Bug-O Gantry - Side Beam Automatic Welding System


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Bug-O Gantry - Side Beam Automatic Welding System | Manualzz

INSTRUCTIONS

PaRTS MaNUaL

SIdE BEaM SYSTEM

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-SBC-4555-IPM-0713

Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do.

a dIVISION OF WELd TOOLING CORPORaTION

280 TECHNOLOGY dRIVE CaNONSBURG, PENNSYLVaNIa 15317-9564 USa

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

SaFETY

PROTECT YOURSELF aNd OTHERS FROM SERIOUS INJURY OR dEaTH.

KEEP CHILdREN aWaY. BE SURE THaT aLL INSTaLLaTION, OPERaTION,

MaINTENaNCE aNd REPaIR PROCEdURES aRE PERFORMEd ONLY BY

QUaLIFIEd INdIVIdUaLS.

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 connec-

tors 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.

5) Never remove or bypass the equipment

power cord ground. Verify the equipment

is grounded in accordance with all appli-

cable local and national electrical safety

codes. If none exist, use International

Electric Code (IEC) 950.

EQUIPMENT daMaGE

POSSIBLE.

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) Always verity 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 worksite and store in

a safe location when not in use.

FaLLING EQUIPMENT

can cause serious personal injury and equipment damage.

Faulty or careless user installation is possible. As a result, never stand or walk underneath equipment.

MOVING PaRTS can cause serious injury.

REad INSTRUCTIONS.

1) Never try to stop the pinion from moving

except by removing power or by using the

STOP control.

before installing and using the equipment.

2) Do not remove any protective panels,

covers or guards and operate equipment.

2

HIGH FREQUENCY WaRNINGS

SPECIaL PRECaUTIONS aRE REQUIREd WHEN USING PLaSMa,

TIG OR aNY WELdING PROCESS THaT USES HIGH FREQUENCY

TO STRIKE aN aRC.

WaRNING: HIGH FREQUENCY CAN EFFECT MACHINE

OPERATION AND THEREFORE, WELD QUALITY.

Read the precautions below before installing and using the equipment.

PRECaUTIONS:

1) Some plasma or welding cables are strong sources of high frequency interference.

NEVER lay a plasma or welding cable across the controls of the machine.

2) Always physically separate the plasma or welding cable leads from the machine

cables. For example, the plasma or welding cable leads should NEVER be bundled

with a pendant cable or the machine power cord. Maximize the separation between

any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures 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 inter-

ference.

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

4

SIdE BEaM SYSTEM

INSTRUCTIONS aNd PaRTS MaNUaL

TaBLE OF CONTENTS

PaGES

5.......Introduction / Mounting

6.......SBC-4555 Motorized Carriage / Exploded View

7.......SBC-4555 Motorized Carriage / Parts List

8.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Exploded View

9.......CWO-3918-MH Carriage Assembly Motorized Horizontal / Parts List

10.....SBC-1065 Floating Car w/ Follower / Exploded View / Parts List

11 .....SBC-1020-DS Dual Side ABR 62"

12.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List

13.....MUG-1145 Carriage Spotter Sub Assy. / Exploded View / Parts List

14.....CWO-1690 Large Horizontal Racker / Exploded View / Parts List

15.....SBC-6110 M-14 Rotational Control / Wiring Diagram

16.....SBC-5997 Bodine Motor w/ Connector / Wiring Diagram

16.....SBC-1635-10-2 Remote Weld Starter (Two Guns) / Wiring Diagram

17.....Warranty

INTROdUCTION

Bug-O Side Beam Systems are custom designed assemblies that are used in a variety of applications such as automated seam welding, beam and stiffener fabrication as well as cutting applications such as stripping and edge preparation. A wide range of gantry and side beam carriage designs are available and can be used to suite a specific application. Systems are available in programmable or manually operated versions. Consult your Bug-O distributor for more information.

MOUNTING

You will need the following:

• Standard allen keys

• Standard wrench set

• Large C clamps 8-10 inch range

1) Loosen bolts (1). There are two bolts per carriage. The slide bolts to the back of the carriage towards the U slot of the motor mount.

2) Install the carriage onto the monorail. Using the large C clamps, tighten the carriage to the monorail. Tighten the

C clamps which will bring the face of the carriage toward the monorail, this will bring the face of the carriage into place. These wheels are (2) on the drawing.

3) Bring the bolts (1) to the monorail and tighten. This will secure the carriage to the monorail. Loosen clamps and slide carriage. This should move easily on the beam.

Repeat process for the second carriage.

Side View

2

1

5

6

SBC-4555 MOTORIZEd CaRRIaGE / EXPLOdEd VIEW

3

15

14

23

13

19

2

6

12

4

5

9

11

27

26

25

20

24

22

8

28

1

17

16

21

18

7

10

SBC-4555 MOTORIZEd CaRRIaGE / PaRTS LIST

16

17

18

19

20

21

22

23

8*

9

10

11

12

13

14

15

ITEM

1

2

3

4

5

6

7

24

25

26

27

28

1

2

1

1

1

1

1

2

QTY

1

1

1

1

1

1

1

4

1

1

2

2

2

2

2

1

1

2

2

1

PaRT NO.

CWO-3918-MH

CWO-5997

CWO-4884

CWO-5768

SBC-4551

CWO-5802

CWO-5804

SBC-6110

CWO-9006

FAS-0357

FAS-0359

FAS-0455

FAS-0558

FAS-0593

FAS-0679

FAS-0955

FAS-0957

FAS-0999

FAS-1350

FAS-2556

SBC-1014

SBC-4540

SBC-4547

SBC-4548

SBC-4549

WAS-0240

WAS-0243

SBC-1635-10-2

* 240 VAC requires SBC-6110-240 Rotation Control

dESCRIPTION

Carriage Assy. Motorized Horiz.

Bodine Motor 156 w/connector

McGill Cyr 1/45

Pinion Gear w/ Key

Shaft Extender

Motor Mount Plate

Guard

Rotation Control Modified

Wheel & Clamp Mount (left)

Hex Hd Cap Scr 1/4-20 x 3/4"

Hex Hd Cap Scr 1/4-20 x 1"

Set Scr 1/4-20 x 1/2" Cup Point

Soc Hd Cap Scr 1/4-20 x 7/8

Soc Hd Cap Scr 3/8-16 x 1-1/2

Soc Hd Shr 3/8" x 1" x 5/16-18

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

Flt Hd Soc Scr 1/4-20 x 3/4"

Flt Hd Soc Scr 3/8-16 x 1"

Hex Jam Nut 1/4-20

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

Control Mount Angle

Side Beam Clutch Assembly

Cot Extension Spring

Stabilizer Block

Stabilizer / Stop Block

1/4" SAE Washer

1/4" Split Lockwasher

Pendant Control (2 guns) (Part of SBC-6110)

7

8

CWO-3918-MH CaRRIaGE aSSEMBLY MOTORIZEd HORIZONTaL /

EXPLOdEd VIEW

CWO-3918-MH CaRRIaGE aSSEMBLY MOTORIZEd HORIZONTaL /

PaRTS LIST

16

17

18

19

20

21

*

8

9

10

11

12

13

14

15

ITEM

1

2

3

4

5

6

7

* Not Shown

2

6

19

22

4

1

1

9

QTY

1

1

1

1

1

1

3

11

3

4

7

7

2

2

PaRT NO.

CWO-9001

CWO-9002-MT

CWO-9003

CWO-9004

CWO-9005

CWO-9006

CWO-9007

CWO-9008

CWO-9011

CWO-9194

CWO-4884

FAS-0557

FAS-0679

FAS-0959

FAS-0999

FAS-1390

FAS-2397

FAS-2399-FT

WAS-0260

WAS-0262

CWO-9490

CWO-9492

dESCRIPTION

Carriage Front Plate

Carriage Top Plate Motorized

Carriage End Plate (L.H.)

Carriage Reinforcement Bar

Wheel & Clamp Mounting Block, Right

Wheel & Clamp Mounting Block, Left

Cam Roller Spacer

Wheel Mount Block

Carriage Back-up Bar

Carriage End Plate (R.H.)

Cam Roller Spacer

Soc Hd Cap Scr 1/4-20 x 3/4"

Soc Hd Cap Scr 3/8 x 1 x 5/16-18

Flt Hd Soc Scr 1/4-20 x 1"

Flt Hd Soc Scr 3/8-16 x 1"

Hex Nut 3/8-16

Hex Hd Cap Scr 3/8-16 x 2-1/2"

Hex Hd Cap Scr 3/8-16 x 3-1/2" full Thread

3/8" Washer

3/8" Split Lockwasher

Lower Cam Roller Assembly

Metric Spacer Plate

9

SBC-1065 FLOaTING CaR W/ FOLLOWER / EXPLOdEd VIEW / PaRTS LIST

10

ITEM

1

2

3

QTY

1

1

1

PaRT NO.

CWO-1690

MUG-1145

ABR-1060

dESCRIPTION

Large Horizontal Racker

Carriage Spotter Sub-Assy

V-Guide Ways 33"

SBC-1020-dS dUaL SIdE aBR 62"

ITEM

1

2

2

3

4

5

6

6

7

8

8

QTY

1

2

2

4

1

2

10

10

44

22

22

PaRT NO.

SBC-1021-DS

SBC-1022

SBC-1023

SBC-1024

SBC-1025

SBC-1029

FAS-0399-SS

WAS-0260-SS

FAS-0535-SS

FAS-0545-SS

WAS-0232-SS

dESCRIPTION

Dual Side Abr Box 65"

Rack 62"

Spacer 62"

T-3 Guide Way 62"

Gusset Assembly

Mtg. Angle

Hex Hd Cap Scr 3/8-16 x 1"

3/8 Washer

Soc Hd Cap Scr #10-24 x 1/2"

Soc Hd Cap Scr #10-32 x 1/2"

#10 Split Lock Washer

11

MUG-1145 CaRRIaGE SPOTTER SUB aSSY. / EXPLOdEd VIEW / PaRTS

LIST

12

ITEM

1

2

3

4

5

6

7

8

9

QTY

1

1

1

1

1

1

1

1

1

PaRT NO.

BUG-2032

FAS-0357

FAS-0557

FAS-1307

MUG-1141

MUG-1142

MUG-1143

MUG-1502

MUG-1579

dESCRIPTION

Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)

Hex Hd Cap Scr 1/4-20 x 3/4"

Soc Hd Cap Scr 1/4-20 x 3/4"

Hex Jam Nut 3/4-16

Bearing, Collet

Knob, Locking

Positioning Plate

Gear Assembly

Retaining Ring For 3/4" Shaft

MUG-1145 CaRRIaGE SPOTTER SUB aSSY. / EXPLOdEd VIEW / PaRTS

LIST

ITEM

1

2

3

4

5

6

7

8

9

QTY

1

1

1

1

1

1

1

1

1

NOTE: WHEN USED FOR MUG-1148 (TORCH SPOTTER),

CUT MUG-1143 (POSITIONING PLATE) TO 2.5" LONG AND

INVERT IN ASSEMBLY AS SHOWN.

PaRT NO.

BUG-2032

FAS-0357

FAS-0557

FAS-1307

MUG-1141

MUG-1142

MUG-1143

MUG-1502

MUG-1579

dESCRIPTION

Knob, Black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)

Hex Hd Cap Scr 1/4-20 x 3/4"

Soc Hd Cap Scr 1/4-20 x 3/4"

Hex Jam Nut 3/4-16

Bearing, Collet

Knob, Locking

Positioning Plate

Gear Assembly

Retaining Ring For 3/4" Shaft

13

CWO-1690 LaRGE HORIZONTaL RaCKER / EXPLOdEd VIEW / PaRTS LIST

F = FIXED WHEEL PLACEMENT

A = ADJUSTABLE WHEEL PLACEMENT

14

8

9

10

11

12

13

14

15

ITEM

1

2

3

4

5

6

7

16

17

18

1

1

2

1

2

2

1

1

QTY

1

1

1

2

2

1

2

3

1

2

PaRT NO.

BUG-2032

CWO-1678

CWO-1679

CWO-1680

CWO-1681

CWO-1687

CWO-4326

CWO-4327

FAS-0557

FAS-1307

MUG-1141

MUG-1142

MUG-1144

MUG-1453

MUG-1579

WAS-0240

CWO-1671

FAS-0559

dESCRIPTION

Knob, black w/ Set Scr 1/4-20 x 3/8" (FAS-0454)

Racker Plate

Pinion 11T

W2 Fixed Leg & Wheel Assy.

W2 Adj. Leg & Wheel Assy.

Mount Plate (Large Racker)

Fixed Leg & Wheel Assy.

Adj. Leg & Wheel Assy.

Soc Hd Cap Scr 1/4-20 x 3/4"

Hex Jam Nut 3/4-16

Bearing Collet

Knob, Locking

Shaft

Stand-off

Retaining Ring

1/4" SAE Washer

Racker Shield

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

SBC-6110 M-14 ROTaTIONaL CONTROL / WIRING dIaGRaM

ITEM PaRT NO.

CB CWO-6525

CORD BUG-9445

dESCRIPTION

0-90Dc Speed Control W/Reset

Power Cord 16/3 Type, So, 10 Amp

GOF-3115 Line Cord 240Vac

FH1 FHO-0188

FUS-0257

FH2 FHO-0188

Fuse Holder

3 Amp

Fuse Holder

FUS WTE 0190 1.5 Amp

LMP CWO-6206 Red Neon Lamp 125V

BUG-1428 Pilot Light 240V

PC1 BUG-1034

PC2 BUG-5527

PC3 MUG-1156

PC4 BUG-9902

CBC1 BUG-9906

SW ARM-2279

K1 BUG-1383

Panel Connector 4-T, M

Panel Connector 17-T, F

Panel Connector 4-T, F

Panel Connector 6-T, F

Cable Connector 6-T, M

Toggle Switch

Relay, 4Pdt, 3A 120V Plug In

120V 240V

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

2

1

1

1

2

1

1

1

1

1

1

1

15

SBC-5997 BOdINE MOTOR W/ CONNECTOR / WIRING dIaGRaM

QTY

1

PaRT NO.

MUG-1616

dESCRIPTION

Cable Connector 4-T, M

SBC-1635-10-2 REMOTE WELd STaRTER (TWO GUNS) / WIRING dIaGRaM

16

ITEM

CC

SW1

SW2

SW3

SW4

R1

QTY

1

1

1

1

1

1

PaRT NO.

BUG-5552

ABP-1069

ABP-1069

CWO-6525

MUG-1258-1

CWO-6213

dESCRIPTION

Cable Connector 17-T, M

Toggle Switch, ON-NONE-ON

Toggle Switch, ON-NONE-ON

0-90 VDC Speed Control w/ Reset, Pot Only

Rotary Switch Assembly

50 OHMS, 10W, 5% Wire Wound

WaRRaNTY

LIMITEd WaRRaNTY

MOdEL ____________________________

SERIaL NO. ________________________ daTE PURCHaSEd: _________________

FOR A PERIOD OF TWELVE (12) MONTHS FROM DELIVERY, BUG-O SYSTEMS WARRANTS TO THE ORIGINAL PURCHASER

(DOES NOT INCLUDE AUTHORIzED DISTRIBUTORS), THAT A NEW MACHINE IS FREE FROM DEFECTS IN MATERIAL

AND WORKMANSHIP AND AGREES TO REPAIR OR REPLACE, AT ITS OPTION, ANY DEFECTIVE PARTS OR MACHINE.

THIS WARRANTY DOES NOT APPLY TO MACHINES, WHICH AFTER OUR INSPECTION, ARE DETERMINED TO HAVE

BEEN DAMAGED DUE TO NEGLECT, ABUSE, OVERLOADING, ACCIDENT OR IMPROPER USAGE. ALL SHIPPING AND

HANDLING CHARGES WILL BE PAID BY CUSTOMER.

BUG-O SYSTEMS MAKES NO WARRANTY OF MERCHANTABILITY AND MAKES NO OTHER WARRANTY, EXPRESSED OR

IMPLIED, BEYOND THE WARRANTY EXPRESSLY SET FORTH ABOVE. BUYER’S REMEDY FOR BREACH OF WARRANTY,

HEREUNDER, SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF NON-CONFORMING PARTS AND MACHINES. UNDER

NO CIRCUMSTANCES SHALL CONSEQUENTIAL DAMAGES BE RECOVERABLE.

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 dISTRIBuTOR/ dEAlER. If HE 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.

17

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