Pentruder 3P8, Operator'S Manual

Page 1: ...Operator s manual Pentruder 3P8 High frequency wire saw and Pentpak High frequency power pack ...

Page 2: ...s at site 8 4 Preparations and mounting 11 Advice about the positioning of the Pentruder 3P8 wire saw 11 Mounting the base plate 11 Mounting 3P8 HF wire saw with column system with cone coupling 12 Mounting 3P8 HF wire saw with with TS track 16 Mounting the 3P8 wire saw modules 21 Assembly of HF motor cords and hoses 24 Attach guards 25 Preparing the power pack 26 5 Cutting 31 Preparations before ...

Page 3: ...tures and benefits of the Pentruder 3P8 HF wire saw We are confident that your investment in this equipment and its many design features will enhance your business competitive edge and profitability Validity of this operator s manual This operator s manual is only valid for the Pentruder 3P8 HF wire saw as described in Chapter 2 Tractive AB always strives to improve the products Therefore we reser...

Page 4: ...be used List of complete machine A Pentruder 3P8 HF wire saw is comprised of the following modules Wire saw modules 1 A 3P8 DP HF 3P8 Drive pulley electric 2 A 3P8 UA 3P8 Upper assembly 3 A 3P8 LA 3P8 Lower assembly Guards 4 A 3P8 LMG 3P8 Telescoping magazine guard 5 A 3P8 TG 3P8 Top guard 6 A 3P8 DPG 3P8 Drive pulley guard 7 A 3P8 SSG 3P8 Slack side telescoping guard HF drive system 8 A Pentpak h...

Page 5: ... is an environmental marking and indicates that this machine contains electrical electronical equipment which should be recycled Please contact your Pentruder Distributor for more information This sign is placed on the Pentpak and gives information about the complete machine as described in Chapter 2 On the wire saw the wire can be run in both directions Please refer to the Operator s manual for w...

Page 6: ...ponsibility of the purchaser that the operator has received the information needed to operate and handle the machine in a safe a correct way Good working practice should always be used along with common sense Tractive cannot foresee every possible situation and this manual is not a substitute for professional skills and experience The Pentruder 3P8 HF wire saw is intended to be used together with ...

Page 7: ... skills and experience The machine may only be operated and serviced by authorized and trained personnel The personnel should be trained by personnel authorized by Tractive A Pentruder machine used in the correct way is a safe and efficient tool If the machine is used improperly this can expose the operator and other persons staying in the same area to extreme danger or even risk of fatal injuries...

Page 8: ...he instructions in 5 2 Startin the HF machine to make sure the diamond wire will not start at and or cut at a too high speed WEAR SAFETY EQUIPMENT All persons working with or in the proximity of the machine should wear safety equipment i e protection helmet protection shoes gloves eye and ear protectors The noise level during cutting might lead to permanent hearing disorders if not ear guards are ...

Page 9: ...ut openings so that no person falls down and hurts himself Secure the concrete before starting work to make sure there is no possibility that concrete blocks may fall down causing injury or damage to persons or property Concrete blocks which are cut free may not be allowed to fall freely as this could compromise the safety of the machine and or diamond tool For drawings of the Machine s Risk area ...

Page 10: ...free running wire section A1 A4 1 Risk area 2 Risk area of the horizontal projection of the wire towards the operator 3 Recommended operator position 4 Power pack 5 Wire drive unit 6 Wire guard 7 Pulley wheel Amax Largest free running wire section A1 A3 1 Risk area 2 Risk area of the horizontal projection of the wire towards the operator 3 Recommended operator position 4 Power pack 5 Wire drive un...

Page 11: ...ll NOT have to be broken off or chamfered before commencing a cut Maximum torque is available from 0 motor speed and the wire can be started smoothly Note a new wire with sharp bead edges is much harder to start over sharp corners than only an ever so slightly used wire With a new wire it may be necessary to chamfer edges on the object to be cut Mounting the base plate The surface where the base p...

Page 12: ... drawings Note The column can rotate around its own axis and be locked in any position Therefore you may prefer to measure your anchor position from the center of the column Meausurements for positioning of wire saw 70 mm column system with BFC5 base plate view from top Meausurements for positioning of wire saw 70 mm column system with BE1 BE2 base plate old type view from top 355 mm 14 inches 240...

Page 13: ...late b Adjust the leveling screws c Level the base plate using the four leveling screws BE2 base plate and column CN 0 5 F M 70 2 Mount the columns or columns a The column is locked by turning the eccentric bolt Clockwise b To release the column the eccentric bolt is turned Counter Clockwise until it lifts from the cone c To remove the eccentric bolt turn it slightly Clockwise again until the load...

Page 14: ...s is 6 fold and can be in excess of 1000 kg during an abrupt jamming of the wire 4 Mount the upper carriage on the column a Loosen the socket on the friction clutch one turn e Slide the carriage over the column with the feed unit pointing downward b Adjust the height of the carriage by turning the feed shaft socket with a ratchet or knuckle bar c Tighten the friction clutch socket Note Tighten fir...

Page 15: ...n the male conical coupling insert an eccentric bolt and tighten hard clockwise with a knuckle bar or ratchet f Now you can mount the carriages on the horizontal column see mounting of carriage Important Be observant so that the eccentric bolt doesn t slip out of the column when the column is mounted on the conical coupling on the pivoting head It MUST be completely flush with the column side face...

Page 16: ...ire saw and Pentpak Original instructions 16 Mounting 3P8 HF wire saw with with TS track 4 4 1 Measurements for positioning TS track The wire cut line will be as shown in the drawing below Measurements for positioning of wire saw TS Track ...

Page 17: ...Operator s manual Pentruder 3P8 HF wire saw and Pentpak Original instructions 17 Stroke of carriage Measurements TS Track ...

Page 18: ...track first and then fastening the assembled rig on the concrete c Tighten the two bolts on the lower clamp d Tighten the upper bolt loosely a Slide the upper clamp in to the track Older tracks with only one rack can be used In this case make sure the rack is on the left side seen from the rack side of the track b Slide the lower clamp in to the track Important Rack on this side if there is only o...

Page 19: ...brace 2 Mount the lower carriage on the track a Open the three clamp nuts b Put the carriage on the track as shown in the picture and align the feed gear with the rack on the track b Tighten all three clamp nuts firmly first by hand and then with a 19 mm spanner to be firmly tightened but not solid Note Tighten moderately to 20 25 Nm 15 18 ft lbs Do not over tighten ...

Page 20: ...15 18 ft lbs Do not over tighten It must be possible for the upper carriage to glide upwards during cutting Note The liners on the track and the liners in the upper carriage must be clean before starting to cut Please also smear the liners in the upper carriage lightly with some grease or oil 4 Mount rear support A rear support is recommended to increase stability The rear support for the saw trac...

Page 21: ... couplings clamp nuts are tightened to avoid injuries this applies to both carriages Do not over tighten the clamp socket WARNING Be careful after having mounted the carriages on the column c Slide the complete lower assembly sideways with the Quick Disconnect Coupling QDC receptacles engaging with the locator studs on the carriage See picture below Fitting the lower assembly Note Tighten the QDC ...

Page 22: ...a 14 mm Allen key socket and a long extension Main drive pulley assembly Fitting of main drive pulley assembly 3 Fit slip clutch not mandatory but recommended and main drive HF motor a Align the splined drive shaft and clamp studs with the holes in the drive pulley assembly plate a Rotate the main drive pulley very slowly by hand until the spline fits and HF motor seats properly c Tighten the clam...

Page 23: ...the upper assembly Attach the upper assembly by sliding the assembly sideways onto the locator studs on the upper carriage Use the lower four studs Note Tighten the QDC lock bolts firmly but do NOT over tighten Assembly of upper magazine assembly Quick disconnect coupling and upper assembly ...

Page 24: ... to be run also over the adjustable swivelling wheels without having to cut the wire Assembly of HF motor cords and hoses 1 Attach the main drive HF motor cord and the 24V feed motor cord 2 Attach water hoses Attach the water hoses to the power pack the HF motor and connect the hose from the motor bracket plate to the swivel wheel yoke ...

Page 25: ...Pentpak Original instructions 25 Attach guards After the wire has been started very slowly and has cut a shallow groove the guards can be fitted The start up procedure is described in 5 1 2 Starting the wire Fitting of guard on Pentruder 3P8 wire saw ...

Page 26: ... forming 4 9 2 High voltage low voltage and water connections Electric power to the HF motor high voltage is supplied by two 9 m 30ft cables joined together HF400 9 30 400V Cable for PP427 PP422 and PP418 HF200 9 30 200 V Cable for PP222 and PP200 The travel motor on the upper carriage is supplied by one smaller diameter orange color 9 m 30 ft cord low voltage packaged together with a 10 mm water ...

Page 27: ... air pump 5 Alternatively if no electric power is available 6 Disconnect the water couplings 7 Blow backwards with compressed air or an air pump in the coupling going to the saw head The check valve in the water ON OFF valve will then open 8 The remaining water in the power pack can then be blown out See picture below Important Leaving water in the Pentpak in sub zero temperatures will destroy com...

Page 28: ...The Wireless Remote Control and Receiver are pre installed paired together Any new pairing of a WRC Wireless Remote Control Hetronic type Nova XL and Receiver type RX14 HL for use with a Pentruder machine has to be done by a workshop authorized by Pentruder and a new Installation Certificate must be filled out See Installation Certificate on page 58 There is a start activating key on the side of t...

Page 29: ...ove the battery from the transmitter 2 Replace the battery with a new charged battery or with the cassette fitted with 3 normal AA batteries 3 Place the charging unit on a clean and dry surface Insert the run down battery into the charger Check that the battery charger is powered with the lighting up of the yellow LED on the outside The ready green LED will start blinking as soon as the battery is...

Page 30: ...ipped with a 32 Amp receptacle To use other sizes than 32 Amp plugs an adapter must be fitted PP222 PP218 PP200 Connect the Pentpak power pack to a 4 pin 200 230 V 3 phase supply with minimum 40 Amp fuses The power pack is equipped with a 63 Amp receptacle To use other sizes than 63 Amp plugs an adapter must be fitted 32 Amp 5 pin Euro standard receptacle 380 480 V 230V on a 400V supply max 10 Amp...

Page 31: ...on to the modules of a complete machine 2 1Fel Hittar inte referenskälla the operator should have the following material at hand Safety equipment as helmet eye and ear protection dust extraction equipment sensitive environments protective clothes shoes and gloves Electrical plugs 32 or 63 Amp when needed extension cables for the power pack Hammer drill to drill holes to secure the base plate M16 H...

Page 32: ...achine Pentpak HF power pack Connector for remote control unit Connector for feed and travel motors on saw head Connector for HF motor on saw head Coupling for water from power pack to hose to saw head Coupling for water supply to the power pack Start button LED type warning lights Emergency Stop button ...

Page 33: ...unge and travel control joystick 3 Water valve ON OFF switch 4 Blade motor ON OFF switch 5 Blade speed control knob potentiometer 6 Feed control knob potentiometer 7 Start key It is not possible to control any functions on the machine unless a remote control is connected to the power pack either via cable or the wireless remote control 1 2 3 4 5 6 7 1 2 3 4 5 6 ...

Page 34: ...ling water from the HF motor clean the wire before it goes into the magazine as traction is improved when the wire is as clean as possible 10 If needed the direction the wire is running in can be revered during start up Flick the blue switch forward once and the direction will be reversed Flick it again and it will go the other correct way again This feature is there to make it easier to cut a sha...

Page 35: ...y when the motor winding temperature is over 140 C 284 F The coolant water should then be left running through the power pack and HF motor to avoid terminal overheating If the water is turned off after the motor has been switched off automatically and when the warning light is on terminal damage to the motor windings may occur Note Pay attention to water flowing to the wire If dry smoke appears th...

Page 36: ...ting rates or cut square metres per hour if you see slack not enough tension in the wire move the Joystick UPWARDS manually some short movements at a time to override the automatic tensioning by the software 5 1 4 Cutting of soft concrete or concrete mixed with soft materials Here are some tricks that can be useful in cutting soft material If you see slack not enough tension in the wire please mov...

Page 37: ...ine has very good traction wire to drive pulley and this eliminates time consuming under water preparation work to chamfer corners and edges the wire has to run over during start up Also the automatic feed control adjusts itself to various conditions it doesn t care if you run the wire fast or slow This is a big advantage over air cylinder tension type wire saws especially when cutting under water...

Page 38: ...k again 6 1 2 The green start button on the Pentpak is ON no indications on the LED warning lights but the machine doesn t respond to any command from the remote control This is one of the few cases which cannot be indicated on the LED warning lights If possible try another remote control The remote control needs to be checked by the authorized Pentruder service workshop 6 1 3 The saw stopped work...

Page 39: ...plugs and receptacles If possible test with replacing the cable Note A voltage meter doesn t always show a voltage drop in one of the phase lines because this cannot be measured without electrical load applied A voltage meter can show normal voltage even though there are voltage losses when the machine is running 6 2 2 LED indicating status for the Pentpak One blink Overcurrent alarm May occur if ...

Page 40: ...example trying to use a 22 kW HF motor with a Pentruder 6 12HF saw head invalid combination Another example would be that a newer model of HF motor is introduced that didn t exist when the Pentpak was delivered If this is the case a software update is required Two blinks HF motor temperature sensor in windings is not working correctly Repair is required Three blinks HF motor or motor cable is not ...

Page 41: ... when connecting the cable is faulty Connect 24V cable to Pentpak and machine If the alarm appears when connecting the connector on the machine needs repair Pentpak is powered and the green start button on the Pentpak button has been pressed One blink Short circuit in the 24V cable machine or any of the feed motors in the machine Two blinks 24V under voltage alarm The voltage has dropped below 18V...

Page 42: ...OT be pointed at any of the rotating parts or connectors on the machine Tractive recommends using covers on the electrical connectors or keep the mating connector connected when cleaning to prevent water and dirt to get into the connectors 7 1 2 Carriages CE 1 Carriages for 70 mm column Preload on rollers CE 1 The roller carriage has four conical rollers to guide the carriage on the column without...

Page 43: ...replace the belt Disassembly 1 Remove the center bolt holding the pulley 14 mm allen key 2 Remove bearing cap and seal 3 Remove all M6 bolts holding belt cover to back cover 5 mm allen key 4 Remove the belt tensioning bolt 6 mm allen key 5 Loosen the bolts holding pulley shaft 8 mm or 5 16 allen key 6 Lift main drive pulley and slide it off the pulley shaft while holding back the cog belt Assembly...

Page 44: ...ynthetic oil with 75W viscosity The oil must meet GL5 specifications Clean the magnetic plug fit it and tighten again Cooling housing at rear of HF motor Fill with 85 ml 2 9 fl oz of Mobil SHC 626 at service 7 2 2 Overload clutches If any of the overload clutches have been overloaded or worn out a Pentruder authorized technician can repair the coupling by replacing the clutch plates 7 2 3 Digital ...

Page 45: ... 44 Pulleys O D Ø mm 500 20 198 7 8 198 7 8 Pitch Ø mm 180 7 1 180 7 1 Groove width for wire 10 mm 0 3930 10 mm 0 3930 10 mm 0 3930 Suits wire Ø mm 8 10 5 16 1 2 8 10 5 16 1 2 8 10 5 16 1 2 Number of wheels 1 4 7 Storage in rollers 6 5 m 21 ft Storage capacity Maximum approximately 20 m 65 ft IP class IP66 Technical data for Pentruder 3P8 Guards 3P8 LMG 3P8 TG 3P8 DPG 3P8 SSG Weight kg lbs 10 22 1...

Page 46: ...cessories As stated in the Operator s manual Pentruder 3P8 High frequency wire saw and Pentpak High frequency power pack Is in conformity with the provisions of the Machinery Directive 2006 42 EC Is in conformity with the provisions of the following other EC directives Low Voltage Directive 2014 35 EU EMC Directive 2004 108 EC In accordance with the EC declaration of conformity the product must no...

Page 47: ...he instructions given by the manufacturer and that all of the necessary tests have been carried out Signed for and on behalf of Tractive AB Borlänge 2015 08 27 Anders Johnsen Technical Director The person responsible for the installation of the WRC Wireless Remote Control Will by connecting the WRC Wireless Remote Control and Receiver to a machine as described in this Operator s manual complete th...