eXact PipeCut 360 system Technical data

Information
english
Exact PipeCut 360 System
Users manual
Guarantee of conformity with EU
requirements
We Exact Tools Oy, Mechelininkatu 15, 00100 Helsinki, Finland, guarantee
that the Exact PipeCut 360 Serial numbers 00000-99999 to which this
statement refers fulfills the basic health and safety requirements mentioned
in the (machine directive) EU directive 98/37/EY. Also the Exact PipeCut
360 fulfills the requirements of standard EN 60745-1:2003 + A1:2003
safety of hand-held electric motor operated tools and the applicable
parts of standard EN 60745-2-5 particular requirements for circular saws
and circular knives.
Also the Exact PipeCut 360 complies with the essential protection
requirements of the Council Directive 89/336/EEC as stated in the Article
4 and the tested product is in compliance with the following Product
Family standards: EN 55014-1 (2000), EN 55014-2 (1997), EN 610003-3 (1995) + Am. A1 (2001)
Helsinki 30.06.2006
Seppo Makkonen
Managing Director
1
Contents
Contents
List of contents
1. Guarantee of conformity with EU requirements
Foreword
3. Technical data
3. Electrical safety
4. Package contents
Safety
5. Safety instructions
6. Use and limitations
Operation
7.
8.
8.
8.
9.
9.
10.
10.
10.
Operating instructions
Before operating the tool
Connection to the mains power supply
Precise setting of the cutting point
Setting the pipe on supports
Attaching the pipe saw to the pipe
Piercing the pipe wall
Sawing around a pipe
Overload protection
Straightness of cut and adjusting wheel
Exact Tools Oy
Mechelininkatu 6
00100 HELSINKI
FINLAND
11. Installing and changing the saw blade
11. Service and maintenance instructions
Tel +358 9 4366750
Fax +358 9 43667550
exact@exacttools.com
www.exacttools.com
Made in EU
12. Environment /Disposal
12. Guarantee/Guarantee conditions
Exploded view (separate attachment)
2
Foreword
Kuva A
Operating, safety, and servicing instructions
Please read this operating, safety, and servicing instructions carefully before
using the pipe saw. Also store this instruction book somewhere accessible to
everyone using the pipe saw. In addition to these instructions, always follow
the official work, health and safety regulations. The Exact PipeCut 360 is meant
for professional use only.
Technical data
Model
Voltage
Power
Speed when unloaded
Intermittent operation
Blade diameter
Blade attachment hole
Weight
Range of use
Max. pipe wall thickness
Pipecut 360
230 / 50 Hz
1400 W
4000 r/min
S3 25%
140 (155) mm
62 mm
14,3 kg
Ø 75 mm – Ø 360 mm
steel 8 mm, plastics 12mm
The Exact PipeCut 360 pipe saw is manufactured in accordance with the EU standard EN 60745-1 and
also standard EN 60745-2-5 exclusive of the requirement which relates to the opening of the blade guards.
(The Exact PipeCut 360 pipe saws use is made easier by being able to open the blade guard without
tools). Also the Exact PipeCut 360 complies with the essential protection requirements of the Council
Directive 89/336/EEC as stated in the Article 4 and the tested product is in compliance with the
following Product Family standards: EN 55014-1 (2000), EN 55014-2 (1997), EN 61000-3-3 (1995)
+ Am. A1 (2001)
The sound pressure level when sawing steel, which is measured according to EN 50144:
95.5 dB(A). When sawing various types of material the sound level may vary and at times exceed
the 85 dB(A) level. Always use ear protectors to protect yourself!
Vibration level: 1.1 m/s2. The weighted acceleration value according to EN 50144 does not exceed 2.5
m/s2.
Electrical safety
The electric motor is designed to be used at the specified voltage only. It can be loaded intermittently for
2.5 min during a 10 min time span (S3 25 %). Always check that the power supply corresponds to the
voltage stated on the rating plate. The Exact 360 pipe saw is double insulated as required by standard
EN 60745-1
Do not take the pipe saw out in the rain. Never use it in wet or damp conditions.
3
Foreword
Exact PipeCut 360 pipecutting system,
Package contents:
Please check the package contains the following items:
Pipesaw case
Exact PipeCut 360 pipe saw
Hard-metal blade 140 x 62 / Z 46 (fitted on the machine)
Cutting holder and supporting holders x2
Hex socket key 2x (5 mm & 2 mm)
Operating instructions
4
Safety
it cannot close in on the sawn gap and clamp onto
the blade. The machine works at its best and safest
when it is used the way for which it was designed.
Safety Instructions
In order to prevent, electrical shocks, injuries,
and the risk of fire the following basic safety
instructions should be followed.
Dress suitably
Do not use clothing that is too loose or jewellery
when using the pipe saw as they could get caught
on moving parts of the machine. When working
outdoors use rubber gloves and non-slip shoes. If
you have long hair, use a hairnet.
Use ear protectors
When working with various materials, the sound
level may vary and at times exceed the 85 dB (A)
limit. Always use ear protectors to protect yourself.
Ensure that your work environment is safe
Ensure that no one else is working close to you and
that there are no objects that could be damaged by
your work.
Use safety goggles
Always use safety goggles to prevent injury to your
eyes from particles thrown up when using the pipe
saw.
Do not damage the power cable
Never carry the pipe saw by its power cable. Do not
pull the plug from the socket by pulling on the cable.
Protect the power cable from heat, oil, and sharp
edges.
Use safety gloves
Always use safety gloves as the edges of cut pipes
are sharp and can cause cuts.
Keep the work area tidy
An untidy work area can be hazardous and may
cause an accident.
Attach the pipe saw correctly
Always ensure that the gripper unit on the pipe saw
is firmly attached on the pipe that is going to be
sawn.
Pay attention to where you are working
Do not take the pipe saw out in the rain. Never use
it in wet or damp areas. Ensure that the working
area is well lit. Never use the pipe saw near
flammable liquids or gases. If the pipe saw does
get left out in the rain or gets wet in some other way,
have it serviced by an approved service agency.
Do not stoop over your work
Always stand maintaining a firm steady stance when
using the pipe saw.
Take proper care of the pipe saw
Keep the pipe saw clean and only use sharp blades.
Always follow the servicing instructions and the
instructions for changing the blade. Check the
condition of the power cable regularly and have it
changed by a qualified electrician if necessary. Also
regularly check the condition of the extension cable
you use and replace it if necessary. Keep the pipe
saw’s handle dry and clean from oil and grease.
Protect yourself from electrical shocks
Avoid coming into contact with objects that conduct
electricity, such as pipe systems, heating radiators,
cookers, washing machines, and refrigerators.
Keep the pipe saw away from children
Keep children away from the pipe saw and its
extension cable. Children under 16 years old must
be supervised.
Take the plug out of the socket
Always disconnect the power to the pipe saw by
removing the plug from the socket when the pipe
saw is not in use, when you change the blade, or
when you service it. Always remove the plug from
the socket before removing the blade guard.
Store the pipe saw correctly
Always store the pipe saw with the motor unit in the
upright position. When you are not using the pipe
saw, keep it in a dry place. Ensure that the storage
place is locked and high enough to be out of the
reach of children.
Avoid unintentional starting
Never carry the pipe saw with your finger on the
power switch while the saw is connected to its power
supply. Check that the power switch is in the off
position and the motor is in the upright position
before putting the plug into a socket.
Do not overload the pipe saw
Using too great a cutting force or too high a pipecutting speed can overload the machine. Always
arrange sawing so that when you cut through the pipe
5
Safety
Extension cables outside
When you work outdoors, always use an extension
cable that is made and approved for outdoor use.
Intended use and limitations
The Exact PipeCut 360 pipe saw is intended for use
as a pipe fitter’s tool at the installation site. The Exact
PipeCut 200 pipe saw can only be used to cut round
pipes, with a diameter of 75 to 360 mm and a
maximum wall thickness of 8mm with steel and 12mm
with plastics. The Exact PipeCut 360 pipe saw can
be used to cut all normal pipe materials, such as
steel, stainless steel, cast iron, copper, aluminum,
and plastic. Exact PipeCut 360 pipe saw is intended
for short, intermittent use. The machine may be
loaded for 2.5 minutes during a 10-minute period
(S3 25 %). The Exact PipeCut 360 pipe saw is not
intended for use in industrial production.
Be alert
Concentrate on your work. Use common sense. Do
not use the pipe saw when you are tired or drowsy.
Never use the pipe saw under the influence of alcohol
or drugs.
Use the right tool
Never use a low-power tool or accessory for work
that requires a high-powered tool. Never use the
pipe saw for purposes for which it is not intended.
Remove the key
Check that the blade key has been removed before
starting the pipe saw.
The pipe saw must never be used in the following
cases, if:
-There is water or another liquid, explosive gases or
poisonous chemicals inside the pipe to be cut.
-The power switch is faulty.
-The power cable is faulty,
-The blade is bent.
-The blade is blunt or in poor condition.
-The plastic components are cracked or have parts
missing.
-The gripper unit is not properly tightened around
the pipe or if it is warped.
-The blade guard cover or moving blade guard has
been damaged or removed from the machine.
-The locking mechanisms do not work properly
(UNLOCK-button).
-The pipe saw has become wet.
Accessories
Only use additional accessories and equipment
recommended by the manufacturer. The use of
another manufacturers accessories may cause an
accident.
Check for damaged parts
Before using the pipe saw, check that: all of its
components are in good condition, are correctly
installed and that all moving parts operate correctly.
Always check the attachments of the blade guard.
Also check that everything else that can affect
operation is in good condition. Never use the pipe
saw if the power switch does not operate properly
or if the cable is damaged. A damaged part should
be repaired or replaced with a new one at an approved
service agency.
When using the pipe saw, the following factors
must always be taken into consideration:
-Ensure that the pipe to be cut is empty.
-Ensure that the blade is correctly installed.
-Ensure that the diameter and thickness of the blade
are suitable for the pipe saw and that the blade is
suitable for the rpm-range of the machine.
-Never use sideways force to stop the blade, always
allow the blade to stop freely.
-Check the attachments of the blade guards.
-Never use excessive force when using the pipe saw.
-Never use the pipe saw to lift the pipe while it is still
attached to the pipe.
-Avoid overloading the electric motor.
-Always follow the safety and operating instructions
and current regulations.
Have your machine repaired at an approved
service agency
Your retailer will give you a list of approved service
agencies. For safety reasons, only approved service
agencies may service or change the machine’s
electrical components.
Do not cut pipes containing asbestos
Asbestos is considered to be carcinogenic substance.
Check the blade
Use only correct blades in good condition, which are
suitable for the material to be cut, for the pipe size
and for the speed of the saw
6
Operation
Fig. A
1.UNLOCK button
2.Power switch
3.Power-switch locking lever
4.Blade-guard cover
5.Blade-guard finger screw
6.Moving blade-guard
7.Edge of moving blade-guard
8.Adjusting wheel
9.Operating handle
10.Spindle-lock button
11.Blade-guard finger screw
12.Motor unit
13.Overload protection
14. Rating plate
15.Gripper unit
16.Gripper adjustment handle
17. Gripper safety
7
Operation
Fig C
Exact PipeCut 200
pipecutting system
operating instructions
Before operating the tool
Ensure that the motor unit is in the upright position.
The yellow mark of the UNLOCK button is visible.
Check that the blade is correctly fitted, in good
condition and suitable for the material to be cut.
Ensure the pipe saw guide wheels rotate.
Precise setting of the cutting point
When you mark the cutting point on the pipe to be
cut, deduct 20 mm from the required dimension
(Easy-to-remember rule: The cutting mark location
requires a measurement of - 20 mm.)(Figure C)
Ensure the support wheels rotate.
Check the operation of the lower blade guard.
Ensure the pipe is empty.
Setting the pipe on supports
Use the system supports when cutting pipes. This
will ensure safe working and optimum result. Work
on flat underground. Lift the pipe onto the cutting
holder so that the sawing point is between the
holders’ wheel pairs. Make sure that the wheels on
all the holders are in contact with the pipe (adjust if
required e.g. with pieces of lumber) (Figure B).
When cutting short pipes (25cm or less) place the
supports so that the cutting point is outside supports
(Figure D). Support the pipe with your left leg, if
required. Proper arrangements will prevent the blade
from jamming as the pipe is cut through.
It plastic pipes have been cut with the pipe saw
(resulting in long, statically charger slivers), open
the blade guard cover, and clean carefully the lower
blade guard and the entire pipe saw.
Connection to the mains power supply
Ensure that the mains voltage is the same as
indicated on the rating plate (Figure A/14). Connect
the pipe saw to the power outlet only after having
checked this.
Fig B
Fig D
8
Operation
Fig E
Attaching the pipe saw to the pipe
Open the pipe saw's gripper unit enough to suit the
diameter of the pipe by rotating the adjustment
handle located at the rear of the saw (Fig. E/1).
Position the pipe saw on top of the pipe so that the
edge of the lower blade guard is at the cutting mark.
Fasten the pipe saw to the pipe by turning the gripper
adjustment handle until the gripper grips firmly the
pipe to be cut (Fig E/2). Lock the mechanism by
turning the gripper safety (Fig E/3). Hold the pipe
in place and ensure that pipe saw moves freely in
the direction the pipe is fed. For sake of safety
ensure the pipe saw leads are to the left of the pipe
saw. The pipe saw is now ready for cutting.
Fig F
2
Piercing the pipe wall
Grip the gripper firmly with your right hand and place
your left foot on top of the pipe approximately 50cm
from the pipe saw. Turn the saw until it leans slightly
forward (Figure H). When starting the motor, first
of all release the power-switch locking lever (Fig
F/1) and push the power switch all the way down
(Fig F/2). Before starting to saw, wait until the blade
reaches full speed. Pierce the pipe wall by pressing
pipe saw operating handle downwards slowly and
evenly until the blade has cut through the pipe wall
(at this stage the pipe must not rotate) and the motor
unit is locked in the sawing position (Fig H/1).. Look
at the UNLOCK button during the piercing operation.
When UNLOCK button is locked, i.e. the yellow
mark disappears (Fig G), pipe saw is locked in the
sawing position, and you can safely start sawing
around the pipe.
1
Fig G
2
1
Fig H
Sawing around the pipe
3
Start sawing by feeding the pipe saw forward and
fix the pipe with your left foot (Fig H/3).. After that
release the pipe (remove your left foot from the pipe)
and turn the pipe saw backwards, whereby the pipe
will also be rotated backwards (Fig J). Start a new
feeding movement, and feed continuously forward
ca. 1/6 of the pipe's circumference. Repeat until the
pipe is cut off (Fig K).
9
Operation
Select the sawing speed as per the material and the
thickness of the wall. Too high speed can damage
the blade, overload the pipe saw and give a poor
sawing result.
Fig J
When the pipe is cut off, push the UNLOCK button
forward until the yellow mark is visible and the locking
is released (Fig L/1). Now raise the motor unit to
starting position (Fig L/2). Release the power switch
(Fig L/3). When the blade has stopped, open the
gripper safety mechanism (Fig L/4) and disengage
the pipe saw from the pipe by loosening the gripper
adjustment handle. (Fig L/5). Ensure that the moving
lower blade-guard is lowered into safety position.
1/8
Fig K
Should there be problems during piercing or sawing,
abnormal sounds or vibrations due to which you have
to interrupt sawing before the pipe is cut through,
release the blade by pushing the UNLOCK button
forward until the UNLOCK button is released, and lift
the motor unit up. Once the problem is cleared, start
sawing again.
Never start the motor, when the motor unit is locked
in sawing position or teeth of the blade contact the
pipe to be sawn.
1
3
Fig L
Overload protection
2
4
The pipe saw is equipped with overload protection.
When the blade is dull or the speed is too high, the
overload protection cuts power automatically. Restore
the power by pushing the overload protection switch
(Fig A/15).
5
Straightness of cut and adjusting wheel
The cut is affected by many factors, e.g. the size of
the pipe, the material, the wall thickness, the quality
of the pipe's surface, the roundness, welded seams,
blade condition, feed rate, operator's experience. For
this reason the result may vary, and the cut may turn
to left or right (misalignment of the cut's starting and
ending point) (Fig M). The pipe saw gripper has one
adjustable wheel (Fig A/9) which be used for improving
the quality of the cut and for reducing the misalignment.
Fig M
The adjustment applies only to the actual pipe size
and material, and the wheel may have to be readjusted
as the blade is worn.
Step to left
10
Step to right
Operation, maintenance
The wheel can be adjusted in 9 positions; mid position
and 4 steps to left and right. To adjust the wheel,
loosen the locking screw (Fig N/1) and turn the
wheel center clockwise or counterclockwise to the
desired position (Fig N/2), and lock the wheel again
(Fig N/3). If the blade has wandered too much to
the right, adjust wheel center clockwise. It the
misalignment is to the left, adjust counterclockwise.
The number of steps depend on the actual
misalignment. Remember to lubricate the adjusting
wheel at regular intervals.
3
1
Fig N
2
Installing and changing the
saw blade
Remove the power plug from the socket. Check that
the motor unit is locked in the upper position.
6
7
Fig O
5
2
4
3
Remove the blade guard cover (Fig. O/1) by opening
the two finger screws (Fig. O/2). Press the spindlelock button (Fig. A/11) and simultaneously rotate
the blade by hand until the spindle-lock button drops
a further distance of about 7 mm. Now the rotation
of the blade is prevented. Use the blade key to open
the blade attachment bolt. Remove the securing bolt
(Fig. O/3), the washer (Fig. O/4), the blade flange
disc (Fig. O/5), and the blade (Fig. O/6).
Before installing a new blade, check that both blade
flange discs are clean. Place a new or sharpened
blade on the back flange disc (Fig. O/7), so that the
marked side of the blade is facing outwards and the
arrows on the blade are facing in the same direction
as the rotation direction markings on the inside of
the blade case. Ensure that the new blade goes
right to the bottom in the back flange disc. Put the
blade flange disc, the washer, and the securing bolt
back in place. Press the spindle lock button and
tighten the blade securing bolt. Put the blade guard
cover back in place and tighten the finger bolts.
1
Fig P
1
4
3
2
Maintenance and servicing
instructions
Remove the power plug from the socket before
servicing or cleaning the pipe saw. All maintenance
operations carried out on the pipe saw’s electrical
components must be carried out at an approved
service agency.
11
Environment, guarantee
Blade
Check the condition of the blade. Replace a bent,
blunt, or otherwise damaged blade with a new one.
Using a blunt blade can overload the pipe saw’s
electric motor. When you notice that the blade is
blunt, do not continue sawing with it, as the blade
may become so badly damaged that it will not be
worth sharpening. A blade in sufficiently good
condition can be sharpened a few times by a
professional sharpening company. Use only Exactblades.
Environment
Separate collection. This product must not
be disposed of with normal household
waste. When your Exact PipeCut 200
machine is worn out, do not dispose of it
with normal household waste. This product
must be recycled separately. Separate
recycling of used products and packaging
facilitate recycling and recovery of
materials. Reusing of recycled materials helps
prevent pollution of environment. According to local
regulations it is possible to deliver household
appliances to municipal rubbish depositories or to
the dealer when buying a new product.
Gripper unit
Clean the gripper unit regularly with compressed
air. Lubricate the gripper’s wheel axles (Fig. P/1)
and its joints (Fig. P/2). Also clean and lubricate the
gripper’s trapezoidal screw (Fig. P/3) and the two
worm screws on it (Fig. P/4).
Guarantee
Blade guard
When you have sawn plastic pipes and then intend
to start sawing metal pipes always clean the inside
of the blade guards. Hot particles derived from
sawing metal will burn plastic particles, which may
release toxic smoke. Make it a rule to clean the
blade guard regularly, and pay special attention to
keep the moving blade guard movement from
becoming hampered. Lubricate the axis of the moving
blade guard regularly.
If the Exact PipeCut 200 pipe saw becomes unusable
due to material or manufacturing faults within 24
months of the date of purchase, we will replace the
damaged parts with new ones or supply an entirely
new or factory-reconditioned pipe saw to replace
the damaged one.
The guarantee is only valid if:
The guarantee card or a dated purchase receipt is
returned to the manufacturer or retailer.
The pipe saw has not been misused.
No attempt has been made by non-approved persons
to repair the saw.
The pipe saw has been used in accordance with
these operating, safety, and servicing instructions.
The guarantee does not apply to blades or the
overload protection.
Motor
Keep the motors cooling vents clean.
Plastic parts
Clean the plastic parts with a soft rag. Only use mild
detergents. Do not use solvents or other strong
detergents as they may damage the plastic parts
and paint surfaces.
Due to continuous product development, the
information in this instruction book may change.
We do not give separate notification of changes.
Power cable
Check the condition of the power cable regularly. A
faulty power cable should always be replaced at an
approved service agency.
Correct use and regular servicing and cleaning will
ensure the continued operation of the pipe saw.
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