OPERATING INSTRUCTIONS - Diamond Products
OPERATING INSTRUCTIONSCONTROL UNIT WSE1621Index 000Translation of the original instructions10999160 en / 01.10.2018
Congratulations!You have decided to purchase a tried-and-tested TYROLIT Hydrostress unit and have thusacquired a highly sophisticated and reliable state-of-the-art device. Only genuine TYROLITHydrostress replacement parts can guarantee quality and interchangeability. If maintenancework is neglected or carried out inexpertly, we will be unable to honour our warranty obligations. All repairs must be carried out by trained personnel only.Our after-sales service is available to help ensure that your TYROLIT Hydrostress units remain inperfect working order.We hope that working with your TYROLIT unit will be a satisfying and fault-free experience.TYROLIT HydrostressCopyright TYROLIT HydrostressTYROLIT Hydrostress AGWitzbergstrasse 18CH-8330 PfäffikonSwitzerlandTel. 0041 (0) 44 952 18 18Fax 0041 (0) 44 952 18 00Page 2WSE1621 Control unit
TYROLIT Hydrostress AGTable of contentsPage1.2.3.4.WSE1621 Control unit1.Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.1What to do in an emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.1System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.2Main components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.3Remote controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.1Overview of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143.2Display elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153.3Positioning the WSE1621P control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253.4Starting the WSE1621P control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263.5Selecting the machine system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.6Selecting the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.7Tool soft start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293.8Selecting the tool station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303.9Power control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313.10 Adjusting the feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313.11 Changing the direction of rotation of the main motor. . . . . . . . . . . . . . . . . . . . . . . .333.12 Daily hour counter / stopwatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343.13 Switching off the WSE1621P control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353.15 Deactivating the EMERGENCY STOP function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Servicing and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374.1High-pressure cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374.2Cleaning the water filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384.3Blowing out water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384.4Rechargeable batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394.5Recycling waste. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Page 3
TYROLIT Hydrostress AGPage 45.Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406.Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416.1Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416.2Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416.3Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426.4Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426.5Recommended ambient temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426.6Remote controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427.EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438.Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44WSE1621 Control unit
TYROLIT Hydrostress AG1 SafetyDANGERFailure to comply with the safety instructions in the “Safety Manuals / System Manuals” may result in serious injury or even death.XX Make sure the “Safety Manuals / System Descriptions” for the relevant type of saw have beenread and understood in full.DANGERDeath or serious injury can be caused by sudden start-up of the machine!XX Before switching on the system, ensure that no other persons are present in the danger areas.XX Switch the system off before connecting or disconnecting cables.XX When leaving the system unattended: switch off and secure the system to prevent it beingswitched on again.Death or serious injury as a result of the sawing machine continuing to run after an accidentXX Ensure that the EMERGENCY STOP button can be reached quickly.Electric shock from live cables and connectors!XX Switch off the WSE1621 Control unit before connecting or disconnecting cables.XX Ensure the power supply is earthed and fitted with an AC/DC sensitive residual currentcircuit breaker (FI type B) with a maximum residual current of 30mA.Risk of fire due to incorrect mains voltage!XX Make sure the mains voltage and mains frequency correspond with the mains settings of theWSE1621 Control unit.WSE1621 Control unitPage 5
TYROLIT Hydrostress AG1.1 What to do in an emergencyXX Press the EMERGENCY STOP button on the remote controller.EMERGENCY STOPIf the EMERGENCY STOP function is activated on the radio remote controller, the power supplyof the main motor is interrupted.In the event of an emergency, the machine systems can also be switched off via the main switchon the WSE1617 control unit.Main switchPage 6WSE1621 Control unit
TYROLIT Hydrostress AG2 Description2.1SystemThe WSE1621 Control unit / Remote controller can be used to operate various TYROLIT machinesystems.System1234WSE1621 Control unitWall saw systemsWire saw systemsCore drilling systemsHand saw systemsM Connection for main/drive motorMv Connection for feed motor(s)Water connectionPage 7
TYROLIT Hydrostress AG2.22.2.1Main componentsMain components Control unitMain components Control unit12345678Page 8Remote controllerConnection for remote controllerHour counterUSB portIndicator lightHousing with gripMain switchPower supply910111213141516Connection for main motorConnection for feed motorSwitchboardWater coupling / water inletWater coupling / water outletRadio antenna / remote queryRadio antenna / remote controllerRemote controller cableWSE1621 Control unit
TYROLIT Hydrostress AG2.2.2Main components Remote controllerMain components of remote controller123456789102.2.3Connection for remote controller cableLocking button (traverse feed)Rotary knob/push button, universalMenu selection buttonTool selection buttonCasingFeed motor potentiometerUSB portMain motor On/OffMain motor potentiometer11121314151617181920DisplayIndicator light (radio & battery)Water On/OffEMERGENCY STOPFeed joystickPulse buttonStart switchBattery compartmentReset buttonSun shieldAccessories for remote controllerThe battery charger is exclusively designed for recharging the original interchangeable rechargeable batteries. The battery holder and the cable insert must not be inserted.Accessories1 2x interchangeable rechargeable batteries2 Rechargeable battery chargerRechargeable battery charger with 10–30 VDC connection3 Remote controller cable4 Battery holder5 KeyWSE1621 Control unitNo. 10999383No. 10984305No.10984840No. 10999372No. 10999384No. 10984309Page 9
TYROLIT Hydrostress AG2.3Remote controllerThe remote controller can be replaced by an accumulator or a battery operated radio remotecontroller. The remote controller can also be operated using a cable.2.3.1Operating modesRadio remote controllerThe transmitter and receiver are a pair of matched units. They cannot be used with otherdevices. The number on the back of the remote controller must match the serial number on themachine name plate.Radio remote controller2.3.2Operating modesRechargeable battery operation:The interchangeable rechargeable battery is inserted in the base of the casing of the remote controller. The operating period with a fully charged battery is approximately 12 hours.The maximum reception distance is 25 m.Ordinary battery operation:The battery insert included in the scope of supply allows operation with three 1.5 V AA batteries. The reception distance is 25 m and the maximum operating time is 1 hour.Cable operation:The cable insert is included in the scope of supply and allows connection of the remote controller to the WSE1621 Control unit. The cable length is 10 m. Cable operation makes it possible towork in areas where radio operation is not allowed (e.g. hospitals).When working with the cable connection, all control signals are transmitted via the electric cable.The rechargeable/ordinary battery holders must not be inserted in the base of the casing during cable operation.Page 10WSE1621 Control unit
TYROLIT Hydrostress AG2.42.4.1ConnectionsEstablishing connections for the control unit99 The control unit is isolated from the power supply99 The connectors and couplings are clean99 Cables and hoses are undamagedControl unit connectionsCutting tool drive motorFeed motorWaterMains supplyCable connection for remote controllerUSB portWSE1621 Control unitPage 11
TYROLIT Hydrostress AG2.4.2Connecting the power and water supplyConnecting motors99 The power supply is earthed and fitted with a residual current operated protective device(FI; max. residual current 30mA)99 Sufficient cable cross-sections: up to 25 m long 5 x 4 mm2, more than 25 m long 5 x 6 mm299 Connectors are clean99 Cables are undamagedConnecting motorsMMvPage 12Cutting tool drive motorFeed motorWSE1621 Control unit
TYROLIT Hydrostress AGConnecting the water supplyWater connectionsThe WSE1621 Control unit is cooled by water. The control unit must also be cooled during dryapplications. The incoming water is routed through the water filter via the control unit and onto the machine system. After cooling the main motor of the machine system during a dry application, the water is drained via a water hose.Control unit connectionsABWSE1621 Control unitWet applicationsDry applicationsPage 13
TYROLIT Hydrostress AG3 Operation3.1Overview of controlsControls123456789101112Page 14Connection for remote controller cableLocking button (traverse feed)Rotary knob/push button, universalMenu selection buttonTool selection buttonFeed motor potentiometerUSB portMain motor potentiometerMain motor On/OffWater On/OffEMERGENCY STOPFeed joystick1314151617181920212223Pulse buttonStart switchBattery compartmentReset buttonConnection for remote controller cableUSB portWater connectionConnection for feed cableWater connectionStart switchConnection for main motor cableWSE1621 Control unit
TYROLIT Hydrostress AG3.2Display elementsDisplay elements12343.2.1DisplayIndicator light (radio & battery)Hour counterIndicator light (ON/OFF)Display fieldsDisplay fieldsA Vario information fieldB Status information fieldVario information fieldThe vario information field displays information regarding faults, power and time.Status information fieldThe status information field displays information regarding the machine system.WSE1621 Control unitPage 15
TYROLIT Hydrostress AG3.2.2Display symbolsStatus information fieldError displaysØ TYROLIT diamond toolSystem displaysØ high-speed diamond toolRepair / service displaysØ drill bitDiamond wireVario information fieldPage 16Operating InstructionsPhaseElectricPhase missingInformationRelayMain motorFC intermediate circuitRepair / serviceFC output stagePotentiometerData exchangePotentiometer 0 positionEMERGENCY STOP function / ONWaterEMERGENCY STOP function / OFFRechargeable battery:Battery emptyContactRechargeable battery:Low battery levelStopwatch / daily hour counterRechargeable battery:Fully chargedElectronicsWSE1621 Control unit
TYROLIT Hydrostress AGVario information fieldInsert feedCurrentAdvance feedOvercurrentFeedUndercurrentMain motor, clockwise direction ofrotationEarthMain motor, counter-clockwise direction of rotationEarth faultOverheatingEqual signThe individual vario symbols can be combined to create statementsExample of an error display:Cause: Overtemperature of main motorAction: Cool with waterExample of vario fieldsDisplay:Error display (1): Main motor (2) has reached overtemperature (3), countermeasure equals (4)cool with water (5).WSE1621 Control unitPage 17
TYROLIT Hydrostress AG3.2.3Display segmentsDisplay fields1 Power supply1/ 3 redRechargeable battery: Battery empty2/ 3 greenRechargeable battery: Low battery level3/ 3 greenRechargeable battery: Fully charged2 Information fieldThe vario information field displays information regarding faults, power andoperating status.3 Display statusThis status indicates an error in the Information field.This status indicates operating/system information in the Information field.This status indicates repair information in the Information field.Potentiometer of the feed motor is not in the 0 position.Page 18WSE1621 Control unit
TYROLIT Hydrostress AG4 Machine system displayWall sawswith TYROLIT diamond toolWall sawswith TYROLIT high-speed diamond toolWire sawsDiamond tool speedCore drillingØ diamond tool5 Type / dimension of cutting toolØ 1200e.g. saw blade with Ø 1200mm (650mm / 825mm / 1025mm / 1200mm / 1600mm)6 Mains power supply display / speed of diamond toolThe mains power supply is displayed in field 6, which, during the cutting procedure, switches to the speed of the diamond tools.16 A mains power supply / G16 A generator32 A mains power supply / G32 A generator. m / s Speed of the diamond tool7 Time field. h00 : 00h time fieldThe machine system is detected automatically during the startup process.The WSE1621 Control unit is preset for a 32 A mains power supply. (32A appears on the display).It is possible to switch to a 16 A mains power supply. The control unit will automatically returnto the 32 A setting when it is restarted.The WSE1621 Control unit will switch off if it is not used for 30 seconds. The control unit can bereactivated by pressing the pulse button (12).WSE1621 Control unitPage 19
TYROLIT Hydrostress AG3.2.4Power display during operationThe current power range is displayed with a coloured bar and a power value(digit adjusts continuously).Ideal scenario: In the second orange segments (in iron in the third red segments).Display of the power for the feed- and main motorA Power display for the main motorB Power display for the feed motorDisplay of the power for the feed- and main motorPower display during operationOperation with less than 40%nominal powerExample:Operation with 40% to 80%nominal powerMotors are operated at 100%Page 20Main motor 80% nominal powerFeed motor 80% nominal powerWSE1621 Control unit
TYROLIT Hydrostress AG3.2.5Examples of an operating screenDisplay fieldsStatus information6The machine system is in the operating mode7Wall saw with TYROLIT saw blade8Ø1200Saw blade diameter Ø1200mmVario informationWSE1621 Control unit1The feed motor operates at a nominal power between 40 and 100%2The main motor operates at a nominal power of 75%3Rechargeable battery: Fully charged4The diamond tool is supplied with water524A938m/s104A1100:12 hCurrent nominal power of the main motor: 24A (adjusts continuously)The speed of the diamond tool is 38m/sCurrent nominal power of the feed motor: 4A (adjusts continuously)The machine system has been in use for 12 minutesPage 21
TYROLIT Hydrostress AG3.2.6Error displaysError displaysPage 22ErrorPossible causeActionMains phase missing Fault during installation Fuse defective Check phases and fusesOvertemperature offrequency converter Absence of cooling Ambient temperaturetoo high No, too little or toohot cooling water Avoid direct contactwith sunlightOvertemperature offeed motors Absence of cooling Ambienttemperature too high Allow control unit tocool down for 3 minutes Avoid direct contactwith sunlightOvertemperature ofcontrol unit components Absence of cooling Ambienttemperature too high Allow control unit tocool down for 3 minutes Avoid direct contactwith sunlightOvertemperature of themain motor Absence of cooling No, too little or toohot cooling water See Technical dataShort circuit fault Blockedmain motor Contact TYROLITafter-sales serviceShort circuit detectionof the main motor Earth fault Contact TYROLITafter-sales serviceMain motor overcurrent Main motor blocked Overcurrent earthfault Contact TYROLITafter-sales serviceWSE1621 Control unit
TYROLIT Hydrostress AGError displaysWSE1621 Control unitErrorPossible causeActionMain motor currentearth fault Electrical connectionearth fault Contact TYROLITafter-sales serviceOvercurrent DC axis Feed motor overloaded Reduce feedDC motor short circuit Blocked feed motor Defective feed motor Contact TYROLITafter-sales serviceThe safety relay nolonger switches properly Hardware defect Contact TYROLITafter-sales serviceThe safety contact nolonger functions properly. Hardware defect Contact TYROLITafter-sales serviceTransformer fault Motor outside of possible parameters Contact TYROLITafter-sales serviceOvervoltage at the feedoutput stage Defective power supply unit Power supply unitoverloaded Contact TYROLITafter-sales serviceEMERGENCY STOPhas been actuated EMERGENCY STOPhas been actuated Radio communicationhas been interrupted Reset the EMERGENCYSTOP push-button,perform the startupprocedure Change the radio frequency by switchingthe key switch on theradio remote controlleron and offPage 23
TYROLIT Hydrostress AGError displaysPage 24ErrorPossible causeActionOvervoltage at the feedoutput stage Defective power supply unit Power supply unitoverloaded Contact TYROLITafter-sales service Switch to generatormodeMain contactor doesnot switch Defective main contactor Contact TYROLITafter-sales serviceFan does not rotate Defective fan Contact TYROLITafter-sales serviceCommunication fault Communication faultdue to interference Contact TYROLITafter-sales serviceDirect current link voltage too low Incorrect mains voltage Check the mains voltage; see Technical dataDirect current link voltage too high Mains overvoltage The saw blade feedsback too much energy. Check the mains voltage; see Technical data Only use diamondsaw blades betweenØ650mm (25.5”) andØ1600mm (63”) Switch to generatormodeWSE1621 Control unit
TYROLIT Hydrostress AG3.3Positioning the WSE1621 Control unitCAUTIONThe WSE1621 Control unit can be damaged if it slips or topples over!XX Make sure the WSE1621 Control unit is level and located on a firm surface (grip at the top).The WSE1621 Control unit should only be switched on when level and upright.Positioning the WSE1621 Control unitCAUTIONRisk of water damage to the WSE1621 Control unit.XX Make sure the WSE1621 Control unit is not positioned in water and that it is located at a safedistance to any splash water.Positioning the WSE1621 Control unitWSE1621 Control unitPage 25
TYROLIT Hydrostress AG3.4Starting the WSE1621 Control unit99 The WSE1621 Control unit is connected to the mains and the water supply.99 The machine system is connected to the WSE1621 Control unit.(See “Operating instructions - Sawing system”)99 The remote controller EMERGENCY STOP (11) has been deactivated.Starting the control unitXX Move the operating elements listed below on the remote controller to their 0 position.Feed motor potentiometer (6)Main motor potentiometer (8)Main motor On/Off (9)Water switch (10)Feed joystick, automatically takes up 0 position (12)Start switch (14)XX Switch on the WSE1621 Control unit by using the main switch (22).XX Switch on the radio remote controller using the start switch (14).–– Indicator lights (radio and battery) initially light up red–– An audible signal is emitted simultaneously–– The TYROLIT logo (A) appears in the display–– The P2 logo and firmware version e.g. r554 appear in the display (B)–– “EMERGENCY STOP information” screen appears in the display (C)–– The indicator light flashes greenPage 26WSE1621 Control unit
TYROLIT Hydrostress AGIf only the remote controller is switched on, the P2 screen will remain on the display.Application: Check display of software version e.g. r554XX Press the blue reset button (16) on the radio remote controller.–– The operating screen (D) appears on the display–– If an error message (E) appears, press the blue reset button (16) again.XX Press the green pulse switch (13)–– The system indicator on the display lights up.–– The feed and main motors are released from this point onwards.–– The control unit automatically detects which machine system is connected.XX Open the water valve on the system supply line.–– The water valve is displayed on the screenXX Press the Water On/Off switch (10) on the remote controller to I.–– Water emerges at the cutting tool.XX otentiometers.Power controlA Power display for the main motorB Power display for the feed motor(the digit value for current consumption adapts continuously)(the digit value for current consumption adapts continuously)6 Feed motor potentiometer7 Main motor potentiometer3.10Adjusting the feedThe feed movements are selected with the joystick (12) and the speed is regulated via thepotentiometer (6).Adjusting the feedThe feed speed is automatically assisted by a feed facility during the cutting process.WSE1621 Control unitPage 31
TYROLIT Hydrostress AG3.10.1Manually adjusting the feed speedFeed speed99 The WSE1621 Control unit has been startedXX Select the required feed speed via the feed potentiometer (6).3.10.2Locking the feedSo that the joystick does not have to be held in position during the travel feed motion, thetravel feed can be locked.Proceed as follows:XX Push the joystick in the desired direction of travel and, at the same time, pressthe locking button (2).XX When the joystick and the locking button (2) are released, the feed is locked.In order to release the feed lock, move the joystick slightly in any desired direction or press thelocking button.Page 32WSE1621 Control unit
TYROLIT Hydrostress AG3.11Changing the direction of rotation of the main motorThis function is only possible for wall sawing applications.The direction of rotation can only be changed before starting the main motor.Changing the direction of rotation of the main motorProceed as follows:XX Press the universal rotary knob/push button (3).–– The current direction of rotation of the main motor is indicated on the display.XX Turn the universal rotary knob/push button (3) until the direction of rotation changes on thedisplay.XX Press the universal rotary knob/push button (3).–– The direction of rotation has been changed and the operating screen is displayed.When the WSE1621 Control unit is restarted, the direction of rotation of the main motor revertsto the default setting.WSE1621 Control unitPage 33
TYROLIT Hydrostress AG3.12Daily hour counter / stopwatchThe WSE1621 Control unit is equipped with a daily hour counter and a stopwatch. The dailyhour counter and the stopwatch can be used during operation as and when required.Daily hour counter / stopwatchAB3.12.1StopwatchDaily hour counterUsing the daily hour counter / stopwatchProceed as follows:XX Press the Menu selection button (4).–– The clock screen appears.XX You can alternate between the stopwatch and the daily hour counter by turning the universal rotary knob/push button (3).When the time measurement is active, it is indicated by an asterisk (C).The stopwatch can be started, stopped and reset to 0 by pressing the universal rotary knob/push b
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