INSTRUCTIONS
AND
PARTS MANUAL
SE-2PTD
PROGRAMMABLE PASS
THROUGH
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-SE2PTD-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 all
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
SE-2PTD
PROGRAMMABLE PASS THROUGH
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5 ..... Introduction / Technical Data / Dimensions
6 ..... Setup
7-8 . . Machine Controls
9 ..... Pendant Control
1 0 ... Pendant Control Character Map
11 ... Switching Programming Modes / Saving Programs / Programming, Data Entry
12 ... Data Required, Saddle Cuts, Offset Cuts, Laterals and Miters
13 ... Programming, Saddle Cuts, Offset Cuts, Laterals and Miters / Cut Types
14 ... Programming, Cutting Holes / Type 5
1 5 ... Programming Shapes
17 ... Data Required, Programming Irregular Shapes / Description of Segment Types
18 ... Auxiliary Modes / Type 6, Quadrant 3 / Mode Chart / Set Percent Speed: Type 6 Quadrant 4
1 9 ... Programming Shapes Operation
2 0 ... Writing A Shape Program
21 ... Programming Segment Chart
22 ... Making A Cut
23 ... Programming Example
24 ... SE-2PTD Equipped For Plasma Cutting
2 5 ... SE-2PTD Equipped For Oxy-Fuel Cutting
26 ... SE-2PTD Common: Exploded View / Parts List
27 ... SE-2PTD Control Panel / Wiring Diagram
28 ... SE-2PTD Control Panel / Electrical Component Chart
2 9 ... CWO-3540 Motor Mount Assembly / Exploded View / Parts List
3 0 ... CWO-3885 SE-2PTD Cabinet Assembly / Exploded View / Parts List
31 ... CWO-4450 Pipe Support Assembly / Exploded View / Parts List
32 ... CWO-5460 Slide Ring Assembly / Exploded View / Parts List
33 ... CWO-5730 10" Gear Assembly / Exploded View / Parts List
34 ... SEO-4145 V-Guide w/Torch Mount / Exploded View / Parts List
3 5 ... SEO-5605-D Linear Drive / Exploded View / Parts List
36 ... BUG-6050 Hand Held Pendant / Wiring Diagram
37 ... SEO-4123 Encoder Wiring Harness / Wiring Diagram / Parts List
38 ... SEO-6050 Wiring Harness / Wiring Diagram / Parts List
3 9 ... SEO-4119 Interconnecting Wiring Harness
4 0 ... Accessories
41 ... Operation Checklist and Troubleshooting
42 ... Programmed Diagnostics for SE-2PTD
43 ... Warranty
4
INTRODUCTION
The SE-2PTD Programmable Pass Through machine provides dual programming capabilities
enabling the user to make saddle cuts, offset cuts, laterals, miters, holes, and shapes in pipes.
The Programmable Pass Through machine is capable of passing pipes from 1" to 4" (25-100mm)
through the spindle. Pipes from 4" to 14" (100-355mm) can be externally chucked by clamping the
I.D. of the pipe. The Programmable Pass Through machine is available for plasma and oxy-fuel
cutting and eliminates the need to make templates or layout complex cuts.
TECHNICAL DATA
Power Requirement: 120 VAC/50-60/1
240 VAC/50-60/1
Speed Range: 3.75 rpm
Cutting Diameter: Pass Through: 1" to 4" (25 mm to 100 mm) O.D.
Externally Chucked: 4" to 14" (25 mm to 355 mm) diameter.
Pipe Weight Capacity: 375 lbs. (170 kg) pass through when supported.
Maximum Overhung Length: 15" (383 mm)
Maximum Overhung Weight: 150 lbs. (68 kg)
Net Weight: 345 lbs. (157 kg)
Shipping Weight: 550 lbs. (249.5 kg)
DIMENSIONS
35"
(889mm)
10"
(267mm)
40"
(1016mm)
19"
(483mm)
5
SETUP
The machine is designed to be xed to a worktable. The machine needs to be bolted to the table
through the mounting holes located in the legs of the machine. The machine is to be operated
from a separate power line; it can be supplied for voltage ratings of 120 or 240 VAC. Verify which
model you have prior to applying power. The torch arm should already be inserted into the linear
drive located on the top of the machine. If it is not, throw the power switch to the “on” position, and
carefully insert the torch arm into the v-wheels located inside of the linear drive from the chuck end.
Slide the torch arm in until the teeth touch the drive gear. Then, using the manual jog switch, drive
the arm back into the machine. Push the reset button so the machine holds its position. Insert the
cutting torch into the torch holder and position the torch so that is centered in line with the chuck axis.
The machine can be used with oxy-fuel or plasma torches. If the machine is set-up for oxy-fuel
cutting, use a three-hose cutting torch and run the hoses to the quick action manifold with solenoid.
The solenoid controls the cutting oxygen. If the machine is set-up for plasma cutting, it will be
equipped with a rotary ground, contact relay, and holding clamp for a plasma torch. Plug the contact
relay into the contact output located on the control panel. Wire the trigger leads for the plasma
machine to the supplied connector and plug into the contact relay box.
Loop the gas hose or plasma cable
over the cable hanger located on the
top of the machine for support. Plug
the programming pendant cable into the
pendant control connection located on
the control panel. Place the programming
pendant in the pendant holster located to
the right of the control panel.
The adjustable pipe support (A) is attached
to the rear of the machine, is used with
long pipes, to help keep the pipe (B)
aligned. Make sure to adjust the height
of the rollers (C) so that the pipe runs true
when rotating. The machine is now ready
to be programmed for operation.
B
C
A
Pipe Support Rear View
6
MACHINE CONTROLS
START / RESUME: Push to start cutting or resume cutting after a pause. If the torch has been
manually positioned off the cut path, the machine will move the torch towards the cut and swing
it into the cut line when reached.
STOP / PAUSE: Computer control is interrupted when pushed until the START / RESUME
button is pushed. If pushed while running, the torch is shut off and the machine stops. Pushing
the START / RESUME button again will resume the cut. When the STOP / PAUSE button is
pushed, the machine can be manually positioned by the MANUAL JOG switch; this does not
change the home reference position unless the RESET button is pushed.
RESET: Resets the computer when pushed and makes whatever position the machine is in the
home position. If the torch or pipe is moved by the MANUAL JOG switch, upon releasing it, the
machine will return to the home position.
SPEED KNOB: Controls the tangential speed of the torch along the cut, from zero to maximum.
The speed will depend on the diameter of the pipe. When the torch arm is moving in or out, the
rotational speed will slow down to keep the resultant speed constant.
MANUAL JOG: When pushed up or down the pipe will jog in the corresponding direction.
When pushed left or right the torch arm will move in the corresponding direction.
CONTACT OUTPUT: When the machine is set-up for plasma cutting the contact relay box
connection is made here. When the machine is set up for oxy-fuel cutting, the manifold solenoid
connection is made here.
PENDANT CONTROL CONNECTION: The programming pendant connection is made here.
POWER CORD: Connect the appropriate voltage 120 or 240 VAC to the machine. Verify which
model you have before applying power.
POWER INDICATOR LIGHT: Indicates that power is being supplied to the machine.
POWER ON / OFF: Switches power “ON” or “OFF”.
CIRCUIT BREAKER: Protects the machine against overload or electrical faults.
MIRROR IMAGE SWITCH: Enables the user to cut mirror image cuts of various cut types.
Simply program the cut with the switch on the standard cut position “S”, then toggle the switch to
the mirror image position “M” to cut a mirror image of the programmed cut.
7
MACHINE CONTROLS, CONT’D.
(MAIN CONTROL PANEL)
CONTACT
OUTPUT
RESET
SPEED
CONTROL
START / RESUME
STOP / PAUSE
MANUAL
JOG
PENDANT
CONTROL
CONNECTION
POWER
CORD
POWER INDICATOR
LIGHT
MIRROR IMAGE
SWITCH
8
CIRCUIT
BREAKER
POWER
“ON / OFF”
(LINEAR DRIVE SIDE VIEW)
PENDANT CONTROL
This is the Pendant Control with keypad and display, which plugs into the Pendant Control
Connection on the control panel.
ALPHA KEYS: Press Keys A, B, C, D, or E for the function desired, as described in the
programming section of this manual.
DIGIT KEYS: Use the digit keys to enter pipe diameters or dimensions.
ENTER: Push the enter button to store the numeric value entered.
BACKSPACE: The backspace key removes the last digit keyed in before pushing the enter
button, if a correction is required.
9
PENDANT CONTROL CHARACTER MAP / Direct and Shifted Characters
Shift Key
U: set Units, inch or metric
R: set Ratio
T: Test drives & encoders, function
V: Version Number
10
SHIFTED CHARACTER SET
E.g. to type U for units, press
Shift Key, then “9”
SWITCHING PROGRAMMING MODES
The machine runs in either the SHAPE PROGRAM, for custom programmed shapes, or the
PIPE PROGRAM, for common pipe intersections
To switch functions:
1. Press “C” on the pendant keypad
2. Release the key immediately
3. Press “F” immediately (within half a second)
The machine should change to the other program:
EXAMPLE: If the machine was in the PIPE PROGRAM, the Message “SHAPE PROG”
will now be displayed on the pendant display. If the machine was in the SHAPE
PROGRAM, the message “PIPE PROG” will now be displayed in the pendant display.
SAVING PROGRAMS
The machine has 10 storage areas numbered cut 0 to 9 in memory, either PIPE PROGRAMS
or SHAPE PROGRAMS can be saved in memory. To switch to a different cut number, Push
“C” on the pendant keypad and enter the desired number. Program data is retained until
reprogrammed. At any time, one of these numbers are selected, it will stay selected even when
power is shut off and turned back on, it will not change until the program number is changed by
the operator.
PROGRAMMING, DATA ENTRY
When entering data with the pendant keypad, multiply inches, degrees, or seconds by 100 and
enter the number without a decimal point. For metric dimensions, multiply mm X 10 or cm X
100.
Example: 350 for 3.5 inches,
800 for 80 mm, on metric machines
1500 for 15 degrees
Press the return button after the number is entered.
11
DATA REQUIRED, Saddle Cuts, Offset Cuts, Laterals, and Miters
TYPE 1: Requires A. Small diameter (pipe being cut)
B. Large diameter (pipe it ts on)
TYPE 2: Requires A. Small diameter
B. Large diameter
C. Offset distance between centerlines
TYPE 3: Requires A. Small diameter
B. Large diameter
C. Offset distance
D. Angle between pipes
TYPE 4: Requires A. Small diameter
B. Cutback distance
C. Angle of miter cut
TYPE 5: Requires A. Small diameter (branch pipe)
B. Large diameter (pipe being cut)
C. Angle
For plasma cutting, a value for the time delay is also required to allow for the delay in initiating
the arc and piercing the material. Longer delays are required for thicker materials.
When entering diameters, use the diameter of the surface along whose intersection the cut
has to be made. Usually they will be the inside diameter of the pipe being cut, and the outside
diameter of the pipe it ts on. This will also allow for any bevel, if necessary.
In TYPE 4 miter cut, cutback refers to the distance on the centerline when making two cuts
opposed to each other, for the middle piece of an elbow. If only one cut is to be made, enter 0 or
just press RETURN for cutback.
NOTE: If the STOP / PAUSE button is pushed, the machine will be in pause mode, and cannot
be programmed. Push the reset button to get back to the ready mode for programming.
12
PROGRAMMING, Saddle Cuts, Offset Cuts, Laterals, and Miters:
All programming described below is done using the PENDANT CONTROL.
NOTE: For programming using the PC option, please refer to the Help menu in the software.
For programming use the following “Alpha Keys”.
Push A: To select the type of cut and enter dimensions.
B: To enter the time delay (for plasma cutting).
C: To change Cut Number in memory (numbers 0 – 9).
D: To display the type and dimensions of the cut.
E: To enter end of cut slowdown.
To program a “Pipe Program” cut, select one of the ve “Digit Keys” corresponding to the type of
cut you wish to make:
TYPE 1: Saddle Cut (centerline).
TYPE 2: Offset Cut (hillside).
TYPE 3: Lateral Cut (offset or centerline, for centerline, put offset = 0).
TYPE 4: Miter Cut.
TYPE 5: Holes (see next page).
* Irregular Shapes (see programming shapes).
CUT TYPES
TYPE 1
SADDLE NOZZLE
CUTS
TYPE 2
OFFSET
SADDLE
NOZZLE
CUTS
(Hillside)
TYPE 3
LATERAL NOZZLE
CUTS
TYPE 4
MITER CUT
TYPE 5
HOLE CUTTING
AT VARIOUS
ANGLES
SHAPE PROGRAM
CUSTOM IRREGULAR
SHAPES
13
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