Hilti DS WS15 User manual

Operating instructions en
DS WS15

2
Contents
1. General information 3–4
2. Description 5–12
3. Tools and accessories 13–16
4. Technical data 17–20
5. Safety precautions 21–25
6. Preparing the saw system for use 27–37
7. Operating the equipment 39–41
8. Care and maintenance 43–48
9. Troubleshooting 49–55
10. Disposal 56
11. Manufacturer's warranty – tools 57
12. EU declaration of conformity (original) 58
ORIGINAL OPERATING INSTRUCTIONS

3
1. 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 instruc-
tions.
Safety notices and their meaning
1.1
Explanation of the pictograms and other
information
1.2
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 infor-
mation.
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
< 4°C
358092
To avoid damage when there is a risk of freezing, the
cooling circuit of the system must be blown out with
compressed air after use.
water in
max 6bar
357824
To avoid damage, do not
exceed a water pressure
of 6 bar.
On the machine
On the control unit
DSW-WG
max 0.3 m
l2
l1
r1 = l1 x 2
r2 = l2 x 2
Return waste
material for
recycling.
Read the operating
instructions before
use.
Symbols
A
Amps
V
Volts Alternating current
∅
Diameter
W
Watts
Hz
Hertz
no
Nominal speed
under no load
mm
Millimeters
/min
Revolutions
per minute
rpm
Revolutions
per minute

4
1. General information
쐃Drive unit with 2 motors, wire storage unit, guide pulleys, wheel assembly and electric cable for connection
to the control unit
쐇Control unit
쐋Air compressor
쐏Air hoses (2×7 m, 1×1 m)
쐄Single pair pulley stand
Water nozzle – long
Water nozzle – flexible
Water hoses
Tool set
쐅Wire guard
쐅




쐄
쐏
쐋
쐇
쐃

5
2. Description
Description 2.1 Areas of application 6
2.2 DS WS15 basic system units 6
2.3 Operating controls 6
2.4 Drive principle 11
2.5 Saw advance and wire storage 11
2.6 Wire guidance 12
2.7 Safety concept for the working area 12

6
Areas of application
The DSWS15 is an electrically-powered wire saw which,
by means of its diamond wires, is capable of sawing
through construction materials ranging from heavily
reinforced concrete to metre-thick masonry. Equipped
with the appropriate accessories, it can be used to cut
openings of all kinds and for the technical demolition of
construction components of any shape, thus present-
ing almost limitless application possibilities. Sawing
operations are normally carried out wet, using water
cooling, but masonry can also be sawn dry.
DS WS 15 basic system units
The basic equipment consists of the following compo-
nents: drive unit, control unit, compressor, 2 single-pair
pulley stands, 1 toolbox containing tools and acces-
sories, 2 water supply nozzles.
2.1
2.2
2. Description
Operating controls
쐃DS WS 15 drive unit
2.3
 쐃
쐋
쐄
쐃Drive unit with 2 motors, wire storage unit, guide pul-
leys, wheel assembly and electric cable for connec-
tion to the control unit
Control unit complete with plug for a 400 V connec-
tion to the electric supply network
Compressor (230 V) for the compressed air supply
to the pneumatic advance system
DS-WS-SPP single-pair pulley stand
The basic equipment includes 2 single-pair pulley
stands. These are adequate for most applications but
it is also possible to use more than 2 single-pair pul-
ley stands for applications where access is difficult
(in cellars, corners, shafts).
Toolbox containing accessories and tools
Long water supply nozzle
For use at the rear of the object being cut, deep in the
saw kerf.
쐆Flexible water supply nozzle
For use at the wire entry point on the return side (slack
side) located at the front of the object being cut.






7
2. Description
T–shaped transportation handle, pull-out type
Folding transportation handle
Transportation or lifting lever for raising the wheels
Lifting points for transportation by crane
Cable and hose storage compartment
400 V electric cables for drive motors
24 V electric cable for control system
2 compressed air connections for advance pressure
cylinder
1 water connection, water supply from construction site
 2 water connections for cooling water supply to the
diamond wire
 2 baseplates for securing the drive unit to the floor
or ground
 Three-point supports, adjustable in height
12








2. Description
 Tension-side guide pulley, adjustable in direction and
position
 Diamond wire lead-in guide
 Slack-side guide pulley – adjustable in direction
 Cylindrical socket for vertical sawing device or for
grip bar
 Wire clamping vice
 Compressed air cylinder stop piece
 Protective cover
 Drive wheel 1, 280 mm dia., fixed
 Drive wheel 2, 280 mm dia., moving, for saw advance
 Storage pulleys, 280 mm dia., moving, for saw advance
 Storage pulleys, 200 mm dia., fixed, for wire storage
21
8
22










9
2. Description
Operating controls
DS WS 15 control unit
2.3
Transportation and lifting bars
Transportation handles
Lifting point for transportation by crane
Folding shelf for the compressor
400 V, 32 amp socket,
supply from electric mains
Two 230 V sockets
Ventilation grille
400 V, 32 amp socket, supply to the drive motors
24 V control circuit socket for the drive unit
 Compressed air supply, supply from the compressor
 2 compressed air connections, supply to the drive
unit
 Protective cover securing latch
3
4
2
5
6
1






10
2. Description
 Control unit cover lock
 Key for control unit cover lock
 DSWS 15 main power switch
 Digital display for wire cutting speed in m/s
 Green “Ready for operation” indicator light (main
power switch ON)
 Red “Error” indicator light - see troubleshooting
section
 Yellow light - “Pneumatic advance at rear stop”
 White light - “Water coolant valve open”
 Ammeter
 Advance pressure in bar
 Regulator for wire drive speed of rotation (controls
cutting speed, see )
 Drive ON, green light
 Drive OFF, red button
 Emergency STOP button
 Water supply, I = ON, green light
 Water supply, O = OFF, red button
 Advance control system ↑↓ forward or back
 Advance pressure regulator , rotary knob (note pres-
sure in bar, see )
Pushed in = locked, pulled out = unlocked
16
15
17 18 19 20 21
22
23 26
14
12 13
24 25 27 28 29

11
2. Description
Drive principle
The wire is driven by 2 electric motors fitted with drive
wheels. The diamond wire is fed around the drive wheels
in the form of a figure eight to ensure optimum grip. The
motors’ performance characteristics and control sys-
2.4
Saw advance and wire storage
The wire advance operates according to the principle of
a block and tackle working in reverse. The advance move-
ment, causing the wire to be drawn in, is effected by two
compressed air cylinders working in opposing direc-
2.5
14
min 3.2 m – max. 12.4 m
1
2
3
4
approx. 1.0 bar
approx. 1.5 bar
approx. 2.0 bar
approx. 2.5 bar
1
Guideline
tem are designed to achieve high initial torque and work-
ing torque.
The wire speed can be infinitely adjusted within the
0–27 m/s range.
tions. Accordingly, the rear pulleys (storage pulleys,
280 mm dia.) are mounted on a moving carriage. The
maximum wire storage capacity is 9.2 m. The minimum
length of wire required by the drive system is 3.2 m.
Wire capacity Wire in drive Wire storage Material thickness
Basic capacity length 3.2 m 2 m per stroke 1 m
1 storage pulley length 4.6 m 2.4 m per stroke 1.9 m
Full capacity length 7.4 m 4.8 m per stroke 4.5 m

12
2. Description
Wire guidance
Guide pulleys are fitted on the wire tension side and on
the return side (slack side). The wire is guided to the
object being sawn by way of these guide pulleys which
can be adjusted in any direction. Wire guides in the form
of single- or twin-pair pulley stands, plunge pulleys etc.,
are mounted at the start and end of the cut. The wire is
thus guided and cuts a controlled arc. The wire guides,
pulleys and supporting steel tube prevent the wire jump-
ing off uncontrollably at the end of the cut and act as a
safety device or as a wire trap in the event of the wire
breaking.
Optimum wire guidance is one of the most important
and demanding tasks in wire sawing. The distribution of
the cut and the arrangement of the pulley stands con-
trol the length and curvature of the arc cut by the wire,
thus influencing both the service life of the wire as well
as the rate of cutting progress.
Safety concept for the working area
2.6
2.7
DSW-WG
l2
l1
r1 = l1 x 2
r2 = l2 x 2

13
3. Tools and accessories
Tools and accessories 3.1 Diamond wires 14
3.2 Accessories for connecting wires 14
3.3 Accessories for securing the drive unit and wire guides 15
3.4 DS-WSRW release pulley 16
3.5 DS-WSPW plunge pulley 16
3.6 DS-WSVC vertical sawing device 16
3.7 DSW-WG wire guard 16

14
3. Tools and accessories
Diamond wires
3.1
IMPORTANT
■Only rubber or plastic coated diamond wires with
springs between the diamond beads may be used
with the DS WS 15 electric wire saw. The wire must
be guaranteed by the manufacturer to be suitable
for cutting at a speed of at least 30 m/s and it must
fit in the grooves in the guide pulleys.
■Coupling together lengths of wire of different dia-
meters and the use of wires that are not round,
wires with loose cutting beads or wires with dam-
aged cores is not permissible.
■Connection of the wire itself and the repair of bro-
ken wires must be carried out in accordance with
the instructions provided by the supplier of the wire.
■Hilti diamond wires of the standard 11 mm diame-
ter are available in fixed lengths of 10 m, 14 m,
18 m, 22 m, 26 m and 30 m (other lengths and oth-
er diameters on request). They are supplied with
factory-fitted quick-release connectors. Various wire
lengths can be joined together, but only if the dia-
mond beads are of the same diameter.
■Diamond wires with a diameter of 9 mm can be used
in conjunction with the pulleys for the standard
11 mm diameter. Wires of less than 8 mm diame-
ter or greater than 13 mm diameter require pulleys
with other groove widths or depths.
■If diamond wires without factory-fitted connectors
are used, the connectors must be fitted in accor-
dance with the manufacturer's instructions.
Accessories for connecting wires
The durability of the wire connection and its efficiency
when sawing depends essentially on use of the optimum
wire connectors and ensuring that they are fitted cor-
rectly.
3.2
Hilti DS-W 11 diamond wire – recommendations for use
Designation Material to be cut Colour Diamond wire dimensions Wire dia. 5.0 mm
Type code Bead dia. Diamond facing No. of
Specification Reinforced concrete mm mm beads / m
DS-W 11 BC Universal, fast cutting Yellow 11 1.5 40
DS-W 11 LC Long life Black 11 1.5 40
DS-W 11 M Masonry, abrasive materials Violet 11 1.5 40
Accessories for Hilti diamond wires
Description Comments / Package Ordering designation
uses contents
Crimping pliers for crimping connectors / sleeves 1 DS-WSTHY
Connector quick-release type 1 DS-WCMV
Pin replacement pin for connectors 10 DS-WP
Sleeve repair sleeve 5 DS-WS
O-ring fitted between coupling / bead 10 O-Ring 10/4.7×2.5
Crimping jaws replacement jaws for crimping pliers 2 DS-WJ
Cutter for cutting diamond wire 1 DC125-S
Correct connection of the wire is an important factor with
respect to SAFETY when wire sawing. Hilti recommends
the following accessories for the connection of wires.
The assembly instructions for Hilti wire connectors are
enclosed in the packaging.

15
3. Tools and accessories
Accessories for securing the drive unit and wire guides
DS WS 15 wire saw tool set
Ordering Quantity Use
designation
DS WS 15 tool set Wire saws
comprising:
Hilti plastic toolbox 1Operator
Accessories, list of contents and uses 1Operator
Wire sawing applications 1Operator
Wire sawing video, PAL VHS 1Operator
Open-end / ring wrench, 19 mm 1Fastening pulley stand
Open-end / ring wrench, 18 mm 1Fastening pulley stand
Hammer, 11/2kg 1Setting anchors, assembly
Screwdriver, 6 mm 1Clamping spindle
BB blow-out pump 햲1Blowing out anchor holes
Folding rule, 2-metre 1Operator
Spirit level 1Operator
Wooden pencil 2Operator
Cleaning cloth 1Operator
Hilti spray 1Operator
Hilti grease dispenser 1Operator
Flat brush 1Operator
Clamping spindle, short, M12S 햳3Pulley stand, drive unit
DD-CN-SML clamping nut 햴3Pulley stand, drive unit
HSD-G M12 setting tool 햵1Fastening anchors
Water connection nipple 햺1Water supply
GK seal 5Water seal for 356700/5
Steel wedge 햶6Securing concrete blocks
Accessories and wearing parts for Hilti wire saw systems
Ordering Quantity Use
designation
M12L clamping spindle, long 햳1Fastening pulley stand, drive unit
HKD-D M12×50 flush anchor 햷50 Hole diameter 16 mm
Water supply, long 햸1Water supply line
Water supply, flexible 햹1Water supply line
DS-WSW200 guide pulley 햽1Pulley stands, WS 15/WSS 30 drive
DS-WSW140 guide pulley 1Plunge saw return pulley
DS-WSW500 drive wheel 햾1DS-WSS 30 drive unit
DS-WSWD280 drive wheel 햿1DS WS15 drive unit
DS-WSWS280 storage pulley 헀1DS WS15 drive unit
DS-WSWS200 storage pulley 헁1DS WS15 drive unit
Cross-type tube clamp 헂1Mounting guide pulleys
Double tube clamp 1Tube extension
Tube, 2ʺ×1 m (60.3 mm outside dia.) 헄1Tube extension
CEE 32A coupling (female) 1For extension cable
Round fuse, 3.15 A, 250 V, fast-acting 10 DS WS15 control unit
Round fuse, 0.63 A, slow-acting 10 DS WS15 control unit
Fuse, 250 V, 40 A 5DS WS15 control unit
DS-WSTHY crimping pliers 1Crimping connectors and sleeves
DS-WCMV connector 햻1Quick-release type
WS-WP pin 10 Spare pin for quick-release connector
DS-WS sleeve 5Repair sleeve
O-ring, 10/4,7×2,5 10 Fitted between connector / bead
DS-WJ clamping jaws 2Spare jaws for crimping pliers
3.3 햲
햻
햽
햵
햾
햶
햿
햷
햸
헁
햹
햴
햳
햺
헄
헀
헂

16
3. Tools and accessories
DS-WSRW release pulley
Item no. 315834
Used in many applications for cutting through very thick
walls or where long cuts have to be made. The release
pulley ensures optimum wire contact length and thus a
high cutting speed.
3.4
DS-WSPW plunge pulley
Item no. 365428 / 247620
For plunge applications of all kinds. At least 2 pulleys are
required. Can also be mounted on the single-pair pulley
stand if necessary.
3.5
DS-WSVC vertical sawing device
Item no. 339312
For simple, fast cuts directly below the wire drive unit.
No further pulleys or wire guidance system is then used
(no single-pair pulley stand). The optimum solution for
applications where the drive normally stands in a hori-
zontal position. For sawing ceiling sections, supporting
beams etc.
3.6
DSW-WG wire guard
Item no. 365426
Wire guards must be fitted in situations where it can-
not be ensured that persons do not enter the danger
area while the equipment is in operation, i.e. the area
in which flying fragments etc. present a risk of injury,
or in situations where there is a risk of damage to prop-
erty or other equipment within this area.
3.7

17
4. Technical data
Technical data 4.1 Power supply 18
4.2 Dimensions and weights 18
4.3 Insulation class 19
4.4 Climatic conditions for operation and storage 19
4.5 Technical data 19
4.6 Noise values 20
4.7 Rating plates 20

18
4. Technical data
Power supply
Electric supply
Mains supply voltage: 400 V, 3–phase, 50/60 Hz
Fuse rating: At least 16 amps, 32 amps recommended.
Generator: Use only generators with an output of at least 40 kVA.
The generator must be earthed when in operation.
Water supply for drive and wire cooling
Cooling water: min. 5 l/min at max. 6 bar
Compressed air for the drive (compressor)
Min. 6 bar and 100 l/min. for the drive pneumatic advance
4.1
Dimensions and weights
Drive
Dimensions 1560×790×920 mm
Weight approx. 266 kg
4.2
Control unit
Dimensions 520×590×1080 mm
Weight approx. 68 kg
Single-pair pulley stand
Dimensions 460×240×560 mm
Weight approx. 23 kg
Compressor
The compressor supplied by Hilti with the equipment or any other compressor that complies with the specified
technical data may be used.
790
920
1590
520 590
1080
240
445
560
295
195
460
200

19
4. Technical data
Insulation class
Drive: protection against water jets
(use of high-pressure cleaning systems is not permissible)
Control unit: protection against water spray
(use of high-pressure cleaning systems is not permissible)
Climatic conditions for operation and storage
– The data specified for the DSWS15 wire saw is guaranteed up to a height of 2000 m above sea level.
– Likewise, the data specified is guaranteed for ambient temperatures within the –15°C to +40°C range (at tem-
peratures below zero with the equipment warmed up before use).
– When dry, the equipment may be stored at temperatures between –20°C and +55°C.
Technical data
DS WS 15 drive unit (supplied and controlled by the DS WS 15 control unit)
Drive wheels 2 ×280 mm dia.
Rated output P1 2 ×7.5 KW continuous output (= 15 kW drive output)
Wire speed Infinitely variable 0 – 27 m/s
Wire storage in the drive Maximum 9.2 m (length of wire min. 3.2 m – max. 12.4 m)
Drive unit dimensions 1560 ×790 ×920 mm
Drive unit weight Approx. 266 kg
Electrical protection class IP 65
Cable length (system cables) 7 m
Cooling system for two 7.5 kW
electric motors Water cooling system: min. 5 l/min at max. 6 bar
DS WS 15 control unit
Rated voltage 400 V ~ 50/60Hz 3P+N+PE or 3P+PE (alternating current)
Rated current 25 amps
Fuse rating 32 amps
Min. fuse rating 16 amps
Mains electrical connection 400 V plug CEE 32 (5-pole)
Ground fault circuit breaker (PRCD) 30 mA in mains supply on site
Control voltage 24 V (DC)
Control unit dimensions 520 ×590 ×1080 mm
Control unit weight Approx. 68 kg
Electrical protection class IP 54
Generator output Min. 40 kVA
4.3
4.4
4.5

20
4. Technical data
Compressor
Compressed air Min. 6 bar
Air volume Min. 100 l/min
Supply connection 230 V
Noise values
Equipment: DSWS15 electric wire saw
Sound pressure level as per
DIN EN ISO 3744 * < 79 dB(A)
* Measured at a distance of 2.8 m from the drive unit
Rating plates for drive unit and control unit
4.6
4.7