INSTRUCTIONS
AND
PARTS MANUAL
CB-1P
PLASMA CIRCLE
BURNER
Please record your equipment identication 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-0215
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
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: 412-331-1776 http://www.bugo.com FAX: 412-331- 0383
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.
1) The equipment is not waterproof. Using
the unit in a wet environment may result
in serious injury. Do not touch equipment
when wet or standing in a wet location.
2) The unused connectors have power
on them. Always keep the unused
connectors covered with the supplied
protective panels. Operation of the
machine without the protective panels
may result in injury.
3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.
1) Do not plug in the power cord with out
rst verifying the equipment is OFF and
the cord input voltage is the same as
required by the machine or serious
damage may result.
2) Always verify both the pinion and
wheels are fully engaged before
applying power or equipment damage
may occur.
3) Do not leave the equipment unattended.
POSSIBLE.
4) Verify the customer supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist, use
International Electric Code (IEC) 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.
4) Remove from the work site and store in
a safe location when not in use.
FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.
Faulty or careless user installation is
possible. As a result, never stand or
walk underneath equipment.
MOVING PARTS can
cause serious injury.
1) Never try to stop the pinion from moving
except by removing power or by using
the STOP control.
2) Do not remove any protective panels,
covers or guards and operate
equipment.
2
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.
NEVER lay a plasma or welding cable across the controls of the machine.
2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.
3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts 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 plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the plasma
or welding source and the machine. Do not plug them into the same outlet box.
6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote
contactor leads on these plasma or welding sources not be connected to the machine.
An alternate solution is to purchase a separate remote contactor isolation box.
3
CB-1P CIRCLE BURNER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5 ...... Introduction / Features
6-7..... Setup and Operation
8 ...... CWO-6210 Rotation Controls
9 ...... CWO-7621 CB-1P Power Source Controls
10 ..... CWO-3951 Plasma Controls
11 ..... Technical Data / Dimensions
12 ..... CBO-1020-NPS, CBO-1020- CB-1P Plasma Circle Burner / Exploded View
13 ..... CBO-1020-NPS, CBO-1020- CB-1P Plasma Circle Burner / Parts List
14 ..... CBO-1020-NPS, CB-1P Plasma Circle Burner / Wiring Diagram
15 ..... CBO-1670 Racking System / Exploded View / Parts List
15 ..... CWO-1685 Small Horizontal Racker / Exploded View / Parts List
16 ..... CWO-3004 Cam Shaft & Spacer Assembly / Exploded View / Parts List
16 ..... CWO-3005 5" Cam Assembly / Exploded View / Parts List
17 ..... CWO-3035 Junction Box Assembly / Parts List / Wiring Diagram
18 ..... CWO-3199 Housing Assembly / Exploded View / Parts List
19 ..... CWO-3418 Transmission / Exploded View / Parts List
19 ..... 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 List
23 ..... CWO-3951 Plasma Control Box / Exploded View / Parts List
24 ..... CWO-3951 Plasma Control Box / Wiring Diagram
25 ..... CWO-6210 Rotation Control / Exploded View / Parts List
26 ..... CWO-6210 Rotation Control / Wiring Diagram / Electrical Component Chart
27 ..... Consolidated Wiring Diagram
28 ..... CWO-1050 120V Power Box / Wiring Diagram
29 ..... CWO-7655 Power Source Replacement Components
30 ..... Carriages
31 ..... Set-Up Instructions for CW-5 / CB-1P Used in Sprinkler Fabrication
32 ..... Set-Up Instructions for CW-5 / CB-1P used in Sprinkler Fabrication
33 ..... Set-Up Diagram for CW-5 / CB-1P Used in Sprinkler Fabrication
34 ..... Preventive Maintenance for CB-1P Plasma Circle Burner
37 ..... Warranty
4
INTRODUCTION
The CB-1P (CBO-1020) Plasma Circle Burner was designed for plasma bevel cutting of one to
twelve inch diameter holes and will cut beveled holes in light wall pipe or vessels with wall thickness up to 5/16" (7 mm). An automatic rise and fall cam controls the torch position for saddle cut
holes up to 2/3 of work diameter. The cables and air hoses supplying the unit pass through slip
rings and 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. 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 xture.
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 horizontal torch positioning system
• Rise and fall cam assembly with 5" (125 mm) of travel
• Brushes and collector rings for plasma current, rated at 200 AMPS
• Brushes and collector rings for all controls, eliminates cable and hose wrap
• Plasma cutting power supply, CutMaster 82 Plus with duty cycles of 65% at 60 AMPS and
100% at 50 AMPS
• Rotation speed and directional controls
• Manual / Off / Automatic control switch
5
SETUP AND OPERATION:
**All page numbers referred to in this section are from this manual unless otherwise specied.**
POWER SUPPLY:
®
The CB-1P Plasma Circle Burner is supplied with a modied Thermal Dynamics CutMaster
Plasma Cutting Power Supply. The power supply provides auxiliary power to the CB-1P Plasma Circle
Burner for the operation of switches, speed control, and the rotational drive. Refer to the Thermal
®
Dynamics CutMaster
82 Plus Plasma Cutting Power Supply operating manual #0-4979 supplied with
this machine for general operation and set-up information.
PLASMA CUTTING TORCH:
The CB-1P Plasma Circle Burner is equipped with a Thermal Dynamics Plasma Cutting Torch model
PCM-120 machine torch. Refer to the Thermal Dynamics Plasma Cutting Torch instruction manual #02818 supplied with this machine for general operation and set-up information.
FIXTURING:
All circle burners have to be xtured in some manner from the top of the shaft. This may be achieved in
one of the following: column & boom, manipulator, or carriage & monorail.
CABLE CONNECTIONS:
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 ve leads that need to be connected as described
below.
82 Plus
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 tting in the top of the CB-1P Shaft Assembly item (11) on page 13.
• Low Frequency Power Cable to the Low Frequency Power Cable.
• High Frequency Power cable to the High Frequency Power Cable.
• The Power Supply Torch Lead (air, control cable, high frequency)to the power supply.
• It is helpful to mount the Junction Box assembly to the top of the carriage or to the manipulator.
CAM
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. Loosen the set screws in the brass block
on the cam, and rotate the cam to the vertical position as shown.
SETTING THE CAM:
The cam setting is equal to the distance “B” subtracted from the
distance “A”.
HORIZONTAL RACK
EXAMPLE:
Let A=3 and B=2
3-2=1
The cam setting is 1.
6
B
A
B
A
TORCH
HOLDER
PIPE
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. The wheels should be snug but not prohibit movement along the
path of travel. The wheels with the hex stand off are adjustable. To adjust
the wheels loosen the hex bolt (A) until the adjustable bushing (B) can be
rotated. Correct the wheel alignment by rotating the adjustable bushing
(B). Once adjusted, hold the adjustable bushing (B) while tightening the
hex bolt (A). Recheck alignment.
B
MACHINE CONTROLS:
Operational parameters can be set using the two control boxes attached to the machine as well as the
controls located on the power supply. Please refer to the sections in this manual.
• CWO-3951 Plasma Controls for descriptions of the control capabilities.
• CWO-6210 Rotation Control for descriptions of the various speed and directional capabilities.
• CWO-7655 Power Source Controls for descriptions of the power supply controls.
A
MAKING A CUT:
1. Position the torch to the starting location using 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” position the cutting process and rotation are both started
by throwing the “HAND/OFF/AUTO” switch to the “AUTO” position.
5. To stop the cutting processes and rotation, throw the “HAND/OFF/AUTO” switch to the “OFF”
position.
WARNING: THIS MACHINE PRODUCES PLASMA ARC RAYS, IT IS NECESSARY TO USE
CORRECT EYE, HEAD, AND BODY PROTECTION.
7
CWO-6210 ROTATION CONTROLS
SPEED
CONTROL
TRAVEL
DIRECTION
ON/OFF
SWITCH
PILOT LIGHT
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. 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.
8
CWO-7655 CB-1P POWER SUPPLY CONTROLS
1
2
43
Thermal Dynamics, Art# A-07886
6
5
7
9
8
10
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. SET is used for setting gas pressure and purging lines. RUN is used for torch
operation. RAPID AUTO RESTART allows for faster restarting of the Pilot Arc for uninterrupted
cutting. The LATCH is used for specic applications, generally hand held cuts.
3. ON / OFF POWER SWITCH:
Controls input power to the power supply. Up is ON, down is OFF.
4. AIR / GAS PRESSURE CONTROL:
Used in the 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 continuing operation.
7. GAS INDICATOR:
Indicator will light when minimum input gas pressure for power supply operation is present. This may
not be enough pressure for torch operation.
8. DC INDICATOR:
Indicator will light while the torch switch is pressed.
9. FAULT ERROR INDICATOR:
Indicator is ON when fault circuit is active. Refer to power supply operation manual for more
instructions.
10. PRESSURE INDICATORS:
Indicator will light according to pressure that was set using Pressure Control Knob.
9
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. 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. The OFF position will stop the entire cutting process including machine rotation.
10
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. (33 kg)
Shipping Weight: 283.5 lbs. (129 kg)
DIMENSIONS
20"
(508 mm)
30"
(762 mm)
34"
(864 mm)
6"
(152 mm)
26"
(660 mm)
11
CBO-1020-NPS, CBO-1020- CB-1P PLASMA CIRCLE BURNER / PARTS LIST
24
23
36
30
9
7
8
4
12
14
18
15
17
19
16
31
39
40
32
34
29
21
5
22
11
20
3
6
2
28
1
38
32
34
35
33
37
10
27
12
25,26
13
41
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