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INSTRUCTIONS
PARTS MANUAL
PLASMA CIRCLE
WITH REMOTE CONTROL
AND A-80 POWER SOURCE
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.
280 TECHNOLOGY DRIVE
PHONE: 412-331-1776
AND
CB-1PR
BURNER
Model Number
Serial Number
Date of Purchase
A DIVISION OF WELD TOOLING CORPORATION
CANONSBURG, PENNSYLVANIA 15317-9564 USA
http://www.bugo.com
LIT-CB-1PR-A80-IPM-0320
FAX: 412- 331- 0383
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Table of Contents
Related Manuals for BUG-O CB-1PR
Summary of Contents for BUG-O CB-1PR
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-CB-1PR-A80-IPM-0320 Bug-O Systems is committed to empowering our customers by providing operator controlled mechanized solutions for their welding, cutting and custom applications. A DIVISION OF WELD TOOLING CORPORATION...
- Page 2 SAFETY PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. EQUIPMENT DAMAGE ELECTRIC SHOCK CAN KILL. POSSIBLE. 1) The equipment is not waterproof. Using the unit in a wet environment may result in serious injury.
- Page 3 HIGH FREQUENCY WARNINGS SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA, TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY TO STRIKE AN ARC. WARNING: HIGH FREQUENCY CAN EFFECT MACHINE OPERATION AND THEREFORE, WELD QUALITY. Read the precautions below before installing and using the equipment. PRECAUTIONS: 1) Some plasma or welding cables are strong sources of high frequency interference.
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Page 4: Table Of Contents
20 ..CWO-3516 CB-1PR Pointer Assembly / Exploded View / Parts List 21 ..CWO-3922 Manifold and Retainer / Exploded View / Parts List 21 ..CWO-3923 CB-1PR Large Brush Assembly / Exploded View / Parts List 22 ..CWO-3941 High Frequency Brush / Exploded View / Parts List 22 .. - Page 5 O-rings enabling the machine to operate continuously in either direction without cable or hose wrap up. The CB-1PR (CBP-2020) Plasma Circle Burner is supplied with a Victor / Thermal Dynamics (CutMaster A80) plasma power supply, 180 degree plasma machine torch and 50' (15 m) control cable / torch lead.
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Page 6: Set-Up And Operation
• Sensor Cable (CWE-1020) from the Remote Pendant to the top gear of the machine • Air Hose Assembly item (2) on page 17 to the hose fitting in the top of the CB-1PR Shaft Assembly item (11) on page 13 •... - Page 7 RISE AND FALL OF THE CAM: All circle burners are equipped with a rise and fall cam assembly. The cam assembly must be aligned before any other settings can be made. To align the cam on the machine, align the horizontal rack parallel to the pipe, then adjust the gun holder so it is perpendicular to the horizontal rack.
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Page 8: Cbp-2000 Remote Pendant
CBP-2000 REMOTE PENDANT The CBP-2020 features remote pendant control. A summary of each control feature is provided below. 1. SPEED DISPLAY: Displays a reference value for rotation speed. 2. SPEED CONTROL: Controls the rotation speed of the machine. 3. TRAVEL DIRECTION: Controls the machine’s direction of rotation, CYCLE when in “MANUAL”. -
Page 9: Plasma Power Source
PLASMA POWER SOURCE 1. OUTPUT CURRENT CONTROL The Current Control is used to set the desired output current, the current can be adjusted from 15-60 amps. For drag cutting applications, the current should not exceed 60 amps. 2. FUNCTION CONTROL The Function Control knob is used to select between four operating modes -- Set, Run, Rapid Auto Restart, and Latch. -
Page 10: Technical Data / Dimensions
TECHNICAL DATA Amperage: 30-80 AMPS, 100 AMP Max. Adjustable Input Voltage: Power Source, see Page 11 120 VAC 50/60 Hz single phase Rotation Speed: 0.2-11 rpm Cam Range: 5" (125 mm) Burning Diameter: 1-12" (25-300 mm) Machine Weight: 170 lbs. (77 kg) Power Source Weight: 73.5 lbs. -
Page 11: Power Supply Electrical Specifications
POWER SUPPLY ELECTRICAL SPECIFICATIONS Rated Output 80 Amps Output Range 30 - 80 Amps, 100 Amps Max., Adjustable Production Piercing and 1/2" (12mm) Cutting Capacity Maximum Piercing and 3/4" (20mm) Cutting Capacity Maximum Edge Start 1 1/4" (30mm) 208-230/460V, 1/3 ph, 50/60 Hz, Input Volts 380/400V, 3 ph, 50/60 Hz, 600V, 3 ph, 60 Hz... - Page 12 CBP-2020 CB-1PR PLASMA CIRCLE BURNER / PARTS LIST ITEM PART NO. DESCRIPTION CBO-1670 Racking System CWO-1685 Small Horizontal Racker CWO-3004 Cam Shaft & Spacer Assembly CWO-3005 5" Cam Assembly CWO-3199 Housing Assembly CWO-3399 Load Spring Assembly CWO-3417 Motor & Transmission Plate Assembly...
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Page 13: Cbp-2020 Cb-1Pr Plasma Circle Burner / Exploded View
CBP-2020 CB-1PR PLASMA CIRCLE BURNER / EXPLODED VIEW... -
Page 14: Cbp-2020 Cb-1Pr Plasma Circle Burner / Wiring Diagram
CBP-2020 CB-1PR PLASMA CIRCLE BURNER / WIRING DIAGRAM... -
Page 15: Cbo-1670 Racking System / Exploded View / Parts List
CBO-1670 RACKING SYSTEM / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION ABR-1070 V-Guide Ways 19" CWO-1675 Vertical Racker CWO-1695 Attachment Block CWO-3450 10.6# Load Spring Assy. CBO-1675 Torch Clamp Assy. FAS-1351 Hex Nut 1/4-20 FAS-2351 Hex Hd Cap Scr 1/4-20 x 1-1/4" CWO-1685 SMALL HORIZONTAL RACKER / EXPLODED VIEW / PARTS LIST ITEM PART NO. -
Page 16: Cwo-3004 Cam Shaft & Spacer Assembly / Exploded View / Parts List
CWO-3004 CAM SHAFT & SPACER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4073 Ball Joint Rod End 5/16-24 RH CWO-5019 Ball Joint Rod End 5/16-24 LH CWO-9078 Spacer 1/2" O.D. x 5/16 I.D. x 3/4" CWO-9357 Cam Shaft Tube FAS-0377 Hex Hd Cap Scr 5/16-18 x 3/4"... -
Page 17: Cwo-3035 Junction Box Assembly / Parts List / Wiring Diagram
CWO-3035 JUNCTION BOX ASSEMBLY / PARTS LIST / WIRING DIAGRAM ITEM PART NO. DESCRIPTION CWO-3033 Cable Assy., Plasma Box CWO-3933 20" Oxygen Hose Assy. CWO-3938 Hose Coupling Assy. CWO-3957-24 24" Low Frequency Power Cable CWO-3958-24 24" High Frequency Power Cable CWO-6288 Terminal Block (6) CWO-6771... -
Page 18: Cwo-3199 Housing Assembly / Exploded View / Parts List
CWO-3199 HOUSING ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION BUG-1296 90 Degree Hose Adaptor CWO-4226 Outlet Bushing CWO-5837 Center Tube Housing CWO-5843 Top Housing Plate CW-5 CWO-5846 Lower Housing Plate CW-5 CWO-5975 Insert 1-5/8" O.D. x 1.376" I.D. x 1" CWO-9339 Angle For Guard FAS-0535... -
Page 19: Cwo-3418 Transmission / Exploded View / Parts List
CWO-3418 TRANSMISSION / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-3276 Pinion Gear Assembly CWO-4068 Transmission SW 3.5:1 CWO-3422 P.M. MOTOR / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4069 Gear, P.M. Motor CWO-4147 P.M. Motor Bracket #970 CWO-5997 P.M. -
Page 20: Cwo-3483 Shaft Assembly Cb-1Pr / Exploded View / Parts List
CWO-3483 SHAFT ASSEMBLY CB-1PR / EXPLODED VIEW / PARTS LIST O-Ring Groove O-Ring Groove ITEM PART NO. DESCRIPTION BUG-9096 Outlet Bushing Oxygen CWO-4202 O-Ring CB-1PR N70 568 322 1-1/4 CWO-5781 Shaft CWO-5975 Insert 1-5/8" O.D. x 1.376 x 1" CWO-3516 CB-1PR POINTER ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. -
Page 21: Cwo-3922 Manifold And Retainer / Exploded View / Parts List
FAS-1351 1/4-20 Hex Nut WAS-0240 1/4" SAE Washer WAS-0243 1/4" Split Lock Washer BUG-2063 1/4" Delrin Washer CWO-3923 CB-1PR LARGE BRUSH ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-4046 Large Brush Holder CWO-4337 Large Brush CWO-5550... -
Page 22: Cwo-3941 High Frequency Brush / Exploded View / Parts List
WAS-0260 3/8" Washer WAS-0262 3/8" Split Lock Washer WAS-0240 1/4" Washer WAS-0243 1/4" Lockwasher CWO-3945 CB-1PR SMALL BRUSH HOLDER / EXPLODED VIEW / PARTS LIST Orange ITEM QTY PART NO. DESCRIPTION CWO-3464 Small CB-1PR Retainer Assembly CWO-9076 Retainer Support (Small) FAS-0539 Soc Hd Cap Scr #10-24 x 1"... -
Page 23: Cbp-2005 Control To Unit Cable
CBP-2005 CONTROL TO UNIT CABLE CWE-1020 SENSOR CABLE SENSOR LEADS SHIELD SHIELD CBP-2010 CONTROL MOUNT ARM... -
Page 24: Cbp-2000 Control Box, Remote Cb-1P Exploded View / Parts List
CBP-2000 CONTROL BOX, REMOTE CB-1P EXPLODED VIEW / PARTS LIST 25,26 24,28,35,36 39,41 19,30 13,14 7,12 18,29,30 ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION CBP-2002 CBP-2000 Enclosure FHO-0188 Fuse Holder, Panel Mount BUG-1764 Meter Display Board Assembly MUG-1156 Panel Connector, 4-T, F MDS-1011... -
Page 25: Cbp-2000 Control Box / Wiring Diagram
CBP-2000 CONTROL BOX / WIRING DIAGRAM (1 OF 3) - Page 26 CBP-2000 CONTROL BOX / WIRING DIAGRAM (2 OF 3)
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Page 27: Cbp-2000 Control Box / Electrical Component Chart
CBP-2000 CONTROL BOX / WIRING DIAGRAM (3 OF 3) ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. PCB1 Power Supply Pcb PCB-5800 PCB2 Micro Control Pcb PCB-5801 PCB3 Relay Board Pcb PCB-2231 PCB4 0-90V Spd Ctrl w/ Isolator CWO-6527 Push Button Switch SWT-1111 Power Switch ARM-2279... -
Page 28: Consolidated Wiring Diagram
CONSOLIDATED WIRING DIAGRAM... -
Page 29: Cbp-2025 Power Supply Replacement Components
ITEM QTY PART NO. DESCRIPTION CWO-7658 CB-1PR Torch Assy. CWO-7658-C1 50' Cable CBP-2025 CB-1PR CM82, Plasma Power Source CBP-2026 Precut & Term 50' Mach Torch CWO-1050 120V Power Box SPK-CBP-2025 Spare Parts Kit * CWO-7655-SPK Spare Parts Kit Includes: Electrode... -
Page 30: Carriages
CARRIAGES CWO-4530 151 Carriage The 151 Carriage mounts on a standard monorail. The carriage allows the operator to move the machine the length of the pipe, while utilizing a lever to position the machine vertically on the work piece. CWO-4540 151P Carriage The 151P Carriage mounts on a standard monorail. -
Page 31: Set-Up Instructions For Cw-5/Cb-1Pr Used In Sprinkler Fabrication
The distance should be 5-11/16" in all three locations. 2. The second method is to put one carriage on the monorail and attach the CB-1PR to it. With the center pin in the burning machine, check all three locations. The burning machine must be plumb on the... - Page 32 Put the CB-1PR cutter machine on the 8" pipe in the stands and bring the carriage to the machine. Lower the shaft coupling over the main shaft on the cutter. Ensure that shaft is fully inserted into the shaft coupling. Rotate the machine so that the plasma leads are in front and parallel to the carriage and tighten the set screws in the shaft coupling to secure the main shaft to the vertical slide assembly.
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Page 34: Preventive Maintenance For Cb-1Pr Plasma Circle Burner
CAUTION: Make sure the input power at the power source is turned off and the high and low frequency power cables, and the 50' control cable (Items # 2, 3,10, on the CB-1PR Electrical Wiring Diagram on page 14) are disconnected from the circle burner prior to working inside the machine. - Page 35 EVERY SIX MONTHS: Refer to CB-1PR Exploded View Parts List. (Page 12) Aluminum Gear Item # 30: Do not grease this gear. Inspect gear teeth (remove all dirt and grease). Lubricate with a dry Teflon or graphite spray lubricant. Replace gear if excessively worn.
- Page 36 Refer to CB-1PR Wiring Diagram. (Page 14) CB-1PR Collector: The collector ring should be sanded once a year. If the collector ring is pitted too badly it should be replaced. Inspect all wires coming out of the collector ring for cut or missing insulation.
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Page 37: Warranty
HOW TO OBTAIN SERVICE: IF YOU THINK THIS MACHINE IS NOT OPERATING PROPERLY, RE-READ THE INSTRUCTION MANUAL CAREFULLY, THEN CALL YOUR AUTHORIZED BUG-O DEALER/DISTRIBUTOR. IF THEY CANNOT GIVE YOU THE NECESSARY SERVICE, WRITE OR PHONE US TO TELL US EXACTLY WHAT DIFFICULTY YOU... - Page 38 NOTES:...
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