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Operators Manual - High Frequency driven Pentruder 3P8 Wire Saw

Pentruder - Stronger than ever! Applying Standards That Are Years Ahead Of the Competition.

Tractive AB 28 January 2009 Page 1

Pentruder is a registered trade mark belonging to Tractive AB.

Contents

Operators Manual for Pentruder

3P8 Wire Saw Drill System

Version:

2.0

Subject:

Pentruder

3P8 Wire Saw System

Support & Service
document

Manual Pentruder 3P8 Wire Saw
V2.0.doc

Summary of Contents for Pentruder 3P8

Page 1: ...head Of the Competition Tractive AB 28 January 2009 Page 1 Copyright 2008 Tractive AB Pentruder is a registered trade mark belonging to Tractive AB Contents Operators Manual for Pentruder 3P8 Wire Saw Drill System Version 2 0 Subject Pentruder 3P8 Wire Saw System Support Service document Manual Pentruder 3P8 Wire Saw V2 0 doc ...

Page 2: ... drilling With wire cutting one is not limited by depth of cut The technique can be used to make cuts through huge objects without damaging the adjacent concrete structures Big sections can be removed reducing cost for splitting block in several pieces Wire cutting is a relatively quiet method and very little vibration is produced It is essential that all personnel working with or in close proximi...

Page 3: ... powerful 18 22 or 27 kW HF motors Wire tensioning is fully automatic with some exceptions The tensioning of the wire is governed by software and a microprocessor digital servo amplifier driven electric feed motor The main drive pulley has a diameter of Ø 500 mm It has a rubber drive ring with a specially designed type of rubber compund giving very good traction wire to rubber even when wet The wi...

Page 4: ...ing and maintenance by just removing one screw Fully enclosing guards protects the operator s and keeps all expensive parts reasonably clean like the carriages main pulley drive system column etc All pulleys can easily be removed from their mountings All bearings are sealed with external seals The main drive pulley is driven by a Gates toothed high torque Carbon cog belt The belt transmission is h...

Page 5: ...bject The 3P8 is powerful enough to pull the wire with sufficient force also when the wire is contact with the cut object over a long distance Most makes and types of sintered wire works well but electroplated wires can not be used on the 3P8 This type of wire can be destroyed in just a few minutes if attempted to be used on the 3P8 Normal results in concrete using a wire that is well adapted to t...

Page 6: ...in the magazine and one on the return or slack side this means that if the upper carriage moves 1 0 m 3 3 ft you have stored eight meters in the magazine Objects 2 2 x 10 m 7 2 x 33 ft has been cut without shortening the wire and then the carriage was moved over 2 5 meters 8 2 ft up taking in over 20 meters 65 ft of wire All 3 3 rollers in the magazine are used always The feed regulation parameter...

Page 7: ...permanent hearing disorders if not ear guards are worn Always check that the equipment is in faultless condition and that all functions are in order before work is commenced Warning The power pack must be disconnected from the power supply by removing the 32 red or 63 Amp blue plug and cable from the power pack before any other electric connections on the power pack are made The power pack must al...

Page 8: ...Before sawing is commenced all persons involved must know how the emergency stop buttons are working Only connect the Pentpak 418 422 or 427 power packs to Pentruder HF motors or other HF equipment which has been manufactured or approved by Tractive AB Safety precautions on site Check with the foreman responsible that all necessary precautions have been performed before commencing work Await the a...

Page 9: ...Operators Manual High Frequency driven Pentruder 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 9 ...

Page 10: ... overview 1 Base plate BE1 with fixed cone coupling or BE2 with swiveling cone coupling 2 Column 0 5 1 2 1 5 2 0m 3 Lower carriage with feed unit 4 Upper carriage 5 Friction brake 6 Electric feed unit 7 Lower assembly 8 Main drive pulley 9 Upper assembly 10 Guard main drive pulley 11 Guard upper assembly 12 Telescopic guard magazine rollers 13 Telescopic guard slack side 11 9 7 2 3 4 1 1 6 5 12 13...

Page 11: ...l the base plate will be mounted on For safety reasons it is very important that the base plate is properly fastened If mounted on brick or porous concrete we recommend to fasten the base plate with M16 5 8 through bolts 2 The wire cut line will be as shown in the drawing below Please note The column can rotate around its own axis and be locked in any position Therefore you may prefer to measure y...

Page 12: ...s Manual High Frequency driven Pentruder 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 12 Overview cut lines view from top ...

Page 13: ...perators Manual High Frequency driven Pentruder 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 13 Stroke of carriage ...

Page 14: ... has a fixed coupling and is more rigid than the BA2 type of swivelling coupling Columns Three types of columns are available a Columns with a female male configuration meaning that each column is fitted with a female conical quick release coupling at one end and a male coupling at the other end It can be extended in each end b Columns with a female coupling in one end and a Jack Screw in the othe...

Page 15: ...ter Clockwise until it lifts from the cone To remove the eccentric bolt turn it slightly Clockwise again until the load on the bolt is gone and then pull out the bolt and then the column can be removed Do not insert your fingers in the bolt hole Fig 2 Base plate BE2 and column CN 0 5 F M 70 Fig 2 Base plate BE2 and column CN 0 5 F M 70 Fig 2 Base plate BE2 and column CN 0 5 F M 70 3 Mount the lowe...

Page 16: ...Page 16 4 Mount the upper carriage on the column 1 Loosen the socket on the friction clutch one turn 19 mm 3 4 spanner 2 Slide the carriage over the column 3 Adjust the height of the carriage by turning the feed shaft socket with a ratchet or knuckle bar 4 Tighten the friction clutch socket Tighten firmly but do not over tighten Fig 4 Carriage CE1 with Electric feed unit ET100 ...

Page 17: ...the carriage with the swiveling rollers pointing towards the surface the base plate is mounted on Warning Be careful after having mounted the carriages on the column Make sure the friction couplings are tightened to avoid injuries this applies to both carriages Do not over tighten the clamp socket Slide the complete lower assy sideways with the Quick Diconnect Coupling recepticles engaging with th...

Page 18: ... Years Ahead Of the Competition Tractive AB 28 January 2009 Page 18 6 Attach the main drive pulley assembly Attach the main drive pulley assembly on the lower magazine assembly by mating the two dowel pins to the dowel holes in the magazine plate Tighten the lock bolt with a 14 mm Allen key socket and a long extension ...

Page 19: ...lley assembly by entering the locator dowels in to the holes in the pulley assembly plate Tighten the lock screws with an 8 mm allen key 5 16 Rock the main drive pulley slightly back and forth to make the spline shaft mesh with the hF motor 8 Attach the upper magazine assembly Attach the upper magazine assembly by sliding the assembly sideways onto the locator studs on the upper carriage Use the l...

Page 20: ...d the 24V feed motor cord Attach the main drive HF motor cord and the 24V feed motor cord 10 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 11 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 on page ...

Page 21: ...Operators Manual High Frequency driven Pentruder 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 21 6 7 ...

Page 22: ...sible safety precautions must be taken to avoid accidents from happening All guards must be fitted on the machine while it is running and the wire must be protected over its whole free length as well as from and to the cut object The wire can break at any time and it is rather impossible to predict when it will break When it breaks it will most likely be in the worst possible way and a bead may be...

Page 23: ...ions is to create as little friction as possible on the slack side Then the cutting will go faster and the feed regulation will work best To use all the power which is available the control tries to maintain a tension in the wire that creates the resistance needed to use the power requirement set on the Remote Control Unit RCU The power consumption the feed control or rather power tension system t...

Page 24: ...for positioning of base plate in relation to wire cut line 7 meters 23ft of wire plus what is needed to reach around the object to cut Several high quality steel crimp sleeves for the wire Universal joints doesn t work well with this machine Hydraulic crimp tool for steel crimp sleeves Water hoses and extensions for power pack and soft thin hose for supplying water to one or several positions alon...

Page 25: ...much free core wire as possible 3 Use a plier to pull off the spring which usually is embedded in plastic or rubber between the beads by standing on the wire and pull the spring off the wire end 4 Clean the core wire by scraping it with a knife If you have a cigarette lighter at hand heat the core wire to burn or soften the plastic or rubber then clean by scraping the wire with a sharp knife edge ...

Page 26: ... or more pilot holes then naturally the wire must be open and crimped once the wire has been run through the pilot holes 13 Make a short loop at one end of the wire clamp the other end or stand on it hold the short loop in your hands and turn the wire counter clockwise the correct amount of turns 14 Crimp the steel sleeve and you are ready to fit the wire over the pulley and wheels on the 3P8 15 T...

Page 27: ...traction is improved when the wire is as clean as possible 5 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 shallow groove on the slack side before the real cutting starts This function is dis...

Page 28: ...m the start it would be easy but less fun 14 Pay attention to water flowing to the wire If dry smoke appears the wire can overheat and may be damaged after a short while Readjust the hoses and or increase water flow Use soft garden hose and press the free end into the cut grove Use as many hoses as possible to cool and clean the wire A good flow of water to the wire is needed for most plastic or r...

Page 29: ...is too much slack you have a risk that the wire will jump off the wheels Use the feed potentiometer the one to the right on the Remote Control Unit RCU to reduce the tension in the wire If you reduce down to 25 50 it will still cut quickly enough in soft material Most of the time you can run full wire speed the left hand potentiometer in soft material but use your feeling also After some time prac...

Page 30: ... maximum speed when cutting under water The 3P8 machine 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 tensio...

Page 31: ...d with the clamp screws 5 To mount the second column on the pivoting head align bolt hole with pull stud hole in the male conical coupling insert an eccentric bolt and tighten hard clockwise with a knuckle bar or ratchet 6 Now you can mount the carriages on the horisontal column see mounting of carriage The column quick coupling is of the same type as on Base Plate BE2 with a swivelling face tooth...

Page 32: ... AB 28 January 2009 Page 32 Important When the eccentric bolt is removed do not put your fingers in the bolt hole to push the bolt out Important When the pivoting head is mounted be sure that the locking screws are tightened to give enough friction between column and pivoting head to keep the pivoting head from sliding down the column in an uncontrolled way ...

Page 33: ...leaning is not possible or allowed due to time pressure Try to clean the machine as well as possible especially directing your attention to the carriages their internal taper rollers and the columns The machine will not work well if the upper tensioning carriage does not run smoothly on the column If a high pressure cleaner is used you must NOT point the nozzle at the seals over the bearings on an...

Page 34: ...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 Losen the bolts holding pulley shaft 8 mm or 5 16 alllen key 6 Lift main drive pulley and slide it off the pulley shaft while holding back the cog belt Assembly 1 Put a new belt on the small cog wheel 2 Slide the main drive pulley on to...

Page 35: ...wheels and support legs 18 5 19 5 kg Weight less wheels and support legs 12 8 13 8 kg Columns CN Chart 2 Technical data for column CN CN 0 5 F M 70 CN 1 2 F M 70 CN 1 5 F M 70 CN 0 5 F J 70 CN 1 2 F J 70 CN 1 5 F J 70 CN 2 0 F P 70 Part No Length mm 508 1200 1500 508 1200 1500 2000 Length inch 20 47 2 59 20 47 2 59 79 Weight kg 6 4 11 9 14 3 6 6 12 1 14 5 17 0 Weight lbs 14 0 26 2 31 5 14 5 26 5 3...

Page 36: ...er Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 36 Pivoting head PD1 Part No Width including coupling and drive socket 236 mm Width housing 106 mm Length 320 mm Depth incl clamp screws 170 mm Weight 7 7 kg ...

Page 37: ...aterial that is being cut The fracturing of the rock seemed different from when cutting with today s powerful wall saws and that s where we are the experts and we also found that the shape of the object and the tension of the wire will play a very important role in the way the diamond edges will remove the material and how quickly this will happen We also found that the way different makes of diam...

Page 38: ...ntruder CBK And The new wire saw the 3P8 And The MD1 HF motor driven 4 speed MG41 gearbox high capacity drill rig for the really tough jobs And Corner chain saw to be fitted on the wall saw track to cut the corners when over cutting is not allowed And Floor saw driven by any of the 18 22 or 27 kW motors October 2009 New Un named drill system available next year for small to very large size core bi...

Page 39: ...d and travel motors Also these are very rugged items designed to withstand the hard environment 3 alloy adapter plates to upgrade existing power packs and HF motors with new connectors All equipment tools wires fittings seals O rings grommets spare parts etc needed to install the new system In addition to that a SUD unit Software Upgrade Unit is needed to do future software upgrades This is an ele...

Page 40: ...of all costs associated with keeping an operator busy or 2 Do you want to maximise the use of your operators time every working day by using all performance enhancing features on the Pentruder machines so they can be be much more productive and MAKE money rather than trying to SAVE you money After having seen a demo of the Pentruder HF machines and after having thought for a while about these two ...

Page 41: ...hine Manufacturer Tractive AB Alderbäcken 35 78193 Borlänge Sweden Category High frequency driven wire saw Type Pentruder 3P8 Wire saw Is in conformity with the provisions of the Machinery Directive 98 37 EC Is in conformity with the provisions of the following other EC directives Low Voltage Directive 73 23 EEC amended by 93 68 EEC EMC Directive 89 336 EEC amended by 92 31 EEC and 93 68 EEC Borlä...

Page 42: ...y with the provisions of the Machinery Directive 98 37 EC Is in conformity with the provisions of the following other EC directives Low Voltage Directive 73 23 EEC amended by 93 68 EEC EMC Directive 89 336 EEC amended by 92 31 EEC and 93 68 EEC We also declare that it is in conformity with directive 2000 14 EC measured in accordance to the Conformity Evaluation Method set out in Annex VI para 5 an...

Page 43: ...r 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 43 The eccentric roller shafts can be adjusted using a spanner and a 15 mm wrench to open and lock the eccenters ...

Page 44: ...Operators Manual High Frequency driven Pentruder 3P8 Wire Saw Pentruder Stronger than ever Applying Standards That Are Years Ahead Of the Competition Tractive AB 28 January 2009 Page 44 ...

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