Hilti DS TS20-E 1.6 Operating Instructions Manual
Operating instructions en
DS TS20-E 1.6
Printed: 09.03.2015 | Doc-Nr: PUB / 5139344 / 000 / 01
2
Contents
1. General information 4
2. Description 5
3. Accessories 6
4. Technical data 7
5. Safety precautions 9
6. Preparations at the workplace 13
7. Setting up the wall saw system 15
8. Operation 24
9. Care and maintenance 28
10. Troubleshooting 30
11. Disposal 33
12. Manufacturer's warranty – tools 34
13. EC declaration of conformity (original) 34
ORIGINAL OPERATING INSTRUCTIONS
DS TS20-E 1.6 3×400 V electric wall saw
It is essential that the operating instructions are read
before the machine is operated for the first time.
Always keep these operating instructions together
with the machine.
Ensure that the operating instructions are with the
machine when it is given to other persons.
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3
Parts and equipment
Saw head
Power unit
Remote control unit
Power cable, control cable and water hose
Transport trolley – saw head
Blade guard - center section
Blade guard – side section
Guide rail with end stop
Accessory box with rail support and toolbox
Transport trolley - accessories
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4
General information
Read the operating
instructions before use.
General warning Warning:
electricity
4x
Removing cooling water from the saw head and power unit
1. Connect the blow-out adapter to the hose on the HIT pump.
2. Turn the bypass valve to the “closed” position and blow out the
saw head 7 times with the HIT pump.
3. Turn the bypass valve to the “open” position and blow out the
saw head 4 times with the HIT pump.
4. Blow out the power unit at the water outlet 4 times with the HIT
pump.
To avoid damage to the equipment,
water pressure must not exceed 6 bar.
358092
To avoid damage when temperatures below freezing are expected, the cooling system must be fully drained by blowing out with the pump provided.
Please refer to the instructions provided in the toolbox.
3
57860
max. 150kg
The saw head and accessory transport trolleys may be lifted by
crane only at the lifting points provided.
Before transport, all items of equipment must be secured to prevent movement or falling.
Never loiter in the vicinity of loads suspended by cranes.
Use only tested and approved lifting gear.
!!
Handle with care!
320489
The power unit may be lifted by crane only at the lifting points
provided.
Never loiter in the vicinity of loads suspended by cranes.
Use only tested and approved lifting gear.
> 5°
357985
The transport trolley may become unstable or run away if stood on
an inclined surface.
Wear
protective gloves.
Wear ear
protection.
Wear
safety footwear.
Wear
respiratory
protection.
Wear
eye protection.
Wear
a hard hat.
1. General information
Safety notices and their meaning
DANGER
Draws attention to imminent danger that could lead to
serious bodily injury or fatality.
WARNING
Draws attention to a potentially dangerous situation that
could lead to serious personal injury or fatality.
CAUTION
Draws attention to a potentially dangerous situation that
could lead to slight personal injury or damage to the
equipment or other property.
NOTE
Draws attention to instructions and other useful information.
Explanation of the pictograms and other
information
1.2
1.1
Symbols
Obligation signs
Warning signs
A
AmpsVVolts
mm
Millimeters
Hz
Hertz
/min
Revolutions
per minute
n
Rated
no-load
speed
rpm
Revolutions
per minute
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General information / Description
Other information
In these operating instructions, the DS TS20-E electric
wall saw is referred to as “the machine”.
Location of identifying data on the machine
The type designation, item number, serial number, year
of manufacture and technical status can be found on the
rating plate on the machine.
Make a note of this data in your operating instructions
and always refer to it when making an enquiry to your
Hilti representative or service department.
1.3
Power unit:
Type: DS EB-TS20 serial no.
Saw head:
Type: DS TS20-E serial no.
Remote control unit:
Type: DS RC-TS20 serial no.
2. Description
Use of the equipment as intended
1. The DS TS20-E is an electrically-powered, rail-guided wall saw designed for cutting lightly to heavily-reinforced concrete, stone or masonry structures with
diamond saw blades of 600 mm, 800 mm, 900 mm,
1000 mm, 1200 mm or 1600 mm in diameter (max-
imum blade diameter for initial cut: 800 mm).
2. All functions of the machine are controlled by an electric remote control unit. The speed of rotation of the
saw blade can be controlled smoothly and steplessly
between 0 and maximum speed.
3. The saw blade drive motor provides a constant power output. Saw advance can be controlled manually
and/or automatically. Thanks to load-dependent advance
control, the saw is very easy to operate. The saw operates virtually fully automatically at the maximum power set on the control unit.
4. Best sawing performance is achieved when the
DS TS20-E is used with the specially-matched Hilti
DS-B wall saw blades. Use only diamond wall saw
blades that comply with the EN 13236 standard and
which have been approved for use at a peripheral cutting speed of at least 63 m/s. Wall saw blades in diameters between 1200 mm and 1600 mm must be
approved for a peripheral cutting speed of at least 80
m/s.
5. Use only anchors of adequate size and load capacity
to secure the machine to the object to be cut.
6. Do not cut materials that may release hazardous or
explosive dust or vapors during the cutting process.
Do not cut inflammable materials.
7. Overhead sawing is possible when additional precautionary measures are taken. For this application,
the blade guard must be equipped with a means of
2.1
water drainage. Care must be taken to ensure that no
persons are present beneath the equipment when sawing overhead. Please consult your Hilti representative for further information and advice.
8. Use only genuine Hilti accessories (available as options)
for angled or stepped cuts or for flush cutting.
9. Check that the electric supply provided at the construction site, no matter whether mains or generator
power, is always equipped with an earth/ground conductor and a ground fault circuit interrupter (PRCD
type A, trigger current max. 30 mA) and that these are
connected. If suspected that the electric supply is not
earthed/grounded, the power unit must be earthed/
grounded by way of the earth/ground terminal provided.
Items supplied as standard
The items supplied on the saw head trolley include:
● Saw head
● Power unit
● Remote control unit
● Power and control cables
● Cooling water hose
● Transport trolley
● Tool set
● Operating instructions
The items supplied on the accessories trolley include:
● DS-BG 80 blade guard for 900 mm dia. saw blade
● Rail supports (4 supports)
● Transport box
● Transport trolley
● Rail connector
Using the accessories listed, the wall saw can be adapted to suit the particular conditions of the application you
intend to carry out.
2.2
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Accessories
3. Accessories
Item no. Designation Use
238000 DS-BG65 blade guard Blade guard for blades up to 650 mm dia.
2051935 DST-BG 80 blade guard Blade guard for 600 to 800 mm dia. saw blades
238002 DS-BG80 center section Blade guard for 600 to 900 mm dia. saw blades *
238003 DS-BG80 side section Blade guard for 600 to 900 mm dia. saw blades
238004 DS-BG120 center section Blade guard for 1000 to 1200 mm dia. saw blades *
238005 DS-BG120 side section Blade guard for 1000 to 1200 mm dia. saw blades
2064904 DST-BG 160 blade guard Blade guard for 1200 to 1600 mm dia. saw blades
Item no. Designation Use
238006 DS-BGF80 center section Blade guard for 600 to 900 mm dia. saw blades
for flush cutting *
238007 DS-BGF80 side section Blade guard for 600 to 900 mm dia. saw blades
for flush cutting
238008 DS-BGF120 center section Blade guard for 1000 to 1200 mm dia. saw blades
for flush cutting *
238009 DS-BGF120 side section Blade guard for 1000 to 1200 mm dia. saw blades
for flush cutting
Item no. Designation Use
284808 DS-R100-L rail Saw guidance
284809 DS-R200-L rail Saw guidance
284810 DS-R230-L rail Saw guidance
371703 DS-ES-L end stop Safety stop for saw head
207137 DS-CP-ML rail clamp Fastening rails
284814 DS-RF-L rail support Fastening rails
284816 DS-RFP-L rail support Fastening rails for angled and stepped cuts
232241 D-CO-ML double taper Extending rails
232244 D-EP-ML eccentric pin Extending rails
Item no. Designation Use
258436 DS-FCA-110 flush-cutting flange Saw blade mounting flange for flush cutting
307188 DS-FCA-110FF auxiliary flange Saw blade mounting flange for flush cutting
* Only to be used with the corresponding side sections!
Item no. Designation Use
284842 DS TS tool set Fastening rails, personal protection, maintenance and
operation
Item no. Designation Use
206856 DS TS20-E power cable, 10 m System cable
206857 DS TS20-E control cable, 10 m System cable
400768 RC extension cable
Extending distance between remote control and power unit 10 ➩ 20 m
228150 Water hose, 10 m System water hose
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Technical data
4. Technical data
Technical data for the DS TS20-E power unit*
DS EB-TS20 3 × 400 V DS EB-TS20 3 × 200 V
Rated voltage 380 to 480 V ~ 200 to 280 V ~
Voltage tolerance ± 10%
Mains frequency 50 / 60 Hz
Pin assignment 3P+N+PE / 3P+PE 3P+PE
Rated current 16 / 25 / 32 A 32 / 50 / 63 A
Mains fuse rating min. / max. 16 / 32 A 32 / 63 A
Power input, max. 19 kW
Generator power rating, min. 20 kVA @ 16 A / 40 kVA @ 32 A 20 kVA @ 32 A / 40 kVA @ 63 A
Ground fault circuit breaker in supply 30 mA (type A)
Cooling water temperature at 4l/min. 4 to 30°C
Cooling water pressure min. / max. 2 to 6 bar
Protection class **** IP 65
Weight 38 kg
Power outlet 230 V / 10 A none
Dimensions l × w × h 73 × 35 × 59 cm
Operating / storage temperature –15°C to +50°C ***
Operating / ambient temperature –15°C to +45°C ***
Leakage current ≤ 10 mA
Insulation resistance at least 300 k Ω
Technical data for the DS TS20-E saw head*
DS TS20-E
Motor power S1** 15 kW
Drive spindle speed 100 to 940 r.p.m.
Protection class **** IP 65
Saw blade diameter 600 mm to 1600 mm dia.
Max. cutting depth 73 cm
Weight 37 kg
Dimensions l × w × h 37.5 × 44 × 32 cm
Operating / storage temperature –15°C to +50°C ***
Operating / ambient temperature –15°C to +45°C ***
4.2
4.1
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Technical data
Technical data for the DS TS20-E remote control unit
DS RC-TS20 remote control unit
Cable length 10 m
Voltage 24 V DC
Protection class **** IP 65
Weight 2.2 kg
Dimensions l × w × h 39 × 19 × 12.5 cm
**** Rated values guaranteed at max. 18°C and heights of up to 2,000 m above sea level.
**** Continuous operation 100%
**** At temperatures below zero, allow the machine to warm up slowly before subjecting to load and drain (blow out) the water from
the cooling circuit after use (a pump is supplied for this purpose).
**** Protection class IP65 in accordance with EN 60529, 6 = protection against entry of dust, 5 = protection against water jets (hose proof)
Technical data for the transport trolleys
Saw head trolley Accessory trolley
Dimensions loaded, L × W × H 106 × 75 × 108 cm 106 × 75 × 140 cm*
Weight loaded ** 121.5 kg 91 kg
Max. permissible total weight 150 kg 150 kg
** With 1 m rail. Height with 2.3 m rail = 245 cm.
** Contents in accordance with list of items supplied, see section 2.2
Noise information (measured in accordance with EN 61029)
Typical A-weighted noise
(power) level: 117.8 dB (A)
Typical A-weighted noise
(pressure) level: 100.3 dB (A)
Wear ear protectors!
Note: The noise pressure level can be reduced by approx. 10 dB(A) when noise-reducing (silent) saw blades are used.
Type plates
4.3
4.4
4.6
4.5
Power unit type plate Saw head type plate Remote control unit type plate
On the rear of the power unit On the underside of the saw head On the side of the remote control unit
= Engineering number
= Spare parts list index
= Serial number
= Year of manufacture
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Safety precautions
5. Safety precautions
WARNING
Failure to observe the instructions listed below may
lead to potentially fatal injury and serious damage to
property or equipment.
Proper organization of the work area
a) Approval must be obtained from the site engineer
or architect prior to beginning drilling or sawing work.
Drilling or sawing work on buildings and other structures may influence the statics of the structure, especially when steel reinforcing bars or load-bearing components are cut through.
b) Ensure that the workplace is well lit.
c) Ensure that the workplace is well ventilated. Expo-
sure to dust at a poorly ventilated workplace may result
in damage to the health.
d) Keep the workplace tidy. Objects which could cause
injury should be removed from the working area. Untidiness at the workplace can lead to accidents.
e) In order to avoid injury and to prevent the diamond
blade becoming trapped or jammed, steel wedges and/or
supports must be used to prevent uncontrolled movement of parts of the structure being cut.
f) Ensure that adequately-sized supports are correctly
installed so that the remaining structure maintains its
stability after completion of the cutting work and removal
of the part cut away.
g) Never loiter in the vicinity of loads suspended by
cranes.
h) The area of the cut or the opening created by the cutting process must be safely and visibly cordoned off
in order to avoid the possibility of persons falling.
i) Wear personal protective equipment. Wear safety
shoes or boots, protective gloves, a hard hat, ear protection and eye protection.
j) Wear respiratory protection if the work causes dust.
5.1
k) Dress properly for the work. Do not wear loose cloth-
ing or jewelry as it could be caught in moving parts.
Contain long hair.
l) Keep children away. Keep other persons away from
the working area.
m) Do not allow other persons to touch the machine
or the extension cord.
n) Avoid unfavorable body positions. Make sure you
work from a safe stance and stay in balance at all times.
o) To avoid presenting a tripping hazard, always ensure
that cables and hoses leading to the machine are laid
flat on the floor.
p) Keep cables and hoses away from rotating parts.
q) In cooperation with the site engineer or architect, ensu-
re that no gas, water, electricity or other supply lines are
located in the cutting area. Any supply pipes or cables
located close to the cutting area present a serious hazard
if damaged while the work is in progress. External metal
parts of the machine could become live if, for example,
an electric supply cable is damaged.
r) Ensure that the cooling water used is drained or
extracted in a suitably controlled manner. Water that is
allowed to drain away or spray around in an uncontrolled manner can lead to damage or accidents. The
fact that water could drain away into internal, hidden
cavities, e.g. in brickwork or masonry, must also be
taken into account.
s) Do not work from a ladder.
t) The machine is not intended for use by children, by
debilitated persons or those who have received no
instruction or training.
u) Children must be instructed not to play with the
machine.
v) Dust from material such as paint containing lead, some
wood species, minerals and metal may be harmful.
Contact with or inhalation of the dust may cause allergic reactions and/or respiratory diseases to the operator or bystanders.
Certain kinds of dust are classified as carcinogenic such
as oak and beech dust especially in conjunction with
additives for wood conditioning (chromate, wood pre-
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CAUTION
Secure the working area. Ensure that no persons can be
injured or property / equipment damaged by falling objects
or debris that may fly off during the sawing operation.
10
Safety precautions
servative). Material containing asbestos must only be
treated by specialists.
Where the use of a dust extraction device is possible
it shall be used. To achieve a high level of dust collection, use a suitable vacuum cleaner of the type recommended by Hilti for wood dust and/or mineral dust
together with this tool. Ensure that the workplace is
well ventilated. The use of a dust mask of filter class
P2 is recommended. Follow national requirements for
the materials you want to work with.
Safety measures at the danger areas
Safety measures must be implemented in the area where sawing is taking place to ensure that operators and
bystanders cannot be injured or property damaged by
debris that may fly off or fall down (broken-off diamond
segments, small stones, sawing slurry, etc.) while
sawing is in progress. Safety measures must also be
implemented in the area not directly visible to the operator, i.e. behind where sawing is taking place.
Persons must NEVER enter the danger area (3 meters
in all directions from the line of the cut to be made)
while the blade drive is switched on.
5.2
3m 3m
3m
1m ∞m
STOP
STOP
STOPSTOP
3m
3m ∞m
3m3m
STOP
STOP
STOP
STOP
1. Approval must be obtained from the site engineer or
site management before beginning the sawing work.
2. Find out whether overcutting at corners is permitted.
If not, the corresponding corner holes must be planned
and drilled first.
3. Check that the area is cordoned off, that supports are
in place and warnings to third parties are displayed.
When setting up and operating the saw system and
when removing parts that have been cut away, always
ensure that no persons are below the area in which you
are working. Falling objects could cause serious injury.
General safety instructions
a) Use the machine only when you have read the oper-
ating instructions and you are familiar with the points
described, and when you have received appropriate
training from a Hilti specialist on safe operating procedures. All warnings and instructions must be observed.
b) Use the right machine for the job. Do not use the
machine for purposes for which it was not intended.
Use it only as directed and when in faultless condition.
c) Use the machine, accessories and saw blades etc.,
in accordance with these instructions and in the manner intended for the particular type of machine, taking
into account the working conditions and the work to
be performed. Use of this machine for operations other
than those intended could result in hazardous situations.
d) Use only the genuine Hilti accessories or ancillary
equipment listed in the operating instructions. Use of
accessories or ancillary equipment not listed in the
operating instructions may present a risk of personal
injury.
e) Take the influences of the surrounding area into
account. Do not use the machine where there is a risk
of fire of explosion. Electric tools and machines generate sparks which may ignite dust or gas.
f) Keep the grips dry, clean and free from oil and grease.
g) Do not overload the machine. It will work more effi-
ciently and more safely within its intended performance
range.
h) Never leave the machine unattended.
i) Store machines in a secure place when not in use.
5.3
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Safety precautions
When not in use, machines must be stored in a dry,
high place or locked away out of reach of children.
j) Always disconnect the machine from the electric supply when it is not in use (e.g. during breaks between
working), before making adjustments, before carrying
out care and maintenance and before changing saw
blades. This safety precaution prevents the machine
starting unintentionally.
k) Remove any adjusting key or wrench before switching the machine on. A wrench or a key left attached to
a rotating part of the machine may cause personal injury.
l) Before use, the machine, the saw blade and accessories must be checked carefully to ensure that all items
function faultlessly and as intended. Check that moving parts function correctly without sticking and that
no parts are damaged. All parts must be fitted correctly
and fulfill all conditions necessary for correct operation of the machine. Damaged parts must be repaired
or replaced properly by an authorized service center.
m) Avoid skin contact with drilling slurry.
n) Wear a protective mask during work that generates
dust. Cutting materials hazardous to the health (e.g.
asbestos) is not permissible.
o) Follow the instructions concerning care and maintenance.
Electrical safety
a) Take steps to avoid the risk of electric shock. Avoid
body contact with earthed or grounded surfaces such
as pipes, radiators, ranges and refrigerators.
b) Check the machine’s supply cord at regular intervals
and have it replaced by a qualified specialist if found to
be damaged. Check extension cords at regular intervals and replace them if found to be damaged.
c) Check the condition of the machine and its accessories. Do not operate the machine and its accessories
if damage is found, if the machine is incomplete or if
its controls cannot be operated faultlessly.
d) Do not touch an electric cable that has been damaged while working. Switch off at the main switch and
unplug the cable at the power outlet.
5.4
e) Damaged or faulty switches must be replaced at a
Hilti service center. Do not use the machine if it cannot
be switched on and off correctly.
f) Have the machine repaired only by a trained electrical specialist (Hilti service center) using genuine Hilti
spare parts. Failure to observe this point may result in
risk of accident to the user.
g) Do not use the supply cord for purposes for which
it is not intended. Never carry the machine by the supply cord. Never pull the plug out of the power outlet by
pulling the supply cord.
h) Do not expose supply cords to heat, oil or sharp
edges.
i) Connect the machine and its ancillary equipment only
to a power source equipped with an earth/ground conductor and ground fault circuit breaker (PRCD). Check
that these items are in perfect working order before
operating the equipment. Install an earth/ground rod
if a generator is used or if no earth/ground conductor
is present in the on-site electric supply. Operation of
the machine without an earth/ground connection is not
permissible under any circumstances. With no
earth/ground connection, faulty insulation on a part of
the machine or inadvertently sawing into a live cable
presents a risk of fatal accident.
j) Make sure that the mains voltage corresponds to the
specification given on the type plate.
k) Electric cables and their plug connectors must be
kept dry. When not in use, close power outlets with the
cover provided.
l) Use only extension cables which have an adequate
conductor cross-section and are approved for the intended field of use. Do not work with extension cables when
they are rolled up. This can result in a drop in output
at the equipment and may cause the cable to overheat.
m) Disconnect the power cable before beginning cleaning and maintenance work or in the event of a lengthy
interruption between periods of operation.
n) Please note that certain components of the power
converter retain an extremely dangerous (potentially
fatal) high voltage for up to 10 minutes after disconnection from the electric supply.
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