Operating Instructions Spare Parts List
Contents
1. FI Einschaltung Ra amp a 88 Steuerung ab oo olo Funk rg 1 2 95 96 1 2 eu ie t a 3 4 s fs WR Kommen soov 2 Pi 4 Kommen 2av 3 Verbindungskabel Er ey en Verbindungskabel nee Lena A 3 Steuerung Funk bes se den ome Achtung I ene Drahtmarkierung 24V t 2avoe Funkeinheit Hetronic Einschaltung Steuerung ab Funk ABB Relais D1 u Motorschutz u2 F1 Not Aus auf Geh use CR 5 L2 3 Li 2 A2 EP At Lg Einschaltung Steuerung ab Funk 1 2 95 96 102 Lemmen soov 5 6 O Klemmen 24v Einspeisung Funk Zuleitung Speisung im RC Geh use 400v is U2 PPH20RR 000 Fig 3 3 28 weu s 21 21 K3M K2M 2 22 At A1 A Al AZ kg 2 Az KIM7H K2M7D KaMTY KAT Wiring diagram ONAR UN Elec box Reversing switch Contactor Thermal relay Interlock Circuit breaker 7a Device protective switch 7b Protective hood 8 EMERG STOP 9a 9b 10 11 12 13 14 Hour counter Rotation lock Phase sequence relay Time relay Connector CEE 63 5 Relay Power supply unit Design and function Operating Instructions Zuleitung 3 x 400V 50 Hz 3L N PE 8 L1 L2 L3 MP E s Fe el 3 a Basle 11 K1M Ei 2 4 6 12 u1v1Ww1 r Va 3 4 3 2 3 Wiring diagram Softstarter Steuerung PPH20RRP und PPH25R2. Transport Transport Safety instructions Crane shackles and transport handles Disposal General Disposal regulations Disposal of the Drive Unit PPH20RR PPH20RR 000 Operating Instructions Introduction PPH20RR 000 0 1 Introduction Congratulations You have decided to purchase a tried and tested TYROLIT Hydrostress AG system and have thus acquired a highly sophisticated and reliable state of the art unit Thanks to the emphasis we place on quality assurance your TYROLIT Hydrostress AG system is another top of the range Swiss product e High performance Reliable operation e High portability Easy handling e Low maintenance costs Only original TYROLIT Hydrostress AG spare parts can guarantee quality and interchangeability In the case of neglected or inappropriate maintenance we will be unable to accept the warranty commitment as specified in our terms of delivery Any repair work must be carried out by trained personnel only If you need more details about how to keep your TYROLIT Hydrostress AG system in perfect condition please contact our after sales service for fur ther information We hope that working with your TYROLIT Hydrostress AG system will be a problem free and fault free experience TYROLIT Hydrostress AG Management Copyright TYROLIT Hydrostress AG May
3. e Is there sufficient oil in the Drive Unit PPH20RR Is there any damage to cables or plugs Has the EMERGENCY STOP been reset Connecting the Drive Unit PPH20RR Connecting the hoses Danger from uncontrolled movements and uncontrolled escape of oil Never connect or disconnect hoses while the drive unit is running Failure to observe this regulation may result in cut wounds or inju ry to body parts as well as damage to property PPH20RR 000 Operating Instructions Operation 5 3 2 2 Hose connections Fig 5 1 Hose connections 4 2 3 4 5 Couplings of main motor Water connection Couplings of feed motor 1 Couplings of feed motor 2 Leak oil connection hydraulic motor Gr 3 Proceed as follows Visual inspection Check Oil leaks from hoses and couplings Couplings for damage and contamination Hoses for damage Push the hose coupling on to its counterpart until you hear it click e Twist the locking ring of the coupling Information If hoses cannot be connected or this cannot be done easily they are un der pressure Release pressure in hoses via the pressure relief device Release pressure in the Drive Unit PPH20RR see Chapter 5 5 3 2 3 B 5 3 Never use force to connect couplings 5 3 2 3 Release pressure in the Drive Unit PPH20RR Proceed as follows e Turn the forward reverse switch on the Drive Un
4. 1 12 Protection class IP 65 Internal control voltage valve control 24V DC Secondary socket Connections 2 sockets 230V 10A with fault current tripping at 10 mA Water Pressure min 2 bar to max 6 bar Quantity min 6 l min at max 250 Noise exposure noise level Depending on the working environment and the connected device the Drive Unit PPH20RR can produce high noise levels during operation Noise danger When operating the PPH20RR drive unit the wearing of hearing protection is mandatory at all times If this instruction is not followed irreparable hearing damage may result Noise level measurement Noise level measured at the ear of the operator 0 5 m from the Drive Unit PPH20RR noise power level according to ISO 3744 drive unit only highest value taken from all operating states at full load mean values from three series of measurements Noise level 83 dB A noise power level 92 dB A Scope of supply e Drive Unit PPH20RR Radio remote control e Water purge pump e Operating Instructions Spare parts list Product description Operating Instructions 1 13 Country list for radio transmission frequency Country Frequency Country Frequency MHz MHz Australia 434 Mexico 458 Belgium 434 New Zealand 434 Bolivia 434 Netherlands 434 Brazil 434
5. 2007 TYROLIT Hydrostress AG Witzbergstrasse 18 CH 8330 Pf ffikon Switzerland Phone 41 0 44 952 18 18 Fax 41 0 44 952 18 00 0 1 Introduction Operating Instructions 0 2 0 3 0 4 Validity of these Operating Instructions This manual is only valid for the following system Drive Unit PPH20RR Standards These Operating Instructions have been prepared in accordance with the CE Machinery Directive Appendix and with the relevant standards in force at the time of printing Delimitation of the system These Operating Instructions describe the use of the Drive Unit PPH20RR PPH20RR 000 Operating Instructions Product description PPH20RR 000 1 1 1 2 1 3 1 4 Product description Application The Drive Unit PPH20RR has been designed as a component for the fol lowing concrete processing systems e Hydraulic wall saw systems e Hydraulic diamond wire saw systems e Hydraulic core drilling systems e Hydraulic chainsaws The applicable mandatory limitations on use and other parameters are con tained in Chapter 1 Technical data 1 7 B 1 4 Safety measures Any use other than for the intended purpose see Chapter 1 1 B 1 1 con stitutes abuse or misuse Operating instructions for connectable equipment In order to ensure safety in the workplace and in danger areas as well as the safe operation of connectable equipment the relevant Operating In structions
6. as fires may also occur Danger of allergic reactions if skin comes into contact with hydraulic oil Persons who have an allergic reaction to hydraulic oil must wear protective gloves and goggles when carrying out work where they come into contact with hydraulic oil Any areas of the skin affected must be rinsed immediately with copious amounts of water Failure to observe this regulation may result in allergic reactions or injury to the eyes PPH20RR 000 2 5 Safety instructions Operating Instructions 2 6 PPH20RR 000 Operating Instructions Design and function 3 Design and function 3 1 Design Fig 3 1 Main components 1 Hydraulic unit 10 Pump assembly 2 Antenna 11 Oil level indicator 3 Oil cooler 12 Radio receiver 4 Pressure gauge 13 Electrical connection 5 Water valve 14 Electrical box 6 Suspension shackle 15 Wheel 7 Electric motor 16 Hood 8 Radio remote control 17 Oiltank 9 Transport handle with hose bracket PPH20RR 000 3 1 Design and function Operating Instructions 3 2 Function 3 2 1 Hydraulic circuit diagram L R w vw aan AP wa 198 n 224 oe 226 623 20 2 ao Ee 9 Al B B Soe AXL waXt IE 25 Pl T 13 13 Pl T L 7 14 A oz 128 Lra gt H 2 f Se S ee j 26 p
7. at the power supply Check power supply building site Power supply phases incorrectly Check power supply connected Phase missing Check power supply Remote controller not switched on or controls in wrong position see Chapter 5 5 4 1 B 5 6 No radio connection Test with cable insert PPH20RR 000 7 1 Corrective maintenance Operating Instructions Fault Possible cause Solution Drive unit starts up but then switches off again Fuse of building site power supply trips Fuse protection too weak Change power supply Incorrect voltage The details on the name plate must correspond to the mains network values voltage and frequency Softstarter has switched drive unit off because Overvoltage in bypass mode red LED in control cabinet flashes 8x Rotor acceleration is terminated after 1 second red LED in control cabinet flashes 6x Turn forward reverse switch to 0 position and wait until fan is no longer audible then restart In event of repeated failure contact TYROLIT Hydrostress AG Customer Service No power although electric motor is running and valves are open Motor runs in wrong direction Change direction of rotation with for ward reverse switch For drive unit with monitoring Inform TYROLIT Hydrostress AG after sales service Defective pump Have pump replaced by TYROLIT Hydrostress AG or an authorised r
8. datae re rare ha Re a i i 4 1 8 Elydrauliesmre seen ir 5 1 9 Electrical equipment 6 1 10 Water Sse a n e E e ee a ees 7 1 11 Noise exposure noise level 7 1 12 Scope of Supplyss2oee seat eee a 7 1 13 Country list for radio transmission frequency 8 2 Safety instructions 1 2 1 Generale asses tester saiae aa ae i aaa eE 1 2 2 General safety rules 1 2 3 Safety principles 2 2 4 Responsibility ar ee 3 2 5 Generally applicable warnings of residual dangers 5 3 Design and function 1 3 1 Design 29 Stee eer yas ee ee Stes cues 1 3 2 FUNCION S sA S6tuiieresere aes sen enger 2 3 3 Radio remote control 5 4 Controls and displays 1 4 1 CONTOS ar rn 1 4 2 Bleciic contole ee ee ee 2 4 3 Displays ses re Rei ee 4 5 Operation 1 5 1 Personnel qualifications 1 5 2 System requirements 1 5 3 Preparatory operations 7 7 2 5 4 Working n rrr ian E iie 6 5 5 After the work 10 6 Servicing 1 6 1 Servicing and maintenance table 1 Overview Operating Instructions II Il 7 1 7 2 8 1 8 2 8 3 9 1 9 3 Corrective maintenance Troubleshooting Storage
9. must in all cases be followed Name plate Fig 1 1 Name plate Product description Operating Instructions 1 5 Information sign Attached to the plastic hood is an information sign containing the following information Hose connections For a description see Chapter 5 5 3 2 1 B 5 2 Pressure stages For a description see Chapter 5 5 4 3 B 5 8 Risk of frost For a description see Chapter 6 6 1 1 B 6 2 e Hydraulic oil For a description see Chapter 6 6 1 2 1 B 6 2 PPH2ORR 40 1 min 501 min 215 bar 180 bar 33 1 min 680 1 min 260 bar 150 bar Fig 1 2 Information sign 1 2 PPH20RR 000 Operating Instructions Product description PPH20RR 000 1 6 1 6 0 1 1 6 0 2 EC Declaration of Conformity Description Hydraulic drive unit Type designation Drive Unit PPH20RR Year of construction 2007 We declare under our own liability that this product complies with the fol lowing directives and standards Directive applied Machinery Directive 2006 42 EC EC EMC Directive 89 336 EC EC Low Voltage Directive 73 23 EC Standards applied EN 12100 1 Safety of machinery Basic concepts general design EN 12100 2 principles EN 294 Safety of machinery Safety distances to prevent upper limbs reaching danger areas EN 349 Safety of machinery Safety distances to avoid crushing of body parts EN 982 Safety of machinery Safety requirements of safety syste
10. or shown on the warning signs attached to the machine Damage caused by defective or neglected maintenance work Independently performed conversions and alterations may affect safety and are not permitted General safety rules Statutory provisions The generally applicable national and local safety and accident prevention provisions and the supplementary operator regulations must be followed and complied with Inspection and maintenance obligation The operator is under an obligation to use the Drive Unit PPH20RR only when it is in a perfect and undamaged condition The maintenance intervals shown in the Operating Instructions must be adhered to without fail Malfunctions and mechanical damage must be rectified without delay Spare parts Only TYROLIT Hydrostress AG original spare parts may be used Otherwise damage can be caused to the Drive Unit PPH20RR or other property and may result in personal injury Power connections The Drive Unit PPH20RR must be connected and coupled in accordance with the Operating Instructions 2 1 Safety instructions Operating Instructions 2 2 2 3 2 3 1 2 3 2 2 3 3 2 3 4 2 3 4 1 2 3 4 2 Safety principles Delimitation of the safety concept The Drive Unit PPH20RR does not affect the safety concept of the connected systems equipment and installations Safety elements Protection from live electrical parts All functional units containing parts wh
11. 5 8 5 4 3 5 4 4 Selecting the pressure stage Once the Drive Unit PPH20RR has been started properly you can select the pressure stage 40 l min 215 bar 50 l min 2 180 bar 3 4 601 min 150 bar 33 l min 1 260 bar Fig 5 6 Selecting the pressure stage Proceed as follows e Set the pressure stage selector switch to the desired pressure stage and turn the main motor potentiometer from 0 to 100 Information The pressure stages can be freely changed and selected during the work operation When changing the pressure stage the cutting tools should not be under load To ensure the optimal tool speeds the data for the relevant connected devices must be taken into consideration Power control The power of the main motor and the feed motor is controlled via the po tentiometer Fig 5 7 Potentiometers 1 Feed motor potentiometer 2 Main motor potentiometer PPH20RR 000 Operating Instructions Operation PPH20RR 000 5 4 5 5 4 6 Feed movements The feed motors for the travel motion and the swivelling can only be con trolled individually by means of the feed joystick Fig 5 8 Feed A Travel feed B Swivel feed Feed locking So that the joystick does not have to be held in position during the travel feed motion the travel feed can be locked Proceed as follows Push the joystick in the desired travel direction and at t
12. AOL Operating Instructions Spare Parts List Drive Unit PPH20RR Index 000 10983818 en 24 10 11 Operating Instructions Manufacturer s address TYROLIT Hydrostress AG Witzbergstrasse 18 CH 8330 Pf ffikon Switzerland Phone 41 0 44 952 18 18 Fax 41 0 44 952 18 00 TYROLIT Hydrostress AG reserves the right to make technical changes without prior notice Copyright 2007 TYROLIT Hydrostress AG CH 8330 Pfaffikon ZH All rights reserved in particular the copying and translation rights The reprinting of these Operating Instructions including extracts is prohib ited No part of these Operating Instructions may be reproduced in any form whatsoever or be processed copied or distributed using electronic systems without the written permission of TYROLIT Hydrostress AG 10983818 en 24 10 11 Operating Instructions Overview PPH20RR 000 Overview Page 0 Introduction 1 0 1 Congratulations sense sees sda ee hak sig sis en 1 0 2 Validity of these Operating Instructions 2 0 3 Standards Sao ga ese er EHE Ase seas 2 0 4 Delimitation of the system 2 1 Product description 1 1 1 Application ksa ern 1 1 2 Safety measures Sr me er de 1 1 3 Operating instructions for connectable equipment 1 1 4 Name palm ra See 5 1 1 5 Information sign 2227 2 1 6 EC Declaration of Conformity 3 1 7 Technical
13. Norway 434 Brunei 434 Austria 434 Bulgaria 434 Poland 434 China 419 Portugal 434 Denmark 434 Puerto Rico 458 Germany 434 Romania 434 Finland 434 Russia 434 France 434 Sweden 434 Greece 434 Switzerland 434 Great Britain 434 Singapore 434 Hong Kong 458 Slovenia 434 India Mumbai 434 Spain 434 India New Delhi 434 South Korea 447 Indonesia 434 South Africa 434 Ireland 434 Taiwan 480 Iceland 434 Thailand 434 Italy 434 Turkey 434 Japan 429 Ukraine 434 Canada 458 USA 458 Croatia 434 USA South America 434 Liechtenstein 434 Venezuela 434 Lithuania 434 United Arab Emirates 434 Luxembourg 434 Malaysia 434 Fig 1 4 Country list for radio transmission frequency PPH20RR 000 Operating Instructions Safety instructions 2 2 2 2 1 2 2 2 2 2 3 2 2 4 PPH20RR 000 Safety instructions General All persons who work on and with the Drive Unit PPH20RR have a duty to read and understand the Operating Instructions Observance of the safety instructions The Drive Unit PPH20RR has been inspected before being shipped and is delivered in perfect condition TYROLIT Hydrostress AG does not accept any liability for damage which is caused by failure to observe the instructions and information provided in the Operating Instructions This applies in particular to Damage caused by improper use and operator error Damage caused by failure to observe safety related information in the Operating Instructions
14. PH20RR 000 5 3 4 EMERGENCY STOP In danger situations the EMERGENCY STOP button must be pressed im mediately Fig 5 3 EMERGENCY STOP 1 EMERG STOP on the Drive Unit PPH20RR 2 EMERG STOP on the radio remote control Deactivating EMERGENCY STOP Information If the EMERG STOP is activated on the radio remote control the LED pilot lamp flashes quickly Fig 5 4 Deactivating EMERGENCY STOP Proceed as follows The following controls must be moved into the 0 position Feed joystick 3 Main motor On Off 5 Turn the EMERG STOP button 1 2 clockwise e Push the main switch 4 to the ON position 5 5 Operation Operating Instructions 5 4 Working 5 4 1 Starting the Drive Unit PPH20RR Information The Drive Unit PPH20RR should only be switched on in a level and upright position If the surface has an incline secure the drive unit to pre vent rolling away Proceed as follows Check that the EMERG STOP buttons on the radio remote control and on the Drive Unit PPH20RR are deactivated Move the controls shown below on the remote controller into the 0 posi tion Fig 5 5 0 position 1 Start switch 2 Feed joystick 3 Main motor On Off Turn the forward reverse switch on the Drive Unit PPH20RR to posi tion 1 e Switch on the radio remote control by means of the Start switch Pilot lamp lights up red first of al
15. RP mit Softstarter L1 ABB Relais D1 Motorschutz a OD ab Speisung 24VDC Verbindungskabel Steuerung Speisung 24 ala Achtung I Drahtmarklerung 24V aoov Ac Speiseeinheit 10A o o Foa Softstartor K2 Eg a Hetronic Funkeinheit Einschaltung Steuerung ab Funk Verbindungskabel Steuerung Funk Achtung I Drahtmarkierung 24V osszass 11L9 LUEFT o0 10982396 11L3 LUEFT 00 Axian tter komplett Q Immernonason KunststoftL fung Saum eee 4 24VDC T l l l l l 1 2 phasig I l l l Einschaltung Einschaltung Sieuenung ah or Funk Li ABB RelaisiD1 Motorschutz Fi Steuerung ab Funk 2 u 2 pal las 26 a e fe o Fl Sidos Steckdosen yo zr y4 P ite alr 9 rare 7 x g RL Kermen soov ts Te Te 40 amp Kommen 24v 5 Dal ls 3 3 z F2 F380 N77 5 2 Js gu 6 Km fag A 43 x2 h 5 MB ve FREE oe H10 x fur wis 7 p 1K A2 R Ka A a Softstart l BE 12 id 1 ri 72 T3 934 v2 W2 U2 v2 u2 w2 Fig 3 4 Wiring diagram Softstarter 1 Elec box 7 Softstarter 2 Reversing switch 3 Circuit breaker 4a Device protective switch 4b Protective hood 5 EMERG STOP 6a Hour counter 6b Rotation lock 8 Connector CEE 63 5 9 Relay 10 Power supply unit 11 Contactor 12 T
16. Select the pressure stage 4 see Chapter 5 5 4 3 B 5 8 Allow theDrive Unit PPH20RR to run for a maximum of 5 seconds e Switch off the Drive Unit PPH20RR see Chapter 5 5 4 7 8 5 10 e Wait for 1 minute e Repeat the start up and shutdown process three times e Check the oil level and top up the hydraulic oil as necessary Fit tank cover The system is now free of air PPH20RR 000 Operating Instructions Corrective maintenance 7 1 Corrective maintenance Troubleshooting The following table will help you to narrow down and rectify the source of the fault Fault Possible cause Solution Drive Unit PPH20RR does not run although the mains cable is connected Forward reverse switch in wrong position see Chapter 5 5 4 1 B 5 6 Emergency stop has been activated Release emergency Stop see Chapter 5 5 3 4 B 5 5 Softstarter has switched drive unit off because Overvoltage as a result of seized rotor red LED in control cabinet flashes 5x Turn forward reverse switch to 0 position and wait until fan is no longer audible then restart In event of repeated failure contact TYROLIT Hydrostress AG Customer Service No voltage at drive unit because Automatic circuit breaker in electric controller has tripped Reset automatic circuit breaker Mains cable is defective Replace the mains cable No voltage
17. ation Electrical data are only valid for the installed loads 3 P LNPE 400 VAC 50 Hz Voltage variations For countries where different mains networks operate the following types are available Drive Unit PPH20RR 200 220 V 50 Hz Drive Unit PPH20RR 380 420 V 50 Hz Drive Unit PPH20RR 200 240 V 60 Hz Drive Unit PPH20RR 420 480 V 60 Hz Drive Unit PPH20RR 380 V 60 Hz A danger will arise if the Drive Unit PPH20RR is operated with a different mains network voltage The details on the name plate must correspond to the mains net work values voltage and frequency Damage may be caused to the unit if it is connected to a different voltage there is also a risk of fire and personal injury Motor Electric motor water cooled Power supply 3 P INPE 380 420 V 50 Hz 420 480 V 60 Hz Current consumption 200 220 V 50 Hz 64 A 380 420 V 50 Hz 32 A 200 240 V 60 Hz 60 A 420 480 V 60 Hz 28 A 380V 60 Hz 35A Output P1 20 kW P2 17 kW Speed at 50 Hz 2880 rpm at 60 Hz 3480 rpm Motor protection Thermal protection Winding thermostat Electrical protection Thermal relay Cooling Water cooling Cooling channels in the aluminium Throughput of cooling water min 6 l min at max 25 C Water connection min 2 bar max 6 bar PPH20RR 000 Operating Instructions Product description PPH20RR 000 1 9 2 3 1 9 2 4 1 9 2 5 1 10 1 11 0 1
18. carried out using the crane shack les provided Only undertake crane transport with serviceable building and mo bile cranes Failure to observe this regulation may lead to serious physical in jury possibly even death and to property damage Danger from the lifting of heavy loads Units which weight more than 30 kg must not be lifted without suit able equipment For transport use the handles provided Always keep handles clean and free of grease Failure to adhere to this regulation may result in physical injury and damage to property Transport Operating Instructions 8 3 Crane shackles and transport handles Fig 8 1 Crane shackles and transport handles 1 Crane shackles 2 Transport handles with hose bracket Danger of falling parts When crane transport is used the Drive Unit PPH20RR must be transported alone without the radio remote control and hoses Failure to observe this regulation may lead to serious physical in jury possibly even death and to property damage 8 2 PPH20RR 000 Operating Instructions Disposal PPH20RR 000 9 1 Disposal General The operator can recycle or dispose of the Drive Unit PPH20RR himself provided that he observes the statutory provisions In order to dismantle the unit correctly and to properly separate the materials some knowledge of mechanical procedures and knowledge abo
19. cturer TYROLIT Hydrostress AG or a company expressly nominated by TYROLIT Hydrostress AG is deemed to be the manufacturer of the products supplied by TYROLIT Hydrostress AG Within the context of an integrated quality and safety control system the manufacturer is entitled to request from the operator information about the products Operator owner The operator named by TYROLIT Hydrostress AG is the primary legal entity responsible for the correct use of the product and for the training and assignment of the authorised personnel The operator sets out the mandatory skills and level of training of the authorised personnel for his company Operator user User is the term employed by TYROLIT Hydrostress AG to designate a person who independently performs the following work e Sets up TYROLIT Hydrostress AG machines or systems for tasks according to the intended purpose Performs tasks independently and monitors these e Locates malfunctions and initiates or performs troubleshooting e Carries out servicing and simple maintenance Monitors the correct functioning of the safety devices Service engineer Service engineer is a term used by TYROLIT Hydrostress AG to designate a person who independently performs the following work e Installs TYROLIT Hydrostress AG machines and systems and controls their correct application Makes adjustments to machines and systems for which special access rights are required Perfo
20. d reverse switch to 0 position and wait until fan is no longer audible then restart In event of repeated failure contact TYROLIT Hydrostress AG Customer Service Main motor potentiometer does not work Defective potentiometer Note see Chapter 5 5 4 2 B 5 7 Inform TYROLIT Hydrostress AG after sales service Defective proportional valve Inform TYROLIT Hydrostress AG after sales service Defective pump Inform TYROLIT Hydrostress AG after sales service No pressure build up in feed circuit Defective potentiometer Inform TYROLIT Hydrostress AG after sales service Defective proportional valve Inform TYROLIT Hydrostress AG after sales service Defective pump Inform TYROLIT Hydrostress AG after sales service PPH20RR 000 7 3 Corrective maintenance Operating Instructions Fault Possible cause Solution No water emerging Water line is blocked Clean the water line Water valve on feed line is closed Open water valve Insufficient water pressure Check water circuit see Chapter 1 1 10 B 1 7 Defective water valve Inform TYROLIT Hydrostress AG after sales service Water filter is blocked Clean the filter or inform TYROLIT Hydrostress AG after sales service 7 4 If you are unable to remedy a fault please call our service centre see man ufacturer s address on th
21. e reverse of the title page To guarantee a rapid and professional solution to the problem it is impor tant that you have prepared as follows before calling Try to describe the fault as accurately as possible Note the type and index designation of your unit name plate e Have the Operating Instructions close to hand Fig 7 1 Name plate PPH20RR 000 Operating Instructions Corrective maintenance PPH20RR 000 7 2 Storage The Drive Unit PPH20RR consists partially of material which can cor rode If you take the unit out of service for an extended period proceed as follows Blow out the water from the water lines e Lightly oil the unit Store in a dry location 7 5 Corrective maintenance Operating Instructions 7 6 PPH20RR 000 Operating Instructions Transport 8 1 8 2 A PPH20RR 000 Transport Transport The Drive Unit PPH20RR is a high quality technical device Protect it against transport damage Do not place any parts on or against the Drive Unit PPH20RR Protect the Drive Unit PPH20RR from impacts The Drive Unit PPH20RR must be secured against rolling away dur ing transport Safety instructions It is essential to observe the following safety instructions especially in re lation to taking the Drive Unit PPH20RR out of service Danger from incorrect crane transport Crane transport should only be
22. epresentative Defective toothed belt Have toothed belt replaced by TYROLIT Hydrostress AG or an authorised representative The hydraulic oil is cloudy light in colour and the tank overflows Defective oil cooler Inform TYROLIT Hydrostress AG after sales service Warning Do not continue operating the unit otherwise hydraulic ele ments could be damaged Coupling leaks Defective seal Defective coupling Replace seal Replace coupling 7 2 PPH20RR 000 Operating Instructions Corrective maintenance Undervoltage at the power supply Overvoltage at the power supply Cross section of power supply cable too small Water supply not correct Fault Possible cause Solution The drive unit stops suddenly Power supply interrupted because electric motor or thermal relay has overheated Reasons Check power supply see Chapter 1 1 9 1 B 1 6 Check power supply see Chapter 1 1 9 1 B 1 6 Use mains cable with correct cross section see Chapter 5 5 3 1 B 5 2 Check water circuit see Chapter 1 1 10 B 1 7 Defective plug connection Check plug connection No radio connection Replace the battery Work with cable insert Softstarter has switched drive unit off because Overheating in control electronics red LED in control cabinet flashes 7x Phase unbalance red LED in control cabinet flashes 9x Turn forwar
23. he same time press the locking switch e When the joystick and the locking button are released the feed is locked Information In order to release the feed lock move the joystick slightly in any desired direction 5 9 Operation Operating Instructions 5 10 5 4 7 5 5 Shutting down the Drive Unit PPH20RR Proceed as follows e Switch off the electric motor main switch of radio remote control Shut off the cooling water Water On Off button of radio remote control e Close the water valve on the Drive Unit PPH20RR Turn the Start switch on the radio remote control into the 0 position Turn the forward reverse switch on the Drive Unit PPH20RR to the 0 position Information Only shut down the Drive Unit PPH20RR with the EMERGENCY STOP in a genuine emergency After the work Proceed as follows Unplug the mains plug Drive Unit PPH20RR e Uncouple the water supply on the Drive Unit PPH20RR e Open the water valve on the Drive Unit PPH20RR Blow out the water from all the lines purge pump e Uncouple the hydraulic hoses Clean the Drive Unit PPH20RR with water Information In order to prevent frost damage if there is a risk of frost the entire water system must be emptied and blown out upon finishing work or prior to extended breaks in the work PPH20RR 000 Operating Instructions Servicing 6 Ser
24. hermal relay 13 LED PPH20RR 000 Operating Instructions Design and function 3 3 3 3 1 3 3 1 1 A 3 3 2 PPH20RR 000 Radio remote control Design Fig 3 5 Remote controller 1 Controls 2 Plastic housing Accessories Fig 3 6 Accessories 4 2 3 4 2x interchangeable battery Battery charger Cable insert Battery insert The battery charger is exclusively for recharging the interchangeable re chargeable battery The battery insert and the cable insert must not be inserted Function The radio remote control allows a secure simple and mobile method of working The operator can at all times be in a position where he has a full view of the unit during operation 3 5 Design and function Operating Instructions 3 6 PPH20RR 000 Operating Instructions Controls and displays 4 Controls and displays 4 1 Controls 10 Fig 4 1 Controls Water and hydraulic couplings Safety socket Schuko socket Forward reverse switch Device protective switch EMERG STOP Water valve Suspension shackle Remote controller 0 Cable connection of remote controller arWwWND gt 0OON OD 4 1 1 Radio remote control 11 10 9 87 6 Fig 4 2 Radio remote control 1 Locking switch 7 Pressure stage selector switch 2 Pilot lamp radio amp battery 8 Water In Out 3 EMERG STOP 9 Main motor potentiometer 4 Main switch of drive unit 10 Ma
25. ich carry hazardous voltages are shock protected by suitable covers Removal of protective devices Protective devices may only be removed if the unit has been switched off disconnected from the mains and is at standstill Safety components in particular may only be removed and refitted by authorised personnel see Chapter 2 2 4 1 B 2 3 Before switching the Drive Unit PPH20RR back on again the safety elements must be checked to ensure correct operation Safety measures organisational Product monitoring obligation Operating personnel must notify changes in operational behaviour or safety related components to a responsible person or the manufacturer immediately Location of the Operating Instructions A copy of the Operating Instructions must be available to staff at all times at the place of use of the equipment PPH20RR 000 Operating Instructions Safety instructions 2 4 2 4 1 2 4 2 2 4 3 2 4 4 2 4 5 PPH20RR 000 Responsibility Authorised personnel Work on or with the TYROLIT Hydrostress AG machines or systems may only be performed by authorised personnel Personnel are considered by TYROLIT Hydrostress AG to be authorised if they meet the necessary training and know how requirements and they have been assigned a precise functional role The personnel qualifications for the corresponding work are contained in the introduction under General of the respective chapters Manufa
26. in motor On Off 5 Start switch 11 Feed motor potentiometer 6 Feed joystick PPH20RR 000 4 1 Controls and displays Operating Instructions 4 2 4 2 4 2 1 4 2 1 1 4 2 1 2 Electric controls Secondary sockets The Drive Unit PPH20RR is equipped with 2 x 230V 10 A secondary sockets with fault current tripping at 10 mA The secondary sockets may only be used with a neutral conductor Fig 4 3 Secondary sockets 1 On Off switch 3 Safety socket 2 Test button 4 Schuko socket Safety socket The safety socket has integral residual current protection and is the active personnel safety device The operating principle of the safety socket is the same as that of a residual current circuit breaker Information Equipment on which the safety socket interrupts the power circuit during operation is defective and must be checked by an electrical engineer and if necessary repaired Monitoring The safety socket must be checked monthly during operation The check can be performed with or without the plug inserted as follows The switch must be in the I position Press the Test button the switch must switch off 0 position Push the switch back into the I position Schuko socket The Schuko socket is connected and protected via the safety socket PPH20RR 000 Operating Instructions Controls and displays 4 2 2 4 2 3 4 2 4 4 2 5 PPH20RR 000 F
27. it PPH20RR to posi tion 1 2 e Switch on the radio remote control by means of the Start switch Press the main switch once on the radio remote control Briefly push the feed joystick in all directions PPH20RR 000 5 3 Operation Operating Instructions 5 4 5 3 3 5 3 3 1 Radio remote control provision Information The transmitter and receiver are a pair of matched units They cannot be used with other devices Power sources The radio remote control can be operated using a rechargeable battery disposable battery or via cable Rechargeable battery operation The interchangeable rechargeable battery is inserted at the housing base The operating period with a fully charged battery is approximately 12 hours The reception distance is 25 m Cable operation The cable insert included in the scope of supply allows connection of the remote controller to the Drive Unit PPH20RR The cable length is 10 m Cable operation makes it possible to work in areas where radio operation is not allowed e g hospitals Fig 5 2 Cable operation Information When working with the cable connection all control signals are transmit ted via the electric cable Battery operation The battery insert included in the scope of supply allows operation with three 1 5 V AA batteries The reception distance is 25 m PPH20RR 000 Operating Instructions Operation P
28. ive Unit PPH20RR Disposal of the Drive Unit PPH20RR To allow proper disposal the components of the Drive Unit PPH20RR must be dismantled This is performed by the client s personnel The dismantled parts of the device are sorted by material type and sent separately to the appropriate collection points Ensure above all that the following parts are correctly disposed of The Drive Unit PPH20RR consists of the following materials Cast aluminium Rolled aluminium products Copper Steel Rubber Rubber nylon fabric Synthetic grease Hydraulic oil Plastic PPH20RR 000
29. l Asignal tone sounds simultaneously Pilot lamp lights up green Second signal tone sounds Pilot lamp flashes green Push the main switch on the radio remote control twice into the ON po sition The electric motor starts 5 6 PPH20RR 000 Operating Instructions Operation PPH20RR 000 5 4 2 Information If the electric motor does not start the forward reverse switch on the Drive Unit PPH20RR must be turned to position 2 In drive units with a softstarter the LED display flashes red on the control cabinet Information If the Drive Unit PPH20RR is switched off after the electric motor has once been started up in order to start up again it is only necessary to press the main switch on the remote controller just once more Press the Water On Off button on the remote controller to Open the water valve on the Drive Unit PPH20RR water emerges from the cutting tool The Drive Unit PPH20RR is ready for operation Soft start The Drive Unit PPH20RR provides the option of a soft start The soft start is used mainly for diamond wire sawing Proceed as follows Start the Drive Unit PPH20RR see Chapter 5 5 4 1 B 5 6 Turn the main motor potentiometer to the 0 position Select the desired pressure stage see Chapter 5 5 4 3 B 5 8 Turn the main motor potentiometer slowly to 100 power 5 7 Operation Operating Instructions
30. ms and their components Hydraulics EN 60204 1 Safety of machinery Electrical equipment of machines Product description Operating Instructions 1 7 1 7 1 1 7 2 1 7 3 Technical data Dimensions 105 120 cm Fig 1 3 Dimensions Weight Operating weight 155 kg Tyres Wheel 30cm Operating pressure 3 bar PPH20RR 000 Operating Instructions Product description 1 8 1 8 1 1 8 2 1 8 3 1 8 4 1 8 5 1 8 6 1 8 7 PPH20RR 000 Hydraulics Main circuit Main circuit 3 pumps Flow rates can be set to 33 40 50 60 I min depending on the cutting tool speed required Flow rates and pressures Stage 33 l min 260 bar Stage Il 40 l min 215 bar Stage III 50 l min 180 bar Stage IV 60 l min 150 bar Same power in all stages Feed circuits Feed circuits 1 pump Two hydraulic feed outputs which can be regulated independently of each other controlled using radio remote control Oil tank Oil tank volume 10 litres Filter quality 20 um Return oil filter Type Tank mounted filter Oil cooling Oil cooler Water oil heat exchanger Couplings and hoses Plug in couplings Type FD and FF non drip Hoses Length 8m filled with hydraulic oil Oil quality TYROLIT Hydrostress AG recommends Hydraulic oil HLP ISO VG 46 Product description Operating Instructions 1 9 1 9 1 1 9 2 1 9 2 1 1 9 2 2 Electrical equipment Inform
31. nges from green to red 4 4 PPH20RR 000 Operating Instructions Controls and displays 4 3 3 Pressure gauge Fig 4 8 Pressure gauge 1 Pressure gauge of main motor 0 bar to 400 bar 2 Pressure gauge of feed motors 0 bar to 250 bar 4 3 4 Oil level indicator MAX MIN Fig 4 9 Oil level indicator Information The quantity of oil between oil MIN and oil MAX is 1 5 litres Different types of hydraulic oil should not be mixed together otherwise the oil will age prematurely Recommended hydraulic oil HLP ISO VG 46 PPH20RR 000 Controls and displays Operating Instructions 4 6 PPH20RR 000 Operating Instructions Operation 5 1 5 2 A 5 2 1 PPH20RR 000 Operation Personnel qualifications The Drive Unit PPH20RR must not be operated by unauthorised person nel Personnel are only authorised if they meet the following requirements Have trained as a concrete cutting expert or have professional experi ence Have received an introduction basic training to the operation of the Drive Unit PPH20RR from a service engineer Have read and understood chapter 2 Safety instructions System requirements A danger will arise if the Drive Unit PPH20RR is operated with a different mains network voltage The details on the name plate must correspond to the mains net work values voltage and frequency The system may be damaged by connec
32. orward reverse switch If the phase position of the power supply to the site is wrong the phases can be turned Device protective switch The device protective switch protects the secondary sockets and thereby protects the devices connected to the sockets The device switch interrupts the circuit in the event of a current surge more than 13A The circuit is restored by pressing the device switch Cable connection of remote controller The radio remote control can be connected to the Drive Unit PPH20RR power supply by means of the cable insert EMERGENCY STOP Pressing the EMERGENCY STOP button switches the system off and pre vents the system being accidentally switched on again Fig 4 4 EMERGENCY STOP 1 EMERG STOP on the Drive Unit PPH20RR 2 EMERG STOP on the radio remote control 4 3 Controls and displays Operating Instructions 4 3 Displays Fig 4 5 Displays 1 Hour counter 4 Pressure gauge of main motor 2 Pilot lamp radio amp battery 5 Oillevel indicator 3 Pressure gauge of feed motors 6 Optional Softstarter LED display 4 3 1 Hour counter The hour counter allows for precise observance of the service intervals 0101010101000 h BW 40 Fig 4 6 Hour counter 4 3 2 Pilot lamp radio amp battery gt A Fig 4 7 LED pilot lamp The LED pilot lamp on the radio remote control flashes green to indicate operational readiness When the battery voltage becomes low the colour cha
33. our point 42 C Viscosity index 170 Viscosity class HLP VG 46 or ISO 3498 HV 46 Wear protection according to DIN 51524 Part 3 HV46 Information Different types of hydraulic oil should not be mixed together otherwise the oil will age prematurely PPH20RR 000 Operating Instructions Servicing 6 1 2 2 Replacing hydraulic oil In order to replace the hydraulic oil you will need A collecting pan for the used hydraulic oil with a capacity of approx 15 litres Open ended spanner size across flats 18 mm for the oil drain plug e Approx 10 litres of hydraulic oil Fig 6 1 Replacing hydraulic oil 1 Oil drain plug Proceed as follows PPH20RR 000 Place the collecting pan below the oil drain plug 1 Open tank cover Remove oil drain plug 1 Drain hydraulic oil completely Screw in oil drain plug 1 Fill tank with new hydraulic oil Bleeding the system Close the tank cover Dispose of waste hydraulic oil in accordance with local regulations 6 3 Servicing Operating Instructions 6 4 Bleeding the system Information Air must be bled from the system whenever the tank has been complete ly emptied and refilled Proceed as follows Open tank cover Fill oil to maximum mark Do not refit the tank cover yet e Short circuit the main circuit with hose Start theDrive Unit PPH20RR see Chapter 5 5 4 1 B 5 6
34. rms repairs complex service work and maintenance work 2 3 Safety instructions Operating Instructions 2 4 2 4 6 2 4 6 1 2 4 6 2 2 4 6 3 Qualification and training Operator owner e A technically trained person in a management position e Has relevant experience in personnel management and danger assessment Has read and understood the Safety instructions chapter Operator user Has trained as a concrete cutting expert or has professional experience e Has received an introduction basic training to the operation of the TYROLIT Hydrostress AG machines and systems from a service engineer Has read and understood Chapter 2 Safety instructions Service engineer Has specialist professional training mechanical electrotechnical Has attended specialist courses at TYROLIT Hydrostress AG Has read and understood the Safety instructions chapter PPH20RR 000 Operating Instructions Safety instructions 2 5 Generally applicable warnings of residual dangers Electric shock due to defective electronic equipment and from time to time during prolonged use Defective parts such as e g cables and plugs must be replaced immediately in the de energized state by electrotechnically trained personnel h The electrotechnical equipment must be checked prior to each use Failure to comply with this regulation may lead to serious physical injury or death Secondary damage such
35. s Per T 5 120 bar 5 128 Fan 28 Fo Tae LI owt Sn see z E m ee 6 6 I min 9 6 I min 18 l min mi 16 31 i 17 Fig 3 2 Hydraulic circuit diagram 1 Electric motor 18 Leak oil nipple 2 Pump assembly 19 Coupling 3 Proportional valve 0 260 bar 20 Nipple 4 Check valve 21 Coupling 5 Pressure relief valve 22 Nipple 6 Pressure gauge 0 400 bar 23 Coupling 7 Oil and water cooler 24 Water valve 8 Aeration filter 25 Pressure valve 20 bar 9 Oil level 26 Proportional valve 5 120 bar 10 Return filter 27 2 2 way seat valve 11 Screw plug 28 Bijour nozzle 12 2 2 way seat valve 29 Pressure maintaining valve 13 4 3 way valve 30 Check valve 14 Pressure relief valve 150 bar 31 Water filter 15 Pressure gauge 0 250 bar 32 Waiter valve 16 Nipple 33 Radial piston pump 17 Coupling 3 2 PPH20RR 000 Operating Instructions Design and function Zuleitung 3 x 400V 50 Hz 3L N PE W213 MPE Wendeschatter 1 0 2 3 2 2 Zuletung Speisung im RC Geh use ae 400V AC Speiseeinheit 10A 1 2 phasig 10982396 11L3 LUEFT 00 Axiall fter komplett Q Sowar 979789 11G2 000PG 29 Kunststoff L ftung 24vDC KDR Wiring diagram Steuerung PPH20RRP und PPH25RRP Funk Lt ABB Relais D1 Motorschutz ab Speisung 24VDC w
36. ting it to a different voltage There is also a danger of fire and injury Connectable equipment All hydraulic units that are designed for the pressure and delivery volume of the Drive Unit PPH20RR see Chapter 1 1 8 B 1 5 Information The Drive Unit PPH20RR is one of a series of drive products available from TYROLIT Hydrostress AG In order to allow expansion of your Drive Unit PPH20RR with suitable devices to create an hydraulic saw or drilling system with optimum per formance please talk to TYROLIT Hydrostress AG 5 1 Operation Operating Instructions 5 3 5 3 1 5 3 2 5 3 2 1 Preparatory operations Visual inspection Before starting work always complete the following visual inspections e Is the power supply earthed fitted with a neutral conductor and a resid ual current circuit breaker e ls the mains protected correctly Design Protection Cable cross section 380 420 V 50Hz 32 A 5x6 mm from 25 50 m 5x10 mm 420 480 V 60 Hz 32 A 5x6 mm from 25 50 m 5x10 mm 380 V 60 Hz 32 A 5x6 mm from 25 50 m 5x10 mm 200 220 V 50 Hz 63 A 5x10 mm from 25 50 m 5x16 mm 200 240 V 60 Hz 63 A 5x10 mm from 25 50 m 5x16 mm Is the water line properly connected to the Drive Unit PPH20RR Information Ensure that the water supply is not interrupted while work is in progress
37. ut the differentiation of waste materials is necessary Before proceeding first of all read Chapter 2 Safety instructions B 2 1 in these Operating Instructions Be sure also to observe all the danger infor mation given here and follow the instructions on how to prevent personal injury and damage to property Safety instructions It is essential to observe the following safety instructions especially in re lation to disposal of the Drive Unit PPH20RR Danger of falling heavy parts When performing the types of work described in this chapter it is absolutely essential to wear the following personal protective equipment goggles protective gloves and safety shoes It is essential to ensure that the work instructions and procedures described in this safety manual are followed Failure to observe this regulation may lead to serious physical in jury possibly even death and to property damage Personnel qualifications Personnel who carry out the work described in this chapter must meet the following conditions Have read and understood the safety instructions in Chapter 2 Have completed their technical training mechanical electrotechnical and are in a position to differentiate the various material groups 9 1 Disposal Operating Instructions 9 2 9 3 Disposal regulations The usual national and regional regulations and directives must be ob served when disposing of the Dr
38. vicing 6 1 Servicing and maintenance table x S 2 8 e 8 a 2 ils Ee 3 D T is de a s 5 8 Q gt gt gt o T a a Be E 22 a Sle lee Hydraulic system Hydraulic hose inspection fy x x x x leakproof condition cleanliness Coupling inspection leakproof condition cleanliness x x xX x Check oil level see Chapter 4 4 3 4 B 4 5 A A x Replace hydraulic oil X see Chapter 6 6 1 2 B 6 2 Water economy Water line 7 l X X X X leakproof condition cleanliness If there is a risk of frost blow out the X water see Chapter 6 6 1 1 B 6 2 Mechanical Retighten accessible screws and nuts x x Major service May only be carried out by TYROLIT Hydrostress AG First service after or an authorised representative 100 operating hours After every 200 operating hours thereafter PPH20RR 000 6 1 Servicing Operating Instructions 6 1 1 6 1 2 6 1 2 1 Blowing out the water Information In order to prevent damage from frost cracks if there is a risk of frost or prior to extended breaks in work the cooling water must be blown out of the system Use the TYROLIT purge pump No 10982667 Oil change Oil quality TYROLIT Hydrostress AG recommends Hydraulic oil HLP ISO VG 46 Other hydraulic oils can be used if they comply with the following specifica tions P
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