DS-WSS 30 Operating instructions Printed: 08.07.
ORIGINAL OPERATING INSTRUCTIONS Congratulations! On purchasing the Hilti DS-WSS 30 wire saw as an addition to the D-LP 32 (30) / DS-TS 32 (30) wall saw system, you have acquired a quality product that provides the highest level of performance, safety and reliability. Uncompromising quality assurance during its manufacture ensures that the system will have a long service life. This manual describes the operating procedures for the DS-WSS 30 only.
General information The operating instructions must be read carefully before the equipment is put into operation. Always keep these operating instructions with the equipment. The wire saw system should be handed over to other persons only complete with the operating instructions. Obligation signs Wear eye protection. Wear a hard hat. Wear protective gloves. Wear respiratory protection. Wear ear protection.
1. General description and technical data for the DS-WSS 30 wire saw 1.1 System DS-WSW 500 drive wheel DS-WSTA tensioning arm DS-WSWD wire distributor DS-WSRP wire length adjustment pulley DS-WSRF rail support (2×) Drive wheel guard Diamond wire guard DS-WSWS water supply D-LP 32 (30) power unit 1.2 Single-pair pulley stand Fastening spindle/nut for rail support or pulley stand DS-WSSP single-pair pulley stand Water supply to kerf DS-WSW 200 guide pulley 1.
1. General description and technical data for the DS-WSS 30 wire saw 1.3 Technical data DS-DS 30 Drive wheel: Guide pulley: Speed (DS-TS 30, 1st gear): Cutting speed: Wire store capacity: Max. diamond wire length: D-LP 32 hydraulic power unit Rated power input at 63A Rated output Rated voltage Ground fault circuit breaker (30 mA) in mains supply on site Max. operating pressure Oil flow rate Dimensions (L×W×H) Weight IP protection code Water cooling with 7 l/min. at max.
2. General warnings 2.1 Don’t attempt to use the hydraulic saw system and DS-WSS 30 wire saw accessory modules without having received the appropriate training from an authorised Hilti specialist. 2.2 Always use the hydraulic saw system in accordance with the wall saw operating instructions and supplementary wire saw system operating instructions. The operating instructions must always be kept at hand. The instructions on anchoring and securing the system must be observed. 2.
3. Warnings and safety precautions for the DS-WSS 30 wire saw 3.1 Make sure sufficient space is available for working safely. If possible, the wire saw should be set up on the floor in an upright position. 3.2 Check the entire system, accessories, power unit, electric cables, hydraulic hoses and accessories for damage and proper functioning before use.
3. Warnings and safety precautions for the DS-WSS 30 wire saw ■ Persons must NEVER enter the danger area while sawing is in progress. ■ Always keep the free wire lengths between the drive unit and object being cut as short as possible (max. 3.5 m) and mount guide pulleys at the wire entry and exit points in order to reduce the risk of whiplash in the event of wire breakage.
3. Warnings and safety precautions for the DS-WSS 30 wire saw 3.11 Never connect or disconnect hydraulic hoses while the power unit is running or while the hoses are under pressure. 3.12 Wear suitable clothing. Don’t wear loose clothing or jewellery which could become caught in moving parts of the machinery. Wear a hard had, protective goggles, protective gloves, safety shoes, ear protectors and a hairnet if you have long hair.
4. D-LP 32 (30) / DS-TS 32 (30) modular saw system comprising: DS-TS32 D-PH34-10 (2x) D-FH4/14-10 1 D-LP 32 (30) 2 D-RC- LP 32 (DS-CB) 7 3 D-PH34-10 (2x) 3 /4 4 D-FH4/14-10 5 DS-RF 6 6 DS-R 230L DS-R 230L 7 DS-TS32 (30) D-RC-LP 32 1 5 DS-RF DS-RF D-LP 32 2 5. D-LP 32 (30) / DS-TS 32 (30) / DS-WSS 30 modular wire saw system DS-WSS30 comprising: 7 1 2 3 4 DS-WSW500 DS-WSTA DS-WSWD DS-WSRP 3 2 5 2x DS-WSRF 6 DS-WSWS 7 2x DS-WS-SPP DS-W10.5 1 7 4 5 10 Printed: 08.07.
6. Setting up the wire saw system 6.1 Through-holes for the diamond wire – Plan the working procedure carefully and precisely before beginning to install the system and before drilling the through-holes. – Drill the through-holes for the diamond wire (see fig. 6.1, no. ). Use a suitable drilling machine, depending on the situation and the base material: 킞 Combihammer TE 70 with 16 mm dia. drill bit 킞 Diamond drilling machine DD 200 with the core bit DD-BS 52 6.
6. Setting up the wire saw system 6.
6. Setting up the wire saw system DSW-WG wire guards DS-WSRW release pulley (Item no. 365426) (Item no. 315834) Wire guards must be fitted in situations where it cannot be ensured that persons do not enter the area in which flying objects present a risk of injury while the equipment is in operation or where there is a risk of damage to property or other equipment within this area. When wire guards are used, check to ensure they are fitted correctly.
7. Basic applications 7.1 Standard vertical cut Water – Optimum cutting length – No tight diamond wire radius in the concrete – Average cutting performance – Normal rate of wire wear Water 2 1 1st step – Relatively short cutting / contact length – High cutting performance – High rate of wire wear Note When the kerf is at the height of pulley , the pulley should be turned and positioned below the wire. Release pulley 7.
7. Basic applications 7.3 Standard horizontal cut Wall saw 7.4 Flush horizontal cut A At the beginning of the cut Pivoting pulley with ball-bearing pivot Pivoting pulley with ball-bearing pivot 15 Printed: 08.07.
7. Basic applications B At the end of the cut Pivoting pulley with ball-bearing pivot Pivoting pulley with ball-bearing pivot Side view Pivoting pulley Saw kerf Diamond wire Note In order to prevent the diamond wire from jumping off the pivoting guide pulleys, we recommend that the wire saw is switched off shortly before completing the cut and that a combihammer is used to break away the small amount of remaining material. 16 Printed: 08.07.
7. Basic applications 7.5 Aligning the guide pulleys As a general rule, all guide pulleys must be aligned with each other so that the diamond wire always runs in the middle of the pulley (minimises pulley wear and reduces the risk of the diamond wire jumping off). 7.5 Water Slack side Water Exception Two guide pulleys on the slack side, between the wire distributor pulleys and the pulley stand at the point the diamond wire enters the concrete, should be set up at a slight angle (see fig. 7.5).
7. Basic applications 7.7 Wire saw application using plunging pulleys Special stands 7.7a 7.7b Pivoting pulleys (to saw head) 200 mm dia. Pivoting pulleys (to saw head) 200 mm dia. Hole 162 mm dia. Hole ∅ 162 mm Length of cut Length of cut Tubular extension 2″ dia. Tubular extension 2″ dia. Tubular extension 2″ dia. Radius at end of cut Tubular extension 2″ dia. Radius at end of cut 20–30 cm 20–30 cm Pivoting plunging pulleys 140 mm dia. Pivoting plunging pulleys 140 mm dia. 7.
8.Diamond wire store The built-in return pulley and wire store pulley can be used to reduce the effective length of the diamond wire by up to 8 m with a rail length of only 2 m (DS-R 200 L). Configuration 1 2×1.5 m =3m Configuration 2 Drive wheel guard End stop Diamond wire guard + Wire length adjusting pulley 2×0.5 m =1m Configuration 3 2 m rail (DS-R200L) + 2×0.5 m =1m Configuration 4 + 2×1.
9. Instructions for connecting Hilti DS-W 10.5 diamond wire Cutting direction Important: The connectors must be fitted, relative to the cutting direction, as shown in the illustration. The diamond wire must be used to cut in one direction only (see arrows). Preparations for the first cut ■ Connectors are already fitted to new diamond wires. ■ The diamond wire must be twisted before joining the connectors by inserting the pin. Twist the diamond wire, approx. 1–1.
9. Instructions for connecting Hilti DS-W 10.5 diamond wire Instructions for fitting DS-WC connectors 1 2 (Item no. 340427) 13 mm Fitting the connector (first 10 mm end, clevis piece) Clamp the diamond wire 3 in the vice with the cutting direction as shown (see arrow) and use an 10 mm angle grinder to cut off the end 13 mm from the first bead. 4 Use pliers to remove the y x spring (pull out). Remove the rubber neatly over a length of 10 mm (using a knife, cigarette lighter or wire brush).
9. Instructions for connecting Hilti DS-W 10.5 diamond wire Instructions for fitting DS-WS repair sleeves A (Item no. 235841) 13 mm Fitting a repair sleeve (first end) Important: The service life of B the connectors is several times that of the repair sleeve. A Clamp the diamond wire in the vice and use an angle grinder to cut off 10 mm the end 13 mm from the C first bead. B Use pliers to remove the spring (pull out).
9. Instructions for connecting Hilti DS-W 10.5 diamond wire Hilti sawing wires and accessories Recommendations: Which specification for which material? Standard diamond wires (sintered beads) BC LC Material Reinforced concrete Desired characteristics Fast cutting Long life Special wires (electroplated beads) Steel 20% Steel 100% Heavily reinforced Solid steel concrete – – DS-W10.5 diamond wires Hilti DS-W10.
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure 10.1 Checks before sawing – The rail supports and guide pulley stands must be correctly fastened (all screws tightened securely. – The saw head must be mounted without play, the saw arm in the vertical position (at 90° to the rail), the camaction rollers engaged (DS-TS 30 1st gear). – The wire tensioning pulley and drive wheel guard must be fitted and secured in position with the clamping screw at the side of the blade guard holder.
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure 3 4 7 60 40 8 9 80 1600 1200 1000 900 2 100 800 mm D-RC-LP 32 II 45 Start I 32 63 Ampere 6 1 10 5 10.2 Remote control unit: controls Pos.1: Electric motor ON (I 킞 II 킞 Start 킞 Release 킞 II) Electric motor OFF (II 킞 I) Pos.2: Hydraulic oil flow rate 0–100 l /min. (controls speed of diamond wire drive wheel) Pos.3: Plunge movement (right / left).
10. DS-WSS 30 wire saw system - checks, operation and the sawing procedure Once initially set, the system regulates itself by way of the automatic advance system. This means that when the diamond wire encounters heavy reinforcement, the drive unit advance speed is reduced automatically until the reinforcement is cut trough. The rate of advance then returns automatically to the speed previously set. 10.4 1. 2. 3. 4.
11. Care and maintenance CAUTION Disconnect the supply cord plug from the power outlet. CAUTION Keep the machine, especially its grip surfaces, clean and free from oil and grease. Do not use cleaning agents which contain silicone. 11.1 Cleaning using high-pressure or steam-cleaning systems Avoid directing the jet towards the bearings and seals when systems of this kind are used for cleaning the guide pulley stands and saw head. 11.
12. Troubleshooting Persons may enter the danger zone only when the Disconnect the equipment from the electric supply drive unit is switched off and the drive pulley has stop- (unplug the supply cord from the power outlet) before ped rotating. Press the EMERGENCY STOP button opening the control unit. before entering the danger zone. Problem Possible cause Solution / measures 1. The diamond wire does not run.
12. Troubleshooting Solution / measures Possible cause Solution / measures – Guide pulleys at the slack side of the wire not set at an angle – The guide pulleys on the slack side of the wire between the wire distributor and the pulley stand, at the point where the diamond wire enters the concrete, should be set at a slight angle. This causes the diamond wire to rotate when running. 12.
12. Troubleshooting Problem Possible cause Solution / measures 4. The wire breaks immediately beside the coupling – The cutting radius of the diamond wire in the concrete is too small. – Install additional guide pulleys. – The wire has been used too long under excessive tension. – Reduce the wire tension by adjusting the saw head advance. Don’t exceed the specified pressure of 120–160 bar in the main hydraulic circuit. – The wire coupling is too long. – Fit shorter wire couplings.
12. Troubleshooting Problem Possible cause Solution / measures 7. The diamond wire vibrates fiercely and at a high frequency. – Excessive wire tension – Reduce the wire tension by adjusting the saw head advance. – Speed (r.p.m.) of the drive wheel is too high. – Reduce speed – Drive wheel running too slowly. The cutting speed of the diamond wire is thus also too low. – Ensure that the speed potentiometer on the remote control unit is set to max.
13. Disposal Return waste material for recycling Most of the materials from which Hilti appliances are manufactured can be recycled. The materials must be correctly separated before they can be recycled. Hilti has already made arrangements in many countries for taking back your old appliance for recycling. Please ask your Hilti customer service department or a Hilti sales representative for further information.
14. Manufacturer's warranty – tools Hilti warrants that the tool supplied is free of defects in material and workmanship. This warranty is valid so long as the tool is operated and handled correctly, cleaned and serviced properly and in accordance with the Hilti Operating Instructions, and the technical system is maintained. This means that only original Hilti consumables, components and spare parts may be used in the tool.
15.
Printed: 08.07.
Hilti Corporation Hilti = registered trademark of Hilti Corp., Schaan W 2270 I 1212 I 1-en I 1 Printed in Liechtenstein © 2012 Right of technical and programme changes reserved S. E. & O. Printed: 08.07.2013 | Doc-Nr: PUB / 5069762 / 000 / 01 315911 / A3 *315911* 315911 LI-9494 Schaan Tel.: +423 / 234 21 11 Fax: +423 / 234 29 65 www.hilti.
