Stop andcontact Struers Service.

Hold-to-run button

7.6

1.

Open the cover.

2.

Without pressing the hold-to-run button, use the joy stick to move the cutting table and/or cuttingarm. If the cutting table and/or the cutting arm move, contact Struers Service.

Cutting table
The stainless steel bands are available as spare parts and must be replaced if they become worn or
damaged.
We recommend that you leave the cover open when the machine is not in use to allow humidity toescape from the cutting table and chamber.

Lubrication
Lubricate the cutting table at regular intervals (approximately every 100 hours) to maintain optimum
performance of the machine. See Lubricate the cutting table ►76.

7.7

Cut-off wheels
How to store bakelite bonded Al2O3 cut-off wheels
Bakelite bonded cut-off wheels are sensitive to humidity. Therefore, do not mix new, dry cut-off
wheels with used damp ones. Store the cut-off wheels in a dry place, horizontally on a flat support.

Maintenance of diamond and CBN cut-off wheels
Follow these instructions to maintain the precision and the quality of the cut of diamond and CBN cutoff wheels:

78•

Never expose the cut-off wheel to a heavy mechanical load, or heat.

•Store the cut-off wheel in a dry place, horizontally on a flat support, preferably under lightpressure.

•

Clean and dry the cut-off wheel before storing to avoid corrosion.

•

Use ordinary detergents to clean the cut-off wheel.

Discotom-100

8 Spare parts

8•

A clean and dry cut-off wheel does not corrode. Therefore, clean and dry the cut-off wheel
before storing. If possible, use ordinary detergents for the cleaning.

•

Dress the cut-off wheel regularly.

Spare parts
Technical questions and spare parts
If you have technical questions or when you order spare parts, state the year of production. The
year of production is engraved on the cylinder arm.
For further information, or to check the availability of spare parts, contact Struers Service. Contact
information is available on Struers.com.

9

Safety Related Parts of the Control
System (SRP/CS)WARNING
The PETG screen must be replaced after a lifetime of 5 years. A label on thescreen indicates when it is due to be replaced.
The gas springs for the cover must be replaced after a lifetime of 1 year and 7
months.
WARNING
Safety critical components must be replaced after a maximum lifetime of 20 years.
Contact Struers Service.
Note
SRP/CS (safety-related parts of a control system) are parts that have an influenceon safe operation of the machine.
Note
Replacement of safety critical components must only be performed by a Struers
engineer or a qualified technician (electromechanical, electronic, mechanical,
pneumatic, etc.).
Safety critical components must only be replaced by components with at least thesame safety level.
Contact Struers Service.

Discotom-100

79

10 In-line filter
Safety related
part

Manufacturer/Manufacturer
description

Manufacturer
catalog no.

Electricalref.

Struers
catalog no.

Emergency
stop,

SchlegelRondex type RV S1

2SA10400

Emergency
stop switch
element

SchlegelRondex type
MTO

-S1

2SB10071

Safety relay

Omron

G9SB-3012-A-KS1 and KS2

2KS10006

Interlock w.
locking

Schmersal

AZM161SK12/12RK-024-YS1

2SS00121

Safety sensor

Schmersal

BNS 120-02Z-SS1

2SS00130

Hold-to-run
buttonSchurter

MSM 22 DP ST-S2

2SA00023

Solenoid valve

Sirai

D132A22 G½x9
2F

-Y1 and -Y2

2YM10132

Frequency
inverter 380480 V/50-60
Hz)

Omron

3G3MX2A4055-E-A1

2PU17550

Frequency
inverter 200240 V/50-60
Hz)

Omron

3G3MX2A2055-E-A1

2PU16550

PCB (Printed
circuit board)

Struers-A3

16013000

Push button 22mm

10 In-line filter
To clean the in-line filter:

80

1.

Unscrew the filter housing.

2.

Clean the filter.

3.

Re-assemble the filter.

Discotom-100

11 Service and repair
Hint
You can also fit the in-line filter to the quick coupling on the recirculation cooling
unit pump. Make sure that the in-line filter is mounted so that the flow arrows
indicate the flow of water towards the cut-off machine.

11 Service and repair
We recommend that a regular service check be carried out yearly or after every 1500 hours ofuse.
When the machine is started up, the display shows information about total operation time and themachines service information.
After 1500 hours of operation time, the display will show a message reminding the user that aservice check should be scheduled.
Note
Service must only be performed by a qualified technician (electromechanical,
electronic, mechanical, pneumatic, etc.).
Contact Struers Service.

11.1

Service information

You can find extensive information about the conditions of all different components in the Service
information menu, located in the 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 diagnosticsof the equipment.
This menu contains read-only information; machine settings cannot be changed or modified.

Discotom-100

81

12 Disposal
Note
The Service Information menus are in English only.

A pop-up message appears after 1,000 hours operation time (or a specified number of months) toremind you that a service check must be scheduled. 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.
Contact your local authorities for information on the correct method of disposal inaccordance with national legislation.
For disposal of consumables and recirculation fluid, follow local regulations.

WARNING
In case of fire, alert bystanders, the fire brigade and cut power. Use a powder fire
extinguisher. Do not use water.

82

Discotom-100

13 Troubleshooting
Note
The recirculation fluid will contain additive and cutting or grinding swarf.
Do not dispose of the recirculation fluid into a main drain.
Follow the current safety regulations for handling and disposal of swarf andadditive for recirculation fluid.
Keep track of which metals you cut or grind and the amount of swarf produced.
Depending on which metals you cut or grind, it is possible that the combination of the metallic
swarf from metals with a large difference in electropositivity, can result in exothermic reactions
when favorable conditions are present.

Examples:The following are examples of combinations which can result in exothermic reactions if a large
amount of swarf is produced during cutting or grinding on the same machine, and when favorable
conditions are present:•

Aluminum and copper.

•

Zinc and copper.

13 Troubleshooting
13.1

Machine problems
Error

Cause

ActionThe machine has stopped
cutting.

The Auto stop function is
active.

Switch the machine off and on
at the main switch to reset Autostop.

During cutting, the cutting
table stops when reaching a
specific point.

The Auto stop function is
active.

Switch the machine off and on
at the main switch to reset Autostop.

The chamber light does notwork.

Replace the lamp.

Remove the plastic cap to gain
access to the fluorescent lamp.
Pull out the lamp and replace it.

Water leaking.

Leak in a recirculation cooling
unit hose.

Check the hose and tighten thehose clamp.

Water overflow in the coolingwater tank.

Remove the excess water inthe tank.

Discotom-100

83

13 Troubleshooting

Error

Cause

ActionIn-line filter needs cleaning
often.

Filter tube needs to bechanged.

Change the filter tube. In somecases, 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 ►80.

The workpieces or the cutting Insufficient additive in coolingchamber are rusty.
fluid.

Use an additive for cooling fluidin the cooling water, at thecorrect concentration as
specified on the label. Check
with a refractometer.
See Accessories andconsumables ►6.

The cover is left closed afteruse.

Leave the cover open to let the
cutting chamber dry.

Cutting chamber shows signs The workpiece is made ofof corrosion.
copper or a copper alloy.

Use a coolant additive that is
specifically formulated forcopper and copper alloys.

Forgotten pass code.

Contact Struers Service.
It is necessary to revert to thefactory settings of the softwareto regain access to themachine.
Note: Stored information andpredefined processes will be
lost.

13.2

84

Cutting problems
Error

Cause

ActionDiscoloration or
burning of theworkpiece.

The hardness of the cut-off wheel isinappropriate for the hardness /dimensions of the workpiece.

Reduce the rotational speed orchange the cut-off wheel. See
Accessories and consumables ►6.

Insufficient cooling fluid.

Check that there is enough water inthe cooling unit.

Discotom-100

13 Troubleshooting

Error

Cause

ActionUnwanted burrs.

The cut-off wheel is too hard.

Reduce the rotational speed orchange the cut-off wheel. See
Accessories and consumables ►6.

The feed speed is too high at the endof the operation.

Reduce the feed speed near the endof the operation.

Lack of support for the workpiece.

If possible, support the workpiece on
both sides.

The cutting
quality differs.

The cooling water hose is clogged.

Clean the cooling water hose and thecooling tube. Check the water flow byturning the cooling valve to cleaning
position.

The cut-off wheel
breaks.

The cut-off wheel is mounted
incorrectly.

Check that the bore/centre hole has
the correct diameter.
Check the cardboard washer on bothsides of the cut-off wheel and replacethem if worn. The nut must be
tightened properly.

The workpiece is clamped incorrectly.

Make sure that only one side of theworkpiece is clamped securely. The
other side should only be fixed lightly.
Use support tools (optional) if thegeometry of the workpiece makes
support necessary.

The cut-off wheel
wears down too
quickly.

The cut-off wheel
does not cut
through theworkpiece.

Discotom-100

The cut-off wheel is too hard.

Reduce the rotational speed orchange the cut-off wheel. See
Accessories and consumables ►6.

The feed speed is set too high.

Reduce the feed speed.

Insufficient cooling fluid.

Check that there is enough water inthe cooling unit.

The rotational speed is too low.

Increase the rotational speed.

The feed speed is set too high.

Reduce the feed speed.

Insufficient cooling fluid.

Check that there is enough water inthe cooling unit.

The rotational speed is too low

Increase the rotational speed.

The cut-off wheel is too soft for thetask.

Select a harder cut-off wheel.

Incorrect cut-off wheel.

Select and adequate cut-off wheel.

The cut-off wheel is worn.

Replace the cut-off wheel with a new
cut-off wheel.

85

13 Troubleshooting

Error

Cause

ActionThe cut-off wheel
vibrates during
the cutting
process.

The workpiece is clamped incorrectly.

Make sure that only one side of theworkpiece is clamped securely. The
other side should only be fixed lightly.
Use support tools (optional) if thegeometry of the workpiece makes
support necessary.

The cut-off wheel is too soft for thetask.

Select a harder cut-off wheel.

Not enough cutting force.

Exert more force on the cut-off wheel.
Note: Large and/or very hard
workpieces may require operator
strength to cut through.

The workpiece
breaks whenclamped.

The cutting force is too high.

Reduce the force on the cut-off wheel.

The bearings are worn.

Contact Struers Service.

The cut-off wheel gets caught in theworkpiece.

Support the workpiece and clamp it on
both sides of the cut-off wheel so thatthe cut stays open.

The workpiece is brittle.

Place the workpiece between two
polystyrene plates.
Note:Always cut brittle workpieces
very carefully.

The sample iscorroded.

The sample has been left in the
cutting chamber for too long.

Remove the sample directly after
cutting. Leave the cover open when
you leave the machine.

Insufficient additive for cooling fluid.

Use an additive for cooling fluid in thecooling water at the correct
concentration. Check with arefractometer.
See Accessories and consumables
►6.

13.3

Error messages
Errors must be corrected before operation can be continued. In some cases, the cutting process
cannot continue before an authorized technician has rectified the error. Turn the machine off at themain switch immediately. Do not attempt to operate the machine before a technician has rectified the
problem.

86

Discotom-100

13 Troubleshooting#
4

Messages

Cause

Action
Do not touch thejoystick during
power on.
Restart themachine.
If the error
remains, contact
Struers Service.

10

Specify thicker
cuts.

20

Press Enter todelete all themethods.
Note: This action
cannot bereversed.

21

Press Enter toreset theconfiguration
parameters tofactory defaults.
Note: Onlyparameters fromthe Option menu
are affected.

Discotom-100

87

13 Troubleshooting#

Messages

Cause

Action34

Cover lockRestart thehandling software machine.
error.
If the error
remains, contact
Struers Service.

35

Insufficient waterpressure was
detected atprocess start up.
or
The waterpressure sensor
or cabling may be
defective.

Check the waterlevel and thefilters.
For some
installations, thein-line filter will
require more
frequent cleaning.
To make thisprocess easier, it
can be moved tothe quick couplingon the Cooli
pump. See In-line
filter ►80.
Check the waterpressure, thenpress F1 tocontinue
operating.
If the error
remains after the
next restart,
contact Struers
Service.

54

88

The MultiCutbatch parameters
require more Xtable movement
than is available.

Change one of thesuggested
process
parameters, orreposition the Xtable.

Discotom-100

13 Troubleshooting#

Messages

Cause

Action67

The method
selected has notbeen named.

Press Enter tosave and namethe method.

69

The cutting motor
cannot rotate, or
rotates slowly
when cutting isstarted.

Clear any
obstruction awayfrom the cut-off
wheel.
Allow the cutting
motor to cool.
If the error
remains after the
next restart,
contact Struers
Service.

77

The emergency
stop internalmonitoring switch
is active, but the
Stop button is notpressed as
expected.

If the error
remains after the
next restart,
contact Struers
Service.

90

MultiCut 4: thecutting position
set has a lower xposition than theprevious one.

When you use
MultiCut 4, youmust set the
cutting positionsin ascendingorder.

Discotom-100

89

13 Troubleshooting#

Messages

Cause

Action92

The load on
motor is too high.

Decrease the
load.

93

The load on
motor is too high.

Decrease theload.
Allow the cutting
motor to cool.
If the error
remains after the
next restart,
contact Struers
Service.

106

107

The cover is open
and the Hold-torun button is
activated for morethan 30 secs
without activating
the joystick ineither x- or ydirection.

Release thebutton or activate
the joystick.
If the message isshown without
activating the
button, there is anerror.Contact
Struers Service.
Restart themachine.
If the error
remains, contact
Struers Service.

90

Discotom-100

14 Technical data

14 Technical data
14.1

Technical data
Capacity

Cut-off wheel

Cut-off wheel motor

Cutting table

Height x Length

65 x 160 mm (2.6 x 6.3")

Diameter

119 mm (4.7")

Cutting length

195 mm (7.7")

Diameter

300 mm (12")

Arbor diameter

32 mm (1.26")

Rotational speed

1500-3000 rpm

Height adjustment of cut-off
wheel

165 mm (6.5")

Width

538 mm (21.2")

Depth

270 mm (10.6")

T-slots

10 mm (0.39")

Max. positioning speed

Y = 20 mm/s (0.8"/s). X= 10mm/s (0.4"/s)

Feed speed

0.05-2.5 mm/s in 0.05 mmsteps (2-200 mils/s in 2 mils
steps)

Laser

Software and electronics

Optional (Laser class up to
2M)
Controls

Touch pad

Display

LCD, TFT-color 5.7", 320 x 240
dots with LED back light

Safety standards

CE-labeled according to EU
directives

REACH

For information about REACH,
contact your local Struers
office.

Operating environment

Discotom-100

Surrounding temperature

5 - 40°C (41 - 104°F)

Humidity

35 - 85 % RH non-condensing

91

14 Technical data

Power supply 1

Power supply 2

Voltage/frequency

3 x 200-240 V / 50-60 Hz

Power inlet

3L + (N) + PE

Power S1

4 kW (5.4 hp)

Current, nominal load

16 A

Current, max.

30 A

Ampere rating of the largest
motor or load

14.7 A

Voltage/frequency

3 x 380-480 V / 50-60 Hz

Power inlet

3L + (N) + PE

Power S1

4 kW (5.4 hp)

Current, nominal load

8A

Current, max.

15 A

Ampere rating of the largest
motor or load

8.5 A

Cooling system

Cooling system 4

ExhaustRecommended capacity

50 m3/h (1750 ft3/h) at 0 mm
(0") water gauge.

Advanced features

X-table, automaticYes, size 240 x 270 mm (9.4" x10.6")

X-stand, manualNo

Rotary standNo

Emergency stop

PL c, Category 1

Safety Circuit
Categories/Performance
Level

Stop category 0
Safety guard

PL d, Category 3
Stop category 0

Safety guard lockPL a, Category B
Stop category 0

Unintended start ofrecirculation fluid

PL b, Category 1

Hold-to-run function

PL d, Category 3
Stop category 0

92

Discotom-100

14 Technical data

Residual Current Circuit
Breaker (RCCB)
Noise level

14.2

Type B, 30 mA (or better) is
required
A-weighted sound emission
pressure level atworkstations

LpA = 79.5 dB(A) (measured
value). Uncertainty K = 4 dB(A)Vibration level

Declared vibration emission

Total vibration exposure toupper parts of the body does
not exceed 2.5 m/s2.

Dimensions and weight

Width (main body)

92 cm (36.1")

Width (with handle andflushing gun)105 cm (41.4")

Width (one tunnel)

Left: 140 cm (55.1")

Width (two tunnels)

N/A

Depth

89 cm (34.9")

Height (guard closed, handle
included)

87 cm (34.2")

Height (guard open)

108 cm (42.5")

Weight204 kg (450 lbs)

Measurements made inaccordance with EN ISO
11202

Cutting capacity
The graph shows the projected cutting capacity under the following conditions:–

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 andclamping technique.

Discotom-100

93

14 Technical data

14.3

Diagrams
Note
If you want to view specific information in detail, see the online version of this manual.

94

Title Discotom-100

No.

Block diagram

16153053 ►95

Water diagram

16151000 ►96

Circuit diagram

See the diagram number on the type plate of theequipment, and contact Struers Service via Struers.com.

Discotom-100

14 Technical data
16153053

Discotom-100

95

14 Technical data
1615100096

Discotom-100

15 Manufacturer

14.4

Legal and regulatory information
FCC noticeThis equipment has been tested and found to comply with the limits for a Class B digital device,pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and canradiate radio frequency energy and, if not installed and used in accordance with the instructions,
may cause harmful interference to radio communications. However, there is no guarantee thatinterference will not occur in a particular installation. If this equipment does cause harmfulinterference to radio or television reception, which can be determined by turning the equipment off
and on, the user is encouraged to try to correct the interference by one or more of the following
measures:•

Reorient or relocate the receiving antenna.

•

Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver isconnected.

15 Manufacturer
Struers ApS
Pederstrupvej 84
DK-2750 Ballerup, Denmark
Telephone: +45 44 600 800
Fax: +45 44 600 801
www.struers.com

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 thismanual. 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.
The manufacturer is to be considered responsible for effects on safety, reliability, andperformance of the equipment only if the equipment is used, serviced, and maintained inaccordance with the instructions for use.

Discotom-100

97

Based on: 16157901 H

Declaration of Conformity
Manufacturer

Struers ApS • Pederstrupvej 84 • DK-2750 Ballerup • Denmark

Name

Discotom-100

Model

N/A

FunctionCut-off machine

Type

615

Cat. no.

06156129, 06156146, 06156229, 06156246
Accessories equipment:
06156901, 06156913

Serial no.

EU

Module H, according to global approach
We declare that the product mentioned is in conformity with the following legislation, directives and standards:
2006/42/EC

EN ISO 12100:2010, EN ISO 13849-1:2015, EN ISO 13849-2:2012, EN ISO 13850:2015, EN ISO
16089:2015, EN 60204-1:2018, EN 60204-1-2018/Corr.:2020

2011/65/EU

EN 63000:2018

2014/30/EU

EN 61000-6-2:2005, EN 61000-6-2:2005/Corr.:2005, EN 61000-6-4:2007, EN 61000-6-4-A1:2011

Additional
standards

NFPA 79, FCC 47 CFR Part 15 Subpart B

Authorized to compile technical file/
Authorized signatory

Date: [Release date]en

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