Bluerock Tools CG-30 Quick start guide

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

MWS-CG-30 TRACK TORCH BURNER MACHINE
UNPACKING THE ITEM
Caution: This machine is packed together with items that may be sharp, oily and overly heavy objects.
Remove the machine from the packaging in a safe manner. Check to ensure all accessories are included with
the item while unpacking. If any parts are found to be missing, contact the retailer as soon as possible. Do
not throw away the packaging until the item is out of the guarantee period. Dispose of the packaging in an
environmentally responsible manner. Recycle if possible. Keep all plastic bags away from children due to
risk of suffocation.
WEEE - Waste Electrical & Electronic Equipment. Note this machine should be disposed of as electrical & electronic waste.
©THE NEWMAN TRADING COMPANY LLC DBA BLUEROCK® TOOLS 2016
1100 SW 16th St • Suite D
Renton, WA 98057
Phone [phone] • Fax [phone]
www.bluerocktools.com

CG-30 TRACK TORCH BURNER MACHINE
Table&of&Contents&
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.! 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!

CG-30 TRACK TORCH BURNER MACHINE
1
Safety
DO NOT USE THIS MACHINE UNLESS YOU HAVE READ THE
OPERATING INSTRUCTIONS!
Welding safety glasses must be worn at
all times in work areas.
Long and loose hair must be
contained.
Appropriate steel toe footwear must be
worn.
Close fitting/protective leather
clothing must be worn.
Leather safety gloves should be worn at
all times and jewelry must not be worn.
Hearing protection should be
worn when using this machine.
Hard-hat must be worn while using
machine.
Dust/fume mask must be worn
while using this machine.
Read operational manual prior to use.
PRE-OPERATIONAL SAFETY CHECKS
ØExamine the power cord and plug for damage. This tool is supplied with a ground plug and
must always be used with the properly grounded circuit.
ØExamine the body of the machine and inspect for damage or defects.
ØExamine the cutting torch tips and torch barrel inside and out for damage and/or defect.
OPERATIONAL SAFETY CHECKS
ØONLY to be operated by qualified personal who have read instructions.
oNOTE: Failure to read and follow instructions could result in electrical shock, fire,
property damage and/or serious injury!
ØDO ensure all non-essential people are clear of the immediate work area.
Chapter
1

CG-30 TRACK TORCH BURNER MACHINE
2
ØDO keep body parts, clothing & power cords clear of turning/cutting pieces.Stay alert and
use common since when using this tool.
ØDO unplug machine, and shut off gas while changing cutting tips so as not to accidentally
turn machine on or cause gas related injuries.
ØDO ensure all tightening points, brackets, wing-nuts, and lever-bolts are tight and stable prior
to turning the machine on and/or starting the gas flame.
ØDO tie a loop in any extension cord connections to prevent cords coming apart and a loss of
power.
ØDO guard against electric shock by preventing body contact with grounded surfaces such as
pipes, radiators, ranges, refrigerators, etc.
ØDO use a dust/fumes extraction system for cutting all materials. The operator should also
wear a protective respiratory device in accordance with welding safety standards.
ØDO NOT make adjustments to machine while the machine is running.
ØDO NOT remove or modify grounding plug. Only to be used on a properly grounded circuit.
ØDO NOT leave the machine running when not in use.
ØDO NOT hold the work piece by hand or using body. Always mechanically clamp or secure
work piece.
ØDO NOT allow flame too close to the machine body. This can cause internal machine
components to fail.
ØDO NOT allow flame to come in contact with power cords.
ØDO NOT operate machine outside of machine specifications.
ØDO NOT touch moving parts or cutting flame while the machine is running as death or
dismemberment could occur.
ØDO NOT remove machine panel while machine is connected to a power source. Only to be
removed for service by qualified personal and put back on the machine after service is
complete.
ØDO NOT allow children or untrained personal to operate machine.
ØDO NOT use this machine in the rain or a wet environment. If using outdoors, make sure the
adhering surface is clean and dry.
ØDO NOT cut into steel that may contain a live electrical wire/circuit.
ØDO NOT operate this machine on a lower voltage as it may result in the motor being at a
reduced power level and the machine could become unreliable while cutting. This could also
limit the motor life and control components.
oNOTE: Use of long small gauge power extension cords can result in decreased
voltage. As local voltages can vary, it may be a good idea to test the voltage at the
end of the extension cord to ensure proper voltage requirements are met. You might
also consult an electrician to make sure the length of cord matches up with the proper
wire gauge for this size motor. Make sure to use outdoor cords when operating
outdoors.

CG-30 TRACK TORCH BURNER MACHINE
3
Specifications
ELECTRICAL DATA
Voltage
120V, 60Hz
Power Connection
US Standard 3 Prong Type B Plug
MECHANICAL DATA
Motor Forward or Reverse
Yes
Cone Disk Drive
Yes
Mechanical Start Stop
Yes
Cutting Tip Types
G02, G03 (similar to Airco Brand)
Cutting Circle Diameter
8”-6.5’ (200-2000mm)
Cutting Depth
3/16” – 4” Depth (8-100mm)
Cutting Speed
0”-30” Per Minute Variable Speed (0-750mm/min)
Straight Line Cut Length
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 Accessories
DESCRIPTION
QTY
Instruction Manual
1
6’ Cutting Track (with circle radius bar)
2
Power Cord
1
Main Spreader Bar
1
Large Troch Bracket Assembly
1
Main Beam Spreader Bar Holder
1
Radius Bar Spike for Circle Cutting
1
G03 Propane Cutting Tips
3
G02 Oxy-Acetylene Cutting Tips
3
Note
UPON RECEIPT, CHECK CAREFULLY TO ENSURE THAT THE MACHINE IS IN GOOD
CONDITION AND HAS ALL ACCESSORIES LISTED ABOVE.
Chapter
2

CG-30 TRACK TORCH BURNER MACHINE
4
Additional accessories for this machine can be found in BLUEROCK ® Tools online shop at
www.bluerocktools.com or from your local retailer.
Cutting Tip Specifications
Type
Model
Cutting
Diameter
(mm)
Cutting
Thickness
(mm)
Cutting
Speed
(mm)
Oxygen
Pressure
(Mpa)
Acetylene
Pressure
(Mpa)
GO2Acetylene
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
G03Propane
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

CG-30 TRACK TORCH BURNER MACHINE
5
Operations
WARNING
DO NOT attempt to use this machine unless you are trained in its proper use as
well as trained in the proper use of gas cutting equipment. THOROUGHLY READ
THROUGH THE ENTIRE MANUAL BEFORE OPERATING THIS MACHINE!
PURPOSE
ØThe purpose of the CG-30 is to cut steel using oxy-acetylene or propane gas flame cutting. The
machine is designed to cut straight and bevel cuts. The torch holder can be adjusted ±15O.
ØThese machines are designed to run along v-frame cutting tracks. This machines comes stock
with 2 pcs of 6’ track (12’ total), but additional track can be used to cut longer runs.
ØThis machine is designed to make horizontal cuts.
OPERATIONAL PRINCIPLES
ØWhen placed on the cutting tracks, the main machine wheels rotate in a forward or reverse
direction. When engaged, the flame cuts into the steel. The machine speed can be increased or
decreased using the variable speed switch. Using the adjusting knobs on the machine, the user
can raise or lower the torch holder.
oWARNING: THE CG-30 is not designed to detect the end of the cutting track. Be careful
not leave the machine cutting unattended as it may fall from the end of the elevated work
piece.
MACHINE COMPONENTS
ØThe main components of the CG-30 are the large torch bracket assembly, torch holder, motor,
electrical control panel, machine body and main spreader bar.
oThe electrical components must be not be removed except by a qualified technician.
Power must be disconnected prior to any service.
ØThis machine has two primary adjusting knobs to position the torch holder.
oThese knobs are both located on the large torch bracket assembly (see figure below).
oThe top knob will adjust the torch holder left to right.
Chapter
3

CG-30 TRACK TORCH BURNER MACHINE
6
oThe side knob will adjust the torch holder up or down.
ØThere are 5 major components located on the machine control panel (see figure below -the white
words indicate the control panel components).
ØThe power cord connection point is where the black power cord plugs in.
oNOTE: Make sure to line up the half round notch in plug with the half round piece in the
plug input.
ØThe machine has a forward/reverse switch located on the main control panel.
oThis directional toggle switch has arrows pointing in the direction the machine will
travel.
oNOTE: There is also a neutral position for this switch in between the positions.
ØWhen the directional toggle has been activated, the start/stop lever will manually engage the
gearing to start machine movement.
oThis lever should be in the “STOP” position if not moving. Turn the “START” position to
engage the movement.
ØThe variable speed switch will increase of decrease the machine speed. 0 symbolizing no
movement and 10 symbolizing fast movement.
ØThe electrical fuse contains a fuse controlling the control board.
oCAUTION: Do not remove the fuse unless the machine is disconnected from power
source.

CG-30 TRACK TORCH BURNER MACHINE
7
SETTING UP THE MACHINE
ØInstall the main spreader bar holder and the main spreader bar.
oTighten the lever lock.
ØInstall the main bracket torch holder assembly.
oFor straight cuts, ensure the torch holder is square (see figure below).

CG-30 TRACK TORCH BURNER MACHINE
8
ØTighten the valve assembly side of the torch assembly above the main spreader bar assembly.
Make sure to tighten the screw to lock in the valve assembly (see figure below for details).
ØInstall the torch holder.
oMake certain the inside if the torch holder is clean and does not have any burrs. Also
make certain any tips you use are free or burrs or defect. It is important the seats are
tight.
ØSee section below on “proper lighting of gas torch”
TRANSPORTING THE MACHINE
ØWhen transporting the machine, always use the carrying handles in the front and back of the
machine.

CG-30 TRACK TORCH BURNER MACHINE
9
ØEnsure the torch tip is in a raised position so it will not get damaged when lifting up the machine
or putting down the machine.
ØIf transporting inside a vehicle, it is recommended to transport it on its side so as to avoid the
item falling over.
ØDO NOT carry the machine by the cord.
ØDO NOT allow the cord or plug to drag along the floor when transporting.
RUNNING THE MACHINE FOR STRAIGHT LINE CUTS
ØDo all pre-operational and operational safety checks from Chapter 1.
ØConsider your security and stability as well as the orientation of the machine in the work area.
oConsider the work surface material, condition, strength, density and rigidity. These
factors directly affect the tools use.
oEnsure the piece being cut will be stable after the cut has been made.
ØEnsure the work surface and machine are free of debris, oil, etc.
ØSet the start/stop lever in the stop position.
ØSet up cutting tracks. Ensure they are straight.
oNOTE: It may be necessary to mechanically clamp or secure the tracks by some method
depending on the application.
ØPlace machine at the start of the cut ensuring the wheels of the machine are set in the V in the
cutting tracks.
oNOTE: Make certain the wheels are free and not in the lock position with the wheel
“wing-nut” slightly loose.
ØSelect appropriate size torch tips for the application. Install tip.
ØConnect applicable gas lines.
oMake certain they are properly secured and there are no leaks. It is highly recommended
that leak testing be performed on the system prior to using the machine.
oEnsure the lines are long enough to complete the cut you are planning.
oALWAYS use gas tank cylinders with properly outfitted regulators/flowmeters.
ØSelect the neutral position in the machine directional toggle switch.
ØSecurely fasten the plug into the machine and lock in using the plug screw.
ØPlug the cord into the external power source.
ØEnsure the torch holder is not too close to the side of the heat guard. It should be set at least
4”s away from the side of the heat guard.
ØAdjust the side knobs to raise the torch tip to a suitable level for lighting.
ØLight the torch flame (see section below on proper lighting of torch flame).
ØAdjust the side knobs a suitable level for cutting though the material.

CG-30 TRACK TORCH BURNER MACHINE
10
ØSelect the drive direction using the toggle switch.
ØSelect the proper speed of the cut using the variable speed switch.
ØActivate the machine start/stop lever to the start position to engage the machine directionally.
ØWhen the cut is complete, stop the machine using the start/stop lever.
ØShut off the torch flame.
USING THE CIRCLE CUTTING ATTACHMENT
ØMap out the circle on the surface of the steel.
ØDrill a hole or use a punch to mark the center of the circle.
ØInstall the radius bar on the side main machine body.
oIf the radius is small, the bar should be placed on the same side of the torch.
oIf the radius is large, the bar and spike should be placed on the opposite side of the
torch.
oPut into the fixed holes and adjust the position of the fixing bar accordingly.
oFasten the nuts to tighten the radius bar.
ØInstall the radius bar spike on the end of the radius bar.
oTighten the spike.
ØLoosen the wing-nut on the wheel so the back wheels can swivel.
ØUse the procedure above to start the machine and make the cut.

CG-30 TRACK TORCH BURNER MACHINE
11
PROPER LIGHTING OF GAS TORCH
ØBefore attempting to light the torch tip follow this check list:
oVerify the regulator pressure adjustment screws are backed out.
oVerify the torch valves are in the closed position.
oPosition yourself away from the front side of the regulator.
oSlowly open the oxygen valve at the cylinder.
oSlowly open the acetylene valve at the cylinder.
oAdjust regulator pressure adjustment screws to the tip pressure.
oOpen and close the torch valves at the machine separately and tune the regulator
pressure settings on the regulator.
ØLighting the torch:
oOpen gas valve ½turn.
oImmediately ignite flame with striker.
§CAUTION: Light flame immediately so gas does not enter machine body or
general atmosphere around the machine.
§Ensure proper ventilation around the work area.
oIncrease gas flow until flame leaves end of tip and smoke is not present.
oDecrease until flame goes back to tip.
oOpen pre-heating oxygen valve and adjust until neutral flame is achieved.
oWhen the temperature of the steel is suitable temperature for the steel plate, open the
cutting oxygen valve.
oAfter adjustment of the flames efficiency, turn on the machine rotation.

CG-30 TRACK TORCH BURNER MACHINE
12
ØAfter cutting is complete, close oxygen cutting valve.
ØNext close pre-heating oxygen valve.
ØLastly, close the gas-cutting valve.
ØIf done using the machine, close oxygen and gas valves on the main cylinder regulators.
oPurge oxygen and gas lines.

CG-30 TRACK TORCH BURNER MACHINE
13
Troubleshooting
Note
SERVICING SHOULD ONLY BE DONE BY A QUALIFIED TECHNICIAN.
DON’T FORGET TO UNPLUG POWER TO UNIT PRIOR TO SERVICE!
No
Problem
Cause
Solution
1
No power to
the machine
1. Machine is not plugged in or issue with power.
2. The fuse is burned.
3. The wires in the control panel, plug or switch
were disconnected or damaged.
1. Check and repair the circuit.
2. Change the fuse
3. Fix the disconnected wire or replace control panel
components.
2
The machine
speed can’t be
adjusted
1. Variable speed switch defective.
1. Repair the variable speed piece
3
Leak gas
and/or flame in
the joint of
torch and
torch cutting
tip.
1. The torch holder inlet is damaged.
2. There is copper burr or materials on the
surface of the torch tip.
1. Softly grind the torch cone with small sand paper to clean
out the burr.
2. Clean the material on the cutting tip. Softly grind the
surface with small sand paper. Change the cutting tip if it is
badly damaged.
4
The flame
goes out as
soon as the
oxygen valve
is opened
The cutting oxygen leaked into the preheating
oxygen area.
1. Copper stain or useless materials on the inner
part of torch
2. The smaller cone of torch cutting mouth was
stuck with some with material or was damaged.
1. Softly grind the most inner part of torch holder with sand
paper to clean out the debris or damage.
2. Softly grind the smaller surface of the cutting mouth.
Change the cutting mouth if it is serious damaged.
5
The steel plate
can’t be cut
through
1. The torch cutting-tip is too small.
2. The flame frequency is not strong enough
3. Low pressure for cutting oxygen
4. The hole channel of cutting mouth may be
jammed
5. The cutting oxygen is not pure.
6. The cutting oxygen was leaked into the
preheating oxygen hole channel.
1. Choose the cutting tip spec according to the cutting
thickness.
2. Increase flame frequency properly.
3. Properly increase the cutting oxygen to ensure the enough
flow speed of cutting oxygen.
4. Clean the useless materials in the torch cutting mouth with
cutting pin.
5. Use oxygen with more than 95% purity.
6. Clean the useless materials on the cutting mouth and
torch, repair the damaged surface and change cutting mouth
if needed.
6
The cutting is
not straight
enough.
1. The steel plate was deformed.
2. The flame line was not straight.
3. Uneven guide channel
4. The torch was poorly fixed and can be moved.
1. Use flat steel plate and calibrate it before cutting.
2. The torch should have an 90o angle with the steel plate and
tightly fixed. Clean the useless materials in the torch cutting
mouth with cutting pin.
3. Calibrate the guide of the machine
4. Tighten all connections.
Chapter
4

CG-30 TRACK TORCH BURNER MACHINE
14
General Maintenance
ØInspect electrical cords and electrical connections.
ØKeep machine clean and free of debris.
ØCheck for misalignment, binding and breakage of all moving parts. If damaged, repair tool before use.
ØCheck to ensure the torch holder is clean and free of debris.
oInspect the inside of the holder as well.
ØInspect all torch tips and ensure they are not damaged and the small cutting holes are clean.
ØInspect cutting hoses to ensure they are not damaged.
ØOccasionally oil the wheels of the machine.
oDO NOT oil and connection points used in the gas/oxy system!
Chapter
5

CG-30 TRACK TORCH BURNER MACHINE
15
Electrical Diagram
Code
Name
Specification
Qty
M
Permanent magnetic DC Motor
ZYT261，110V，24W，3600r/min
1
T1
Power transformer
220V/110V/6.3V
1
T2
Pulse transformer
E193 Input voltage transformer
1
S1、S2
Knob switch
KN3 3A/250V
2
H
Indictor light
XDX1-H-6.3V
1
F
Fuse
RF1-20-2A
1
V1、V2
Silicon diode
1N4004，1A/400V
2
V3
Thyristor
KP5A/400V
1
C1
Capacitor
CJ30 1uf/500v
1
C2
Capacitor
CD15 10uf/400v
1
C3
Capacitor
CD11 33Uf/400v
1
R1
Resistor
RJ 12Ω/1W
1
R2
Resistor
RJ 1.5KΩ/0.5W
1
R3
Resistor
RJ 4.7KΩ/0.5W
1
R4
Resistor
WX-050 4.7KΩ/0.5W
1
Power cord
YQ-3×0.5/10m, connector plugs CF44 3×10A/250V
1
Knob
K18-1
1
Chapter
6