Dimas PP 455E User manual

DIMAS PP 455E
English .................................................. 3
Deutsch ................................................33
Italiano ..................................................63
Nederlands........................................93

Operator's Manual PP 455E
English - 3
Contents
English
Contents
Key to symbols.............................................................. 5
Safety Instructions...................................................... 6
Introduction..................................................................... 9
What is what................................................................. 11
Technical data............................................................. 13
Assembling/Installing equipment................... 15
Fit the hydraulic unit................................................... 15
Work procedure for wall sawing...................... 17
Start blade rotation...................................................... 17
After work is completed............................................. 17
Water valve..................................................................... 17
Dismantling the equipment...................................... 18
Work procedure for wire cutting............................ 18
Menu functions.............................................................. 19
Start menu....................................................................... 19

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Contents Operator's Manual PP 455E
Operations menu.......................................................... 20
Charge the battery....................................................... 21
Settings............................................................................. 22
Error messages............................................................ 27
Maintenance................................................................. 29
EU declaration of conformity............................. 31

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Key to symbolsOperator's Manual PP 455E
Key to symbols
The symbols below are used on the machine and in this
Operator's Manual. It is important that the user
understands the significance of these in order to work with
the machine safely.
Manual
Please read the Operator's Manual carefully and
understand the contents before the machine is started.
Protective equipment
Always wear:
• Approved protective helmet.
• Approved hearing protection.
• Approved protective glasses or a visor, and other
essential safety equipment.
Warning
A large warning triangle with the text “Warning” signifies
that there is a risk of serious personal injury or even
death.
Caution
A smaller warning triangle with the text “Note” signifies
that there is a risk of minor personal injury or damage to
the machine.
Remark
A hand with a raised index finger with the text “Attention”
signifies that a described element demands extra
attention.
CE
This symbol indicates that the machine conforms to
applicable EU directives.
Electrical Warning
This symbol warns that there is high voltage present.
Environmental marking
Symbols on the product or its packaging indicate that this
product can not be handled as domestic waste. It must
instead be submitted to an appropriate recycling station
for the recovery of electrical and electronic equipment.
By ensuring that this product is taken care of correctly,
you can help to counteract the potential negative impact
on the environment and people that can otherwise result
through the incorrect waste management of this product.
For more detailed information about recycling this product,
contact your municipality, your domestic waste service or
the shop from where you purchased the product.

6 - English
Safety Instructions Operator's Manual PP 455E
Safety Instructions
During the design and production of Dimas products,
great importance is placed on safety, as well as effective-
ness and ease of use. To ensure that the machine
remains safe you must pay attention to the following
points:
WARNING!
This machine is only intended for use
together with a DIMAS WS 355, WS 463, WS
462, WS 460 and CS 2512. All other use is
forbidden.
CAUTION
Under no circumstances may the machine be
started without observing the safety
instructions. Should the user fail to comply
with these, Husqvarna Construction Products
Sweden AB or its representatives are free
from all liability both directly and indirectly.
Read through these operating instructions and
make sure that you understand the contents
before starting to use the machine. Should
you, after reading these safety instructions,
still feel uncertain about the safety risks
involved you must not use the machine Please
contact your dealer for more information.
• Check that all couplings, connections and hydraulic
hoses are in full working order.
• All operators shall be trained in the use of the machine.
The owner is responsible for ensuring that the
operators receive training.
• Make sure that all hoses and electrical cables are
connected to themachine correctly before you start the
machine.
• People and animals can distract you, causing you to
lose control of the machines. For this reason, you
should concentrate and focus on the task at hand.
• Never leave the machine unsupervised with the motor
running.
• Make sure no clothing, hair or jewellery can fasten in
moving machine parts.
• Onlookers can be injured. You should never, therefore,
start the machine without being certain that no people
or animals are within the work area. Secure the work
are by cordoning off if necessary.
• Never disconnect any of the hydraulic hoses without
first shutting off the unit and ensuring the motors have
stopped completely.
• If despite all precautions an emergency situation
should arise, press the red emergency stop button on
the top of the unit or press the green start/stop button
on the remote control.
• Wear suitable personal protective equipment, such as
a helmet, protective shoes, eye and hearing protection.
Hearing protection must always be worn as sound
levels exceed 85 dB(A).
• Working close to power lines:
When using hydraulic tools close to power lines, the
hydraulic hoses must be marked and approved as “non-
conducting dielectric”. The use of any other type of
hoses can result in serious physical injury or even death.
When replacing hoses, hoses marked “non-conducting
dielectric” must be used. The hoses must be regularly
checked for their electrical conductive insulation in
accordance with special instructions.
• Working close to gas conduits:
Always check and mark out where gas pipes are
routed. Working close to gas pipes always entails
danger. Make sure that sparks are not caused in view
of the risk of explosion. Remain concentrated and
focused on the task. Carelessness can result in
serious personal injury or death.
• Mark out all hidden pipes such as water pipes and gas
pipes.
• Check that power cables andthe Canbus cable are not
damaged or can be damaged while working.
• Check tools, hoses, and connections daily for leakage.
A crack or leak can cause “hydraulic fluid injection” in
the body or result in other serious personal injury.
• Do not exceed the rated working pressure for the
specific tool or hydraulic hose. Increased pressure can
cause leakage or bursting.
• Do not check for leakage with your hands, contact with
the leak can result in serious personal injury caused by
the high pressure in the hydraulic system.
• The tool must not be carried or lifted by the hoses.
• Do not misuse hoses.
• Do not use hoses that are twisted, worn, or damaged.
• Check that the hoses are connected correctly to the tool
and that the hydraulic couplings lock as intended before
pressurising the hydraulic system. The couplings are
locked by turning the outer sleeve on the female cou-
pling so that the slot moves away from the ball.

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Safety InstructionsOperator's Manual PP 455E
The pressure hoses in the system must always be
connected to the tool’s intake. The return hoses in the
system must always go to the tool's outlet. Confusing
the connections can cause the tool to work in reverse,
which can result in personal injury.
• Keep the hydraulic couplings clean and free of dirt.
• Always switch on the unit's emergency stop switch
before transporting the equipment.
• Check that the hydraulic hoses are not damaged and
cannot become damaged during cutting. Leakage can
lead to the risk of slipping.
• Make sure that there is always another person close at
hand when you use the machines, so that you can call
for help if an accident should occur.
• Do not use machines if they do not function as they
should.
• Do not modify safety equipment. Check regularly that
they function as they should. The machine must not be
run with defective or disassembled safety equipment.
• Regulations for the prevention of accidents, and other
general safety and occupational health regulations,
must always be followed.
• Make sure that you always have a first-aid kit close at
hand when using the machines.
• Keep all parts in good working order and ensure that
all fixtures are properly tightened. Replace all worn or
damaged decals.
• Store the machines in a locked area, where they are
inaccessible to children and adults who have not been
trained to operate the machines.
• Pay attention to the risk of fire from sparks and heat. If
there are no local fire protection regulations for cutting
or grinding machines, follow the regulations for
welding.
WARNING!
Always use approved protective clothing
and approved protective equipment when
using the machine. Protective clothing and
protective equipment cannot eliminate
accident risks, but by using the right
clothes and equipment you can reduce the
seriousness if an accident should occur.
Ask your dealer about approved and
recommended protective clothing and
protective equipment.

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Safety Instructions Operator's Manual PP 455E

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IntroductionOperator's Manual PP 455E
Introduction
DIMAS PP 455E is the latest hydraulic unit from Dimas.
The unit is a further developed of the former unit PP 355E
and has been produced to match the new DIMAS
products and products to be launched in the future.
PP 455 is a very compact hydraulic unit, only 970 mm
high.
Among the new major features is the water cooled motor,
which means the user can use more power for longer
periods than before. New improved software, adjustable
handle and the possibility to attach a wall saw from the
WS 400 series on the unit are other new features that
facilitate the daily use of the product.
PP 455E is supplied with the following equipment:
1 x hydraulic unit
1 x remote control with radio control*
1 x charging adapter (12 V/230 V)*
1 x bag for the radio unit with accessories*
1 x hose assembly, 8 m
1 x Canbus cable, 8 m
*The machine is only equipped with a radio on some
markets.

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Introduction Operator's Manual PP 455E

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What is whatOperator's Manual PP 455E
What is what
1. Handle
The handle is adjustable vertically so that it can easily
be adjusted to suit the operator.
2. Hydraulic connections
The machine has six hydraulic couplings in total. Some
couplings have a red marking sign on the coupling.
The hoses with red discs should be connected to these
couplings.
3. Remote control
The remote control is used to control the unit and saw.
The remote control is radio controlled, but can also be
controlled using the supplied Canbus cable. On some
markets, the machine is not certified for radio and on
these markets, the unit can only be controlled using
the cable.
4. Saw attachment
A Dimas wall saw from the WS 400 series can easily
be secured in the attachment on the hydraulic unit
during transport. The saw attachment is only mounted
on units sold with a saw or according to the customer's
wishes. When transporting the unit, the hose assembly
can be secured around the attached saw. The
hydraulic connections on the hose assembly can be
connected to the hydraulic unit during transport
5. Electric motor on/off
This is the only control that can start the motor.
Stop the electric motor by pressing the start button
again, pressing the emergency stop button on the
power unit or pressing the emergency stop button on
the left-hand side of the remote control.
6. Blade rotation and start water coolant
Control to start the blade rotation and the water coolant
for the blade. In order for the blade to reach full power,
the control must be turned to the right-hand end
position.
When wire cutting this controls the wire speed.
7. Display
Information is given on the display about essential
settings, service requirements and any faults.
When working, the display shows the current main
pressure for blade rotation (not the motion pressure).
8. Blade motion
Control for moving the blade. From here you control
the blade motion or the magazine tension when wire
cutting.
9. Trolley motion
Control for horizontal motion of the saw unit. The
direction and speed are controlled from here. When
the horizontal motion is increased, the blade rotation
pressure also increases. This can be read on the
display.
1
4
2
3
5
6
7
8910
11
12
13
14
15
16
17
17

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What is what Operator's Manual PP 455E
10.Option keys
The arrow keys are used to:
• Scroll through the menus.
• Increase/decrease numerical values.
The confirmation key is used to:
• Open sub-menus.
• Confirm values that have been adjusted with the keys.
• Switch on/switch off sensors.
11.Electrical socket
The power to drive the unit is connected here.
12.230 V single phase socket
Only available on markets where the incoming power
has a neutral.
13.Personal protection/Fuses
14.Lifting eye
An excellent aid when the saw is to be lifted using a
crane or the like.
15.Water flow valve
Inside the machine, there is a water valve that opens
the water flow to the blade/wire when the unit is
connected to the power.
The water coolant flow starts as soon as the blade
rotation knob is moved from its zero position. The
water coolant can, therefore, be activated without
starting the electric motor. This can be advantageous,
for example, when cleaning the equipment. Adjust the
water flow by turning the water flow valve.
16.Water connector
Connect the incoming water coolant to the coupling at
the bottom of the motor. The maximum permitted
pressure on the incoming water is 5 bar and the
minimum permitted flow is 5 litres/minute.
Connect the water hose that feeds the blade/wire with
water coolant to the coupling above the hydraulic
connections.
17.Emergency stop
Dimas PP 455E is equipped with 2 emergency stop
buttons. One on top of the unit and one on the remote
control’s side (not visible in the figure). Both emer-
gency stops are reset by turning the knob clockwise.
NOTE!
A lower water pressure and flow than those
specified can result in the hydraulic unit not
receiving sufficient cooling, which means that
the unit can not be run at full power for as long
as with a sufficient flow. A too low water
coolant flow can also result in the blade/wire
not being cooled sufficiently, which means that
they will wear extremely quickly.

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Technical dataOperator's Manual PP 455E
Technical data
Specified hydraulic output ___________ 25 kW (33.5 hp)
Max. hydraulic oil flow (at 63 A) _______ 65 l/min (17 gal/min)
Weight, hydraulic unit incl. oil_________ 140 kg (310 lbs)
Power supply:
Europe + Australia 5-pin_____________ 400 V (32-63 A), 50 Hz
Europe + Asia 4-pin ________________ 400 V (32-63 A), 50 Hz
Norway 5-pin _____________________ 400 V (32-63 A) 50 Hz
________________________________ 230 V (80 A) 50 Hz
Japan 4-pin_______________________ 200 V
________________________________ (80 A) 50, 60 Hz
USA 4-pin________________________ 480 V (63-32 A) 60 Hz
Canada 4-pin _____________________ 600 V (20-40 A) 60 Hz
Optional equipment ________________ 2 x 230 V wall socket
NOTE!
The higher ampere rating applies for
maximum output.
Noise level according to ISO/DIS 11201. Sound pressure
at the operator's ear without load 78 dB(A)
Sound power level according to the directive 2000/14/EC.
Measured noise level 97 dB(A). Guaranteed noise level
102dB(A)

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Technical data Operator's Manual PP 455E

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Assembling/Installing equipmentOperator's Manual PP 455E
Assembling/Installing
equipment
When the machine has been transported to a suitable site,
it should be connected:
1. Check the hydraulic fluid level in the power unit. This is
checked with the level indicator.
Min. level = red line
Max. level = black line
Do not exceed the max. level when filling the tank with
hydraulic fluid. The hydraulic fluid expands when it
gets hot and can overflow if the level is too high. Tank
volume 16 l (4.2 US gallons).
2. Connect the incoming power cable (400 V, 63 A or 400
V, 32 A European connector). The cable must be
three-phase and earthed. When the machine is
equipped with a single phase socket there must also
be a neutral otherwise the single phase socket on the
distribution box will not work.
The power unit must be connected through a 63 A fuse
in order to use maximum power. If connected through
a 32 A fuse, the saw mustbe operated at low pressure,
and with that cut less effectively to avoid overloading
the fuse.
3. Connect the incoming water hose to the water coupling
on the bottom of the motor front on the hydraulic unit .
4. Connect the remote control using the supplied Canbus
cable. Tighten the cable connector screws by hand.
When the machine is equipped with a radio, a radio
antenna can be connected instead of a Canbus cable.
This is screwed into the same socket as where the
Canbus cable should have been fitted.
Fit the hydraulic unit
1. Check that the emergency stop switches on the unit
and the remote control have not been actuated by
turning them in the direction of the arrow.
When everything is okay the remote control’s display
shows “Connect the hose assembly”.

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Assembling/Installing equipment Operator's Manual PP 455E
2. Connect the hose assembly. There are two types of
hydraulic hoses for the unit:
On a wall saw in the WS 400 series, the four thin hoses
control the saw's motion motors, i.e. the saw's blade
motion and the saw's trolley motion. The two thick
hoses drive the blade.
When a wire saw CS 2512 is connected to the unit, the
two thin hoses control the tension on the magazine
arm while the two thick hoses drive the wire.
Some couplings on the unit have a red markingsign on
the coupling. The hoses with red discs should be
connected to these couplings.
Connect the water hose between the unit and the
saw's water connector and open the water flow valve
on top of the unit by turning the handwheel anti-
clockwise.
When the power cable and water hoses and hose
assembly are connected, the machine can be started.
Confirm with “OK”.
3. The display now shows “SELECT FUSE 32A”. If the
available fuse is 32 A, confirm this by pressing the
membrane key marked “OK”. If there is a 63 A fuse
available, press the membrane key marked “up arrow”.
The display now indicates “SELECT FUSE 63A”.
Confirm this by pressing the membrane key marked
“OK”. ( “Menu functions / 2. Select fuse”.)
4. The hydraulic output must be set according to which
machine is connected to the hydraulic unit. Select one
of the following:
•25 kW, 230 bar, 65 l/min
• 15 kW, 210 bar, 45 l/min or
• 9 kW, 140 bar, 40 l/min
Press OK to confirm the selection. The first step is then
shown.
5. The display now shows “DIMAS PP 455E START
ELECTRIC MOTOR”. (“Menu functions/Operation
menu/1.a DIMAS PP-455, Start electric motor”.) If the
display does not show this, follow the instructions
shown on the display.
Starting the electric motor
1. Before you start the motor, check that:
•The incoming electrical cable has been connected to a
fuse rated at least 25 A.
• The 32 A or 63 A power setting is chosen (see page
20 “Installing the hydraulic power unit”).
• All knobs on the remote control have been turned to
their zero positions. If this is not done, a message on
the display will prompt you to do so.
• The hoses have been connected to a device.
2. Start the electric motor by pressing the remote
control’s green button once. The Y/D start takes place
automatically. The rotation direction is always correct
due to an automatic phase relay.
To stop the electric motor, press the green button on
the remote control once more.

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Work procedure for wall sawingOperator's Manual PP 455E
Work procedure for wall
sawing
Start blade rotation
1. Turn the controls for blade rotation and water coolant
to their maximum positions to start blade rotation and
the water coolant.
The amount of water can be adjusted manually with
the knob on the top of the unit.
2. Start the blade motion by turning the blade motion
knob on the remote control in the desired direction.
3. Start the horizontal motion by turning the horizontal
motion knob in the desired direction.
After work is completed
1. After the work is completed, turn off the blade rotation
and water flow by turning the blade rotation and water
coolant start knobs on the remote control back to “0”
2. Turn off the electric motor by pressing the remote
control's green button.
Water valve
When the power to the hydraulic unit is disconnected, the
water valve opens so that the cooling system can be
drained prior to transport and to avoid the risk of the
cooler and motor freezing in sub-zero temperatures. The
unit can be transported vertically or horizontally. If the
power is cut during sawing, the water can be turned off by
turning the water flow valve on top of the power unit
clockwise to the stop position. The water flow connected
to the hydraulic tool can also be reduced by turning the
water flow valve.

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Work procedure for wall sawing Operator's Manual PP 455E
Dismantling the equipment
1. Allow the motor to stop completely.
2. Disconnect the power supply cable before
disconnecting the water hoses.
3. Disconnect the hydraulic hoses.
4. If there is a risk of freezing, drain the water from the oil
cooler by disconnecting both hoses, opening the water
flow valve, and tilting the unit forwards.
CAUTION
Always clean all the equipment at the end of
the working day. Do not use a high pressure
washer to clean the machine.
Work procedure for wire cutting
When all the equipment has been assembled cutting can
start. In order for the saw to cut as efficiently as possible it
should be started as follows:
1. Assemble the pressure reduction block supplied with
the wire saw on the hydraulic unit according to the
instructions on the block.
2. Connect the two smaller hydraulic hoses to the
pressure reduction block. The hoses in the hose
assembly marked with a red disc by the coupling shall
be connected to the hose on the pressure reduction
block that is also fitted with a disc.
3. Close the valve on the pressure reduction block by
turning the knob anti-clockwise until it stops and then
two turns back.
4. Start the electric motor by pressing the remote
control’s green button once.
Press the green button on the remote control once
more to stop the motor.
5. Set the feeding flow on the unit to max by turning the
control on the remote control clockwise.
6. Tension the wire by carefully turning the knob on the
pressure reduction block clockwise until the wire is
tensioned sufficiently. Make sure to always check that
the wire is seated correctly in all the wheels on the
saw.
7. Start the wire drive by turning the control for motor
rotation on the remote control clockwise.

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Work procedure for wall sawingOperator's Manual PP 455E
8. Carefully increase the motor speed by turning the
control for motor rotation. A suitable working pressure
when cutting usually lies between 100 and 130 bar, but
varies depending on how many wheel sets are used in
the magazine, how much wire is in use and the
hardness of the material to be cut.
9. When material is cut away the working pressure can
drop, which is shown on the display, and the magazine
must be tensioned. Do this by turning the knob on the
pressure reduction block clockwise.
10.The output tension on the magazine is shown by an
indicator on the machine (shown in the min position).
When the magazine cylinder is fully tensioned, the
machine must be stopped and the wire must be wound
around a new wheel set. Then continue to cut as
above.
CAUTION
Always clean all the equipment at the end of
the working day.
Menu functions
The menus, shown on the display, are grouped in menus,
sub-menus (“Settings”) and part menus. The menus are
divided into two sections:
• Start menu: Here you can select under which
conditions the hydraulic unit shall work.
• Operations menu: Information concerning the
operating status is shown here.
Start menu
The start menu is shown each time the power to the
hydraulic unit is switched on. The menu consists of three
steps:
DIMAS PP 455E Connect hose assembly
• Press OK when all hoses are connected. Step 2 is then
displayed.
Select fuse
The fuse rating must be set according to the fuse the
hydraulic unit is connected to.
Select 16 A, 32 A or 63 A
• Press OK to confirm the selection. Step three is then
displayed.
Select the output
The hydraulic output must be set depending on the
machine connected to the hydraulic unit. Select one of the
following options:
25 kW, 230 bar, 65 l/min (3300 psi, 17 US gpm)
15 kW, 210 bar, 45 l/min (3000 psi, 12 US gpm)
9 kW, 140 bar, 40 l/min (2000 psi, 10 US gpm)
• Press OK to confirm. The first step is then shown on
the operations menu.

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Work procedure for wall sawing Operator's Manual PP 455E
Operations menu
The operations menu starts after step 3 in the start menu.
All information about operations andall setting options are
accessed from this menu.
The operations menu consists of eight menus:
1a. Dimas PP-455, 1b Status
2. Water coolant ON/OFF?
3. Phase 1, Phase 2, Phase 3
4. Settings
5. Time
6. Total machine time
7. Battery status (only machines equipped with a radio)
8. Radio channel (only machines equipped with a radio)
1.a DIMAS PP-355, Start electric motor
Press the green button on the remote control to start
the electric motor.
1b. Status
Status is the main information that is always shown on
the display when the hydraulic unit with connected
machine is operational:
• STATUS OK, signifies that the unit is operational and
no warning messages have been issued.
• KV xx, where KV represents water coolant and xx ON
or OFF. What is shown depends on whether the water
coolant is switched on or off.
• yyy BAR, where yyy represents the instantaneous
operating pressure.
• When time is switched on:
mm:ss, is also shown, i.e. the time in minutes and
seconds.
2. Water coolant
Turn on and turn off the water coolant by pressing OK.
The display then shows: STATUS OK KV OFF/ON yyy
BAR. Now press arrow down to continue in the
operations menu.
3. Phase 1, Phase 2, Phase 3
The instantaneous main voltage to the hydraulic unit is
shown under each phase name.
When the voltage becomes low, an error message is
shown on the display, see the section “Error
messages”.
CAUTION
Long electrical cables with a small core cross
section can result in a voltage drop. The
hydraulic unit can then warn of a too low
voltage.
4. Settings
Via this sub-menu a number of values can be changed
to affect the hydraulic unit's characteristics.
To access the sub-menu: State the four digit PIN-code
0012 with the help of the arrow keys and the OK
button.
To save the settings; select “Save” in sub-menu 3
“OUT SETTINGS”.
Refer to the “SETTINGS” section for complete
information about the setting options,
5. Time
The function is used to measure the amount of time a
job takes. The time is counted from when the saw
starts working. Select:
• ON, to enable.
• OFF, to disable.
• RESET TIME, to reset.
Quit by pressing OK. The main information “Status” is
then shown on the display.
When you select time ON (and when the hydraulic unit
is operational, see 1.b) 00:00 is also shown in the
lower right corner of the display. Press arrow down to
continue in the operations menu.
The total time that the hydraulic unit has been
operational is shown here. The time is stated in hours
and minutes (hhhh:mm).