SET MAKINA TIGERFILL Manual

TIGERFILL
Maintenance and Instructions Manual

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WARNING
SET-A Makina
This manual contains important information on safety. Before carrying out any handling or use
operation consult this use and maintenance manual.
This manual contains copyright reserved information. All rights reserved.
Any form of reproduction, adaptation, or translation without the previous written consent of
SET-A Makina is forbidden.
SET-A Makina is not liable for direct or indirect damage to persons or objects due to the use of
this manual or machine in conditions different than those prescribed or which do not guarantee
the operator's safety.
All data contained in this manual are indicative and not binding, given that SET-A Makina
reserves the right to modem or vary its machines without any previous warning.
General Information
Manual content and use
Keep this manual in a dry and safe place for future reference, so that it is not ruined and is always
available for consultation.
This manual cannot replace the user's experience but it does supply all the information for correct
machine use.
If you need copies or up-dates, exclusively contact the SET-A Makina, which will supply indications on
the matter and solve any problems.

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CONTENTS
CONTENTS ............................................................................................................................................. 2
GENERAL NOTES ON DELIVERY.......................................................................................................... 3
Guarantee............................................................................................................................................ 3
Parts subject to wear are not covered by the guarantee...................................................................... 3
Modifications To The Machine ............................................................................................................. 3
Identification Of Spare Parts ................................................................................................................ 3
MACHINE DESCRIPTION....................................................................................................................... 4
SAFETY................................................................................................................................................... 5
General Information Concerning Safety............................................................................................... 5
Safety Prescriptions ............................................................................................................................. 5
HANDLING AND TRANSPORTATION.................................................................................................... 7
TRACK POSITIONING ............................................................................................................................ 8
MACHINE POSITIONING........................................................................................................................ 9
START-UP OPERATIONS..................................................................................................................... 10
WORKING OPERATION ....................................................................................................................... 12
SUGGESTIONS..................................................................................................................................... 14
Suggestions for correct starting operations........................................................................................ 15
DIAMOND WIRE JOINING .................................................................................................................... 16
MAINTENANCE..................................................................................................................................... 18
SETTING PARAMETERS OF PID DEVICE........................................................................................... 19
APPENDIX I - ELECTRICAL DIAGRAMS
APPENDIX II - PART LISTS

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GENERAL NOTES ON DELIVERY
On receipt of the machine, open the package and check that:
•The equipment is not damaged.
•In the case of transport damage, inform the forwarder and / or the transport insurance company
In a detailed way, immediately on delivery.
•The supply corresponds to the order specifications
If any pieces are missing, immediately inform the SET-A Makina within 8 days of receipt.
Guarantee
The machine is supplied and guaranteed to be free from fabrication faults or defective material for a
period of 1 year from the date on the transport document.
This guarantee, concerning faults and defects due to material, manufacturing and processing, is valid on
condition of reporting them within 8 days time after the relative identification.
Parts proved to be defective will be reaired or replaced, at the discretion of the SET-A Makina, on
condition that the said defect does not depend on failure to observe the use and maintenance
instructions, bad or unsuitable use of the equipment or on normal wear.
The parts to be replaced or repaired will be made available ex-our workshop.
The user shall sustain the shipment and transport costs, plus those for the labour, travel and board, if
the repair should necessitate the presence of one of our technicians.
Parts subject to wear are not covered by the guarantee.
Modifications To The Machine
SET-A MAKİNA reserves the right to make all necessary modifications to the machines it manufactures
without any prior notice.
Machine identification
The machine is identified by the number indicated on the card.
Identification Of Spare Parts
When requesting spare parts, always indicate the machine's serial number found on the test card and
the no. of the required part taken from the enclosed lists of spares.

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MACHINE DESCRIPTION
MOD. TIGERFILL SERIAL No. TK__________________
Diamond Wire Saw Machine called TIGERFILL which is equipped with electric engine at 75 Horse
Power; gives opportunity to work with a diameter of 800 mm. Pulley with 42 m/sec. Speed and with a
diameter of 1000 mm pulley 52 m/sec.
Movement speed on the rail is being controlled with a special electronic card according to the values
selected before concerned with the cutting intensity for fixing the tension on the wire and for stopping
the rotation of the pulley and movement of the machine incase of any malfunction or wire rupture.
Auxiliary engine with 1,5 Horse Power helps the machine to change position fast over the rail.
Turning of main pulley with 360° and 600 mm right – left movement is obtained mechanically.
2 rails with 3 meters length is given with the machine.
Upon request the machine can be supplied with:
•A special instrument that increases the initial speed of the wire on the pulley slowly. Through
machine will use less energy from the main electric welding.
•Special equipment which helps the First movement of the diamond wire and prevents it from
bending much, until the cutting; can be used all horizontal and vertical and has a pulley with a
diameter of 400 mm. (for upper uses).
•Special equipment same with the mentioned above and which can be positioned to down.
•HAND PRESS, special press which is positioned at the inside of the handle with its hydraulic
pomp for adding wire.
•Scissors fort he diamond wire.

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SAFETY
General Information Concerning Safety
In particular, measures designed to prevent risks to operators were adopted during the design and
construction phases.
The complete documentation of the safety measures adopted is contained in the technical dossier
deposited at the offices of the SET-A Makina.
For some risks it was not possible to find solutions at the design level. In these cases, this manual
indicates the safety prescriptions to adopt to operate in the safest way.
WARNING: SET-A Makina recommends complying with the instructions, procedures and
recommendations of this manual, to adopt all precautions suggest by the technique and to
comply with the accident prevention regulations in force.
Safety Prescriptions
•The installation, maintenance, and use of the machine is reserved to specialised staff.
•Before performing any cleaning or maintenance intervention, check that the power supply is
disconnected.
•Do not remove the fixed protections of the machine protecting the mobile elements.
•Do not put your hands in the pairs where there is a danger of being crushed or trapped.
•The operator should stay by the control group in the most distant and protected position.
•When working and performing control operations the operator must always position himself
behind the control group.
•When the machine or its parts are handled it must idle and the power supply must be
disconnected. This must be performed by specialized staff with the appropriate tools.
•If it is necessary to replace machine components, exclusively use original spare parts.

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Before utilization:
•Verify that all the bolts of the machine are adequately screwed;
•Verify the absence of aerial electrical lines which can interferer with the machine operating
range;
•Check the tracks and operating areas preparing all bracing structures;
•Efficiently stabilize the machine;
•Verify the efficiency of the blocking systems and ground machine clamping;
•Signal the operating area exposed to high noise levels;
•Limit the area around the machine to avoid entrance of unauthorized persons.
During utilization:
•Report immediately any inappropriate functioning or dangerous situations;
•The operator's position needs to be such as not to be in contact with the parts in movement;
•Do not intervene on mobile parts during the functioning of the machine;
•Do not get distracted.
After utilization:
•remove the air supply to the machine
•correctly position the machine without leaving the tool suspended;
•stop the translation carriage;
•carry out the review and maintenance operations needed to reuse the machine with the power
supply disconnected;
•in the maintenance operations comply with the indications of this manual.
The operator should wear: accident prevention shoes
•protection helmet
•protection glasses
•gloves
•auricular earphones
•it is suggested to wear padded clothes
WARNING: SET-A Makine will not be responsible or liable for any eventual damege to persons or things
due to not following the safety norms and suggestions enclosed in the booklets which are supplied.
WARNING: during cutting phase, place control
panel in a safe spot as far as possible away from
the machine and place protection so that the
operator does not incur in any risk if the diamond
wire breaks. Do not pass by, stop or do any type
of work in the area of the diamond wire; this
distance varies depending on the length of the
wire.

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HANDLING AND TRANSPORTATION
WARNING: movement and transport of machine should be done by specialised or trained
persons. Weight kg 1700 (3748 Lbs)
ATTENTION: To lift the machine properly it is a must to utilize the lifting plate supplied by us.
•The fixed lifting eyebolt must by aligned to the alignment indicator (in this configuration the
motor-flywhell body is aligned to the machine’s body).
•Remove the safety lifting eyebolt from the lifting plate (supplyed by us).
•Insert the lifting plate into the fixed lifting eyebolt (as shown in figure).
•Replace the safety lifting eyebolt.
•Lift the machine by lock the lifting device into the lifting eyelet.

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TRACK POSITIONING
Looking at the face to be cut, align the track (A) in line with the hole (B) as shown. A tolerance (left or
right to the hole) of 10 cm, max 15 cm is allowed.
Place the track on small wooden beams in order to avoid any bending of the track. These have to be
placed properly aligned. It is not a must., but we suggest to level these (the 360° rotation of the flywheel
allows to adjust it properly).
The joining of the tracks is done with the hook (part. C e D –fig. 2bis).

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MACHINE POSITIONING

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START-UP OPERATIONS
WARNING: Check that the electric supply (voltage and frequency) is the same as showed on the
electrical board of the machine.
1. Insert the electric cable into the point A of the machine (fig. 3). Cable must has the right section
depending by the voltage and distance which exist between the feeding source and machine.
2. Plug in the cable which connects the control panel (fig. 5).
3. Turn on main switch (C) on position 1.
At this point the machine is ready to work.

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CONTROL PANEL
1. Electric Lamp
2. Stop Lamp
3. Emergency Push Button
4. Flywheel Rotation (Clockwise)
5. Flywheel Rotation (Counter Clockwise)
6. Flywheel Rotation Stop Button
7. Machine Backward Movement
8. Machine Forward Movement
9. Stop Push Button for Forwards / Backwards Machine
10. Manual / Automatic Switch
11. Machine Backward Manual Speed Control
12. Main Engine Ampere Indıcator
13. Left / Right Rotation of Flywheel Block (360°)
14. Left / Right Translation of Flywheel Block
Warning: in case of an emergency situation press the button number 3.

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WORKING OPERATION
During the cutting process of the machine for using correctly with the control panel;
•Control if the number 2 emergency stop button is open or not (off condition).
•Control if the light is on at the number 1 lamp.
•Put the diamond wire over pulley (See pages 12-13 for the wire adding operations).
•Adjust the rotating Wheel which is placed near by the machine (A Point Figure 5) with the
section which the pulley of it will be done, by rotating to be at the same bent. You can rotate
through all two directions at 360°. By placing the same rotating Wheel to the B Point, you can
adjust it as fitting to the same level with the section that its pulley will be done.

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When the main engine is closed, you can adjust the tension of the diamond wire by moving the machine
on the rail forward and backward with the buttons 6 and 7. For stopping the machine take your hand
from button.
Rotation direction of the pulley can be controlled with the button number 3 (clockwise) and with the
button number 4 (counter clockwise).
For operating the machine firstly switch the number 9 key to manual position. Now, you can operate the
pulley by selecting its rotation direction. Then, you can start the reverse walking of the machine by
switching the number 6 button. You can adjust the adequate speed with the number 11 potentiometer.
You can fix the reverse walking speed with the number 10 potentiometer by switching the number 9 key
to automatic position.
Number 10 potentiometer firstly must be at “0”, than it must be increased till finding the right speed.
Walking of the machine at this point must be controlled with the number 12 ampere indicator
automatically (At a constant speed).
For stopping the machine at automatic walking speed, bring the number 10 potentiometer to “0” and by
switching the number 8 button, stop the reverse walking.
Before stopping the rotation of the pulley, let the wire to turn for 5-10 seconds idle. Thus, wire will open
a place for itself on the rock and will not be pressed during the operation.
Warning: If the wire break off or the tension on the wire is excessively high while working at
automatic mode, machine will stop automatically. (over 95 Amp. or below 40 Amp.)
Warning: If the machine will not be use for along time, wire must not be tense.

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SUGGESTIONS
A. At starting phase the wire has to be lose;
B. Once starter the wire has to be tensioned so that there is a slight are
from the small pulley up to where the wire comes out of the hole drilled.
It is preferable that the direction of rotation is as per fig. 6 so that the
water can be poured from above and the wire can have a constant flow
over itself and the water be brought towards the top.
At the start-up phase the wire must not be tensioned –Fig. 6 (A).
After the machine has been starter up, the wire has to be slightly
tensioned (B) as this point the wire is cutting the “rough” angles (E) – (D).
The small pulleys (C) have to be completely closet (as per drawing) in
order to have a maximum of surface contact of the wire on the flywheel
itself.
At this point the speed suggested is approx. 20 cm/hour. It is extremely
important that this speed is not increased as it would stop the wire
turning on itself and so cause irregular consumption of the diamond beads (ovalize or wear on one
side).
WARNING: an excessive amount of water
poured down the hole could cause a high
stress due to the quantity of water to rise
and therefore can increase the
amperometer level and consequently stop
the machine.

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NOTE: the suggested speed for cutting on granites is from 19 to 26 m/sec. And from 30 to 40
m/sec on marble. It is always wise to work at low speeds while initiating cut.
Suggestions for correct starting operations
WARNING: if during the cut starting phase the wire is sliding on the flywheel rubber belt; few
seconds are enough for burning the rubber belt.
Avoid the wire sliding during the cut starting phase, in case of sliding, stop immediately the machine and
check :
•the wire tensioning
•the guide wheels position.
If the guide wheels are too open, the contact area between the wire and the rubber belt is not enough,
the following problems could happen:
- the wire is sliding on the flywheel rubber
- the rubber burns

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DIAMOND WIRE JOINING
Cut with appropriate shears the steel wire half way between the two pearls (see fig. 7)
Remove, on both ends of the wire, the plastic covering in order to leave free space for the joint (fig. 8)
To allow the wire to rotate, it is very important that in order not to damage the wire, before joining the
wire it should be wound approx. 1.5 times per meter of wire (example: with 40 m wire also 30 times in
the opposite direction); to help you in this operation we suggest to knot the two ends as per fig. 9.
After having wound the two ends “A”+”B”, holding them strongly in order not to let them unwind,
introduce the joint and press accordingly.

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Make sure that the two extreme ends of the wire are well prepared as previously described (fig. 8) and
that they fit perfectly inside the joint (fig. 10), this in order to not allow any water or mud to get between
joint and wire, as this would cause a breakage in the wire after only a few minutes of cutting.
With the special press “HANDI-PRESS”, make 4 cross-presses on the joint, the first two in one way,
then turn the joint 90° and do the other two as per fig. 11.
WARNING: it is extremely important to change joint every 8-10 hours of work. Cut the wire at
point “A” and “B” as indicated in fig. 12 and proceed joining as per fig. 7-8-9-10-11.
NOTE: check that the diamond wire works in the rubbered flywheel groove.

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MAINTENANCE
1. Keep the wall box and machine cover absolutely closed. At the end of every workday, clean the
inside of the machine and inside of the Wall box by opening the covers. Do not use compressed
air while cleaning the Wall box.
2. Keep the control panel’s cover closed. After disconnecting the connection cable from the
machine for transportation, do not throw the plug on the floor, for preventing the entry of dust,
isolate eith a nylon bag. Clean the plugs once or twice a week.
3. Everyday; by usıng the grease nipples at shaft, reducer and bearing accessories which moves
the pulley mechanism, grease them.
4. Once a month; grease the reducer which is at the engine walking system.
5. At the end of every workday; clean the shaft and worm screw which moves the head of the
pulley mechanism with compressed air and cloth.
6. Before starting to work; control the pulley rubber. Rubber which became thin and deformed,
causes damage because of the contact of diamond wire to the pulley. Change the damaged
rubber.

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SETTING PARAMETERS OF PID DEVICE
1) Push the “ ►” (ENTER) button until the “SET” appears on the screen.
2) Push the “ESC” (Escape) button until the “SET1” appears on the screen, then push and release “
►” (Enter) button.
3) Push “ ►” button when “SETL” value appears on the screen, push “ ►” button again and after
that the “030” value can be seen on the screen.
SETL: a parameter for the machine to stop if the wire breaks off. This parameter needs to be set
related to the current when the machine is running in idle. (for example if the machine’s idle current
draw is 35 ampere, the SETL parameter needs to be set to 37 ampere).
4) When the SETL screen is on, push the “ESC” button.
5) “SETLt” screen will apeear. (SETLt [seconds]: the time for stopping the machine if the wire breaks
off)
6) Push the “ ►” button for couple of seconds and change the parameter. (for example “02.0”)
7) Push the “ESC” button. And “SETH” screen will be open.
8) SETH parameter has to be set relating to the motor’s maximum working current. If the motor has a
working current of 125 ampere, the SETH parameter needs to be 110 ampere. The SETH
parameter has to be 10% less then the current draw of electric motor.
9) Push the “ESC“ button and “SETHt” screen will appear. (SETHt : the parameter which stops the
machine if it has difficulty on running)
10) Push the “ ►” Enter button and change the parameter shown on the screen to “11.0”.
11) Push the “ESC” button until the “CONF” screen appears and push “ ►” button.
12) “FILLET” screen will appear.
13) Push “ ►” button and set the parameter to “93” and push “ ►” couple of seconds until it saves the
parameter and release.