DS TS20-E 1.6

DS TS20-E 1.6
DS TS20-E 1.6
Operating instructions
Printed: 07.07.2013 | Doc-Nr: PUB / 5139344 / 000 / 00
en
ORIGINAL OPERATING INSTRUCTIONS
DS TS20-E 1.6 3×400 V electric wall saw
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
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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.
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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General information
1. General information
A
V
Hz
mm
Amps
Volts
Hertz
Millimeters Revolutions Revolutions Rated
per minute per minute no-load
speed
1.1 Safety notices and their meaning
DANGER
Draws attention to imminent danger that could lead to
serious bodily injury or fatality.
n
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.
358092
WARNING
Draws attention to a potentially dangerous situation that
could lead to serious personal injury or fatality.
/min rpm
CAUTION
Draws attention to a potentially dangerous situation that
could lead to slight personal injury or damage to the
equipment or other property.
Removing cooling water from the saw head and power unit
4x
1. Connect the blow-out adapter to the hose on the HIT pump.
NOTE
2. Turn the bypass valve to the “closed” position and blow out the
Draws attention to instructions and other useful inforsaw head 7 times with the HIT pump.
mation.
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.
1.2 Explanation of the pictograms and other
information
60
max. 150kg
General warning
35
78
Warning signs
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.
Warning:
electricity
Obligation signs
Wear
a hard hat.
Wear
protective gloves.
320489
! !
Wear
eye protection.
Handle with care!
Wear
safety footwear.
Wear
respiratory
protection.
Wear ear
protection.
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°
Read the operating
instructions before use.
To avoid damage to the equipment,
water pressure must not exceed 6 bar.
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357985
Symbols
The transport trolley may become unstable or run away if stood on
an inclined surface.
General information / Description
Power unit:
1.3 Other information
In these operating instructions, the DS TS20-E electric Type: DS EB-TS20
wall saw is referred to as “the machine”.
serial no.
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.
Saw head:
2. Description
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.
2.1 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 (maximum 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
Type: DS TS20-E
serial no.
Remote control unit:
Type: DS RC-TS20
serial no.
2.2 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.
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Accessories
3. Accessories
Item no.
284808
284809
284810
371703
207137
284814
284816
232241
232244
Designation
DS-R100-L rail
DS-R200-L rail
DS-R230-L rail
DS-ES-L end stop
DS-CP-ML rail clamp
DS-RF-L rail support
DS-RFP-L rail support
D-CO-ML double taper
D-EP-ML eccentric pin
Use
Saw guidance
Saw guidance
Saw guidance
Safety stop for saw head
Fastening rails
Fastening rails
Fastening rails for angled and stepped cuts
Extending rails
Extending rails
Item no.
238000
2051935
238002
238003
238004
238005
2064904
Designation
DS-BG65 blade guard
DST-BG 80 blade guard
DS-BG80 center section
DS-BG80 side section
DS-BG120 center section
DS-BG120 side section
DST-BG 160 blade guard
Use
Blade guard for blades up to 650 mm dia.
Blade guard for 600 to 800 mm dia. saw blades
Blade guard for 600 to 900 mm dia. saw blades *
Blade guard for 600 to 900 mm dia. saw blades
Blade guard for 1000 to 1200 mm dia. saw blades *
Blade guard for 1000 to 1200 mm dia. saw blades
Blade guard for 1200 to 1600 mm dia. saw blades
Item no.
238006
Designation
DS-BGF80 center section
238007
DS-BGF80 side section
238008
DS-BGF120 center section
238009
DS-BGF120 side section
Use
Blade guard for 600 to 900 mm dia. saw blades
for flush cutting *
Blade guard for 600 to 900 mm dia. saw blades
for flush cutting
Blade guard for 1000 to 1200 mm dia. saw blades
for flush cutting *
Blade guard for 1000 to 1200 mm dia. saw blades
for flush cutting
* Only to be used with the corresponding side sections!
Item no.
258436
307188
Designation
DS-FCA-110 flush-cutting flange
DS-FCA-110FF auxiliary flange
Use
Saw blade mounting flange for flush cutting
Saw blade mounting flange for flush cutting
Item no.
284842
Designation
DS TS tool set
Use
Fastening rails, personal protection, maintenance and
operation
Item no.
206856
206857
400768
228150
Designation
DS TS20-E power cable, 10 m
DS TS20-E control cable, 10 m
RC extension cable
Water hose, 10 m
Use
System cable
System cable
Extending distance between remote control and power unit 10 ➩ 20 m
System water hose
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Technical data
4. Technical data
4.1 Technical data for the DS TS20-E power unit*
DS EB-TS20 3 × 400 V
Rated voltage
380 to 480 V ~
Voltage tolerance
± 10%
Mains frequency
50 / 60 Hz
Pin assignment
3P+N+PE / 3P+PE
Rated current
16 / 25 / 32 A
Mains fuse rating min. / max.
16 / 32 A
Power input, max.
19 kW
Generator power rating, min.
20 kVA @ 16 A / 40 kVA @ 32 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
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
DS EB-TS20 3 × 200 V
200 to 280 V ~
3P+PE
32 / 50 / 63 A
32 / 63 A
20 kVA @ 32 A / 40 kVA @ 63 A
none
4.2 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 ***
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Technical data
4.3 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)
4.4 Technical data for the transport trolleys
Saw head trolley
Dimensions loaded, L × W × H
106 × 75 × 108 cm
Weight loaded **
121.5 kg
Max. permissible total weight
150 kg
Accessory trolley
106 × 75 × 140 cm*
91 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
4.5 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.
4.6 Type plates
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
k) Dress properly for the work. Do not wear loose clothing or jewelry as it could be caught in moving parts.
Contain long hair.
l) Keep children away. Keep other persons away from
WARNING
Failure to observe the instructions listed below may the working area.
lead to potentially fatal injury and serious damage to
m) Do not allow other persons to touch the machine
property or equipment.
or the extension cord.
5.1
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.
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, ensure that no gas, water, electricity or other supply lines are
b) Ensure that the workplace is well lit.
located in the cutting area. Any supply pipes or cables
c) Ensure that the workplace is well ventilated. Expo- located close to the cutting area present a serious hazard
sure to dust at a poorly ventilated workplace may result if damaged while the work is in progress. External metal
in damage to the health.
parts of the machine could become live if, for example,
an electric supply cable is damaged.
d) Keep the workplace tidy. Objects which could cause
injury should be removed from the working area. Untidi- r) Ensure that the cooling water used is drained or
ness at the workplace can lead to accidents.
extracted in a suitably controlled manner. Water that is
allowed to drain away or spray around in an uncone) In order to avoid injury and to prevent the diamond trolled manner can lead to damage or accidents. The
blade becoming trapped or jammed, steel wedges and/or fact that water could drain away into internal, hidden
supports must be used to prevent uncontrolled move- cavities, e.g. in brickwork or masonry, must also be
ment of parts of the structure being cut.
taken into account.
f) Ensure that adequately-sized supports are correctly s) Do not work from a ladder.
installed so that the remaining structure maintains its
stability after completion of the cutting work and removal t) The machine is not intended for use by children, by
debilitated persons or those who have received no
of the part cut away.
instruction or training.
g) Never loiter in the vicinity of loads suspended by
u) Children must be instructed not to play with the
cranes.
machine.
h) The area of the cut or the opening created by the cutting process must be safely and visibly cordoned off v) Dust from material such as paint containing lead, some
wood species, minerals and metal may be harmful.
in order to avoid the possibility of persons falling.
Contact with or inhalation of the dust may cause alleri) Wear personal protective equipment. Wear safety gic reactions and/or respiratory diseases to the operashoes or boots, protective gloves, a hard hat, ear pro- tor or bystanders.
Certain kinds of dust are classified as carcinogenic such
tection and eye protection.
as oak and beech dust especially in conjunction with
j) Wear respiratory protection if the work causes dust. additives for wood conditioning (chromate, wood pre9
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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.
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.
5.2 Safety measures at the danger areas
5.3 General safety instructions
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.
a) Use the machine only when you have read the operating 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.
Persons must NEVER enter the danger area (3 meters Use it only as directed and when in faultless condition.
in all directions from the line of the cut to be made) c) Use the machine, accessories and saw blades etc.,
while the blade drive is switched on.
in accordance with these instructions and in the manner intended for the particular type of machine, taking
3m
3m
3m
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.
STOP
STOP
3m
3m
3m
3m
∞m
STOP
1m
STOP
STOP
STOP
STOP
∞m
STOP
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 efficiently and more safely within its intended performance
range.
CAUTION
Secure the working area. Ensure that no persons can be
h) Never leave the machine unattended.
injured or property / equipment damaged by falling objects
or debris that may fly off during the sawing operation. i) Store machines in a secure place when not in use.
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Safety precautions
When not in use, machines must be stored in a dry, e) Damaged or faulty switches must be replaced at a
Hilti service center. Do not use the machine if it cannot
high place or locked away out of reach of children.
be switched on and off correctly.
j) Always disconnect the machine from the electric supply when it is not in use (e.g. during breaks between f) Have the machine repaired only by a trained electriworking), before making adjustments, before carrying cal specialist (Hilti service center) using genuine Hilti
out care and maintenance and before changing saw spare parts. Failure to observe this point may result in
blades. This safety precaution prevents the machine risk of accident to the user.
starting unintentionally.
g) Do not use the supply cord for purposes for which
k) Remove any adjusting key or wrench before switch- it is not intended. Never carry the machine by the suping the machine on. A wrench or a key left attached to ply cord. Never pull the plug out of the power outlet by
a rotating part of the machine may cause personal injury. pulling the supply cord.
l) Before use, the machine, the saw blade and accessories must be checked carefully to ensure that all items h) Do not expose supply cords to heat, oil or sharp
function faultlessly and as intended. Check that mov- edges.
ing parts function correctly without sticking and that i) Connect the machine and its ancillary equipment only
no parts are damaged. All parts must be fitted correctly to a power source equipped with an earth/ground conand fulfill all conditions necessary for correct opera- ductor and ground fault circuit breaker (PRCD). Check
tion of the machine. Damaged parts must be repaired that these items are in perfect working order before
or replaced properly by an authorized service center. operating the equipment. Install an earth/ground rod
m) Avoid skin contact with drilling slurry.
n) Wear a protective mask during work that generates
dust, e.g. dry cutting. Connect a dust removal system.
Cutting materials hazardous to the health (e.g. asbestos)
is not permissible.
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.
o) Follow the instructions concerning care and maintenance.
j) Make sure that the mains voltage corresponds to the
specification given on the type plate.
5.4 Electrical safety
k) Electric cables and their plug connectors must be
kept dry. When not in use, close power outlets with the
a) Take steps to avoid the risk of electric shock. Avoid cover provided.
body contact with earthed or grounded surfaces such
as pipes, radiators, ranges and refrigerators.
l) Use only extension cables which have an adequate
conductor cross-section and are approved for the intendb) Check the machine’s supply cord at regular intervals
ed field of use. Do not work with extension cables when
and have it replaced by a qualified specialist if found to
they are rolled up. This can result in a drop in output
be damaged. Check extension cords at regular interat the equipment and may cause the cable to overheat.
vals and replace them if found to be damaged.
c) Check the condition of the machine and its acces- m) Disconnect the power cable before beginning cleansories. Do not operate the machine and its accessories ing and maintenance work or in the event of a lengthy
if damage is found, if the machine is incomplete or if interruption between periods of operation.
its controls cannot be operated faultlessly.
n) Please note that certain components of the power
d) Do not touch an electric cable that has been dam- converter retain an extremely dangerous (potentially
aged while working. Switch off at the main switch and fatal) high voltage for up to 10 minutes after disconunplug the cable at the power outlet.
nection from the electric supply.
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Safety precautions
Never enter the danger area (e.g. to change the saw
blade, remove the blade guard side section, hammer
a) The machine may be operated only by specialists in wedges, etc.) before the blade drive is switched off
trained in concrete cutting techniques, referred to in and the blade has come to a standstill. Press the EMERthe following as “operators”. These persons must be GENCY STOP button before entering the danger area.
familiar with the content of these operating instructions Do not touch rotating parts.
and must have been trained in their safe application by
a Hilti specialist.
Observe the permissible drive unit parameters, blade
rotation speed and advance speed while sawing.
b) Stay alert, watch what you are doing and use common sense when working. Do not use the equipment Use only saw blades that comply with the requirements
when you are tired or under the influence of drugs, alco- of EN 13236. Fit the blades the right way round (obserhol or medication. A moment of inattention while oper- ve correct direction of rotation).
ating the equipment could result in serious injury.
Use of blades with laser-welded segments can reduce
c) The user and any other persons in the vicinity must the risk of segments breaking and flying off.
wear suitable eye protection, a hard hat, ear protection,
protective gloves and safety footwear while the equip- Check the blade mounting flange and blade for damage (e.g. cracks in the steel disc) and degrease the blament is in use.
de mount each time before operating the wall saw.
5.5 Requirements to be met by users
5.6 Safety during operation
Check that the wall saw and its components, the saw
blade and all accessories are in good condition and in
perfect working order before use. Any damage or malfunctions must be rectified in a PROFESSIONAL manner before operation commences.
Always put on gloves before touching the saw blade as
it can get hot.
Use only fastening materials of adequate size (anchors,
bolts, etc.) to fasten the rail supports.
Use only the accessories recommended in these operating instructions. Use of other accessories may result
in personal injury or damage.
Position the electric power unit outside the danger area. If equipment such as scaffolding, platforms or ladders
is used, check that this equipment complies with reguSawing may begin only once the wall saw system (rail
lations, that it is undamaged and set up in accordance
supports) have been fastened securely to a solid surwith regulations.
face and the other parts of the system have been assembled or installed correctly (all bolts tightened, the saw The operator must take measures to ensure that no
head positioned securely on the rail, locking levers clo- persons enter or loiter in the danger area at any time
sed, end stops fitted). A falling object could result in while the saw is in operation. This also applies to the
serious personal injury or damage to property or equip- area not immediately visible to the operator, i.e. the
ment.
area behind or below the object in which the cut is being
made. If necessary, a large area must be cordoned off
NEVER stand in the direction of radial flight of a runor security personnel posted.
ning saw blade. Always use the appropriate blade guard
(DS-BG for normal cutting, DS-BGF for flush cutting). Stay alert at all times. Monitor the progress of the sawing
operation and keep an eye on the cooling water system
Always operate the machine from the closed side of
and the area surrounding the workplace. Do not opethe blade guard, i.e. the protected side, when corner
rate the machine if your full attention is not on the job.
cuts are made with the blade guard in the partly open
position. The operator must take additional precauti- No modifications may be made to the saw system.
ons (fit a cover, plank of wood, boards etc.) where Modification of the factory-set drive parameters is stricnecessary.
tly prohibited.
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Preparations at the workplace
5.7 Safety instructions for transporting the
equipment
Avoid lifting and carrying heavy objects. Use suitable
lifting equipment and means of transport and share
heavy loads between several people.
Use the handles provided for transportation. Always
keep the handles clean and free of grease.
Bear in mind that the machine could fall over. Stand it
only on a solid, level surface.
Make sure that the saw system and its components
cannot move about or fall over during transportation.
6. Preparations at the workplace
6.1 Planning the cutting sequence, marking the
cutting line and fastening points
1. The parts to be cut out are usually marked by the client.
A rational cutting sequence can be followed when the
rail supports are cleverly positioned.
2. If necessary, adjust the size and weight of the concrete blocks to the prevailing conditions by making
dividing cuts (i.e. depending on the work order, the
means of handling the blocks, the crane or the maximum floor loading capacity and size of doors).
3. Use steel wedges and supports, as necessary, to secure
the sections of concrete while sawing.
The machine may be lifted by crane only at the lifting
points provided using tested and approved lifting gear.
Before lifting, check that all removable items of equipment are securely attached to the two transport trolleys or locked in position. Never loiter under loads suspended by crane.
1
2
3
4
5
6.2 Clarifying the situation and securing the
workplace
Have you made sure there are no hazardous pipes or
cables (gas, water, electricity etc.) in the cutting area?
Have the effects of the cutting work on the stability of
the structure been clarified and are the supports in place
capable of taking up the resulting loads?
Can the possibility of hazards or damage as a result of
the cooling water used be ruled out?
Have safety measures been implemented to ensure that
no persons can be injured or property and equipment
damaged by falling objects or debris that may fly off during the sawing operation?
Can the parts of the structure that are to be sawn out be
removed safely in a controlled operation and subsequently disposed of?
Does the electric supply and water supply available for
use meet the specified requirements?
Is the required equipment in the correct specification
available for use?
Has the work to be carried out been approved in full by
the site engineer or architect?
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Preparations at the workplace
6.3 Electric power supply / fuse rating
CAUTION
Irrespective of whether using mains power or generator power, always check that an earth/ground conductor and ground fault circuit breaker are present in the
electric supply 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.
Voltage version
3 × 400 V 3 × 200 V
Minimum fuse rating
16 A
32 A
Maximum fuse rating
32 A
63 A
Ground fault circuit breaker (FI) Type A 30 mA
6.4 Electric power connection /
power cable plugs
Voltage version 3 × 380–480 V
Pin
3P + N* + PE
assignment
32A 6h
PinL3
L2
assignment
N
L1
PE
3 × 200–280 V
3P + PE 63A 9h
L1
L2
PE
L3
L1 = phase 1, L2 = phase 2, L3 = phase 3, N = neutral conductor,
PE = earth / ground
* The 230 V outlet on the power unit functions only when the neutral conductor (N) is connected.
The CEE connector supplied, if required, should be fitted to your power cable by an authorized electrician.
The remote control unit indicates the voltage and shows
an error in the event of any one of the phases (L1, L2,
L3) providing no power.
6.5 Extension cables / conductor cross section
■ Use only extension cables which are approved for the
intended field of use and with conductors of adequate
cross section.
■ In accordance with EN 61029-1, conductors must
have at least the following cross sections: 1.5 mm2
for 16 A, 4 mm2 for 32 A and 10 mm2 for 63 A (conductor cross section = cross-sectional area of individual conductors).
■ Inadequate conductor cross sections and long cables
result in a drop in voltage and may cause the cable to
overheat.
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■
Extension cables must be fully unrolled before the
wall saw is put into operation.
6.6 Cooling water supply
1. When the cooling water has a temperature of 18°C, a
flow rate of approx. 4 l/min is required for cooling the
power unit and saw head.
2. Use only clean cooling water.
3. For dry sawing applications (e.g. masonry), the excess
water can be drained away by using the bypass function at the saw head.
4. The machine’s automatic cut-out will be activated in
the event of inadequate cooling.
5. Where pressure in the water supply line is low, a nonreturn valve should be fitted in order to prevent dirty
water finding its way into the water supply.
NOTE
In order to prevent damage to the seals, a small quantity
of water is allowed to reach the saw blade by way of the
drive spindle even when the bypass valve is fully closed.
Setting up the wall saw system
7. Setting up the wall saw system
7.1 Connecting the power unit
NOTE
Operating the main swith several times in quick succession will cause the electric supply to be temporarily interrupted. Wait for a few seconds before switching on again.
1. Set the current input limiter to the corresponding fuse rating. Connect the earth/ground terminal to an
earth/ground rod if the unit is powered by a generator.
2. Connect the power cable (observe the information on the type plate ).
3. Remove the protective cap and connect and secure the remote control unit .
4. Close the protective caps by fitting them together.
5. Move the main switch to the “I” position. The “Ready” indicator then lights.
6. Connect the external cooling water hose . Water pressure must not exceed 6 bar.
Parts
No.
Designation
Error indicator (red)
“Ready” indicator (green)
Main switch
Current input limiter
230 V power outlet (only with 3 × 400 V version)
Automatic fuse / circuit breaker and ready indicator for 230 V outlet
Power cable connector
Socket for remote control unit
Cooling water connection (feed)
Type plate
Plug for saw head control cable
Plug for saw head power cable
Cooling water connection (exit)
Earth/ground terminal
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Setting up the wall saw system
7.2 Fastening the rail supports
CAUTION
■ Failure to observe the spacing shown may cause the
saw to wander off course and, in extreme situations,
may result in failure of the anchor fastenings.
■ Adequately dimensioned and correctly installed fastenings are essential in order to ensure efficient and
safe operation of the equipment.
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.
■ The construction materials and conditions encountered at the location where sawing is to be carried out
vary from site to site. Should you be unsure of the
strength of the supporting material and have doubts
about the solidity of the fastening obtained, please
contact Hilti Customer Service for technical advice.
NOTE
■ During installation, the leveling screws should not
project beyond the contact surface of the rail supports.
■ Use the DS-RFP rail support for angled and stepped
cuts.
Rail support for regular cutting
Rail support for angled and stepped cutting
Parts
No.
Designation
Contact surface
Anchor slot for fitting rail support
Leveling screws
Rail clamping plate
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Rail clamping screw
Clamping screw for angle adjustment
Clamping plate for stepped cuts
Setting up the wall saw system
1. Mark the positions of the anchor holes for the rail supports.
2. Drill the anchor holes (depth and diameter in accordance with the manufacturer’s instructions).
3. Clean the holes (remove the drilling dust).
4. Insert and expand the anchors (e.g. Hilti HKD-D M12) using the setting tool.
5. Screw in the fastening screws (8.8 grade with collar nut, supplied in the accessory box) to their full depth by hand.
6. Position and align the rail supports and then tighten the collar nuts slightly.
432mm
230mm
176mm
176mm
25 0mm
139mm
74
mm
235mm
139mm
595m m
736mm
235mm
235mm
183mm
274mm
361mm
139 m m
230m m
Main dimensions of the DS TS20-E (in mm)
Anchor hole distance
max. 50 cm
max. 170 cm
max. 100 cm
Maximal permissible rail support distance
7.3 Fitting the rail
1. Fit the rail clamp to the rail.
2. Position the rail with fitted rail clamp on the rail support and close the clamping plate.
3. Turn the rail support until at right angles to the rail and then tighten the clamping plate securely.
4. Compensate for any difference in level by adjusting the leveling screws.
5. Align the rail at the correct distance from the cutting line and then tighten the fastening screws.
6. Fit end stops at both ends of the rail.
NOTE
The rail clamps cannot be used with the rail supports for angular cutting.
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Setting up the wall saw system
1
2
4
6
6
5
1
3
Parts
A
No.
Designation
Rail
Rail clamp
Rail support
Rail clamping plate
Rail clamping screw
Leveling screws
Clamping plate for stepped cuts
C
B
A [°]
B [cm]
0°
5°
10°
15°
20°
25°
30°
35°
40°
45°
23
23.8
24.8
26.0
27.6
29.5
31.8
34.6
38.1
42.5
∅ 700 mm
28
24.9
22.0
18.8
15.5
12.0
8.3
7
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∅ 800 mm
33
29.9
26.9
23.7
20.2
16.5
12.7
8.6
C [cm]
∅ 900 mm
38
34.9
31.8
28.5
24.9
21.1
17.0
12.7
8.3
∅ 1000 mm
43
39.8
36.8
33.3
29.6
25.6
21.3
16.8
12.2
7.3
∅ 1200 mm
53
49.8
46.6
43.0
39.0
34.6
30.0
25.0
19.8
14.4
∅ 1600 mm
73.0
69.7
66.3
62.4
57.8
52.7
47.3
41.4
35.1
28.5
Setting up the wall saw system
7.4 Extending the rail
NOTE
■ When long cuts are to be made, tapered connectors and eccentric pins can be used to join individual rails together to form a rigid unit.
1. Clean the tapered connector and connector sleeves.
2. Insert the tapered connector and secure it with an eccentric pin.
3. Slide the rail onto the tapered connector and also secure it with an eccentric pin.
4. To release the connection, turn the eccentric pins in the opposite direction and push out the tapered connector.
3
1
5
2
3
4
3
Parts
No.
Designation
No.
Rail
Tapered connector
Eccentric pins
Designation
1
/2" square drive wrench
Tapered sleeve
7.5 Mounting the saw head
NOTE
■ The DS-FCA-110 flush-cutting flange should be mounted on the saw head for flush-cutting applications.
1. Press the release button on the locking lever and push the locking lever downwards.
2. Position the saw head on the previously fastened rail.
3. Check that the guide rollers are correctly aligned. The center of the guiding surface should be in line with
the middle of the guide roller.
4. Press the release button and pull the locking lever upwards.
5. Check the position of the guide rollers (move the levers several times) and check that the clamping lever
engages correctly before letting go of the saw head.
3
4
3
3
1
2
3
1 /
2
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Setting up the wall saw system
Parts
No.
Designation
Clamping lever
Release button
Guide roller
Guiding surface
7.6 Adjusting the blade guard
1. Release the clamping screw on the saw arm.
2. Pivot the blade guard holder into the desired position.
3. Tighten the clamping screw .
3
2
Parts
No.
Designation
Blade guard holder
Clamping screw
Hex. socket wrench, 8 mm AF
1
7.7 Connecting the power cable, remote control unit and cooling water hose to the power unit and saw head
CAUTION
■ To avoid damage to the parts, check that the plug and socket are clean and in good condition before connecting. Clean the parts or remedy any damage before connecting them.
■ When unplugging, always grip the plug and not the cable. Fit the protective cap immediately.
■ Do not use the plug as a grip or carrying handle.
■ Do not allow the cables to become tangled and place them carefully so that the plug connectors are not lying
in water. The cables must be long enough to allow the saw head to move freely.
1. Remove the protective caps.
2. Align the plug carefully with the socket and push it in all the way without using excessive force.
3. Close the securing sleeve and check that it engages.
4. Close the protective caps together.
5. Connect the cooling water hose.
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Setting up the wall saw system
1
1
5
2
3
2
3
4
Parts
No.
Designation
No.
Designation
Power cable plug / socket
Control cable plug / socket
Cooling water hose connectors
Protective cap
Securing sleeve
7.8 Fitting the saw blade
NOTE
■ Use the DS FCA flush-cutting flange and flush-cutting blade guard (available as accessories) for flush-cutting
applications.
■ Use only the original Hilti screw (10.9 grade steel) as the central blade mounting screw.
■ Before operating the wall saw each time, always check the mounting flange and saw blade for damage, cracks or
discoloration caused by overheating and clean the saw blade if it has been oiled or greased.
1. Position the saw blade on the saw arm, taking care to observe the correct direction of rotation.
2. Fit the blade flange and mounting screw. Tighten the screw 4 only slightly.
3. Align the saw blade so that the mounting holes for flush cutting lie between the water grooves.
4. Tighten the mounting screw securely with the 19 mm AF ring wrench (110 Nm).
5
1
4
2
3
1
3
Parts
No.
Designation
No.
Designation
Saw blade
Centering and mounting flange
Saw blade flange
Mounting screw
Mounting holes for flush cutting
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Setting up the wall saw system
7.9 Fitting the blade guard
NOTE
Should it prove impossible to use the blade guard due
to specific circumstances at the working area, special measures must be taken, such as construction
of a temporary enclosure (e.g. using forming boards),
to protect the surrounding area from flying fragments
etc. while sawing.
■ Use the DS-FCA flush-cutting flange and flush-cutting blade guard (available as accessories) for flushcutting applications.
■ Keep the holes for the side section guide pins clean
in order to prevent sticking of the side sections.
■ Keep the blade guard clean. Clean it regularly each
time after use to ensure that it remains in good working order.
■
1
4
5
2
CAUTION
Remove the side section only immediately before beginning a corner cut.
1. Push the center section of the blade guard , or the
complete blade guard, onto the blade guard holder
.
2. Fit the blade guard side section by engaging the metal hooks with the center section and then close
the clamp . Secure the blade guard to the blade
guard holder by pulling the rubber strap over the tensioning lug.
3. To remove the side section , open the clamp and
lift the side section away from the center section.
3
6
Parts
No.
Designation
Blade guard center section
Blade guard side section
Guide pin
Blade guard holder
Guide rollers
Clamp
Tensioning lug
Rubber tensioning strap
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7
8
Setting up the wall saw system
7.10 Adjusting the blade cooling water flow rate
Set the water regulating valve to the desired flow rate.
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Operation
8. Operation
8.1 Checks before beginning sawing
1. On-site preparations must be completed (supports, water collection, etc.).
2. The power unit must be positioned outside the danger zones. The areas in front of and behind the object where
sawing is to take place are danger zones and must be secured and cordoned off. No persons may remain in a
danger zone.
3. The power cable and water supply must be connected to the power unit. The power supply must be earthed /
grounded and equipped with a ground fault circuit breaker. The water supply must be within the permitted
pressure range.
4. The rail supports and rails must be aligned and fastened correctly, with all screws and nuts tightened securely.
5. The saw head must be mounted correctly and the locking levers engaged. Move the locking levers back and
forward slightly to check that they are engaged correctly.
6. The power and control cables and water hoses must be laid out, connected correctly and the locking sleeves
engaged.
7. The saw blade must be mounted in the correct direction of rotation and the mounting screw at the saw blade
flange (or six countersunk screws for flush cutting) tightened securely.
8. The blade guard and end stop must be fitted securely.
9. The remote control unit and control cable must be connected.
10. The emergency stop button on the remote control unit must be disengaged and reset.
11. All control knobs on the remote control unit must be in the “Off” or “Neutral” position.
12. The operator should be wearing the remote control unit (using the shoulder strap).
13. The “Ready” indicators on the power unit and remote control unit must light.
14. The safety precautions must be observed.
8.2 Description of the remote control unit
21
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22
Operation
No.
Description
Function
Saw blade drive motor on / off
Saw blade speed
Direction of advance
Direction of plunge movement
Speed regulation for controls 3 and 4
Rapid movement for control 5
Cooling water on / off
Emergency stop switch
Reset switch for emergency stop
Overheating cut-out
Temperature warning
Zero position error
Emergency stop indicator
Fault in electric supply
Service indicator
Theft protection
Emergency of indicator
Starting blade drive: Turn to START (switch returns to
position II when released)
Position II = saw blade drive running
Position I = saw blade drive “Off”
Infinite (stepless) speed regulation – display position
.
Selects direction of advance of the saw on the rail.
Selects direction of saw blade plunge movement.
Manual and / or automatic advance or plunge
movement-display position .
For rapid advance and plunge movement when saw
blade drive is switched off.
Controls cooling water supply to saw blade.
Water flows when not under power.
Press in an emergency! Leave pressed in when setting
up or changing blades etc.
Turn knob in direction of arrow to release – display
position .
Reset must be pressed after releasing the emergency
stop button – display position .
Lights when the machine has switched itself off due to
overheating.
Lights when cooling is inadequate.
Lights when one or more knobs are not in the zero or
neutral position when switching on.
Lights when the emergency stop button is pressed or
when not reset.
Lights when a phase is missing, voltage is too low or
too high or out of synchronization.
Lights when servicing is due (end of service interval).
Servicing should be carried out by Hilti.
Not active.
Lights when the emergency stop has not been reset –
switch .
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Operation
Operating hours counter
Power indicator
Supply voltage
Fault indicator
21
Speed indicator
Warning
22
Recommended speed range
After switching on, the following information is
displayed: power unit firmware version (Exx), saw
head firmware version, operating hours and total saw
head operating hours.
The actual power input is displayed during operation
of the saw (in %).
During operation, turn starting switch to “Start”
(voltage is displayed).
The code displayed can help to localize a possible
fault (e.g. Er01).
Can be adjusted by the knob at position .
Operation of the saw without blade guard and end
stops fitted is not permissible!
NOTE
To read the mains input voltage while the saw is in operation (only 3x400V version), proceed as follows:
1. Turn the starting switch to the “Start” position and hold it there.
2. The voltage reading is shown in the display in volts.
To read the mains input voltage while the saw is stationary (only 3x400V version), proceed as follows:
1. Turn the starting switch to the “I” position.
2. Set the saw blade speed control knob to the maximum speed position.
3. Turn the starting switch to the “Start” position and hold it there.
4. The voltage reading is shown in the display in volts.
The procedure described below can be used to reverse the positions of the switch controlling direction of advance:
1. Turn the starting switch to the “I” position.
2. Set the advance speed control knob to the zero position.
3. Set the saw blade speed control knob to the maximum speed position.
4. Operate the direction of movement control switch or .
5. Turn the starting switch to the “Start” position and hold it there.
6. When reversal of control direction has been successful, “L__R” is shown in the display .
8.3 Operating the saw
1. Use the plunge and advance controls and the speed regulation knob to move the saw head along the
rail to where the cut is to be started and then return all switches / knobs to the “Neutral” or “Zero” position. For
rapid movement, turn the speed regulation knob to the right, beyond the pressure point , as far as it will go.
2. Switch on the cooling water .
3. Switch on the saw blade drive and then use the speed control to set the desired speed (please observe recommended speeds). Wait until the blade runs up to speed.
4. Select the direction of plunge movement and advance speed and then bring the blade slowly to the desired
cutting depth (cut into the concrete). Set the plunge movement and speed regulator back to the “Neutral”
or “Zero” position when the desired depth has been reached.
5. Select the direction of longitudinal advance and the desired speed , e.g. 100%. Make the initial cut at reduced
power (60%).
6. At the end of the cut, turn the speed control to the “Zero” position and switch off the longitudinal advance .
7. Repeat steps 4 to 6 until the desired depth is reached.
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Operation
8. Once the cut has been completed or the maximum depth reached, use the plunge movement direction control
to lift the saw blade out of the kerf while the blade is still rotating, bringing the saw and saw arm to the 90°
position.
9. Subsequently turn all switches / knobs (advance direction, advance speed, blade speed, water supply and starting switch) back the “Neutral” or “Zero” position and then press the emergency stop button.
10. If necessary, fit a larger diameter saw blade (max. 1600 mm dia.) and repeat the procedure.
8.4 Guidelines and guide values
1. The initial or guide cut
The initial cut is also known as the guide cut. This cut should always be made with the saw arm in the trailing
position. Depending on the material being cut (hard, soft or masonry) the guide cut should be made to a depth
of between 4 and 5 cm. The guide cut should always be made at reduced power (e.g. 60%). This prevents the
blade wandering off course and ensures a straight cut.
PD[
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FP
P
FP
P
PP FP
PP FP
PP
FP
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2. Subsequent cuts
After the guide cut has been made, sawing can continue with the saw arm in either the trailing position (pulling
the blade) or leading position (pushing the blade). The depth of subsequent cuts again depends greatly on the
material, but may be between 10 and 15 cm. These cuts can be made at full (100%) power.
8.5 Remaining cutting distances with the DS TS20-E saw head
S [cm]
20
25
30
35
40
45
50
A [cm]
∅ 700
mm
12.4
21.0
∅ 800
mm
10.2
15.9
25.1
∅ 900
mm
8.7
13.2
19.4
29.3
∅ 1000
mm
7.6
11.4
16.3
22.9
33.5
∅ 1200
mm
6.2
9.0
12.6
17.1
22.8
30.3
42.1
∅ 1600
mm
4.5
6.5
8.9
11.8
15.2
19.3
23.9
A
S
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Operation / Care and maintenance
8.6 Dismantling the saw system
1. Pivot the saw arm to the 90° position. Switch the machine off, disconnect the cables and fit the protective caps
to the plugs and sockets.
2. Disconnect the water hose from the saw head and clean the blade guard, saw head and rail system.
3. Remove and clean the blade guard and saw blade.
4. Remove the saw head from the rail and clean these parts.
5. Disconnect the cables and water hose from the power unit and fit the protective caps to the plugs and sockets.
6. Clean the cables and hoses, roll them up and attach them securely to the transport trolley.
7. Stow the saw head, rail system parts, blade guard and accessories securely on the transport trolley.
CAUTION
To avoid the possibility of damage, always switch off at the main switch before disconnecting the power cable.
To avoid damage when temperatures below freezing are expected, the cooling system must be fully drained by
blowing out with the pump provided.
■
■
9. Care and maintenance
9.1 Cleaning
1. Disconnect the system from the electric supply.
2. Clean the entire set of equipment after finishing work or before long breaks between periods of use.
3. Do not allow dirt and slurry to dry out and adhere to the parts.
4. When cleaning, pay particular attention to the operating surfaces, threads, connectors, toothed sections, points
of contact between moving parts, operating controls and safety or operating information plates.
5. Fit the protective caps to all plugs and connectors.
6. Clean the power unit, remote control unit, and cable with a damp cloth.
7. Use a medium-hard brush and water to clean the saw head, rails, blade guard system and transport trolley.
CAUTION
■ Do not use high pressure cleaning systems to clean the power unit, saw head, remote control unit or cables.
Water finding its way into these parts may cause malfunctions and damage to the equipment.
■ If concrete formwork parting agent or oil is used on the equipment (to help prevent concrete adhering to it) take
care to ensure that the product used contains no solvents.
■ Products containing solvents may attack and damage the seals or other parts of the casing.
358092
< 4°C
To avoid damage when temperatures below freezing are expected, the cooling
system must be fully drained by blowing out with the pump provided.
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Care and maintenance
9.2 Maintenance
Parts
Rail supports
Procedure
Daily
Check the contact and clamping surfaces, clean if necessary.
●
Check the threads for smoothness and ease of operation,clean and
grease if necessary.
Rails
Check the contact and running surfaces, clean if necessary.
●
Check the toothing for damage and wear, replace the rail if necessary.
Check the tapered sleeves, clean and lubricate with oil if necessary.
●
Blade guard
Check and clean working parts and inside/outside surfaces.
●
Check that the guide rollers are free to move and clean or replace
the parts if necessary.
Check the condition of the rubber tensioning straps
and replace if necessary.
●
Saw head
Check the locking mechanism for security of engagement, have it
repaired if necessary
●
Check the guide rollers for ease of operation and excessive play,
have them replaced / repaired as necessary.
Check the plug connectors for cleanliness and damage. Blow out
with compressed air or have the parts replaced if necessary.
●
Check the saw blade mounting flange and mounting screw, clean
or replace if necessary.
●
Check the saw head for oil or water leakage and have it repaired if
necessary.
Check the water flow and replace the mesh filter at the water supply
connection if necessary.
Power unit
Check the switches and indicator lamps for correct operation and
have them replaced if necessary.
●
Check the plug connectors for cleanliness and damage. Blow out
with compressed air or have the parts replaced if necessary.
●
Check the power unit for water leakage and have it repaired if necessary.
Check the water flow and replace the mesh filter at the water
supply connection and descale if necessary.
Remote control Check the switches and indicator lamps for correct operation.
unit
Clean the parts or have them replaced if necessary.
●
Check the plug connectors for cleanliness and damage. Blow out
with compressed air or have the parts replaced if necessary.
●
Water hose
Check the couplings for cleanliness, ease of operation and leakage.
Clean and lubricate the couplings if necessary (lubricant spray).
●
Check the hose for leakage.
Cables / plugs Check the plug connectors for cleanliness, damage and ease of
operation. Blow out with compressed air or have the parts
replaced if necessary.
●
Check the cables for damage and replace them if necessary.
●
Transport trolley Check the tyre pressure (2.1 bar or 30 psi).
Tool set
Check for completeness.
Weekly
●
●
●
●
●
●
●
●
●
●
●
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Care and maintenance / Troubleshooting
9.3 Statutory requirements
The electrical and mechanical safety of the saw system and its accessories such as electric extension cables must
be checked at the specified intervals in accordance with national regulations.
In countries of the European Union, following the provisions of EN 60204-1, the checks listed below are recommended:
■ Measurement of earth / ground conductor resistance (max. 0.3 ohms).
■ Instead of the insulation resistance test in accordance with EN 60204-1, leakage current during operation should
be measured, as this provides a very quick indication of the possibility of an insulation fault.
■ Measurement of earth /ground conductor current (max. 3.5 mA during operation, with the machine placed on
an insulated surface).
■ Functional and visual check of the emergency stop switch, operating controls, indicator lamps, seals, cables,
blade guard and support system in order to detect faults that could present a hazard.
9.4 Service intervals
We recommend that the system is checked at a Hilti service center after every 200 operating hours. This will ensure
that the equipment is ready for use when required and help avoid high subsequent costs.
NOTE
The service indicator lights when servicing is necessary.
10. Troubleshooting
10.1 The meaning of error codes and the measures to be taken to remedy faults
The electric wall saw is quipped with a fault diagnosis and error display system that allows the operator to localize faults and, as far as possible, to remedy these without assistance.
While doing so, should it be necessary to enter the danger area, all safety instructions, particularly those listed in
Section 5, must be observed.
Should it prove impossible to remedy the fault yourself, you can assist Hilt Service by describing the fault as precisely as possible and by stating the error code displayed by the remote control unit.
Displayed on remote control
Fault
Possible cause
No display
No display on power unit or
remote control unit
Electric supply not connected
or faulty
Er50
Er51
Er52
Er53
Er20
Er21
Machine has switched itself
off due to overheating
Cooling water insufficient or
too warm
Machine cannot be
switched on
Temperature sensor in the
saw head is faulty
Recommended measures to
remedy fault
– Check the electric supply
– Check the plug connections
– Return the remote control and
power unit to Hilti Service
– Allow to cool with cooling
water flowing / restart
– Return the saw head to Hilti
Service
– Return the saw head to Hilti
Service
Symbol 11 lights
Er89
Er90
Machine cannot be
switched on
Temperature sensor in the
power unit is faulty
– Return the power unit to Hilti
Service
Symbol 12 lights
Er54
Er55
Er56
Warning before cut–out due
to overheating
Cooling water insufficient or
too warm – power unit is
overheating
– Improve the cooling
– Return the power unit to Hilti
Service
Symbol 11 lights
Symbol 11 lights
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Troubleshooting
Symbol 12 blinks
slowly
Sr60
Sr61
Warning before cut–out due
to overheating
Main motor or advance motor
is overheating
Symbol 12 blinks
rapidly
Sr60
Sr61
Warning of imminent cut-out
due to overheating
Main motor or advance motor
is overheating
Symbol 12 blinks
slowly
Sr62
Sr63
Sr64
Warning before cut–out due to
overheating
Symbol 12 blinks
rapidly
Sr62
Sr63
Sr64
Warning of imminent cut-out
due to overheating
Cooling water insufficient or
too warm
Ambient temperature too high
(Sr64)
Cooling water insufficient or
too warm
Ambient temperature too high
(Sr64)
One or more control knobs or
switches not in the "0” or
neutral position
Longitudinal and plunge
advance operated
simultaneously
The motor brake has been
activated
Symbol 13 lights
Saw blade drive cannot be
switched on
Symbol 13 lights
Advance movement doesn’t
function
Symbol 13 lights
Zero position indicator lights
as the blade is coming to a
standstill
Machine cannot be switched
on
Symbol 14 lights
Symbol 14 lights
Er11
Machine cannot be switched
on
Symbol 15 blinks
Er44
Machine cannot be switched
on or switches itself off
Symbol 15 lights
Er42
Er43
Machine cannot be switched
on or switches itself off
Symbol 15 blinks
slowly
Sr45
Sr46
Warning that electric power is
inadequate
– Improve the cooling
– Observe the application guidelines
– Return the saw head to Hilti
Service
– Improve the cooling
– Observe the application guidelines
– Return the saw head to Hilti
Service
– Improve the cooling
– Place the power unit in the shade
– Return the saw head to Hilti
Service
– Improve the cooling
– Place the power unit in the shade
– Return the saw head to Hilti
Service
– Return all knobs and switches
to the "0” or neutral position
and restart
– Operate the advance controls
individually
– None required
The emergency stop switch is in – Release the emergency stop
the pressed-in position
button / restart
– Have the fault repaired by Hilti
Service
Break in the emergency stop / – Check the motor cable and
motor cable circuit
plug connections
– Return the saw head, motor cable
and power unit to Hilti Service
Difference between phases
– Check the electric supply
> 10%
– Return the power unit to Hilti
Service
Electric power is inadequate
– Check the electric supply
– Return the power unit to Hilti
Service
Electric power is inadequate
– Check the electric supply
– Return the power unit to Hilti
Service
Symbol 16 lights
No fault
Service interval has been
reached
– Return the saw head to Hilti for
servicing
Symbol 18 lights
Machine cannot be switched
on
Emergency stop reset button
hasn’t been pressed
– Press the reset button / restart
The machine doesn’t function
Remote control unit and saw
head not compatible with each
other
– Check compatibility and
replace the remote control unit
with one of the correct type
– Return remote control and
power unit to Hilti Service
Display
Er00
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Troubleshooting
Display
Er01
Er02
The machine doesn’t function
correctly
Faulty connection between
the remote control and power
unit
Display
The machine doesn’t function
correctly
Fault in the remote control
electronics
Display
Er04
Er05
Er06
Er07
Er12
Display
Er30
Display
Er33
Display
Er35
Display
Er36
Display
Display
Display
Er40
Er41
Er80
Display
Er81
Er82
Er83
Er84
Er85
Er86
Er87
Er88
Er91
Display
Display
Display
– Check plug connectors and cable
– Replace the remote control unit
– Return remote control and
power unit to Hilti Service
– Replace the remote control
– Return the remote control to
Hilti Service
Machine cannot be switched
on
Break in the connection between – Check the control cable and
the power unit and the saw head plug connections
– Return the saw head, control cable
and power unit to Hilti Service
The machine has switched
The slip clutch has been
– Observe the application guidelines
itself off
activated as a result of how the – Return the saw head to Hilti
saw is being used
Service
The machine has switched
Saw used incorrectly - overload – Observe the application guideitself off
Saw blade stuck
lines
Short circuit
– Return the saw head, cable and
power unit to Hilti Service
The machine has switched
Saw used incorrectly
– Observe the application guidelines
itself off
Excessive lateral friction
– Return the power unit to Hilti
Blade segments polished
Service
Saw blade cannot rotate
Saw blade stuck
– Release the blade / restart
– Return the power unit to Hilti
Service
The machine has switched itself off Electric supply voltage too high – Check the electric supply
The machine has switched itself off Electric supply voltage too low – Check the electric supply
The machine doesn’t function Electronic fault in the power unit – Return the power unit to Hilti
correctly
Service
The machine doesn’t function Electronic fault in the power unit – Return the power unit to Hilti
Service
The machine doesn’t function Electronic fault in the power unit – Return the power unit to Hilti
Service
Machine cannot be switched
Contactor K1 or K2 in the
– Return the power unit to Hilti
on
power unity is faulty
Service
The machine doesn’t function
Safety loop for emergency stop – Replace the remote control
is faulty
– Return power unit to Hilti Service
10.2 Causes of faults with no error code and how they can be remedied
Description of fault
Blade wanders off course
Low sawing performance
Possible cause
Inadequate blade tension
Saw blade segments have lost cutting power
No guide cut made or guide cut not straight
Play at the guide rollers
Rail not securely fastened
Rail distorts (twists)
Unsuitable saw blade specification
Depth of cut too high
Power setting too low
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Recommended measures to remedy the fault
Check the tension / replace the blade
Check the specification / replace the blade
Observe instructions and guide values
Check the play / replace the rollers or rail
Check and improve the fastenings
Install additional rail supports
Check the specification / change to other
specification if possible
Check depth of cut / reduce if possible
Check the setting / increase if possible
Troubleshooting / Disposal
The machine is not receiving enough current
Drop in performance due to wandering off course
Drop in performance due to high reinforcement
content
Saw blade speed too high or too low
Check the setting / increase if possible
See "Blade wanders off course”
Check the reinforcement content / change
position of cut if possible
Check the speed / increase or reduce if
possible
10.3 Repairs
CAUTION
■ The machine may be operated, serviced and repaired only by authorized personnel who have been trained by
Hilti. This personnel must be informed of any special hazards that may be encountered.
■ Repairs to electrical components may be carried out only by trained electrical specialists.
■ NEVER open the covers on the machine while on a construction site.
■ The capacitors in the power unit retain a voltage for approx. 2 minutes after disconnection from the electric
supply.
11. Disposal
11.1 Disposal of the machine
Return waste material for recycling
■
■
Machine and packaging must be sorted for environment-friendly recycling.
Plastic components are marked to facilitate categorized recycling.
Only for EU countries
Disposal of electric tools together with other household waste is not permissible!
In observance of European Directive on waste electrical and electronic equipment and its implementation in accordance with national law, electric tools that have reached the end of their life must be
collected separately and returned to an environmentally compatible recycling facility.
11.2 Disposal of drilling and sawing slurry
■ With regard to environmental aspects, allowing drilling or sawing slurry to flow directly into rivers, lakes or the
sewerage system without suitable pre-treatment is problematical.
■ In addition to the following recommended pre-treatment procedures, the applicable national regulations must
be observed when disposing of drilling or sawing slurry. Ask the local authorities concerned for further information.
We recommend the following pre-treatment
■ Collect the drilling and sawing slurry (e.g. using a suitable industrial vacuum cleaner).
■ The fine content of the drilling and sawing slurry should be separated from the water by allowing it to settle
(e.g. leave standing for some time or add a coagulation agent).
■ Solid material from the drilling and sawing slurry should be deposited at a construction waste
■ Water from the drilling and sawing slurry should be neutralized (e.g. by adding a large quantity of water or other
neutralization agents) before it is allowed to flow into the sewerage system.
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Manufacturer's warranty – tools / EC declaration of conformity (original)
12. 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.
13. EC declaration of conformity
(original)
Designation:
Type:
Year of design:
Serial number:
Electric wall saw
DS TS20-E 1.6
2004
from 1001 to 9999
We declare, on our sole responsibility, that this product
complies with the following directives and standards:
This warranty provides the free-of-charge repair or 2006/42/EC, 2004/108/EC, EN 60204-1, EN ISO 12100,
replacement of defective parts only over the entire lifes- 2011/65/EU.
pan of the tool. Parts requiring repair or replacement
as a result of normal wear and tear are not covered by This equipment complies with the applicable standard
provided that the short-circuit power SSC at the interthis warranty.
face point between the user’s supply and the public
Additional claims are excluded, unless stringent supply network is greater than or equal to 6.8 MVA. It
national rules prohibit such exclusion. In particular, is the responsibility of the installer or user of the equipHilti is not obligated for direct, indirect, incidental ment to ensure, by consultation with the supply netor consequential damages, losses or expenses in work operator if necessary, that the equipment is connecconnection with, or by reason of, the use of, or inabil- ted only to a supply with a short-circuit power SSC of
ity to use the tool for any purpose. Implied warranties greater than or equal to 6.8 MVA.
of merchantability or fitness for a particular purpose
are specifically excluded.
For repair or replacement, send tool or related parts Hilti Corporation,
immediately upon discovery of the defect to the address Feldkircherstrasse 100, FL-9494 Schaan
of the local Hilti marketing organization provided.
This constitutes Hilti's entire obligation with regard to
warranty and supersedes all prior or contemporaneous comments and oral or written agreements con- Paolo Luccini
cerning warranties.
Head of BA Quality and
Process Management
Business Area Electric
Tools & Accessories
02 / 2013
Johannes Wilfried Huber
Senior Vice President
Business Unit Diamond
02 / 2013
Technical documentation filed at:
Hilti Entwicklungsgesellschaft mbH
Zulassung Elektrowerkzeuge
Hiltistrasse 6
86916 Kaufering
Deutschland
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Hilti Corporation
Printed: 07.07.2013 | Doc-Nr: PUB / 5139344 / 000 / 00
2073825 / A2
2073825
Hilti = registered trademark of Hilti Corp., Schaan
W 4298 I 0413 I 1_en I 1
Printed in Liechtenstein © 2013
Right of technical and programme changes reserved S. E. & O.
*2073825*
LI-9494 Schaan
Tel.: +423 / 234 21 11
Fax: +423 / 234 29 65
www.hilti.com
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