INSTRUCTIONS

AND

PARTS MANUAL

CIR-O

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-CIRO-IPM-0319

Bug-O Systems is committed to empowering our customers by providing operator controlled mechanized solutions for their welding, cutting and custom applications.

A DIVISION OF WELD TOOLING CORPORATION

280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, 15317-9564 USA

PHONE:1-412-331-1776 http://www.bugo.com FAX:1-412-331-0383

2

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.

ELECTRIC SHOCK can kill.

EQUIPMENT DAMAGE

POSSIBLE.

1.The equipment is not waterproof. Using the unit in a wet environment may result in serious injury. Do not touch the equipment when wet or standing in a wet location.

2.Never open the equipment without first unplugging the power cord or serious injury may result.

3.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.

4.Never remove or bypass the equipment power cord ground. Verity the equipment is grounded in accordance with all applicable local and national electrical safety codes. If none exist, use lnternational Electrical Code (IEC) 950.

1. Do not plug in the power cord without first verifying the equipment is OFF and the cord input voltage is the same as required by the machine or serious damage may result.

2. Do not leave the equipment unattended.

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.

READ INSTRUCTIONS

Read the instruction manual before installing and using the 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.

CAUTION

Remove from work site and store in a safe location.

NOTES

23

NOTES

22

CIR-O

PRECISION CIRCLE BURNER,

BEVELER AND WELDER

INSTRUCTION AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

4............TECHNICAL DATA

5,6.........OPERATING INSTRUCTIONS

7............BUG-5100-F DC III DRIVE UNIT

8............CIR-O / EXPLODED VIEW

9............CIR-O / PARTS LIST

10..........BUG-5100-F DC III DRIVE UNIT / EXPLODED VIEW

11 ..........BUG-5100-F DC III DRIVE UNIT / PARTS LIST

12..........BUG-5100-F DC III DRIVE UNIT / WIRING DIAGRAM

12..........ELECTRICAL COMPONENT CHART

13..........VACUUM SUPPORT KIT

14..........VACUUM PUMP / EXPLODED VIEW

15..........VACUUM PUMP / PARTS LIST

16..........TEMPLATE KIT

17..........TEMPLATE KIT / PARTS LIST

18..........CIR-O WITH ANNULAR CARRIAGE

19..........CIR-O SPEED RANGE CHART

20..........TROUBLESHOOTING GUIDE

21..........WARRANTY

3

4

TECHNICAL DATA

Power Requirement: 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1

CIR-3303 CIR-3323 CIR-3313

CIR-4404 CIR-4424 CIR-3313

CIR-5505 CIR-5525 CIR-5515

Cutting Range: Inside Diameter Outside Diameter

CIR-3301,3323,3313 3"-14" (75-356 mm) 26"-56" (660-1422 mm)

CIR-4404,4424,4414 3"-22" (75-559 mm) 34"-64" (864-1626 mm)

CIR-5505,5525,5515 3"-30" (75-760 mm) 42"-72" (1060-1830 mm)

Net Weight: CIR-3303,3323,3313 CIR-4404,4424,4414 CIR-5505,5525,5515

48 lbs. (21.8 kg) 65 lbs. (29.5 kg) 90 lbs.(40.9 kg)

Shipping

Weight: 66 lbs. (30.0 kg) 90 lbs. (40.8 kg) 128 lbs. (56.0 kg)

Speed Range: See chart on page 19.

CIR-3

CIR-4

CIR-5

24" (610 mm)

32" (813 mm)

40" (1016 mm)

“X”

“X” = 8.19 (208 mm)

With 2" Legs.

“X” = 11.19 (284 mm)

With 5" Legs.

WARRANTY

LIMITED 3-YEAR

WARRANTY

MODEL ___________________________

SERIAL NO. _______________________

DATE PURCHASED: ________________

WHERE PURCHASED: ______________

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 war ranty 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 represen tation 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 what soever 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 de livered pursuant hereto shall be for repair or replacement (at Manufacturer’s option) of the machines or parts affected by such breach.

Distributor’s Warranty:

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 Dis tributor 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 DIFFICULTY YOU HAVE

EXPERIENCED. BE SURE TO MENTION THE MODEL AND SERIAL NUMBERS.

21

TROUBLESHOOTING GUIDE

PROBLEM CAUSE REMEDY

Does not run- No power to

Indicator light off. machine.

Check power line supply voltage.

Plug in line cord firmly.

Does not run, Wiring shorts. Disconnect machine and indicator light off. examine internally; rewire at fault.

Circuit breaker tripped. If none found, throw direction switch to ‘OFF’, reset breaker and plug in.

Shorted motor. If breaker does not trip, replace drive unit.

Faulty speed If breaker trips again, replace control board. control board.

Burned out transformer.

(OR)

Replace transformer.

Does not run. indicator light on.

Bad connection. Check wiring connections, 12 VAC should appear across secondary of transformer.

Tighten terminal screws on speed control board.

Unit runs, but no

Faulty speed control board.

Faulty speed

If DC Volts = 0 across leads to motor; replace control board.

Replace control board. control over speed. control board. (Check connection first).

NOTE:

Make sure unit is pugged into correct voltage.

(120 VAC, 240 VAC, 42 VAC) corresponding to model number rating.

12 VAC should appear across secondary of transformer in all DC III Drive

Units.

20

B

A

OPERATING INSTRUCTIONS

X

E H

Q

I

KJ Y W

O

P

F

Z

AA

R

C

D

S

V

T L

U

INTRODUCTION

Your new CIR-O is ready for operation when you receive it. A few minutes spent reading the following will help you become familiar with the operation and capabilities of your machine.

The CIR-O Carriage (C) should operate freely on the Ring Track (D) . The carriage has three adjustable Wheel Logs (A) . By loosening the Flat Socket

Head Screws (B) these logs may be rotated for adjustment. To check Wheel

(AA) adjustment, hold one wheel and move the carriage. When properly adjusted the wheel should barely slip.

The Cam Clutch (E) engages the drive pinion to the Ring Gear (F) by changing the position of the Drive Module (I) . The Thumb Nut (H) locks the Cam

Clutch (E) in position.

Turning the Potentiometer Knob (K) regulates speed. The Switch (J) controls forward-off-reverse. Throw the switch in the direction you want the carriage to travel.

The CIR-O is furnished with four symmetrically-located Legs (L) . A variety of Magnetic Feet and legs (S) , (T) , (U) , and (V) are available to increase the versatility of the CIR-O machine.

5

6

OPERATING INSTRUCTIONS (CONT’D.)

POWER SUPPLY

The DC III drive operates on 120 volt, (42VAC), (240VAC), 50/60 Hz. The Circuit

Breaker (O) protects the unit against overload or electrical faults,

CAUTION: IF THE CIRCUIT BREAKER OPENS, FIND AND CORRECT THE

CAUSE OF FAILURE BEFORE RESETTING.

TORCH

The Torchholder (P) will accept any standard American machine torch (barrel diameter 1-3/8" (34 mm) with 1/4"-square (6 mm) 32-pitch rack). The 32-pitch pinion is standard. Specify a 24-pitch pinion if desired. The Short Hose Assembly (Q) connects the torch to the Quick-acting Manifold Assembly (R) .

The supply hoses are to be connected to the open side of the quick-acting manifold assembly.

Proper torch operation is essential to quality cuts. We suggest that you follow the torch manufacturers’ instructions carefully, being sure to use a clean tip of the proper size.

MAGNETIC SUPPORTS

Several Types of magnetic supports are available for use with the CIR-O to stabilize the machine as listed below:

(S) Outrigger Support Assemblies ; CON-1010 - used in multiples of two or four to stabilize CIR-O on plate, cylinders or heads where two legs must be longer than the other two,

(T) Magnet Foot Assemblies ; CIR-9000 - may be used in sets of four or more to position CIR-O on vertical or out-of-position, flat surfaces.

(U) Leg and Magnet Foot Assemblies ; CON-1040 (four required) - may be used for flat or irregular surfaces.

(V) Offset Leg and Magnet Assemblies ; CIR-9002 (four required) - use with a bevel cutting head or adjustable tip adaptor - to eliminate the “blind” spot under the ring.

SETUP

A center-punch mark and a radius mark are the only layout required. The Center

Pin Assembly (Z) extends below the CIR-O base and is placed in the centerpunch mark. The CIR-O is then eased down to the work on the center pin. This movement locates the entire machine “on center.” The Rack (W) with Torchholder (P) is then positioned over the radius mark.

OPERATION

In order to provide a smooth start, it is recommended that the starting hole be drilled or pierced inside or outside the radius mark. Center the torch tip over the radius mark and secure the Rack Stop (X ) firmly against the Post Assembly

(Y) . [The side of the post assembly to which the rack stop is positioned depends upon whether the material inside or outside the cut is scrap]. Begin the cut from the starting hole and, after carriage travel is begun, move the Torch Rack (W ) slowly against the Rack Stop (X) . This action “feathers-in” the cut eliminating a notch.

INSIDE RING

INSIDE RING

CIR-O SPEED RANGE CHART

Capacities and Speed Ranges

INSIDE RING

INCH

DIAMETER

IPM INCH

DIAMETER

IPM

3 .4-8 75 10-210

6 .8-16 150 20-420

10 .4-28 250 35-700

14 2-39 350 50-1000

26 3.5-70 650 90-1805

30 4-80 750 105-2100

34 4.5-92 850 120-2400

38 5.2-105 950 130-2640

42 5.7-115 1050 150-3000

46 6.3-125 1140 160-3200

50 6.8-135 1250 175-3500

56 7.6-155 1420 200-4000

3 .3-5 75 7-140

6 .6-11 150 14-280

10 .9-18 250 23-460

14 1.3-26 350 32-650

18 1.7-33 450 42-840

22 2-40 550 50-1000

34 3.2-63 850 80-1600

38 3.5-70 950 87-1760

42 3.9-78 1050 97-1950

46 4.3-85 1150 105-2130

50 4.6-93 1250 115-2300

54 5-100 1350 125-2500

58 5.4-110 1450 135-2700

64 6-120 1625 150-3000

3 .2-4 75 5-100

6 .4-8 150 10-210

10 .7-13 250 17-350

14 1-19 350 42-500

18 1.3-25 450 32-640

22 1.5-30 550 38-760

26 1.8-37 650 45-900

30 2-41 750 52-1050

42 2.9-57 1050 73-1458

46 3.2-63 1150 80-1600

50 3.4-68 1250 87-1750

54 3.7-75 1350 94-1900

58 4-80 1450 100-2000

62 4.3-85 1550 105-2150

66 4.5-90 1650 115-2300

72 4.9-100 1825 125-2500

19

CIR-O WITH ANNULAR CARRIAGE

3

4

9

2 8

5

1

7

CIR-3304

CIR-4405

CIR-5506

6

CIR-0 III w/ANNULAR CARRIAGE

CIR-0 IV w/ANNULAR CARRIAGE

CIR-0 V w/ANNULAR CARRIAGE

ITEM QTY PART NO

1

2

3

4

5

6

7

8

9

1

1

1

1

1

4

1

1

1

BUG-2440

BUG-5100-F

BUG-9180-10

CIR-1010-3

CIR-5031

CON-1003

DESCRIPTION

Base, Post (Block)

DC III Drive Unit Assembly (150: 1)

7/8" (22 mm) Rod, 10" (254 mm) Long

Twin Hose Assembly 32" (812 mm)

42" (1066 mm): CIR-1010-4

50" (1270 mm): ClR-1010-5

Carriage Plate-Annular

Leg 2" (50 mm)

CON-(3,4,5)000 Ring & Gear Assembly

GOF-3025

PAN-1010

2-Hose Quick-Acting Manifold

Panograph Assembly with Torchholder

18

BUG-5100-F DC III DRIVE UNIT

DRIVE UNIT OPERATION

Rotating Cam Knob (B) will move the drive pinion in and out of engagement with the ring gear.

To lock drive into position, tighten the 1/4-28 Wing Nut (A) .

To disengage the drive pinion from the ring gear, loosen the 1/4-28 Wing

Nut (A) and turn Knob (B) counterclockwise. Turn Knob (B) clockwise to engage the drive pinion with the ring gear, re-tighten the 1/4-28 Wing Nut

(A) to lock in position.

When Power Cord (C) is plugged into the appropriate power source, Pilot

Light (D) will glow. Switch (E) controls the direction of travel, with the cen ter position set at “OFF”. Knob (F ) controls the speed. Circuit Breaker (G) protects the unit against overload or electrical faults.

CAUTION: IF THE CIRCUIT BREAKER OPENS, FIND AND CORRECT

THE CAUSE OF FAILURE BEFORE RESETTING.

B A

C

E

F

D G

TECHNICAL DATA

DC III DRIVE UNIT

Power Requirement: BUG-5100-F 120 VAC/50-60/1

BUG-5102-F

BUG-5104-F

VAC/50-60/1

Dimensions:

Net Weight:

Shipping Weight:

Speed:

7.12" L x 6.75" W x 6.75" H

(180 x 172 x 172 mm)

16 lbs. (7.3 kg)

20 lbs. (9.1 kg)

2-50 ipm (50-1270 mm/min)

(Measured at Drive Pinion)

Load Capacity: *30 lbs. (14 kg)

[Measured at Drive Pinion]

*Note: Speed and load ratings apply at radius of ring gear. Speed is proportional to radius at any other point, and load rating is inversely proportional to

radius.

7

8

CIR-O / EXPLODED VIEW

20

21

11

24

17

2

3

7

4

18

19

23

13

1

16

15

5

6

12

22

10

9

14

8

TEMPLATE KIT / PARTS LIST

CIR-9030 [FOR CIR-3]

CIR-9040 [FOR CIR-4]

CIR-9050 [FOR CIR-5]

2

10

2

12

11

13*

6

4

5

1

9

8

7

ITEM QTY

1

8

9

10

11

12

13

2

3

4

5

6

7

1

1

1

4

1

4

4

4

8

1

1

1

PART NO.

BUG-2440

BUG-2915

BUG-9180-10 1/8" (22 mm) rod, 10" (254 mm) Long

CIR-9031

CIR-9032

CON-1004

CON-1040

FAS-0257

FAS-2553

PAN-1009

PAN-1018

PAN-1033

--------------

DESCRIPTION

Base, Post (Block) - Order separately

Torchholder Assembly

Spacer Leg

Aluminum Master Template Guide

(For CIR-3)

Alignment Bars (included with

Ring Gear Assembly)

Magnet Foot and Leg Assembly-Order separately-use of 4 recommended with this kit

Rnd Hd Scr 1/4-20 x 3/4"

Soc Hd Cap Scr 1/4-20 x 1-1/2"

(included with Ring Gear Assembly)

Tensioner

Rod w/Key-10" (254 mm) Long

Rod Clamp

Torches are not furnished with kit, order separately

17

TEMPLATE KIT

The purpose of the TEMPLATE KIT is to permit cutting of elliptical and obround holes. The manner of accomplishing this job involves dragging the torch barrel against a template which is made 11/16" (18 mm) larger on the radius than the cut-out desired (when using standard US machine torches).

The TEMPLATE KIT consists of a master layout template (aluminum sheet), which is used to locate the bolt holes and center on the actual template which should be made from 1/8" (3 mm) masonite or similar material.

A full-size drawing of the shape to be cut, should be made showing a center point, then add 11/16" (18 mm) to the radius. (Because the torch body drags against the template, adding one-half the diameter of the torch to the drawing will put the center of the torch tip in the right position.)

MAKING THE TEMPLATE

Lay the aluminum master layout template on the masonite board. Transfer the holes from the master by tracing with a pencil or use a quick-drying spray paint. Next, position the oversized drawing, so that the center point is directly over the center on the template and the shape is located symmetrically between the ‘leg holes’ (see sketch Page 17, number 8. Trace [or spray] the outline onto the template.)

Next, drill the holes in the template. Then, cut-out the outside circle (outside of the template) and the shape to be cut (on the inside).

MOUNTING THE TEMPLATE

The four CIR-9031 spacer legs should be screwed into the ring gear. (Remove existing 2" (50 mm) legs.) The template is then placed on these legs and the

2" (50 mm) legs, or 5" (127 mm) legs, when using the recommended CON-

1040 leg and foot assemblies) are screwed - through the template - into the

CIR-9031 spacer legs, which clamp the template under and parallel to the ring gear. Insert four round head screws (see sketch Page 17, number 12) through the template - into the alignment bars (see sketch Page 17, number 7.)

SET UP

Place the rod [see sketch Page 17 number 5 in the base post on the carriage.

Slip the tensioning assembly (see sketch Page 17, number 6) on the rod.

Install machine torch in torchholder - make sure torch is straight up-and-down in both planes. Adjust tensioning assembly so that torch maintains firm contact with template when carriage is rotated. Connect hoses. Place machine on work - locate feet and lock in position.

STARTING THE CUT

Lock tensioning assembly so that the torch tip is over scrap area, piece - or start the cut in starting hole. When preheat is complete start motor (carriage travel), release tensioning assembly and let it gradually swing to template -

(this action ‘feathers’ the start into the cut.)

16

CIR-O / PARTS LIST

PARTS LIST / CIR-O

12

13

14

15

16

17

18

19

8

9

10

11

20

21

22

23

24

ITEM QTY PART NO.

1

2

3

4

5

6

7

2

3

1

1

4

4

1

4

5

1

1

1

BUG-1996

BUG-1998

BUG-2010

BUG-2407

3

2

1

1

1

4

1

1

1

1

1

2

BUG-2440

BUG-2915

BUG-5100-F

CIR-9002

CIR-9020

CIR-9021

CIR-1010-3

DESCRIPTION

Fixed Leg & Wheel Assembly

Adjustable Leg & Wheel Assembly

Wheel w/Bearing

Post Assembly (Vertical)

Base Post (Block)

Torchholder Assembly

DC III Drive Unit Assembly (150:1)

120 VAC 240 VAC BUG-5102-F

42 VAC- BUG-5104-F

Offset Leg & Magnet Foot (Optional)

Magnet Foot

Leg (Specify Length w/Suffix)

Lengths Available: 5" (127 mm)

8" (203 mm) 10" (254 mm)

Twin Hose Assembly 32" (812 mm)

42" (1066 mm) CIR-1010-4

50" (1270 mm) CIR-1010-5

CON-(3,4,5)000 Ring & Gear Assembly

CON-(3,4,5)041 Carriage Plate

CON-1003

CON-1042

CON-1043

FAS-0986

FAS-2736

GOF-3025

HOB-1025

PAN-1015

PAN-1033

PAN-1043

WAS-0230

Leg-2" (50 mm)

Center Pin Support Bar

Center Pin Assembly 9" (228 mm)

Fit Hd Soc Sor 5/16-24 x 5/8

Fil Hd Set 10-24 x 2-1/4

2-Hose Quick-Acting Manifold

Rack Stop

Rack 22-5/8" (574 mm)

Rod Clamp

Spacer

#10 Washer

9

BUG-5100-F DC III DRIVE UNIT /

EXPLODED VIEW

31

7

2 26 5

8

22

25

6

35

14

17

15

27

9

21

4

11 10

24

29

29

32

3

1

15

13

16

12

30

23

20

19

33

18

10

34

28

VACUUM PUMP / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 ARV-2017 1/4" Brass Vacuum Relief Valve

2 1 ARV-2014 Vacuum Gage

3 1 ARV-2018 1/4" NPT Union Cross, Female

4 2 ARV-2012 1/4" NPT Nipple

5 1 ARV-2016 1/4" NPT Brass Check Valve, F

6 2 ARV-1107 3/8" Hose Barb x 1/4" NPT-M

7

8

2 ARV-1005 11/16" x .112 Thk

1 ARV-1004-P Hose 3/8" ID x 11/16" OD

9 1 ARV-1012 Female Quick Connector

10 1 ARV-2019 Pump

11

12

1 ARV-1999 Foot Support

1 ARV-2021 120 VAC Power Cord w/Switch

13 1 ARV-2013 Handle

14 1 ARV-2011 Body

15 4 ARV-2010 Vane

16 1 ARV-2009 Shroud

17 2 ARV-2003 End Cap

18 2 ARV-2004 Felt

19 2 ARV-2005 O-ring

20 2 ARV-2002 End Cap Assembly

1 ARV-2001 Filter / Muffler 21

22

23

24

1 ARV-2006 Muffler Box

1 ARV-2007 Gasket

1 ARV-2008 End Plate

ARV-2020 VACUUM PUMP KIT, 120 VAC 60 HZ/1 PH

ARV-2030 VACUUM PUMP KIT, 220 VAC 50 HZ/1 PH

The VACUUM PUMP KITS are 1/6 HP units that provide 15" (381 mm) Hg. on continuous duty. The ARV-2020/2030 Pump will support 30 vacuum cups.

A Repair Kit, ARV-1029 is available for the ARV-2020 and ARV-2030 pumps.

The kit contains (4) vanes, (1) body gasket, filter felts for the muffler, oiler filter, oiler wick, a cover gasket and separator felt for the oiler filter.

LUBRICATION OF ARV-2020 AND ARV-2030 VACUUM PUMP KITS:

Fill jar to line indicated on “oil level decal” to avoid wetting felt, which would increase oil feed. Use SOCONY DTE LIGHT OIL OR EQUIVALENT PETRO-

LEUM BASE OIL WITHOUT DETERGENTS . One filling should last 20-50 hours of operation. For slower feed, pull wick downward so that less wick is exposed to air stream. Using the same oil as above, oil the motor bearings yearly with 1/2 teaspoon or 30 drops.

15

VACUUM PUMP / EXPLODED VIEW

1

3

4

2

16

17

18 20

19

15

21

5 6

7

22

23

8

24

12

7

9

6

14

10

13

BUG-5100-F DC III DRIVE UNIT / PARTS LIST

ITEM QTY PART NO.

*1

25

26

27

28

29

30

*31

32

33

34

35

17

18

19

20

*21

22

23

*24

10

11

12

13

14

15

16

*2

*3

4

5

6

7

8

9

1

1

1

1

1

1

1

1

1

1

1

1 BUG-5116

1

1

4

BUG-1393

BUG-1415

BUG-1550

BUG-1725

BUG-2255

BUG-2767W

BUG-2924

BUG-2988

1 BUG-5111

BUG-5112

BUG-5113

BUG-5114

BUG-5119

BUG-5120

BUG-5121

1

1

BUG-5122

BUG-5128

1 BUG-5131

1

1

1

1

1

BUG-9444

BUG-9445

BUG-9446

BUG-9614

BUG-9675

1 BUG-9677

1 BUG-9687

2

8

7

1

1

FAS-0112

FAS-0114

FAS-0124

FAS-0654

2

4

BUG-2923

FAS-1320

FAS-2824

1 GOF-3019

1 WAS-0240

DESCRIPTION

Volt Trap 120 VAC

Pilot Light 120 VAC

Gear Motor 150:1

Precision Speed Control

Toggle Switch

Wing Nut 1/4-28

Reset Button Seal

End Plate

Cover

End Plate

Cam Clutch

Swivel Plate

Stud

Knob

Cam Clutch Assembly

(includes Items 6,11,13,14,17,35)

Stand Off

Delrin Washer

Drive Pinion w/Long Shaft

Sleeve

Tool Kit

Power Cord 120 VAC

Cord Grip

Needle Bearing

Transformer 120 VAC

Potentiometer

Knob

Pan Hd Scr 6-32 x 1/4

Pan Hd Scr 6-32 x 3/8

Pan Hd Scr 8-32 x 3/8

Soc Hd Shidr Scr 5/16 x 3/8 x 1/4-20

Circuit Breaker w/Reset .7A

Hex Nut 8-32

Fit Hd Slt Scr 8-32 x 1-3/4

Handle

1/4 Washer

*See Electrical Component Chart for 240 VAC and 42 VAC part numbers.

11

14 11

BUG-5100-F DC III DRIVE UNIT / WIRING

DIAGRAM / ELECTRICAL COMPONENT CHART

120 (42) VAC

INPUT

CB

A

BLK

WHT

D

BLK

V

WHT

T TAN

TAN

RED

DK. BLU

DK. BLU

YEL

7

8

5

6

3

4

1

2

F

240 VAC

INPUT

A BLK

WHT

CB

BLK

T

D

P

S

PK

GY

BLK

RED

M

ELECTRICAL COMPONENT CHART

ITEM DESCRIPTION

PART NUMBER

BUG-5100-F

240 VAC

A

CB

F

S

P

D

V

T

M

Power Cord

Circuit Breaker

Pilot Light

Volt Trap

BUG-9445 GOF-3115

BUG-2923 (.7A) BUG-2952 (.5A)

BUG-1415

BUG-1393

BUG-1428

BUG-1563

Transformer

Gear Motor

Precision Speed Control

Toggle Switch

BUG-9675 GOF-3112

* BUG-1550 (150:1)

BUG-1725

BUG-2255

Potentiometer Control BUG-9686

* BUG-1600 (50:1)

BUG-1595 (100:1)

BUG-9442

BUG-2933 (2A)

BUG-1427

BUG-1393

BUG-1466

12

VACUUM SUPPORT KIT

CON-1006 VACUUM SUPPORT KIT can be mounted on any CIR-O or CON-

O ring base with standard CON-1003 legs. Vacuum pump kits are available for operation on 120 VAC [ARV-2020] or 240 VAC [ARV-2030]

Each vacuum cup holds 50 lbs (22 kg).

(Dirt and scale block vacuum lines; blow-out when clogged).

Keep flame 4" (100 mm) away from cups when burning or welding. Silicone vacuum cups will withstand a temperature of 600°F (318° C).

10 1

2

9 6

7

8

5

4

3

ITEM

1

PART NO. DESCRIPTION

ARV-1004-14 Hose 14" (355 mm)

2

3

4

5

6

7

8

9

10

ARV-1005

ARV-1013

ARV-2020

ARV-2030

ARV-1034

ARV-1107

ARV-1109

ARV-1116

CON-1007

CON-1020

Hose Clamp

Male Quick Connector 1/4 NPT

Vacuum Pump Kit (I 20 VAC/60 Hz/1 Ph)

Vacuum Pump Kit (220 VAC/60 Hz/1 Ph)

Choke Nipple

3/8" Hose Barb 1/4 NPT

Protective Cap

Vacuum Cup (Silicone) 50 lbs. (22 kg)

Vacuum Leg

Double Swivel Clamp Assembly

Vacuum Pump is not included in CON-1006 Vacuum Support Kit.

13

BUG-5100-F DC III DRIVE UNIT / WIRING

DIAGRAM / ELECTRICAL COMPONENT CHART

120 (42) VAC

INPUT

CB

A

BLK

WHT

D

BLK

V

WHT

T TAN

TAN

RED

DK. BLU

DK. BLU

YEL

7

8

5

6

3

4

1

2

F

240 VAC

INPUT

A BLK

WHT

CB

BLK

T

D

P

S

PK

GY

BLK

RED

M

ELECTRICAL COMPONENT CHART

ITEM DESCRIPTION

PART NUMBER

BUG-5100-F

240 VAC

A

CB

F

S

P

D

V

T

M

Power Cord

Circuit Breaker

Pilot Light

Volt Trap

BUG-9445 GOF-3115

BUG-2923 (.7A) BUG-2952 (.5A)

BUG-1415

BUG-1393

BUG-1428

BUG-1563

Transformer

Gear Motor

Precision Speed Control

Toggle Switch

BUG-9675 GOF-3112

* BUG-1550 (150:1)

BUG-1725

BUG-2255

Potentiometer Control BUG-9686

* BUG-1600 (50:1)

BUG-1595 (100:1)

BUG-9442

BUG-2933 (2A)

BUG-1427

BUG-1393

BUG-1466

12

VACUUM SUPPORT KIT

CON-1006 VACUUM SUPPORT KIT can be mounted on any CIR-O or CON-

O ring base with standard CON-1003 legs. Vacuum pump kits are available for operation on 120 VAC [ARV-2020] or 240 VAC [ARV-2030]

Each vacuum cup holds 50 lbs (22 kg).

(Dirt and scale block vacuum lines; blow-out when clogged).

Keep flame 4" (100 mm) away from cups when burning or welding. Silicone vacuum cups will withstand a temperature of 600°F (318° C).

10 1

2

9 6

7

8

5

4

3

ITEM

1

PART NO. DESCRIPTION

ARV-1004-14 Hose 14" (355 mm)

2

3

4

5

6

7

8

9

10

ARV-1005

ARV-1013

ARV-2020

ARV-2030

ARV-1034

ARV-1107

ARV-1109

ARV-1116

CON-1007

CON-1020

Hose Clamp

Male Quick Connector 1/4 NPT

Vacuum Pump Kit (I 20 VAC/60 Hz/1 Ph)

Vacuum Pump Kit (220 VAC/60 Hz/1 Ph)

Choke Nipple

3/8" Hose Barb 1/4 NPT

Protective Cap

Vacuum Cup (Silicone) 50 lbs. (22 kg)

Vacuum Leg

Double Swivel Clamp Assembly

Vacuum Pump is not included in CON-1006 Vacuum Support Kit.

13

VACUUM PUMP / EXPLODED VIEW

1

3

4

2

16

17

18 20

19

15

21

5 6

7

22

23

8

24

12

7

9

6

14

10

13

BUG-5100-F DC III DRIVE UNIT / PARTS LIST

ITEM QTY PART NO.

*1

25

26

27

28

29

30

*31

32

33

34

35

17

18

19

20

*21

22

23

*24

10

11

12

13

14

15

16

*2

*3

4

5

6

7

8

9

1

1

1

1

1

1

1

1

1

1

1

1 BUG-5116

1

1

4

BUG-1393

BUG-1415

BUG-1550

BUG-1725

BUG-2255

BUG-2767W

BUG-2924

BUG-2988

1 BUG-5111

BUG-5112

BUG-5113

BUG-5114

BUG-5119

BUG-5120

BUG-5121

1

1

BUG-5122

BUG-5128

1 BUG-5131

1

1

1

1

1

BUG-9444

BUG-9445

BUG-9446

BUG-9614

BUG-9675

1 BUG-9677

1 BUG-9687

2

8

7

1

1

FAS-0112

FAS-0114

FAS-0124

FAS-0654

2

4

BUG-2923

FAS-1320

FAS-2824

1 GOF-3019

1 WAS-0240

DESCRIPTION

Volt Trap 120 VAC

Pilot Light 120 VAC

Gear Motor 150:1

Precision Speed Control

Toggle Switch

Wing Nut 1/4-28

Reset Button Seal

End Plate

Cover

End Plate

Cam Clutch

Swivel Plate

Stud

Knob

Cam Clutch Assembly

(includes Items 6,11,13,14,17,35)

Stand Off

Delrin Washer

Drive Pinion w/Long Shaft

Sleeve

Tool Kit

Power Cord 120 VAC

Cord Grip

Needle Bearing

Transformer 120 VAC

Potentiometer

Knob

Pan Hd Scr 6-32 x 1/4

Pan Hd Scr 6-32 x 3/8

Pan Hd Scr 8-32 x 3/8

Soc Hd Shidr Scr 5/16 x 3/8 x 1/4-20

Circuit Breaker w/Reset .7A

Hex Nut 8-32

Fit Hd Slt Scr 8-32 x 1-3/4

Handle

1/4 Washer

*See Electrical Component Chart for 240 VAC and 42 VAC part numbers.

11

14 11

BUG-5100-F DC III DRIVE UNIT /

EXPLODED VIEW

31

7

2 26 5

8

22

25

6

35

14

17

15

27

9

21

4

11 10

24

29

29

32

3

1

15

13

16

12

30

23

20

19

33

18

10

34

28

VACUUM PUMP / PARTS LIST

ITEM QTY PART NO. DESCRIPTION

1 1 ARV-2017 1/4" Brass Vacuum Relief Valve

2 1 ARV-2014 Vacuum Gage

3 1 ARV-2018 1/4" NPT Union Cross, Female

4 2 ARV-2012 1/4" NPT Nipple

5 1 ARV-2016 1/4" NPT Brass Check Valve, F

6 2 ARV-1107 3/8" Hose Barb x 1/4" NPT-M

7

8

2 ARV-1005 11/16" x .112 Thk

1 ARV-1004-P Hose 3/8" ID x 11/16" OD

9 1 ARV-1012 Female Quick Connector

10 1 ARV-2019 Pump

11

12

1 ARV-1999 Foot Support

1 ARV-2021 120 VAC Power Cord w/Switch

13 1 ARV-2013 Handle

14 1 ARV-2011 Body

15 4 ARV-2010 Vane

16 1 ARV-2009 Shroud

17 2 ARV-2003 End Cap

18 2 ARV-2004 Felt

19 2 ARV-2005 O-ring

20 2 ARV-2002 End Cap Assembly

1 ARV-2001 Filter / Muffler 21

22

23

24

1 ARV-2006 Muffler Box

1 ARV-2007 Gasket

1 ARV-2008 End Plate

ARV-2020 VACUUM PUMP KIT, 120 VAC 60 HZ/1 PH

ARV-2030 VACUUM PUMP KIT, 220 VAC 50 HZ/1 PH

The VACUUM PUMP KITS are 1/6 HP units that provide 15" (381 mm) Hg. on continuous duty. The ARV-2020/2030 Pump will support 30 vacuum cups.

A Repair Kit, ARV-1029 is available for the ARV-2020 and ARV-2030 pumps.

The kit contains (4) vanes, (1) body gasket, filter felts for the muffler, oiler filter, oiler wick, a cover gasket and separator felt for the oiler filter.

LUBRICATION OF ARV-2020 AND ARV-2030 VACUUM PUMP KITS:

Fill jar to line indicated on “oil level decal” to avoid wetting felt, which would increase oil feed. Use SOCONY DTE LIGHT OIL OR EQUIVALENT PETRO-

LEUM BASE OIL WITHOUT DETERGENTS . One filling should last 20-50 hours of operation. For slower feed, pull wick downward so that less wick is exposed to air stream. Using the same oil as above, oil the motor bearings yearly with 1/2 teaspoon or 30 drops.

15

TEMPLATE KIT

The purpose of the TEMPLATE KIT is to permit cutting of elliptical and obround holes. The manner of accomplishing this job involves dragging the torch barrel against a template which is made 11/16" (18 mm) larger on the radius than the cut-out desired (when using standard US machine torches).

The TEMPLATE KIT consists of a master layout template (aluminum sheet), which is used to locate the bolt holes and center on the actual template which should be made from 1/8" (3 mm) masonite or similar material.

A full-size drawing of the shape to be cut, should be made showing a center point, then add 11/16" (18 mm) to the radius. (Because the torch body drags against the template, adding one-half the diameter of the torch to the drawing will put the center of the torch tip in the right position.)

MAKING THE TEMPLATE

Lay the aluminum master layout template on the masonite board. Transfer the holes from the master by tracing with a pencil or use a quick-drying spray paint. Next, position the oversized drawing, so that the center point is directly over the center on the template and the shape is located symmetrically between the ‘leg holes’ (see sketch Page 17, number 8. Trace [or spray] the outline onto the template.)

Next, drill the holes in the template. Then, cut-out the outside circle (outside of the template) and the shape to be cut (on the inside).

MOUNTING THE TEMPLATE

The four CIR-9031 spacer legs should be screwed into the ring gear. (Remove existing 2" (50 mm) legs.) The template is then placed on these legs and the

2" (50 mm) legs, or 5" (127 mm) legs, when using the recommended CON-

1040 leg and foot assemblies) are screwed - through the template - into the

CIR-9031 spacer legs, which clamp the template under and parallel to the ring gear. Insert four round head screws (see sketch Page 17, number 12) through the template - into the alignment bars (see sketch Page 17, number 7.)

SET UP

Place the rod [see sketch Page 17 number 5 in the base post on the carriage.

Slip the tensioning assembly (see sketch Page 17, number 6) on the rod.

Install machine torch in torchholder - make sure torch is straight up-and-down in both planes. Adjust tensioning assembly so that torch maintains firm contact with template when carriage is rotated. Connect hoses. Place machine on work - locate feet and lock in position.

STARTING THE CUT

Lock tensioning assembly so that the torch tip is over scrap area, piece - or start the cut in starting hole. When preheat is complete start motor (carriage travel), release tensioning assembly and let it gradually swing to template -

(this action ‘feathers’ the start into the cut.)

16

CIR-O / PARTS LIST

PARTS LIST / CIR-O

12

13

14

15

16

17

18

19

8

9

10

11

20

21

22

23

24

ITEM QTY PART NO.

1

2

3

4

5

6

7

2

3

1

1

4

4

1

4

5

1

1

1

BUG-1996

BUG-1998

BUG-2010

BUG-2407

3

2

1

1

1

4

1

1

1

1

1

2

BUG-2440

BUG-2915

BUG-5100-F

CIR-9002

CIR-9020

CIR-9021

CIR-1010-3

DESCRIPTION

Fixed Leg & Wheel Assembly

Adjustable Leg & Wheel Assembly

Wheel w/Bearing

Post Assembly (Vertical)

Base Post (Block)

Torchholder Assembly

DC III Drive Unit Assembly (150:1)

120 VAC 240 VAC BUG-5102-F

42 VAC- BUG-5104-F

Offset Leg & Magnet Foot (Optional)

Magnet Foot

Leg (Specify Length w/Suffix)

Lengths Available: 5" (127 mm)

8" (203 mm) 10" (254 mm)

Twin Hose Assembly 32" (812 mm)

42" (1066 mm) CIR-1010-4

50" (1270 mm) CIR-1010-5

CON-(3,4,5)000 Ring & Gear Assembly

CON-(3,4,5)041 Carriage Plate

CON-1003

CON-1042

CON-1043

FAS-0986

FAS-2736

GOF-3025

HOB-1025

PAN-1015

PAN-1033

PAN-1043

WAS-0230

Leg-2" (50 mm)

Center Pin Support Bar

Center Pin Assembly 9" (228 mm)

Fit Hd Soc Sor 5/16-24 x 5/8

Fil Hd Set 10-24 x 2-1/4

2-Hose Quick-Acting Manifold

Rack Stop

Rack 22-5/8" (574 mm)

Rod Clamp

Spacer

#10 Washer

9

8

CIR-O / EXPLODED VIEW

20

21

11

24

17

2

3

7

4

18

19

23

13

1

16

15

5

6

12

22

10

9

14

8

TEMPLATE KIT / PARTS LIST

CIR-9030 [FOR CIR-3]

CIR-9040 [FOR CIR-4]

CIR-9050 [FOR CIR-5]

2

10

2

12

11

13*

6

4

5

1

9

8

7

ITEM QTY

1

8

9

10

11

12

13

2

3

4

5

6

7

1

1

1

4

1

4

4

4

8

1

1

1

PART NO.

BUG-2440

BUG-2915

BUG-9180-10 1/8" (22 mm) rod, 10" (254 mm) Long

CIR-9031

CIR-9032

CON-1004

CON-1040

FAS-0257

FAS-2553

PAN-1009

PAN-1018

PAN-1033

--------------

DESCRIPTION

Base, Post (Block) - Order separately

Torchholder Assembly

Spacer Leg

Aluminum Master Template Guide

(For CIR-3)

Alignment Bars (included with

Ring Gear Assembly)

Magnet Foot and Leg Assembly-Order separately-use of 4 recommended with this kit

Rnd Hd Scr 1/4-20 x 3/4"

Soc Hd Cap Scr 1/4-20 x 1-1/2"

(included with Ring Gear Assembly)

Tensioner

Rod w/Key-10" (254 mm) Long

Rod Clamp

Torches are not furnished with kit, order separately

17

CIR-O WITH ANNULAR CARRIAGE

3

4

9

2 8

5

1

7

CIR-3304

CIR-4405

CIR-5506

6

CIR-0 III w/ANNULAR CARRIAGE

CIR-0 IV w/ANNULAR CARRIAGE

CIR-0 V w/ANNULAR CARRIAGE

ITEM QTY PART NO

1

2

3

4

5

6

7

8

9

1

1

1

1

1

4

1

1

1

BUG-2440

BUG-5100-F

BUG-9180-10

CIR-1010-3

CIR-5031

CON-1003

DESCRIPTION

Base, Post (Block)

DC III Drive Unit Assembly (150: 1)

7/8" (22 mm) Rod, 10" (254 mm) Long

Twin Hose Assembly 32" (812 mm)

42" (1066 mm): CIR-1010-4

50" (1270 mm): ClR-1010-5

Carriage Plate-Annular

Leg 2" (50 mm)

CON-(3,4,5)000 Ring & Gear Assembly

GOF-3025

PAN-1010

2-Hose Quick-Acting Manifold

Panograph Assembly with Torchholder

18

BUG-5100-F DC III DRIVE UNIT

DRIVE UNIT OPERATION

Rotating Cam Knob (B) will move the drive pinion in and out of engagement with the ring gear.

To lock drive into position, tighten the 1/4-28 Wing Nut (A) .

To disengage the drive pinion from the ring gear, loosen the 1/4-28 Wing

Nut (A) and turn Knob (B) counterclockwise. Turn Knob (B) clockwise to engage the drive pinion with the ring gear, re-tighten the 1/4-28 Wing Nut

(A) to lock in position.

When Power Cord (C) is plugged into the appropriate power source, Pilot

Light (D) will glow. Switch (E) controls the direction of travel, with the cen ter position set at “OFF”. Knob (F ) controls the speed. Circuit Breaker (G) protects the unit against overload or electrical faults.

CAUTION: IF THE CIRCUIT BREAKER OPENS, FIND AND CORRECT

THE CAUSE OF FAILURE BEFORE RESETTING.

B A

C

E

F

D G

TECHNICAL DATA

DC III DRIVE UNIT

Power Requirement: BUG-5100-F 120 VAC/50-60/1

BUG-5102-F

BUG-5104-F

VAC/50-60/1

Dimensions:

Net Weight:

Shipping Weight:

Speed:

7.12" L x 6.75" W x 6.75" H

(180 x 172 x 172 mm)

16 lbs. (7.3 kg)

20 lbs. (9.1 kg)

2-50 ipm (50-1270 mm/min)

(Measured at Drive Pinion)

Load Capacity: *30 lbs. (14 kg)

[Measured at Drive Pinion]

*Note: Speed and load ratings apply at radius of ring gear. Speed is proportional to radius at any other point, and load rating is inversely proportional to

radius.

7

6

OPERATING INSTRUCTIONS (CONT’D.)

POWER SUPPLY

The DC III drive operates on 120 volt, (42VAC), (240VAC), 50/60 Hz. The Circuit

Breaker (O) protects the unit against overload or electrical faults,

CAUTION: IF THE CIRCUIT BREAKER OPENS, FIND AND CORRECT THE

CAUSE OF FAILURE BEFORE RESETTING.

TORCH

The Torchholder (P) will accept any standard American machine torch (barrel diameter 1-3/8" (34 mm) with 1/4"-square (6 mm) 32-pitch rack). The 32-pitch pinion is standard. Specify a 24-pitch pinion if desired. The Short Hose Assembly (Q) connects the torch to the Quick-acting Manifold Assembly (R) .

The supply hoses are to be connected to the open side of the quick-acting manifold assembly.

Proper torch operation is essential to quality cuts. We suggest that you follow the torch manufacturers’ instructions carefully, being sure to use a clean tip of the proper size.

MAGNETIC SUPPORTS

Several Types of magnetic supports are available for use with the CIR-O to stabilize the machine as listed below:

(S) Outrigger Support Assemblies ; CON-1010 - used in multiples of two or four to stabilize CIR-O on plate, cylinders or heads where two legs must be longer than the other two,

(T) Magnet Foot Assemblies ; CIR-9000 - may be used in sets of four or more to position CIR-O on vertical or out-of-position, flat surfaces.

(U) Leg and Magnet Foot Assemblies ; CON-1040 (four required) - may be used for flat or irregular surfaces.

(V) Offset Leg and Magnet Assemblies ; CIR-9002 (four required) - use with a bevel cutting head or adjustable tip adaptor - to eliminate the “blind” spot under the ring.

SETUP

A center-punch mark and a radius mark are the only layout required. The Center

Pin Assembly (Z) extends below the CIR-O base and is placed in the centerpunch mark. The CIR-O is then eased down to the work on the center pin. This movement locates the entire machine “on center.” The Rack (W) with Torchholder (P) is then positioned over the radius mark.

OPERATION

In order to provide a smooth start, it is recommended that the starting hole be drilled or pierced inside or outside the radius mark. Center the torch tip over the radius mark and secure the Rack Stop (X ) firmly against the Post Assembly

(Y) . [The side of the post assembly to which the rack stop is positioned depends upon whether the material inside or outside the cut is scrap]. Begin the cut from the starting hole and, after carriage travel is begun, move the Torch Rack (W ) slowly against the Rack Stop (X) . This action “feathers-in” the cut eliminating a notch.

INSIDE RING

INSIDE RING

CIR-O SPEED RANGE CHART

Capacities and Speed Ranges

INSIDE RING

INCH

DIAMETER

IPM INCH

DIAMETER

IPM

3 .4-8 75 10-210

6 .8-16 150 20-420

10 .4-28 250 35-700

14 2-39 350 50-1000

26 3.5-70 650 90-1805

30 4-80 750 105-2100

34 4.5-92 850 120-2400

38 5.2-105 950 130-2640

42 5.7-115 1050 150-3000

46 6.3-125 1140 160-3200

50 6.8-135 1250 175-3500

56 7.6-155 1420 200-4000

3 .3-5 75 7-140

6 .6-11 150 14-280

10 .9-18 250 23-460

14 1.3-26 350 32-650

18 1.7-33 450 42-840

22 2-40 550 50-1000

34 3.2-63 850 80-1600

38 3.5-70 950 87-1760

42 3.9-78 1050 97-1950

46 4.3-85 1150 105-2130

50 4.6-93 1250 115-2300

54 5-100 1350 125-2500

58 5.4-110 1450 135-2700

64 6-120 1625 150-3000

3 .2-4 75 5-100

6 .4-8 150 10-210

10 .7-13 250 17-350

14 1-19 350 42-500

18 1.3-25 450 32-640

22 1.5-30 550 38-760

26 1.8-37 650 45-900

30 2-41 750 52-1050

42 2.9-57 1050 73-1458

46 3.2-63 1150 80-1600

50 3.4-68 1250 87-1750

54 3.7-75 1350 94-1900

58 4-80 1450 100-2000

62 4.3-85 1550 105-2150

66 4.5-90 1650 115-2300

72 4.9-100 1825 125-2500

19

TROUBLESHOOTING GUIDE

PROBLEM CAUSE REMEDY

Does not run- No power to

Indicator light off. machine.

Check power line supply voltage.

Plug in line cord firmly.

Does not run, Wiring shorts. Disconnect machine and indicator light off. examine internally; rewire at fault.

Circuit breaker tripped. If none found, throw direction switch to ‘OFF’, reset breaker and plug in.

Shorted motor. If breaker does not trip, replace drive unit.

Faulty speed If breaker trips again, replace control board. control board.

Burned out transformer.

(OR)

Replace transformer.

Does not run. indicator light on.

Bad connection. Check wiring connections, 12 VAC should appear across secondary of transformer.

Tighten terminal screws on speed control board.

Unit runs, but no

Faulty speed control board.

Faulty speed

If DC Volts = 0 across leads to motor; replace control board.

Replace control board. control over speed. control board. (Check connection first).

NOTE:

Make sure unit is pugged into correct voltage.

(120 VAC, 240 VAC, 42 VAC) corresponding to model number rating.

12 VAC should appear across secondary of transformer in all DC III Drive

Units.

20

B

A

OPERATING INSTRUCTIONS

X

E H

Q

I

KJ Y W

O

P

F

Z

AA

R

C

D

S

V

T L

U

INTRODUCTION

Your new CIR-O is ready for operation when you receive it. A few minutes spent reading the following will help you become familiar with the operation and capabilities of your machine.

The CIR-O Carriage (C) should operate freely on the Ring Track (D) . The carriage has three adjustable Wheel Logs (A) . By loosening the Flat Socket

Head Screws (B) these logs may be rotated for adjustment. To check Wheel

(AA) adjustment, hold one wheel and move the carriage. When properly adjusted the wheel should barely slip.

The Cam Clutch (E) engages the drive pinion to the Ring Gear (F) by changing the position of the Drive Module (I) . The Thumb Nut (H) locks the Cam

Clutch (E) in position.

Turning the Potentiometer Knob (K) regulates speed. The Switch (J) controls forward-off-reverse. Throw the switch in the direction you want the carriage to travel.

The CIR-O is furnished with four symmetrically-located Legs (L) . A variety of Magnetic Feet and legs (S) , (T) , (U) , and (V) are available to increase the versatility of the CIR-O machine.

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TECHNICAL DATA

Power Requirement: 120 VAC/50-60/1 240 VAC/50-60/1 42 VAC/50-60/1

CIR-3303 CIR-3323 CIR-3313

CIR-4404 CIR-4424 CIR-3313

CIR-5505 CIR-5525 CIR-5515

Cutting Range: Inside Diameter Outside Diameter

CIR-3301,3323,3313 3"-14" (75-356 mm) 26"-56" (660-1422 mm)

CIR-4404,4424,4414 3"-22" (75-559 mm) 34"-64" (864-1626 mm)

CIR-5505,5525,5515 3"-30" (75-760 mm) 42"-72" (1060-1830 mm)

Net Weight: CIR-3303,3323,3313 CIR-4404,4424,4414 CIR-5505,5525,5515

48 lbs. (21.8 kg) 65 lbs. (29.5 kg) 90 lbs.(40.9 kg)

Shipping

Weight: 66 lbs. (30.0 kg) 90 lbs. (40.8 kg) 128 lbs. (56.0 kg)

Speed Range: See chart on page 19.

CIR-3

CIR-4

CIR-5

24" (610 mm)

32" (813 mm)

40" (1016 mm)

“X”

“X” = 8.19 (208 mm)

With 2" Legs.

“X” = 11.19 (284 mm)

With 5" Legs.

WARRANTY

LIMITED 3-YEAR

WARRANTY

MODEL ___________________________

SERIAL NO. _______________________

DATE PURCHASED: ________________

WHERE PURCHASED: ______________

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 war ranty 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 represen tation 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 what soever 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 de livered pursuant hereto shall be for repair or replacement (at Manufacturer’s option) of the machines or parts affected by such breach.

Distributor’s Warranty:

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 Dis tributor 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 DIFFICULTY YOU HAVE

EXPERIENCED. BE SURE TO MENTION THE MODEL AND SERIAL NUMBERS.

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