Serial N... MX1 Chain Driven Pipe Cutting and Bevelling Machine Parts and Operating Manual

Serial N... MX1 Chain Driven Pipe Cutting and Bevelling Machine Parts and Operating Manual

Table of contents Section Description Page 1.0 General Information 2 2.0 Specification 2 2.1 General Specification 2 2.2 Feature 2 Figure 1 Table 1 Wheel Positions Chain Lengths 3 3 2.3 Cutting Tips and Torches 4 2.4 Dimension and weight 5 Figure 2 Machine Dimensions 5 3.0 Operating Instruction 6 3.1 Chain length 6 3.2 Lengthen & shorten drive chain 6 3.3 Cutting 16 & smaller pipe diameters 6 3.4 Cutting pipe under certain conditions 7 Table 3 Guide Band Requirements 8 3.5 How to fit Cutting Torch 8 3.6 Starting Manual Cutting Process 8 3.7 220 V ac Motorized Cutting Process 8 3.8 110 V ac Motorized Cutting Process 8 3.9 Disassembly of Manual Model After use 9 3.10 Disassembly of 220 V ac Motorized Model 9 3.11 Disassembly of 110 V ac Motorized Model 9 4.0 Safety Devices 9 5.0 Conditions of Use 9 6.0 Maintenance 9 7.0 Warranty 10 7.1 General Conditions 10 7.2 Limitations 10 Warranty Certificate 11 8.0 Recommended Non-use Conditions 12 9.0 Material Composition of Components 12 Table 4 MX1 Chain Machine Trouble Shooting Guide 13 Figure 5 Parts Drawing of MX1 Chain Machine 14 1

1.0- GENERAL INFORMATION If the manual should be lost or damaged, it is possible to obtain a copy by emailing info@sawyermfg.com. When requesting a manual, please provide the following information: Type of Machine and Model Serial Number Supplier Name and address of the User Correct address where to deliver the copy of the manual. This manual is supplied with the machine All operators, maintenance employees and other personnel should read the manual as it concerns safe operation, spare parts and warranty. The manual should be kept in a clean and humidity free environment with easy reach of the operators. All operators should read the manual prior to attempting to install, use, perform maintenance or dismantle the MX1 Chain Machine. The supervisor should make sure the operators understand the operation of the MX1 Chain Machine and the cutting torch (and any other accessories) being used. Do not damage or remove any labels or the nameplate fitted on the machine. Accidents can be prevented by operators familiarising themselves with the operation of this unit prior to installation. 2.0 - SPECIFICATION 2.1 - General Specification The MX1 Chain driven cutting and bevelling machine is designed to manually rotate an oxygen/fuel machine cutting torch around pipes 4 (102 mm.) and larger in diameter. The MX1 Chain Machine can be used with any gas cutting machine torch (acetylene, Butane, propylene, natural gas or propane gas) or Plasma cutting torch which has a diameter of 30 or 35 mm. For larger diameter plasma torches, and optional larger torch holder will be required. If vertical adjustment of the cutting torch is necessary then a rack will need to be added to the torch. 2.2. - Features The MX1 Chain Machine frame, which is an alloy aluminium casting, is fitted with a forwarding device, tensioning cam handles, wheels and a rack device to support the torch. The MX1 chain machine is attached to the pipe being cut by means of a 3-mesh chain. The forwarding device rotates the machine around the pipe during the cutting operation. Two hand cranks are used to move the forwarding device composed of a worm screw and a bronze toothed rim that are joined to the chain pinion. Two tensioning cams provide tension to the chain to secure the machine to the pipe. The forwarding device moves upward on two stainless steel columns as tension is applied to the chain. The rack device provides movement perpendicular to the machine s line of travel and a knob with pinion positions it. 2

Figure 1 Wheel Position Table 1. Length of chain required for different pipe diameters. Pipe diameter* In/mm 4 / 102 6 / 152 8 / 203 10 / 254 12 / 305 16 / 406 18 / 457 Wheel Position A B B B B B B Chain length (In/mm) 28 / 711 34 / 864 40 / 1016 46 / 1168 52 / 1321 62 / 1575 68 / 1727 Pipe diameter* In/mm 20 / 508 22 / 559 24 / 610 26 / 660 28 / 711 30 / 762 32 / 813 Wheel Position B B B B B B B Chain length (In/mm) 74 / 1881 80 / 2032 86 / 2184 93 / 2362 99 / 2515 105 / 2667 111 / 2819 Pipe diameter* In/mm 36 / 914 38 / 965 40 / 1016 42 / 1067 48 / 1219 50 / 1270 52 / 1321 Wheel Position B B B C C C C Chain length (In/mm) 123 / 3124 129 /3277 135 / 3429 142 / 3607 161 / 4089 167 / 4242 173 / 4394 *The pipe diameter listed is the nominal pipe size; for the actual pipe outside diameters refer to a commercial pipe chart to calculate the nominal pipe size or contact info@sawyermfg.com for clarification. For sizes larger than 52, please contact info@sawyermfg.com for guidance. 3

2.3 Torches and Cutting tips: The MX1 unit is suitable for use with most standard cutting torches with a barrel diameter of 30mm or 35mm. For larger barrels, a custom torch holder can be supplied at additional cost. For information on the correct cutting tips for the pipe wall thickness being cut, please refer to the torch manufacturer s guidelines. 4

2.4 - Dimension and weight. Figure 1 Machine Dimensions Net Weight Shipping Weight Machine Description (lbs/kg) (lbs/kg) MX1 Unit : 45 / 20.4 63 / 28.4 Shipping Dimensions MX1 Unit : 10 X 15 X 30 254 X 381 X 762mm 5

3.0 - OPERATING INSTRUCTION 3.1 - Chain length Drive chain length required is determined by the diameter of pipe to be cut. Table 1 of Section 2.2 shows the chain length for various diameters of pipe. 3.2 How to lengthen/shorten the Drive Chain. From Table 1 of Section 2.2, select the drive-chain length required. If the chain length is incorrect, proceed as follow: - To lengthen the drive-chain. - Select the chain segments required to extend the chain to the length mentioned in Table 1 of Section 2.2. - If the current chain is currently unjoined, then proceed to the next step. If the chain is joined, then safely remove a single chain pin using a pin hammer. These can be supplied by Sawyer MFG if required. - Check the chain ends to make sure that they meet your application requirement. - Add the required amount of additional chain to the ends and secure using a Chain Link Kit (optional). - To shorten the drive chain. - Select the chain segments required to shorten the chain to the length mentioned in Table 1 of the Section 2.2. - If the chain is joined, then safely remove a single chain pin using a pin hammer. These can be supplied by Sawyer MFG if required. - Measure along from the unlinked chain point until you reach the correct position to remove the correct amount of chain. Repeat previous step. - Check the chain ends to make sure that they meet your application requirement. - Secure using a Chain Link Kit (optional). 3.3 Cutting 16 pipe diameters and smaller with the MX1 Machine. - Check the area where the MX1 Chain Machine wheel and chain will be placed on the pipe for deformed areas on the pipe surface before placing the machine on the pipe. Remove as much of the deformity as possible before commencing. - Set the machine onto the side of the pipe which is to remain on the pipe stand; with the wheels of the torch arm side of the machine between 6-8 (152-203mm) away from the cut line. The distance from cut line to the wheels is dependent on the torch bevel angle. Warning: Irreparable damage to the MX1 Chain Machine may occur if the machine is set up on the side of the pipe which is being removed. - Place chain over the chain sprocket and allow the chain to flow down over each side of the pipe; between the wheels of the MX1 unit. Alternatively, if the chain is already connected and there is enough slack, it may be possible to slide the unit over the end of the pipe. In this instance, skip the next step. - Connect the chain ends using a Chain Link Kit underneath the pipe. - Pull the tensioning levers simultaneously to apply the required tension to the chain. The MX1 unit should now be securely held onto the pipe. - For a square cut, rotate the MX1 Chain Machine 1 full turn around the pipe to ensure the chain is squared with the OD of the pipe. - The MX1 machine is now ready for the installation of the fuel torch. Note: if the pipe is spiral welded, excessively out of round or is vertical or angled; it may be necessary to use a Guide Band for accuracy. 6

3.4 The MX1 Guide Band is recommended when cutting pipe under the following conditions: If the pipe to be cut is spiral welded, severely out of round, vertical, angled or over 18 diameter when additional accuracy is required. - MX1 Guide Bands are made from spring steel, and are suitable for multiple pipe sizes. Please refer to the MX1 Guide Band instructions to determine which segments are required for your pipe size; and for instructions on use. Figure 4 Warning: The latch should not be forced closed as this will cause damage to the latch or deform the end of the receiver section. - Place the wheels of the MX1 Chain Machine over the guide strip; so the unit is straddling the band. - Pull the drive chain over the chain sprocket and allow it to hang on either side of the guide band. - Connect the chain in the same way detailed in section 3.2 - Rotate the tensioning levers (Item N - 8E) simultaneously applying tension to the chain. - The MX1 Chain Machine is now ready for installation of the fuel torch. 7

3.5 How to fit the Cutting Torch. The 1 3/8 (35mm) torch holder is offered with a knob for 32 pitch or metric pinion to adjust the torch tip to the required height. - Operators should read the torch manufacturer s instructions for proper use of then cutting torch. - Use the correct the gas for the type of torch purchased. - Verify the torch cutting tip is the correct tip for the type of gas and pipe thickness. - A plasma cutting system with machine cutting torch can be used with the MX1 Chain Machine to cut stainless steel and non-ferrous pipes. - Set gas and oxygen regulators to the pressure specified by the manufacturer for the type of gas that is being used. - Install the torch into the torch holder and rotate the knob with pinion to adjust the torch tip to the correct pipe height. - Tighten screw so that the torch moves up and down with some friction. 3.6 STARTING THE MANUAL CUTTING PROCESS - Light the torch per the manufacturer s instructions. - Preheat the pipe to the desired temperature. - Rotate the crank handle while applying the cutting oxygen to the torch to minimise notching of the pipe. - Rotate the crank handle until the torch has completed the cut. Take care to ensure a continuous, correct speed. - Turn off the cutting oxygen valve as soon as the cut is complete - Turn off the gas and oxygen to the gas torch. 3.7 STARTING THE 220VAC MOTORIZED CUTTING PROCESS - Refer to the 220V motor kit instructions for set up guidance. - Move the motor control box forward/reverse switch to the Off Position. - Light the gas torch per the manufacturer s instructions. - Preheat the pipe to the desired temperature. - Move the motor control box forward/reverse switch to the desired direction, while applying the cutting oxygen to the gas torch to minimise notching of the pipe. - Increase the Speed Regulator clockwise as needed to achieve the desired cut quality. - Rotate the machine around the pipe until the cut is complete. - Turn off the cutting oxygen valve as soon as the cut is complete - Move the forward/reverse switch on the Motor control box to the Off position. - Turn off the gas and oxygen to the gas torch. 3.8 STARTING THE 110VAC MOTORIZED CUTTING PROCESS - Refer to the 110V motor kit instructions for set up guidance. - Move the motor control box forward/reverse switch to the Off Position. - Light the gas torch per the manufacturer s instructions. - Preheat the pipe to the desired temperature. - Move the motor control box forward/reverse switch to the desired direction, while applying the cutting oxygen to the gas torch to minimise notching of the pipe. - Increase the Speed Regulator clockwise as needed to achieve the desired cut quality. - Rotate the machine around the pipe until the cut is complete. - Turn off the cutting oxygen valve as soon as the cut is complete - Move the forward/reverse switch on the Motor control box to the Off position. - Turn off the gas and oxygen to the gas torch. 8

3.9 DISASSEMBLY MANUAL MODEL AFTER USE - Allow the torch to cool before handling. - Remove the cutting torch from the torch holder. Check the functionality of the gas torch and cutting tip. - Pull the tensioning levers simultaneously releasing the chain tension. - Remove the Chain Link Kit from the chain, splitting the chain and allowing the machine to be removed from the pipe. If the machine is being moved to be used on an identical pipe size, it may be possible to slide the unit off the end of the pipe once the tensioning levers have released the pressure on the chain. - Remove the Chain Machine from the pipe. - If the Guide Band has been used, remove from pipe by releasing the latch; taking care the band doesn t spring from the pipe and cause injury. 3.10 DISASSEMBLY 220VAC MOTORIZED MODEL AFTER USE - Move the power switch to the off position. - Disconnect the power supply to the 220vac electrical source. - Disconnect the power supply to the 220V motor. - Follow instructions as per 3.9 3.11 DISASSEMBLY 110VAC MOTORIZED MODEL AFTER USE - See 3.10 4.0. - SAFETY DEVICES 4.1 Accident Prevention Rules. The operator should follow all shop, national, and manufacturer standard Safety Procedures for the safety of the operator using the MX1 Chain Cutting Machine such as: - During the cutting process, all the personnel not associated with the process should stay at a safe distance. - Persons in the work area should always wear safety equipment; including gloves, safety shoes and clothing suitable for the work environment and the ambient temperature. - While the MX1 Machine is in operation, all personnel working in the vicinity of the machine should wear safety glasses or other eye protection. - Before starting the cutting operation, check all connections to the torch on oxygen and gas regulators to make sure they are tight. - Ensure cutting speed is appropriate for the wall thickness of the pipe being cut. - Keep the work area clear of all flammable material. - Always wear safety glasses or face shield when removing slag, grinding dust and other debris from the work area. 5.0 CONDITIONS OF USE 5.1 Provided use condition The MX1 Chain Machine is designed to cut pipe having a minimum nominal pipe diameter of 4 (102mm). It is not recommended to fit the guide belt and the drive chain on heavily dented pipe or pipe having a weld cap in excess of 3/8 (9.5mm) in order to avoid disfigurement of the guide strip and overloading of the drive chain. Cutting of vertical pipe should not be attempted without the use the MX1 Guide Band. 6.0. - MAINTENANCE 6.1 Routine Maintenance - Routine maintenance should be planned in advance to avoid down time. - The period between routine maintenance checks should be shortened if the machine is in constant use. - Check the machine to make sure it has not been dropped. - Replace all worn parts during the routine maintenance inspection. - Maintain the gas torch and the oxygen and gas regulators per the manufacturer s instructions. - Check daily all oxygen and gas hoses for burns and abrasions. - Oxygen and gas bottles should be checked in accordance to the required safety standards. 9

6.2 Extraordinary Maintenance The machine does not require specific maintenance under normal conditions. Please contact Sawyer MFG for assistance and suggestions to obtain best machine performance or prior to disassembly of the MX1 Machine. Please inform manufacturer of any problems that occur or any suggestions to improve the performance of the cutting machine. Your suggestions will aid in updating future machines. 7.0 - WARRANTY 7.1 - General Conditions Sawyer MFG offers a 12 month return-to-base warranty on this product. The warranty is valid for the above mentioned period and only for the parts that have defective design or defective material. Complaints must be sent directly to Sawyer MFG with an explanation of the defects. Sawyer MFG will provide full instructions for repair or replacement, free of charge for the defective parts; provided the defect was not caused by any of the conditions stated in 7.2 Any transport expenses or/and service will be covered by the customer. 7.2 - Limitations Sawyer MFG is not responsible for the following: - Improper use of the machine. - Use against the national and/or international regulation in force. - Improper or ill-fitting connection(s). - Improper maintenance. - Unauthorised modifications and/or services. - Use of non-original spare parts or specific components not called for in this operating Manual. - Failure to observe the operating instructions. - Unusual events such as natural disasters, terrorism, acts of God or any other extraordinary events which would void a standard insurance policy. 10

Warranty SAWYER MANUFACTURING COMPANY MX1 Cutting and Bevelling Machine Version Manual Motorised Serial No:.. Purchase Date:.. Dealer:.. Customer Name:... Address:.. This machine is warranted for a period of 12 (twelve) months from the Date of delivery Registered on:.. by Sawyer MFG (Signature and stamp) For more information please contact: Sawyer MFG 7799 S Regency Drive Tulsa, OK 74131 USA info@sawyermfg.com 11

8.0- MX1 CHAIN CUTTING MACHINE IS NOT RECOMMENDED FOR USE UNDER THE FOLLOWING CONDITIONS - MX1 Chain Machine is specially designed to cut and bevel pipes. - All obstacles must be removed before operation to ensure proper clearance around the pipe. - The flame of the cutting torch should never be positioned in the direction of the operator or other people. - Never use the cutting torch with an improper gas. - For Proper use of the cutting torch and tip refer to the specific Manual for the torch. - Switch off the Cutting Machine and torch prior to any type of machine maintenance. 9.0 Material Composition of the components The components of MX1 Chain Machine are made from the following materials: Carbon steel Aluminium Brass Plastic worm screw, bolts, floating device, wheels, shaft, spring. Main body unit, U body unit, torch holder. Pinion, torch holder support, slide, toothed rim Crank, knob, handle. 12

Table 4 MX1 Chain Machine Trouble Shooting Guide Symptom Probable Cause Corrective Action Machine slips on the pipe Machine is cutting the pipe out of square Motorised Machines only 1. Drive Chain is too long. 1. Shorten chain as necessary. 2. Pipe surface is too smooth. 2. Rough up surface of pipe so the chain will grip on the pipe. 3. Weld bead is too tall. 1. The Machine has not been taken 1 full turn around the pipe prior to cutting. 2. A guide band was not used when cutting pipe larger than 18. 3. A guide band was not used when cutting spiral weld pipe. 4. A guide band was not used when cutting pipe on an angle. 5. A guide band was not used when cutting Vertical pipe. 6. A large plasma torch is being used with the machine. 7. There is too much play between rack holder and torch support 8. The out of round device is not always in contact with the pipe during machine s rotation around the pipe. 3. Grind down weld bead flush with pipe surface. 1. When the machine is used without guide band, rotate the machine 1 full rotation around the pipe prior to cutting the pipe 2. Install the guide band on pipe. 3. Install the guide band on pipe. 4. Install the guide band on pipe. 5. Install the guide band on pipe. 6. Install the guide band on pipe. 7. Tighten screws in torch support. 8. Adjust the out of round device so that it is always contacting the pipe through the machine s entire rotation. 1. No voltage at power source. 1. Restore power at source. Machine does not operate in forward or reverse 2. Fuse is blown 2. Replace fuse. 3. Connection between motor control box and machine loose or disconnected. 3. Reconnect wiring Machine will not climb uphill when cutting thick wall pipe 1. Motor is operating below its curve power. 1. Use a cutting tip 1 to 2 sizes larger 13

Figure 4 Exploded parts drawing of the MX1 Chain Machine 14