Volume 1.1 OPERATIONAL MANUAL MODEL: CG-30 TRACK TORCH/BURNER MACHINE. by BLUEROCK Tools

Transcription

1 Vlume 1.1 OPERATIONAL MANUAL MODEL: CG-30 TRACK TORCH/BURNER MACHINE by BLUEROCK Tls

2 UNPACKING THE ITEM Cautin: This machine is packed tgether with items that may be sharp, ily and verly heavy bjects. Remve the machine frm the packaging in a safe manner. Check t ensure all accessries are included with the item while unpacking. If any parts are fund t be missing, cntact the retailer as sn as pssible. D nt thrw away the packaging until the item is ut f the guarantee perid. Dispse f the packaging in an envirnmentally respnsible manner. Recycle if pssible. Keep all plastic bags away frm children due t risk f suffcatin. WEEE - Waste Electrical & Electrnic Equipment. Nte this machine shuld be dispsed f as electrical & electrnic waste. THE NEWMAN TRADING COMPANY LLC DBA BLUEROCK TOOLS SW 16 th St Suite D Rentn, WA Phne Fax

3 Table f Cntents SAFETY 1 PRE-OPERATIONAL SAFETY CHECKS 1 OPERATIONAL SAFETY CHECKS 1 SPECIFICATIONS 3 INCLUDED ACCESSORIES 3 ADDITIONAL ACCESSORIES FOR THIS MACHINE CAN BE FOUND IN BLUEROCK TOOLS ONLINE SHOP AT OR FROM YOUR LOCAL RETAILER. 4 CUTTING TIP SPECIFICATIONS 4 OPERATIONS 5 PURPOSE 5 OPERATIONAL PRINCIPLES 5 MACHINE COMPONENTS 5 SETTING UP THE MACHINE 7 TRANSPORTING THE MACHINE 8 RUNNING THE MACHINE FOR STRAIGHT LINE CUTS 9 USING THE CIRCLE CUTTING ATTACHMENT 10 PROPER LIGHTING OF GAS TORCH 11 TROUBLESHOOTING 13 GENERAL MAINTENANCE 14 ELECTRICAL DIAGRAM 15

4 Chapter 1 Safety DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE OPERATING INSTRUCTIONS! Welding safety glasses must be wrn at all times in wrk areas. Apprpriate steel te ftwear must be wrn. Lng and lse hair must be cntained. Clse fitting/prtective leather clthing must be wrn. Leather safety glves shuld be wrn at all times and jewelry must nt be wrn. Hearing prtectin shuld be wrn when using this machine. Hard-hat must be wrn while using machine. Dust/fume mask must be wrn while using this machine. Read peratinal manual prir t use. PRE-OPERATIONAL SAFETY CHECKS Ø Examine the pwer crd and plug fr damage. This tl is supplied with a grund plug and must always be used with the prperly grunded circuit. Ø Examine the bdy f the machine and inspect fr damage r defects. Ø Examine the cutting trch tips and trch barrel inside and ut fr damage and/r defect. OPERATIONAL SAFETY CHECKS Ø ONLY t be perated by qualified persnal wh have read instructins. NOTE: Failure t read and fllw instructins culd result in electrical shck, fire, prperty damage and/r serius injury! Ø DO ensure all nn-essential peple are clear f the immediate wrk area. 1

5 Ø DO keep bdy parts, clthing & pwer crds clear f turning/cutting pieces. Stay alert and use cmmn since when using this tl. Ø DO unplug machine, and shut ff gas while changing cutting tips s as nt t accidentally turn machine n r cause gas related injuries. Ø DO ensure all tightening pints, brackets, wing-nuts, and lever-blts are tight and stable prir t turning the machine n and/r starting the gas flame. Ø DO tie a lp in any extensin crd cnnectins t prevent crds cming apart and a lss f pwer. Ø DO guard against electric shck by preventing bdy cntact with grunded surfaces such as pipes, radiatrs, ranges, refrigeratrs, etc. Ø DO use a dust/fumes extractin system fr cutting all materials. The peratr shuld als wear a prtective respiratry device in accrdance with welding safety standards. Ø DO NOT make adjustments t machine while the machine is running. Ø DO NOT remve r mdify grunding plug. Only t be used n a prperly grunded circuit. Ø DO NOT leave the machine running when nt in use. Ø DO NOT hld the wrk piece by hand r using bdy. Always mechanically clamp r secure wrk piece. Ø DO NOT allw flame t clse t the machine bdy. This can cause internal machine cmpnents t fail. Ø DO NOT allw flame t cme in cntact with pwer crds. Ø DO NOT perate machine utside f machine specificatins. Ø DO NOT tuch mving parts r cutting flame while the machine is running as death r dismemberment culd ccur. Ø DO NOT remve machine panel while machine is cnnected t a pwer surce. Only t be remved fr service by qualified persnal and put back n the machine after service is cmplete. Ø DO NOT allw children r untrained persnal t perate machine. Ø DO NOT use this machine in the rain r a wet envirnment. If using utdrs, make sure the adhering surface is clean and dry. Ø DO NOT cut int steel that may cntain a live electrical wire/circuit. Ø DO NOT perate this machine n a lwer vltage as it may result in the mtr being at a reduced pwer level and the machine culd becme unreliable while cutting. This culd als limit the mtr life and cntrl cmpnents. NOTE: Use f lng small gauge pwer extensin crds can result in decreased vltage. As lcal vltages can vary, it may be a gd idea t test the vltage at the end f the extensin crd t ensure prper vltage requirements are met. Yu might als cnsult an electrician t make sure the length f crd matches up with the prper wire gauge fr this size mtr. Make sure t use utdr crds when perating utdrs. 2

6 Chapter 2 Specificatins ELECTRICAL DATA Vltage Pwer Cnnectin 120V, 60Hz US Standard 3 Prng Type B Plug MECHANICAL DATA Mtr Frward r Reverse Cne Disk Drive Mechanical Start Stp Cutting Tip Types Cutting Circle Diameter Cutting Depth Cutting Speed Straight Line Cut Length Yes Yes Yes G02, G03 (similar t Airc Brand) ( mm) 3/16 4 Depth (8-100mm) 0-30 Per Minute Variable Speed (0-750mm/min) Any SHIPPING DATA 2 Package Shipping Weights 1) 31 lbs 2) 21 lbs 2 Shipping Packages 1) 26 x 12 x 11 2) 1 x 9 x 71 Included Accessries DESCRIPTION QTY Instructin Manual 1 6 Cutting Track (with circle radius bar) 2 Pwer Crd 1 Main Spreader Bar 1 Large Trch Bracket Assembly 1 Main Beam Spreader Bar Hlder 1 Radius Bar Spike fr Circle Cutting 1 G03 Prpane Cutting Tips 3 G02 Oxy-Acetylene Cutting Tips 3 Nte UPON RECEIPT, CHECK CAREFULLY TO ENSURE THAT THE MACHINE IS IN GOOD CONDITION AND HAS ALL ACCESSORIES LISTED ABOVE. 3

7 Additinal accessries fr this machine can be fund in BLUEROCK Tls nline shp at r frm yur lcal retailer. Cutting Tip Specificatins Cutting Diameter (mm) Cutting Thickness (mm) Cutting Speed (mm) Oxygen Pressure (Mpa) Acetylene Pressure (Mpa) Type Mdel GO 2 Acetylene Cutting tip # >0.03 # # # # # # # # # # # G0 3 Prpane Cutting tip # >0.03 # # # # # # # # # #

8 Chapter 3 Operatins WARNING DO NOT attempt t use this machine unless yu are trained in its prper use as well as trained in the prper use f gas cutting equipment. THOROUGHLY READ THROUGH THE ENTIRE MANUAL BEFORE OPERATING THIS MACHINE! PURPOSE Ø The purpse f the CG-30 is t cut steel using xy-acetylene r prpane gas flame cutting. The machine is designed t cut straight and bevel cuts. The trch hlder can be adjusted ±15 O. Ø These machines are designed t run alng v-frame cutting tracks. This machines cmes stck with 2 pcs f 6 track (12 ttal), but additinal track can be used t cut lnger runs. Ø This machine is designed t make hrizntal cuts. OPERATIONAL PRINCIPLES Ø When placed n the cutting tracks, the main machine wheels rtate in a frward r reverse directin. When engaged, the flame cuts int the steel. The machine speed can be increased r decreased using the variable speed switch. Using the adjusting knbs n the machine, the user can raise r lwer the trch hlder. WARNING: THE CG-30 is nt designed t detect the end f the cutting track. Be careful nt leave the machine cutting unattended as it may fall frm the end f the elevated wrk piece. MACHINE COMPONENTS Ø The main cmpnents f the CG-30 are the large trch bracket assembly, trch hlder, mtr, electrical cntrl panel, machine bdy and main spreader bar. The electrical cmpnents must be nt be remved except by a qualified technician. Pwer must be discnnected prir t any service. Ø This machine has tw primary adjusting knbs t psitin the trch hlder. These knbs are bth lcated n the large trch bracket assembly (see figure belw). The tp knb will adjust the trch hlder left t right. 5

9 The side knb will adjust the trch hlder up r dwn. Ø There are 5 majr cmpnents lcated n the machine cntrl panel (see figure belw -the white wrds indicate the cntrl panel cmpnents). Ø The pwer crd cnnectin pint is where the black pwer crd plugs in. NOTE: Make sure t line up the half rund ntch in plug with the half rund piece in the plug input. Ø The machine has a frward/reverse switch lcated n the main cntrl panel. This directinal tggle switch has arrws pinting in the directin the machine will travel. NOTE: There is als a neutral psitin fr this switch in between the psitins. Ø When the directinal tggle has been activated, the start/stp lever will manually engage the gearing t start machine mvement. This lever shuld be in the STOP psitin if nt mving. Turn the START psitin t engage the mvement. Ø The variable speed switch will increase f decrease the machine speed. 0 symblizing n mvement and 10 symblizing fast mvement. Ø The electrical fuse cntains a fuse cntrlling the cntrl bard. CAUTION: D nt remve the fuse unless the machine is discnnected frm pwer surce. 6

10 SETTING UP THE MACHINE Ø Install the main spreader bar hlder and the main spreader bar. Tighten the lever lck. Ø Install the main bracket trch hlder assembly. Fr straight cuts, ensure the trch hlder is square (see figure belw). 7

11 Ø Tighten the valve assembly side f the trch assembly abve the main spreader bar assembly. Make sure t tighten the screw t lck in the valve assembly (see figure belw fr details). Ø Install the trch hlder. Make certain the inside if the trch hlder is clean and des nt have any burrs. Als make certain any tips yu use are free r burrs r defect. It is imprtant the seats are tight. Ø See sectin belw n prper lighting f gas trch TRANSPORTING THE MACHINE Ø When transprting the machine, always use the carrying handles in the frnt and back f the machine. 8

12 Ø Ensure the trch tip is in a raised psitin s it will nt get damaged when lifting up the machine r putting dwn the machine. Ø If transprting inside a vehicle, it is recmmended t transprt it n its side s as t avid the item falling ver. Ø DO NOT carry the machine by the crd. Ø DO NOT allw the crd r plug t drag alng the flr when transprting. RUNNING THE MACHINE FOR STRAIGHT LINE CUTS Ø D all pre-peratinal and peratinal safety checks frm Chapter 1. Ø Cnsider yur security and stability as well as the rientatin f the machine in the wrk area. Cnsider the wrk surface material, cnditin, strength, density and rigidity. These factrs directly affect the tls use. Ensure the piece being cut will be stable after the cut has been made. Ø Ensure the wrk surface and machine are free f debris, il, etc. Ø Set the start/stp lever in the stp psitin. Ø Set up cutting tracks. Ensure they are straight. NOTE: It may be necessary t mechanically clamp r secure the tracks by sme methd depending n the applicatin. Ø Place machine at the start f the cut ensuring the wheels f the machine are set in the V in the cutting tracks. NOTE: Make certain the wheels are free and nt in the lck psitin with the wheel wing-nut slightly lse. Ø Select apprpriate size trch tips fr the applicatin. Install tip. Ø Cnnect applicable gas lines. Make certain they are prperly secured and there are n leaks. It is highly recmmended that leak testing be perfrmed n the system prir t using the machine. Ensure the lines are lng enugh t cmplete the cut yu are planning. ALWAYS use gas tank cylinders with prperly utfitted regulatrs/flwmeters. Ø Select the neutral psitin in the machine directinal tggle switch. Ø Securely fasten the plug int the machine and lck in using the plug screw. Ø Plug the crd int the external pwer surce. Ø Ensure the trch hlder is nt t clse t the side f the heat guard. It shuld be set at least 4 s away frm the side f the heat guard. Ø Adjust the side knbs t raise the trch tip t a suitable level fr lighting. Ø Light the trch flame (see sectin belw n prper lighting f trch flame). Ø Adjust the side knbs a suitable level fr cutting thugh the material. 9

13 Ø Select the drive directin using the tggle switch. Ø Select the prper speed f the cut using the variable speed switch. Ø Activate the machine start/stp lever t the start psitin t engage the machine directinally. Ø When the cut is cmplete, stp the machine using the start/stp lever. Ø Shut ff the trch flame. USING THE CIRCLE CUTTING ATTACHMENT Ø Map ut the circle n the surface f the steel. Ø Drill a hle r use a punch t mark the center f the circle. Ø Install the radius bar n the side main machine bdy. If the radius is small, the bar shuld be placed n the same side f the trch. If the radius is large, the bar and spike shuld be placed n the ppsite side f the trch. Put int the fixed hles and adjust the psitin f the fixing bar accrdingly. Fasten the nuts t tighten the radius bar. Ø Install the radius bar spike n the end f the radius bar. Tighten the spike. Ø Lsen the wing-nut n the wheel s the back wheels can swivel. Ø Use the prcedure abve t start the machine and make the cut. 10

14 PROPER LIGHTING OF GAS TORCH Ø Befre attempting t light the trch tip fllw this check list: Verify the regulatr pressure adjustment screws are backed ut. Verify the trch valves are in the clsed psitin. Psitin yurself away frm the frnt side f the regulatr. Slwly pen the xygen valve at the cylinder. Slwly pen the acetylene valve at the cylinder. Adjust regulatr pressure adjustment screws t the tip pressure. Open and clse the trch valves at the machine separately and tune the regulatr pressure settings n the regulatr. Ø Lighting the trch: Open gas valve ½ turn. Immediately ignite flame with striker. CAUTION: Light flame immediately s gas des nt enter machine bdy r general atmsphere arund the machine. Ensure prper ventilatin arund the wrk area. Increase gas flw until flame leaves end f tip and smke is nt present. Decrease until flame ges back t tip. Open pre-heating xygen valve and adjust until neutral flame is achieved. When the temperature f the steel is suitable temperature fr the steel plate, pen the cutting xygen valve. After adjustment f the flames efficiency, turn n the machine rtatin. 11

15 Ø After cutting is cmplete, clse xygen cutting valve. Ø Next clse pre-heating xygen valve. Ø Lastly, clse the gas-cutting valve. Ø If dne using the machine, clse xygen and gas valves n the main cylinder regulatrs. Purge xygen and gas lines. 12

16 Chapter 4 Trubleshting Nte SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN. DON T FORGET TO UNPLUG POWER TO UNIT PRIOR TO SERVICE! N Prblem Cause Slutin 1 N pwer t the machine 2 The machine speed can t be adjusted 3 Leak gas and/r flame in the jint f trch and trch cutting tip. 4 The flame ges ut as sn as the xygen valve is pened 1. Machine is nt plugged in r issue with pwer. 2. The fuse is burned. 3. The wires in the cntrl panel, plug r switch were discnnected r damaged. 1. Check and repair the circuit. 2. Change the fuse 3. Fix the discnnected wire r replace cntrl panel cmpnents. 1. Variable speed switch defective. 1. Repair the variable speed piece 1. The trch hlder inlet is damaged. 2. There is cpper burr r materials n the surface f the trch tip. The cutting xygen leaked int the preheating xygen area. 1. Cpper stain r useless materials n the inner part f trch 2. The smaller cne f trch cutting muth was stuck with sme with material r was damaged. 1. Sftly grind the trch cne with small sand paper t clean ut the burr. 2. Clean the material n the cutting tip. Sftly grind the surface with small sand paper. Change the cutting tip if it is badly damaged. 1. Sftly grind the mst inner part f trch hlder with sand paper t clean ut the debris r damage. 2. Sftly grind the smaller surface f the cutting muth. Change the cutting muth if it is serius damaged. 5 The steel plate can t be cut thrugh 6 The cutting is nt straight enugh. 1. The trch cutting-tip is t small. 2. The flame frequency is nt strng enugh 3. Lw pressure fr cutting xygen 4. The hle channel f cutting muth may be jammed 5. The cutting xygen is nt pure. 6. The cutting xygen was leaked int the preheating xygen hle channel. 1. The steel plate was defrmed. 2. The flame line was nt straight. 3. Uneven guide channel 4. The trch was prly fixed and can be mved. 1. Chse the cutting tip spec accrding t the cutting thickness. 2. Increase flame frequency prperly. 3. Prperly increase the cutting xygen t ensure the enugh flw speed f cutting xygen. 4. Clean the useless materials in the trch cutting muth with cutting pin. 5. Use xygen with mre than 95% purity. 6. Clean the useless materials n the cutting muth and trch, repair the damaged surface and change cutting muth if needed. 1. Use flat steel plate and calibrate it befre cutting. 2. The trch shuld have an 90 angle with the steel plate and tightly fixed. Clean the useless materials in the trch cutting muth with cutting pin. 3. Calibrate the guide f the machine 4. Tighten all cnnectins. 13

17 Chapter 5 General Maintenance Ø Inspect electrical crds and electrical cnnectins. Ø Keep machine clean and free f debris. Ø Check fr misalignment, binding and breakage f all mving parts. If damaged, repair tl befre use. Ø Check t ensure the trch hlder is clean and free f debris. Inspect the inside f the hlder as well. Ø Inspect all trch tips and ensure they are nt damaged and the small cutting hles are clean. Ø Inspect cutting hses t ensure they are nt damaged. Ø Occasinally il the wheels f the machine. DO NOT il and cnnectin pints used in the gas/xy system! 14

18 Chapter 6 Electrical Diagram Cde Name Specificatin Qty M Permanent magnetic DC Mtr ZYT261,110V,24W,3600r/min 1 T1 Pwer transfrmer 220V/110V/6.3V 1 T2 Pulse transfrmer E193 Input vltage transfrmer 1 S1 S2 Knb switch KN3 3A/250V 2 H Indictr light XDX1-H-6.3V 1 F Fuse RF1-20-2A 1 V1 V2 Silicn dide 1N4004,1A/400V 2 V3 Thyristr KP5A/400V 1 C1 Capacitr CJ30 1uf/500v 1 C2 Capacitr CD15 10uf/400v 1 C3 Capacitr CD11 33Uf/400v 1 R1 Resistr RJ 12Ω/1W 1 R2 Resistr RJ 1.5KΩ/0.5W 1 R3 Resistr RJ 4.7KΩ/0.5W 1 R4 Resistr WX KΩ/0.5W 1 Pwer crd YQ-3 0.5/10m, cnnectr plugs CF A/250V 1 Knb K