Bug-O Heavy Duty Stand Alone Linear Weaver ipm Owner's Manual

INSTRUCTIONS
AND
PARTS MANUAL
WPD-2500
H.D. STAND ALONE
LINEAR WEAVER
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-WPD-2500-IPM-0424
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: 412-331-1776 https://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
connectors covered with the supplied
protective panels. Operation of the
machine without the protective panels
may result in injury.
3. Never open the equipment without
first unplugging the power cord or
serious injury may result.
4. Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
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.
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 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.
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.
Read the instruction manual before
installing and using the equipment.
2
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.
HIGH FREQUENCY WARNINGS
SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,
TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY
TO STRIKE AN ARC.
WARNING: HIGH FREQUENCY CAN EFFECT MACHINE
OPERATION AND THEREFORE, WELD QUALITY.
Read the precautions below before installing and using the equipment.
PRECAUTIONS:
1)
Some plasma or welding cables are strong sources of high frequency
interference. NEVER lay a plasma or welding cable across the controls of the
machine.
2)
Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be
bundled with a pendant cable or the machine power cord. Maximize the
separation between any machine cables and the plasma or welding cables.
3)
Strictly follow the grounding procedures specified for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of
high frequency noise. They may require a grounding rod be driven into the earth
within six feet (2 meters) of the plasma or welding unit to become compatible
with an automatic cutting or welding process.
4)
If the high frequency is produced using a spark gap, adjust the points so the gap
is as small as possible. The larger the gap, the higher the voltage and the higher
the interference.
5)
Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same
outlet box.
6)
High frequency noise may enter the machine through the plasma or welding
supply remote contactor leads. Some plasma and welding sources can produce
noise spikes of up to several thousand volts. These sources are not compatible
with automated cutting and welding equipment. It is recommended that the
remote contactor leads on these plasma or welding sources not be connected to
the machine. An alternate solution is to purchase a separate remote contactor
isolation box.
3
WPD-2500 H.D. STAND
ALONE LINEAR WEAVER
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5............... Introduction / Features / Technical Data
6............... Linear Weaver Setup
7............... WPD-2500 Standalone Weaver / Major Components
7............... WPD-2400 Dimensions
8............... WPD-2400 Weaver Unit / Exploded View
9............... WPD-2400 Weaver Unit / Parts List
10............. WPD-2400 Weaver Unit Motor Plate Assembly / Wiring Diagram
11.............. BUG-6330-HD Control Box
12............. BUG-6330-HD Control Box / Exploded View
13............. BUG-6330-HD Control Box / Parts List
14............. BUG-6330-HD Control Box / Wiring Diagram / Electrical Component Chart
15............. BUG-5475 Weaver Racking Group / Exploded View / Parts List
16............. BUG-6336 Connector Wiring Harness / Wiring Diagram
17............. BUG-6337 Timer Wiring Harness / Wiring Diagram
17............. BUG-6318 Weave Wiring Harness / Wiring Diagram
18............. BUG-5570 Power Circuit Box / Exploded View / Parts List
19............. Power Circuit Box / Wiring Diagram
20............. Warranty
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
4
INTRODUCTION
The WPD-2500 H.D. Stand Alone Linear Weaver is a self contained machine used for weave welding.
It can be installed as part of a welding fixture, or mounted on a drive carriage running on a track.
The H.D. Linear Weaver is particularly useful for weaving v-groove welds in a butt joint. The Weaver
box is attached on the end of an adjustable rack, held by a rackholder that can be mounted on the front
of the drive carriage, or directly on the welding fixture.
FEATURES
•
•
•
•
•
•
•
•
High torque, low inertia motor for precise stops and starts
High speed Linear Weaver for weaving, with independent control of right and left dwell times
High motor gearing which prevents the crossarm from moving when the unit is turned off
Closed loop speed control for adjustable and repeatable control of critical welding or cutting parameters
Closed loop position control to prevent drift from the center weld position
Clutch, to enable rapid installation or replacement of the weaver cross arm
Gun mounting group with adjustable racking block for accurate positioning of the gun
Contactor ON/OFF switch
TECHNICAL DATA
Power
Requirement:
120 VAC/50-60/1
240 VAC/50-60/1
42 VAC/50-60/1
Dimensions:
7.25" L x 5.50" W x 5.37" H (184 x 140 x 137 mm)
Net Weight:
13.5 lbs (6.0 kg)
Shipping Weight: 16.5 lbs (7.5 kg)
Speed:
2-100 in/min (51-2540 mm/min)
Cycles:
2.5 cycles per second at 1/8" (3mm) stroke
1.6 cycles per second at 1/4" (6mm) stroke
1.0 cycles per second at 1/2" (12mm) stroke
0.7 cycles per second at 1.0" (25mm) stroke
(at maximum speed and 0 dwell)
Load Capacity:
10 lbs (4.5 kg)
5
LINEAR WEAVER SETUP
1) WEAVER CONTROL MODULE AND LINEAR WEAVER INSTALLATION
The Weaver Control Module plugs into the top of the Master Drive Unit. Use a flat head screw
driver to firmly secure the four corners of the module.
Place the Linear Weaver on a flat surface, connector side up. Remove connector cover plate from
MPD-1000. Loosen, but do not remove, the bolts that hold the Master Drive Module to the carriage.
Plug the Master Drive Module into the Linear Weaver. The connectors should fit together easily
and do not need forced. Attach the Linear Weaver to the carriage using the two weaver mounting
bolts. DO NOT SUBSTITUTE LONGER BOLTS. Retighten the bolts that hold the Master Drive
Unit to the carriage.
2) CROSSARM WHEEL ADJUSTMENT AND ALIGNMENT
Always check the crossarm wheel adjustment before using the machine.
The wheels are too loose and need adjustment if the crossarm can move
up and down. Normal gear backlash will permit crossarm side to side
movement of approximately 0.02" (0.5 mm).
If the wheels need adjustment, remove the left and right weaver end
covers. The two top wheels are adjustable. Loosen the hex bolt (A) until
the adjustable bushing (B) can be rotated. Correct the wheel alignment by
rotating adjustable bushing (B).
B
A
Check for proper alignment by using a finger to keep one of the wheels from
rotating while manually moving the crossarm. The wheels are adjusted too
tight if firm finger pressure is not enough to prevent wheel rotation. Once
aligned, hold the adjustment bushing (B) still while tightening the hex bolt
(A). Recheck alignment.
3) REALIGNING THE CROSSARM
(includes crossarm INSTALLATION and REMOVAL)
D
Rotate the clutch knob (C) fully counterclockwise.
LEFT SIDE
This disengages the drive pinion from the rack.
C
Remove the two socket head screws from the
crossarm (D). The crossarm may be removed from
or installed into the Linear Weaver at this time.
Turn on the AC power. Rotate the four-turn steering
control knob and the weave speed knob on the
Weaver Control Module fully clockwise. Turn the
start/stop switch to START. Set the mode selector
switch to NO WEAVE. Align the crossarm (D) so
that 1 7/8" (48 mm) of the crossarm protrudes from
the left side of the Linear Weaver. To insure proper
gear mesh, gently rock the crossarm back and forth
about 1/16" (2 mm) while engaging the pinion using
CAUTION: IMPROPER GEAR
the clutch knob (C).
MESH MAY CAUSE PINION, RACK, OR
LINEAR WEAVER DAMAGE.
Set the weave amplitude to maximum. Use the steering knob on the control module to move the
crossarm to both the extreme left and the extreme right. Perform measurements to determine if The
crossarm is installed too far left or too far right. Repeat the crossarm realigning procedure changing
the 1 7/8" (48 mm) dimension as required. Reinstall the two crossarm screws.
6
WPD-2500 STAND ALONE LINEAR WEAVER / MAJOR COMPONENTS
BUG-9447 Wrench 7/16"
BUG-9449 Hex Key Kit Special
BUG-6330-HD
Control Box
WPD-2400
Linear Weaver
BUG-5570, BUG-5572,
BUG-5574
Power Circuit Box
BUG-5295 Rod Mount Assembly &
BUG-9180-6 Rod
BUG-5571
Power Cable 2x
WPD-2400 DIMENSIONS
7.25"
(184 mm)
Max
11.23"
(285 mm)
5.84"
(148 mm)
23.3"
(592 mm)
5.5"
(140 mm)
7
WPD-2400 WEAVER UNIT / EXPLODED VIEW
12 X8
4X 13
1
5
20
13 x2
4
34
8X 23
31 X 2
8X 18
A 9
8X 16
7
32
B 9
35
28
10 X2
4X 17
4X 6
17 X4
25
33
11 X2
22
19
3
33
29
30
8
24
27
2
8
26
15 X4
WPD-2400 WEAVER UNIT / PARTS LIST
ITEM PART #
1 BUG-1338
2 BUG-1590
3 BUG-1853
4 BUG-2005
5 BUG-2414
6 BUG-2593
7 BUG-5455
8 BUG-5462
9 CDS-1212
10 CWO-4020
11 CWO-4021
12 FAS-0114
13 FAS-0124
14 FAS-0557
15 FAS-0815
16 FAS-0104
17 FAS-0925
18 FAS-1305
19 FAS-1325
20 FAS-2121
21 MPD-1013
22 MPD-1042
23 WAS-0201
24 WPD-1002
25 WPD-1004
26 WPD-1025
27 WPD-1028
28 WPD-1035
29 WPD-1103
30 WPD-1106
31 WPD-1110
32 WPD-1150
33 WPD-1178
34 WPD-2420
35 BUG-9628
A BUG-9909
B BUG-9856
PARTS LIST
DESCRIPTION
QTY
NAMEPLATE
1
GEAR MOTOR (80:1)
1
MACHINED RACK 7-1/2
1
LABEL, BUG-O
1
LABEL, PATENT
1
GLIDE FLAT
4
GUN MOUNTING GROUP
1
RIGHT ANGLE CLAMP
1
WEAVER UNIT WIRING HARNESS
1
FIXED LEG & WHEEL ASSY
2
ADJ. LEG & WHEEL ASSY
2
PAN HD SCR 6-32 X 3/8 BLACK
8
PAN HD SCR 8-32 X 3/8
6
SOC HD CAP 1/4-20 X 3/4
2
FLT HD SLT SCR 6-32 X 1/2
4
4-40 x 3/8 PAN GEAD, BLACK
8
FLD HD SOC SCR 8-32 X 1/2"
10
HEX NUT 4-40
8
#8-32 NYLON HEX NUT
1
PAN HD SCR 8-32 X 1 1/4 BLACK
1
CLUTCH PLATE
1
INDUCTOR, POTTED
1
#4 INTERNAL STAR LOCKWASHER
8
WEAVER BASE PLATE
1
MOTOR MOUNT PLATE
1
POT/GEAR ASSY
1
PINION, 3/4 PD 24 T W/ SET SCR
1
CLUTCH ASSY
1
DUST PLATE
1
OSCILLATOR MOUNT PLATE
1
SIDE PANEL
2
CROSS ARM 15.50"
1
POST W/ FASTENERS
1
COVER PANEL
1
CAP & CHAIN ASSY
1
PANEL CONNECTOR, 6T, M
1
PANEL CONNECTOR, 2T, F
1
9
WPD-2400 WEAVER UNIT / WIRING DIAGRAM





























10



BUG-6330-HD CONTROL BOX
STEERING CONTROL
WEAVE
SPEED
AMPLITUDE
DWELL
LEFT
DWELL
RIGHT
POWER
ON/OFF
WELD
CONTACT
WEAVE / NO WEAVE
TO LINEAR WEAVER
POWER SUPPLY
11
BUG-6330-HD / CONTROL BOX / EXPLODED VIEW
2
7
1
10
18
10
16
17
10
4
10
3
13
15
20
9
6
10
21
19
10
10
22
5
11
12
8
14
12
BUG-6330-HD CONTROL BOX / PARTS LIST
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
*
*
*
QTY
1
1
1
1
1
1
4
1
8
14
2
2
8
4
8
1
1
1
1
1
3
2
1
1
1
PART NO.
BUG-1770
BUG-5757
BUG-5760
BUG-6331
BUG-6332
BUG-6333
BUG-9621
CDS-1068
FAS-0104
FAS-0114
FAS-0224
FAS-0824
FAS-1305
SFX-1292
WAS-0201
BUG-5761
ARM-2279
BUG-1869
BUG-9909
BUG-9902
BUG-9677
BUG-5054
BUG-6336
BUG-6318
BUG-6337
DESCRIPTION
Motor Control Board
Knob
Control Board
Front Panel
Rear Panel
Mounting Bracket
Knob
Mounting Bracket
Pan Hd. Scr. #4-40 x 3/8 Lg.
Pan Hd. Scr. #6-32 x 3/8 Lg.
Pan Hd. Scr. #10-32 x 3/8 Lg.
Flat Hd. Slt. Scr. #8-32 x 3/8 Lg.
Hex Nut #4/40
Bumper
#4 Internal Star Lock Washer
SW-2 Toggle Switch, SPDT
SW-1 Toggle Switch, DPST
SW-3 Toggle Switch, SPDT
Panel Connector, 6-T, M
Panel Connector, 6-T, F
Potentiometer, 10K
Potentiometer, 500K
Connector Wiring Harness
Weave Wiring Harness
Timer Wiring Harness
* not shown
13
BUG-6330-HD CONTROL BOX / WIRING DIAGRAM /
ELECTRICAL COMPONENT CHART
ELECTRICAL COMPONENTS
14
ITEM
PART NO.
DESCRIPTION
CN-2
BUG-9909
Panel Connector, 6-T, M
CN-3
BUG-9902
Panel Connector, 6-T, F
P-1,2,3
BUG-9677
Pot, 10 K
P-4,P-5
BUG-5054
Pot, 500 K
PCB-1
BUG-5760
Control Board
PCB-2
BUG-1770
Motor Control Board
SW-1
ARM-2279
Toggle Switch, DPST
SW-2
BUG-5761
Toggle Switch, SPDT
SW-3
BUG-1869
Toggle Switch, SPDT
BUG-5475 WEAVER RACKING GROUP / EXPLODED VIEW / PARTS LIST
1
5
2
4
3
ITEM
1
2
3
4
5
QTY
1
1
1
1
1
PART NO.
BUG-5455
BUG-1853
BUG-5462
WPD-1178
WPD-1150
DESCRIPTION
Gun Mounting Group
Machined Rack 7-1/2
Right Angle Clamp
Post w/ Fasteners
Cross Arm 15.5"
15
BUG-6336 CONNECTOR WIRING HARNESS / WIRING DIAGRAM
CNN-022A 10-PIN HOUSING
INCLUDES:
(1) CNN-022A-P 10 PIN HOUSING
(MOLEX P/N 09-50-8101)
(10) CNN-0220 PIN .156
(MOLEX P/N 08-50-0106)
BLK
RED
TAN (X)
BLU (B)
TAN (Z)
WHT/BLU
YEL
BLU (A)
BUG-9902
PANEL CONNECTOR 6-T, F
(DESC: DMS3102A14S(D235))
BLU
WHT/BLU
C
B
D
A
VIO
RED
BLK
E
F
BLU
BUG-9909
PANEL CONNECTOR 6-T, M
(DESC: DMS3102A14S-6P(D235))
WHT/GRN
COM
TAN
E
F
D
A
TAN
BLU
TAN
TAN
TAN
TAN
TAN
TAN

TAN
C
B
YEL
WHT/GRN
ARM-2279 TOGGLE SWITCH,
ON-OFF, DPST (EATON
P/N 7310K38)
TAN (Z)
BLU (A)
TAN (X)
VIO
WHT/GRN (E)
WHT/GRN (D)
CNN-0128 8-PIN HOUSING
INCLUDES:
(1) CNN-0128-P 8 PIN HOUSING
(MOLEX P/N 22-01-3087)
(8) CNN-0120 PIN .100
(MOLEX P/N 08-05-0114)
16
BUG-6337 TIMER WIRING HARNESS / WIRING DIAGRAM
BUG-6318 WEAVE WIRING HARNESS / WIRING DIAGRAM
(3) BUG-9677 10 K-Ohm POT
GRY
CNN-012A
10-PIN HOUSING
BLU
ORG
RED
GRY
GRN
BLK
BLU
YEL
W/GN
WHT
RED
BLU
BLU
TEL
GRN
WHT
W/GN
GRN
RED RED
ORG
BLK
BUG-5761 SWITCH
TOGGLE SPDT ON-OFF-ON
17
BUG-5570 POWER CIRCUIT BOX / EXPLODED VIEW / PARTS LIST
4
5
11
17
15
7
9
6
8
12
14
13
2
3
16
1
10
ITEM
QTY
PART NO.
DESCRIPTION
1
1
ARM-2279
Toggle Switch
*2
1
BUG-2923
Circuit Breaker .7A
3
1
BUG-2924
Reset Button Seal
*4
1
BUG-5218
Transformer
5
1
BUG-5573
Enclosure
*6
1
BUG-9445
Power Cord
7
1
BUG-9446
Cord Grip
8
1
BUG-9486
Panel Connector, 2-T, M
9
1
BUG-9487
Cable Connector, 2-T, F
10
1
BUG-9884
On-Off Switch Plate
11
1
BUG-9902
Panel Connector, 6-T, F
12
8
FAS-0204
Rnd Hd Scr 4-40 x 3/8
13
1
FAS-1224
But Hd Soc Hd Scr 8-32 x 3/8
14
8
FAS-1305
Hex Nut 4-40
15
1
FAS-1320
Hex Nut 8-32
16
4
SFX-1292
Bumper
17
1
WAS-0221
#8 Star Lockwasher
* See Electrical Component Chart for 240 VAC and 42 VAC Part Numbers
18
POWER CIRCUIT BOX / WIRING DIAGRAM
S
CN 1
CB
A
B
F
C
E
TAN
RED
BLU
BLU
TAN
YEL
GY
T
BLK
GRN
VT
PC
WH
D
WHT/BLK/GR
WHT/BLK/GR
A
B
CN 2
ELECTRICAL COMPONENT CHART
BUG-5570
BUG-5572
BUG-5574
ITEM
DESCRIPTION
120 VAC
PART NO.
240 VAC
PART NO.
42 VAC
PART NO.
CB
Circuit Breaker
BUG-2923
BUG-2952
BUG-2933
PC
Power Cord
BUG-9445
GOF-3115
BUG-9442
T
Transformer
BUG-5218
BUG-5231
BUG-5232
VT
Volt Trap
BUG-1393
BUG-1563
BUG-1393
CN-1
Panel Connector
BUG-9902
CN-2
Panel Connector
BUG-9486
S
Toggle Switch
ARM-2279
19
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 warranty period an additional two (2) years which will provide
three (3) total years from the date of original invoice to customer. This warranty does not apply to machines
which, after Manufacture’s inspection are determined by Manufacturer to have been damaged due to neglect,
abuse, overloading, accident or improper usage. All shipping and handling charges will be paid by the customer.
The foregoing express warranty is exclusive and Manufacturer makes no representation or warranty (either
express or implied) other than as set forth expressly in the preceding sentence. Specifically, Manufacturer makes
no express or implied warranty of merchantability or fitness for any particular purpose with respect to any goods.
Manufacturer shall not be subject to any other obligations or liabilities whatsoever with respect to machines or
parts furnished by Manufacturer.
Manufacturer shall not in any event be liable to Distributor or any customer for any loss of profits, incidental or
consequential damages or special damages of any kind. Distributor’s or customer’s sole and exclusive remedy
against Manufacturer for any breach of warranty, negligence, strict liability or any other claim relating to goods
delivered pursuant hereto shall be for repair or replacement (at Manufacturer’s option) of the machines or parts
affected by such breach.
Distributor’s Warranty:
In no event shall Manufacturer be liable to Distributor or to any customer thereof for any warranties, representations
or promises, express or implied, extended by Distributor without the advance written consent of Manufacturer,
including but not limited to any and all warranties of merchantability or fitness for a particular purpose and all
warranties, representations or promises which exceed or are different from the express limited warranty set forth
above. Distributor agrees to indemnify and hold Manufacturer harmless from any claim by a customer based
upon any express or implied warranty by Distributor which exceeds or differs from Manufacturer’s express limited
warranty set forth above.
HOW TO OBTAIN SERVICE:
If you think this machine is not operating properly, re-read the instruction manual carefully, then call your
Authorized BUG-O dealer/distributor. If they cannot give you the necessary service, write or phone us to
tell us exactly what difficulty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.
20