TYROLIT Hydrostress WSE1217P Operating Instructions Manual

Operating Instructions
Control unit WSE1217
Index 000
Original operating instructions
10991497en / 15.11.2016
Congratulations!
With a Hydrostress unit from TYROLIT, you have chosen a tried and tested piece of equipment
which has been designed and built to leading technical standards. Only genuine TYROLIT Hydrostress replacement parts can guarantee quality and interchangeability. If maintenance work
is neglected or carried out inexpertly we will be unable to honour our warranty obligations. Any
repair work must be carried out by trained personnel only.
Our after sales service is available to help ensure that your TYROLIT Hydrostress units remain in
perfect working order.
We hope that working with your TYROLIT unit will be a satisfying and fault-free experience.
TYROLIT Hydrostress
Copyright © TYROLIT Hydrostress
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Tel. 0041 (1) 952 18 18
Fax 0041 (1) 952 18 00
Page 2
TYROLIT Hydrostress AG
1 Safety
DANGER
Failure to comply with the safety instructions in the «Safety Manuals / System Handbooks» may
result in serious injuries or even death.
XX Make sure that the «Safety Manuals / System Descriptions» for the relevant type of saw have
been fully read and understood.
DANGER
Death or serious injury can be caused by sudden start-up of the machine.
XX Before switching on the system, ensure that no other persons are present in the danger areas.
XX Switch the system off before connecting or disconnecting cables.
XX Switch the system off when you leave and secure it so that it cannot be switched back on
again.
Death or serious injury as a result of the sawing machine continuing to run after an accident.
XX Ensure that the EMERGENCY STOP button can be reached quickly.
Electric shock from live cables and connectors.
XX Switch off the control unit WSE1217 before connecting or disconnecting cables.
XX Ensure that the power supply is earthed and fitted with a residual current operated protective device (FI Typ B) with a maximum residual current of 30mA.
Risk of fire due to incorrect mains voltage.
XX Make sure that the mains voltage and mains frequency match control unit mains settings
WSE1217.
1.1
In case of emergency
XX Press the EMERGENCY STOP button on the remote controller.
If the EMERGENCY STOP is activated on the radio remote controller, the LED warning light flashes rapidly.
In an emergency the sawing machine can be also switched off using the main switch on the
control unit WSE1217.
EMERGENCY STOP
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TYROLIT Hydrostress AG
2 Description
2.1
Main components control unit
Main components control unit
1
2
3
4
5
6
2.2
Operating hours counter
Main switch
Feed motor connection
Remote controller connection
Mains connector
Water nipple / water inlet
7
8
9
10
11
12
Water connection / water outlet
Main motor connection
Name plate
Indicator lights
Mains system selection button
Reset button
Main components remote controller
Main components remote controller
1
2
3
4
5
6
7
Page 4
Feed potentiometer
On / Off main motor
Main motor potentiometer
Water On / Off
Diameter selector switch
Traverse feed joystick
Starter switch
8
9
10
11
12
13
Pulse switch Control unit
EMERGENCY STOP
Indicator lights
Warning light (radio & battery)
Position lock switch (Traverse feed)
Casing
TYROLIT Hydrostress AG
2.3
Remote controller
The remote controller can be replaced by an accumulator or a battery operated radio remote
controller. Additionally the remote controller can be operated using a cable.
Radio remote control
The transmitter and receiver are a pair of matched units. They cannot be used with other devices.
2.4
Operating modes
Rechargeable battery operation:
The interchangeable rechargeable battery is inserted in the base of the casing. The operating
period with a fully charged battery is approximately 12 hours. The reception distance is 25 m.
Battery operation:
The battery holder included in the scope of supply allows operation with three 1.5 V AA batteries. 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 control unit WSE1217. The cable length is 10 m. Cable operation makes it possible to
work in areas where radio operation is not allowed (e.g. hospitals)..
With cable operation all control signals are transmitted via the power cable.
The rechargeable/ordinary battery holders may not be inserted in the base of the casing during
cable operation.
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TYROLIT Hydrostress AG
2.5
Accessories Remote control
The battery charger is exclusively for recharging the interchangeable rechargeable battery. The
battery holder and the cable insert must not be inserted.
Accessories
1 2x Interchangeable rechargeable batteries
2 Rechargeable battery charger
Rechargeable battery charger with
10-30 VDC connection
3 Remote control cable
4 Battery holder
5 Key
Page 6
No. 10984306
No. 10984305
No.10984840
No. 10991362
No. 10984307
No. 10984309
TYROLIT Hydrostress AG
3 Connections
3.1
Making remote control and motor connections
99 The control unit is isolated from the power supply
99 Connectors/plugs are clean
99 Cables are undamaged
XX
3.2
Making the mains connection and water supply
99 The power supply is earthed and fitted with a residual current operated protective device
(FI Typ B; max. residual current 30mA)
99 Cable cross-section is sufficient: for up to 25 m long 5 x 4 mm2, more than 25 m long 5 x 6 mm2
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TYROLIT Hydrostress AG
4 Operation
4.1
Overview of operating elements
Operating elements
1
2
3
4
5
6
7
Position lock switch (Traverse feed)
Water On / Off
EMERGENCY STOP
Pulse switch Control unit
Starter switch
Feed potentiometer
On / Off Main motor
8
9
10
11
12
13
Main motor potentiometer
Diameter selector switch
Traverse feed joystick
Main switch Control unit
Reset button
Mains system selection button
The control unit WSE1217 can also be used for wire sawing and core drilling with suitable
TYROLIT Hydrostress system components.
Wire sawing:
To change to the control unit WSE1217 wire sawing mode the rotary switch (9) (diameter
selector switch) is turned to the symbol wire sawing.
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TYROLIT Hydrostress AG
4.2
Starting the control unit WSE1217
CAUTION
The control unit WSE1217 can be damaged if it slips or overturns!
XX Make sure that the control unit WSE1217 stands horizontally (handle at top).
99 Control unit WSE1217 is connected to the mains and the water supply.
99 The sawing machine is connected to the control unit WSE1217.
(see «Operating instructions - Sawing machine )
99 The remote control EMERGENCY STOP has been deactivated.
Starting the control unit WSE1217
XX Move the controls shown below on the remote controller to the 0 position.
Feed potentiometer (6)
Starter switch (5)
Feed joy stick (10)
Main motor On/Off (7)
XX Switch on the control unit WSE1217 using the main switch (11).
XX Switch on the radio remote controller using the starter switch (5).
–– Warning lights (radio and battery) at first show red
–– An audible signal sounds simultaneously
–– Indicators flash coloured
–– Second audible signal sounds
–– Indicators show coloured
–– Warning light flashes green
XX Press the remote control pulse switch (4) briefly in the ON-position.
All indicator lights except the warning lights and the group alarm on the remote controller
go off.
XX Press the reset button (12) on the control unit.
XX Press the remote control pulse switch (4) briefly in the ON-position.
The the control unit 'ready' lights show green.
XX Open the water valve on the system supply line.
XX Press the Water On/Off switch (2) on the remote control unit to I.
–– Water flows from the cutting tool
XX Press the main motor On/Off switch (7) on the remote controller to position I.
–– The electric motor starts if the main motor potentiometer is at the max. position.
XX The control unit WSE1217 has started and ready for operation.
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TYROLIT Hydrostress AG
4.2.1
Remote control frequency change
Remote control frequency change
The remote control systems are equipped with a frequency generator for frequency selection.
If the systems malfunction or the radio link is interrupted (another transmitter, range, empty
battery), the systems immediately go into EMERGENCY OFF mode.
New frequency search:
You can select the next frequency by switching the start switch on the remote control off and
back on.
The off/on switching procedure is limited to four attempts (channels). If the system has not
found a suitable frequency after four attempts, you must change to cable operation.
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TYROLIT Hydrostress AG
4.3
Select mains network
The control unit WSE1217 is preset for a 32 A power supply network. (32A Button lights
up). It is possible to switch over to a 16 A power supply network. The system automatically returns to the 32 A settings when it is restarted.
XX To set the power supply network to 16 A press the power network selector (13), the button
light goes out.
Resetting must take place directly after switching on the control unit WSE1217.
4.4 Tool soft start
The control unit WSE1217 offers the possibility for a tool soft start. The soft start is particularly applicable in the case of diamond wire saws.
Proceed as follows:
XX Start the control unit WSE1217, see 4.2.
XX Turn the main motor (8) potentiometer to the 0 position.
XX Press the switch main motor (7) to I.
XX Select the desired output level, see 4.5.
XX Turn the main motor (8) potentiometer slowly to 100% power.
4.5
Select tool station
After the control unit WSE1217 has been started correctly the tool station can be selected.
Selecting the power level
Proceed as follows:
XX Set the diameter selector switch to the desired tool and turn the main motor potentiometer
from 0 to 100%.
The tool stations may not be changed during operation.
The tool stations are set with reference to the tool diameter for the optimum rotational speed
and cutting performance.
The rotational speed can be reduced using the main motor potentiometer but at the same time
the power is reduced.
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TYROLIT Hydrostress AG
4.6
Power control
The main motor and the feed motor power are controlled via the potentiometers.
Power control
Feed motor potentiometer (6)
Main motor potentiometer (8)
4.7
Adjusting the feed
The feed movements are selected with the joystick.
Adjusting the feed
During the cutting process the feed speed is automatically assisted by a feed facility.
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TYROLIT Hydrostress AG
4.7.1
Manually adjusting the feed speed
99 Control unit WSE1217 has been started
XX Select the required feed speed via the feed potentiometer (6).
4.7.2
Feed stop
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:
XX Push the joystick in the desired travel direction and at the same time press
the locking switch (1).
XX When the joystick and the locking switch are released the feed is locked.
In order to release the feed lock, move the joystick slightly in any desired
direction.
4.8
Switching off the control unit WSE1217
Proceed as follows:
XX Switch off electric motor (7) On / Off Main motor.
XX Turn off cooling water, switch (2) Water On / Off.
XX Close water valve on control unit WSE1217.
XX Turn the start switch (5) on the remote controller to the 0 position.
XX Switch on the control unit WSE1217 using the main switch (11).
CAUTION
Frost damage to control unit WSE1217!
XX Blow out any water if there is a risk of frost (see chapter 4.9, Blowing out water).
Stop the wall saw WSE1217 only in an emergency using the EMERGENCY STOP function.
4.9
Blowing out the water
99 Main switch is set to OFF
XX Disconnect the mains plug.
XX Disconnect all water lines.
XX Connect blow out pump to the water nipple.
XX Blow out water until all of the cooling water has been removed.
XX Remove the pump.
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TYROLIT Hydrostress AG
4.10
Deactivating EMERGENCY STOP
If the EMERGENCY STOP is activated on the radio remote controller, the radio and battery light
(8) flash.
Deactivating EMERGENCY STOP
The following controls must be moved the 0 position:
Feed potentiometer (6).
Feed joy stick (10).
Main motor On/Off (7).
Turn the EMERGENCY STOP button (3) clockwise.
Press pulse switch control unit (4) to the ON position.
4.11
After termination of work
Proceed as follows:
XX Turn the main switch on the control unit WSE1217 to the 0-position.
XX Withdraw the mains plug (control unit WSE1217).
XX Disconnect the water hoses on control unit WSE1217.
XX Blow out the water from all the lines (blow out pump).
XX Disconnect electric cable.
XX Clean the control unit WSE1217, the remote controller and the cable with a damp
cloth.
Cleaning using high pressure cleaning equipment is not permitted.
Products containing cleaning agent can damage parts of the control unit WSE1217, the
radio remote controller and the cable.
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TYROLIT Hydrostress AG
5
Responding to displays
Symbols on the control unit / remote controller
Symbols on the control unit
Symbols on the remote controller
1
2
3
4
5
6
7
8
9
10
11
Service
Fault within the control unit
Control unit external fault
Temperature
Mains connector
EMERGENCY STOP
Potentiometers
Radio and battery remote control
Cooling water
Group alarm
Ready for operation lights
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TYROLIT Hydrostress AG
Power and error displays on the control unit
Symbol
Response
Possible cause
Action
Lights up red
After the first 100 operating
hours, then after every 200 operating hours.
Carried out only by TYROLIT Hydrostress AG
or an authorised representative
Lights up red
Fault:
- current overload
- short circuit
- earth fault Main motor
- defective feed motor
The control unit will not start.
XX Check network connection.
XX Check cable.
XX Replace feed motors.
XX Contact TYROLIT Hydrostress AG customer service.
Lights up red
Defective :
- main contactor
- brake resistance
- over current Motor
- CAN fault
- group fault
The control unit will not start.
XX Contact TYROLIT Hydrostress AG customer service.
XX Check network connection.
Lights up red
Overheated:
- cooling element
- control unit
- main motor
The control unit will not start.
XX Check cooling. Wait until it can be restarted. Before starting
press the reset button.
XX Avoid direct contact with sun light.
Lights up red
Phase missing
The drive unit will not start or switches off during operation.
XX Check the mains fuse in the distribution box and switch it on
if necessary.
XX Have the site power supply checked.
XX Have the extension cables, plugs and sockets
checked for faults.
Page 16
Lights up red
The EMERGENCY STOP has been
activated
- CAN fault
XX Deactivate the EMERGENCY STOP.
XX Contact TYROLIT Hydrostress AG customer service.
Lights up red
Feed potentiometer not in zero
position
The control unit will not start.
XX Set the feed potentiometer to 0.
TYROLIT Hydrostress AG
Power and error displays on the remote controller
Symbol
Response
Possible cause
Action
Flashes red
Rechargeable battery voltage
too low
XX Recharge rechargeable battery.
Flashes rapidly
green
No radio connection
The EMERGENCY STOP has been
activated
XX Switch on the control unit.
XX Defective receiver.
XX No receiver matched connection, see page 5.
No light shows
No water flow
The control unit will start, but motor does not run.
XX Press the cooling water button (LED shows blue).
Lights up red
or flashes
• Group alarm on the control
unit
• On operating the pulse switch
control unit the main motor
On/Off switch is in the position On
XX Observe control unit fault indicators.
XX Press the control unit reset button.
Lights up green
The motor is ready to start
No light shows
Contactor not ready
XX Operate control unit pulse switch.
Shows the current power range
Ideally: At the third, orange coloured diode (in iron fourth, red diode).
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TYROLIT Hydrostress AG
6 Servicing and maintenance
After damage
X
X
X
X
XX Check the condition and cleanliness
of connections.
X
X
X
X
XX Check water lines for cleanliness and
leaks.
X
X
X
X
X
X
X
X
Annually
XX Check the condition and cleanliness
of electric cables, plugs/connectors
and switches.
Weekly
After faults
Water supply
On finishing
work
Electrical system
Before starting up
Maintenance and servicing table
X
XX Clean water filter
XX Blow out the water if there is a risk of
frost.
X
Complete control
unit WSE1217
XX Clean with damp cloth
no high pressure cleaner
X
Service
XX To be performed by TYROLIT Hydrostress AG or an authorised workshop.
First service after 100 operating hours
Further services after every further 200 operating hours
Cleaning using high pressure cleaning equipment is not permitted.
Cleaning using high pressure cleaning equipment can damage the control unit and the remote
controller.
Products containing cleaning agent can damage parts of the control unit WSE1217, the
radio remote controller and the cable.
6.1
Clean water filter
Clean water filter
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TYROLIT Hydrostress AG
7 Faults
Faults
Faults
Possible cause
Solution
Control unit does not run
although the mains cable
is connected
Control unit is switched off
XX Switch control unit on, see Chapter 4.
Mains cable is defective
XX Replace the mains cable.
No voltage at the power supply (building site)
XX Check the power supply.
Power supply phases incorrectly connected
XX Check the power supply.
Phase missing
See the chapter «Responding to displays».
The control unit starts and
then switches off again
Building site power supply cut-off unit
trips
XX Check and if necessary adapt the cut-off protection.
XX If necessary change the power supply.
XX See chapter «Responding to displays».
No power, even though
the control unit is running
Incorrect voltage
Defective main motor
XX Make sure that the control unit voltage and frequency
match the mains supply specifications.
XX Contact TYROLIT Hydrostress AG customer service.
The control unit suddenly
switches off
Over or under voltage
XX Check the power supply. Refer to fault indicator.
Cross section of power supply cable too
small
XX Check the power supply.
Defective plug connection
XX Check the plug connection.
XX Check the power supply.
Group alarm
XX Refer to fault indicator.
• Main motor potentiometer is in 0-position
• Defective main motor On / Off switch
on remote controller
The remote controller 'ready to operate'
light does not come on.
XX Contact TYROLIT Hydrostress AG customer service.
XX Do not start control unit, see Chapter 4.2
EMERGENCY STOP activated
XX Deactivate EMERGENCY STOP, see Chapter 4.10.
Overheating
XX Check the water circuit and the plug-in couplings.
XX Refer to fault indicator.
No water
XX Switch on the water supply.
XX Refer to fault indicator.
Remote controller not
working
Rechargeable battery or battery have
too little charge
XX Replace rechargeable battery and recharge or install
cable operation.
XX Replace batteries.
Feed potentiometer indicates no function
• Defective potentiometer in the remote
controller
• Feed motors not connected
• Defective feed motor
• Joystick is in the zero position
XX Contact TYROLIT Hydrostress AG customer service.
XX See Chapters 3.1 / 4.6 / 4.7
Feed motor fails to
build up power
Remote controller potentiometer is defective or in the 0-position
XX Contact TYROLIT Hydrostress AG customer service.
XX See Chapter 4.7.1
Defective cable
XX Contact TYROLIT Hydrostress AG customer service.
Motor fault
XX Contact TYROLIT Hydrostress AG customer service.
Main motor is not running
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TYROLIT Hydrostress AG
Faults
Faults
Possible cause
Solution
No water emerging
Water line blocked
XX Clean the water line.
Water valve on the supply or water hose
are closed
XX Open the water valve.
Insufficient water pressure
XX Make sure that the water pressure is at least 2 bar.
Water filter is blocked
XX Remove filter and clean
XX Contact TYROLIT Hydrostress AG customer service.
Switch for the radio remote controller
defective
XX Contact TYROLIT Hydrostress AG customer service.
• Water valve on the control unit
WSE1217 is defective
• Switch for the radio remote control
defective
XX Stop water leaks using the hose water valve.
XX Contact TYROLIT Hydrostress AG customer service.
Uncontrolled water leak
Group alarm on the remote controller
Page 20
XX See chapter «Responding to displays».
TYROLIT Hydrostress AG
8 Technical data
Dimensions
Technical data
Parameter
Value
Type
Frequency converter
Weight
Control unit WSE1217
incl. remote controller
22 kg
Remote controller separate
2 kg
Protection class
IP 65
Connection values
380 to 420 VAC / 50 Hz / 60 Hz
Type
Frequency converter
Power consumption
16 to 32 A (400 V/ 50 Hz)
Power
at 16 A
8 kW
at 32 A
17 kW
Computer / Remote controller
24 VDC
Feed drives
48 VDC
Main drive unit
400 VAC, 0..400 Hz
Cooling the control unit
Water cooling the power semiconductors
Cooling water flow rate
min. 4 l/min at max 25 °C
Water connection
2 to 6 bar
Internal control voltages
Water
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TYROLIT Hydrostress AG
9 EU Declaration of Conformity
Description
Control unit
Type designation
WSE1217
We declare under our sole responsibility that this product complies with the following directives and standards:
Applied directives
2006/42/EG
2014/30/EU
2012/19/EU
1999/5/EG
Applied standards
EN 15027 : 2007 + A1 : 2009
EN 12100 : 2010
EN 60204-1 : 2006 + A1 : 2009
EN 6100-6-2 : 2005
EN 6100-6-4 : 2007 + A1 : 2011
TYROLIT Hydrostress AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Pfäffikon, 28.04.2011
Pascal Schmid
Development leader
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TYROLIT Hydrostress AG
10 Spare parts
Page 23