Bug-O Systems CB-2 Technical reference manual

INSTRUCTIONS
and
PARTS MANUAL
CB-2, CB-3
CIRCLE BURNER
Please record your equipment identication 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-CB2-CB3-IPM-0422
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: [phone] http://www.bugo.com FAX: [phone]
Bug-O Systems is committed to empowering our customers by providing operator
controlled mechanized solutions for their welding, cutting and custom applications.

2
MOVING PARTS can
cause serious injury.
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.
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.
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.
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.
4) Remove from the work site and store in
a safe location when not in use.
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.
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.
EQUIPMENT DAMAGE
POSSIBLE.
SAFETY

3
HIGH FREQUENCY WARNINGS
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE
OPERATION AND THEREFORE, WELD QUALITY.
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
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 specied 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.

4
TABLE OF CONTENTS
CB-2, CB-3 CIRCLE BURNER
INSTRUCTIONS AND PARTS MANUAL
PAGE
5 ......Introduction / Features
6 ......Setup and Operation
7 ......Making a Cut
8 ......CWO-6210 Rotation Control for CBO-2000/CBO-2002
9 ......Technical Data: (CB-2 Circle Burner) / Dimensions
10 .....Technical Data: (CB-3 Circle Burner) / Dimensions
11 ......CBO-2000 CBO-2002 CB-2 Circle Burner / Exploded View / Parts List
12 .....100-0437 CB2, CB3 COM Group / Exploded View / Parts List
13 .....CBO-2000 CBO-2002 CB-2 Circle Burner / Wiring Diagram
14 .....CBO-3000 CBO-3002 CB-3 Circle Burner / Exploded View / Parts List
15 .....CBO-3000 CBO-3002 CB-3 Circle Burner / Wiring Diagram
16 .....CWO-1635 Racking System CB-2, CB-3 / Exploded View / Parts List
16 .....CWO-1690 Large Horizontal Racker / Exploded View / Parts List
17 .....CWO-3193 CB-2, CB-3 Housing Assembly / Exploded View / Parts List
17 .....CWO-3205 7" Cam Assembly / Exploded View / Parts List
18 .....CWO-3358 CB-2, CB-3 Motor & Transmission Plate / Exploded View / Parts List
18 .....CWO-3359 Transmission SW 5:1 / Exploded View / Parts List
19 .....CWO-3361 P.M. Motor Assembly / Exploded View / Parts List
19 .....CWO-3425 CB-2, CB-3 Camshaft & Spacer Assembly / Exploded View / Parts List
20 .....CWO-3501 CB-2, CB-3 Shaft Assembly / Exploded View / Parts List
20 .....CWO-3920 Slide Bar Mounting Assembly / Exploded View / Parts List
21 .....CWO-3960 CB-2, CB-3 Small Brush Assembly / Exploded View / Parts List
21 .....CWO-3961 CB-2, CB-3 Small Retainer Block / Detail View
22 .....CWO-6210 Rotation Control / Exploded View / Parts List
23 .....CWO-6210 Rotation Control / Wiring Diagram / Electrical Component Chart
24 .....CWO-6210-CB2 CWO-6210-CB2-240 Rotation Control / Exploded View / Parts List
25 ..... CWO-6210-CB2 CWO-6210-CB2-240 Rotation Control / Wiring Diagram / Electrical Component Chart
26 .....CWO-3073 CB-2 Frame / Exploded View / Parts List
27 .....Accessories / CWO-3744 Manipulator Bracket / CWO-3895 Hillside Kit / CWO-3744 Manipulator
Bracket / Exploded View / Parts List
28 .....CB-3 & CB-3H Circle Burner (only) - Burning Hillside Holes
30 .....Preventive Maintenance / CB-2, CB-3 Circle Burner
32 .....Warranty

5
INTRODUCTION:
The CB-2 (CBO-2000 & CBO-2002) Circle Burner uses oxy-fuel for square or beveled hole cuts using a
single cutting pass. The CB-2 is mounted on a special frame with a releasable permanent magnet base
specially designed for use on vessels and large diameter pipe.
The CB-3 (CBO-3000 & CBO-3002) Circle Burner also uses oxy-fuel for single pass, square or beveled
hole cuts. Mounted on a column and boom, manipulator or xture, the CB-3 is designed for use on
vessels, large diameter pipe, domed heads and at plate.
FEATURES:
• 1-1/2 h.p. P.M. Motor and rotational speed control
• Rotation speed of 0.1-2 r.p.m.
• 100% duty cycle
• Adjustable vertical and horizontal torch positioning system
• Rise and fall cam assembly with 7" (178 mm) of travel
• 2 hose machine torch w / tip adjuster, includes tips
• Cutting capacities: 1.5"-42" (38-1067 mm) bevel cut holes, 4"-48" (102-1219 mm) square
cut holes
• Brushes and collector rings for all controls, eliminates cable and hose wrap

6
SETUP AND OPERATION:
**All page numbers referred to in this section are from this manual unless otherwise specied.**
POWER SUPPLY: Uses standard 120/50-60/1 VAC or 240/50-60/1 VAC. The part number indicates
voltage. (CBO-2000 and CBO-3000 are 120 VAC and CBO-2002 and CBO-3002 are 240 VAC).
OXY-FUEL CUTTING TORCH: The CB-2, CB-3 Circle Burner is equipped with a Victor 2-Hose Machine
Oxy-Fuel Torch model 204-A w/rack. Refer to the Victor Oxy-Fuel Cutting Torch instruction manual
supplied with this machine for general operation and set-up information. -H Machines are supplied with a
Harris torch.
FIXTURING: All circle burners (excluding CB-2) 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 a xture devise.
OXYGEN / FUEL CONNECTIONS: The CB-2, CB-3 Circle Burner is designed to accept standard oxy-
fuel hose tting connections. These connections are located at the top of the shaft on all models.
SETTING THE CAM: The cam setting is
equal to the distance “B” subtracted from
the distance “A”.
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 (on the CB-2 align the
horizontal rack parallel to the frame with the torch next
to the frame). 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.
*For detailed information on burning hillside holes see p.27
MACHINE CONTROLS: Various speed and directional capabilities can be controlled using the CWO-6210
Rotation Control. Please refer to CWO-6210 Rotation Control (page 21) section in this manual.
WHEEL ADJUSTMENT: The CB-2, CB-3 Racking System CWO-1635 (Item #3
page 11 or 13) and the Large Horizontal Racker CWO-1690 (Item #4 page 11 or
13) 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.
EXAMPLE:
Let A=3 and B=2
3-2=1
The cam setting is 1.
B A
Frame
Horizontal Rack
Cam
BA BA

7
MAKING A CUT:
1. Position the torch to the starting location using the CWO-1635 Racking System. Ensure
that the torch is at the appropriate position, standoff distance and angle.
2. Ignite torch. Refer to the torch manufacture instructions.
3. Preheat the spot were the cut is to be started. Before cutting action can start, the base
metal must be preheated to a bright cherry red. When the red spot appears, depress the
cutting oxygen lever slowly and rmly.
4. Start cutting rotation (forward or reverse) by using the Travel Direction Control located on
the CWO-6210 Rotation Control (for operating instruction see page 8).
5. To stop the cutting processes and rotation, throw the oxygen lever to the “OFF” position
and the travel direction control to the “BRAKE” position.
WARNING: IT IS NECESSARY TO USE CORRECT EYE, HEAD, AND BODY PROTECTION.

8
CWO-6210 ROTATION CONTROL FOR CBO-2000/CBO-2002
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 counterclockwise 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.
Speed Control
On/Off Switch Pilot Light
Travel Direction

9
TECHNICAL DATA: (CB-2 CIRCLE BURNER)
Rotation speed: 0.1-2 r.p.m.
Cam Range: 0-7" (0-178 mm)
Cutting Diameter: For Square Cut Holes: 4"-48" (102-1219 mm)
For Bevel Cut Holes: 1.5"-42" (38-1067 mm)
Height: 37.5" (953 mm)
Net Weight: 210 lbs. (95.3 kg)
Shipping weight: 290 lbs. (132 kg)
DIMENSIONS: 54"
(1372 mm)
37.5"
(953 mm)
27"
(686 mm)
Max Cutting
Radius
(See Above)
24"
(610 mm)

10
TECHNICAL DATA: (CB-3 CIRCLE BURNER)
Rotation speed: 0.1-2 r.p.m.
Cam Range: 0-7" (0-178 mm)
Cutting Diameter: For Square Cut Holes: 4"-48" (102-1219 mm)
For Bevel Cut Holes: 1.5"-42" (38-1067 mm)
Height: 38.5" (978 mm)
Net Weight: 125 lbs. (56.7 kg)
Shipping weight: 230 lbs. (104 kg)
DIMENSIONS:
40"
(1016 mm)
38.5"
(978 mm)
21"
(533 mm)
Max Cutting Radius
(See Above)