BUG-O CB-1P Instructions And Parts Manual Download Page 1

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INSTRUCTIONS

AND

PARTS MANUAL

CB-1P

PLASMA CIRCLE

BURNER

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Model Number

Serial Number

Date of Purchase

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above.

LIT-CB-1P-IPM-0614

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA

PHONE: 412-331-1776 http://www.bugo.com FAX: 412-331- 0383

Bug-O Systems is guided by honesty, integrity and

ethics in service to our customers and in all we do.

Summary of Contents for CB-1P

Page 1: ...mber Date of Purchase Whenever you request replacement parts or information on this equipment always supply the information you have recorded above LIT CB 1P IPM 0614 A DIVISION OF WELD TOOLING CORPORATION 280 TECHNOLOGY DRIVE CANONSBURG PENNSYLVANIA 15317 9564 USA PHONE 412 331 1776 http www bugo com FAX 412 331 0383 Bug O Systems is guided by honesty integrity and ethics in service to our custom...

Page 2: ...EC 950 5 Never remove or bypass the equipment power cord ground Verify the equipment is grounded in accordance with al applicable local and national electrical safety codes In none exist use International Electric Code IEC 950 READ INSTRUCTIONS Read the instruction manual before installing and using the equipment 1 Do not plug in the power cord with out first verifying the equipment is OFF and the...

Page 3: ...ounts of high frequency noise They may require a grounding rod be driven into the earth within six feet 2 meters of the plasma or welding unit to become compatible with an automatic cutting or welding process 4 If the high frequency is produced using a spark gap adjust the points so the gap is as small as possible The larger the gap the higher the voltage and the higher the interference 5 Some pla...

Page 4: ...CWO 3422 P M Motor Exploded View Parts List 20 CWO 3483 Shaft Assembly CB 1P Exploded View Parts List 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 CWO 3945 CB 1P Small Brush Holder Exploded View Parts ...

Page 5: ...tMaster 82 plasma power source 180 degree plasma machine torch and 50 15 m control cable torch lead The CB 1P CBO 1020 Plasma Circle Burner requires both 220 50 60 1 and 120 50 60 1 to operate The unit must be mounted on a carriage or fixture FEATURES 1 12 HP P M motor and rotational speed control 180 degree plasma machine torch 50 ft 15 m control cable torch lead Adjustable vertical and horizonta...

Page 6: ...CTIONS The CB 1P Plasma Circle Burner is equipped with a Junction Box Assembly CWO 3035 shown on page 17 The Junction Box Assembly is supplied with five leads that need to be connected as described below Connect 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 ...

Page 7: ... the Racking System CWO 1670 Ensure that the torch is at the appropriate position standoff distance and angle 2 Connect the ground cable to the work piece The ground cable must make good electrical contact with the work 3 With the Arc ON OFF switch in the OFF position and the HAND OFF AUTO switch in the HAND position set the rotation direction and speed 4 With the Arc ON OFF switch in the ON posit...

Page 8: ... TRAVEL DIRECTION Controls the direction in which the machine will travel Select the left arrow for clockwise rotation brake for stop and the right arrow for counter clockwise rotation ON OFF SWITCH The On Off switch enables disables power to the rotation control box PILOT LIGHT The Pilot Light indicates whether the machine is on off as dictated by the on off switch ON OFF SWITCH PILOT LIGHT TRAVE...

Page 9: ...he SET mode to adjust the air gas pressure Pull knob out to adjust then push in to lock 5 AC INDICATOR Steady light indicates power supply is ready for operation Blinking light indicates interlock mode Refer to power supply operation manual for more instructions 6 TEMP INDICATOR Indicator will light when power supply internal temperature is above the normal operational limits Let unit cool before ...

Page 10: ...en 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 The AUTO position will start the entire cutting operation based on the operator s settings including machine rotation when the ARC ON OFF switch is in the ON position...

Page 11: ...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 33 kg Shipping Weight 283 5 lbs 129 kg DIMENSIONS 30 762 mm 34 864 mm 20 508 mm 6 152 mm 26 660 mm ...

Page 12: ...12 12 24 23 30 18 15 17 19 22 5 16 31 20 29 27 13 11 34 32 10 25 26 33 35 32 34 1 28 2 6 3 4 8 9 7 14 21 38 39 40 41 37 36 CBO 1020 NPS CBO 1020 CB 1P PLASMA CIRCLE BURNER PARTS LIST ...

Page 13: ...CB 1P Small Brush Holder 20 1 CWO 3951 Plasma Control Box 21 1 CWO 4050 1 Bearing w Fasteners 22 1 CWO 4060 1 1 4 Bearing w Fasteners 23 1 CWO 5075 1 1 4 ID Trantorque 24 1 CWO 5220 Guard Assembly 25 1 CWO 6210 Rotation Control Box 26 1 CWO 6110 L Rotation Control Mounting 27 1 CWO 6423 CB 1P Control L Bracket 28 1 CWO 6424 CB 1P Control MT Spacer 29 1 CWO 6426 Plasma Control MT Bracket 30 1 CWO 9...

Page 14: ...14 CBO 1020 NPS CB 1P PLASMA CIRCLE BURNER WIRING DIAGRAM ...

Page 15: ...Fixed Leg Wheel Assy 8 2 CWO 4021 Adj Leg Wheel Assy 9 1 CWO 4112 Bracket 10 1 FAS 0355 Hex Hd Cap Scr 1 4 20 x 1 2 11 2 FAS 0534 Soc Hd Cap Scr 10 24 x 3 8 12 4 FAS 0557 Soc Hd Cap Scr 1 4 20 x 3 4 13 1 FAS 1307 Hex Jam Nut 3 4 16 14 1 FAS 1351 Hex Nut 1 4 20 15 1 MUG 1141 Bearing Collet 16 1 MUG 1142 Knob Locking 17 1 MUG 1144 Shaft 18 2 MUG 1453 Stand Off 19 1 MUG 1579 Retaining Ring 20 3 WAS 0...

Page 16: ...ex Hd Cap Scr 5 16 18 x 2 9 3 WAS 0250 5 16 SAE Washer ITEM QTY PART NO DESCRIPTION 1 2 BUG 2098 Delrin Washer 3 8 I D 2 1 BUG 9012 Locking Collar 3 1 CWO 4026 Base Plate 5 Cam 4 2 CWO 4027 End Plate 5 Cam 5 1 CWO 4028 Center Block 5 Cam 6 1 CWO 4029 Screw 5 Cam 7 2 CWO 4031 Rod 5 Cam 8 1 CWO 4032 Knob 9 1 CWO 5199 Scale 10 4 FAS 0434 Set Scr 10 24 x 3 8 11 1 FAS 0444 Set Scr 10 32 x 3 8 12 2 FAS ...

Page 17: ...le 6 1 CWO 6288 Terminal Block 6 7 1 CWO 6771 Machined Enclosure Cover 8 1 CWO 6772 JB Support Block 9 2 CWO 6767 Cord Grip 1 1 4 Wire 10 4 FAS 0235 Rnd Hd Scr 10 24 x 1 2 11 4 FAS 0527 Soc Hd Cap Scr 8 32 x 3 4 12 1 FAS 0359 Hex Hd Cap Scr 1 4 20 x 1 13 2 FAS 0915 Flt Hd Soc Scr 6 32 x 1 2 14 2 FAS 1310 Hex Nut 6 32 15 2 FAS 1351 Hex Nut 1 4 20 16 1 FAS 2351 Hex Hd Cap Scr 1 4 20 x 1 1 4 17 2 WAS...

Page 18: ...ptor 2 1 CWO 4226 Outlet Bushing 3 1 CWO 5837 Center Tube Housing 4 1 CWO 5843 Top Housing Plate CW 5 5 1 CWO 5846 Lower Housing Plate CW 5 6 2 CWO 5975 Insert 1 5 8 O D x 1 376 I D x 1 7 3 CWO 9339 Angle For Guard 8 3 FAS 0535 Soc Hd Cap Scr 10 24 x 1 2 9 8 FAS 0548 Soc Hd Cap Scr 10 32 x 3 8 9 5 6 3 6 4 7 8 9 1 2 ...

Page 19: ... 1 CWO 3276 Pinion Gear Assembly 2 1 CWO 4068 Transmission SW 3 5 1 2 1 CWO 3422 P M MOTOR EXPLODED VIEW PARTS LIST ITEM QTY PART NO DESCRIPTION 1 1 CWO 4069 Gear P M Motor 2 1 CWO 4147 P M Motor Bracket 970 3 1 CWO 5997 P M Motor 4 3 TERM WTE 1508 8 Fork Blue 14RB 8FL T B 1 2 3 4 ...

Page 20: ...O 4202 O Ring CB 1P N70 568 322 1 1 4 3 1 CWO 5781 Shaft 4 1 CWO 5975 Insert 1 5 8 O D x 1 376 x 1 CWO 3516 CB 1P POINTER ASSEMBLY EXPLODED VIEW PARTS LIST 1 2 3 2 4 O Ring Groove O Ring Groove ITEM QTY PART NO DESCRIPTION 1 1 CWO 4238 CB 1P Center Pin 2 1 CWO 9131 Compression Spring 3 1 FAS 0559 Soc Hd Cap Scr 1 4 20 x 1 3 2 1 ...

Page 21: ...AS 0240 1 4 SAE Washer 11 1 WAS 0243 1 4 Split Lock Washer 12 2 BUG 2063 1 4 Delrin Washer ITEM QTY PART NO DESCRIPTION 1 1 CWO 7624 Large Brush Holder Support 2 1 CWO 3266 Attachment Bar 3 1 CWO 3263 Large Brush Holder 4 2 CWO 3264 Spring Clip 5 2 CWO 4337 Large Brush 1 1 2 x 3 4 x 2 6 1 CWO 5550 Micarta Bushing 7 2 FAS 0305 Hex Hd Cap Scr 1 2 13 x 2 8 1 FAS 0357 Hex Hd Cap Scr 1 4 20 x 3 4 9 1 W...

Page 22: ...Brush Holder 9 5 CWO 5875 Cap 10 5 CWO 5876 Clip 11 1 CWO 7609 CB 1P Small Brush Retainer 12 5 TERM WTE 0602 6 Fork Blue CWO 3945 CB 1P SMALL BRUSH HOLDER EXPLODED VIEW PARTS LIST 3 8 9 4 1 2 6 7 5 ITEM QTY PART NO DESCRIPTION 1 1 CWO 5833 Brush 3 4 Sq x 3 4 LG 2 1 CWO 5849 Brush Holder 3 4 Sq Brush 3 1 CWO 7625 Hi Freq Brush Holder Support 4 1 FAS 2355 Hex Hd Cap Scr 1 4 20 UNC x 2 5 1 FAS 2393 H...

Page 23: ...le Switch 2 1 BUG 2287 Power Receptacle 3 1 CWO 5672 Cover Face Plate 4 1 CWO 6207 Toggle Switch On Off 5 1 CWO 6288 Terminal Block 6 1 CWO 6367 Plasma Control Box 7 2 FAS 0115 Pan Hd Scr 6 32 x 1 2 8 2 FAS 1310 Hex Nut 6 32 9 2 GOF 3021 Press Nut 10 2 WAS 0211 6 Star Lock Washer 6 9 5 10 4 7 2 8 1 6 3 ...

Page 24: ...24 CWO 3951 PLASMA CONTROL BOX WIRING DIAGRAM ...

Page 25: ...10 HEX NUT 6 32 15 2 FHO 0188 FUSE HOLDER 16 1 FUS 0190 FUSE 1 5 AMP 17 1 FUS 0257 FUSE 3 AMP 18 1 MUG 1258 1 ROTARY SWITCH ASSEMBLY 19 10 SCW WTE 0264 6 32 X 1 4 SHT MT SCR 20 3 TERM WTE 0197 6 RED FORK 21 6 WAS 0211 6 INTERNAL STAR WASHER 22 42 WRE WTE 0501 18 3 SJO 300V CORD 23 1 MUG 1589 HOLE PLUG 500 24 1 BUG 1562 MULTI TURN POTENTIOMETER 25 4 FAS 0401 4 40 X 3 8 PAN HD 26 4 SCF 1001 4 40 SEL...

Page 26: ... INDICATES ITEMS THAT ARE SUPPLIED TOGETHER ELECTRICAL COMPONENT CHART ITEM DESCRIPTION PART NO 1 TOGGLE SWITCH ARM 2279 2 RED NEON LAMP CWO 6206 3 SPEED CONTROL BOARD W RESISTOR CWO 6525 4 FUSE 1 5 AMP FUS 0190 5 FUSE 3 AMP FUS 0257 6 ROTARY SWITCH MUG 1258 1 3 6 2 1 4 5 ...

Page 27: ...FREQ LOW FREQ HIGH FREQ JUNCTION BOX TRIGGER SWITCH SIMPLIFIED SMALL POWER BOX WHITE BLACK GREEN AC POWER IN LARGE CONNECTORS LOW FREQ HIGH FREQ SLIP RINGS ORANGE RED WHITE BLACK BLUE ORANGE RED WHITE BLACK BLUE GREEN BLACK WHITE GREEN WHITE BLACK GREEN WHITE BLACK GREEN MOTOR MOTOR WIRES CWO 6110 ROTATION CONTROL SWITCHED AC POWER TO ROTATION BOX PLUG AC FEMALE BLACK 1 2 WHITE GREEN ORANGE RED WH...

Page 28: ...28 CWO 1050 120V POWER BOX WIRING DIAGRAM ...

Page 29: ... PART NO DESCRIPTION 1 1 CWO 7596 50 CB 1P 50ft Machine Torch Hypertherm 2 1 CB 1P Plasma Power Source 3 1 CWO 1045 3 Plasma CB 1P Interface Cable 4 1 CWO 1050 120V Power Box Note For consumable chart see Powermax 65 or 85 instruction manual 3 2 4 1 ...

Page 30: ...1M Carriage mounts on a standard mono rail or bridge crane type setups The carriage allows the operator to move the machine the length of the pipe while utilizing an electric motor to mechanically position the machine vertically on the work piece CWO 4530 151 Carriage The 151 Carriage mounts on a standard monorail The carriage allows the operator to move the ma chine the length of the pipe while u...

Page 31: ... red in color After the heat has been applied take a large rag and a bucket of water and cool the heated area After the area has been cooled check the beam again Repeat as necessary PIPE STANDS The pipe stands consist of 3 pipe in floor flanges with a 2 1 2 or 3 angle welded to the top of the pipe and they should be spaced and aligned as shown See pg 30 The two stands should have some sort of clam...

Page 32: ...he 8 pipe and bring its carriage to it Lower the shaft coupling down over the main shaft Rotate the machine so that the welding lead on top of the machine will be on your left This will put the electrical connector on the right Tighten the set screws in the shaft coupling to secure the main shaft to the vertical slide assembly It is important for the machines to hang plumb Left to right adjustment...

Page 33: ...E BOLT 1 4 6 MM CABLE 10 HARNESS SNAPS WITH SWIVEL EYES TO SUPPORT CABLES AND HOSES 3 8 9 5 MM X 3 76 MM FLAT BAR 1 1 2 38 MM PIPE 4 X 8 X 1 4 102 X 203 X 6 MM WALL RECTANGULAR TUBING WELDER 5 PIPE 8 PIPE BURNER CAST IRON FLANGES 3 76 MM PIPE PIPE VISE 8 203 MM 76 2 M PLASMA POWER SOURCE WELDING POWER SOURCE 5 1 5 M 6 1 8 M 8 2 4 M 6 1 8 M 5 1 5 M 40 1 M 36 914 MM 30 762 MM 22 559 MM 5 31 135 MM 1...

Page 34: ...move all dirt grease and rust Check hardened ways for nicks and replace if necessary Lubricate with a dry spray lubricant Adjust wheels for snug fit and smooth operation Lubricate racker pinion with a dry Teflon or graphite spray lubricant Small Vertical Racker Item 2 Inspect wheels remove all dirt grease and rust Adjust wheels for snug fit and smooth operation Lubricate racker pinion and wheels w...

Page 35: ...cal component fails refer to CWO 6210 Rotation Control electrical component chart for replacement parts or return for service Large Brush Holder Support Inspect brush holder Make sure constant tension is being applied on the brushes Brushes should move freely within the brush holder Check brushes for arc build up If brushes are pitted they will need replaced Remove the brushes and sand them to ens...

Page 36: ...m 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 All wires should be fastened to the center shaft with a nylon cable tie Tighten four set screws if needed Manifold Power Cable Ensure that the cable is fastened tightly to the large...

Page 37: ...bligations or liabilities whatsoever with respect to machines or parts furnished by Manufacturer Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits incidental or consequen tial damages or special damages of any kind Distributor s or customer s sole and exclusive remedy against Manufacturer for any breach of warranty negligence strict liability or a...

Page 38: ...38 NOTES ...

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