SIRI ITALY 100 Operating instructions
WET CUTTING SAW
ITALY 100
OPERATING AND MAINTENANCE MANUAL
Italy 100 cutter Use and Maintenance Manual Ver. 1.1
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Contents
1 INTRODUCTION.................................................................................. 5
1.1 General ...............................................................................................5
1.2 General information on machine use........................................................6
1.3 General precautions regarding machine use..............................................6
1.4 Pictographs relating to operator qualification ............................................7
1.5 Pictographs relating to safety .................................................................8
2 MACHINE PRESENTATION .................................................................. 9
2.1 General ...............................................................................................9
2.2 General notes ....................................................................................10
2.3 Airborne noise emission.......................................................................10
2.4 Technical data....................................................................................10
2.5 Identification plates ............................................................................11
2.6 Type of discs usable ............................................................................ 12
3 SAFETY COMPONENTS AND RESIDUAL RISKS................................... 13
3.1 Mechanical safety devices ....................................................................13
3.1.1 Disc guard .........................................................................................13
3.2 Electrical safety devices....................................................................... 13
3.2.1 Magnetothermal switch........................................................................ 13
3.3 Residual risks.....................................................................................14
3.3.1 Risk of cuts........................................................................................14
3.3.2 Risk to the eyes..................................................................................14
3.3.3 Risk to hearing ...................................................................................14
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4 INSTRUCTIONS FOR USE AND MAINTENANCE .................................. 15
4.1 Introduction....................................................................................... 15
4.2 Permitted use..................................................................................... 15
4.3 Required personal protection devices.....................................................15
4.4 General warnings................................................................................ 15
4.5 Warnings on use................................................................................. 16
4.6 Warnings on machine maintenance .......................................................17
5 MACHINE INSTALLATION AND STARTUP .......................................... 19
5.1 Handling the machine..........................................................................19
5.2 Preparing the working area .................................................................. 19
5.3 Assembling the machine ......................................................................20
5.3.1 Material provided................................................................................ 20
5.3.2 Fitting the legs ................................................................................... 20
5.3.3 Releasing the carriage .........................................................................21
5.4 Connecting to the mains ......................................................................22
5.5 Filling the cooling water tank ................................................................ 22
5.6 Turning on the machine....................................................................... 23
5.6.1 On/off switch .....................................................................................23
5.6.2 Adjusting the water flow ...................................................................... 23
6 MACHINE USE................................................................................... 25
6.1 Basics for machine use ........................................................................ 25
6.2 Operation .......................................................................................... 25
6.2.1 Linear cut ..........................................................................................25
6.2.2 Diagonal cut ...................................................................................... 27
6.2.3 Angle cut........................................................................................... 28
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7 MACHINE MAINTENANCE AND SPARE PARTS.................................... 31
7.1 Warnings on machine maintenance .......................................................31
7.2 Periodic maintenance schedule ............................................................. 31
7.2.1 Daily maintenance ..............................................................................31
7.2.2 Weekly maintenance ...........................................................................32
7.2.3 Monthly maintenance ..........................................................................32
7.2.4 Half-yearly maintenance ......................................................................33
7.3 Scheduled maintenance summary table .................................................34
7.4 Troubleshooting..................................................................................34
7.4.1 Insufficient cooling water flow .............................................................. 34
7.4.2 Difficult carriage sliding .......................................................................34
7.4.3 Poor cutting performance..................................................................... 35
7.5 Placing the cutter out of service ............................................................35
7.6 Exploded drawings and list of spare parts...............................................36
DECLARATION OF CONFORMITY .................................................................. 39
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1 Introduction
IMPORTANT
BEFORE CARRYING OUT ANY OPERATIONS ON THE MACHINES, THE TRAINED
OPERATORS AND TECHNICIANS MUST CAREFULLY READ THE INSTRUCTIONS
CONTAINED IN THIS MANUAL (AND IN THE ATTACHED DOCUMENTS) AND
FOLLOW THEM WHILE CARRYING OUT THE VARIOUS OPERATIONS.
IF YOU HAVE ANY DOUBTS CONCERNING THE INTERPRETATION OF THESE
INSTRUCTIONS, CALL OUR TECHNICAL SERVICE FOR HELP.
1.1 GENERAL
This instruction manual refers to:
MACHINE TYPE: ITALY 100
SERIES AND TYPE: ........
YEAR OF MANUFACTURE: 20....
This manual contains the main information on storage, transport, installation, use,
supervision and maintenance of the machine. This manual forms an integral part of the
machine and must be kept throughout its lifetime for future consultation.
If your copy of the manual becomes unreadable, ask the manufacturer for a new copy:
SIRI SRL
Via R. Dalla Costa 44/46
41122 MODENA (ITALY)
Tel. 059/313191 - Fax 059/311362
MEMBER OF THE EXPO CONSORTIUM - MODENA
specifying the machine type and the serial or order number printed on the machine
identification plate.
THE OFFICIAL LANGUAGE CHOSEN BY THE MANUFACTURER IS ITALIAN.
The manufacturer shall not be held liable for translations into other languages which do
not match the source language and meaning.
This manual reflects the machine status at the time it is supplied and cannot be
considered inadequate if updated following new experience. SIRI reserves the right to
update the manuals without any obligation to update earlier versions or to informusers
of machines supplied previously. All proposed updates to the manual and/or the
machines shall be considered provided for information purposes only.
Should you need any information on machine updates, SIRI Customer Service will
gladly help you.
SIRI is relieved of all responsibility for improper use of the machine, for example:
a) Use by untrained staff
b) Use not in compliance with the regulations in force
c) Incorrect installation
d) Power supply defects
e) Poor maintenance
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f) Unauthorised modifications or operations
g) Use of non-genuine spare parts or not specifically for the model
h) Total or partial inobservance of the instructions
i) Exceptional events.
1.2 GENERAL INFORMATION ON MACHINE USE
The aim of this manual is to provide the user with general knowledge of the machine as
well as maintenance instructions to ensure its good functioning.
Before starting any installation, maintenance and repair operations, carefully read this
manual. It contains all the necessary information for proper use of the machine and to
prevent injury. ·
The frequency of the checking and maintenance operations described in this manual is
the minimum necessary to ensure efficiency, safety and a long life of the machine in
normal operating conditions. Nonetheless, you should constantly monitor the machine
and promptly take action in the event of faults. ·
All routine maintenance operations, checks and lubrication must be carried out with the
machine off and disconnected from the energy supplies (electrical and other).
WARNING
Any unauthorised modification or tampering with the machine and its safety
systems relieves the manufacturer of all responsibility in terms of warranty
and safety.
1.3 GENERAL PRECAUTIONS REGARDING MACHINE USE
This machine has been designed and constructed to be used according to the standard
rules of conduct when working with machines; the manufacturer therefore takes for
granted that the machine operators are knowledgeable with these rules.
The user is responsible for informing and training the operators and ensuring
that everyone that will be operating on the machine read these instructions.
•Where a safety key selector or safety key lock is provided, the maintenance
technician or the operator must remove the key and personally pocket it or put
it in safe place where unauthorised staff cannot access it.
•Do not allow unauthorised staff to operate on the machine.
•DO NOT START THE MACHINE IF IT MALFUNCTIONS IN ANY WAY
•Before using the machine, make sure that any dangerous condition has
appropriately been eliminated.
•Make sure that all the guards and other protections are in place and that all the
safety devices are present and in working order.
•Make sure that there are no foreign objects in the operating area.
•When there is a risk of being hit by projecting or falling solid parts or similar,
wear goggles with side shields, a hard hat and gloves if necessary.
•Personal protection devices must be used where prescribed.
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PRECAUTIONS REGARDING ELECTRICAL EQUIPMENT
Connection, startup, maintenance, measurements and adjustments of the electrical
equipment or its components may only be carried out by qualified electricians. When
working on live electrical components, strictly observe the regulations in force.
1.4 PICTOGRAPHS RELATING TO OPERATOR QUALIFICATION
The meaning of the symbols used in this manual is given below. These symbols are
shown at the beginning of a paragraph to indicate the staff the paragraph addresses, it
being understood that the contents of this MANUAL MUST BE FULLY READ and therefore
MUST BE KNOWN TO all the machine users and everyone that will be performing any
type of operation on it.
Generic worker: operator with no specific skills capable of carrying out only
simple tasks on instructions of qualified technicians.
Hoisting and handling means driver: operator qualified for use of material
and machine lifting and transport means (strictly following the instructions of
the manufacturer), in compliance with the laws in force in the country of use.
Mechanical maintenance technician: qualified technician capable of
running the machine in normal conditions, operating it using the hold-down
buttons with the guards deactivated, and operating on mechanical devices to
carry out adjustments, maintenance or repairs. A mechanical maintenance
technician is normally not qualified to operate on live electric systems.
Electrical maintenance technician: qualified technician capable of running
the machine in normal conditions, operating it using the hold-down buttons
with the guards deactivated, and operating on electrical devices to carry out
adjustments, maintenance or repairs. The electrical maintenance technician
is qualified to operate on live electric systems in electric cabinets and junction
boxes .
Manufacturer's technician: qualified technician made available by the
manufacturer and authorised to carry out complex operations in particular
conditions or in any case as agreed with the user. The manufacturer’s
technicians have mechanical and/or electrical skills.
1.5 PICTOGRAPHS RELATING TO SAFETY
Below are the safety pictograms used on the machine and/or in this manual.
Risk of cuts: Warns the operators that if the operation described is not
carried out according to the safety rules, there is a risk of cutting the hands.
Risk of electrocution: Warns the operators that if the operation described
is not carried out according to the safety rules, there is a risk of electric
shock.
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Risk of projecting fragments: Warns the operators that if the operation
described is not carried out according to the safety rules, there is a risk of
being hit by projecting fragments.
Wear a protective headset: Warns the operators that a headset must be
worn as there is an implicit risk of damage to hearing.
Wear protective clothing: Warns the operators to wear protective
goggles and gloves to prevent injury.
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2 MACHINE PRESENTATION
2.1 GENERAL
The Italy 100 cutter has been designed and constructed to make linear, diagonal and
45° angle cuts in ceramic, marble, granite, porcelain stoneware, Klinker and terracotta
tiles. The diamond disc supplied with the machine is only suitable for cutting ceramic
tiles; for all other materials, use specific discs.
Referring to the figure above, the cutter is made up of the following units:
1) Sliding motor unit (tiltable for 45° angle cuts)
2) Motor
3) Universal diamond disc Italy 100 = 200mm Ø
4) Sliding unit supports
5) Tank
6) Power cable
7) Removable legs
8) Support table
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2.2 GENERAL NOTES
•The machine is intended for industrial use in normal environmental conditions as
defined in point 4.4 of EN 60204-1. These conditions refer to machine use.
•The machine may only be used by specifically trained staff and who have read the
contents of this manual.
•The machine is manually operated.
2.3 AIRBORNE NOISE EMISSION
The sound pressure level was measured in the normal operator working position, i.e.
20cm from the short side of the machine where the tile positioning squares are located.
The value indicated in the table below refers to the machine operating with a continuous
crown disc.
Measurement Sound pressure (dB)
Sound pressure level 90.5 dB (referring to
20µµPa)
Sound power level 97 dB (referring to 1pW)
The measurements were made in accordance with ISO 11201 and ISO 3744.
The sound pressure level generated by the machine is such that anti-noise
protection must be used (headset or ear plugs).
2.4 TECHNICAL DATA
The table below lists the technical data of the machine.
Parameter Value
Electrical power supply SEE THE MOTOR IDENTIFICATION PLATE
Absorption SEE THE MOTOR IDENTIFICATION PLATE
Motor rpm SEE THE MOTOR IDENTIFICATION PLATE
Motor condenser capacity SEE THE MOTOR IDENTIFICATION PLATE
Degree of protection SEE THE MOTOR IDENTIFICATION PLATE
Insulation class F
Maximum cutting length 100 cm
Maximum length for 45° angle cut 100 cm
Maximum tile sides for 45° cut 70cm x 70cm
Maximum cutting height 42 mm
Diamond disc type 200mm Ø continuous crown
Weight 55 kg
Dimensions 154 x 57 x 106 cm (LxDxH)
The operating temperature must be between 0 and 45°C
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2.5 IDENTIFICATION PLATES
The machine has been constructed in compliance with the requirements of Machine
Directive 2006/42/EC and Electromagnetic Compatibility Directive 2004/108/EC. The
declaration of conformity is attached to this manual.
When contacting Customer Service, exactly quote the model, serial number and year
of manufacture of the machine to facilitate fast and precise replies. This data is found
on the identification plate installed on your machine.
The machine and motor unit identification plates are positioned on the outside of the
right-hand side upright as shown in the figure.
It is prohibited to alter and remove these identification plates.
The identification plates bear the following data:
- Manufacturer’s name and address
- Machine type
- Serial number
-CE marking and year of manufacture of the machine.
- Power voltage in volts and frequency in Hz
- Maximum absorption in amperes
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2.6 TYPE OF DISCS USABLE
The machine may only be used with the cutting discs listed and shown below:
A) Continuous crown disc for ceramic and porcelain stoneware tiles
B) Turbo disc for terracotta, ceramic and marble tiles
C) Sector disc for stone, concrete, granite, hard stone and marble
WARNING
Mount only safety continuous crown or turbo discs on the cutter.
It is strictly prohibited to use toothed discs normally used for cutting wood,
iron or similar. SIRI declines all responsibility for improper disc use.
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3 Safety components and residual risks
3.1 MECHANICAL SAFETY DEVICES
3.1.1 Disc guard
The cutting disc is protected by a plastic guard that prevents access to the largest part
of its circumference excluding the lower area where the material is cut. The guard is
made up of two parts (internal and external) joined to each other with four screws; the
internal part is fastened to the motor unit. The external part may be removed only and
exclusively when the machine is disconnected from the mains, when you need to
replace the cutting disc.
As well as providing protection against contact with the blade, it performs the function
of directing the cooling water flow down into the collection tank.
WARNING
It is strictly prohibited to start the machine when the external part of the
guard is not in place.
3.2 ELECTRICAL SAFETY DEVICES
3.2.1 Magnetothermal switch
The cutter is equipped with a magnetothermal press switch with a minimum voltage
disconnecting switch. The switch is open (i.e. machine off) when it is in position “0” and
closed (i.e. machine started) when it is in position “1”. If the power fails when the
switch is in position “1”, it is automatically switched to “0”. This prevents the machine
from restarting when the power is restored until the switch is pressed back into position
“1”. The switch also has the function of protecting the motor, automatically switching to
“0” following a short-circuit or prolonged use in overload conditions. If the switch trips
due to an overload, before restarting the machine, wait a few minutes to allow the
thermal device incorporated in the switch to cool down.
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3.3 RESIDUAL RISKS
Despite the safety devices adopted, there are some residual risks intrinsic to cutting
operations.
3.3.1 Risk of cuts
There is a risk of being cut by the cutting blade in the arched section where it cannot be
protected by the guard. It is therefore strictly prohibited to come close to the cutting
disc with any part of the body, both when the machine is off and operating. All the
machine operators and anyone that passes close by or might be passing close by the
machine must be informed of this risk and how to behave.
WARNING
It is strictly prohibited to come close to the cutting blade with the hands and
the face when the machine is connected to the mains.
3.3.2 Risk to the eyes
There is a risk of the cooling water splashing or fragments projecting onto the hands
and face. It is therefore obligatory to wear goggles during machine operation
WARNING
It is strictly prohibited to use the machine without wearing protective goggles.
3.3.3 Risk to hearing
The sound level reached during operation is such that it will damage hearing in the
event of prolonged exposure. It is therefore obligatory to wear an anti-noise headset
during machine operation.
WARNING
It is obligatory to wear an anti-noise headset during machine operation.
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4 Instructions for use and maintenance
In relation to the characteristics of the materials cut, before carrying out any
operations on the machine, carefully read the entire operating manual paying
particular attention this section. All the operators that will be working on the
machine must read the instructions contained in this section and they must be
easily accessible and clearly visible.
4.1 INTRODUCTION
The machine has been designed and constructed in compliance with the requirements of
Machine Directive 2006/42/EC taking into account normal and reasonably foreseeable
improper use.
4.2 PERMITTED USE
The Italy 100 cutter has been designed and constructed to make linear, diagonal and
45° angle cuts in ceramic, marble, granite, porcelain stoneware, Klinker and terracotta
tiles. The diamond disc supplied with the machine is only suitable for cutting ceramic
tiles; for all other materials, use specific discs.
4.3 REQUIRED PERSONAL PROTECTION DEVICES
It is obligatory to wear protective goggles and an anti-noise headset. These devices are
at the expense of the customer.
Wear a protective headset
Wear protective goggles
4.4 GENERAL WARNINGS
•Operators, maintenance technicians and anyone who is to operate and/or come
close to the machine may not wear clothes with wide sleeves nor laces or belts
that may pose a risk to safety. Long hair must be tied up and a cap worn so
that it cannot pose a risk.
•The working area must be kept clear of any foreign objects and the floor must
be treated with a non-slip coating (at the expense of the customer).
Alternatively, non-slip mats may be used.
•The machine must be used and maintained according to the instructions
contained in this manual and the procedures described case by case.
•The operators that are to work on the machine must be adequately trained
through training and refresher courses.
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•The machine connections (and any accessory devices) must be earthed for
electrostatic discharge.
•It is strictly prohibited to operate on any part of the machine before it has come
to a complete halt and only after pulling the plug from the power socket. Only
following this operation may the mechanics and workers carry out maintenance
or repair procedures.
•Do not deactivate the safety devices or ignore the warnings and alarms, be they
automatically communicated or given on labels fixed on the machine.
•Do not operate the machine when the guards have been removed.
4.5 WARNINGS ON USE
The cutter must be used only for the intended use declared by the manufacturer. In
particular, it is prohibited to use the cutter, even partially, in one of the
following conditions:
•With the guards removed and/or with the safety devices deactivated, faulty or
missing
•If the cutter has not properly been installed
•In explosive atmospheres or in places where there is a risk of fire
•In dangerous conditions or when the cutter is malfunctioning
•Improper use of the cutter by untrained personnel
•Use not in compliance with the specific regulations
•In the event of power supply defects
•After unauthorised modifications or operations
•Total or partial inobservance of the instructions
•With materials and tools different from those specified by the manufacturer.
The machine is not intended for use in one or more of the following conditions:
•Environments with an average temperature higher than +35°C in a period of 24
hours
•Environments with relative humidity higher than 95%
•At altitudes of over 3000 m above sea level.
If finding potentially dangerous situations for the operator during machine
use, the employer is obliged to immediately inform SIRI S.r.l. thereof in
writing.
IMPORTANT
Any deviation or departure from the above mentioned rules requires a specific
written declaration by SIRI S.r.l. Any modification not authorised by the
manufacturer which alters the machine functions affecting the risks and/or
generating additional risks, shall be the sole responsibility of the person who
made the said modifications. Modifications made without the manufacturer’s
authorisation shall lead to forfeiture of the warranty and invalidate the
declaration of conformity issued in accordance with Machine Directive
2006/42/CE.
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4.6 WARNINGS ON MACHINE MAINTENANCE
WARNING
All the routine and extraordinary maintenance operations must be carried out
with the machine off.
Disconnect the machine from the mains by pulling the plug from the power
socket.
•Only specialised and specially trained staff should be allowed access to the
machine for any maintenance operation.
•It is not permitted for any reason whatsoever to modify, tamper with or alter
the machine structure and/or the devices fitted.
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5 Machine installation and startup
5.1 HANDLING THE MACHINE
The machine can be handled manually or with a pallet transporter. Two persons are
required for manual handling, gripping the machine standing in front of the short sides
of the tank. Before any type of machine handling operation, lock the motor carriage
using the locking hook provided to prevent the cutting head from sliding during
transport. Be careful during lifting and transport to prevent the machine from falling or
overturning.
If handling the machine with a pallet transporter, position in front of one of two long
sides, insert the forks and make sure that they completely engage the containment tank
until emerging on the opposite side. Also make sure that the symmetry axis of the forks
is on the same vertical as the barycentre of the machine with the motor unit locked
using the hook provided.
Some machine versions are equipped with two legs with castors. In this case, the
machine can be moved by one person lifting it from the opposite side (feet side, without
rollers) and pushing it in the desired direction.
5.2 PREPARING THE WORKING AREA
The working area must be prepared by the user creating the following conditions:
- Prepare the place of installation as required by the local regulations in force on health
and safety in the workplace
- Prepare suitable natural and/or artificial lighting in order to guarantee good visibility
at any point of the machine and without dangerous reflections and stroboscopic effects.
It is advisable to provide for an average lighting of 500 Lux
- Prepare the electric power supply in compliance with the regulations in force in the
place of installation as well as an efficient earthing system.
- Prepare a disconnecting switch with automatic protection against short-circuits,
discharges to earth and leakage between the electric power line and the machine
(differential magnetothermal switch)
The machine must be
positioned in such a way that
the minimum spaces
indicated in the figure are
respected. The floor must be
perfectly level and not
slippery. The same figure
shows the position of the one
operator required to operate
the machine.
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5.3 ASSEMBLING THE MACHINE
The machine must be installed by qualified staff who have carefully read and
understood the information contained in this manual. In case of doubt, consult
the manufacturer. The user is responsible for ensuring that the installation
complies with the relative regulations in force.
5.3.1 Material provided
The following tools are provided with the machine, which are useful for machine
adjustments and disc replacement:
1) 19mm socket wrench
2) 10mm/13mm monkey spanner
3) 5mm Allen wrench
A tank plug is also provided
5.3.2 Fitting the legs
The machine is supported on four square tubular legs. Two operators are required to
assemble them on the machine body. One at a time, fit the four legs in the respective
housings on the four corners of the tank as shown in the figure. Then, when the upper
through hole of the leg is in correspondence to the upper part of the oblique slit in the
leg, fit the pin and the upper nut. Then fit the second pin and the relative knob and
tighten everything so that you have the configuration shown in the enlargement in the
figure. If the machine is supplied with 2 legs equipped with castors, these must be fitted
on the side opposite to where the operator stands.
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5.3.3 Releasing the carriage
After fitting the four legs and checking that the machine is stable, fit the flexible
corrugated tube from the inside of the tank and let it drop to the outside so that it can
move freely.
Then release the carriage held in place at the end of travel by
means of a hook-shaped tab that ties the carriage to the rear
upright of the track preventing it from moving during the
machine movement operations. Then loosen the bolt (which
may also be the butterfly type) positioned on the cutting head
and slightly turn the hook around the bolt that fastens it to the
track upright as shown in the detail in the figure. In so doing,
the carriage will be free to move along the track.
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