Hilti Ds-wss 30 User Manual
Operating instructions en
DS-WSS 30
Printed: 07.03.2016 | Doc-Nr: PUB / 5069762 / 000 / 02
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ORIGINAL OPERATING INSTRUCTIONS
Contents
General information 3
1. General description and technical data for the DS-WSS 30 wire saw 4
2. General warnings 6
3. Warnings and safety precautions for the DS-WSS 30 wire saw 7
4. D-LP 32 (30) / DS-TS 32 (30) modular saw system 10
5. D-LP 32 (30) / DS-TS 32 (30) / DS-WSS30 modular wire saw system 10
6. Setting up the wire saw system 11
7. Basic applications 14
8. Diamond wire store 19
9. Instructions for connecting Hilti DS-W 10.5 diamond wire 20
10. DS-WSS 30 wire saw system - checks, operation, and sawing procedure 24
11. Care and maintenance 27
12. Troubleshooting 28
13. Disposal of the DS-WSS 30 / D-LP 32 wire saw 32
14. Manufacturer's warranty – tools 33
15. EC declaration of conformity (original) 34
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. The saw system functions only in conjunction with the Hilti D-LP 32 hydraulic power unit. Please refer to the D-LP 32 / DS-TS 32 operating instructions for information about operation of the power unit.
These operating instructions are intended for the use of concrete cutting service contractors and their experienced personnel, referred to on the following pages as “the operator”. Before operating the Hilti D-LP 32 (30) / DS-TS 32 (30) /
DS-WSS 30 wire saw system, the operator must read and understand these operating instructions and receive training from a Hilti specialist.
Thanks to its modular design, the DS-WSS30 wire saw system can be quickly and easily fitted to the standard saw
system. Its new design concept, offering maximum convenience and safety in use, opens up an almost endless range
of applications in demolition, cutting and remedial work in steel reinforced concrete, masonry and stone. The variable
oil flow rate of the D-LP 32 (30) / DS-TS 32 (30) wall saw system used to power the wire saw ensures smooth, gentle
starting, and automatic regulation of the wire sawing process and greatly reduces strain on the operator.
This system therefore provides the prerequisites for efficient, economical and safe operation. We would like to wish you
every success in your work and thank you for placing your confidence in Hilti products.
Printed: 07.03.2016 | Doc-Nr: PUB / 5069762 / 000 / 02
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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.
Safety notices and their meaning
DANGER
Draws attention to imminent danger that will 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 an instruction or other useful information.
Explanation of the pictograms and other information
General warning Warning:
electricity
Warning:
avoid hand injuries
Wear protective gloves.
Wear safety footwear. Wear respiratory
protection.
Wear ear protection.
Wear eye protection. Wear a hard hat.
Warning signs
Obligation signs
Warning:
Risk of cutting injury
Return waste
material for
recycling.
Read the operating
instructions before use.
Symbols
A
Amps
V
Volts Alternating current
∅
Diameter
W
Watts
Hz
Hertz
n
o
Nominal speed
under no load
mm
Millimeters
/min
Revolutions per minute
rpm
Revolutions per minute
STOP
Stop
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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
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
1.1 System
1.2
1. General description and technical data for the DS-WSS 30 wire saw
Printed: 07.03.2016 | Doc-Nr: PUB / 5069762 / 000 / 02
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1. General description and technical data for the DS-WSS 30 wire saw
1.3 Technical data
DS-DS 30
Drive wheel: 500 mm dia.
Guide pulley: 200 mm dia.
Speed (DS-TS 30, 1stgear): 800 r.p.m.
Cutting speed: approx. 20 m / sec.
Wire store capacity: 8 m diamond wire
Max. diamond wire length: 30 m
D-LP 32 hydraulic power unit
Rated power input at 63A 43 kW
Rated output 32 kW
Rated voltage 400 V / ~ 50 Hz, 3P+N+PE or 3P+PE
Ground fault circuit breaker (30 mA) in mains supply on site
Max. operating pressure 210 bar
Oil flow rate 30–100 l/min
Dimensions (L×W×H) 790×540×1090 mm
Weight 220 kg
IP protection code IP 44
Water cooling with 7 l/min. at max. 6 bar and water temperature 20° C
D-RC-LP32 remote control unit
Control voltage 24 V = (direct current)
Dimensions (L×W×H) 390×180×120 mm
Weight 2.2 kg
IP protection code IP 65
Cable length 10 m
Cable length with extension 20 m
Noise information (measured in accordance with EN 15027)
Wear ear protection!
Mean A-weighted sound power level LwA105 dB (A)
Mean A-weighted emission sound pressure level at the workplace LpA85 dB (A)
Uncertainty for the stated sound level: 3 dB (A)
1.4 Special accessories
Special stand with 140 mm dia. plunging pulley
Release pulley
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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 Approval must be obtained from the site engineer or site management before sawing. Sawing work can negatively
affect the stability of a building or other structure, particularly when reinforcing bars or supporting members are
cut through. Ensure that there are no concealed gas, water, electricity or other supply lines in the area in which
sawing work is to be carried out.
2.4 The area in front of, behind or below the surface where sawing work or drilling is to be carried out must be secured
in such a way that persons or equipment cannot be injured or damaged by falling blocks of concrete or by concrete slurry. Where necessary, cores or blocks of concrete should be secured to prevent them from falling.
2.5 Operators and all other persons must stay clear of the area when a load is being lifted by a crane.
2.6 Concrete blocks with a weight of several tons may be sawn out with the Hilti saw. Measures for securing and
transporting these concrete blocks must be planned and implemented. Make use of the steel wedges contained
in the set of tools for securing concrete blocks. Keep the working area clean and tidy and cordon off openings.
2.7 National regulations and laws, as well as the operating instructions and the safety information applicable to
the accessories employed must be observed.
2.8 The D-LP 32 (30) / DS-TS 32 (30) / DS-WSS 30 saw system must NOT be operated in environments where a risk
of explosion exists unless special safety precautions are taken.
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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. Wearing parts, accessories and safety-relevant devices, such as the diamond wire
drive wheel, return pulleys, diamond wire and couplings, diamond wire guard and drive wheel guard, end stop,
drive wheel mounting screw, hydraulic couplings, etc., must be checked particularly carefully. Check that all parts
have been assembled correctly and consider all other factors that could influence operation of the equipment.
Contact your Hilti representative or Hilti service centre if faults or deficiencies are found. Repairs to electrical parts
must be carried out by a qualified electrical specialist.
3.3 Metal anchors of M12 size should be used for fastening the DS-WSRF rail support and DS-WSSPP single-pair pulley stand. The fastening used must be suitable for the base material in question and must not work loose. Suitable
Hilti anchors are, e.g. HKD-D, HSA-A, HIT or HEA. If masonry is loose or crumbling, we recommend that through
holes are drilled and M16 threaded rods with clamping nuts used for fastening.
3.4 Fastening screws of at least 8.8 grade as per ISO should be used for the rail supports or, alternatively, use the
DD-CS M12 S-SM clamping spindle with DD-CN-SML quick-release clamping nut.
3.5 An end stop must always be fitted at the end of the rail to prevent unintentional advance beyond this point (prevents the saw head coming off the end of the rail).
3.6 It is essential that the specified checks are carried out before sawing.
3.7 The drive wheel guard (see fig. 3.7, no. 1) and diamond wire guard (see fig. 3.7, no. 2) MUST ALWAYS BE FITTED
when the saw is in use. These guards prevent parts flying out in the direction of tension should the diamond wire
break. NEVER stand in a position in line with the diamond wire while the saw is running.
12
2
1
3.7
3. Warnings and safety precautions for the DS-WSS 30 wire saw
3.8 ■ Safety measures must be implemented in the area where sawing is taking place so that operators and
bystanders cannot be injured or property damaged by a broken sawing wire or debris that may fly off
during the sawing operation (wire connectors, diamond beads, spacing springs, small stones, sawing slurry, etc.). Safety measures must also be implemented in the area not directly visible to the operator, i.e. behind where sawing is taking place.
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■ 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. The whiplash effect causes great acceleration of the sawing
wire, resulting in parts of the wire lashing out or flying off with great force.
■ Make sure there are no objects such as scaffolding etc. within the wire whiplash area. In the event of
wire breakage, the whiplashing end of the wire may be deflected in an unexpected direction by such
objects.
■ The danger area has a radius of at least twice the free length of wire that would be unleashed in the
event of wire breakage (shown in yellow) and also includes the areas in the extended axes of the direction in which the wire is running (shown in gray). The danger area cannot be limited unless suitable
means of protection are employed (protective walls, curtains or wire guards etc.). The protective
devices must be arranged and mounted in a way that stops the wire lashing out in the event of wire
breakage and reliably prevents objects or fragments flying off.
■ The operator is responsible for cordoning off the area. If necessary, safety personnel must be posted
to prevent access to a wide area around the workplace
■ 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.
■ Children must be instructed not to play with the machine.
■ The machine is not intended for use by children, by debilitated persons or those who have received
no instruction or training.
■ Before beginning work, check the working area (e.g. with a metal detector) to ensure that no concealed electric cables or gas and water pipes are present.
External metal parts of the machine may become live if, for example, an electric cable is damaged
inadvertently. This presents a serious risk of electric shock.
3.9 ALWAYS SWITCH OFF THE WIRE SAW BEFORE ADJUSTING THE WATER SUPPLY. Readjustment of the water supply nozzle at the single-pair pulley stand or at any other position while the saw is running, in order to bring it into
line with the diamond wire, is STRICTLY PROHIBITED.
3.10 The wire length adjusting pulley (DS-WSRP wire store) must always be fitted, even when not in use. The flexible
wire guard can then be fitted in accordance with the instructions.
276377 05.06
r2=l2 x 2
l
2
l
1
r
1
=l
1
x 2
3.8
3. Warnings and safety precautions for the DS-WSS 30 wire saw
Printed: 07.03.2016 | Doc-Nr: PUB / 5069762 / 000 / 02
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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. A face mask should be worn to protect the respiratory system when working in enclosed areas.
3.13 Avoid body positions in which the back is bent when carrying motor units or other heavy components. Maintain
a secure stance and always stay in balance, especially when using ladders or when working from scaffolding.
3.14 Check all screws on the DS-TS 32 (30) saw, tensioning arm, diamond wire guard and drive wheel guard which
could work loose due to vibration.
3.15 Disconnect the electric extension cable from the mains supply when the equipment is not in use, during transport and before inspection or maintenance. Ensure that the hydraulic power unit is switched off before changing
the diamond wire or before adjusting the position of the guide pulleys. As an additional safety measure, it is recommended that the EMERGENCY STOP button is pressed and left in the OFF position.
3.16 Use of the Hilti diamond wire saw system is permitted only in conjunction with the other DS-WSS 30 components
listed in these instructions. The use of individual components for wire sawing, e.g. only the drive wheel, is prohibited as this could present a serious hazard to the operating personnel.
3.17 For further information, please refer to the D-LP 32 (30) / DS-TS 32 (30) operating instructions.
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4. D-LP 32 (30) / DS-TS 32 (30) modular saw system
5. D-LP 32 (30) / DS-TS 32 (30) / DS-WSS30 modular wire saw system
DS-R 230L
DS-TS32
DS-RF
D-PH34-10 (2x)
D-FH4/14-10
DS-RF
D-LP 32
D-RC-LP 32
comprising:
1 D-LP 32 (30)
2 D-RC- LP 32 (DS-CB)
3 D-PH34-10 (2x)
4 D-FH4/14-10
5 DS-RF
6 DS-R 230L
7 DS-TS32 (30)
1
6
5
3
/
4
7
2
2x DS-WS-SPP
7
DS-WSWS
6
2x DS-WSRF
5
DS-WSRP
4
DS-WSWD
3
DS-WSTA
2
DS-WSW500
1
DS-W10.5
7
6
5
7
4
123
DS-WSS30 comprising:
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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
6.2 Fastening to the base material
WARNING
Use an anchor suitable for the material on which you are working and observe the anchor manufacturer’s instructions.
NOTE
Hilti M12 metal expansion anchors are usually suitable for fastening diamond core drilling equipment
to uncracked concrete. Under certain conditions it may be necessary to use an alternative fastening
method. Please contact Hilti Technical Service if you have any questions about secure fastening.
– Rigid and secure fastenings are the basic prerequisite for efficient and safe sawing. We recommend the use of
Hilti drilling and anchoring systems.
– Fasteners suitable for the base material in question should be used to fasten the rail supports and single-pair
pulley stands. For example, a minimum edge distance of 18 cm must be observed when setting the Hilti HKD
M12 metal expansion anchor. As a general rule, this anchor should be set ≥ 5 mm below the surface of the concrete. After drilling the hole, the dust should be blown out.
– Hilti HIT adhesive anchors can be used in masonry etc. or, alternatively, through-holes drilled and threaded rods
used.
6.3 Recommended fastening method using the clamping spindle and clamping nut
For fastening the rail supports and single-pair pulley stands, Hilti recommends use of the HKD-D anchor in conjunction with the double-thread clamping spindle and clamping nut with pivoting baseplate.
Advantages
1. Flexible clamping nut / baseplate provides secure fastening even on uneven surfaces and when anchor holes
are drilled at an angle.
2. Coarse thread pitch for rapid assembly and disassembly
3. The anchor can be set deeper.
6.1 6.2
Clamping nut with pivoting baseplate
Double-thread clamping spindle
Through-hole for the diamond wire
Printed: 07.03.2016 | Doc-Nr: PUB / 5069762 / 000 / 02
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