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INSTRUCTIONS
PARTS MANUAL
PLASMA CIRCLE
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.
280 TECHNOLOGY DRIVE
AND
CB-1P
BURNER
Model Number
Serial Number
Date of Purchase
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.
A DIVISION OF WELD TOOLING CORPORATION
PHONE: 412-331-1776
CANONSBURG, PENNSYLVANIA
http://www.bugo.com
LIT-CB-1P-IPM-0614
15317-9564 USA
FAX: 412- 331- 0383
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Related Manuals for BUG-O CB-1P
Summary of Contents for BUG-O CB-1P
- Page 1 Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. LIT-CB-1P-IPM-0614 Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do. 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-1P Pointer Assembly / Exploded View / Parts List 21 ..CWO-3922 Manifold and Retainer / Exploded View / Parts List 21 ..CWO-3923 CB-1P 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-1P (CBO-1020) Plasma Circle Burner is supplied with a Victor / Thermal Dynamics (CutMaster 82) plasma power source, 180 degree plasma machine torch and 50' (15 m) control cable / torch lead.
- Page 6 • Plasma Box Cable Assembly to the terminal connector in the main gear at the top of the machine. • Air Hose Assembly to the hose fitting in the top of the CB-1P Shaft Assembly item (11) on page 13.
- Page 7 WHEEL ADJUSTMENT: The CB-1P Racking System (CWO-1670) and the Small Vertical Racker (CWO-1685) are equipped with adjustable wheels. Always check these components for proper wheel adjustment before using the machine. The wheels need adjustment if you can cock or wiggle the components out of alignment.
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Page 8: Cwo-6210 Rotation Controls
CWO-6210 ROTATION CONTROLS SPEED CONTROL TRAVEL DIRECTION PILOT LIGHT ON/OFF SWITCH SPEED CONTROL: Controls the speed in which the machine travels. The depicted lines 0 to 100 should not be construed as inches per minute of travel. They should be considered as reference points only. TRAVEL DIRECTION: Controls the direction in which the machine will travel. - Page 9 CWO-7655 CB-1P POWER SUPPLY CONTROLS 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.
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Page 10: Cwo-3951 Plasma Controls
CWO-3951 PLASMA CONTROLS ARC ON/OFF HAND/OFF/AUTO ARC ON/OFF: The OFF position disables the cutting process, allowing machine rotation without starting the cutting process when the HAND/OFF/AUTO switch is thrown to the HAND position. The ON position enables the cutting process when the HAND/OFF/AUTO switch is thrown to the AUTO position. HAND/OFF/AUTO: The HAND position allows the operator to rotate the machine when the ARC ON/OFF switch is in the OFF position to check torch position as well as the cam setting. -
Page 11: Technical Data / Dimensions
TECHNICAL DATA Amperage: 15-60 AMPS Input Voltage: 208/440 VAC 50/60 Hz single or three phase 120 VAC 50/60 Hz single or three 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 12 CBO-1020-NPS, CBO-1020- CB-1P PLASMA CIRCLE BURNER / PARTS LIST 25, 26...
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Page 13: Cbo-1020-Nps, Cbo-1020- Cb-1P Plasma Circle Burner / Exploded View
CBO-1020-NPS, CBO-1020- CB-1P PLASMA CIRCLE BURNER / EXPLODED VIEW 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... -
Page 14: Cbo-1020-Nps Cb-1P Plasma Circle Burner / Wiring Diagram
CBO-1020-NPS CB-1P 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 QTY 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 QTY 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-1P / Exploded View / Parts List
CWO-3483 SHAFT ASSEMBLY CB-1P / EXPLODED VIEW / PARTS LIST O-Ring Groove O-Ring Groove ITEM PART NO. DESCRIPTION BUG-9096 Outlet Bushing Oxygen CWO-4202 O-Ring CB-1P 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-1P 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-1P LARGE BRUSH ASSEMBLY / EXPLODED VIEW / PARTS LIST ITEM PART NO. DESCRIPTION CWO-7624 Large Brush Holder Support CWO-3266 Attachment Bar... -
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-1P SMALL BRUSH HOLDER / EXPLODED VIEW / PARTS LIST Orange ITEM QTY PART NO. DESCRIPTION CWO-3464 Small CB-1P Retainer Assembly CWO-9076 Retainer Support (Small) FAS-0539 Soc Hd Cap Scr 10-24 x 1"... -
Page 23: Cwo-3951 Plasma Control Box / Exploded View / Parts List
CWO-3951 PLASMA CONTROL BOX / EXPLODED VIEW / PARTS LIST ITEM QTY PART NO. DESCRIPTION BUG-2255 Toggle Switch BUG-2287 Power Receptacle CWO-5672 Cover Face Plate CWO-6207 Toggle Switch On-Off CWO-6288 Terminal Block CWO-6367 Plasma Control Box FAS-0115 Pan Hd Scr 6-32 x 1/2" FAS-1310 Hex Nut 6-32 GOF-3021... -
Page 24: Cwo-3951 Plasma Control Box / Wiring Diagram
CWO-3951 PLASMA CONTROL BOX / WIRING DIAGRAM... -
Page 25: Cwo-6210 Rotation Control / Exploded View / Parts List
CWO-6210 ROTATION CONTROL / EXPLODED VIEW / PARTS LIST 13,14,21 21,14,13 15,17 15,16 25,26 ITEM QTY PART NO. DESCRIPTION ARM-2279 TOGGLE SWITCH BUG-9445 POWER CORD CON-PS04M PLUG, STRAIGHT 4-PIN MALE BUG-9687 KNOB FLUTED BUG-9694 KNOB CSR-WTE-1597 CORD STRAIN RELIEF CWO-6216 ROTATION BOX FRONT PANEL CWO-5547B ROTATION BOX REAR PANEL... -
Page 26: Cwo-6210 Rotation Control / Wiring Diagram / Electrical Component Chart
CWO-6210 ROTATION CONTROL / WIRING DIAGRAM / ELECTRICAL COMPONENT CHART = INDICATES ITEMS THAT ARE SUPPLIED TOGETHER. ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO. TOGGLE SWITCH ARM-2279 RED NEON LAMP CWO-6206 SPEED CONTROL BOARD W/RESISTOR CWO-6525 FUSE 1.5 AMP FUS-0190 FUSE 3 AMP FUS-0257 ROTARY SWITCH... -
Page 27: Consolidated Wiring Diagram
CONSOLIDATED WIRING DIAGRAM... -
Page 28: Cwo-1050 120V Power Box / Wiring Diagram
CWO-1050 120V POWER BOX / WIRING DIAGRAM... - Page 29 POWER SUPPLY REPLACEMENT COMPONENTS ITEM QTY PART NO. DESCRIPTION CWO-7596-50-CB-1P 50ft Machine Torch Hypertherm CB-1P Plasma Power Source CWO-1045-3 Plasma CB-1P Interface Cable CWO-1050 120V Power Box Note: For consumable chart, see Powermax 65 or 85 instruction manual.
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Page 30: Carriages
CARRIAGES CWO-4530 151 Carriage The 151 Carriage mounts on a standard monorail. The carriage allows the operator to move the chine 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-1P 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-1P to it. With the center pin in the burning machine, check all three locations. The burning machine must be plumb on the... -
Page 32: Set-Up Instructions For Cw-5 / Cb-1P Used In Sprinkler Fabrication
INSTALLING CARRIAGES AND MACHINES ON THE MONORAIL Assemble carriages and put them on the rail. The CW-5 welder is put on the carriage that is nearest to the welding power source and the CB-1P cutter nearest to the plasma power source. -
Page 34: Preventive Maintenance For Cb-1P 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-1P Electrical Wir- ing Diagram) are disconnected from the circle burner prior to working inside the machine. - Page 35 Do not grease slide rails or cam pinion. Lubricate with a dry Teflon or graphite spray lubricant. Replace cam pinion if excessively worn. Tighten all fasteners as needed. Refer to CB-1P Electrical Component Chart. (Page 14) M-14 Rotation Control: Open control box use an air hose to blow out dust and dirt. Check all wires for breaks and replace if necessary.
- Page 36 Refer to CB-1P Wiring Diagram. (Page 14) CB-1P 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
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 HAVE EXPERIENCED. BE SURE... - Page 38 NOTES:...
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