PP 100. Safety and operating instructions. Hydraulic power packs. Construction Tools PC AB Original instructions

Transcription

1 PP 100 Safety and operating instructions Hydraulic power packs

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3 PP 100 Contents Contents Introduction... 5 About the Safety and operating instructions... 5 Safety instructions... 5 Safety signal words... 5 Personal precautions and qualifications... 5 Personal protective equipment... 5 Drugs, alcohol or medication... 5 Installation, precautions... 5 Operation, precautions... 6 Maintenance, precautions... 8 Storage, precautions... 8 Overview... 9 Design and function... 9 Main parts... 9 Labels... 9 Data plate Safety label Caution: fill with oil before use Electrical hazard label Water pressure label Electrical connection label Installation Quick-release couplings Hydraulic oil Hoses and connections Connecting hoses Connecting new hydraulic hoses Disconnecting hoses Hose length Water connection Electrical connection Transport Lifting the power pack Operation Operating Preparation before starting Start and stop Power on demand Emergency stop Reinforced cooling and power reduction When taking a break Maintenance Hydraulic oil refill Every day Every 300 hours Disposal Storage Technical data

4 Contents PP 100 Machine data Noise declaration statement Troubleshooting Advanced Troubleshooting Service data download Diagnostic files EC Declaration of Conformity EC Declaration of Conformity (EC Directive 2006/42/EC)

5 PP 100 Safety and operating instructions Introduction Epiroc is a leading productivity partner for the mining, infrastructure and natural resources industries. With cutting-edge technology, Epiroc develops and produces innovative drill rigs, rock excavation and construction equipment, and provides world-class service and consumables. The company was founded in Stockholm, Sweden, and has passionate people supporting and collaborating with customers in more than 150 countries. Construction Tools PC AB Box Kalmar Sweden About the Safety and operating instructions The aim of the instructions is to provide you with knowledge of how to use the power packs in an efficient, safe way. The instructions also give you advice and tell you how to perform regular maintenance on the power packs. Before using the power packs for the first time you must read these instructions carefully and understand all of them. Safety instructions To reduce the risk of serious injury or death to yourself or others, read and understand the Safety and operating instruction before installing, operating, repairing, maintaining, or changing accessories on the machine. Post this Safety and operating instruction at work locations, provide copies to employees, and make sure that everyone reads the Safety and operating instruction before operating or servicing the machine. For professional use only. In addition, the operator or the operator's employer must assess the specific risks that may be present as a result of each use of the machine. Safety signal words The safety signal words Danger, Warning and Caution have the following meanings: WARNING CAUTION Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Personal precautions and qualifications Only qualified and trained persons may operate or maintain the machine. They must be physically able to handle the bulk, weight, and power of the machine. Always use your common sense and good judgement. Personal protective equipment Always use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum: Protective helmet Hearing protection Impact resistant eye protection with side protection Respiratory protection when appropriate Protective gloves Proper protective boots Appropriate work overall or similar clothing (not loose-fitting) that covers your arms and legs. Drugs, alcohol or medication WARNING Drugs, alcohol or medication Drugs, alcohol or medication may impair your judgment and powers of concentration. Poor reactions and incorrect assessments can lead to severe accidents or death. Never use the machine when you are tired or under the influence of drugs, alcohol or medication. No person who is under the influence of drugs, alcohol or medication may operate the machine. Installation, precautions DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. 5

6 Safety and operating instructions PP 100 DANGER Electrical hazard The machine is not electrically insulated. There is a risk of electrical shocks if the electrical cable is not treated correctly. If the machine is not connected correctly, serious injuries or death may result. See section "Operation, precautions" for more information regarding electrical hazards. WARNING Hydraulic oil at high pressure Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent injury. Immediately consult a doctor if hydraulic oil has penetrated the skin. Never use your fingers to check for hydraulic fluid leaks. Keep your face away from any possible leaks. Never operate the machine without covers. WARNING Hydraulic oil Spilled hydraulic oil can cause burns, accidents due to slippery conditions and will also harm the environment. Take care of all spilled oil and handle it according to your safety and environmental regulations. Never dismount the hydraulic machine when the hydraulic oil is hot. CAUTION Skin eczema Hydraulic oil can cause eczema if it comes in contact with the skin. Avoid getting hydraulic oil on your hands. Always use protective gloves when working with hydraulic oil. Wash hands after contact with hydraulic oil. CAUTION Moving parts Risk for crushed hands and fingers. Never check bores or passages with hands or fingers. Operation, precautions DANGER Fire hazard If a fire starts in the machine, it can cause injury. If possible use an AB(E)-class powder extinguisher, otherwise use a B(E)-type carbon dioxide fire extinguisher. DANGER Explosion hazard When working on certain materials and when using certain materials in machine parts, sparks and ignition can occur. Explosions will lead to severe injuries or death. Never operate the machine in any explosive environment. Never use the machine near flammable materials, fumes or dust. Make sure that there are no undetected sources of gas or explosives. DANGER Electrical hazard The machine is not electrically insulated. If the machine is not connected correctly, serious injuries or death may result. Never place the power pack in a position where it risks being drowned by water. Ensure that the machine is earthed and that the earth connection has been checked at regular intervals for correct functionality. Operation of the machine without an earth connection presents a risk of fatal accident. Use a DC-sensitive residual current circuit breaker (RCCB) protected supply. The RCCB must be checked for correct functionality according to the specifications from the manufacturer. Never modify the electrical plug or socket. Check that the mains voltage corresponds with the information stated on the data plate on the machine. Only cerified technicians are allowed to service the electrical motor. Do not open any of the motor covers. Unauthorized service work on the motor might lead to power pack malfunction and possibly serious injuries or death. DANGER Electrical cable hazard There is a risk of electrical shocks if the electrical cable is not treated correctly, this can lead to serious injuries or death. Never move the machine by dragging the electrical cable. 6

7 PP 100 Safety and operating instructions Disconnect the cable only by pulling the socket, never pull the electrical cable. Do not expose the electrical cable to heat, oil, and sharp edges. Make sure the electrical cable is not pinched in doors, fences or similar. Check that the electrical cable, extension cable, and cable plug are intact and in good condition. Never connect a damaged electrical cable to the machine. Never touch the electrical cable if it becomes damaged while working. Disconnect the main supply and then disconnect the electrical plug from the socket. WARNING Whipping hose Hoses under pressure can whip uncontrollably if the hose connection becomes loose. A whipping hose can cause severe injuries. To reduce this risk: Turn of the power pack before loosening the connection of a hose. Check that the hose and the connections are not damaged. Never carry or drag the machine by the hoses. WARNING Abuse hazard Never abuse or strike the power pack. This may cause machine breakdown. Never strike or abuse the equipment. Make sure that the frame is clean and free of oil. Never rest on the power pack. Never throw objects on the power pack. WARNING Cover protection The covers of the power pack must be in place. Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent injury. Never operate the machine without covers. Immediately consult a doctor if hydraulic oil has penetrated the skin. WARNING Dust and fume hazard Dusts and/or fumes generated or dispersed when using the machine may cause serious and permanent respiratory disease, illness, or other bodily injury (for example, silicosis or other irreversible lung disease that can be fatal, cancer, birth defects, and/or skin inflammation). Some dusts and fumes created by drilling, breaking, hammering, sawing, grinding and other construction activities contain substances known to the State of California and other authorities to cause respiratory disease, cancer, birth defects, or other reproductive harm. Some examples of such substances are: Crystalline silica, cement, and other masonry products. Arsenic and chromium from chemically-treated rubber. Lead from lead-based paints. Dust and fumes in the air can be invisible to the naked eye, so do not rely on eye sight to determine if there is dust or fumes in the air. To reduce the risk of exposure to dust and fumes, do all of the following: Operate and maintain the machine as recommended in the safety and operating instructions. Read the attached machine's safety and operating instructions. WARNING Overheated power pack The power pack can become overheated and cause burns. Never turn off the cooling water. WARNING Falling power pack If the power pack tips over and fall, it may cause serious injury. Place the power pack in a safe position where it cannot fall and cause damage. WARNING Slipping, tripping and falling hazards There is a risk of slipping, tripping or falling, for example tripping on hoses or on other objects. Slipping, tripping or falling can cause injury. To reduce this risk: Always make sure that no hose or other object is in your way or in any other person's way. Always make sure you are in a stable position with your feet as far apart as your shoulder width and keeping a balanced body weight. 7

8 Safety and operating instructions PP 100 WARNING Slipping hazard There is a risk of slipping on spilled oil, it may cause serious injury. To reduce this risk: Wipe immediately up spilled oil from the ground. Make sure that the frame is clean and free of oil. WARNING Involuntary start Involuntary start of the machine may cause injury. Keep your hands away from the start and stop device until you are ready to start the machine. Learn how the machine is switched off in the event of an emergency. Stop the machine immediately in all cases of power supply interruption. WARNING Noise hazard High noise levels can cause permanent and disabling hearing loss and other problems such as tinnitus (ringing, buzzing, whistling, or humming in the ears). To reduce risks and prevent an unnecessary increase in noise levels: Risk assessment of these hazards and implementation of appropriate controls is essential. Operate and maintain the machine as recommended in these instructions. Select, maintain and replace the working tool as recommended in these instructions. If the machine has a silencer, check that it is in place and in good working condition. Always use hearing protection. Use damping material to prevent work pieces from 'ringing'. Never modify the machine. Modified machines are not covered by warranty or product liability. Always use approved original parts, tools, and accessories. Change damaged parts immediately. Replace worn components in good time. WARNING Hot components Under normal working conditions the engine components, particularly the exhaust system, will get hot. The hydraulic oil, pump, valve, and tank can also reach high temperatures that can cause burns. Never touch a hot exhaust system, hydraulic oil, pump, valve or tank. WARNING Accessory hazards Accidental engagement of accessories during maintenance or installation can cause serious injuries, when the power source is connected. Never inspect, clean, install, or remove accessories while the power source is connected. Storage, precautions Keep the machine and tools in a safe place, out of the reach of children and locked up. WARNING Nominal pressure If the maximum nominal pressure for the hydraulic machine is exceeded, it can result in material damage and personal injury. Always run the hydraulic machine with a tool that does not require a continuously higher pressure than the stated nominal pressure. See section "Technical data". Maintenance, precautions WARNING Machine modification Any machine modification may result in bodily injuries to yourself or others. 8

9 PP 100 Safety and operating instructions Overview H I L To reduce the risk of serious injury or death to yourself or others, read the Safety instructions section found on the previous pages of this manual before operating the machine. F G J K Design and function PP 100 is a hydraulic power pack designed for operating hydraulic rock drills of type RD 100. No other use is permitted. PP 100 is fitted with a (10 kw) electric motor. The oil flow for PP 100 is 38 l.p.m (10 US gal/min) and nominal pressure 120 bar (1,740 psi). The motor is cooled by a water flow of minimum 12 l/min (US 3.2 gal/min) with a maximum temperature of 20 C and pressure below 13 bar (189 psi), in normal operation. See the spare parts list for accessories, spare parts and electrical schematics. See the overhauling instructions for service guide. Main parts Fluid connection side A B A. Hydraulic oil inlet B. Water outlet C. Hydraulic oil outlet D. Water inlet E. Reinforced cooling water outlet Electrical connection side E C D Q N O P F. Hydraulic oil volume indicator G. Electrical connector H. Emergency stop I. On/Off button J. Data plate K. USB memory stick connector L. Safety label (Top) M. Oil drainage N. LED 3, oil error O. LED 2, temperature error P. LED 1, operation error Q. Electrical connection label NOTICE Do not use the USB memory stick connector for other than the USB stick. For the use of the USB memory stick connector, see chapter Advanced diagnostics. Labels The machine is fitted with labels containing important information about personal safety and machine maintenance. The labels must be in such condition that they are easy to read. New labels can be ordered from the spare parts list. M 9

10 Safety and operating instructions PP 100 Data plate A B G C J K To avoid injury, before using or servicing tool, read and understand separately provided safety instructions. Caution: fill with oil before use DE F H I A. Machine type B. Serial number C. The warning symbol together with the book symbol means that the user must read the safety and operating instructions before the machine is used for the first time. D. Maximum nominal operating pressure E. Maximum permitted hydraulic oil flow F. Document number of the Safety and operating instructions. G. Maximum relief valve setting H. Electrical data I. Year of manufacture. J. The CE symbol means that the machine is ECapproved. See the EC Declaration of Conformity which is delivered with the machine for more information. K. The EAC symbol means that the machine is EAC approved. Electrical hazard label Water pressure label Safety label Electrical connection label E L1 P L2 L3 L1 - Phase 1 L2 - Phase 2 L3 - Phase 3 P - Pilot wire E - Earth 10

11 PP 100 Installation Quick-release couplings The original hydraulic hoses are fitted with Flat- Face quick-release couplings that are strong and easy to clean. NOTICE Wipe all couplings clean before connecting. Ensure that couplings are clean and correctly engaged before operation. Failure to do so may result in damage to the quick couplings and cause overheating and cause foreign matter to enter the hydraulic system. Hydraulic oil In order to protect the environment, use of biologically degradable hydraulic oil (HFD-U) is recommended. No other fluids must be used. Viscosity (preferred) cst. Make sure to only use clean oil and filling equipment. When the machine is used continuously, the oil temperature will stabilise at a working temperature level. This will, depending on the type of work and the cooling capacity of the hydraulic system, be between C ( F). At working temperature, the oil viscosity must be within the preferred limits. The viscosity index indicates the connection between viscosity and temperature. The machine must not be used, if oil viscosity fails to remain within the permitted area, or if the working temperature of the oil does not fall between 20 C (68 F) and 60 C (140 F). Hoses and connections Connecting hoses NOTICE Make sure that the hydraulic oil hoses are filled before connection. 1. Put the power pack in standby mode by pressing the On/Off-button. 2. Make sure that the couplings are clean and operational. 3. Attach the return line hose and the pressure line hose according to matching colors. The red color is for pressure line, the blue color is for return line. 4. Start the unit by pressing the On/Off-button. Run the power pack to fill up the hydraulic circuit. Check the hydraulic oil volume, LED 3. Connecting new hydraulic hoses Fill up the hoses with oil prior to first usage. The hoses will require approximately 2 liters (0,53 US gal) of oil per 10 meter (32,8 feet) hose length. NOTICE Empty hoses will drain the power pack of oil and might prevent it from starting. 1. Connect the pressure and return line hoses to the power pack and then connect them in a closed loop. 2. Start and run the power pack for 2 minutes in idle mode. The oil in the hoses will pass through the oil filter and will be cleaned. 3. Disconnect the pressure and return line from each other and connect them to the RD 100. Disconnecting hoses 1. Put the power pack in standby mode by pressing the On/Off-button. 2. Remove the feed line hose and the return line hose. The couplings are unlocked by moving the collar back on the coupling. Hose length A one way hose length of maximum 10 m (33 ft) is recommended. Water connection The power pack is water-cooled. The water has a flushing function for the attached machine during operation. NOTICE Ensure that all couplings are clean before connection. Connect the water hose to the water inlet connection on the power pack and connect the attached machine's water hose to the water outlet connection, see section "Main parts". Check the flow of the water. Make sure that water is sprayed out from the bores on the attached machine's working tool. Electrical connection NOTICE Ensure that all connectors are clean before connection. Safety and operating instructions The power pack must be connected to alternating current supply that complies with the information given on the data plate. The electrical cable must be between a minimum of 20 meters (65,6 feet) and a maximum of 100 meters (328 feet). Use an electrical cable with conductors of adequate cross section in order to avoid a drop 11

12 Safety and operating instructions PP 100 in the machine's performance and overheating of the extension cord. The recommended conductor cross section is 2.5 mm2 over a length of 100 meter. See section "Main parts" for electrical connection. NOTICE Failure to comply with the cable length specification can lead to equipment damage. The power pack is equipped with a 2-wire module for ground supervision. The remaining steps to ensure electrical connection safety needs to be applied on the power supply side. Ensure that the main supply is equipped with an emergency stop. Connect the power pack to the main supply only when it is ready for use. Disconnection from the main supply must be by way of an isolating switch. Shut off the main supply prior to disconnecting the electrical cable. Always connect the power pack to main supply that is equipped with a DC-sensitive residual current circuit breaker (RCCB) rated at max 30 ma. The RCCB must be checked for correct functionality according to the specifications of the manufacturer of the RCCB. Ensure that the earth connection has been checked for correct functionality. The power pack must be connected to a Pilot relay. An example of a compliant relay is the MSR-9 by Switching Systems (Pty) Ltd. The connection must be made acccording to the Pilot relay manufacturer instruction. The monitoring circuit must be intrinsically safe in accordance with EN NOTICE The circuit diagram for the installation of the power pack can be found in the power pack spare parts list (nr ). During transport make sure the power pack is secured. Ensure that the power pack is upright during transportation and lifted with approved lifting equipment. Drain the water system if there is risk of freezing to avoid damage to the power pack motor. Transport WARNING Falling power pack If the power pack tips over and fall, it may cause serious injury. Place the power pack in a safe position where it cannot fall and cause damage. 12

13 PP 100 Safety and operating instructions Lifting the power pack Operation Two persons are required when lifting the machine. Grasp the frame on the machine's short sides, see illustration below. Lift the power pack and move it to its intended destination. WARNING Involuntary start Involuntary start of the machine may cause injury. Keep your hands away from the start and stop device until you are ready to start the machine. Learn how the machine is switched off in the event of an emergency. Stop the machine immediately in all cases of power supply interruption. Operating When moving the machine a shorter distance, grasp frame on the power pack's short side, see illustration below. Pull the machine to its intended destination. When lifting the power pack with a forklift, fit the lifting strap in the manner shown in the illustration below. Preparation before starting The following checks must be made each time the power pack is used. All these checks concern the operation of the power pack. Some concern safety: Clean all safety labels. Replace the missing or damaged labels. Remove dirt and debris. Inspect the power pack and hoses generally for signs of damage. Check that all cables are intact and in a good condition. Fill up the hydraulic hoses with oil before start. Check for oil leakages under the power pack. Ensure that the hydraulic couplings are clean and operational. Check all fastenings. Place the power pack in a safe position, to prevent tilting during operation. Maximum 45º tilt. The prefered position is the hydraulic end as highest point. Check that the machine is connected to an earthed electrical outlet socket, according to instructions in section "Electrical connection". Connect the power supply (A), see illustration below. 13

14 Safety and operating instructions PP 100 A B throttle the engine is increasing to work mode. Release the throttle and the power pack returns to idling mode. Emergency stop In case of emergency during operation, press the emergency stop (A). The power pack will stop and the LED 1 (B) indicator lights continuously. A B Check the hydraulic oil level, LED 3 (B). Inspect the LED indicators (B). Flashing or continuous lighting LEDs indicate errors that need to be adressed before start. Start and stop A C 1. Switch on the main supply. The On/Off button (A) on the top of the power pack is flashing (0,5 Hz), the machine is in stand-by mode. 2. Start the power pack by pressing the On/Off button, the button lights up. 3. Stop the power pack by pressing the On/Off button, the button is flashing (0,5 Hz). The machine is in stand-by mode. 4. If the On/Off button, in stand-by mode, is flashing fast (2 Hz) the machine must be serviced. 1. Check and correct the error before restarting the power pack. 2. Reset the emergency stop (A) by turning the emergency stop button. 3. Press the On/Off button (C) to get the power pack in stand-by mode. 4. Start the power pack by pressing the On/Off button (C). NOTICE Do not use the emergency stop to shut off the power pack during normal operation. Reinforced cooling and power reduction The cooling water outlet (A) is used during reinforced cooling. Power on demand The power pack is equipped with a power on demand function. When pressing the On/Offbutton, the RD 100 is in idling mode with a low RPM. When pressing the attached machine's 14

15 PP 100 Safety and operating instructions parts is not covered by warranty or product liability. When cleaning mechanical parts with solvent, comply with appropriate health and safety regulations and ensure there is satisfactory ventilation. For major service of the machine, contact the nearest authorised workshop. After each service, check that the machine's vibration level is normal. If not, contact the nearest authorised workshop. Water flows from the cooling water outlet if the machine is starting to be overheated. LED 2 indicates enhanced cooling and power reduction. Following scenario is possible: If the power pack becomes slightly overheated, it will drain out water from the cooling water outlet. LED 2 is flashing slow (0,5 Hz). If the machine still is overheated, the power will be reduced. LED 2 is flashing fast (2 Hz). If the power pack is very overheated it will shut down. LED 2 lights continuously. Allow the power pack to cool before restarting it. When taking a break During all breaks the machine must be placed in such a way that there is no risk for it to be unintentionally started. Make sure to place the machine on the ground, so that it can not fall. Switch off the main supply in the event of a longer break or when leaving the workplace. Disconnect the electrical cable and use caps to protect the contacts. Switch off the water supply in the event of a longer break or when leaving the workplace. Maintenance Regular maintenance is a basic requirement for the continued safe and efficient use of the machine. Follow the maintenance instructions carefully. Before starting maintenance on the machine, clean it in order to avoid exposure to hazardous substances. See Dust and fume hazard. Use only authorised parts. Any damage or malfunction caused by the use of unauthorised A WARNING Slipping hazard There is a risk of slipping on spilled oil, it may cause serious injury. To reduce this risk: Wipe immediately up spilled oil from the ground. Make sure that the frame is clean and free of oil. Hydraulic oil refill Refill oil when LED 3 is flashing, see "Hydraulic oil". 1. The power pack must be in stand-by mode, flashing 0,5 Hz. 2. Disconnect the hydraulic hoses. 3. Connect the top-up tank to the hydraulic oil inlet, see "Main parts" (A). 4. Refill oil until the oil volume indicator pin pops out (can be felt with finger), see "Main parts" (F). 5. Disconnect the top-up tank. 6. Tilt the power pack, approximate 30 with the fluid connection side as the highest point. The tank ventilating system will be automatically activated to ventilate trapped air in the oil tank. 7. Level the power pack. 8. If the oil volume indicator pin does not pop out, repeat the steps 3-7 again until the oil volume indicator pin pops out. 9. Fill up the hydraulic hoses with oil and connect them. 10. Wipe up any spilled oil from the ground and manage it in respect to local restrictions. Every day Never perform maintenance when the power pack is running. 15

16 Safety and operating instructions PP 100 Clean and inspect the machine and its functions each day before starting work. Do not use a pressure washer for cleaning. Conduct a general inspection for leaks and damage and wear. Change damaged parts immediately. Replace worn components in good time. Never use the equipment if there is suspicion that it is damaged. Never strike or abuse the equipment. Make sure that all the attached and related equipment, such as hoses, cable connectors, and couplings are in good condition. Check the hydraulic oil volume. Check the hydraulic couplings and the hoses. All fasteners and other threaded components to be tightened according to the torque stated in the spare parts list. Every 300 hours The on/off button will signal (flashing 2Hz) that the service inteval is reached. The machine must be inspected and serviced by authorised staff, trained for this task. Disposal A used machine must be treated and scrapped in such a way that the greatest possible portion of the material can be recycled and any negative influence on the environment is kept as low as possible. Before a used machine is scrapped it must be emptied and cleaned from all hydraulic oil. The remaining hydraulic oil must be deposited and any negative influence on the environment is to be kept as low as possible. Storage Check that the machine is properly cleaned before putting it away for storage. Store the machine in a dry place. Keep the machine in a safe place, out of the reach of children and locked up. Drain the water system if there is a risk of freezing. Up to three units can be stacked on top of each other for convenient storage. 16

17 PP 100 Safety and operating instructions Technical data Machine data PP Power supply 525 V ± 10%, 50 Hz, 12 A 440 V ± 10%, 50/60 Hz, 17 A 380 V ± 10%, 50/60 Hz, 17 A Peak current 15 A (< 4 ms) 21 A (< 4 ms) 21 A (< 4 ms) Input power, kw (HP) 10 (13.4) Height, mm (in.) 352 (13.9) Width, mm (in.) 402 (15.8) Length, mm (in.) 695 (27.4) Ambient temperature range, C ( F) 5 to 40 (41 to 104) Weight incl oil, kg (lb) 45 (99) Flow, l/m (ft 3 /min) 38 (1.4) Hydraulic oil temperature, C ( F) 20 to 60 (68 to 140) Nominal pressure, bar (psi) 120 (1,740) Pump type Helical rotor pump, directly driven from the motor shaft. Oil tank capacity, litres (US gal) 8.7 (2.3) Filtration Cooling system Motor type Voltage interruption limit Voltage dips limit 10 µ filter in return line. Filter by-pass valve. Water Inverter controled 3 phase PM motor. Supply interrupted or at zero voltage for not more than 3 ms at any random time in the supply cycle with more than 1 s between successive interruptions. Voltage dips not exceeding 20 % of the peak voltage of the supply for more than one cycle (20ms) with more than 1 s between successive dips. Overvoltage limit Transient voltage increase 0,5s repeated < 1time/min: 20 % Transient voltage increase 3ms repeated < 1time/min: 40 % Socket PC1 5 pole, 3P, Pilot +E Electrical safety IP class Installed with residual current device Earth supervision Earth in cable screen IP66 Noise declaration statement Type Sound pressure EN ISO Lp1 db(a) rel 20uPa Noise Declared values Lw2 guaranteed db(a) rel 1pW Sound power 2000/14/EC Lw measured db(a) rel 1pW PP Sound pressure level according to EN ISO at 1 metre distance. 2 Guaranteed sound power according to EN ISO 3744 in accordance with directive 2000/14/EC inclusive spread in production. 17

18 Safety and operating instructions PP 100 These declared values were obtained by laboratory type testing in accordance with the stated directive or standards and are suitable for comparison with the declared values of other tools tested in accordance with the same directive or standards. These declared values are not adequate for use in risk assessments and values measured in individual work places may be higher. The actual exposure values and risk of harm experienced by an individual user are unique and depend upon the way the user works, in what material the breaker is used, as well as upon the exposure time and the physical condition of the user, and the condition of the breaker. We, Construction Tools PC AB, cannot be held liable for the consequences of using the declared values, instead of values reflecting the actual exposure, in an individual risk assessment in a work place situation over which we have no control. 18

19 PP 100 Safety and operating instructions Troubleshooting Operation status, LED 1 Status LED 1 Remedy Start with unconnected hydraulic hoses Lights continuously Connect the hydraulic hoses. Overvoltage Lights continuously Check and remedy the power supply. Undervoltage, <30% nominal voltage Lights continuously Check and remedy the power supply. Low voltage, power reduction Flashing (0.5 Hz) Check and remedy the power supply or drill with reduced power. Phase failure, phase diconnected Lights continuously Check and remedy the power supply. Motor failure Lights continuously Contact authorized service workshop if the problem persists after power pack restart. Temperature status, LED 2 Status LED 2 Remedy High temperature enables enhanced cooling High temperature enables power reduction Flashing slow (0.5 Hz) - Flashing (2 Hz) - Overheated, engine stopped Lights continuously Cool down for 15 minutes, use cooling water flow. Oil status, LED 3 Status LED 3 Remedy Low oil level warning Flashing slow (0.5 Hz) No disruption. Low oil level, engine stopped Lights continuously Top up hydraulic oil. Air in the oil tank Flashing (2 Hz), when the ventilating valve is activated. Only venting in stand-by mode. Never start the power pack when the ventilating valve is activated. Oil temperature Lights continuously Check water supply. Cool down for 30 minutes. Repeated indication, service is needed. Contact nearest authorised workshop. Water pressure status, LED 1, LED 2, LED 3 Status LED 1, LED 2, LED 3 Remedy Low water pressure All LEDs flash slowly (0.5 Hz) Check water supply. Water pressure needs to be above 4 Bar. Service status, On/off button Status On/off button Remedy Service interval reached Flashing (2 Hz) Service interval reached (by default set to 300 hours). Perform service according to maintenance instructions. 19

20 Safety and operating instructions PP 100 Advanced Troubleshooting The PP100 is equipped with a USB service data interface (A) used for advanced diagnostics. The data interface is used for download of log files. The files can be used as an aid in fault finding, in case that the normal troubleshooting described in this manual is not sufficient. The interface can also be used for future software upgrades. A Use a USB memory stick preformatted as FAT16 or FAT32. NOTICE The USB memory should not contain any files prior to the first setup. Connect the USB stick to a PC and open the root folder. Open a text application, preferably Notepad, and create a text file containing a single row. The row should read ReadErrorLogC. Save the file as text with the name pcmd.pp. NOTICE The diagnostics tool is case sensitive. Make sure the "ReadErrorLogC" command is spelled correctly and is using the correct case. NOTICE Some text applications will automatically add a suffix ".txt" to the file name. Make sure that the file is named "pcmd.pp" and not "pcmd.pp.txt". Service data download 1. Put the PP100 in standby mode. 2. Insert the USB stick containing the command file. 3. LED 1-3 will start to flash. The data transfer will take less than 30 seconds. All LEDs will light continuously when the data transfer is complete. 4. Remove the USB stick. The USB stick contains a newly created folder. The folder will have the same name as the serial number of the machine. The folder contains 2 files called Deviceinfo.txt and Errorlog.txt. 20

21 PP 100 Safety and operating instructions NOTICE A single USB stick can be used to download diagnostics from several PP100. A unique sub folder with serial number will be created for each machine. NOTICE A USB stick can be used for consecutive diagnostic downloads without having to be erased in between. All new error log information is appended to the existing error log file. The diagnostic files can either be used for end user diagnostics or sent to an autorised workshop for review. Diagnostic files The file Deviceinfo.txt contains the following information: Linte text Serial number: <Serialnumber> Uptime: <Hours> Drilltime: <Hours> Time to service: <Hours > CU SW: <Version> PU SW: <Version> ASNR: <Serialnumber> Comment PP100 Serial number. Total uptime (drill time + idle time + stand-by time). Total drill time. Time to next service. Set to 300 hours. Control unit software version. Power unit software version. Driver unit serial number. The information in this file can be used to determine how much time the machine is used, both actual running time, but also idle and standby. The remaining information in the file concerns software versions in the different control and power units. This information can be used by an authorised workshop to determine if a software upgrade is needed. NOTICE Software upgrades can only be performed by an authorised workshop. The error log file Errorlog.txt contains the following information: Line text ERRORLOG_START <Timestamp> <Timestamp> <Errornumber> <Errorname> ERRORLOG_DONE Event Timestamp for errorlog start.this row also contains the serial number of the machine. Error with number <ErrorNumber> and with the name <Error name> Time for the error. <Timestamp>. End of Errorlog. The different error messages are explained in the table below: Error log no. Error text Description Remedy 0 ERR_MINOR_LOW_VOLTAGE Low supply voltage, < 0.90 * Supply voltage. Output power is reduced. 3 ERR_START_WITHOUT_HYDRAULICS Start without hydraulic hoses connected. 4 ERR_HIGH_VOLTAGE High supply voltage, >1,1 * Supply voltage; PP100 to standby. 5 ERR_MAJOR_LOW_VOLTAGE Low supply voltage, < 0.70 * Supply voltage; PP100 to standby. - Connect the hydraulic hoses. Check and remedy the power supply. Check and remedy the power supply. 21

22 Safety and operating instructions PP 100 Error log no. Error text Description Remedy 7 ERR_PHASE_LOSS Supply phase loss. Check and remedy the power supply. 35 ERR_WINDING_HIGH_TEMP_MEDIUM Power reduction ERR _ROTOR_HIGH_TEMP_MEDIUM Power reduction ERR _DRIVER_HIGH_TEMP_MEDIUM Power reduction ERR _WINDING_HIGH_TEMP_MAJOR High motor temp, PP100 to standby. 39 ERR _ROTOR_HIGH_TEMP_MAJOR High motor temp, PP100 to standby. 40 ERR _DRIVER_HIGH_TEMP_MAJOR High motor temp, PP100 to standby. Cool down for 15 minutes, use cooling water flow. Cool down for 15 minutes, use cooling water flow. Cool down for 15 minutes, use cooling water flow. 50 ERR_OIL_LOW_LEVEL_MAJOR Low oil volume, PP100 to standby. Top up hydraulic oil. 51 ERR_TOO_HIGH_OIL_TEMP High oil temp, PP100 to standby. Check water supply. Cool down for 30 minutes. Repeated indication, service is needed. Contact nearest authorised workshop. 53 ERR_LOW_WATER_PRESSURE Incoming water pressure low. Check water supply. Water pressure needs to be above 4 Bar. 54 INFO_WATER_PRESSURE_RESTORED Incoming water pressure restored. - The error messages can also be used to determine if the media supply is working as expected. The timestamp will aid in finding during what time the electrical or water supply to the machine was insufficient or faulty. Power supply Error no. 0,4,5,7 Check electrical supply Water supply Error no , 51 and 53 Insufficient cooling or too low water pressure. Check water supply. The time stamp for each error in the log file is GMT. The clock will not need to be adjusted, nor should battery replacement be needed, during the lifetime of the machine. 22

23 PP 100 Safety and operating instructions EC Declaration of Conformity EC Declaration of Conformity (EC Directive 2006/42/EC) We, Construction Tools PC AB, hereby declare that the machines listed below conform to the provisions of EC Directive 2006/42/EC (Machinery Directive) and 2000/14/EC (Noise Directive). Hydraulic Power Pack Nominal pressure (bar) Guaranteed sound power level [db(a)] Measured sound power level [db(a)] PP The product conforms to the provisions of the following further Directives: 2014/35/EU, LVD 2014/30/EU, EMC 2011/65/EU, RoHS 2000/14/EC appendix VIII, OND The following harmonised standards were applied: EN 4413:2010 Notified body involved for directive: NoBo no.0038 Lloyd's Register Verification Limited 71 Fenchurch Streeet London EC3M 4BS United Kingdom Technical Documentation authorised representative: Conny Sjöbäck Construction Tools PC AB Dragonvägen 2 Kalmar General Manager: Jenny Heimersson Manufacturer: Construction Tools PC AB Box Kalmar Sweden Place and date: Kalmar,

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