Vlume 1.1 OPERATIONAL MANUAL MODEL: CG-211Y PIPE TORCH/BURNER MACHINE by BLUEROCK Tls
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. THE NEWMAN TRADING COMPANY LLC DBA BLUEROCK TOOLS 2016 1100 SW 16 th St Suite D Rentn, WA 98057 Phne 206.604.8363 Fax 425.572.5167 www.bluercktls.cm
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 WWW.BLUEROCKTOOLS.COM OR FROM YOUR LOCAL RETAILER. 3 CUTTING TIP SPECIFICATIONS 4 OPERATIONS 5 PURPOSE 5 OPERATIONAL PRINCIPLES 5 MACHINE COMPONENTS 5 SETTING UP THE MACHINE 6 TRANSPORTING THE MACHINE 7 RUNNING THE MACHINE 8 PROPER LIGHTING OF GAS TORCH 10 TROUBLESHOOTING 12 GENERAL MAINTENANCE 13
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 bdy f the machine and inspect fr damage r defects. Ø Examine the bdy and hses f the cutting assembly. 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 fire, prperty damage and/r serius injury! Ø DO ensure all nn-essential peple are clear f the immediate wrk area. Ø DO keep bdy parts, clthing & pwer crds clear f turning/cutting pieces. Stay alert and use cmmn since when using this tl. 1
Ø DO shut ff gas while changing cutting tips s as nt t accidentally 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 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 flame running when nt in use. Ø DO NOT hld the wrk piece by hand r using bdy. Always mechanically clamp r secure. Ø DO NOT allw flame t clse t the machine bdy. This can cause 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 stand under machine while running. The machine can fall and cause damage r harm t the user. 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. 2
Chapter 2 Specificatins MECHANICAL DATA Frward r Reverse Mvement Type Wrmwheel Electricity Used Cutting Tip Types Minimum Pipe Cutting Diameter Cutting Depth Cutting Speed Cutting Mvement Precisin Bevel Angle Machine Main Structure Material Yes Manual Hand Pwer Yes N G02, G03 (similar t Airc Brand) 4 (100mm) t 24 (600mm) with Chain Prvided With additinal chain there is n maximum pipe size. Up t 2 Thick (5mm min t 50mm max) Manual Depends n user 0.039 per 40 (1mm/1000mm) 0-45 Degrees Ally-aluminum (Zl101) SHIPPING DATA Shipping Weight 1) 32 lbs Shipping Package Size 1) 13 x 13 x 17 Included Accessries DESCRIPTION QTY Instructin Manual 1 87 f Chain 1 Large Wheel (fr smaller pipe) 2 Trch Bracket Assembly 1 G02 Oxy-Acetylene Cutting Tips 3 G03 Oxy-Prpane Cutting Tips 3 Nte UPON RECEIPT, CHECK CAREFULLY TO ENSURE THAT THE MACHINE IS IN GOOD CONDITION AND HAS ALL ACCESSORIES LISTED ABOVE. Additinal accessries fr this machine can be fund in BLUEROCK Tls nline shp at www.bluercktls.cm r frm yur lcal retailer. 3
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 #00 0.8 5-10 600-450 0.2-0.3 >0.03 #0 1 10-20 480-380 0.2-0.3 0.03 #1 1.2 20-30 400-320 0.25-0.35 0.03 #2 1.4 30-50 350-280 0.25-0.35 0.03 #3 1.6 50-70 300-240 0.3-0.4 0.04 #4 1.8 70-90 260-200 0.3-0.4 0.04 #5 2 90-120 210-170 0.4-0.6 0.04 #6 2.4 120-160 180-140 0.5-0.8 0.05 #7 2.8 160-200 150-110 0.6-0.9 0.05 #8 3.2 200-280 90-60 0.6-1.0 0.05 #9 3.6 270-350 90-60 0.7-1.1 0.05 #10 4 350-400 70-50 0.7-1.2 0.06 G0 3 Prpane Cutting tip #0 0.7 5-10 800-450 0.2-0.3 >0.03 #1 0.9 10-20 480-300 0.2-0.3 0.03 #2 1.2 20-35 400-320 0.3-0.4 0.03 #3 1.5 35-60 350-280 0.3-0.4 0.03 #4 1.8 60-90 300-240 0.4-0.6 0.04 #5 2.1 90-130 260-200 0.4-0.6 0.04 #6 2.5 130-180 220-180 0.4-0.6 0.04 #7 2.7 180-250 200-160 0.5-0.7 0.05 #8 3.1 250-330 180-140 0.5-0.7 0.05 #9 3.5 330-380 130-90 0.6-0.8 0.05 #10 4 380-450 90-50 0.6-0.8 0.05 4
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-211Y is t cut steel pipe using xy-acetylene r prpane gas flame cutting. The machine is designed t cut straight and bevel cuts. This machine is used fr seamless steel pipe cutting and beveling. It s suitable fr wrk in utside areas where there is n electricity available. OPERATIONAL PRINCIPLES Ø When placed n pipe, 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 human pwer. Using the adjusting knbs n the machine, the user can raise r lwer the trch hlder. WARNING: 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-211Y are the clutch carriage, trch hlder assembly, machine bdy, wheels and chain Ø This machine has tw primary adjusting knbs t psitin the trch hlder. These knbs are bth lcated n the trch bracket assembly and main spreader bar (see figure belw). The spreader bar adjuster knb will adjust the trch hlder left t right. The side trch height knb will adjust the trch hlder up r dwn. 5
SETTING UP THE MACHINE Ø Install the main spreader bar and the trch hlder assembly. Tighten the apprpriate wing-nuts. Ø Install the trch hlder int the trch hlder assembly. 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. See sectin belw n prper lighting f gas trch Fr straight cuts, ensure the trch hlder is square (see figure belw). 6
Ø Tighten the valve assembly side nt the tp f the flat steel bar left f the main chain tightener wing nut (see figure abve). Ensure it is secured tightly. Ø Install the large wheels if yu are ging t be cutting smaller pipe (see figure belw). Nte: Yu d nt want the middle f the machine t high center n smaller pipe, hence the need fr the large wheels. TRANSPORTING THE MACHINE Ø When transprting the machine, always carry under the machine wheels. 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 n pipe. Ø If transprting inside a vehicle, it is recmmended t transprt it n its side s as t avid the item falling ver. It is als recmmended t prtect the wheels frm damage by placing n nnabrasive surface. Ø DO NOT carry the machine by the hses. 7
RUNNING THE MACHINE 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. WARNING: 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. NOTE: The machine will deviate frm the cut if the material is nt clean (bare) and seamless. Ø Carefully place machine at the start f the cut ensuring the wheels gently make cntact with the cutting surface. If cutting pipe, it is generally easiest t start at the tp f the pipe. Ø Adjust the main chain tightening wing-nut s that the clutch carriage assembly is in a lw psitin. Ø Lp the chain thrugh the tp f the clutch sprcket and arund the pipe. Ø Interlck the chain as in the illustratin belw. Take ut the apprpriate number f chain lengths s the chain is mderately tight. A quick way t figure ut the specific number f chain lengths t use can be fund using the fllwing equatin: D=d+12 D= The number f sectins d= The diameter f pipe. 8
12= Cnstant Example: d=299mm=29.9cm=30 sectins f chain. D=30+12=42 Sectins f Chain Ttal, S yu wuld use 42 sectins f chain fr a pipe 299mm in diameter. Ø Tighten up the main chain tightening wing-nut until the machine is adequately tight. D nt ver-tighten wing-nut. Ensure the chain is at a straight 90 degree t the pipe. Ø Engage the clutch handle n the clutch carriage assembly. This shuld engage the wrm-wheel and allw fr activated mvement when the handle is turned. Turn the handle t ensure mvement Ø Select apprpriate size trch tips fr the applicatin. Install tip. Ø Select cutting angle. 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 Ensure the trch hlder is nt t clse t the side f the machine bdy. 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. Ø Cut material by rtating the wrm-wheel handle. CAUTION: Make certain the user is clear f the flame when manually rtating the handle. Ø When the cut is cmplete, stp the machine rtatin. Ø Shut ff the trch flame. 9
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 and 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. Ø After cutting is cmplete, clse xygen cutting valve. Ø Next clse pre-heating xygen valve. Ø Lastly, clse the gas-cutting valve. 10
Ø If dne using the machine, clse xygen and gas valves n the main cylinder regulatrs. Purge xygen and gas lines. 11
Chapter 4 Trubleshting Nte SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN. N Prblem Cause Slutin 1 Leak gas and/r flame in the jint f trch and trch cutting tip. 1. The trch hlder inlet is damaged. 2. There is cpper burr r materials n the surface f the trch tip. 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. 2 The flame ges ut as sn as the xygen valve is pened 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 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. 3 The steel can t be cut thrugh 4 The cutting is nt straight enugh. 5 The clutch will nt engage. 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 pipe was defrmed. 2. The flame line was nt straight. 3. Uneven pipe surface 4. The trch was prly fixed and can be mved. 5. The chain is nt straight 1. The clutch carriage is damaged 2. The clutch is dirty 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 rund steel and calibrate it befre cutting. 2. The trch shuld have a 90 angle with the steel and tightly fixed. Clean the useless materials in the trch cutting muth with cutting pin. 3. Fix surface irregularities. 4. Tighten all cnnectins. 5. Straighten the chain. 1. Repair r replace the carriage 2. Lubricate the clutch and ensure it mves freely 12
Chapter 5 General Maintenance Ø Inspect valve assembly cnnectins. Ø Lubricate all mving parts in the clutch assembly. Ø Keep machine clean and free f debris. Make sure t frequently clean metal scraps frm the rll wheels. 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 DO NOT il and cnnectin pints used in the gas/xy system! 13