BUG-O Systems SE-4PTD User Manual

INSTRUCTIONS

and

PARTS MANUAL

SE-4PTD

PROGRAMMABLE

PASS THROUGH

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-SE4PTD-IPM-0107

CYPRESS WELDING EQUIPMENT INC.

A DIVISION OF WELD TOOLING CORPORATION

3001 West Carson Street • Pittsburgh, PA USA 15204-1899

Telephone: [phone] • 1-800-245-3186 • Fax: [phone]

http://www.cypressweld.com

SAFETY

PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. BE SURE THA T ALL INSTALLATION, OPERATION, MAINTENANCE
AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

MOVING P ARTS can

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 first
unplugging the power cord or serious
injury may result.

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.

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.

F ALLING 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.

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.

2

PLASMA CUTTING can

produce destructive High

Voltage at High Frequency.

1) If using plasma, see that the machine as
well as the plasma power source is
properly grounded.

2) Do not use older model plasma machines
meant for manual operation. These can
leak high frequency at high voltages,
which can cause dangerous shock, as
well as destroy control circuits.

3) Read the instruction manual page on
plasma cutting carefully , and follow all
precautions.

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 specified 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-4PTD

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5 .........Introduction/Description/Set-Up

6 .........Pipe Support / Plasma Cutting

7 .........Panel Controls

8 .........Operation

9 .........Programming Module

10 ....... Programming/ Cutting

11 ....... Cutting Holes: Type 5

12 ....... Data Entry

14 ....... Instructions for Dual Function SE-4PTD

15 ....... Des crip tio n/ Op eration

17 ....... Shape Programming

18 ....... Program Chart

19 ....... Data Entry for Programming

21 ....... Auxiliary Modes

22 ....... Set % speed

23 ....... Programming Examples

24 ....... SEO-4400 T echnical Data

25. ......SEO-4400 T echnical Data Dimensions

26. ......SEO-4400 SE-4PTD Programmable Pass through/ Parts List

27. ......SEO-4400 Control Panel Component Layout/ Parts List

28. ......SE-4PTD Wiring Diagram

29. ......Electrical Component Chart

30. ......SE-4PTD Internal S tructure/ Parts List

31. ......SEO-4465 Rotating Drive/ Parts List

32. ......SEO-41 13 SE-4PTD Encoding Wiring Harness

33. ......SEO- 41 19 SE-4PTD Interconnecting Wiring Harness

34. ......BUG- 5605-PT Linear Drive (100:1)/ Parts list

35. ......BUG-5607 Linear Drive Wiring Drive Harness

36. ......Pendant Control Wiring Diagram

37-39... Operation Checklist and T roubleshooting

40. ......Warranty

4

Patents Pending

INTRODUCTION

The Programmable Pass Through machine automates the end preparation of pipes for fabrication
using a program that makes saddle cuts, offset (hillside) cuts, lateral cuts and mitre cuts. The SE-4PTD
rotates a pipe held in its three-jaw chuck while driving a cutting torch back and forth along the pipe axis,
so that the torch cuts a contour on one pipe to fit onto another pipe of larger diameter . Pipes from 4”
(100 mm) to 12.5” (318 mm) outside diameter can be chucked internally in the machine. Smaller pipes
require optional extension jaws. The SE-4PTD is suitable for plasma and oxy-fuel cutting and elimi­nates the need to make templates or layout complex cuts.

DESCRIPTION

The SE-4PTD is designed to sit on a work table. The machine can be used with oxy-fuel torched or
plasma. If the machine is set up for oxy-fuel cutting, the 3-hose cutting torch is connected to the solenoid
manifold located on the left hand side of the machine. If the machine is set up for a plasma torch, it will
be equipped with a rotary ground and holding clams for a plasma torch. The suggested method of
plasma cutting will be air plasma. Power requirements are 240 V AC single phase and a clean air
supply for the plasma source. The SE-4PTD should be operated from a separate power line; it can be
supplied for voltage ratings of 120, or 240 V AC.

Panel controls include St art, Stop, and Reset push buttons, a joystick for manual positioning, and speed
control knob which are shown on page 4, Panel Controls. All programming is done using a hand held
terminal, with keypad and display . (See page 9).

SET-UP

Place the SE-4PTD on a work table, preferable bolting it down through the mounting holes located in the
legs of the machine. Plug the power cord into the power line. The torch arm should be already inserted
into the linear drive located on top of the SE-4PTD. If it is not, throw the power switch on, and carefully
insert the slide into the V-wheels inside the linear drive from the chuck end. Then, using the manual
joystick control, drive the arm back in to the machine. Push the reset button so the machine holds its
position.

Insert the cutting torch into the torch holder by loosening the clamping lever and adjusting its position so
that the torch is centered in line with the chuck axis. Then, lock the torch holder in place.

For plasma, mount the relay contact box on the short post located on the top right hand side of the
machine above the control panel. Plug the relay into the contact output. Wire the trigger leads for the
plasma machine to the supplied connector and plug into the relay box.

Loop the gas hose or plasma cable over the cable hanger located on the top right hand side of the
machine above the control panel, for support. Plug the programming pendant cable into the 6-pin
connector located on the control panel.

5

The adjustable pipe support (A) is attached to the rear of the machine, for use with long pipes, to help
keep the pipe (B) aligned (see below). Make sure to adjust the height of the rollers (C) so that the pipe
runs true when rotating. T wo threaded rods are provided for different diameter ranges; use the 4 ¼''
(108mm) rod (D) for diameters from 8'' (203mm) to 12'' (305mm) and the 7 ¼'' (184mm) rod for diam­eters from 4''(102mm) to 8'' (203 mm).

The SE-4PTD is now ready to be programmed for operation.

PIPE SUPPORT

SE-4PTD REAR VIEW PLASMA CUTTING

The SE-4PTD can be used successfully for plasma cutting; however it is important to take certain
precautions to avoid interference and protect the control circuits. (These comments also apply to the
TIG welding or any process that uses high frequency to strike an arc.) An external relay box is available
separately or in the welding kit to provide the contact signal to the plasma source.

PRECAUTIONS:

1. NEVER lay the plasma gun cable across the top of the machine. The further away from the machine
it can be routed and supported, the better.

2. See that all grounding procedures specified for the plasma source are followed diligently.

3. If the high frequency is produced using a spark gap, adjust the points so that the gap is as small as
possible. The larger the gap, the higher the voltage and stronger the interference.

4. We strongly recommend you disconnect the Hand Held T erminal (programming pendant) when
running the machine. Any length of wire act s as an antenna to receive HF radiation, and though the
cable is shielded, it is possible for some induced voltage to leak through.

5. Use separate power line branched whenever possible to power the plasma source and the ma­chine. Do not plug them into the same outlet box.

6. Though there is an internal power line filter, an external protective device will always help. Computer
equipment line protection boxes are readily available at low cost, with surge suppression and line
filtering circuitry . The machine can be plugged into the power line through one of these boxes.

6

PANEL CONTROLS

The function of various buttons and knobs on the control panel are described below:

START (Black push-button):

Computer control is interrupted when pushed until the start button or Reset button is pushed. If
pushed while running, the torch is shut of and the SE-4PTD stops. Pushing the start button again
will resume the cut. When Stop is pushed, the machine can be manually positioned by the joystick
switch; this does not change the home reference position unless the Rest button is again pushed.

RESET (Small push-button):

Reset the computer when pushed and makes whatever position the machine is in the home refer­ence position. If the torch or pipe is moved by the joystick, upon releasing it, the SE-4PTD 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.

SE-4PTD PANEL CONTROLS

WELD
CONTACT RESTART START ST OP MANUAL JOG

POWER
CORD

POWER INDICA TOR POWER ON/OFF CIRCUIT BREAKER

TO PENDANT

CONTROL

SPEED

CONTROL

LIGHT

7

OPERA TION
T o make a cut:

1. Set up the SE-4PTD with pipe in position and power up.

2. Program the desired cut. (Refer to the instructions under programming.)

3. Push the red Stop button and use the joystick to manually move to the st arting point.

4. Push the Reset button to fix the starting point here.

5. For oxy-fuel, turn on and ignite the pre-heat gases, and wait until is hot enough to start the
cut. Push the Start button; the solenoid for cutting oxygen or plasma trigger is turned on
and the machine starts the cut (after the delay which has been set for plasma).

NOTE: TYPE 4, MITRE
If a cutback dimension has been entered, the SE-4PTD will make one cut, shut off
the gas or arc, back up the given distance, and rotate the 180°. The machine will
pause here until S tart button is pressed again, and then repeat the same cut but
rotated 180° from the first.
T o make a dry run without cutting:

1. Push Stop button and hold down.

2. Push St art button and hold down.

3. Release Stop button (quickly , after no. 2 above).

4. Release St art button.
The machine will move along the programmed cut without turning on the contacts for plasma,

or the cutting solenoid.

8

PROGRAMMING MODULE

This is a hand held terminal with key pad and displayed which
plugs in to the control panel. Press keys A, B, C, D, or E for the
function desired, as described in the Programming instructions
on page 12. Use the digit keys to enter pipe diameters or other
dimensions; push the Enter button to store the numeric value
entered. The Backspace key removes the last digit before
pushing the Enter button, in case a correction is required.

9

PROGRAMMING

For programming, the following keys on the keypad are used:

Push A: To select the time delay for plasma cutting.

B: T o enter the time delay for plasma cutting.
C. T o display the Cut No. in memory (Nos. 0-99)
D. T o display the type and dimensions of cut.
E. T o enter end of cut slowdown.

T o Program a cut, select one of five types as follows:

T ype 1: Saddle Cut on centerline.
T ype 2: Saddle Cut offset (hillside).
T ype 3. Lateral Cut, offset or on centerline (for center line, put offset = 0)
T ype 4: Mitre Cut
T ype 5: Holes (see next page)

CUT TYPES 1 to 4:

10

CUTTING HOLES: TYPE 5

Select T ype 5 to cut a hole on the side of a pipe. Using Type 5, the machine is programmed to cut
holes in pipes for branching joints, either square (T -joints) or angled (laterals). The joint must be on
centerline.

The display will ask for small diameter , and then large diameter. Enter the diameter of the branch pipe
for small diameter , and then large diameter, as shown in the diagram, and the diameter of the pipe
being cut for large diameter . Next the display will prompt for angle. Enter the angle, in degrees x 100
(e.g. for 60° enter 6000). For square cuts you must enter 9000 (for 90°).

NOTE:
The type 5 Cut is provided on both the standard SE-4PTD and the Dual program SE-4PTD machines.

11

Data Entry
When entering data on the keypad, multiply inches, degrees, or seconds by 100 and enter the

number without a decimal point. For metric dimensions, multiply mm x10 or cm x100.

For Example: 350 for 3.5 inches,

800 for 80mm on metric machines
1500 for 15°

Press the return button after the number is entered.
Data Required:

TYPE 1: Requires 1. Small diameter (pipe being cut)

2. Large diameter (pipe it fits on)

TYPE 2: Requires: 1. Small diameter

2. Large diameter

3. Offset distance between centerlines

TYPE 3: Requires: 1. Small diameter

2. Large diameter

3. Offset

4. Angle between pipes

TYPE 4: Requires: 1. Small diameter

2. Cutback distance

3. Angle of mitre cut

For plasma cutting, a value for the time delay is also required to allow for the delay in striking the arc.
A commonly used delay is 3 seconds (enter 300 on the terminal keypad).

12

When entering diameters, use the diameters of the surface along whose intersection the cut has
been made. Usually they will be the inside diameter of the pipe being cut, and the outside diam­eter of the pipe it fits on. This will also allow for any bevel, if necessary .

In TYPE 4, 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 for
cutback.

NOTE: If the red Stop button is pushed, the machine will be in the p ause mode, and

cannot be programmed. Push the Reset button to get back to the ready mode
for programming.

Program Memory:
The SE-4PTD has memory storage for 100 cuts. These are numbered Cut No. 0-99. to switch to

a different Cut No. push “C” on the keypad and enter the number . Cut data is retained until pro­grammed.

Type 4 Mitre Cut: Showing Cutback Length CB.

13

INSTRUCTIONS FOR THE DUAL FUNCTION SE-4PTD SHAPE
PROGRAMMING

The following pages describe the shape programming capabilities of the dual function machines.
Arbitrary shapes can be programmed and cut on a pipe mounted in the chuck.

PROGRAMMING SHAPES ON THE SE-4PTD
The capability is provided only on the Dual function SE-4PTD. Cuts of any arbitrary shape can be

programmed, by building up the shape from the sequence of straight lines and circular arcs.
Programming is very similar to the Shape Machine- see detailed Shape Machine programming

instructions.
ONE IMPORT ANT DIFFERENCE is that for every change of pipe diameter in the machine, the new

diameter has to be entered in the machine. If the machine is set to cut a square hole on a 4 inch or
100 mm pipe, and an 8 inch or 200 mm diameter pipe is put in the chuck, the hole will be rectangular ,
stretched out to twice the dimension in the circumferential direction.

Press ‘E’ on the keypad to enter diameter; the display will ask for pipe diameter first, and then the
segment end slowdown as in the Shape Machine.

The shapes are laid out on a flat surface as if the pipe is slit and opened up flat, and the cut line devel­oped on it.

If the Shape Machine PC program is used to download shapes, the pipe diameter has to be entered
manually as the program does not handle it. This can be done from the computer if desired, by the F9
function “emulate pendant”. From there, press E and follow the prompts.

NOTE: the machine must be connected to the PC for “emulate pendant” functions; turn power ON and
press the Reset button.

SWITCHING FUNCTION IN DUAL FUNCTION MACHINE

The dual function SE-4PTD machine under either the Shape program, for custom programmed
shapes, or the Pipe program, for pipe intersections.

T o switch functions,

Press ‘C’ on the keypad,
Release the key immediately ,
Press ‘F’ immediately (within half a second)

The machine should change to the other program:

If the machine is in the Pipe program, the message “Shape prog” should be

displayed. If in the Shape program, the message “Pipe prog” should be displayed.

14

DESCRIPTION

The machine has 10 storage areas in memory for different programmed shapes, numbered 0 to 9.
At any time, on e of these shape numbers is active, and will stay selected even when power is shut
off and turned back on, until the shape number is changed by the operator .

All programming is done with the hand-held terminal provided; this may be plugged into the con­nector on the control panel of the machine or unplugged as anytime. The terminal is not needed to
run the machine once programmed.

Shapes are built up only from the segments provided; circular arcs and straight lines, square or
inclined, by selecting type and quadrant for each segment. A shape can have up to 50 segments.
Some other operations, like solenoid On/Off, time delay , or repeat another shape, also count as
one segment each if used.

In normal operation, first position the torch at the starting point. Next turn on the preheat gases, and
wait until the required preheat is reached. Push the Run button; the machine will turn on the cutting
oxygen and start cutting the current shape. At the end of the shape the machine will turn off the
cutting oxygen and stop. Manually turn off the preheat gases.

When plasma cutting, an external contact relay is used instead of cutting oxygen solenoid. A delay
to allow for striking the arc should be the first segment programmed.

OPERATION

When power is turned on, the torch becomes the reference St art position.
There are three options (the hand held terminal is not needed for the first two):

1. MOVE- T o change the St art position, push the STOP button, move the machine manually to
the required position using the 4-way joystick, and push the RESET button.

2. RUN- Push the STAR T/RUN button to cut a shape.

3. PROGRAM (entry or change) – The programming operation is selected by pressing keys A,

B, C, D, E.
A: All segments; data entry for a new shape consists of total number of segments.

Data for each: T ype (arc, x/y line of slope)

Quadrant 1-4
Size (radius, or x/y dimension)

See Shape programming for details.

15

For Example, a 2 inch diameter circle could be four segments:

1. 2, 1, 100 Counterclockwise arc, quadrant 1, 1.00 inch radius

2. 2, 2, 100 Counterclockwise arc, quadrant 2, 1.00 inch radius

3. 2, 3, 100 Counterclockwise arc, quadrant 3, 1.00 inch radius

4. 2, 4, 100 Counterclockwise arc, quadrant 4, 1.00 inch radius

The data should be tabulated on paper from a diagram before entering.
B. Program Segment
Press B on terminal to re-program a single segment. This is useful if there is an error in data for

just one segment, so the whole shape does not have to be re-entered.
C. CHANGE shape number
Press C on terminal to change the current shape number , and enter the desired number at the

prompt. The program switched to the new number in memory , and to whatever shape is

stored there.
D. DISPLA Y Shape Data
Press D to display the data for the current shape. The terminal display shows total No. of seg-

ments, and data for each segment one by one each time you press enter .
E. END of segment Slowdown
Press E to set deceleration value for the shape, when the machine approaches the end of each

segment. This is useful when the shape has sharp corners, to prevent overshoot. 99 is maxi-

mum slowdown, 0 is no slowdown.

IMPORTANT

1. Once the Hold button is pressed, computer control is halted until the RUN or the resent button is
pressed. Therefore the programming cannot be done with the hand held terminal in this state; the
Reset button should be pressed first.

2. After pushing A and programming a new shape, End of Segment Slowdown will still have the old
value unless reprogrammed. T o Set a new value, push E.

16

SHAPE PROGRAMMING

The shape to be cut on the pipe must be first laid out flat as if the pipe is slit along the length and
opened out.

1. Draw the required shape on the paper to some convenient scale.

2. Refer to the Segment Chart and divide the shape into straight line straight line and arc segments.

3. Decide on the operation sequence and mark any other operations such as turning torch on or off,
or delay .

4. Numbering all the segments in sequence, including other operations if any , and make a table
with required data. Example for a clockwise circle starting from the top: (dimensions
described fir metric version

Segment: No. T ype Quadrant Dimensions

1. 1 1 300 (30 mm)

2. 1 4 300

3. 1 3 300

4. 1 2 300

5. With machine turned on and the pendant plugged in, select which shape number
this will be – for instance, No. 3.
Push C: display reads Shape No._
Push 3 for No. 3, press Enter key (backwards arrow).
The program is now in Shape No. 3.

6. Push A: display read “T otal Segments?”
Push 4 for 4 segments and Enter . Display reads “1 Type?” waiting for segment 1
data.

7. Push 1 for type, clockwise arc. (refer to programming Chart on next page)
Display reads “Quadrant?”
Push 1 for quadrant 1
Display reads “mm x 10”
Push 3, 0, 0 Enter, for 300, which is 30.0 mm
Segment 1 has now been entered,
Display reads “2. type?”, asking for data for Segment 2.

8. Repeat above steps to enter data for segments, in sequence.
Display will read “Ready” after all segments are entered.
The Shape program is now stored in memory as Shape No. 3
and the machine is ready to cut the shape.

17

PROGRAMMING CHART

SEGMENT TYPES: QUADRANT

#1 #2 #3 #4

1. Clockwise 90 degree Arc

2. Counterclockwise 90 degree Arc

3. X or Y axis line

4. Oblique Line

5. Functions

6. Functions

7. Clockwise Partial Arc

8. Counterclockwise Partial Arc

WELD / OXY

ON

REPEAT

ANOTHER

SHAPE

WELD / OXY

OFF

PIPE CUT

NUMBER

WAIT FOR

START

BUTTON

AUXILIARY

MODES

TIME

DELA Y

PERCENT

SPEED

18

DATA ENTRY required for Programming

T o Program a complete new shape (press ‘A’)
Count the number of segments or operations and enter the total.
For each segment, enter:

T ype: Select form 1 through 8
Quadrant: 1, 2, 3 or 4; refer to chart
Size: one or more dimensions per segment as described below

100 per inch or 10 per mm (depending on machine version); or for
time, 100 per second of delay .
(e.g. 150 = 1.5”, or for metric 375 = 37.5 mm)

Detailed description of T ypes
T ype 1.

Clockwise, 90° arc segments.
Quadrant determined by which quarter of a full circle makes the arc. (See chart)
Dimensions required: Radius only .

T ype 2.
Counterclockwise, 90° arc segments

Quadrant determined by which quarter of a full circle makes the arc. (See chart)
Dimensions required: Radius only .

T ype 3.
Lines along X or Y axis.

Quadrant determined by direction of movement. (See chart)
(East: 1, North: 2, West: 3, South: 4).
Dimensions required: Length only .

T ype 4.
Angled straight line.

Quadrant determined by direction of movement. (See chart)
(NE: 1, NW: 2, SW: 3, SE: 4).
Dimensions required: (1) X- dimension; movement along X axis

(2) Y- dimension; movement along Y axis

19

Type 5.
Functions or other operations.
Quadrant by selection function. (See chart)

1. Weld/ oxygen ON: turn ON contact Relay or cutting oxygen solenoid.
Dimensions required: none

2. Weld/ oxygen OFF
Dimensions required : None

3. Pause: machine stops and waits until S tart/ Run button is pushed again.
Dimensions required: None

4. Delay: Machine stops and hold position for a programmed time period, up to 99.99
Seconds.
Dimensions required: time in .01 seconds units. (e.g. 250 for 2.5 seconds)

Type 6.
Special functions.
Quadrant by selecting function.

1. Repeat: Another complete shape will be repeated the specified number of times.
Shape No. of the repeated shape MUST BE LOWER than the Shape No. of the
current shape being programmed. Therefore it CANNOT BE USED IN
SHAPE No. 0
Data required: (1) Shape No. to be repeated

(2) Number of times.

2. Ellipse: This is provided for making a complete true ellipse, always starting from
the left (west extremity) and moving clockwise.
Dimension required: (1) diameter along X- axis

(2) diameter along Y - axis

3. Auxiliary modes: Provides commands to turn On or OFF two line-switching
outputs independently , and also switch speeds from set speed to Rapid Traverse
and back. Mode numbers are from 0 to 7; see table page 36 to select mode.

4. Set percent speed
Used to change speed of the machine in the middle of a shape to a lower speed. See details
page 22.

Type 7.
Clockwise arc, must be less than 180°.
Quadrant determined by direction of end point of arc relative to the start point. (See chart)
Dimensions required:

(1) X- dimensions: offset along X-axis from start to end point
(2) Y -dimensions: offset Y - axis from start to end point
(3) Radius of arc.

20

T ype 8.
Counterclockwise arc, must be less than 180°.
Quadrant determined by direction of end point of arc relative to the start point. (See Chart)
Dimensions required:

(1) X-dimension: offset along X-axis from S tart to end point.
(2) Y -dimension: offset along Y -axis from start to end point.
(3) Radius of arc.

AUXILIARY MODES: Type 6, Quadrant 3

These are additional controls to independently turn the two internal Solid State Relay output s ON and
OFF , and to switch the machine into Rapid T raverse Mode or Set speed.

The machine is shipped with OUTPUT (1) wired to the external relay or solenoid connector . By
default, this output turns ON when the St art button is pressed to run a shape, and turns OFF at the
end. The output is taken from screws (3) and (4) on the 4-terminal strip, on the controller inside the
machine.

ONL Y OUTPUT (1) IS NORMALL Y USED.
OUTPUT (2) is present at screws (1) and (2) on the controller , but not wired. By default the output is

OFF when a shape is started, until turned ON by command T ype 5, Quad 1. Both the SEO-4470
Plasma Cutting Kit and the SEO-4490 Oxyfuel Cutting kit use only output (1). Subsequently while
running, the T ype 5 ON and OFF command turns both outputs On and Off together, and both Of f at
the end.

When programming T ype 6 Quad 3, a Mode number is required to be entered. The eight auxiliary
modes, numbered 0 through 7, allow the setting of a mode with any combination of outputs On or
Off, and choice of set speed by the speed knob, or maximum speed regardless of setting. The
combinations are listed in the table below:

Mode No Output 1 Output 2 Speed
0 Off Off Set
1 Off On Set
2 Off Off HI
3 Off On HI
4 On Off Set
5 On On Set
6 On Off HI
7 On On HI

21

SET % SPEED, FRACTION OF SET SPEED: TYPE 6, QUADRANT 4

Selecting T ype 6-4 allows the speed to change to a fraction of the set speed. Display will read
“Speed %”, and data entry is accepted from 1 to 99. Entering 0 or just Return will make the speed
100%, which is the same as set speed.

When the program reaches a T ype 6-3 segment while running, the speed will change to the per­cent entered, and continue at this setting until there is a later T ype 6-3 segment which changed it to
another % setting or back to 100%.

Note: If T ype 6-3 has been set for HI (rapid traverse), then this setting will cut down the HI speed to
the same %.

Settings below 10% are not recommended.

22

PROGRAMMING EXAMPLES

T o cut a slot in a pipe like the one in the diagram shown below:
The cut is split in to a sequence of straight lines or circular arcs that make up the desired pattern.
Next, these should be listed in a table with the T ype, Quadrant and required dimensions (refer to the

programming Chart). The table for the shape is listed below .
T o program the shape, press ‘A ’, then enter the total segment at the prompt. (6 in the example

below).
Next enter the data for each segment- T ype, Quadrant and dimensions- as prompted.
Finally an End of Segment slowdown value is entered, and the display will read ‘Ready’.
FOR THE FIRST CUT OF A GIVEN DIAMETER, IN THE SHAPE PROGRAM, THE PIPE DIAM-

ETER MUST BE ENTERED.
Press ‘E’ on the keypad, when the display will first ask for the diameter , and then the Slowdown

value.

Segment T y p e Quad Dimensions

1 1 3 400
2 3 2 600
3 1 2 400
4 1 1 400
5 3 4 600
6 1 4 400

The first segment is a clockwise
90° arc, which is T ype 1, Quad 3
and the required dimension is the
radius, set here as 40 mm.

23

TECHNICAL DATA

Power SEO-4400 120 V AC / 50-60 Hz /1.0 A
Requirements SEO-4402 240 V AC / 50-60 Hz /0.7 A

Cutting Diameter Pass through 8'' to 12.5” O.D. (200 to (315 mm)

or 4 to 8'' (100 to 200 mm) with optional extension jaws. Smaller
diameters can be handled at lower cutting speeds – see chart

below.
Additional Short lengths of pipe up to 20'' (508 mm) diameter can be chucked
Capacity: internally .

Maximum Length: 18'' (457 mm)

Maximum Weight: 150 lbs (68 kg)*
Rotation S peed 0.15 to 3.0 rpm

(See charts for surface speed at various diameters)

*NOTE: When using the pass through feature, the maximum weight of the pipe should not exceed
500 lbs (227 kg). it is very important to have the pipe supports in alignment with the machine to
support the pipe in back of the SE-4PTD. If the pipe is projecting from either end of the machine,
more than 30'' (760 mm), it must be supported in rotating pipe stands.

24

TECHNICAL DATA/ DIMENSIONS

Cut T ypes: 1. Saddle Cuts

2. Offset (Hillside) Cut

3. Lateral Cuts

4. Mitre Cuts, Single Cut or 3-Piece Elbow

5. Holes

Dimensions: 53'' L x 24'' W x 37'' H

(1343 x 610 x 940 mm)
Net Weight 830 lb (377 kg)
Shipping Weight 1030 lb (467 kg)

SE-4PTD PROGRAMMABLE PASS THROUGH

25

SEO-4400 SE-4PTD PROGRAMMABLE PASS THOUGH 120 VAC

PARTS LIST
Item Qty Part number Description

1 1 BUG- 5605-PT Linear Drive (100:1)
2 1 BUG-6050 Hand Held Pendant
3 1 BUG-9444 Tool Kit
4 1 CWO-9238 Chuck with 3 Master Jaws
5 1 SEO-4145 V -Guide with T orch Mount
6 1 SEO-4405 Cabinet, Bare
7 1 SEO-4410 Control Panel 120 V
8 4 SEO-4449 Lifting Lug
9 1 SEO-4460 Main S pindle Assembly
10 1 SEO-4465 Rotating Drive

26

SEO-4410 CONTROL PANEL 120 V/ COMPONENT LAYOUT

PARTS LIST

Item Part No. Qty Description

1 ARM-2279 1 T oggle Switch, DPST , On-Off
2 BUG-1393 1 Volt T rap 120 V AC
3 BUG-1415 1 Pilot Light
4 BUG-1435 1 Sta-kon Connector
5 BUG-1536 3 Push-button Switch SP NO
6 BUG-1537 1 Cap Black
7 BUG-1557 1 Cap Red
8 BUG-1770 1 Motor Control Board
9 BUG-1775 1 Motor Control Board
10 BUG-2924 1 Reset Button Seal
1 1 BUG-2931 1 Circuit Breaker 1.0 A
12 BUG-5218 2 Transformer 1 17V 50/60 Hz
13 BUG-6028 2 T erminal Block
14 BUG-6029 2 Bracket
15 BUG-6069 1 Filter
16 BUG-9445 1 Power Cord 120 V

Item Part no Qty Description

17 BUG-9446 1 Cord Grip
18 BUG-9686 1 Potentiometer Control
19 BUG-9688 1 Dial
20 BUG-9884 1 On-Off Switch Plate
2 1 CAP-0223 1 Cap. 022 Film
2 2 F AS- 01 1 4 4 Pan Hd Screw 6-23 x 3/8
2 3 FAS-0124 7 Pan Hd Screw 8-32 x 3/8
2 4 FAS-0204 1 2 Rnd Hd Screw 4-40 x 3/8
2 5 FAS-0225 4 Rnd Hd Screw 8-32 x ½
2 6 FAS-1305 8 Hex Nut 4-40
2 7 FAS-1320 7 Hex Nut 8-32
28 MUG-1 156 1 Panel Connector, 4-t, F
2 9 PRS-1065 1 Joystick
3 0 SEO-4151 1 Panel
3 1 SEO-6030 1 Control Module
32 WAS-0221 3 #8 Star Lockwasher

27

SE-4PTD PROGRAMMABLE PASS THROUGH WIRING DIAGRAM

28

SE-4PTD PROGRAMMABLE PASS THROUGH
ELECTRICAL COMPONENT CHART

Item Description SEO-4400 SEO-4402 SEO-4404

120 V AC 240 VAC 42 V AC

PC Power Cord BUG-9445 GOF-3115 BUG-9942
CB Circuit Breaker BUG-2931 BUG-2923 ARM-2278

1.0 A 0.7 A 3.0 A
PL Pilot Light BUG-1415 BUG-1428 BUG-1427
VT Volt Trap BUG-1339 BUG-1563 BUG-1393
T Transformer BUG-5218 BUG-5231 BUG-5232
P Potentiometer BUG-9686
SW1 T oggle Switch (power) ARM-2279
SW2 PB Switch (start) BUG-1536
SW3 PB Switch (stop) BUG-1536
SW4 PB Switch (Reset) BUG-1536
SW5 Joystick Switch PRS-1065
TB T erminal Block BUG-6028
LF Line Filter BUG-6069
CM Control Module BUG-6030
MC1 Motor Control Board BUG-1775
MC2 Motor Control Board BUG-1770
EN Encoder BUG-6093
CN1 Connector (Pendant) BUG-9902
CN2 Connector (Rotating Drive) BUG-9902
CN3 Connector (Linear Drive) BUG-9909
CN4 Connector (Auxiliary) MUG-1 156
M1 Gear Motor (100:1) BUG-5209
M2 Gear Motor (100:1) BUG-1595

29

SE-4PTD INTERNAL STRUCTURE

PARTS LIST
Item Qty Part No Description

1 1 SEO-4106 Cable Support
2 2 SEO-4415 Leg
3 4 SEO-4426 Gusset Plate
4 10 SEO-4427 St and Of f
5 4 SEO-4428 Joining Angle
6 2 SEO-4429 Top Cam Roll Plate
7 2 SEO-4430 Top Filler Plate
8 2 SEO-4431 Bottom Cam Roll Plate
9 2 SEO-4432 Cam Roll Follower
10 8 SEO-4433 Cam Roll Follower
11 8 SEO-4434 Hex-Nut 1” x 14 Thread
12 8 SEO-4439 1” Flat Washer
13 1 SEO-4453 Support Foot
14 1 SEO-4454 Support Plate
15 1 SEO-4455 Support Assembly

30

SEO-4PTD ROTATING DRIVE

PARTS LIST

Items Qt y Part NO Description
1 1 BUG-5209 Gear Motor (100:1)
2 1 FAS-0386 Hex Hd Cap Screw 5/16 – 24 x 5/8'' Lg
3 8 FAS-0388 Hex Hd Cap Screw 5/16-24 x 7/8'' Lg
4 2 FAS-0527 Soc Hd Cap Screw 8-32 x 3/4'' Lg
5 3 FAS-0559 Soc Hd Cap Screw 1/4 -20 x 1'' Lg
6 1 SEO-4125 Encoder Assembly

[Includes (1) BUG-6039 Encoder]
7 1 SEO-4435 Gear Assembly
8 1 SEO-4441 Encoder Block
9 1 SEO-4446 Motor Mount Plate
10 1 SEO-4447 Motor Mount Angle
1 1 1 SEO-4448 Motor Mount Support Angle
12 9 WAS-0250 5/16 SEA Washer

31

SEO-4113 ENCODER WIRING HARNESS

Part NO. Description Wire

BUG-6106 Ferrite Bead 10x30 20A WG
BUG-9902 Panel Connector, 6-T , Female
CAP-0103 Capacitor , .01 Film
CNN-0125 5-Pin Housing Assembly
CNN-0128 8-Pin Housing Assembly
GOF-3037 Male Connector

32

SEO-4119 INTERCONNECTING WIRE HARNESS

Wire NO. Color

1 Blue
2 Pink
3 Tan
4 Blue
5 Tan
6 Pink
7 Gray
8 Orange
9 Tan
10 Blue
11 Tan

Wire NO. Color

12 Orange
13 Brown
14 Brown
15 Gray
16 Blue
17 Yellow
18 White/ Blue
19 Blue
20 Red
21 Green
22 Orange
23 Pink

33

BUG-5605-PT LINEAR DRIVE (100:1)

PARTS LIST

ITEM QTY PART NO DESCRIPTION

1 4 BUG-1528 Spacer
2 1 BUG-1595 Gear Motor (100:1)
3 1 BUG-5611 Base, Linear Drive
4 1 BUG-5612 Cover
5 2 BUG-5613 Side Panel
6 1 BUG-5617 Cable Assy. Linear Drive
7 1 BUG-5618 Mounting Plate
8 2 BUG-5670 Adj. Leg & Wheel Assy
9 2 BUG-5675 Fixed Leg & wheel Assy
10 1 BUG-6040 Gear/ Encoder Assy
11 14 FAS-0114 P A B hd Scr 6-23 x 3/8 Black
12 4 FAS-0204 Rnd Hd Slt Scr 4-40 x 3/8
13 3 FAS-0529 Soc Hd Cap 8-32 x 1
14 2 FAS-0537 Soc hd cap 10-24 x 3/4
15 8 FAS-0557 Soc Hd Cap 1/4 - x 3/4
16 1 FAS- 0829 Flt Hd Slt Scr 8-32 x 1”
17 4 FAS-1305 HEX Nut 4-40
18 1 GOF-3014 Drive Pinion W/ Set Screw
19 4 SEO-4444 Stand of f 1 1/4 dia x 5” LG
20 1 SEO-6050 Mirror image retro fit kit

34

SEO-6050 Mirror Image Retro Fit Kit

Part No Description Wire

BUG-9909 Panel Connector, 6-T, male 10x30 20 A WG
CAP-1105 Capacitor, 1.0 Ceramic (CK06BK105K) all wires 9” long
CNN-0125 5-Pin Housing Assembly
GOF-3037 Male Connector
SWT-3601 T oggle Switch

35

PENDANT CONTROL WIRING DIAGRAM

BUG-6050 BUG-9906
Hand Held Terminal Cable Connector, 6-T, Male

A______ BLACK CIRCUIT COM
B______ YELLOW: TX (TRANSMIT)
C______ ORANGE: RX (RECEIVE )9600 BAUD
D______ BROWN: SIGNAL GROUND
E______ RED: POWER (5 V)
F ______SHIELD DRAIN WIRE, BARE

TOUCHING FOIL SHIELDING

NOTE: OTHER WIRES SHOULD BE TRIMMED AND

UNABLE TO TOUCH TERMINAL PINS.

36

OPERATION CHECKLIST and TROUBLESHOOTING

1. Plug in the machine and turn on the Power switch. Operate the manual joystick in all 4 directions
in turn. This overrides any speed command from the computer control. If the drive runs in a
corresponding direction, and the speed can be varied with the speed pot, this indicates

a) the speed control boards are OK
b) the controller circuit is supplying the required voltage.

If only one motor does not run correctly and the other one does, then it is likely
that the motor’s speed control is faulty.

If both do not operate properly , then there may be a bad component on the
control module that prevents proper voltage to be supplied to the joystick.

A bad connection in the speed signal line to the speed board may also run the
motor in one direction only at full speed.

Manual control must function correctly before checking the computer control

2. Attach the Hand held Pendant and push the Reset button. The display should read “Reset OK”.
Push “D” on the keypad and push “Return” until the display shows the Cut No. and all the data for
the cut.

If the display functions, this indicates
a) the communication line is functioning
b) the computer is operating its program
If the message “Reset Ok” comes up but Pushing “D” or any other key has no effect, there could

be a false signal coming in from the stop button, due to a wire short or damaged switch.

3. Disconnect the Hand held T erminal and turn power on.
T oggle the joystick in all 4 directions after pushing “Reset”. When the joystick is let go, the ma-

chine should go back to its original position.

This confirms the computer is running its program, and also interfacing correctly with the encod­ers and the speed signal outputs to the speed boards.

If one motor returns home and not the other, then the computer may not be receiving the encoder
signals properly from that axis- encoder pick up gear or coupling may be loose or the pin in the
encoder plug may not be making a good connection.

If a motor returns home from one direction but not from the other, the speed control may be faulty
and drive only in one direction.

37

PROGRAMMED DIAGNOSTICS FOR SE-4P

Some simple diagnostic tests are available in the program, by using the Hand Held T erminal. These
require using the “Shift” key on the keypad: refer to the keypad character map for shifted characters, to
use these commands.

If the machine is a DUAL FUNCTION SE4-PD or SE-4PTD, change function to the PIPE PROGRAM to
perform the following tests.

Press “T” for Test

The display should show “D-E-F?”

Next press D to check Drives

E for Encoders
F to Finish; get back to main menu

After selecting either D or E, for Drive or Encoder , the display will show “Axis No.”
Press 1 for Axis 1: rotation, or 2 for Axis 2: longitudinal motion.
If Drive was selected, the corresponding axis selected should run

1 second forward (display will show ‘F’)
1 second back (display will show ‘B’)

The drive should move at the speed set by the speed pot, regardless of whether encoder pulses are
being counted.

If Encoder was selected, the encoder count of the corresponding encoder (1 or 2) should
scroll up continuously in the display . Press any key to stop. Rotating the encoder in either
direction will increase or decrease the displayed count, if the computer is successfully
counting the pulses from it. The encoder can be rotated manually if disengaged, or by using
the joystick to move in the desired direction.

Note: the count is in hexadecimal notation (number base 16), (10 H=16 decimal, 400 H =
1024 decimal).

1 rotation of the encoder corresponds to 400 (HEX) counts.

Program Version:
Press “V” to determine the V ersion. No.; e.g. SEO41, which will show on the display .

38

39

WARRANTY

Model _____________________________

Limited 3-Year Warranty

For a period ending one (1) year from the date of invoice, Manufacturer warrants that any new machine or part is free
from defects in materials and workmanship and Manufacturer agrees to repair or replace at its option, any defective part
or machine. HOWEVER, if the invoiced customer registers the Product Warranty by returning the Warranty Registration
Card supplied with the product within 90 days of the invoice date, or by registering on-line at www.bugo.com, Manufacturer
will extend the warranty period an additional two (2) years which will provide three (3) total years from the date of original
invoice to customer. This warranty does not apply to machines which, after Manufacture’s inspection are determined by
Manufacturer to have been damaged due to neglect, abuse, overloading, accident or improper usage. All shipping and
handling charges will be paid by the customer.

The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty (either express or
implied) other than as set forth expressly in the preceding sentence. Specifically, Manufacturer makes no express or
implied warranty of merchantability or fitness for any particular purpose with respect to any goods. Manufacturer shall not
be subject to any other obligations 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 consequen­tial 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 any other claim relating to goods delivered pursuant hereto shall be
for repair or replacement (at Manufacturer’s option) of the machines or parts affected by such breach.

Distributor’s Warranty:

Serial No. __________________________
Date Purchased: ____________________
Where Purchased:___________________

In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations or
promises, express or implied, extended by Distributor without the advance written consent of Manufacturer, including but
not limited to any and all warranties of merchantability or fitness for a particular purpose and all warranties, representations
or promises which exceed or are different from the express limited warranty set forth above. Distributor agrees to indemnify
and hold Manufacturer harmless from any claim by a customer based upon any express or implied warranty by Distributor
which exceeds or differs from Manufacturer’s express limited warranty set forth above.

HOW TO OBTAIN SERVICE:
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

difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.

40