Speed Weaver II

INSTRUCTIONS
AND
PARTS MANUAL
SPEED WEAVER II
Bug-O Systems is guided by honesty, integrity and
ethics in service to our customers and in all we do.
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-SPWV-IPM-1211
A DIVISION OF WELD TOOLING CORPORATION
16
PHONE:1-412-331-1776 http://www.bugo.com FAX:1-412-331-0383
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, 15317-9564 USA
safety
PROTECT YOURSELF AND OTHERS FROM SERIOUS INJURY OR
DEATH. KEEP CHILDREN AWAY. BE SURE THAT ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
EQUIPMENT DAMAGE
POSSIBLE.
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 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 equip ment is grounded in accordance with all applicable local and national electrical
safety codes. If none exist, use lnterna tional Electrical Code (IEC) 950.
READ INSTRUCTIONS
Read the instruction manual before installing
and using the equipment.
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 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.
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
do not leave equipment unattended
when not in use!
Remove from work site and store in a safe location.
2
15
SPEED WEAVER II
INSTRUCTION AND PARTS MANUAL
BUG-5300 120 VAC/50-60/1
BUG-5302 240 VAC/50-60/1
BUG-530442 VAC/50-60/1
TABLE OF CONTENTS
PAGE
5............ INTRODUCTION / FEATURES
6............ TECHNICAL DATA / ASSEMBLY / OPERATION
7............ WHEEL ADJUSTMENT / WELD CONTACTS
8, 9........ FUNCTIONS AND CONTROLS / WELD PATTERNS
10.......... BUG-5300 SPEED WEAVER II / PARTS LIST
11...........BUG-5300 SPEED WEAVER II / EXPLODED VIEW
12.......... WIRE LIST / WIRING DIAGRAM
13.......... ELECTRICAL COMPONENT CHART
13.......... TROUBLESHOOTING GUIDE
14.......... KITS
15.......... WARRANTY
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
14
3
THIS PAGE IS INTENTIONALLY LEFT BLANK
INSTRUCTION
AND
PA
%/$1.
A DIVISION OF WELD TOOLING CORPORATION
7+,6
PHONE:1-412-331-1776 http://www.bugo.com FAX:1-412-331-0383
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, 15317-
INTRODUCTION:
The SPEED WEAVER II is a compact, precision, all-position machine,
designed for maximum versatility in oscillation. Its solid-state controls with
graduated dials provide adjustable and readily repeatable control of critical
weld parameters.
The unit will oscillate up to 160 cycles per minute at a stroke of .125" (3 mm).
A stroke adjustment of .125 to 2" (3 to 51 mm), a wide speed range of 6 to
152 ipm (152 to 3810 mm/m), and independently adjustable left and right
dwell time of 0 to 3 seconds will cover any commonly encountered welding
requirements.
The Speed Weaver II is designed to mount on any BUG-O carriage or fixture.
Its lightweight permits easy movement of the machine from one welding
location to another.
FEATURES:
• All Solid-state control circuitry
• Non-contact proximity sensors for end of stroke limits
• Minimum stroke .125" (3 mm) to 2" (51 mm) maximum
• High speed oscillation - 160 cycles/min at .125" (3 mm) stroke
• Wide speed range, 6-150 ipm (152-3810 mm/m)
• New welding mode: tractor stop during dwell
• Positive holding torque during dwell
• Independent dwell control, each side, 0-3 seconds
• Digital dial control with lock for weave amplitude
• Straight line mode: (stringer pass)
12
5
WARRANTY
TECHNICAL DATA
Power
Requirement - 60 watts at rated voltage:
BUG-5300 120 VAC/50-60/1
BUG-5302 240 VAC/50-60/1
BUG-5304 42 VAC/50-60/1
Dwell Time:
8.75
6.5"H x 8.5"L x 8.75"W
(165 mm x 216 mm x 222 mm)
not including rail and torch
mounting
6.5
19 lbs. (8.6 kg)
Shipping Weight: 22 lbs. (10 kg)
Linear Speed:
Stroke:
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.
0 to 3 secs. each side
Dimensions:
Net Weight:
Limited Warranty
6 to 150 ipm
(152-3810 mm/m)
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.
.125" to 2" (3 to 51 mm)
Cycles / Minute: (Maximum speed, zero dwell left and right)
Stroke: (in.) .125 .25 .50 1.0 2.0
(mm) 3
6
12 25 51
Cycles: 160 120
8
5 60 37
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 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.
ASSEMBLY AND
OPERATION ASSEMBLY:
Figure 1
MOUNTING:
The Weaver is normally mounted an a BUG-O drive carriage; bolt the mounting
bar on the Weaver to the front end of the carriage or fixture (Fig. 1).
(Fig. 2) A swivel mount is available for mounting the Weaver so that it can
pivot around 2 axis. This enables it to make fillet weld or other angled-weave
welds. The swivel mount bolts to the carriage and the Weaver in turn bolts
to the swivel mount.
Mounts to
Weaver
Mounts to
Carriage
6
BUG-5195 Weaver Swivel Mount
Figure2
15
WHEEL ADJUSTMENT
kits
BUG-1916
Includes:
DC SPEED WEAVING KIT
(120/50-60/1)
1BUG-0343
BUG-O DC-IV
1.5-30 ipm (38-762 mm/min)
1BUG-9444
1BUG-5300
1BUG-5195
1BUG-2975
1ARR-1080
1ARR-1085
5ARM-2325
Tool Kit
Speed Weaver II
Weaver Swivel Mount
Cable Mounting Assembly
H.D. Rigid Rail 93-1/2" (2.37 m)
H.D. Rigid Rail 46-1/2" (1.18 m)
Magnet Bar, Swivel w/Release
BUG-1917
Same as above, except with
240 VAC BUG-O DC-IV BUG-0443
and Speed Weaver II BUG-5302
BUG-1918
Same as above, except with
42 VAC BUG-O DC-IV BUG-0543
and Speed Weaver II BUG-5304
Includes:
The gauge of the wheels is adjusted to the supplied rail
before being shipped. The wheels on the forward side of
the Weaver are externally adjustable - they have stainless shim washers under them. If it is ever necessary to
readjust them, rotate the Hex Head Bolt (K) with a 1/2"
wrench until the wheels are snug in the rail groove but
can still be forced to slip with finger pressure.
CROSS-RAIL INSERTION:
K
To insert the rail, turn the mode selector switch to any of the three weave
positions, with the power off. Plug in the Weaver power cord.
Insert the rail from the right, guiding the rail into each pair of wheels successively, until the rack meshes with the drive pinion, then throw the power switch
on. The rail will start oscillating automatically.
WELD CONTACTS:
For weld contact control, remove the trigger-switch leads from the welding
gun and connect them to the “amphenol” plug provided, that mates with the
connector on the Weaver panel.
OPERATION:
1.Setup the rail on the work, parallel to, and at a suitable distance from the weld joint, using magnet bars, vacuum cups, or other fastening means.
2.De-clutch the drive on the BUG-O carriage and slide it along the rail
to the desired location with the Weaver mounted on it. Engage the drive clutch.
3.Rack the welding gun into position, set the nozzle angle and clamp in place. Run the welding cable through the cable anchor and clamp
in place.
4.Set the weave speed and dwell left and right by the control knobs on
the panel, set the weave amplitude on the dial counter, and rotate the Mode selector switch to the weave position for the welding mode desired.
BUG-5195
Weaver Swivel Mount
14
5.Set the speed and direction of travel of the tractor drive, and plug the BUG-O power cord into the Weaver outlet.
6.Plug the Weaver cord into the power outlet and throw the power switch
on. After checking all settings and operations, push the weld contact switch
to the “On” position to start welding.
The machine will now travel down the track weaving a perfectly uniform weld precisely to the parameters set until shut off.
7
FUNCTIOn AND CONTROLS
ELECTRICAL COMPONENT CHART
1.The Speed Control Knob (A) sets the traverse speed of the cross rails: turn clockwise to increase speed. Common weaving speeds are from “20” to “30” on the graduated dial.
2.Two Dwell Control Knobs (B, C) set the time interval that the torch
dwells at each end of the stroke - one control for each side. Dwell time can
be set from 0 to 3 seconder independently for left and right side of weave.
3.The Amplitude Control Knob (D) on the side of the machine sets the
length of the weave stroke between .125 and 2" (3 to 51 mm). The dial counter
reads 100 for every .125" (3 mm) of stroke, eg. a reading of 0300 would give
a .375” (9.5 mm) weave. The dial counter has a lever on the bottom that locks
the amplitude setting.
4.Power Controls.
Toggle Switch (E) is used to turn power ON and OFF to the machine.
Circuit Breaker (F) is rated at 0.7A (.5A for 240V) and provides protection
against overloads. If it pops up it can be reset by pushing down.
CAUTION: Find and correct the cause of overload before resetting.
5.Weld Contact Controls.
Toggle Switch (G) turns the Weld contacts ON when momentarily pushed forward and released, and turns them OFF when pushed back.
The Weld Contacts are wired into the terminals on the “Amphenol” Connector (H); the leads from the trigger switch on the welding gun should
be connected to the mating connector provided.
DESCRIPTION
FUNCTION
ITEM
PART NUMBER
120 VAC
2
40 VAC
42 VAC
BUG-5300 BUG-5302
BUG-5304
BUG-1393
VT Volt Trap
BUG-1393 BUG-1563
PC Power Cord
BUG-9445 GOF-3115 BUG-9445
CB Circuit Breaker
BUG-2921 BUG-2952 BUG-2933
BUG-5321 BUG-9595 BUG-5321
PO Power Socket
T
Transformer
BUG-5001 BUG-5002
MCB Motor Control Board
BUG-1770
Tractor Switch
BUG-5333
WCB Weaver Circuit Board
BUG-5335
ARM-2279
BUG-9486
TCB
SW1
Power ON-OFF Switch
WT
Connector-Weld Contact
SW2
Toggle Sw.-Weld Cont.
BUG-5323
SW3
Rotary Sw.-Mode Select
BUG-1548
Pl Speed Pot., 1 OK
P2,P3 Dwell Pot. L&R
SN Sensor Assy. L&R
M Gear Motor
BUG-5054
BUG-5325
BUG-1600
BUG-5003
BUG-9686
NOTE: The Weld Contacts will also shut off if the power to the Weaver is interrupted or turned off for any reason.
TROUBLESHOOTING GUIDE
B, C
D
PROBLEM
CAUSE
REMEDY
Machine dead. No Power.
Circuit-breaker
popped.
J
Weaver runs, tractor dead.
Bad tractor switch. Replace tractor switch BUG-5333
(plug in on Weaver board).
G
Weaver does not Faulty speed board. Replace speed board BUG-1770.
stop in dwell.
A
F
E
Check supply line for power
Plug power cord in firmly.
Find cause of overload
correct and reset breaker.
H
8
13
WIRE LIST
ITEM
W/BLK W/BRN W/RD
W/OR
W/GRN W/BLU W/GY
W/B/OR W/B/GRN-1
W/B/GRN-2
W/B/BLU BLK-1
BLK-2 BLK-3
BLK-4
BRN
RED
OR-1
OR-2
OR-3
OR-4
OR-5
YEL-1
YEL-2
YEL-3
YEL-4
GRN-1 GRN-2 LT.BLU
BLU-1
BLU-2
BLU-3
BLU-4
VIO
GY-1
WHT-1 WHT-2 WHT-3 TN-1
TN-2
TN-3
TN-4
PINK
12
WIRING DIAGRAM
DISCRIPTION
Switched line power, weave board to tractor outlet
Speed signal voltage, weave to speed board, 0-8 V
Weld contact switch control to weave board, 8 or -5 V
Made select switch to weave board
Stop on dwell, weave board to selector switch
Fwd/Rev signal, 0 or 8 V, weave board to speed board
Step, 0 or 8 V, weave board to selector switch
Delay left, pot to weave board
Weld contact, weave board to amphenol
Weld contact, weave board to amphenol
Delay right, pot to weave board
Input line to power switch, hot side
Power line, switch to circuit-breaker
Power line to weave board, for tractor switch
Power line from circuit-breaker to transformer
Speed signal fr om speed pot to weave board, 0-8 V
Motor current
Weld switch to selector switch, 8 V line
Selector switch to dwell pot-right
Dwell pot-right to dwell pot-left
Dwell pot-left to speed pot
Speed pot to 8 V supply from weave board
-5 V from speed board to weld switch
Weld contact switch to mode select switch, -5 V
Select switch to sensor connector, -5 V
Select switch to sensor connector, -5 V
Power line ground, line cord to machine case
Ground, case to tractor power socket
Circuit common (O V), speed board to speed pot
Common (O V), selector switch to motor
Common, speed board to selector switch
Common, transformer C.T. to speed board
Transformer C.T. to weave board, O-V ref.
Sensor input, left, sensor to weave board
Sensor input, right
Power input line
Line power, on-off switch to outlet
Line power, outlet to 20 V.C.T. transformer
Transformer sec., supply to speed board
Transformer sec., supply to weave board
Transformer sec., supply to speed board
Transformer sec., supply to weave board
Motor current, speed board to selector switch
6. Mode Selector Switch.
The 5-position Switch (J) is used to select any one of four welding
modes, described below, or to eject the cross rail.
A.RUN: In this mode, power to the tractor is always on, and the tractor travels continuously both during weave and dwell.
Weave speed and dwell time both affect the weld patterns.
B.STEP: The tractor travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not affect the weld pattern, dwell time does.
C.TRACTOR STOP ON DWELL: This is a new mode that has proven very advantageous in certain cases. The tractor and oscillator travel simultaneously during the weave stroke, both
stop during dwell. Dwell time thus does not affect the weld
pattern, it controls the weld deposit on each side.
D.NO WEAVE: In this mode oscillation is stopped and only the tractor moves, to make stringer passes.
E. Switching to the fifth position will eject the rail.
WELD PATTERNS:
A
B
C
D
When mounted on a tractor plugged into its panel, the Weaver
produces the above weld patterns; shown for increasing dwell time or
tractor speed from left to right.
9
BUG-5300 SPEED WEAVER II / PARTS LIST
ITEM QTY
1
1
2
1 *3 1 4
1 5
1 6
1 7
1 8
2 *9 1 10 1 11 2 *12 1 13 2 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 *31 1 32 1 33 1 34 1 35 1 36 2 37 1 38 1 39 1 40 1 41 14 42 3 45 4 46 2 47 2 48 4 49 3 50 2 51 4 52 1 53 3 PART NUMBER ARM-2279
ARR-1150
BUG-1393
BUG-1548
BUG-1577
BUG-1600
BUG-1770
BUG-1982-N
BUG-2923
BUG-2924
BUG-2956-N
BUG-5001
BUG-5054
BUG-5308
BUG-5309
BUG-5311
BUG-5312
BUG-5313
BUG-5314
BUG-5319
BUG-5321
BUG-5323
BUG-5325
BUG-5333
BUG-5335
BUG-5339
BUG-5451
BUG-5455
BUG-9198
BUG-9444
BUG-9445
BUG-9446
BUG-9486
BUG-9487
BUG-9603
BUG-9621
BUG-9628
BUG-9676
BUG-9686
BUG-9694
FAS-0114
FAS-0124
FAS-0527
FAS-0559
FAS-0735
FAS-1305
FAS-1320
FAS-2351
GOF-3012
GOF-3014
WAS-0221
DESCRIPTION
Toggle Switch (Power)
Cross Rail Assembly
Volt Trap 120 VAC
Rotary Switch (Mode Select)
Short Arm Hex Key
Gear Motor (50:1)
Motor Control Board
Nylon Ext Adj Leg & Wheel Assembly
Circuit Breaker 0.7 Amp
Reset Button Seal
Nylon Fixed Leg & Wheel Assembly
Transformer 120 VAC
Potentiometer, 500K (Dwell)
Rackholder Adaptor Plate
Spacer
Base
Screw
Side Panel
Side Panel
Cover
Power Receptacle
Toggle Switch (Weld Contact)
Sensor Assembly (includes both sensors)
Tractor Switch
Weaver Circuit Board
Mounting Bar
3.5” Rackholder
Gun Mounting Group
Right Angle Rack
Tool Kit
Power Cord 120 VAC
Cord Grip
Panel Connector, 2-T, M
Cable Connector, 2-T, F
Pillow Block
Knob
Cap & Chain Assembly
Dial Counter
Potentiometer Control
Knob
Pan Hd Scr 6-32 x 3/8 Lg
Pan Hd Scr 8-32 x 3/
Soc Hd Cap Sor 8-32 x 314 Lg
Soc Hd Cap Scr 1/4-20 x 1” Lg
Fil Hd Scr 10-24 x 1/2 Lg
Hex Nut 4-40
Hex Nut 8-32
Hex Hd Cap Scr 1/4-20 x 1 1/4 Lg
Stand-off
Pinion
# 8 Internal Star Lockwasher
BUG-5300 / EXPLODED VIEW
38
41
1
28
39
10
9
40
22
34
4
2
36
44
37
33
48
21
13
14
36
13
41
18
27
43
0
7
3
29
42
32
20
12
25
8
31
26
53
24
6
49
50
51
16
8
5
30
46
11
19
15
23
17
47
35
45
52
41
See Electrical Component Chart for 240 VAC and 42 VAC part numbers.
10
11
THIS PAGE IS INTENTIONALLY LEFT BLANK
(IF LOOKING FOR PAGE 11 SEE PREVIOUS PAGE)
INSTRUCTION
AND
PA
%/$1.
A DIVISION OF WELD TOOLING CORPORATION
7+,6
PHONE:1-412-331-1776 http://www.bugo.com FAX:1-412-331-0383
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA, 15317-
WIRE LIST
ITEM
W/BLK W/BRN W/RD
W/OR
W/GRN W/BLU W/GY
W/B/OR W/B/GRN-1
W/B/GRN-2
W/B/BLU BLK-1
BLK-2 BLK-3
BLK-4
BRN
RED
OR-1
OR-2
OR-3
OR-4
OR-5
YEL-1
YEL-2
YEL-3
YEL-4
GRN-1 GRN-2 LT.BLU
BLU-1
BLU-2
BLU-3
BLU-4
VIO
GY-1
WHT-1 WHT-2 WHT-3 TN-1
TN-2
TN-3
TN-4
PINK
12
WIRING DIAGRAM
DISCRIPTION
Switched line power, weave board to tractor outlet
Speed signal voltage, weave to speed board, 0-8 V
Weld contact switch control to weave board, 8 or -5 V
Made select switch to weave board
Stop on dwell, weave board to selector switch
Fwd/Rev signal, 0 or 8 V, weave board to speed board
Step, 0 or 8 V, weave board to selector switch
Delay left, pot to weave board
Weld contact, weave board to amphenol
Weld contact, weave board to amphenol
Delay right, pot to weave board
Input line to power switch, hot side
Power line, switch to circuit-breaker
Power line to weave board, for tractor switch
Power line from circuit-breaker to transformer
Speed signal fr om speed pot to weave board, 0-8 V
Motor current
Weld switch to selector switch, 8 V line
Selector switch to dwell pot-right
Dwell pot-right to dwell pot-left
Dwell pot-left to speed pot
Speed pot to 8 V supply from weave board
-5 V from speed board to weld switch
Weld contact switch to mode select switch, -5 V
Select switch to sensor connector, -5 V
Select switch to sensor connector, -5 V
Power line ground, line cord to machine case
Ground, case to tractor power socket
Circuit common (O V), speed board to speed pot
Common (O V), selector switch to motor
Common, speed board to selector switch
Common, transformer C.T. to speed board
Transformer C.T. to weave board, O-V ref.
Sensor input, left, sensor to weave board
Sensor input, right
Power input line
Line power, on-off switch to outlet
Line power, outlet to 20 V.C.T. transformer
Transformer sec., supply to speed board
Transformer sec., supply to weave board
Transformer sec., supply to speed board
Transformer sec., supply to weave board
Motor current, speed board to selector switch
6. Mode Selector Switch.
The 5-position Switch (J) is used to select any one of four welding
modes, described below, or to eject the cross rail.
A.RUN: In this mode, power to the tractor is always on, and the tractor travels continuously both during weave and dwell.
Weave speed and dwell time both affect the weld patterns.
B.STEP: The tractor travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not affect the weld pattern, dwell time does.
C.TRACTOR STOP ON DWELL: This is a new mode that has proven very advantageous in certain cases. The tractor and oscillator travel simultaneously during the weave stroke, both
stop during dwell. Dwell time thus does not affect the weld
pattern, it controls the weld deposit on each side.
D.NO WEAVE: In this mode oscillation is stopped and only the tractor moves, to make stringer passes.
E. Switching to the fifth position will eject the rail.
WELD PATTERNS:
A
B
C
D
When mounted on a tractor plugged into its panel, the Weaver
produces the above weld patterns; shown for increasing dwell time or
tractor speed from left to right.
9
FUNCTIOn AND CONTROLS
ELECTRICAL COMPONENT CHART
1.The Speed Control Knob (A) sets the traverse speed of the cross rails: turn clockwise to increase speed. Common weaving speeds are from “20” to “30” on the graduated dial.
2.Two Dwell Control Knobs (B, C) set the time interval that the torch
dwells at each end of the stroke - one control for each side. Dwell time can
be set from 0 to 3 seconder independently for left and right side of weave.
3.The Amplitude Control Knob (D) on the side of the machine sets the
length of the weave stroke between .125 and 2" (3 to 51 mm). The dial counter
reads 100 for every .125" (3 mm) of stroke, eg. a reading of 0300 would give
a .375” (9.5 mm) weave. The dial counter has a lever on the bottom that locks
the amplitude setting.
4.Power Controls.
Toggle Switch (E) is used to turn power ON and OFF to the machine.
Circuit Breaker (F) is rated at 0.7A (.5A for 240V) and provides protection
against overloads. If it pops up it can be reset by pushing down.
CAUTION: Find and correct the cause of overload before resetting.
5.Weld Contact Controls.
Toggle Switch (G) turns the Weld contacts ON when momentarily pushed forward and released, and turns them OFF when pushed back.
The Weld Contacts are wired into the terminals on the “Amphenol” Connector (H); the leads from the trigger switch on the welding gun should
be connected to the mating connector provided.
DESCRIPTION
FUNCTION
ITEM
PART NUMBER
120 VAC
2
40 VAC
42 VAC
BUG-5300 BUG-5302
BUG-5304
BUG-1393
VT Volt Trap
BUG-1393 BUG-1563
PC Power Cord
BUG-9445 GOF-3115 BUG-9445
CB Circuit Breaker
BUG-2921 BUG-2952 BUG-2933
BUG-5321 BUG-9595 BUG-5321
PO Power Socket
T
Transformer
BUG-5001 BUG-5002
MCB Motor Control Board
BUG-1770
Tractor Switch
BUG-5333
WCB Weaver Circuit Board
BUG-5335
ARM-2279
BUG-9486
TCB
SW1
Power ON-OFF Switch
WT
Connector-Weld Contact
SW2
Toggle Sw.-Weld Cont.
BUG-5323
SW3
Rotary Sw.-Mode Select
BUG-1548
Pl Speed Pot., 1 OK
P2,P3 Dwell Pot. L&R
SN Sensor Assy. L&R
M Gear Motor
BUG-5054
BUG-5325
BUG-1600
BUG-5003
BUG-9686
NOTE: The Weld Contacts will also shut off if the power to the Weaver is interrupted or turned off for any reason.
TROUBLESHOOTING GUIDE
B, C
D
PROBLEM
CAUSE
REMEDY
Machine dead. No Power.
Circuit-breaker
popped.
J
Weaver runs, tractor dead.
Bad tractor switch. Replace tractor switch BUG-5333
(plug in on Weaver board).
G
Weaver does not Faulty speed board. Replace speed board BUG-1770.
stop in dwell.
A
F
E
Check supply line for power
Plug power cord in firmly.
Find cause of overload
correct and reset breaker.
H
8
13
WHEEL ADJUSTMENT
kits
BUG-1916
Includes:
DC SPEED WEAVING KIT
(120/50-60/1)
1BUG-0343
BUG-O DC-IV
1.5-30 ipm (38-762 mm/min)
1BUG-9444
1BUG-5300
1BUG-5195
1BUG-2975
1ARR-1080
1ARR-1085
5ARM-2325
Tool Kit
Speed Weaver II
Weaver Swivel Mount
Cable Mounting Assembly
H.D. Rigid Rail 93-1/2" (2.37 m)
H.D. Rigid Rail 46-1/2" (1.18 m)
Magnet Bar, Swivel w/Release
BUG-1917
Same as above, except with
240 VAC BUG-O DC-IV BUG-0443
and Speed Weaver II BUG-5302
BUG-1918
Same as above, except with
42 VAC BUG-O DC-IV BUG-0543
and Speed Weaver II BUG-5304
Includes:
The gauge of the wheels is adjusted to the supplied rail
before being shipped. The wheels on the forward side of
the Weaver are externally adjustable - they have stainless shim washers under them. If it is ever necessary to
readjust them, rotate the Hex Head Bolt (K) with a 1/2"
wrench until the wheels are snug in the rail groove but
can still be forced to slip with finger pressure.
CROSS-RAIL INSERTION:
K
To insert the rail, turn the mode selector switch to any of the three weave
positions, with the power off. Plug in the Weaver power cord.
Insert the rail from the right, guiding the rail into each pair of wheels successively, until the rack meshes with the drive pinion, then throw the power switch
on. The rail will start oscillating automatically.
WELD CONTACTS:
For weld contact control, remove the trigger-switch leads from the welding
gun and connect them to the “amphenol” plug provided, that mates with the
connector on the Weaver panel.
OPERATION:
1.Setup the rail on the work, parallel to, and at a suitable distance from the weld joint, using magnet bars, vacuum cups, or other fastening means.
2.De-clutch the drive on the BUG-O carriage and slide it along the rail
to the desired location with the Weaver mounted on it. Engage the drive clutch.
3.Rack the welding gun into position, set the nozzle angle and clamp in place. Run the welding cable through the cable anchor and clamp
in place.
4.Set the weave speed and dwell left and right by the control knobs on
the panel, set the weave amplitude on the dial counter, and rotate the Mode selector switch to the weave position for the welding mode desired.
BUG-5195
Weaver Swivel Mount
14
5.Set the speed and direction of travel of the tractor drive, and plug the BUG-O power cord into the Weaver outlet.
6.Plug the Weaver cord into the power outlet and throw the power switch
on. After checking all settings and operations, push the weld contact switch
to the “On” position to start welding.
The machine will now travel down the track weaving a perfectly uniform weld precisely to the parameters set until shut off.
7
WARRANTY
exploded view / bug-5100-_bg
dc iv drive unit 28
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7
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41
18
8
16
35
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27
9
12
24
34
4
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14
10
36
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35
3
15
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38
22
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.
11
40
20
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.
29
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32
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.
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.
25
33
Model _____________________________
Serial No. _________________________
Date Purchased: __________________
Where Purchased:________________
Distributor’s Warranty:
31
37
Limited 3-Year
Warranty
30
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15