Dancutter DC SUPER FLEX User manual
Dancutter a/s Livøvej 1 DK-8800 Viborg P +45 9651 2150 info@dancutter.dk dancutter.com
September 2020
Instructions
DC SUPER FLEX
Before you take this equipment in enterprise, you must read these operating instructions very carefully.
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September 2020
1.0 Manufacture .................................................................................................................. s. 3
2.0 Model Type ..................................................................................................................... s. 4
3.0 Safety Instructions......................................................................................................... s. 4
4.0 Technical Description .................................................................................................... s. 5
5.0 Service and Maintenance .............................................................................................. s. 6
6.0 Instructions .................................................................................................................... s. 7
7.0 Hose reel......................................................................................................................... s. 8
8.0 25M vs 50M.................................................................................................................... s. 9
9.0 Cutter ............................................................................................................................ s. 10
10.0 Control unit............................................................................................................s. 11 - 13
11.0 Cutting tools..........................................................................................................s. 14 - 15
12.0 Replacing the Air Motor...............................................................................................s. 16
13.0 Water Separator and Oil Lubricator.............................................................................s. 17
14.0 Installation of centring tool set w/brushes ................................................................ s. 18
15.0 Installation of centring tool set w/wheels............................................................s.19 - 20
16.0 Declaration of Conformity ...........................................................................................s. 21
Contents
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Dancutter a/s
Livøvej 1
DK-8800 Viborg
Tel: +45 9651 2150
info@dancutter.dk
CVR/VAT no.: 26672678
1.0 Manufactur
Technical support
If you experience problems with the cutter or if you have any
technical questions, please write to support@dancutter.dk
Order
If you need spare parts or cutting heads, please write to
order@dancutter.dk
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September 2020
Identication:
System Type: Mobile cutter unit
Model: DC SUPER FLEX
• Only start the air sander when the cutter is in the pipeline.
• Remove the air connection when the cutter is rolled back
onto the hose reel.
• Remove the air connection before relling with washer uid.
2.0 Model Type
3.0 Safety Instructions
• Screws, adapter, cutting tools, etc. must be inspected
weekly for wear and damage and must be replaced or tight-
ened if necessary.
• Place a refrigeration dryer between the compressor and the
cutter system.
• If the hose reel is to be placed on its side, the oil lubricator
glass MUST be removed (13.4)
In the event of new product developments, Dancutter reserves the right to change the technical description without advance notice.
Specications
Control Unit
September 2020
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Extremely exible and user-friendly cutter that can work in
small pipes. The stainless steel frame contains 25 or 50 m
supply hose which the cutter is xed direct on to. The supply
hose is supplying air, sprinkler and power to the cutter and is
used to push the cutter to the working position hereafter the
control of the cutter takes place on the supplied control Unit.
Working area is 70 - 150 mm / 3 - 6 in. In order to work in 150
mm the skip set, that is in the toolbox, have to be mounted.
The DC
SUPER FLEX has a built-in slip ring to the camera, which
allows 360° continuously rotation of the milling motor There is
also built-in lock and slip ring on the stainless steel frame, so
the cutter can freely be moved back and forth with the supply
hose, while workingwith and operating the cutter.
The camera has a side-mounted spray nozzle for cleaning
the camera lens, which is activated on the Control Unit, from
which the continuously rotation and forward/reverse move-
ment of the cutter is controlled by the two joystick.Cutter has
a built-in forward/backward movement of 60 mm. Raising
the milling motor is controlled also at one of these joysticks.
4.0 Technical Description
External diameter: 60 mm, 2.4 in
L: 350mm - B: 300 mm - H: 150 mm
Air motor: 15000 RPM
Weight: 7 kg, 15.4 lb
Air preassure: 10 bar, 145 psi
Power supply: 24VAC
Power supply: 110 / 220 VAC
Weight:
25 m: 58 kg, 128 lb
50 m: 71 kg, 156.5 lb
L: 1000 mm - B: 550 mm - H: 1030 mm
Air supply: 650 l/min, 22 cfm
Supply hose: 25 m or 50 m
There is a built-in 12.1 ” color monitor in the lid of the control
unit. The cutter can move through two successive 45° bends
in a 75 mm pipe, and a 90° bend/angle of a relined 110 mm
pipe.
Wheels on the stainless steel frame, provides an easy andhas-
sle free movement to and from the workplace. There are
mounted oil lubricates and water separator at the stainless
steel frame.
Max water content delivered by compressor per m3supply air
should be maximum: 20g/m3.
Cutting engine consists of an air motor, which runs at up to
15,000 revolutions per minute. It has an air consumption of
650 litres/minute and need 7 bar working pressure. The com-
pact cutters are made from a resistant stainless steel alloy
- which gives a minimum maintenance of the cutter.
The stainless steel frame measuring: Width: 550 mm. Length:
1000 mm. Height: 1030 mm.
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September 2020
• Always replace the covers on the Cable, Control Unit after
use in order to protect the power connectors.
• Be careful with the compressed air line to avoid dirt getting
into the air supply.
• Avoid water/moisture on the control unit, as it is not splash
proof. Close it after use and hang it on the hose reel to
protect the screen and the switches.
• It is recommended to remove the cover behind the camera
and clean this area, especially after working in downpipes
from below.
• After use, place the cutter in the hose reel so that the air
motor is vertical, so that any moisture formation can drain
out of the air motor and into the hose.
• Only use distilled water or washer uid on the cutter, as
normal- water will cause lime scale on the valve and sluice.
• Pneumatic oil must be used on the oil lubricator and
MARINE grease in the air motor.
5.0 Service and Maintenance
Service overwiew
Part - parts - service Daily Weekly Other
Cleaning the cutter x
Re-lling with pneumatik oil x 13.4
Lubricate the ball and piston x
Grease in the air motor x
Examine parts and tighten or replace them x
Clean the tilt function and lubricate with oil x
Lubricate the drum shaft with a couple of drops of oil x
Rell washer uid As required
Replace air lter As required
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The cutter is dimensioned so that it can work in all types of
pipe, from 70 up to 125 mm. Depending on the internal con-
dition of the pipe, the DC SUPER FLEX can be passed through
90° bends in a 100 mm tube. However, it is important that the
black hoses (8.3) between the individual parts on the cutter
are not subjected to twisting or bends exceeding 80 degrees
when only the hose is bent.
With the extension kit, it is possible to work in tubes up to
Ø150 mm. (See section 12 )
Start by placing the hose reel and the control unit where the
work will be performed. Then connect the power 110/220 V to
the control Unit.
Connect the compressed air from the compressor with the air
inlet (13.2) on the hose reel. In connection with the compres-
sor, use a refrigeration dryer in order to avoid freezing in the
small hoses and the sluice units.
Now guide the cutter out of the hose reel and into the pipe
where it will work. If the cutter needs to pass through a sharp
bend to reach the work site, the insertion should be followed
on the monitor (9.8) so the operator can lift/swivel the cutter
arm when it reaches the bend, thereby facilitating entry. Re-
member to lay
down the cutter arm again when the bend has been passed.
If a long distance must be travelled, it is recommended to use
the foot plate that is mounted on the frame when inserting and
removing the cutter.
The cutter is now in position and ready for operation.
Turn on the cutting air using the switch on the Control Unit
6.0 User Instructions
(9.9) and let it run for a while before opening the tap to the
camera’s tank (7.5). Slowly lift the cutter arm by moving the
joystick (9.3) back towards the operator so that the cutting
head (8.7) touches the working area. For connector open-
ings, it is important that the cutter is moved backwards and
forwards. This is performed with the joystick (9.5) on the con-
nector while simultaneously rotating the cone milling tool. This
is performed by moving the joystick (9.13) to the right and left
respectively.
It is important to have worked a large part on the connector
before the cone milling tool goes through the sleeve, because
this minimises the risk of the cutter/cone milling tool getting
stuck inside the pipe. It is also recommended to reduce some
of the pressure on the cutter arm just before the cone milling
tool passes through the sleeve. This is performed by moving
the joystick (9.13) forward. In order to move farther forward or
backward than the hose length reaches, use the yellow hose to
push/pull the cutter into position.
The speed of rotation can be adjusted on a potentiometer on
the Control Unit. (9.12)
In order not to damage the conveying motor, it must be driven
back to the closed state before the cutter is withdrawn from
the tube after use. (8.1) The yellow hose is used to pull the
cutter back to the hose reel when the cutting is completed.
Remember to clean and lubricate the cutter according to
section (5.0) for service and maintenance of DC SUPER FLEX.
Close the tap to the camera’s tank (7.5), disconnect the air and
power supplies.
Close the Control Unit and hang it back on the hose reel.
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September 2020
7.0 Hose reel
1. Base plate
2. Filling the washer uid
3. Camera cleaning
4. Lock and Slip rings house
5. Tap for air to the tank
6. Water separator and oil lubricator
7. Cutter
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3
2
7
4
1
5
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8.0 DC SUPER FLEX 25 M vs. 50 M
DC SUPER FLEX 25
DC SUPER FLEX 50
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9.0 Cutter
1. Back - forward movement
2. Rotary motor
3. Flexible hose
4. Turning point with built-in slip ring and air and water sluice
5. Camera
6. Camera cleaning
7. Cutting Head
8. Grease
2
1
6
3
7
8
5
4
In the event of new product developments, Dancutter reserves the right to change the technical description without advance notice.
Control Unit
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Power supply: 110 / 220 VAC
10.0 Control Unit
Weight: 7 kgL: 350 mm - B: 300 mm - H: 150 mm
1. FW/BW
2. VIDEO OUT
3. VIDEO IN
4. OVERLOAD FW/BW
5. REVERSE FW/BW
6. CAMERA
7. LIGHT
8. GRINDER
9. REVERSE TURN
10. OVERLOAD TURN
11. REGULATOR
12. TURN/RAISE ARM
13. CAMERA CLEAN
14. EMERGENCY
1
2
3
4
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13
12
11
10
5 6 7 8 9
Protect the control unit – on which switches and joystick are
mounted – from water/moisture/snow, as it is not watertight.
Therefore take shelter with the control unit in rainy/snowy
weather. Always close the lid after use to protect the screen
and switches.
The following is a description of the individual switches on the
control unit.
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September 2020
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2
3
4
14
13
12
11
10
56789
1. FW/BW: use the joystick to operate the cutter’s forward/
back movement.
2. VIDEO OUT: outlet for showing the camera image on an
external screen.
3. VIDEO IN: outlet for an external camera, if necessary (turn
the camera knob to “2”).
4. OVERLOAD FW/BW: the green LED should preferably icker/
shine when the forward/back drive is operating. If the electric
motor is overloaded, the red LED will shine and an acoustic
alarm will sound for about 5 seconds. After this, the power
supply to the motor will be disconnected. The controls will
switch back on again after about 10 seconds.
5. REVERSE FW/BW: this function reverses the signal to the
“FW/BW” joystick. Use this function if you are using an exter-
nal camera sees in the opposite direction from the camera
on the cutter. Turn the knob to the “left” position for normal
operation. Turning the knob to the right makes the joystick
work in reverse.
6. CAMERA: use this switch to turn on the camera on the cut-
ter. (Pos. “2”: external camera) (Pos. “1”: camera on the cutter)
7. LIGHT: use this switch to turn on the camera light.
8. GRINDER: start the Cutter by turning the switch to pos. “1”.
9. REVERSE TURN: this function reverses the signal to the
joystick “turn/raise arm”. Use this function if you are using an
external camera which sees in the opposite direction from
the camera on the cutter. Turn the knob to the “left” position
for normal operation. Turning the knob to the right makes
the joystick work in reverse. The “arm: up/down” function is
unchanged regardless of the switch position.
10. OVERLOAD TURN: the green LED should preferably icker/
shine while the rotation function is operating. If the electric
motor is overloaded, the red LED will shine and an acoustic
alarm will sound for about 5 seconds. After this, the power
supply to the motor will be disconnected. The controls will
switch back on again after about 10 seconds.
11. REGULATOR: use this knob to adjust the speed of the
cutter’s rotation function. The function is not available on DC
MAXI FLEX.
12. TURN/RAISE ARM: moving the joystick right or left acti-
vates the cutter’s rotation function to the right/left. Pulling the
joystick away from the screen raises the cutter arm. Pushing
the joystick towards the screen lowers the arm. The up/down
speed of the arm is preset at the factory.
13. CAMERA CLEAN: pressing the button activates the
camera cleaner. The button shines green when the function is
active. Press the button again to switch off the camera cleaner
(the light in the button will turn off).
14. EMERGENCY: activating the emergency-stop button will
disconnect all 24 V DC supplying the electric motor and the
magnetic valves for air. The only function retained is the power
supply for the cutter’s camera so it is possible for the operator
to view the cutter as it is being withdrawn from a pipeline.
WiFi is built into the control unit to provide a wireless connec-
tion for a VR headset (optional accessory).
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Always replace the covers on the CABLE AND CONTROL UNIT
after use in order to protect the power connectors.
Always hang the Control Unit in its place after use.
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September 2020
DJ1938-14
The standard cutter is equipped with an AG 50 air engine,
where air is blown forward to blow dust away from the cam-
era.
11.0 Cutting tools
The cutting tool is replaced by using the Allen key supplied. It
may be necessary to clean the bolt in the grin ding motor, by
which the cone milling tool is secured rst.
DK3015-16
Dancutter recommends using the following cutter heads for re-opening of laterals.
DK3713-16
DK2020-18
DK4623-16
DK2629-16
Specials tools for 75 mm/3”
Cutter head DK3713-16
Special tool DK3713-V - DK3713-B
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DKA1022
DD9008
Dancutter recommends using the following diamond heads for concrete.
Dancutter recommends using the following cutting discs for iron/steel
DD4623 DD3015
DD9023
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September 2020
Raise the arm so that the 5mm Allen key can be inserted and
loosen the screw on both sides (11.1).
12.0 Replacing the Air Motor
The air motor can then be pulled out and replaced.
Install the motor in revers order.
11.1
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Fill oil before using the cutter. REMEMBER, replenishing the
oil when the top of the oil can be seen in the glass (13.5). It
is important that the glass does not run out of oil, as this will
damage
the air motor and impair its performance.
Only use pneumatic oil (Part number: DCHY29307)
The lter (Part number P57106) in the water separator (13.4)
must be changed as necessary. In case of problems with the
1. Adjusting the mist lubricator
2. Air inlet from the compressor
3. Air outlet for the camera tank
13.0 Water Separator and Oil
Lubricator
air supply, clean the lter if necessary.
The mist lubricator must not be adjusted, as this has been
congured at the factory.The mist lubricator must be kept
upright during transport. If the fram is placed on its side, the
glass must
be removed to prevent oil owing into the camera tank.
DURING transport with the device, always close the tap at the
air outlet for the camera tank.
4. Atomatic water separator
5. Oil tank
6. Air outlet for sluice
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4
5
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September 2020
The hollow/recess on the individual half-globes in the centring
tool set, must ALWAYS face towards the air motor. Were the
spotfacings are tapped into the Half-Globes. This is especially
14.0 Installation of centring
tool set w/brushes
important for the unit mounted at the rotation point (8.4), as
it would otherwise tighten and prevent the smooth rotation of
the air motor.
Position the spotfacings facing forwards.
Installation of centring tool set
The centring kit must be tightened so
that the increase on the trailing edge
of the individual places on the cutter is
continued up the individual blocks.
When operating in the downpipes, mount
the supplied brushes into the holes on
the individual blocks in the centring tool
set.
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15.0 Installation of centring tool set
w/wheels
Place the cutter underneath the three centrings rings so that
the rotary centring ring is ush with the air motor.
NOTE! Place the middle centring ring so that the internal clear-
ance allows the slip ring system to rotate.
Slip ring
Rotary Slip ringAir motor Fixed Fixed
IMPORTANT! Remove the cover before installing the centring
tool set.
There is a spotfacing on the periphery of each part of the cen-
tring tool set. When installing, it is VERY IMPORTANT that the
spotfacings are positioned one on top of the other.
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September 2020
Position the spotfacings facing forwards.
Position the spotfacings one on top of the other. There is a spotfacing on each of the centring rings to indicate
which side of the ring should face the air motor.
Spotfacing
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