1 DIMAS PP 455E English... 3 Deutsch Italiano Nederlands... 93
3 Operator's Manual PP 455E Contents English Contents Key to symbols... 5 Safety Instructions... 6 Introduction... 9 What is what Technical data Assembling/Installing equipment Fit the hydraulic unit Work procedure for wall sawing Start blade rotation After work is completed Water valve Dismantling the equipment Work procedure for wire cutting Menu functions Start menu English - 3
4 Contents Operator's Manual PP 455E Operations menu Charge the battery Settings Error messages Maintenance EU declaration of conformity English
5 Operator's Manual PP 455E Key to symbols Key to symbols The symbols below are used on the machine and in this Operator's Manual. It is important that the user understands the significance of these in order to work with the machine safely. Manual Please read the Operator's Manual carefully and understand the contents before the machine is started. Remark A hand with a raised index finger with the text Attention signifies that a described element demands extra attention. CE This symbol indicates that the machine conforms to applicable EU directives. Protective equipment Always wear: Approved protective helmet. Approved hearing protection. Approved protective glasses or a visor, and other essential safety equipment. Electrical Warning This symbol warns that there is high voltage present. Warning A large warning triangle with the text Warning signifies that there is a risk of serious personal injury or even death. Caution A smaller warning triangle with the text Note signifies that there is a risk of minor personal injury or damage to the machine. Environmental marking Symbols on the product or its packaging indicate that this product can not be handled as domestic waste. It must instead be submitted to an appropriate recycling station for the recovery of electrical and electronic equipment. By ensuring that this product is taken care of correctly, you can help to counteract the potential negative impact on the environment and people that can otherwise result through the incorrect waste management of this product. For more detailed information about recycling this product, contact your municipality, your domestic waste service or the shop from where you purchased the product. English - 5
6 Safety Instructions Operator's Manual PP 455E Safety Instructions During the design and production of Dimas products, great importance is placed on safety, as well as effectiveness and ease of use. To ensure that the machine remains safe you must pay attention to the following points: WARNING! This machine is only intended for use together with a DIMAS WS 355, WS 463, WS 462, WS 460 and CS All other use is forbidden. CAUTION Under no circumstances may the machine be started without observing the safety instructions. Should the user fail to comply with these, Husqvarna Construction Products Sweden AB or its representatives are free from all liability both directly and indirectly. Read through these operating instructions and make sure that you understand the contents before starting to use the machine. Should you, after reading these safety instructions, still feel uncertain about the safety risks involved you must not use the machine Please contact your dealer for more information. Check that all couplings, connections and hydraulic hoses are in full working order. All operators shall be trained in the use of the machine. The owner is responsible for ensuring that the operators receive training. Make sure that all hoses and electrical cables are connected to the machine correctly before you start the machine. People and animals can distract you, causing you to lose control of the machines. For this reason, you should concentrate and focus on the task at hand. Never leave the machine unsupervised with the motor running. Make sure no clothing, hair or jewellery can fasten in moving machine parts. Onlookers can be injured. You should never, therefore, start the machine without being certain that no people or animals are within the work area. Secure the work are by cordoning off if necessary. Never disconnect any of the hydraulic hoses without first shutting off the unit and ensuring the motors have stopped completely. If despite all precautions an emergency situation should arise, press the red emergency stop button on the top of the unit or press the green start/stop button on the remote control. Wear suitable personal protective equipment, such as a helmet, protective shoes, eye and hearing protection. Hearing protection must always be worn as sound levels exceed 85 db(a). Working close to power lines: When using hydraulic tools close to power lines, the hydraulic hoses must be marked and approved as nonconducting dielectric. The use of any other type of hoses can result in serious physical injury or even death. When replacing hoses, hoses marked non-conducting dielectric must be used. The hoses must be regularly checked for their electrical conductive insulation in accordance with special instructions. Working close to gas conduits: Always check and mark out where gas pipes are routed. Working close to gas pipes always entails danger. Make sure that sparks are not caused in view of the risk of explosion. Remain concentrated and focused on the task. Carelessness can result in serious personal injury or death. Mark out all hidden pipes such as water pipes and gas pipes. Check that power cables and the Canbus cable are not damaged or can be damaged while working. Check tools, hoses, and connections daily for leakage. A crack or leak can cause hydraulic fluid injection in the body or result in other serious personal injury. Do not exceed the rated working pressure for the specific tool or hydraulic hose. Increased pressure can cause leakage or bursting. Do not check for leakage with your hands, contact with the leak can result in serious personal injury caused by the high pressure in the hydraulic system. The tool must not be carried or lifted by the hoses. Do not misuse hoses. Do not use hoses that are twisted, worn, or damaged. Check that the hoses are connected correctly to the tool and that the hydraulic couplings lock as intended before pressurising the hydraulic system. The couplings are locked by turning the outer sleeve on the female coupling so that the slot moves away from the ball. 6 - English
7 Operator's Manual PP 455E Safety Instructions The pressure hoses in the system must always be connected to the tool s intake. The return hoses in the system must always go to the tool's outlet. Confusing the connections can cause the tool to work in reverse, which can result in personal injury. Keep the hydraulic couplings clean and free of dirt. Always switch on the unit's emergency stop switch before transporting the equipment. Check that the hydraulic hoses are not damaged and cannot become damaged during cutting. Leakage can lead to the risk of slipping. Make sure that there is always another person close at hand when you use the machines, so that you can call for help if an accident should occur. Do not use machines if they do not function as they should. Do not modify safety equipment. Check regularly that they function as they should. The machine must not be run with defective or disassembled safety equipment. Regulations for the prevention of accidents, and other general safety and occupational health regulations, must always be followed. Make sure that you always have a first-aid kit close at hand when using the machines. Keep all parts in good working order and ensure that all fixtures are properly tightened. Replace all worn or damaged decals. Store the machines in a locked area, where they are inaccessible to children and adults who have not been trained to operate the machines. Pay attention to the risk of fire from sparks and heat. If there are no local fire protection regulations for cutting or grinding machines, follow the regulations for welding. WARNING! Always use approved protective clothing and approved protective equipment when using the machine. Protective clothing and protective equipment cannot eliminate accident risks, but by using the right clothes and equipment you can reduce the seriousness if an accident should occur. Ask your dealer about approved and recommended protective clothing and protective equipment. English - 7
8 Safety Instructions Operator's Manual PP 455E 8 - English
9 Operator's Manual PP 455E Introduction Introduction DIMAS PP 455E is the latest hydraulic unit from Dimas. The unit is a further developed of the former unit PP 355E and has been produced to match the new DIMAS products and products to be launched in the future. PP 455 is a very compact hydraulic unit, only 970 mm high. Among the new major features is the water cooled motor, which means the user can use more power for longer periods than before. New improved software, adjustable handle and the possibility to attach a wall saw from the WS 400 series on the unit are other new features that facilitate the daily use of the product. PP 455E is supplied with the following equipment: 1 x hydraulic unit 1 x remote control with radio control* 1 x charging adapter (12 V/230 V)* 1 x bag for the radio unit with accessories* 1 x hose assembly, 8 m 1 x Canbus cable, 8 m *The machine is only equipped with a radio on some markets. English - 9
10 Introduction Operator's Manual PP 455E 10 - English
11 Operator's Manual PP 455E What is what What is what Handle The handle is adjustable vertically so that it can easily be adjusted to suit the operator. 2. Hydraulic connections The machine has six hydraulic couplings in total. Some couplings have a red marking sign on the coupling. The hoses with red discs should be connected to these couplings. 3. Remote control The remote control is used to control the unit and saw. The remote control is radio controlled, but can also be controlled using the supplied Canbus cable. On some markets, the machine is not certified for radio and on these markets, the unit can only be controlled using the cable. 4. Saw attachment A Dimas wall saw from the WS 400 series can easily be secured in the attachment on the hydraulic unit during transport. The saw attachment is only mounted on units sold with a saw or according to the customer's wishes. When transporting the unit, the hose assembly can be secured around the attached saw. The hydraulic connections on the hose assembly can be connected to the hydraulic unit during transport 5. Electric motor on/off This is the only control that can start the motor. Stop the electric motor by pressing the start button again, pressing the emergency stop button on the power unit or pressing the emergency stop button on the left-hand side of the remote control. 6. Blade rotation and start water coolant Control to start the blade rotation and the water coolant for the blade. In order for the blade to reach full power, the control must be turned to the right-hand end position. When wire cutting this controls the wire speed. 7. Display Information is given on the display about essential settings, service requirements and any faults. When working, the display shows the current main pressure for blade rotation (not the motion pressure). 8. Blade motion Control for moving the blade. From here you control the blade motion or the magazine tension when wire cutting. 9. Trolley motion Control for horizontal motion of the saw unit. The direction and speed are controlled from here. When the horizontal motion is increased, the blade rotation pressure also increases. This can be read on the display. English - 11
12 What is what Operator's Manual PP 455E 10.Option keys The arrow keys are used to: Scroll through the menus. Increase/decrease numerical values. The confirmation key is used to: Open sub-menus. Confirm values that have been adjusted with the keys. Switch on/switch off sensors. 11.Electrical socket The power to drive the unit is connected here V single phase socket Only available on markets where the incoming power has a neutral. 13.Personal protection/fuses 14.Lifting eye An excellent aid when the saw is to be lifted using a crane or the like. 15.Water flow valve Inside the machine, there is a water valve that opens the water flow to the blade/wire when the unit is connected to the power. The water coolant flow starts as soon as the blade rotation knob is moved from its zero position. The water coolant can, therefore, be activated without starting the electric motor. This can be advantageous, for example, when cleaning the equipment. Adjust the water flow by turning the water flow valve. 16.Water connector Connect the incoming water coolant to the coupling at the bottom of the motor. The maximum permitted pressure on the incoming water is 5 bar and the minimum permitted flow is 5 litres/minute. Connect the water hose that feeds the blade/wire with water coolant to the coupling above the hydraulic connections. 17.Emergency stop Dimas PP 455E is equipped with 2 emergency stop buttons. One on top of the unit and one on the remote control s side (not visible in the figure). Both emergency stops are reset by turning the knob clockwise. NOTE! A lower water pressure and flow than those specified can result in the hydraulic unit not receiving sufficient cooling, which means that the unit can not be run at full power for as long as with a sufficient flow. A too low water coolant flow can also result in the blade/wire not being cooled sufficiently, which means that they will wear extremely quickly English
13 Operator's Manual PP 455E Technical data Technical data Specified hydraulic output 25 kw (33.5 hp) Max. hydraulic oil flow (at 63 A) 65 l/min (17 gal/min) Weight, hydraulic unit incl. oil 140 kg (310 lbs) Power supply: Europe + Australia 5-pin 400 V (32-63 A), 50 Hz Europe + Asia 4-pin 400 V (32-63 A), 50 Hz Norway 5-pin 400 V (32-63 A) 50 Hz 230 V (80 A) 50 Hz Japan 4-pin 200 V (80 A) 50, 60 Hz USA 4-pin 480 V (63-32 A) 60 Hz Canada 4-pin 600 V (20-40 A) 60 Hz Optional equipment 2 x 230 V wall socket NOTE! The higher ampere rating applies for maximum output. Noise level according to ISO/DIS Sound pressure at the operator's ear without load 78 db(a) Sound power level according to the directive 2000/14/EC. Measured noise level 97 db(a). Guaranteed noise level 102dB(A) English - 13
14 Technical data Operator's Manual PP 455E 14 - English
15 Operator's Manual PP 455E Assembling/Installing equipment Assembling/Installing equipment 3. Connect the incoming water hose to the water coupling on the bottom of the motor front on the hydraulic unit. When the machine has been transported to a suitable site, it should be connected: 1. Check the hydraulic fluid level in the power unit. This is checked with the level indicator. Min. level = red line Max. level = black line Do not exceed the max. level when filling the tank with hydraulic fluid. The hydraulic fluid expands when it gets hot and can overflow if the level is too high. Tank volume 16 l (4.2 US gallons). 4. Connect the remote control using the supplied Canbus cable. Tighten the cable connector screws by hand. When the machine is equipped with a radio, a radio antenna can be connected instead of a Canbus cable. This is screwed into the same socket as where the Canbus cable should have been fitted. 2. Connect the incoming power cable (400 V, 63 A or 400 V, 32 A European connector). The cable must be three-phase and earthed. When the machine is equipped with a single phase socket there must also be a neutral otherwise the single phase socket on the distribution box will not work. The power unit must be connected through a 63 A fuse in order to use maximum power. If connected through a 32 A fuse, the saw must be operated at low pressure, and with that cut less effectively to avoid overloading the fuse. Fit the hydraulic unit 1. Check that the emergency stop switches on the unit and the remote control have not been actuated by turning them in the direction of the arrow. When everything is okay the remote control s display shows Connect the hose assembly. English - 15
16 Assembling/Installing equipment Operator's Manual PP 455E 2. Connect the hose assembly. There are two types of hydraulic hoses for the unit: On a wall saw in the WS 400 series, the four thin hoses control the saw's motion motors, i.e. the saw's blade motion and the saw's trolley motion. The two thick hoses drive the blade. When a wire saw CS 2512 is connected to the unit, the two thin hoses control the tension on the magazine arm while the two thick hoses drive the wire. Some couplings on the unit have a red marking sign on the coupling. The hoses with red discs should be connected to these couplings. Connect the water hose between the unit and the saw's water connector and open the water flow valve on top of the unit by turning the handwheel anticlockwise. Press OK to confirm the selection. The first step is then shown. 5. The display now shows DIMAS PP 455E START ELECTRIC MOTOR. ( Menu functions/operation menu/1.a DIMAS PP-455, Start electric motor.) If the display does not show this, follow the instructions shown on the display. Starting the electric motor 1. Before you start the motor, check that: The incoming electrical cable has been connected to a fuse rated at least 25 A. The 32 A or 63 A power setting is chosen (see page 20 Installing the hydraulic power unit ). All knobs on the remote control have been turned to their zero positions. If this is not done, a message on the display will prompt you to do so. The hoses have been connected to a device. 2. Start the electric motor by pressing the remote control s green button once. The Y/D start takes place automatically. The rotation direction is always correct due to an automatic phase relay. To stop the electric motor, press the green button on the remote control once more. When the power cable and water hoses and hose assembly are connected, the machine can be started. Confirm with OK. 3. The display now shows SELECT FUSE 32A. If the available fuse is 32 A, confirm this by pressing the membrane key marked OK. If there is a 63 A fuse available, press the membrane key marked up arrow. The display now indicates SELECT FUSE 63A. Confirm this by pressing the membrane key marked OK. ( Menu functions / 2. Select fuse.) 4. The hydraulic output must be set according to which machine is connected to the hydraulic unit. Select one of the following: 25 kw, 230 bar, 65 l/min 15 kw, 210 bar, 45 l/min or 9 kw, 140 bar, 40 l/min 16 - English
17 Operator's Manual PP 455E Work procedure for wall sawing Work procedure for wall sawing Start blade rotation 1. Turn the controls for blade rotation and water coolant to their maximum positions to start blade rotation and the water coolant. After work is completed 1. After the work is completed, turn off the blade rotation and water flow by turning the blade rotation and water coolant start knobs on the remote control back to 0 2. Turn off the electric motor by pressing the remote control's green button. The amount of water can be adjusted manually with the knob on the top of the unit. 2. Start the blade motion by turning the blade motion knob on the remote control in the desired direction. 3. Start the horizontal motion by turning the horizontal motion knob in the desired direction. Water valve When the power to the hydraulic unit is disconnected, the water valve opens so that the cooling system can be drained prior to transport and to avoid the risk of the cooler and motor freezing in sub-zero temperatures. The unit can be transported vertically or horizontally. If the power is cut during sawing, the water can be turned off by turning the water flow valve on top of the power unit clockwise to the stop position. The water flow connected to the hydraulic tool can also be reduced by turning the water flow valve. English - 17
18 Work procedure for wall sawing Operator's Manual PP 455E Dismantling the equipment 1. Allow the motor to stop completely. 2. Disconnect the power supply cable before disconnecting the water hoses. 3. Disconnect the hydraulic hoses. 4. If there is a risk of freezing, drain the water from the oil cooler by disconnecting both hoses, opening the water flow valve, and tilting the unit forwards. Press the green button on the remote control once more to stop the motor. CAUTION Always clean all the equipment at the end of the working day. Do not use a high pressure washer to clean the machine. 5. Set the feeding flow on the unit to max by turning the control on the remote control clockwise. Work procedure for wire cutting When all the equipment has been assembled cutting can start. In order for the saw to cut as efficiently as possible it should be started as follows: 1. Assemble the pressure reduction block supplied with the wire saw on the hydraulic unit according to the instructions on the block. 2. Connect the two smaller hydraulic hoses to the pressure reduction block. The hoses in the hose assembly marked with a red disc by the coupling shall be connected to the hose on the pressure reduction block that is also fitted with a disc. 6. Tension the wire by carefully turning the knob on the pressure reduction block clockwise until the wire is tensioned sufficiently. Make sure to always check that the wire is seated correctly in all the wheels on the saw. 7. Start the wire drive by turning the control for motor rotation on the remote control clockwise. 3. Close the valve on the pressure reduction block by turning the knob anti-clockwise until it stops and then two turns back. 4. Start the electric motor by pressing the remote control s green button once English
19 Operator's Manual PP 455E Work procedure for wall sawing 8. Carefully increase the motor speed by turning the control for motor rotation. A suitable working pressure when cutting usually lies between 100 and 130 bar, but varies depending on how many wheel sets are used in the magazine, how much wire is in use and the hardness of the material to be cut. 9. When material is cut away the working pressure can drop, which is shown on the display, and the magazine must be tensioned. Do this by turning the knob on the pressure reduction block clockwise. 10.The output tension on the magazine is shown by an indicator on the machine (shown in the min position). When the magazine cylinder is fully tensioned, the machine must be stopped and the wire must be wound around a new wheel set. Then continue to cut as above. Menu functions The menus, shown on the display, are grouped in menus, sub-menus ( Settings ) and part menus. The menus are divided into two sections: Start menu: Here you can select under which conditions the hydraulic unit shall work. Operations menu: Information concerning the operating status is shown here. Start menu The start menu is shown each time the power to the hydraulic unit is switched on. The menu consists of three steps: DIMAS PP 455E Connect hose assembly Press OK when all hoses are connected. Step 2 is then displayed. Select fuse The fuse rating must be set according to the fuse the hydraulic unit is connected to. Select 16 A, 32 A or 63 A Press OK to confirm the selection. Step three is then displayed. Select the output CAUTION Always clean all the equipment at the end of the working day. The hydraulic output must be set depending on the machine connected to the hydraulic unit. Select one of the following options: 25 kw, 230 bar, 65 l/min (3300 psi, 17 US gpm) 15 kw, 210 bar, 45 l/min (3000 psi, 12 US gpm) 9 kw, 140 bar, 40 l/min (2000 psi, 10 US gpm) Press OK to confirm. The first step is then shown on the operations menu. English - 19
20 Work procedure for wall sawing Operator's Manual PP 455E Operations menu The operations menu starts after step 3 in the start menu. All information about operations and all setting options are accessed from this menu. The operations menu consists of eight menus: 1a. Dimas PP-455, 1b Status 2. Water coolant ON/OFF? 3. Phase 1, Phase 2, Phase 3 4. Settings 5. Time 6. Total machine time 7. Battery status (only machines equipped with a radio) 8. Radio channel (only machines equipped with a radio) 1.a DIMAS PP-355, Start electric motor Press the green button on the remote control to start the electric motor. 1b. Status Status is the main information that is always shown on the display when the hydraulic unit with connected machine is operational: STATUS OK, signifies that the unit is operational and no warning messages have been issued. KV xx, where KV represents water coolant and xx ON or OFF. What is shown depends on whether the water coolant is switched on or off. yyy BAR, where yyy represents the instantaneous operating pressure. When time is switched on: mm:ss, is also shown, i.e. the time in minutes and seconds. 2. Water coolant Turn on and turn off the water coolant by pressing OK. The display then shows: STATUS OK KV OFF/ON yyy BAR. Now press arrow down to continue in the operations menu. 3. Phase 1, Phase 2, Phase 3 The instantaneous main voltage to the hydraulic unit is shown under each phase name. When the voltage becomes low, an error message is shown on the display, see the section Error messages. CAUTION Long electrical cables with a small core cross section can result in a voltage drop. The hydraulic unit can then warn of a too low voltage. 4. Settings Via this sub-menu a number of values can be changed to affect the hydraulic unit's characteristics. To access the sub-menu: State the four digit PIN-code 0012 with the help of the arrow keys and the OK button. To save the settings; select Save in sub-menu 3 OUT SETTINGS. Refer to the SETTINGS section for complete information about the setting options, 5. Time The function is used to measure the amount of time a job takes. The time is counted from when the saw starts working. Select: ON, to enable. OFF, to disable. RESET TIME, to reset. Quit by pressing OK. The main information Status is then shown on the display. When you select time ON (and when the hydraulic unit is operational, see 1.b) 00:00 is also shown in the lower right corner of the display. Press arrow down to continue in the operations menu. The total time that the hydraulic unit has been operational is shown here. The time is stated in hours and minutes (hhhh:mm) English
21 Operator's Manual PP 455E Work procedure for wall sawing 7. Battery status (only machines equipped with a radio) This function checks the remote control s battery. Different messages are shown on the display, depending what is currently happening with the battery: 0% BATTERY 100% When the remote control is connected and the battery is being charged a horizontal column is shown below the 0 % % scale. The column length against the scale shows how much of the charge remains in the battery. CHARGING THE BATTERY Shown when the remote control is connected and the battery is charging. The charging time from 0 % to 100 % is approximately 9 hours. BATTERY FULLY CHARGED Shown when the battery is charged to 100 %. BATTERY DISENGAGED shown when the battery is disengaged from the remote control. The message is also shown when the charging unit in the remote control has been damaged. Charge the battery NOTE! This chapter only concerns machines equipped with a radio. The remote control is equipped with a 7.2 volts battery. The emergency stop on the remote control should always be in the extended position when charging. The battery can be charged as follows: With the Canbus cable (Part No ) With the charging cable to the 12 volts outlet in the car (Part No ) With the charging cable to the battery charger (Part No ) With the Canbus cable Connect the Canbus cable between the remote control and the unit. Make sure that none of the emergency stops are pushed in and that the power unit is voltage fed. Display CHARGING THE BATTERY. The power unit can be used during charging. Charging takes approximately 10 hours. With the charging cable Connect the charging cable between the remote control and the 12 volt outlet in the car. Check that the emergency stop on the remote control is not pushed in. The display shows CHARGING THE BATTERY when charging is in progress. The charging time is approximately 6 hours. NOTE! ONLY 12 V To charge with the battery charger Connect the charging cable between the remote control and the battery charger. Now connect the battery charger to a 230 volts mains socket. Check that the emergency stop on the remote control is not pushed in. The display shows CHARGING THE BATTERY when charging is in progress. The charging time is approximately 6 hours. NOTE ONLY 230 V English - 21
22 Work procedure for wall sawing Operator's Manual PP 455E 8. Radio channel When the remote control is only used in battery mode, a radio antenna must first be connected to the unit: Remove any cable connection. Push in the antenna's connector in the socket on the hydraulic unit. Make sure that the slot in the antenna connector aligns in the socket. Screw on the connector's ring on the socket. A radio channel must be selected when the antenna is connected. Select: 0, 1 or 2 Confirm the selection by pressing OK and then arrow down. The main information Status is then shown on the display. Press arrow down again to continue in the operations menu. Settings All Setting options for the hydraulic unit and the remote control are accessed via this sub-menu. A four digit code must be entered to access the settings sub-menu. This code is The code is stated one digit at a time, from left to the right. The arrow keys scroll from 0-9 and the OK button confirms. The SETTINGS menu consists of seven sub-menus, which in turn consist of a number of part menus: 1. Select language 2. Adjust the hydraulic valve for the blade 3. Adjust the hydraulic valve for the feed 4. Sensor on/off calibrate 5. Hydraulic unit settings 6. Basic setting 7. Out settings The numbers refer to the following headings. 1. Select language Using this sub-menu you can set the language you wish to use on the display. The sub-menu always has the heading in English. The selected language is stated under heading. To select the language: Scroll using the arrow keys until the required language is shown. Press OK. Press the down arrow to continue to the next submenu. 2. Adjust the hydraulic valve for the blade This sub-menu contains setting options for the rotation of the blade and consists of three part menus: 2.1 Change the start point for the blade 2.2 Change the end point for the blade 2.3 Change the ramp time for the blade 2.1. Change the start point for the blade The start point value should be adjusted so that the blade rotation is as low as possible when the blade rotation knob (pos. 2) is turned from its left-hand position. A too low value results in the need to turn the knob before the blade starts to rotate. A too high value results in the blade rotating too quickly when the knob is turned English
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