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Wire saw technology
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CEDIMA WIRE SAW TECHNOLOGY
Today the sawing with diamond wires off ers 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 off er 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 eff ectively 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 off er you the appropriate wire for each material.
up and below: automatic wire saw CSA-1001 creating separation cuts
Compact dimensions at high wire storage capacityLight, modular aluminium construction Highest daily output by hydraulic feed control and automatic cutting force controlCentral wire guidance (in and out) with swivel rolls Due to large wire storage capacities no change of wire necessary in case of diff erent cutting surfacesShort set-up timesHigh 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
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!!ImportantWhile 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
fi xing of mini wire saw CSA-100 H for a horizontal cut directly to a concrete pier
CEDIMA WIRE SAW TECHNOLOGY
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.
automatic wire saw CSA-1001 H: vertical cut through a bridge cheek
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CSA-1001
CSA-100
AUTOMATIC WIRE SAWS
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
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.
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).
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OPERATING MODE OF WIRE STORAGE
min. wire lengthin the machine
max. wire lengthin the machine
max. available wire storage capacity
CSA-100110 storage rolls
6,5 m 20,5 m 14,0 m
CSA-100114 storage rolls
6,5 m 27,5 m 21,0 m
CSA-1008 storage rolls
4,0 m 10,5 m 6,5+1,5* m
cutting surface
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 sur-faces can be implemented without repositioning the machine or shortening the wire.
position of the packages of rolls in the wire storage compartment with diff erent cutting surfaces and identical wire length
* by displacing the machine on the guiding tube
CSA-1001 with10 storage rolls
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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 Hgearwheel 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 alterationshydraulic power packs with an output from 10 to 24 kW are applicableconnection by drop-free quick-couplings, sets of hoses with pressure reliefwire drive wheels made of aluminium with interchangeable rubber bandages
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hydraulic power pack HAG-12.20 with control panel for feed of wire saws and fully hydraulic wall saw WS-451 H
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 coolerremovable electric motor for easy transport
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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 DRIVES
Hydraulic power packs
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
hydraulic power pack HAG-12.10 with control panel HSP-12 for wire saws and
fully-hydraulic wall saw WS-451 H
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HSP-12
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
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 fl ow feedoil fl ow wire drive
set of hoses 3-parts
set of hoses 2-parts
HYDRAULIC DRIVES
set of hoses 2-parts
set of hoses 3-parts
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HIGH-FREQUENCY ELECTRIC DRIVES
electrique drive console with HFM-18.1 at CSA-1001 E high-frequency electric motor HFM-18.1 at CSA-100 E
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
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
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.
The modern high-frequency electric drives for CEDIMA automatic wire saws off er 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 consolewire drive wheels made of aluminium with exchangeable rubber bandages
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mini hydraulique power pack HAG-2 for feed
universal high-frequency controle HF-27.1and universal remote controle
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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
oil fl ow feed
operating current wire drive
connecting schemaCSA-1001 E and CSA-100 E
electric control line
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.
set of hoses 2-parts
HIGH-FREQUENCY ELECTRIC DRIVES
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MINI AUTOMATIC WIRE SAW CSA-100
position for horizontal cut
position for vertical cut
The CSA-100 automatic wire saw can be opera-ted 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.
CSA-100 E with foot MF-6000 for wall or ground mouting
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 kghigh output of up to 20 kWpatented protective technologyeither hydraulic drive (HM-19/23) or high-frequency electric drive HFM-18.1variable wire speed 0 - 27 m/s with high-frequncy electric driveautomatic feed for relieving the operatorextremely easy transport and mountinghigh-grade storage-rolls and guide pulleys made of aluminium with interchangeable rubber bandageswide range of accessories
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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
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
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
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* enlargement possible by extension of guiding tubes
circular saw CAZ-3200 cutting an opening into a concrete tube
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WIRE GUARD SET WITH WATER COLLECTION FUNCTION
In order to increase the safety for your operating staff CEDIMA has developed highly eff ective wire guard systems that will reduce considerably the risk of injury following a wire breakage (fl ying beads and whip-lashing diamond wire).
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 equipmentitem for operation with description
25 CSA-1001wire 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-100wire 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 holder27 all types CSA quick-mounting holder wire guard profi le for the operation with wire guiding devices
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DIAMOND WIRES
fi g. 2fi g. 1 fi g. 3
To guarantee the undisturbed function and the longest possible life of your CEDIMA diamond wire you are kindly requested to observe the following recommendations
Turning in the diamond wire before closingIn 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 wireFor 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 wireFor 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 dia-mond 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 eff ective working with CEDIMA diamond wires.
type application
orange 10,5 mm concrete with up to 3 % shares of reinforcement and soft to hard aggregates
blue 11,0 mm concrete with up to 3-8 % shares of reinforcement and hard to extremely hard aggregates
red 10,5 mm abrasive materials
black 8,8 mm fi nal cut in soft to hard materials with up to 6 % shares of reinforcement
black 10,5 mm steel, stainless steel, fi bre plastics, hard natural stones, glass, ceramics, special applications
black 8,8 mm fi nal cut in steel, stainless steel, fi bre plastics, hard naturals stones, glass, ceramics, special applications
Handling of diamond wires
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360°
56 mm
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2
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4
5
67
8
9
1011
12
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14
15
15
15
16
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18 19
20 21
22 23
25
26
27
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5
5
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WIRE SAW TECHNOLOGY ACCESSORIES
wire guard set(description of scope of delivery in chart on page 12)
end caps GEKA
wire guard profi lesclamping yoke
end caps
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WIRE SAW TECHNOLOGY ACCESSORIES
Wire drive wheels and storage rollsitem operation with description1 CSA-1001 wire drive wheel Ø 600 mm with interchangeable bandage2 CSA-1001 bandage for wire drive wheel Ø 600 mm3 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 description4 all CSA wire guide pulley Ø 270 mm with hard rubber contact surface and assembly tube5 CSA-1001 swivel roll Ø 270 mm with interchangeable bandage and mounting device CSA-1001- CSA-1001 bandage for swivel roll Ø 270 mm6 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 mm7 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 holder11 all CSA fl exible jet with GEKA-coupling12 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 description13 CSA-100 MF-6000, foot for mounting to wall and ground with mounting tube, 0-45° titable14 CSA-100 precision swivel foot with mounting tube, pivoting by 360° 15 all CSA mounting foot for fi xing the mounting tubes and immersion column16 all CSA mounting tube 1 m long16 all CSA mounting tube 2 m long17 all CSA T-mounting tube for fi xing of swivel rolls18 all CSA rigid scaff old coupling19 all CSA rotating scaff old coupling
Wire guard equipment
item description20 steel wire clamps for closing diamond wires 10,5 and 11 mm20 steel wire clamps for closing diamond wires of 8,8 mm21 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 joints23 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
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assembly of a wire saw for horizontal cuts (seen from an upper position)
EXAMPLES FOR WIRE SAWING OPERATIONS
Cutting a wall openingFor 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.
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 vertical cuts
The wire saw operating as an immersion sawIf 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 correspon-ding blind hole drillings.The wire „immerses“ into the material to be cut.
max. immersion depth 2500 mm
blind hole drilling Ø 250 mm
Wire sawing in narrow areasBy means of swivel rolls the diamond wire can be led to the cut through cramped areas of narrow passages.
immersion columns with prepared slurry removal
CEDIMA® Diamantwerkzeug- und Maschinenbaugesellschaft mbHLärchenweg 3 • 29227 Celle/DeutschlandTel. +49 (0)51 41 / 88 54 - 0 • Fax +49 (0)51 41 / 86 42 7Internet: www.cedima.com • E-Mail: [email protected]
