Wire saw technology

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Wire saw technology

Wire saw technology


CEDIMA WIRE SAW TECHNOLOGY

up and below: automatic wire saw CSA-1001 creating separation cuts

Today the sawing with diamond wires offers almost unlimited possibilities to

professional users. Thanks to modern wire saw technology it is no problem any

longer to cut conrete, reinforced conrete of masonry which before was a task of

high complexity. By using swivel rolls and wire guide pulleys cuts in any direction

and of any kind become possible. Also in places diffi cult to access and in extremely

narrow areas where a wall saw cannot be used the wire saw technology can be

applied without any problems.

CEDIMA disposes of many years of experience in the development and the

construction of powerful wire sawing machines that meet all requirements on job

sites. From the automatic wire saw CSA-100 for small to medium surfaces to the

CSA-1001 with a wire storage capacity of 21 m for large surfaces we offer you the

suitable machine for each sawing application.

All the CEDIMA automatic wire saws are equipped with an automatic cutting

force control that provides constantly the correct wire tension while cutting. This

ensures a permanent maximum output at the lowest possible tool costs. Due to the

extensively automated cutting operation the operator‘s job is effectively eased and

possible mistakes due to mishandling are widely avoided.

According to your requirements and preferences hydraulic wire drives or drives with

modern, powerful high-frequency electric motors are available.

The construction of the automatic wire saws allows looping of a maximum wire

length around the drive wheel, this involving a high power transmission.

The modular design of the machines and the wide range of accessories enable you

to compose your wire sawing equipment according to your special requirements.

We shall be glad to offer you the appropriate wire for each material.









Compact dimensions at high wire storage capacity

Light, modular aluminium construction

Highest daily output by hydraulic feed control and automatic cutting force

control

Central wire guidance (in and out) with swivel rolls

Due to large wire storage capacities no change of wire necessary in case of

different cutting surfaces

Short set-up times

High fl exibility due to hydraulic of high-frequency electric drives

Completely encapsulated systems for maximum operator‘s safety

(wire guard system)

Wide range of accessories


2


CEDIMA WIRE SAW TECHNOLOGY

! Important

While using wire saw technology the safety of your operators as well as the

CE-conformity of the equipment can only be guaranteed if the machines are

operated according to the attached operating manuals.

automatic wire saw CSA-1001: horizontal cut of a bridge pier

automatic wire saw CSA-1001 H: vertical cut through a bridge cheek

fi xing of mini wire saw CSA-100 H for a horizontal cut directly to a concrete pier

Mounted on a special platform the CSA-1001 H separates an industrial chimney by horizontal cuts.

Including platform the separated piece is lifted by a crane.

3


AUTOMATIC WIRE SAWS

The wire storage compartments of the CEDIMA automatic wire saws have been designed as a

light aluminium construction and despite the low weight a high resilience is achieved.

The connections for the feed are equipped with quick couplings.

A high-solid, durable hydraulic cylinder in the interior keeps a constant tenseness of the wire

and retracts the free wire as per requirement.

The drive can easily be converted from hydraulic to electric by changing the drive panel

(CSA-1001) or the drive motor (CSA-100).

CSA-1001

The wire storage rolls made of aluminium are equipped with a rubber bandage

for the wire guidance. In case of wear the bandage can be replaced without any

problems. Thus the costs for storage rolls are considerably reduced.

CSA-100

technical data CSA-1001 CSA-100

dimensions and weights of the automatic wire saws

transport dimensions L x W x H mm 1950 x 600 x 550 1050 x 300 x 460

weight of basic machine without drive kg 130 54

weight of hydraulic drive panel with drive wheel kg 50 -

weight of hydraulic motor HM-19 kg - 6,8

operational weight hydraulic without wire kg 180 60,8

weight of electric drive panel with drive wheel kg 55,5 -

weight of high-frequency electric motor HFM-18.1 with 10 m motor cable kg 19,5 19,5

operational weight electric without wire kg 205 73,5

required hydraulic connecting values

oil quantity for feed l/min 1 - 15 1 - 15

max. operating pressure of feed bar 100 100

4


OPERATING MODE OF WIRE STORAGE

CSA-1001 with10 storage rolls

The functionality of the wire storage is similar to a

chain-block. In the interior the diamond wire is laid in

an endless loop around 2 packages of rolls. The rear

package of rolls can be moved hydraulically.

For the starting position the 2 packages of rolls are

directly adjoined. The diamond wire has to be mounted

on at least 2 rolls of package. While cutting, the rear

package of rolls is moved backwards. This way, the wire

set free during the sawing process is pulled into the

machine.

When reaching the fi nal stop, the cutting operating is

interrupted by the operator, the rear package of rolls

is moved forward again and the wire set free is looped

around the remaining storage rolls. This procedure can

be repeated until all the storage rolls are lined with wire.

Due to this operating mode large cutting surfaces

can be implemented without repositioning

the machine or shortening the wire.

CSA-1001

10 storage rolls

CSA-1001

14 storage rolls

CSA-100

8 storage rolls

min. wire length

in the machine

position of the packages of rolls in the wire storage compartment

with different cutting surfaces and identical wire length

max. wire length

in the machine

max. available wire

storage capacity

6,5 m 20,5 m 14,0 m

6,5 m 27,5 m 21,0 m

4,0 m 10,5 m 6,5+1,5* m

* by displacing the machine on the guiding tube

cutting surface

5


HYDRAULIC DRIVES

Powerful hydraulic motors are available for the drive of CEDIMA automatic wire saws. Already existing hydraulic components, e.g. of the CEDIMA wall saw, can be used

without prior alterations.







powerful drive panels with axial piston motors (45 und 63 cm³) for CSA-1001 H

gearwheel motors HM-19 or HM-23 for CSA-100 H

available components of the CEDIMA wall saw technology, such as hydraulic power packs, control panels or hydraulic motor HM-23 (only for CSA-100 H) can be used

without prior alterations

hydraulic power packs with an output from 10 to 24 kW are applicable

connection by drop-free quick-couplings, sets of hoses with pressure relief

wire drive wheels made of aluminium with interchangeable rubber bandages

technical data of hydraulic drives CSA-1001 H CSA-100 H

max. output of hydraulic motors kW 24 20

oil quantity of hydraulic drive l/min 30 - 54 25 - 40

max. operating pressure of drive bar 250 250

Hydraulic power packs






triple gear pump for 3 oil circuits (HAG-324 and HAG-12.20)

tandem gear pump for 2 oil circuits (HAG-12.10)

control panel for feed of wire saws CSA-100 H and CSA-1001 H or

fully-hydraulic wall saw (HAG-324 and HAG-12.20)

water-oil cooler

removable electric motor for easy transport

hydraulic power pack HAG-12.10 with control panel HSP-12 for wire saws and

fully-hydraulic wall saw WS-451 H

hydraulic power pack HAG-12.20 with control panel for

feed of wire saws and fully hydraulic wall saw WS-451 H

type HAG-12.10 HAG-12.20 HAG-324

output electric motor S1/S6 15/20 kW 15/20 kW 18,5/24 kW

voltage/amperage 400 V/50 Hz/32 A 400 V/50 Hz/32 A 400 V/50 Hz/35 A

hydraulic pump tandem wheel gear triple wheel gear triple wheel gear

oil fl ow capacity operating circuit 30/44 l/min 30/44 l/min 40/54 l/min

oil fl ow capacity control circuit 14 l/min* 6 l/min 6 l/min

operating pressure 250 bar 250 bar 250 bar

solenoid valve yes no yes

hydraulic control panel - yes accessory

oil quantity in tank 11 l 11 l 11 l

weight of electric motor 62 kg 62 kg 71 kg

total weight 130 kg 130 kg 137 kg

dimensions L/W/H 640/560/970 mm 640/560/970 mm 640/560/1000 mm

* using control circuit: in operating circuit 30l/min available

6


HYDRAULIC DRIVES

set of hoses 3-parts

Examples for connection

• CSA-1001 H + HAG-12.10 + hydraulic control panel HSP-12

• CSA-100 H + HAG-12.20 with additional control panel for feed

oil flow wire drive

oil flow feed

set of hoses 3-parts

set of hoses 2-parts

HSP-12

set of hoses 2-parts

Necessary components for the operation of CSA-1001 H CSA-100 H

CSA-1001 automatic wire saw with 2 swivel rolls and 10 storage rolls, without wire drive unit and wire drive wheel X

- - - wire drive unit for CSA-1001 H with hydraulic motor (45 oder 63 cm³) and drive wheel guard X

- - - wire drive wheel Ø 600 mm with interchangeable bandage X

CSA-100 automatic wire saw with 2 mini swivel rolls, 8 storage rolls and ground mouting foot, without wire drive motor X

HM-19/23 hydraulic motor (19 or 23 cm³) for drive of drive wheel X

- - - set of hoses 3-parts, 10 m long, for drive of drive wheel X X

for the operation of HAG-12.10 and control panel HSP-12

HAG-12.10 hydraulic power pack; 15 kW/400 V; 30/44 l/min; 250 bar X X

HSP-12 hydraulic control panel X X

- - - set of hoses 2-parts, 10 m long, for feed at drilling and wire sawing X X

for the operation of HAG-324 or HAG-12.20 with control panel for feed

HAG-324 hydraulic power pack; 18,5 kW/400 V; 40/54 l/min; 250 bar X

HAG-12.20 hydraulic power pack; 15 kW/400 V; 30/44 l/min; 250 bar X X

- - - hydraulic control panel HAG-324 for feed control X X

- - - set of hoses 2-parts, 10 m long, for feed at wire sawing with HAG-324 and HAG-12.20 X X

7


HIGH-FREQUENCY ELECTRIC DRIVES

The modern high-frequency electric drives for CEDIMA automatic wire saws offer an almost loss-free availability of output at the wire drive wheel. The wire speed can be

regulated infi nitely by means of the universal control box (also available as remote control).

• high-frequency electric motor HFM-18.1 with 18 kW output, connection: CSA-100 E directly, CSA-1001 E by special motor console

• wire drive wheels made of aluminium with exchangeable rubber bandages

electrique drive console with HFM-18.1 at CSA-1001 E

high-frequency electric motor HFM-18.1 at CSA-100 E

The high-frequency drives are controlled by means of the powerful universal control HF-27.1. With its peak

capacity of 27 kW the control performs a future-proof investment in the modern high-frequency technology. The

automatic machine identifi cation assures that the required commands are loaded directly on connection. All the

functions can be carried out by means of a light universal control box.

mini hydraulique power pack HAG-2 for feed

technical data

HAG-2

motor output S1 kW 0,25

voltage/amperage V/Hz/A 230/50/16

oil fl ow capacity l/min 1,2

operating pressure bar 95

oil quantity in tank l 1,2

total weight with oil kg 23,5

dimensions L/W/H mm 415/235/340

universal high-frequency controle HF-27.1and universal remote controle

technical data

HF-27.1

output S1/S6 kW 18,5/27

frequency range Hz 0 – 310

dimensions LxWxH mm 590/290/375

weight kg 27

8


HIGH-FREQUENCY ELECTRIC DRIVES

The CEDIMA high-frequency electric components are characterised by their versatile applicability at drilling or sawing concrete. With the help of the high-frequency universal

control HF-27.1 you can, already today, drive all the electrical automatic wire saws as well as the wall saws WS-290 and WS-450 EE.

The high-frequency electric motor HFM-18.1 is suited for powering wire saws as well as wall saw WS-451 EE.

The mini hydraulic power pack HAG-2, providing the wire feed when wire sawing, serves as automatic drill feed when diamond drilling technology is used.

connecting schema

CSA-1001 E and CSA-100 E

set of hoses 2-parts

operating current wire drive

oil flow feed

electric control line

necessary components for the operation of CSA-1001 E CSA-100 E

CSA-1001 automatic wire saw with 2 swivel rolls and 10 storage rolls, without wire drive unit and wire drive wheel X

- - - wire drive unit with high-frequency electric motor HFM.18.1 with drive wheel guard (without motor) X

- - - wire drive wheel Ø 600 mm with interchangeable bandage X

CSA-100 automatic wire saw with 2 mini swivel rolls, 8 storage rolls and ground mouting foot, without wire drive motor X

HFM-18.1 high-frequency electric motor, 18.1 kW, with 10 m cable X X

HAG-2 power pack for hydraulic feed; 230 V/50 Hz, 1,2 l/min, 0 - 95 bar X X

HF-27.1 high-frequency universal control, 27 kW, 400 V/32 A X X

- - - set of hoses 2-parts, 10 m long, for feed at drilling and wire sawing X X

- - - connecting cable HF-27.1 to HAG-2 X X

- - - universal control box with 10 m cable X X

- - - universal remote control box (alternatively to universal control box) X X

9


MINI AUTOMATIC WIRE SAW CSA-100

The mini automatic wire saw CSA-100 has especially been developed for medium and small separating cuts

with diamond wires. Despite the considerably compact dimensions the machine allows a wire storage of up to

6,5 m. There are additional 1,5 m wire by displacing the machine on the mounting tube.










consequent implementation of the one-man-principle by modular construction,

no single component weighs more than 21 kg

high output of up to 20 kW

patented protective technology

either hydraulic drive (HM-19/23) or high-frequency electric drive HFM-18.1

variable wire speed 0 - 27 m/s with high-frequncy electric drive

automatic feed for relieving the operator

extremely easy transport and mounting

high-grade storage-rolls and guide pulleys made of aluminium with interchangeable rubber bandages

wide range of accessories

CSA-100 E with foot

MF-6000 for wall or ground

mouting

position for vertical cut

position for horizontal cut

The CSA-100 automatic wire saw can be operated

with a precision swivel foot that allows the

machine to turn steplessly around its longitudinal

axis.

By this it becomes possible with only two dowel

fi xings to cut an opening without additional wire

guide pulleys.

The operation of the machine is exclusively permitted with mounted

wire guard.

10


CIRCULAR SAW CAZ-3200

Circular wire saw CAZ-3200 for cutting openings in walls or ceilings.

• for cutting large-sized, circular openings in concrete of masonry of diametres

between 0,52 and 3,2* m at a maximum wall thickness of 1,1* m.

• fl ush cutting possible at a diametre of at least Ø 1,3 m

• short set-up times and easy handling

• automatic cutting force control

• wire tensioning roll to compensate varying wire loads

• drive by hydraulic power packs of 10 - 30 kW output, e.g. HAG-12.10

* enlargement possible by extension of guiding tubes

Operational method of the circular saw CAZ-3200

A core drilling of 120 mm diametre is created in the centre of the circle to be cut.

This hole serves to mount the circular saw and to guide the diamond wire on the

opposite side. Wire guide pulleys lead the wire to the cut.

A hydraulic motor drives the endlessly looped diamond wire. Driven hydraulically,

the circular saw revolves the central point and a circular opening is being cut.

circular saw CAZ-3200 cutting an opening into a concrete tube

technical data of circular saw CAZ-3200

dimensions and weights

weight of central drive unit kg 42

total weight kg 108

required hydraulic connecting values

required oil quantity for hydraulic drive l/min 30

max. operating pressure of hydraulic drive bar 250

required oil quantity for feed l/min 1 - 15

operating pressure of feed bar 100

11


WIRE GUARD SET WITH WATER COLLECTION FUNCTION

In order to increase the safety for your operating staff CEDIMA has developed highly effective wire guard systems that will reduce considerably the risk of injury following a

wire breakage (fl ying beads and whip-lashing diamond wire).

3

1

2

2

3

CSA-100 (1) with mounted wire guard system (2) and wire guiding devices (3)

The CEDIMA wire guard systems is a simple possibility to cover completely the freely running wire parts that

represent potential danger.

U-profi les made of aluminium are put on the wire and fi xed with rubbers. These profi les are available in

various lengths. On both ends the wire guard profi les are fi tted to the swivel rolls that continue to rotate

unimpaired. The closed back side of the profi le is mounted in the direction the wire could possibly swing out.

The wire guard profi les are available for all CEDIMA automatic wire saws. For the CSA-100 the system is

equipped with an additional water collection function. By means of the sealing elements and end caps that

belong to the set most of the slurry can be collected and suctioned.

long wire guiding device with lang with mini swivel roll and guide pulley

wire guard profi le - aluminium- with end cap,

suction connection and end cap GEKA

holder for wire guard profi le for

direct mounting to the wall

quick-mounting holder for wire guard

profi le for operation with wire guiding

device

Wire guard equipment

item for operation with description

25 CSA-1001

wire guard set consisting of: wire guard profi le made of aluminium (5 x 2,3 m; 4 x 1,15 m; 3 x 0,76 m),

4 end caps made of aluminium for wire guard profi le, 6 clamping yokes for mounting the wire guard profi les directly to the wall, fi xing material

25 CSA-100

wire guard and water collecting set consisting of: wire guard profi le made of aluminium (1 x 3 m; 1 x 2,5 m; 1 x 2 m; 1 x 1,5 m; 1 x 1 m; 2 x 0,75 m; 1 x 0,5

m),2 end caps PUR for wire guard profi le, 3 x end caps for GEKA-connection, 1 x suction connection GEKA, 6 clamping yokes for mounting the wire guard profi les

directly to the wall, fi xing/sealing material

26 CSA-1001 retrofi tting set for mounting wire guard profi le to swivel rolls Ø 270 mm without holder

27 all types CSA quick-mounting holder wire guard profi le for the operation with wire guiding devices

12


DIAMOND WIRES

type

orange 10,5 mm

blue 11,0 mm

red 10,5 mm

black 8,8 mm

black 10,5 mm

black 8,8 mm

application

concrete with up to 3 % shares of reinforcement and soft to hard aggregates

concrete with up to 3-8 % shares of reinforcement and hard to extremely hard aggregates

abrasive materials

fi nal cut in soft to hard materials with up to 6 % shares of reinforcement

steel, stainless steel, fi bre plastics, hard natural stones, glass, ceramics, special applications

fi nal cut in steel, stainless steel, fi bre plastics, hard naturals stones, glass, ceramics, special applications

Handling of diamond wires

To guarantee the undisturbed function and the longest possible life of your CEDIMA diamond wire you are kindly

requested to observe the following recommendations

fi g. 1 fi g. 2

fi g. 3

Turning in the diamond wire before closing

In order to prevent a one-sided wear of the wire it has to be turned in around its longitudinal axis before being closed. This produces a tension that makes the wire turning

while cutting, thus an even wear of the diamond wire is obtained.

After having laid on the diamond wire in the storage compartment and around the workpiece to be cut, take the end of the wire coming out of the machine and form a loop

(fi g. 1). Now continue to turn the wire in its twisting direction (fi g. 2).

As guiding value we recommend 1 to 1,5 complete turns per metre diamond wire, i.e. 20 to 30 turns for 20 m wire length.

Closing the diamond wire

For closing the diamond wire remove the rubber coating at both ends as well as the spring very close to the diamond bead as shown in fi g.2. Insert the steel core in both sides

of the steel wire clamp. Make sure that the clamp is not positioned too close to the diamond beads as shown in fi g. 3 below. To guarantee the best possible fl exibility of the

wire, 2-3mm steel core should be left free on both sides (fi g. 3 centre). Now press the steel wire clamp with an appropriate hydraulic jointing clamp (available at CEDIMA),

thus creating a tensile strength connection (fi g. 3 above). When using articulated joints please act accordingly. Using screw-type connectors, make sure that the sleeve of the

connector is mounted at the towing side of the diamond wire. The running direction of the diamond wire is indicated by arrows on the rubber coating.

Opening the diamond wire / repair after a wire

For opening the diamond wire and for the repair after a wire breakage please proceed as described in the „Product recommendations for handling and repair of CEDIMA diamond

wires“, attached to each wire delivery. Here you will also fi nd safety recommendations for the use. Please observe the safety recommendations for a safe and effective

working with CEDIMA diamond wires.

13


WIRE SAW TECHNOLOGY ACCESSORIES

56 mm

8

13

27

7

6

1

4

360°

2

16

14

5

15

5

3

5

17

10

26

12

18 19

11

15

24

5

20 21

9

22 23

15

wire guard set

(description of scope of delivery in chart on page 12)

25

clamping yoke

wire guard profi les

end caps GEKA

end caps

14


WIRE SAW TECHNOLOGY ACCESSORIES

Wire drive wheels and storage rolls

item operation with description

1 CSA-1001 wire drive wheel Ø 600 mm with interchangeable bandage

2 CSA-1001 bandage for wire drive wheel Ø 600 mm

3 CSA-1001 additional rolls Ø 300 mm for increasing wire storage capacity

- CSA-100/1001 CSA-1001: bandage for storage roll Ø 300 mm / CSA-100: bandage for wire drive wheel

Wire guidance and water supply to the wire

item operation with description

4 all CSA wire guide pulley Ø 270 mm with hard rubber contact surface and assembly tube

5 CSA-1001 swivel roll Ø 270 mm with interchangeable bandage and mounting device CSA-1001

- CSA-1001 bandage for swivel roll Ø 270 mm

6 CSA-100 mini swivel roll Ø 200 mm with interchangeable hard rubber bandage and mounting device for wire guard set CSA-100

- CSA-100 bandage for mini swivel roll Ø 200 mm

7 all CSA wire guiding device short with wire guide pulley (ca. 300 mm)

8 all CSA wire guidance device long with mini swivel roll and guide roll (ca. 900 mm)

9 all CSA immersion column with immersion roll Ø 230 mm for cuts in blind holeØ 250 mm, length 2,5 m, with suction hose, without swivel roll and mounting foot

10 all CSA wire guide pulley for fl ush cutting Ø 300 mm, with holder

11 all CSA fl exible jet with GEKA-coupling

12 all CSA water lance with GEKA-coupling

- all CSA throttle-check-valve - starting aid CSA-1001 and CSA-100 (supports starting the wire under complicated conditions)

Mounting accessories

item for operation with description

13 CSA-100 MF-6000, foot for mounting to wall and ground with mounting tube, 0-45° titable

14 CSA-100 precision swivel foot with mounting tube, pivoting by 360°

15 all CSA mounting foot for fi xing the mounting tubes and immersion column

16 all CSA mounting tube 1 m long

16 all CSA mounting tube 2 m long

17 all CSA T-mounting tube for fi xing of swivel rolls

18 all CSA rigid scaffold coupling

19 all CSA rotating scaffold coupling

Wire guard equipment

item description

20 steel wire clamps for closing diamond wires 10,5 and 11 mm

20 steel wire clamps for closing diamond wires of 8,8 mm

21 articulated joints for closing and opening of diamond wires 10,5 and 11 mm

- spare pin for articulated joints

22 device for opening and closing of articulated joints

23 hydraulic jointing clamp with press chucks for closing diamond wires of 10,5 and 11 mm

- press chucks for closing of diamond wires of 8,8 mm

24 fi bre cutting discs for separating diamond wire

15


EXAMPLES FOR WIRE SAWING OPERATIONS

Cutting a wall opening

For making a rectangular opening four steps are necessary. The

wire is led through two prepared core drilling holes at the corners

of the area to be cut. Wire guide pulleys and swivel rolls lead the

diamond wire from the machine to the cut.

assembly of a wire saw for vertical cuts

For horizontal cuts the diamond wire can be guided on its

shortest way to a horizontal cutting position by means of parallel

positioned swivel rolls.

assembly of a wire saw for horizontal cuts

(seen from an upper position)

The wire saw operating as an immersion saw

If the diamond wire connot be led around the material to be cut

due to structural reasons the wire saw is operated with the help of

immersion columns. Two immersion rolls are placed into corresponding

blind hole drillings.

The wire „immerses“ into the material to be cut.

immersion columns with prepared slurry removal

max. immersion depth 2500 mm

blind hole drilling Ø 250 mm

Wire sawing in narrow areas

By means of swivel rolls the diamond wire can be led to the cut

through cramped areas of narrow passages.

CEDIMA ® Diamantwerkzeug- und Maschinenbaugesellschaft mbH

Lärchenweg 3 • 29227 Celle/Deutschland

Tel. +49 (0)51 41 / 88 54 - 0 • Fax +49 (0)51 41 / 86 42 7

Internet: www.cedima.com • E-Mail: info@cedima.com

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