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Hilti DS WS10, Operating Instructions Manual

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Operating instructions

en

DS WS10 /

DS WS10-E

Printed: 08.07.2013 | Doc-Nr: PUB / 5069736 / 000 / 01

Summary of Contents for DS WS10

Page 1: ...Operating instructions en DS WS10 DS WS10 E Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 2: ...ooting 59 63 11 Disposal 64 12 Manufacturer s warranty 65 13 EC declaration of conformity original 66 It is essential that the operating instructions are read before the machine is operated for the fi...

Page 3: ...nector with regulating valve 1 2 square drive wrench Toolbox for tools and accessories DS WS10 E electric wire saw Compact wire saw with electric drive Control unit with air compressor Air hoses 2 7 m...

Page 4: ...the control unit Location of identification data on the machine The type designation and serial number can be found on the type identification plate on the machine Make a note of this data in your op...

Page 5: ...cription 2 1 Use of the equipment as directed 6 2 2 Components 6 2 3 Operating controls 7 2 4 Drive principle 11 2 5 Saw advance and wire storage 11 2 6 Wire guidance 11 5 Printed 08 07 2013 Doc Nr PU...

Page 6: ...nd must have been trained in their safe appli cation by a Hilti specialist National regulations and legislation as well as the information in the operating instructions and safety precautions concerni...

Page 7: ...nd stop 1 1 1 1 2 3 1 2 7 6 7 3 5 4 9 2 8 Base plate Leveling screws Anchor slot Connecting taper Positioning template Grip Edge indicating line of cut Wire entry point Pivotable drilling point indica...

Page 8: ...6 2 5 1 2 Pivoting pulley crossbar Attachment point and clamp Pivoting pulley locking lever Wire storage pulley Guard mounting hole Hollow axles Guard 1 2 2 3 4 5 5 DS WS10 E electric drive unit Moun...

Page 9: ...nce cylinder connection Air compressor DS WS10 water connection Coupling water outlet from hydraulic unit Flow regulation and shut off valve Water hose connection cooling water nozzles 3 2 1 3 2 DS WS...

Page 10: ...ector saw advance unit Wheel assembly Vice for use when connecting wire ends 1 2 10 4 Green lamp ready for operation Red lamp lights when a fault occurs Yellow lamp lights when servicing is required E...

Page 11: ...neumatic cylinder In addition the drive pulley is mounted on a moving carriage The length of wire that can be stored on the pulleys depends whether a single or double return system is used i e with or...

Page 12: ...12 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 13: ...ension optional 16 3 3 Pulley stand optional 16 3 4 Release pulley optional 16 3 5 Wire guard optional 16 3 6 Accessories for setting up and operating the wire saw and wire guides 17 3 7 Accessories a...

Page 14: ...probabil ity of wire breakage due to fatigue Use only diamond wires with beads of a diameter within the 8 12 mm range Other diameters may cause the wire to jump off the pulleys or result in damage to...

Page 15: ...535 315 028 315 029 50 384 536 370 500 376 630 371 985 371 990 100 384 537 370 426 376 631 371 986 371 991 per m 384 539 376 635 376 634 377 830 377 781 377 782 with factory fitted flexible connectors...

Page 16: ...adius at the rear of the object to be cut 3 4 Wire storage extension optional The wire storage extension can be used to increase wire storage capacity from 250 cm to 500 cm 3 2 Wire guards optional 3...

Page 17: ...arking Wooden pencil 2 335500 Marking Cleaning cloth 1 334211 Cleaning Hilti spray 1 308976 Lubrication Hilti grease dispenser 1 203086 Lubrication Flat brush 1 3206 Cleaning Protective goggles 1 5205...

Page 18: ...18 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 19: ...chnical data for the DS WS10 E control unit 20 4 3 Dimensions and weights 21 4 4 Technical data for the DS WS 10 and DS WS10 E 22 4 5 Compressed air supply 23 4 6 Wire storage capacity and length requ...

Page 20: ...l notice when the flow rate limiting device is activated as the drive unit then no longer runs smooth ly audible and visual indication CAUTION Do not under any circumstances operate the saw at a flow...

Page 21: ...0 Dimensions of DS WS10 E control unit DS WS10 E 3x400 V DS WS10 E 3x200 V Weight 68 5 kg 78 5 kg 590 1060 660 Dimensions of drive and wire storage unit Weight of DS WS10 E 81 2 kg Weight of DS WS10 6...

Page 22: ...mbient temperature range storage 15 to 50 C 15 to 50 C 15 to 50 C Ambient temperature range operation 15 to 45 C 15 to 45 C 15 to 45 C Please refer to the D LP15 and D LP32 operating instructions CAUT...

Page 23: ...cm 230 cm 230 cm Storage capacity 110 cm 250 cm 220 cm 500 cm Wall thickness max 55 cm 125 cm 110 cm 250 cm 4 6 Compressed air supply The compressor for the air supply is supplied as part of the wire...

Page 24: ...1900 min 1 Serial number 01 0001000 357147 Hilti trademark of Hilti Corporation Schaan LI Made in Austria DS WS10 E 400 V from DS EB WS10 7I min at max 30 C IP 65 358232 07 A Serial number 01 0001000...

Page 25: ...rea 26 5 2 Safety measures at the danger area 26 5 3 General safety measures 27 5 4 Electrical safety 28 5 5 Requirements to be met by users 29 5 6 Safety during operation 29 5 7 Safety instructions f...

Page 26: ...in long hair 5 1 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...

Page 27: ...is responsible for cordoning off the area If necessary safety personnel must be posted to prevent access to a wide area around the workplace r 1 l 1 x 2 r 2 l 2 x 2 r 3 l 3 x 2 l3 l1 l 2 STOP STOP ST...

Page 28: ...issible o Follow the instructions concerning care and main tenance p Children must be instructed not to play with the machine q The machine is not intended for use by children by debilitated persons o...

Page 29: ...taining asbestos may be worked on only by specialists Where the use of a dust extraction device is possi ble it shall be used To achieve a high level of dust 5 5 collection use a suitable vacuum clea...

Page 30: ...WS10 E is not permissible Safety instructions for transporting the wire saw Avoid lifting and carrying heavy objects Use suitable lift ing equipment and means of transport and share heavy loads betwee...

Page 31: ...amples of applications 32 6 4 Determining the necessary wire capacity and wire length 33 6 5 Clarifying the situation and securing the workplace 34 6 6 Electric power supply fuse rating DS WS10 E 34 6...

Page 32: ...L 0 2 L H 6 2 6 1 When the length of the cut L is 1 5 meters the distance H should thus be 0 3 meters 1 5 meters 0 2 0 3 meters When planning the wire guidance system take care to ensure that the leng...

Page 33: ...cut 2 Wire length required approximation Minimum length required for rigging the saw length at tension side 2 thickness of object to be cut length of cut length at slack side The minimum wire lengths...

Page 34: ...the electric power supply at the construction site must be as follows Voltage version 3 x 400 V 3 x 200 V Fuse rating 32 A 63 A Ground fault circuit breaker 30 mA type A 30 mA type A 6 6 6 5 DS WS10...

Page 35: ...Use only clean cooling water Where pressure in the water supply line is low a non return valve should be fitted in order to prevent dirty water finding its way into the water supply 35 Printed 08 07...

Page 36: ...36 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 37: ...pulley crossbar 40 7 7 Mounting the drive unit 40 7 8 Connecting the air hose to the pneumatic cylinder 43 7 9 Pulling the wire through rigging and connecting the wire 41 7 10 Fitting the guards 42 7...

Page 38: ...position of the through holes has a direct influence on the accuracy of the cut We therefore recommend use of a diamond core drilling rig for drilling though thick walls or where only low tolerances a...

Page 39: ...ten the clamping nut and leveling screws Attaching the guide rail unit 7 3 1 2 square wrench Eccentric pin Guide rail unit Push the guide rail onto the connecting taper and insert the eccentric pin fu...

Page 40: ...t in the carriage Push in the clamping pins and tighten them in a clock wise direction Fit the end stop Fitting the end stop CAUTION Do not under any circumstances operate the saw with out a correctly...

Page 41: ...wire back and forward manually in a sawing motion until the wire can be moved freely by hand 7 9 Feed the wire through the hollow axles of the pulley stands if used and subsequently through the hollow...

Page 42: ...can be released after tightening the return lock CAUTION Release the advance movement locking lever and the piston rod clamp only after ensuring that the advance cylinder is not under pressure Fittin...

Page 43: ...sed air hoses to the compressor and to the control unit DS WS10 E Fit the T piece connector to the hydraulic unit DS WS10 Connect the cooling nozzle water hoses to the 3 way connector DS WS10 Fit the...

Page 44: ...D LP32 Connect the power cable and secure the plug DS WS10 E CAUTION The hydraulic hoses used must be of a length sufficient to allow the hydraulic power unit to be positioned out side the immediate...

Page 45: ...e sawing procedure 8 2 Setting the starting cutting pressure 46 8 3 The starting procedure 47 8 4 Checks while sawing is in progress 48 8 5 Readjusting saw advance at the end of the stroke 48 8 6 Step...

Page 46: ...the saw ing wire Is the advance cylinder stroke length adequate Have the electric cables water hoses air hoses and where applicable the hydraulic hoses DS WS10 been laid in a safe position connected c...

Page 47: ...while simultaneously increasing the advance pressure CAUTION Switch the main drive off immediately if the wire does not begin to run right away The drive pulley will suffer damage if the sawing wire s...

Page 48: ...lleys must be realigned or the advance pressure adjusted Take care to ensure that the hydraulic pressure DS WS10 remains within the 80 to 120 bar range or respectively the electric current drawn DS WS...

Page 49: ...operation Before cutting right through take care to ensure that the wire when released from the kerf can be caught by the guide pulleys mounted at the cutting line Reduce wire speed before cutting ri...

Page 50: ...50 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 51: ...diagram for DS WS10 E 3x200 V control unit control circuit 54 9 5 Electrical circuit diagram for DS WS10 E 3x400 V control unit 55 9 6 Electrical circuit diagram for DS WS10 E 3x400 V control unit con...

Page 52: ...cut Pay special attention to the toothed rack and other surfaces of the guide rail and all other moving parts and controls Clean all parts of the system except electrically powered units such as the c...

Page 53: ...1 Schaltplan DS WS10 E 3x200V 1 2 3 400 24V Tr 01 200V 0 63 AT F 04 250V 2 5 AT F 05 250V 63 A gL M L ftermotor Zuleitung 6 mm Leitung 6 mm Motoranschlussleitung 4 mm 5 11 Ampermeter 10 30 24 Lampe 20...

Page 54: ...C A1 A2 MS 01 9 5 9 5 42 41 NOT AUS T 01 1 2 2 10 K 02 1 2 3 3 4 5 6 7 8 9 10 10 St rung Motor Ein St rung 3 4 1 02 2008 Gepr nd Gez Koschler Name Datum Plattner Ges mbh Blattnummer DS WS10 E Blattanz...

Page 55: ...0 E 3x400V 1 2 3 400 24V Tr 01 400V 0 63 AT F 04 250V 13 A C F 06 Max 800 Watt Max 800 Watt 250V 3 15 AT F 05 250V 35 A gL M L ftermotor Zuleitung 6 mm Leitung 6 mm Motoranschlussleitung 2 5 mm 5 11 A...

Page 56: ...1 A2 MS 01 9 5 9 5 42 41 NOT AUS T 01 1 2 2 10 K 02 1 2 3 3 4 5 6 7 8 9 10 10 St rung Motor Ein St rung 3 4 1 02 2008 Gepr nd Gez Koschler Name Datum Plattner Ges mbh Blattnummer DS WS10 E Blattanzahl...

Page 57: ...Pneumatic circuit diagram for DS WS10 DS WS10 E 9 7 9 Cleaning maintenance and repair 57 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 58: ...58 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 59: ...e strongly during sawing 61 10 11 The air compressor doesn t start 62 10 12 The air compressor can t build up pressure 62 10 13 Drive pulley speed begins to fluctuate rapidly audible DS WS10 62 10 14...

Page 60: ...avel Check that the carriage moves smoothly and easily on the rail The drive pulley is badly worn Replace the drive pulley 10 2 10 1 The wire jumps off the drive pulley or guide pulley when starting T...

Page 61: ...ue running and renew them if necessary Check the pulley grooves and clean them out if nec essary 10 10 10 9 Too little cooling flushing water dust is created Direct the flow of water exactly toward th...

Page 62: ...tlets for faults or loose contacts A fuse in the control box is defective Replace the defective fuse spare fuses are located in the control unit Mains supply fuse Transformer fuse Relay 2x 10 14 10 13...

Page 63: ...saw has been in operation for at least 200 hours The drive unit and control panel must be returned for servicing as soon as possible in order to prevent dam age The saw has been in operation for 250 h...

Page 64: ...hat have reached the end of their life must be collected separate ly and returned to an environmentally compatible recy cling facility The disposal of drilling or sawing slurry directly into rivers la...

Page 65: ...r are not covered by this warranty Additional claims are excluded unless stringent nation al rules prohibit such exclusion In particular Hilti is not obligated for direct indirect incidental or conse...

Page 66: ...s greater than or equal to 1 3 MVA It is the responsibility of the installer or user of the equipment to ensure by consultation with the supp ly network operator if necessary that the equipment is con...

Page 67: ...67 Printed 08 07 2013 Doc Nr PUB 5069736 000 01...

Page 68: ...lti Corp Schaan W 3591 I 1212 I 1 en I 1 Printed in Liechtenstein 2012 Right of technical and programme changes reserved S E O Hilti Corporation LI 9494 Schaan Tel 423 2342111 Fax 423 2342965 www hilt...

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