BUG-O Systems Flame Cutting User Manual

FLAME

CUTTING

HANDBOOK

2

BUG-O SYSTEMS

BUG-O Systems’ Kits are assembled from modular
components. Each kit was originally an adaptation to
meet an actual problem. The concept is both practical
and economical, and is quickly and easily adapted
on the job site.

Initially developed to carry cutting torches in a precise
work path, the primary aim of the BUG-O System is
movement at controlled speed and direction in any
position. The secondary function is to provide suitable
holding or clamping devices to make BUG-O integral
with both the workpiece and the cutting or welding
tool.

BUG-O is more than a flame cutting system- it’s a
revolution in welding procedures. Ingenious customers
have developed hundreds of ways to cut time and
costs by putting this system to work for them, and
most of the these applications have saved the cost of
the unit on the first job.

With BUG-O Systems you can double your welding
production!

The nucleus of the BUG-O System of modular path
and rate control components is the BUG-O. It is a
self-propelled multipurpose carriage and rail system
with infinitely variable speeds. A steel pinion meshes
with a machine-cut steel rack to provide a positive
drive. The BUG-O is locked onto a rail, which is
mounted on the work.

The BUG-O unit is suitable for use with the most
advanced electric welding processes. It is also the
practical way to carry any process requiring precision
movement; in applications such as gouging, spraying,
guiding ultrasonic inspection and others.

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PRECISION HOLE BORING,

BEVELING AND WELDING

HOB-O cuts, bevels or welds in any position….. any
plane or angle. Carry the tool to the work. HOB-O
weighs only 30 lbs. (18.6 kg)… can be moved and
placed in minutes by one man. Powerful magnets
lock it to the workpiece …. exactly where you want it.
Easily adjustable, the HOB-O flame bores holes from
1'' to 8'' (25-200mm) diameter, inside the machine
and 14-1/2'' to 48'' (368-1220mm) diameter, out side.
Self-propelled, it has an infinitely variable speed control
to suit any application. HOB-O gives you the precision
of drilling … the speed of flame boring … and the
convenience of a portable tool costing less than one
4'' high speed drill bit.

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A DIVISION OF WELD TOOLING CORPORATION

3001 WEST CARSON STREET PITTSBURGH, PA USA 15204

PHONE: [phone] www.bugo.com FAX: [phone]

PREFACE

This booklet has been prepared to show how to
operate and maintain “Gas Cutting” equipment.
Specifically, it shows how to set up, light, set travel
speed and position the “Cutting Torch” for a quality
cut.

WELD TOOLING CORPORATION. 2008

280 TECHNOLOGY DRIVE

CANONSBURG, PA 15317 U.S.A.

PHONE: [phone]

FAX: [phone]

For Additional Information Please

Go to Our Website: www.bugo.com

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INTRODUCTION

GAS CUTTING OF FERROUS

(CARBON STEEL) METALS

Gas cutting is a process of preheating carbon steel to
its combustion temperature, then burning it rapidly by
means of a regulated jet of oxygen. A cutting torch is
used for this operation.

The process is primarily a chemical one. It is based
on the chemical relationship of oxygen to iron metals
that have been heated to a temperature of 1400° to
1600° F (760° to 871° C). Only the metal within the
direct path of the oxygen jet is affected.

In cutting, a “kerf” is formed. This is a narrow slit having
uniformly smooth and parallel walls. A skilled workman
using a BUG-O and a machine cutting torch can
maintain the following tolerances with respect to
squareness and straight alignment of the cut surface:
1/32nd of an inch (.79mm) on plate thickness up to 4
inches (100mm) and 1/16th of an inch (1.58mm) on
plate thicknesses from 4 to 12 inches (100 to 300 mm).

In actual gas cutting, the iron or steel removed from
the “kerf” is not entirely burned or consumed by the
oxygen. About 30 to 40 percent of the met al is washed
out of the cut as unconsumed or metallic iron due to
the eroding effect of the oxygen jet.

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CONTENTS

BUG-O Systems ................................................. 3

HOB-O................................................................ 4

Preface ............................................................... 5

Introduction ......................................................... 7

Safety Instructions........................................ 10-1 1

Instructions and Precautions for Gas Cutting

A. Safety ........................................................... 12

B. Burning Equipment ....................................... 12

1. Torches ................................................. 12

2. Hoses ................................................... 13

3. Regulators ............................................ 14

4. Tips....................................................... 15

5. BUG-O Machine.................................... 16

C. St art-Up Procedure....................................... 17

1. Hooking-Up........................................... 17

2. Burning Tips.......................................... 18

3. BUG-O Machine.................................... 18

4. Lighting the Torch and Setting

the Preheat Flame................................. 19

5. Adjusting the Preheat Flame

for Making a Square Edge Cut ............. 19

6. Starting Cut ........................................... 20

7. Observing the Cut ................................. 21

D. Procedure for Making a St arting Hole........... 24

E. Observing a Cut Being Made ........................ 24

F. Bevel Cutting................................................. 29

Cutting Notes .................................................... 33

Machine Cutting Tip Chart................................. 34

LIT-FCH-IPM-0608

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SAFETY INSTRUCTIONS

EVERY TIME a machine cutting torch is used the
following safety and operation precautions MUST BE
PRACTICED! Deviation from the following safety and
operation instructions can result in fire, explosion,
damage to the apparatus or injury to the operator.

1. Inspect the inlet connections, valves, and torch
head for dirt, dust, oil, grease, or damaged parts.
Dirt or dust can be removed with a clean cloth.

DO NOT USE THE CUTTING TORCH IF OIL
OR GREASE IS PRESENT! Have your

manufacturer’s repair center clean the torch or
repair any damage.

2. Inspect the torch head. The tapered seating
surface must be in good condition. If dents, burrs
or burned seats are present, the seat must be
resurfaced. If the torch is used with poor setting
surface, backfire or backflash may occur and
damage the equipment.

3. Select the required size and type of cutting tip.
Inspect the tip seating surface for damage.
REMEMBER- these seating surfaces prevent
premature mixing of gases that can cause fire
and explosions. If the tapered seats on the tip
are damaged, DON’T USE IT! Inspect the preheat
and cutting oxygen holes. Sp atter can stick on or
in these holes but can be removed with a tip
cleaner.

4. Insert the tip in the Cutting T orch head and tighten
securely .

5. Adjust the regulator delivery pressures according
to the size and type of tip being used.

6. IMPORT ANT: Always purge out the cutting oxygen
passages by opening the cutting oxygen valve
(at least five seconds before lighting the torch.)
Open the fuel valve approximately one-half turn
and ignite the gas with a spark lighter. Adjust the
fuel valve until the flame clears the end of the tip
about ½ inch (13mm), then reduce slightly to
return the flame to the tip.

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7. Slowly open the preheat oxygen valve until a

neutral flame is established (a sharp inner cone).

SPECIAL NOTE FOR TWO HOSE MACHINE
TORCHES ONLY: After the neutral flame has

been established as described, open the cutting
oxygen valve. Note that the preheat flames
change slightly from neutral to a carburizing flame
with a feather. With the cutting oxygen flowing,
adjust the preheat oxygen valve until the preheat
flames are again neutral.

8. If you experience a backfire or backflash (a hissing

sound when the flame is burning inside the cutting
torch) IMMEDIATELY turn off the preheat oxygen
valve, then shut off the torch fuel valve. Allow the
cutting torch to cool before attempting to re-use it. If
trouble persists, call your manufacturer’s repair center.

9. WHEN YOU FINISH YOUR CUTTING

OPERA TION:
a. First shut off the oxygen preheat valve, then

shut off the torch fuel valve. If this procedure
is reversed, a “pop” may occur. The “pop”
throws carbon soot back into the torch and
may in time partially plug it.

b. Close both cylinder valves.
c. Open the torch oxygen preheat valve, and

release the pressure in the hose and regulator.
Close the torch valve.

d. Turn the adjusting screw on the oxygen

regulator counter-clockwise until the adjusting
spring pressure is released.

e. Open the torch fuel valve and release the

pressure in the hose.

f. Repeat “d” using fuel regulator.
g. Close all valves on torch handle and the

cutting attachment.

NOTE: The use of Reverse Flow Check Valves is
strongly recommended to reduce the possibility of
mixing gases in the hoses and regulator. Mixed gases
will rapidly burn once the torch is lighted. These
combustible gases can explode in the hoses, regulators
or cylinders, resulting in serious injury to the operator.

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