INSTRUCTIONS
AND
PARTS MANUAL
AGS-4000(120VAC)
AGS-4100(240VAC)
ARC GOUGING SYSTEM
Please record your equipment identication 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-AGS-4000-IPM-1214
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.
EQUIPMENT DAMAGE
ELECTRIC SHOCK can kill.
1) The equipment is not waterproof.
Using the unit in a wet environ-
ment 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.
1) Do not plug in the power cord without
rst verifying the equipment is OFF
and the cord input voltage is the same
as required by the machine or serious
damage may result.
2) Always verity both the pinion and
wheels are fully engaged before apply ing power or equipment damage may
occur.
POSSIBLE.
3) Never open the equipment without
rst unplugging the power cord or
serious injury may result.
4) Verify the customer-supplied power
connections are made in accordance
with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)
950.
5) Never remove or bypass the equip ment power cord ground. Verify the
equipment is grounded in accor-
dance with all applicable local and
national electrical safety codes. If
none exist, use International Electric
Code (IEC) 950.
READ INSTRUCTIONS.
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.
1) Never try to stop the pinion from mov ing except by removing power or by
using the STOP control.
Read the instruction manual before
installing and using the equipment.
2
2) Do not remove any protective panels,
covers or guards and operate equip ment.
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. Maxi-
mize the separation between any machine cables and the plasma or welding
cables.
3) Strictly follow the grounding procedures specied 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 recom-
mended 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
AGS-4000 ARC GOUGING SYSTEM
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
5 .....................Introduction / Standard Features
6 .....................Additional Features
7 .....................Bug-O Technical Data / Dimensions
8 .....................Arcair® N7500 Technical Data
9-11 ..................System Congurations
9 .....................System Congurations / Bug-O Kits With Arcair® Automatic Gouging System
9 .....................System Congurations / AGS-4172 Arcair® N7500 Mounting Group
10 ....................System Congurations / Bug-O Kits Without Arcair® Automatic Gouging System
11 .................... System Congurations / Bug-O Supplied Arcair® N7500 Automatic Gouging System
11 .................... System Congurations / Arcair® N7500 Automatic Gouging System Spare Parts
12-16 ................. Setup
17 ....................Arc Gouging Module
18 ....................Digital Readout Calibration
19 ....................AGS-4172 Arcair® Mounting Group / Exploded View / Parts List
20 ....................MPD-1000 Master Drive Unit / Exploded View
21 ....................MPD-1000 Master Drive Unit / Parts List
22 ....................AC Power Wiring Diagram
23 ....................Signal Wiring
24-27 ................. ARR & AFR Rail, Mounting and Carriages Options
24 ....................Aluminum Rigid Rail / Cross Section / Exploded View / Parts List
25 ....................AFR-3000 Semi Flex Rail / Cross Section / Exploded View / Parts List
26 ....................ARM-2010 / AFR-2010 On/Off Magnet Assembly
26.....................ARR & AFR Vacuum Assemblies
27.....................MPD-1065 Releasable Carriage / Exploded View / Parts List
28-29 ................. BRR Rail, Mounting and Carriages Options
28 ....................BRR-1180 Bent Rigid Rail / Cross Section / Application View / Parts List
28 ....................Complete Ring Rail Assemblies
29 ....................Magnet Attachments
29 ....................Vacuum Supports
29 ....................BUG-5910 Tube Carriage / Exploded View / Parts List
30-33 .................FMD Rail, Mounting and Carriages Options
30 ....................Hi-Flex Rail / Cross Section / Exploded View / Parts List
31 ....................FMD-2010 R.E. On/Off Magnet Assembly
31 ....................FMD-1220 / FMD-1230 Hi-Flex Vacuum Supports and Vacuum Pump
32 ....................FMD-1105 Hi-Flex Carriage / Exploded View
33 ....................FMD-1105 Hi-Flex Carriage / Parts List
34 ....................Vacuum Pump / Exploded View
35 ....................Vacuum Pump / Parts List
36 ....................ARV-1036 Vacuum Support Bar for ARR, AFR and BRR Rails
36 ....................ARV-1036 Vacuum Support Bar / Exploded View / Parts List
37 ....................FMD-1036 Vacuum Support Bar for FMD Rail / Exploded View / Parts List
38-43 ................. Troubleshooting Guide
44 ....................Notes
45 ....................Master Drive Wiring Diagram / MPD-1000 / MPD-1002 / MPD-1004
46 ....................Warranty
4
INTRODUCTION
The Arc Gouging Modular Drive System is the only product in the industry built using modular
components. The system consists of a master drive, plug-in control module, and interchangeable
carriages that are easily assembled.
The system runs in any position using Bug-O Rail (four options are available) which is held to the
work surface by magnets or a vacuum system.
Rail options include:
• Aluminum Rigid Rail available in 8' (2.37 m) and 4' (1.18 m) lengths
• Aluminum Semi-Flex Rail available in 8' (2.37 m) length with a minimum bending radius of 15' (5 m)
• Bent Rigid Rail, bent to specic dimensions and dedicated to a specic inside or outside
diameter. For working on Outside Diameters the smallest diameter is 20" (508 mm). For working
on Inside Diameter the smallest diameter is 31" (787 mm)
• Hi-Flex Rail available in 5' (1.47 m) length with a minimum bending radius of 30" (760 mm)
The ARC Gouging conguration consists of a carriage, appropriate for the rail to be used, master
drive, racking group and control module.
The Master Drive is rated at 60 lbs (27 kg) vertical load. The machine is equipped with overload
protection.
STANDARD FEATURES
The Master Drive incorporates the following standard internal features:
• High torque, low inertia motor for precise starts and stops
• Dedicated fail-safe brake with three times the stopping and holding power of the motor
• Motor overload protection which turns off the motor and engages the brake when excessive load
is placed on the machine
• Closed loop speed control for adjustable and repeatable control of arc gouging parameters
• Closed loop position control to prevent position creep when the machine stops
5
ADDITIONAL FEATURES
1. Arc Gouging Control Module
2. Master Drive is recongurable by the user for different applications, by changing
carriages to run on different rail types
3. Clutch to enable rapid manual repositioning of the carriage anywhere on the track
4. Wheel engagement knob, which enables placement of the releasable carriage
anywhere on the track
5. Optional cable mounting bar with anchor clamp to keep gouging, pneumatic, contact
wires and power cables away from work surface
6. Contactor ON/OFF switch
7. Power Entry Box with:
a) Input Power Fuse
b) Machine ON/OFF Switch
c) Power Cord Mating Connector
8. Standard Carrying Handle
9. Digital Speed Display for increased control
10. Optional Carrying Handle and Mounting Bar
11. Gouging Contactor Receptacle
5
10
6
1
9
2
3
4
11
8
7
6
BUG-O TECHNICAL DATA
MASTER DRIVE UNIT
Power Requirements:
MPD-1000 120VAC/50-60Hz/1Ph 2Amp fuse
AGS CONTROL MODULE
Power Requirements:
AGS-1000 120VAC/50-60-Hz/1Ph (a)
MPD-1002 240VAC/50-60Hz/1Ph 3Amp fuse
Dimensions: 7.50" L x 6.00" W x 2.50" H
Dimensions: 7.75" L x 6.00" W x 4.25" H
(191 L x 152 W x 54 mm H)
(197 L x 152 W x 108 mm H)
Net Weight: 1.75 lbs (0.8 kg)
Load Capacity: Vertical 60 lbs (27 kg) **
Horizontal 100 lbs (45 kg)
Shipping Weight: 3.0 lbs (1.4 kg)
Speed Range: 2-120 in/min (51-3048 mm/min)
Net Weight: 10 lbs (4.5 kg)
Shipping Weight: 13 lbs (5.9 kg)
DIMENSIONS
Master Drive Unit Control Module
6.00"
(152 mm)
2.50"
(64 mm)
15"
(381 mm)
7.13"
(181 mm)
6.00"
(152 mm)
7.75"
(197 mm)
4.25"
(108 mm)
AGS-1002
** The Master Drive Unit is rated at 60 lbs
(27 kg) vertical load. The international
Robotics Standards Rating requires
a minimum of 2:1 continuous-duty
safety margin on all power train and
electronic components. The machine is
equipped with overload protection.
7.50"
(191 mm)
19.8" (502.92 mm)
Min: 17" (431.8 mm)
Max: 29.15" (740.4 mm)
7
Arcair® N7500 TECHNICAL DATA
Power Requirements: N7500 120VAC/50-60Hz/1Ph
240VAC/50-60Hz/1Ph
2
Air Requirements: Pressure: 80 PSI (5.6 kg/cm
Flow Rate: 63 CFM (17892.9 L/min)
Dimensions:
Remote Pendant: (5.5" W x 3.375" H x 9.25" D)
(140 W x 86 H x 235 mm D)
Net Weight: 2.4 lbs (1.08 kg)
Control Box: 14" W x 12.5" H x 10.75" D)
(355 W x 317 H x 273 mm D)
Net Weight: 29.8 lbs (13.5 kg)
Torch Head: 6.5" W x 9.5" H x 12.5" D
(165 W x 241 H x 317 mm D)
Net Weight: 11.9 lbs (5.4 kg)
) (5.1 Bar)
For a complete list of specications and operating instructions refer to Arcair’s
N7500 Automatic Gouging System Operating Manual.
8
SYSTEM CONFIGURATIONS
A
A
E
B C D
A
F
AGS-4000 MDS Gouging Kit for Rigid Rail 120 VAC
Includes:
ITEM PART NO. QTY DESCRIPTION
A AGS-4120 1 N7500 Arcair® Gouging System
w/ Cables 120VAC
B-H AGS-4050* 1 Rigid Gouging Bug-O Drive 120VAC
Includes:
ITEM PART NO. QTY DESCRIPTION
B MPD-1065 1 12" Releasable Carriage
C MPD-1000+ 1 Master Drive Unit 120VAC
D AGS-1002 1 Arc Gouging Control Module
E AGS-4172 1 Arcair® N7500 Mounting Group
F BUG-2975 1 Cable Mounting Assembly
G ARR-1080 1 Heavy Duty Aluminum Rail
H ARM-2010 5 R.E. On/Off Magnet
G H
AGS-4002 MDS Gouging Kit for Rigid Rail 240 VAC
Kit remains the same with the exception of the following changes:
*AGS-4052 Rigid Gouging Bug-O Drive 240VAC
+
MPD-1002 Master Drive Unit 240VAC
9
SYSTEM CONFIGURATIONS, CONT’D.
F
A
EB
G
D
C
A
AGS-4100 MDS Gouging Kit for Hi-Flex Rail 120 VAC
Includes:
ITEM PART NO. QTY DESCRIPTION
A AGS-4120 1 N7500 Arcair® Gouging System
w/ Cables 120VAC
B-G AGS-4050* 1 Hi-Flex Gouging Bug-O Drive 120VAC
Includes:
ITEM PART NO. QTY DESCRIPTION
B FMD-1105 1 Hi-Flex Carriage
w/ Handle & Clamp
C MPD-1000+ 1 Master Drive Unit 120VAC
D AGS-1002 1 Arc Gouging Control Module
E AGS-4172 1 Arcair® N7500 Mounting Group
F BUG-2975 1 Cable Mounting Assembly
G FMD-2170 1 Hi-Flex Rail
w/ 8 R.E. On/Off Magnet
AGS-4102 MDS Gouging Kit for Hi-Flex Rail 240 VAC
Kit remains the same with the exception of the following changes:
*AGS-4052 Hi-Flex Gouging Bug-O Drive 240VAC
+
MPD-1002 Master Drive Unit 240VAC
10
SYSTEM CONFIGURATIONS, CONT’D.
AGS-4172 Arcair® N7500 MOUTING GROUP
PART NO. QTY DESCRIPTION
AGS-4173 1 Spacer Block
FAS-2359 2 Hex Hd Cap Scr 1/4 - 20 x 3-1/2"
BGV-1165-LS 1 Clamp Block Long Handle Shaft
BUG-5169-15 1 Rack w/ Torchholder, 15" Long
BUG-5178 1 H.D. Rack w/ Clamp
BUG-5173A 1 Rod
BUG-5173B 1 1/2 - 13 Threaded Stud, 1.5" Long
BUG-O Supplied Arcair® N7500 Automatic Gouging System
AGS-4020 N7500 Arcair® GOUGING SYSTEM 120VAC/240VAC
PART NO. QTY DESCRIPTION
AGS-4021 1 Remote pendant
AGS-4022 1 Control Box, 120VAC/240VAC
AGS-4023 1 Torch Head
AGS-4024 1 Air Regulator
AGS-4025 1 Electrode Holder
Arcair® N7500 Automatic Gouging System Spare Parts
Arcair® N7500 AUTOMATIC GOUGING SYSTEM SPARE PARTS
PART NO. QTY DESCRIPTION
AGS-4030 1 AC Power Supply Cable, 10 ft (3 m) 120VAC
AGS-4032 AC POWER SUPPLY CABLE, 10 ft (3 m) 240VAC
PART NO. QTY DESCRIPTION
AGS-4030 1 AC Power Supply Cable, 10 ft (3 m) 120VAC
BUG-9593 1 240VAC Twist-lock Plug
BUG-9594 1 240VAC Connector Body
BUG-9233 1 Label, 240V
AGS-4040 ARC GOUGING KIT CABLES
PART NO. QTY DESCRIPTION
AGS-4041 1 Power Supply Communication Cable, 25 ft (8 m)
AGS-3056 1 Air Hose Assembly, 25 ft (8 m)
AGS-4043 1 Remote Pendant Cable Assembly, 25 ft (8 m)
AGS-4044 1 Motor Cable Assembly, 25 ft (8 m)
AGS-3055 1 Power Cable Assy. 25 ft (8 m)
900-16-W10 1 Black 16ga Stranded 1000V Sensing Lead, 25 ft (8 m)
MWC-200 1 200 AMP On/Off Magnetic Ground
AGS-4120 N7500 Arcair® GOUGING SYSTEM & CABLES 120VAC
PART NO. QTY DESCRIPTION
AGS-4020 1 N7500 Arcair® Gouging System 120VAC/240VAC
AGS-4040 1 Arc Gouging Kit Cables
AGS-4030 1 AC Power Supply Cable, 10 ft (3 m) 120VAC
AGS-4122 N7500 Arcair® GOUGING SYSTEM & CABLES 240VAC
PART NO. QTY DESCRIPTION
AGS-4020 1 N7500 Arcair® Gouging System 120VAC/240VAC
AGS-4040 1 Arc Gouging Kit Cables
AGS-4032 1 AC Power Supply Cable, 10 ft (3 m) 240VAC
11
SETUP
1) POSITIONING THE RAIL (ARR, AFR)
Attach the rail parallel to the joint to be gouged. Position the rail using magnet plate or vacuum
cups. Wipe the track grooves free of dirt and debris. This will prevent binding and premature rail
and wheel wear. Lubricate the rack using a dry spray, if desired, for extended track life.
2) INSTALL CARRIAGE ON RAIL
2a) MPD-1065 CARRIAGE
Turn the wheel engagement knob (A) on the side of the carriage fully counter clockwise
to disengage the wheels. Then rotate the Master Drive Unit clutch knob (B) fully counter
clockwise to disengage the drive pinion. The carriage can now be placed anywhere on the
track. Turn the wheel engagement knob (A) clockwise to engage the wheels rmly in the
V-grooves. Verify all four wheels are in the grooves. Manually move the carriage along the
track to verify the motion is smooth and the wheel alignment is correct. Rotate the Master
Drive Unit clutch knob (B) fully clockwise while gently rocking the machine forward and
backward to engage the drive pinion. The rocking motion is necessary to help insure proper
gear mesh.
2b) POSITIONING BUG-5910* TUBE CARRIAGE ONTO ARR, AFR OR BRR RAIL
A
BUG-5910 TUBE CARRIAGE
The Tube Carriage features a split carriage body for quick and easy placement on the rail. It
has a carrying capacity of 100 lbs (45 kg). The carriage also offers four (4) wheel positions
for circumferential applications over a wide range of diameters and at applications. It is used
with BUG-O Aluminum Rigid Rail, Extra Heavy Duty Aluminum Rigid Rail, Semi-Flex Rail and
Bent Rigid Rail.
* BUG-5910 is the only carriage that will mount to BRR rail. It will also mount to ARR and
AFR rails with some adjustments.
12
SETUP, CONT’D.
2c) INSTALLING BUG-5910 TUBE CARRIAGE
1. Select the correct pair of holes on each side of the carriage for the rail diameter being
used (see chart). If the wheels are not attached to the correct set of holes, remove them
and bolt the wheel brackets in selected holes. Tighten the bolts until the brackets are
snug, but still free to rotate.
2. Use the wheel engagement knob (A)
to open the split carriage. On the drive
unit, loosen and turn the clutch knob
(B) counter clockwise to declutch the
drive pinion.
3. Place the carriage on the rail with the
wheels in the rail grooves. Use the
wheel engagement (A) knob to close
the carriage then move the carriage
back and forth a few inches. The
Carriage BRR-1210
Wheel Rail ID Pipe OD
Hole Set in mm in mm
A 20 - 25 500 - 635 9 - 21 230 - 530
B 23 - 35 585 - 890 12 - 31 300 - 790
C 30 - 44 760 - 1120 18 - 40 455 - 1015
D 41 - 60 1040 - 1525 29 - 54 735 - 1375
E 75 - 174 1905 - 4420 64 - 170 1625 - 4320
F at rail at rail
Note: Chart values are for reference only
wheels on their mounting brackets will align themselves correctly in the rail grooves.
4. Verify that the wheels are properly aligned, then tighten the wheel mounting bolts to lock
them in position. Rotate the clutch knob (B) clockwise while gently rocking the carriage
back and forth to engage the drive pinion with the rack.
5. Verify that the pinion is properly engaged in the rack. The correct wheel position will
provide a minimum of 1/8" (3 mm) engagement between the drive pinion and the rack.
NOTE: The pinion height may need to be adjusted for some rail or pipe sizes.
6. Position and clamp the weld gun, cutting torch, cables, etc. and proceed with the
operation.
A
B
D
C
E
F
13
SETUP, CONT’D.
2d) POSITIONING FMD-1105 HI-FLEX CARRIAGE ON TO FMD HI-FLEX RAIL
The Hi-Flex Carriage has a carrying
capacity of 100 lbs (45 kg). Used ONLY
on Hi-Flex Rail (FMD-1050).
Turn the wheel engagement knob
(A) on the side of the carriage fully
counter clockwise to disengage the
wheels. Then rotate the Master Drive
Unit clutch knob (B) (below) fully
counter clockwise to disengage the
drive pinion. The carriage can now
be placed anywhere on the track.
Turn the wheel engagement knob (A)
clockwise to engage the rail rmly in
the V-groove of the bearing wheels.
Manually move the carriage along the
track to verify the motion is smooth and
the wheel alignment is correct. Rotate
the Master Drive Unit clutch knob (B)
fully clockwise while gently rocking
the machine forward and backward to
engage the drive pinion. The rocking
motion is necessary to help insure
proper gear mesh.
A
FMD-1105 Hi-Flex Carriage
B
3) WHEEL ADJUSTMENT AND ALIGNMENT ON ARR, AFR AND BRR RAILS
Always check for proper carriage wheel
adjustment before using the machine. Turn
the wheel engagement knob (A) on the side of
the carriage until the wheels are fully moved
towards the center of the carriage (engaged).
Then rotate the master drive clutch knob
(B) fully counter clockwise to disengage the
drive pinion. Slide the carriage onto the end
of the track. The wheels should slide into the
V-grooves and the carriage will move smoothly
along the track if the wheels are properly
aligned.
The wheels along one side of the carriage have stainless
steel shim washers (C) underneath. These wheels are
adjustable. Readjust these wheels (if necessary) by rotating
the hex bolt (D) with a 1/2" wrench.
Grasp the sides of the carriage. The wheels are too loose if it
is possible to move the carriage from side to side or up and
down. Use a nger to keep one of the adjustable wheels from
rotating as the carriage is manually pushed along the track.
The wheels are too tight if rm nger pressure is not enough
to prevent wheel rotation. Repeat the process for the other
adjustable wheel.
C
D
14
B
A
SETUP (CONT’D.)
4) REMOTE CONTACTOR WIRING
Connect to the Right Side of ARC GOUGING Control Box 120VAC outlet, see page 16.
Pins A and B ……………. Connection for Arc Gouger
5) ARC GOUGING HEAD SET-UP
Install AGS-4172 Arcair® N7500 Mounting Group
to the front of the BUG-O Carriage.
BUG-5173
AGS-4172 Arcair® N7500 Mounting Group
The “TORCH HEAD” of the N7500 Automatic Gouging System is mounted to BUG-5173 of
AGS-4172 Arcair® N7500 Mounting Group.
The attachment is
made at this location, from
either side of the head.
Arcair® “TORCH HEAD”
6) POSITION “TORCH HEAD”
a. Position the Torch Head above the work piece.
b. Using the Angle Gauge supplied with the N7500, adjust the Torch head to the work piece.
The angle gauge sets the torch angle and electrode stick-out and aligns the nozzle.
c. The air should ow between the electrode and the work piece.
Charts, graphs and other data in this manual are based on a 45° electrode angle, but you can
use electrode angles from 45° to 60°. Users should develop their own standards based on shop
conditions and application.
15
SETUP (CONT’D.)
7) CONNECTING POWER TO ARC GOUGING MODULE
Plug the Master Drive Unit power cord into the appropriate power supply, MPD-1000 into
120VAC/50-60Hz/1Ph or MPD-1002 into 240VAC/50-60Hz/1Ph.
Plug the Arcair® N7500 Automatic Gouging System into the appropriate power supply
120VAC/50-60Hz/1Ph or into 240VAC/50-60Hz/1Ph.
Plug the AGS-1002 ARC Gouging Control Module into the 120VAC Power Outlet on the N7500
Control Box.
Plug AGS-1002 here
NOTE: This is the only location to plug the AGS-1002 Power Cord to. Not doing so WILL
prevent proper operation of the BUG-O Tractor System and Gouging System.
Complete setup and installation of Arcair® N7500 Automatic Arc Gouging System according
to their instructions. When completed both BUG-O and Arcair® systems should be ready to
operate.
8) ALIGNMENT
With TORCH HEAD mounted and set to proper angle, adjust the left right and vertical racks to
align Carbon rod with joint to be gouged. Tighten rmly in place and begin.
IMPORTANT!
DO NOT permit CARBON ROD to touch plate. Set a minimum of 1/8" from tip of carbon rod
to work surface. Failing to heed this precaution could lead to irreparable damage to TORCH
HEAD, CONTROL BOX, PENDANT, MASTER DRIVE, ARC GOUGING CONTROL MODULE
and IS NOT covered under warranty.
16
ARC GOUGING MODULE
MACHINE OPERATION
Turn the main power “ON” at the power entry box. Set the following parameters on the AGS-1002
ARC Gouging Control Module
DIGITAL SPEED DISPLAY
SPEED CONTROL
TRAVEL DIRECTION SWITCH
GOUGING ON/OFF
SPEED CONTROL: Sets the tractor speed from 2-120 in/min (5.1-304.8 mm/min).
CARRIAGE TRAVEL SWITCH: Provides FORWARD/STOP/REVERSE direction control.
DIGITAL READOUT: The display is dual function.
a) PRESET SPEED - Displayed when the CARRIAGE TRAVEL SWITCH is OFF or motion is
halted by a motor overload condition.
b) MEASURED SPEED - Displayed when power is applied to the motor.
(This will be the same as the Preset Speed.)
The readout is factory set to display the carriage speed in in/min for 120VAC systems and cm/
min for 240VAC systems. The display can be rescaled as required, or readjusted to read in/
min by following the instructions found in the “DIGITAL READOUT CALIBRATION” section of
this manual (pg. 18).
GOUGING ON/OFF: Opens/closes a pair of independent 1 Amp contacts (pins A & B) at the arc
contactor receptacle.
NOTE: A safety interlock will automatically open the ARC Gouging contacts in the
motor overload protection halts machine motion. Clear the overload by turning
the Direction Travel Switch to OFF. Resetting the overload fault will not cause
the contacts to automatically reclose. Use the GOUGING ON/OFF switch to
restart the ARC Gouging unit after clearing the overload.
REPLACEMENT POTS AND SWITCHES
DIRECTION TRAVEL SWITCH:
Switch and Spacer MDS-1112
Black Pointer Knob BUG-9694
SPEECH CONTROL:
10KΩ Pot., 3-3/4 Turn PCB-1026
Black Knob MDS-1017
Knob Seal Nut MDS-1046
GOUGING ON/OFF:
Switch and Spacer MDS-1115
Toggle Switch Boot MDS-1047
17
DIGITAL READOUT CALIBRATION
Internal Control Module adjustments enable the user to change between the factory-set in/min
(120 VAC) and cm/min (240 VAC). The display can also be recalibrated, if required, to give an
accurate speed readout.
STEP 1: Remove endplate
STEP 2: Set Switch 1 & 2
SW 1 SW 2
in/min Down Down
cm/min Up Down
STEP 3: Apply power to the Modular Drive.
Maximize the tractor speed using
the Control Module front panel
STEP 4: Set the speed display using
a small slotted screwdriver
STEP 5: Reinstall endplate
18
AGS-4172 Arcair® MOUNTING GROUP / EXPLODED VIEW / PARTS LIST
4
3
2
6
5
1
PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 BUG-5178 H.D. 8" Rack w/ Clamp 1
2 BUG-5173A Rod 1
3 BUG-5173B 1/2-13 Threaded Stud 1
4 BUG-5169-15 H.D. Rack w/ Torchholder 15" 1
5 BGV-1165-LS Clamp Block Long Handle Shaft 1
6 AGS-4173 Spacer 1
7 FAS-0557 Soc Hd Cap 1/4-20 x 3/4 2
7
19
MPD-1000 MASTER DRIVE UNIT / EXPLODED VIEW
45
20
43
6
46
11
44
10
21
15
54
41
11
12
14
1
51
4
42
48
53
14
39
38
55
2
52
40
7
30
19
32
23
11
10
35
28
13
54
9
22
29
16
49
24
15
27
26
11
17
36
3
33
34
50
25
31
5
47
18
6
37
13
8
20
MPD-1000 MASTER DRIVE UNIT / PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 BUG-1034 Panel Connector, 4-T, Male 1
2 WPD-1013 Rubber Ring Gasket 1
3 BUG-9444 Tool Kit 1
4 FAS-0104 Pan Hd Screw #4-40 x 318 Long 4
5 FAS-0107 Pan Hd Screw #4-40 x 3/4 Long 2
6 FAS-0114 Pan Hd Screw #6-32 x 3/8 Long 6
7 FAS-0504 Soc Hd Cap Scr #4-40 x 3/8 Long 4
8 FAS-0557 Soc Hd Cap Scr 1/4-20 x 3/4 Long 4
9 FAS-0902 Flt Hd Soc Scr #4-40 x 1/4 Long 3
10 FAS-0905 Flt Hd Soc Scr #4-40 x 1/2 Long 19
11 FAS-0914 Flt Hd Soc Scr #6-32 x 3/8 Long 11
12 FAS-0915 Flt Hd Soc Scr #6-32 x 1/2 Long 1
13 FAS-0923 Flt Hd Soc Scr #8-32 x 5/16 Long 8
14 FAS-1305 Hex Nut #4-40 6
15 FAS-1310 Hex Nut #6-32 3
16 FAS-1325 Hex Nut #8-32 Nylon 2
17 FAS-2823 Flt Hd Slt Scr #8-32 x 1-1/2 Long 1
18 GOF-3012 Spacer 1/2 OD x 5/16 Long 1
19 GOF-3014 Drive Pinion w/ Key and Set Screw 1
20 MDS-1019 Snap Rivet, Black 4
*21 MPD-1001 Power Cord 120 VAC 1
22 MPD-1006 Side Panel 1
23 MPD-1007 Heat Sink 1
24 MPD-1008 Filter 1
25 MPD-1009 Fan Assembly 1
26 MPD-1011 Base Panel 1
27 MPD-1012 Mounting Block 1
28 MPD-1090 Matched Clutch Plates 2
**29 BUG-2593 Glide Flat 1
30 MPD-1015 Gear Motor (60:1) 1
31 MPD-1016 Clutch Assembly (Includes items 32 through 37) 1
32 BUG-1216 Ball Joint 1
33 BUG-1857 Knob 1
34 FAS-0945 Fit Hd Soc Scr #10-32 x 1/2 Long 1
35 FAS-1341 Hex Jam Nut #10-32 1
36 FAS-1390 Hex Nut 3/8-16 2
37 MPD-1017 3/8-16 Threaded Stud 1
38 MPD-1018 Wiring Harness-Speed Board to Motor 1
39 MPD-1019 Wiring Harness-Interconnect to Speed Bd/Control 1
40 MPD-1020 Wiring Harness-Interconnect to Speed Bd/Power 1
41 MPD-1025 Power Entry Module 1
* 42 MPD-1026 Fuse 2A 1
43 MPD-1029 Connector Cover Plate 1
44 MPD-1031 Cover Panel (Includes item # 20) 1
45 MPD-1038 Gasket for 50-Pin Connector 1
46 MPD-1039 Gasket for 50-Pin/3-Pin Connector 1
47 MPD-1042 Inductor, Potted-with Connectors 1
48 MUG-1617 Cable Connector, 4-T, Female, Elbow 1
*49 PCB-1000 Speed Board 1
* 50 PCB-1005-120 Power Supply Assembly 165W 120 VAC 1
51 PCB-1010 Interconnect Board 1
52 PCB-1012 Position Card 1
53 WAS-0201 #4 Internal Star Lockwasher 6
54 WAS-0211 #6 Internal Star Lockwasher 3
55 WPD-1012 Brake Assembly 1
* See Electrical Component Chart for 240 VAC Part Numbers
**Included in Item 28.
21
AC POWER WIRING DIAGRAM
PEM
PC
F1
*F2
BLK
J1
RED
GRN GRN
FUSE BOX
RED
RFI
RED BLK
BLU
RED
PS
AC
POWER
OUT
BLK
120 VAC
&
240 VAC
BLK
DC OUT
ELECTRICAL COMPONENT CHART
MPD-1002 MPD-1004
ITEM DESCRIPTION 120 VAC 240 VAC
F1,F2* Fuses (1) MPD-1026 2A (2) MPD-1027 3A
PC Power Cord MPD-1001 MPD-1003
PS Power Supply PCB-1005-120 PCB-1005-240
J1 Connector w/Pins MPD-1021
PEM Power Entry Module MPD-1025
RFI Filter Module MPD-1008
*F2 replaced with bus wire on 120 VAC
22
PART NUMBER
SIGNAL WIRING
PS
A
B
C
D
FROM
CONTROL
MODULE
WHT/RED
WHT/BLK
WHT/OR
RED
F
BLK
PUR
PUR
YEL
YEL
CI
50 LINE
RIBBON
+ 15 V
GND
- 15 V
FAN +
FAN -
1
CONTACT
2
3
4
CONTACT
INTERCONNECT
SIGNALS
A
B
INPUTS
OUTPUTS
PCB 1
+ 15 V
GND
- 15 V
SPEED
CARD
WHT/RED
WHT/BLK
WHT/OR
C2
18 LINE
C3
50 LINE
RIBBON
MOTOR
OUT
POSITION
IN AND
BRAKE
OUT
SPEED
CONTROL
PCB 2
TO
OSCILLATOR
OR
ACCESSORIES
BLK
RED
C4
10 LINE
RIBBON
CK
CHOKE
PCB 3
POSITION
M
GEAR
MOTOR
B
BRAKE
PARTS LIST
ITEM DESCRIPTION PART NUMBER
B Brake Assembly WPD-1012
Cl Contactor Cable Assembly MPD-1036
C2 DC Power Cable Assembly MPD-1020
C3 Speed Card Cable Assembly MPD-1019
C4 Motor Wiring MPD-1018
CK Inductor Pot Assembly (Choke) MPD-1042
F Fan Assembly MPD-1009
M Gear Motor MPD-1015
PCB1 Interconnect Card PCB-1010
PCB2 Tractor Speed Card PCB-1000
PCB3 Position Sensor Card PCB-1012
PS Power Supply (see AC Wiring Diagram)
23
ALUMINUM RIGID RAIL / CROSS SECTION / EXPLODED VIEW /
PARTS LIST
ALUMINUM RIGID RAIL is a rigid channel section made of high quality alloy to machine tool
tolerance as in the section view below. A machined gear rack is mounted on the rail, with which the
drive pinion of the carriage meshes. The wheels of the carriage travel in opposed grooves at either
side of the rail, locking the carriage to the rail.
Heavy Duty (H.D) aluminum four-legged rigid rail is
supplied in two lengths:
ARR-1080 [93-1/2" (2.37 m)] called 8' (2.37 m) rail
ARR-1085 [46-1/2" (1.18 m)] called 4' (1.18 m) rail
Extra Heavy Duty aluminum four-legged rigid rail is also
available:
ARR-1250 [93-1/2" (2.37 m)] called 8' (2.37 m) rail
ARR-1200 [46-1/2" (1.18 m)] called 4' (1.18 m) rail
5
ARR CROSS SECTION VIEW
ARR-1080/ARR-1085
A
C
D
B
A 2.75" (70.mm)
B 4.0" (102.mm)
C 0.375" (9.5 mm)
D 0.875" (22.mm)
3
4
1
2
6
PARTS LIST - ARR-1080 (ONLY)
ITEM PART NO. DESCRIPTION QTY
1 ARR-1002 Rack 1
2 ARR-1027 Splicer Bar 2
3 ARR-1028 Carriage Bolt 2
4 ARR-1081 Rail Extrusion 1
5 FAS-0375 Hex Hd Cap Scr 5/16-18x1/2 2
6 FAS-1370 Hex Nut 5/16-18 2
(Consult Factory for parts to ARR-1085, ARR-1250 or ARR-1200)
RAIL FOR LONGER SPANS:
When unsupported rail paths longer than 8' (2.37 m) rail are required, multiple sections of
(
standard rail are mounted on plate, I beam, channel or box sections.
24
AFR-3000 SEMI-FLEX RAIL / CROSS SECTION / EXPLODED VIEW /
PARTS LIST
SEMI-FLEX RAIL can be bent inside or outside to a minimum radius of 15' (5 m) without
permanent deformation. A splice plate is mounted at one end of each ex-rail section for
connecting multiple sections of rail. A rack adjusting tool is supplied with every two (2)
rails, for moving the rack on the rail. Available in 8' ( 2.37 m) lengths. Use at least four (4)
attachments - vacuum cups or magnets - on each section of Semi-Flex Rail.
AFR CROSS SECTION VIEW
A
Minimum Radius
15' (5 m)
8'
(2.37 m)
8'
(2.37 m)
B
A 2.75" (70 mm)
B 4.0" (102 mm)
C 0.33" (8.5 mm)
D 0.500" (12.7 mm)
C
D
2
4
1
5
8
7
ITEM PART NO. DESCRIPTION QTY
1 AFR-1015 Spacer Washer 16
2 AFR-2001 Rack Adjuster Tool 1
3 AFR-3002 Splice Plate 1
4 AFR-3006 Rack 1
5 AFR-3009 Extrusion, Punched 1
6 FAS-0955 Screw, Flt Hd Soc 1/4-20 x 1/2 4
7 FAS-1446-HW S.T. Slt. Hx. #10-32 x 5/8 16
8 WAS-0230 #10 Washer 16
6
3
PARTS LIST
25
ARM-2010 / AFR-2010 ON/OFF MAGNET ASSEMBLY
STANDARD MAGNET ASSEMBLIES
MAGNET PLATE ASSEMBLIES mount ARR rail quickly and conveniently right on the work surface.
Magnets cannot exert maximum pull on dirty material. Remove excessive paint, scale and rust from
the area on which the magnets will be placed.
KEEP MAGNETS CLEAN before positioning, wipe off magnetic particles which adhere to the poles.
ARM-2010 & AFR-2010 - The Bug-O/
Mag-switch, Switchable On/Off Rare-Earth
magnet assembly provides for quick rail
positioning without ghting the magnet. The
lighter weight, at just 1.7 lb. (0.77 kg), less
than all other magnet assemblies, improves
handling. 250 lbs (113.4 kg) holding
capacity. ARM-2010 Fits standard ARR-rails
and AFR-2010 Fits AFR Rails.
ARM-2010
AFR-2010
ARR & AFR VACUUM ASSEMBLIES
ARV-1085 VACUUM KIT
FOR ARR-1085 4' (1.18 MM)
RIGID RAIL
ARV-1080 VACUUM KIT
FOR ARR-1080 8' (2.37 MM)
RIGID RAIL
26
MPD-1065 RELEASABLE CARRIAGE / EXPLODED VIEW / PART LIST
Two carriages are available for the Modular Drive System when using BUG-O Aluminum Rigid and
Semi-Flex Rails. Both carriages are made of a high-strength, lightweight aluminum alloy, with wheels
that ride in opposed recessed rail grooves.
The MPD-1065 Releasable 12" (305 mm) Carriage can be placed anywhere on the track by using
the knob located on the side of the carriage, which engages or disengages the wheels from the rail.
The MPD-1055 18" (457 mm) Carriage provides an extended deck for mounting accessories, wire
feeder, etc. The pinion from the drive unit engages the rack on the rail, providing positive drive in all
positions. On each carriage, one set of wheels is adjustable to allow for smooth, accurate travel. All
wheels contain permanently lubricated, sealed bearings and their steel components are plated to
resist corrosion.
The MPD-1065 Releasable 12" Carriage has a carrying capacity of 100 lb (45 kg) and can be
placed anywhere on the rail by using the knob located on the side of the carriage, which engages or
disengages the wheels from the rail. Use with BUG-O Aluminum Rigid or Semi-Flex Rails.
6
5
4
2
3
ITEM PART NO DESCRIPTION QTY
1 BUG-1984 External Adj. Leg & Wheel Assembly 2
2 FAS-0545 Screw, Soc Hd Cap #10-32 x 1/2 2
3 MPD-1045 Fixed Leg & Wheel Assembly 2
4 MPD-1049 Handle, Black 1
5 MPD-1059 Knob Screw (Included w/ Carriage) 1
6 MPD-1066 Carriage 1
1
27
BRR-1180 BENT RIGID RAIL / CROSS SECTION / APPLICATION VIEW /
PARTS LIST
BENT RIGID RAIL (BRR) is a rigid section of high quality alloy bent for circumferential applications. A
machined gear rack is mounted on the rail, with which the pinion of the drive unit meshes, providing
positive drive in all directions. The wheels of the carriage travel in opposed grooves at either side of
the rail, securing the carriage to the rail. The rail can be ordered as a complete ring (BRR-1210-__)
or as individual sections (BRR-1180). When ordering, specify the work diameter (inside or outside),
method of mounting and if a complete ring is required. On larger diameters, rail can be “leapfrogged”
around the vessel to reduce the quantity needed. Maximum section length is 80" (2 m).
BRR CROSS SECTION VIEW
A
C
D
B
A 2.75" (70 mm)
B 4.0" (102 mm)
C 0.375" (9.5 mm)
D 0.875" (22 mm)
PARTS LIST
PART NO. DESCRIPTION QTY
ARR-1002 Rack 1
ARR-1027 Splicer Bar 2
ARR-1028 Carriage Bolt 2
ARR-1044-E Rail Extrusion 1
FAS-0375 Hex Hd Cap Scr 5/16-18 2
FAS-1370 Hex Nut 5/16-18 2
COMPLETE RING RAIL ASSEMBLIES
Ring Rails and Tube Size Ranges
Work Diameters
PART NO. INCHES MM INCHES MM
(1) BRR-1210-20 9-16 230-400 20 500
(2) BRR-1210-27 16-23 410-580 27 680
(3) BRR-1210-34 23-30 590-760 34 860
(4) BRR-1210-41 30-37 770-940 41 1040
(5) BRR-1210-48 37-44 950-1120 48 1220
* Ring Rails do not include attachments.
BRR-1210-_
Note: Adjustable magnet support legs (ARM-2480),
shown above, are sold separately.
Ring
Inside Diameter
Work
Diameter
28
Ring ID
MAGNET ATTACHMENTS VACUUM SUPPORTS
A minimum of three (3) magnet plate or
screw feet assemblies are required for each
ring rail section.
Support Bar
w/ Screw Feet
ARM-2380
4.5" (114.3 mm) of Adj.
Also available as a
kit of three (3)
ARM-2390
Support Bar
w/ Magnets
ARM-2480
3.5" (88.9 mm) of Adj.
Also available as a
kit of three (3)
ARM-2490
Support Bar
w/ R.E On/Off Magnets
ARM-2580
3.5" (88.9 mm) of Adj.
Also available as a
kit of three (3)
ARM-2590
Vacuum Supports may be used instead of magnets to mount the Ring Rail on non-magnetic
work pieces. Each Vacuum Support System
requires a Vacuum Pump Kit for operation.
ARV-1240-20 20" Dia. Vacuum Support System
ARV-1240-27 27" Dia. Vacuum Support System
ARV-1240-34 34" Dia. Vacuum Support System
ARV-1240-41 41" Dia. Vacuum Support System
ARV-1240-48 48" Dia. Vacuum Support System
ARV-2020 120VAC Vacuum Pump Kit
ARV-2030 220VAC Vacuum Pump Kit
BUG-5910 TUBE CARRIAGE / EXPLODED VIEW / PARTS LIST
The Tube Carriage features a split
carriage body for quick and easy
placement on the rail. It has a carrying
capacity of 100 lb (45 kg). The carriage
also offers six (6) wheel positions for
circumferential applications over a
wide range of diameters. Use with
BUG-O Aluminum Rigid, Semi-Flex or
Bent Rigid Rails.
ITEM PART NO DESCRIPTION QTY
1 BUG-5907 Skirt 2
2 BUG-5512 Knob 1
3 BUG-5918 Fixed Wheel Assembly 2
4 BUG-5920 Adj. Wheel Assembly 2
1
2
3
4
29
HI-FLEX RAIL / CROSS SECTION / EXPLODED VIEW / PARTS LIST
Hi-Flex Rail (FMD) & Corresponding Attachments
The FMD Flex Rail can ex from a straight to
a 30" (760 mm) radius inside or outside. The
R 30"
(760 mm)
rail is made from a tempered, wear resistant,
stainless steel with a steel rack. It is designed
for use with the FMD Hi-Flex Carriage and MDS
Drive System. The rail comes in 57.7" (1.47 m)
lengths and can be held in place with magnets
FMD Hi-Flex Rail can
ex inside or outside to
a minimum radius of 30"
(760 mm).
or vacuum cups. An optional stiffener can be
installed behind the rail for heavy duty, straight
line applications.
FMD-1050 HI-FLEX RAIL / CROSS SECTION / ASSEMBLED VIEW / PARTS LIST
3.995"
(102 mm)
0.250"
(6.4 mm)
3, 5
1
0.080"
(2 mm)
R 30"
(760 mm)
4
6
2, 7
ITEM PART NO. DESCRIPTION QTY
1 FAS-0376 Hex Hd Cap Screw 5/16-18 x 5/8 Long 4
2 FAS-1370 Hex Nut 5/16-18 4
3 FAS-1444 Phlp Pan Hd Scr #10-32 x 3/8 Long 196
4 FMD-1051 Track 1
5 FMD-1052 Rack Section, 3 Teeth 98
6 FMD-1053 Flex-Rail Splice Plate 1
7 WAS-0250 5/16 SAE Washer 4
FMD-2170 Hi-Flex Rail
with R.E. On/Off Magnets
30
FMD-2010 R.E. ON/OFF MAGNET ASSEMBLY
STANDARD MAGNET ASSEMBLIES
MAGNET PLATE ASSEMBLIES mount ARR rail quickly and conveniently right on the work surface.
Magnets cannot exert maximum pull on dirty material. Remove excessive paint, scale and rust from
the area on which the magnets will be placed.
KEEP MAGNETS CLEAN before positioning, wipe off magnetic particles which adhere to the poles.
FMD-2010 - The New, Bug-O/Mag-switch, Switchable On/Off Rare-Earth magnet assembly
provides for quick rail positioning without ghting the magnet. The lighter
weight, at just 1.7 lb. (.77 kg), less than all other magnet assemblies,
improves handling. 250 lb (113.4 kg) holding capacity. Fits standard
FMD-rails.
FMD-2010
FMD-1220 / FMD-1230 HI-FLEX VACUUM SUPPORTS AND VACUUM PUMP
FMD-1220 Vacuum Support for (1) FMD-1050*
FMD-1230 Vacuum Support for additional FMD-1050*
*FMD-1050 rail sold separately.
FMD-1036
VAC Support Bar For Hi-Flex Rail.
ARV-1060 Leap Frog Kit
For ARV-1080 & ARV-1085.
Used to reposition rail without losing vacuum.
ARV-2020 120VAC/50-60 Hz/1Ph
ARV-2030 240VAC/50-60 Hz/1Ph
The ARV-2020 (ARV-2030) Vacuum Pump Kit is
recommended for use with a maximum of four (4)
pieces of rail, or sixteen (16) vacuum bars.
31
FMD-1105 12" HI-FLEX RAIL CARRIAGE / EXPLODED VIEW
20
19
15
16
5
12
2
17
18
21
6
4
1
3
9
12
4
1
3
8
7
12
13
14
13
32
10
2
11
13
14
FMD-1105 12" HI-FLEX RAIL CARRIAGE / PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 BUG-2012 Bearing 8
2 BUG-2848 Cam Bearing 2
3 CON-1029 Washer 5/16 x .015 8
4 FAS-0386 Hex Hd Cap Scr 5/16-24 x 5/8" 8
5 FAS-0959 Flt Hd Soc Scr 1/4-20 x 5/8" 4
6 FMD-1026 Carriage Cover 1
7 FMD-1068 Fixed Wheel Mounting Block 1
8 FMD-1069 Adj. Wheel Mounting Block 1
9 FMD-1071 Threaded Shaft 1
10 FMD-1072 Knob & 1/4-20 x 1/4 Set Screw 1
11 FMD-1081 Bearing Block 1
12 FMD-1083 Dowel Pin 1/2" x 2" Long 2
13 BUG-2841 Washer 5/8" O.D. x 5/16" I.D. Teon 4
14 FAS-0659 Soc Hd Shr Scr 5/16-18 x 1" 2
15 MPD-1035 Handle w/ Cable Anchor (includes items 16-21) 1
16 MPD-1044 Mounting Angle 1
17 MPD-1047 Post for Handle 1
18 CON-1020 Swivel Clamp Assembly 1
19 BUG-2708 Clamp 1
20 FAS-0959 1/4-20 X 1" Flat Hd Socket 1
21 FAS-0557 Soc Hd Cap 1/4-20 x 3/4 2
33
VACUUM PUMP / EXPLODED VIEW
ARV-2020 VACUUM PUMP KIT, 120 VAC 60HZ/1PH
ARV-2030 VACUUM PUMP KIT, 240 VAC 50HZ/1PH
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.
16
17
19
18
1
14
20
15
2
3
4
5
6
21
7
8
22
23
24
12
7
6
9
34
10
13
11
VACUUM PUMP / PARTS LIST
ITEM PART NO. DESCRIPTION QTY
1 ARV-2017 1/4'' Brass Vacuum Relief Valve 1
2 ARV-2014 Vacuum Gage 1
3 ARV-2018 1/4'' NPT Union Cross, Female 1
4 ARV-2012 1/4'' NPT Nipple 2
5 ARV-2016 1/4'' NPT Brass Check Valve, F 1
6 ARV-1107 3/8'' Hose Barb x 1/4'' NPT-M 2
7 ARV-1005 11/16'' x .112 Thk Clamp 2
8 ARV-1004-P Hose 3/8'' ID x 11/16'' OD 1
9 ARV-1012 Female Quick Connector 1
10 ARV-2019 Pump 1
11 ARV-1999 Foot Support w/ Fasteners 1
12 ARV-2021 120 VAC Power Cord w/ Switch 1
*
13 ARV-2013 Handle 1
14 ARV-2011 Body 1
15 ARV-2010 Vane 4
16 ARV-2009 Shroud 1
17 ARV-2003 End Cap 2
18 ARV-2004 Felt 2
19 ARV-2005 O-ring 2
20 ARV-2002 End Cap Assembly (Includes parts 17-19) 2
21 ARV-2001 Filter/Mufer 1
22 ARV-2006 Mufer Box 1
23 ARV-2007 Gasket 1
24 ARV-2008 End Plate 1
†
240 VAC requires the items below
* BUG-9233 Label, 240 VAC 1
* BUG-9593 240 VAC Twist Plug 1
* BUG-9594 240 VAC Connector Body 1
* ARV-2021 120 VAC Power Cord w/ Switch 1
†
240 VAC Replacement Power Components
*Not Shown
35
ARV-1036 VACUUM SUPPORT BAR FOR ARR, AFR AND BRR RAILS
VACUUM CUPS are used for mounting the rail to the workpiece when magnet bars
will not hold. EXAMPLE: Stainless steel or nonferrous surfaces. The surface must be
smooth and nonporous.
Each vacuum bar is tted with two (2) cups and will exert a maximum pull of 100 lbs. (45 kg).
ARV-1036 VACUUM SUPPORT BAR / EXPLODED VIEW / PARTS LIST
8
3
1
4
5
3
4
7
2
6
ITEM PART NO. DESCRIPTION QTY
1 ARR-9008 Spacer Tube 2
2 ARV-1034 Choke Nipple 2
3 ARV-1107 3/8 Hose Barb x 1/4 NPT-M 2
4 ARV-1109 Protective Cap 2
5 ARV-1111 Support Bar 1
6 ARV-1116 Vacuum Cup (Silicone) 2
7 FAS-0252 Rnd Hd Scr 1/4-20 x 1/4 2
8 FAS-2372 Hex Hd Cap Scr 5/16-18 x 1-1/4 2
NOTE: Keep ame or arc at least 4" (101 mm) away from vacuum cups. Vacuum cups can be used on
preheated material to 600
ARV-1036 Vacuum Support Bar is used on all ARR, AFR and BRR rails.
36
0
F (3150 C). Each vacuum cup exerts a maximum pull of 50 lbs. (22.6 kg).
FMD-1036 VACUUM SUPPORT BAR FOR FMD RAIL / EXPLODED VIEW /
PARTS LIST
7
7
8
3
8
6
2
4
2
6
3
5
5
1
1
ITEM PART NO DESCRIPTION QTY
1 ARV-1034 Choke Nipple 2
2 ARV-1107 3/8" Hose Barb 2
3 ARV-1109 Protective Cap 2
4 ARV-1111 Support Bar 1
5 ARV-1116 Vacuum Cup 2
6 FAS-0252 Rnd Hd Scr 1/4-20 x 1/4" 2
7 FAS-2374 Hex Hd Cap Scr 5/16-18 x 1-3/4" 2
8 FMD-2014 Flex Rail Spacer Tube 2
37
ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE
BUG-O’s Modular Drive System is a system that permits mixing and matching of components to
build a customized solution to specic applications. This provides the owner the ability to replace
and remove individual components while troubleshooting, which signicantly reduces time and effort
required to troubleshoot the system. The recommended troubleshooting procedure is as follows:
BUG-O’s ARC Gouging MODULAR DRIVE SYSTEM is a marriage of BUG-O Systems Drive
and Rail System with ARCAIR® AUTOMATIC GOUGING SYSTEM. The only electrical / control
connection between the BUG-O and the Arcair® Control Box is the MODULE POWER CORD to the
120VAC Power Outlet on N7500 Control Box.
If problems do occur, it is imperative that the two systems are isolated and tested separately to
conrm that each unit is operating properly. Then, after conrming each system is functioning
properly the only remaining issue is the connection between the two systems.
1) Verify that there are no loose electrical or mechanical connections.
2) Verify that the Gouging power sources are properly grounded and it’s ground clamp is attached
to the work piece.
3) Ensure the High Frequency Warnings in the front of this IPM are not being violated.
4) When possible, swap out each component in the system one at a time with a known good
component. For example, replace the Control Module on a defective machine with the Control
Module from a working machine. Often this will pinpoint the defective component quickly.
5) Remove all attached components. All attached components are removed to limit the number
of components affecting the operation and complexity of the system. Assemble a base system
composed of a Control Module and a Master Drive. Test the base system. If the base system
does not work, troubleshoot the base system to a circuit board level using the Base System
Test Procedure. If possible, test the Control Module by swapping it with a known good module.
6) Finish installing the components one at a time. Test the system after each installation in order to
identify the problem component(s).
38
ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE, (CONT’D.)
PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY
Speed display is not Power switch is OFF. 1A Turn ON the main ON/OFF switch located in the power entry
lit and tractor does module. (see Figure 1)
not run.
No power to machine. 1B Verify the power cord is OK and the correct voltage exists at the
outlet.
Blown fuse. 1C Unplug the power cord. Check the machine’s power input
fuse(s). The fuse(s) is located in the power entry module and is
accessible without opening the case.
Faulty accessory 1D Remove any accessory plugged into the master drive accessory
attached to the port (see gure 2). Plug in the power cord and turn on the main
master drive power.
accessory port.
a) If the speed display does not light, proceed with test 1E
b) If the speed display lights, install the connector cover on
the accessory port. NOTE: FAILURE TO INSTALL THE
CONNECTOR COVER ON THE ACCESSORY PORT
AFTER COMPLETING THIS TEST MAY CAUSE
SERIOUS INJURY FROM ACCIDENTAL ELECTRICAL
SHOCK.
Set the tractor for continuous forward motion at full speed.
If the control module has any type of motion enable
switch, turn it to enable.
1) If the tractor does not work properly, proceed with step 2A.
2) If the tractor operates correctly, the accessory removed
from the accessory port is defective.
Faulty power entry 1E Remove the connector cover or any attached accessory from the
module. master drive accessory port (see Figure 2). Verify the power line
voltage is on the two outer pins of the three pin connector (see
Figure 2). The center pin is chassis ground.
NOTE: INSTALL THE CONNECTOR COVER ON THE
ACCESSORY PORT AFTER COMPLETING THIS TEST.
FAILURE TO INSTALL THE COVER MAY CAUSE SERIOUS
INJURY FROM ACCIDENTAL ELECTRICAL SHOCK.
If the voltage is not present, rerun tests 1A, 1B, 1C, 1D and 1E.
A second failed 1E test indicates bad internal AC wiring or a
defective power entry module. Open the master drive case (see
Figure 3). Examine the AC wiring and rewire at fault or replace
the power entry module assembly. NOTE: The replacement
power entry module is provided with the accessory port’s three
pin AC connector prewired.
39
ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE, (CONT’D.)
PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY
Defective RFI 1F Disconnect the two RFI lter output wires (see Fig. 1). Turn ON
the main power. Verify the power line exists on the two output
wires. Reconnect the wires. Replace the RFI lter if the power
line voltage is not present
Bad Power 1G Turn ON main power. The Green LED’s LI and L2 (see Fig 1)
Supply will light if the power supply is OK. If the LED’s are OFF, unplug
the power supply output connector (see Fig. 1). The connector
wiring is: White & Red is +15 V DC (+/- 2V). White & Black is
DC ground. White & Orange is -15 V DC (+/- 2V). Measure
voltages at the connector.
a) A bad voltage indicates a defective power supply. Replace
the power supply.
b) Correct voltages indicate the power supply is OK, however,
there is a short in the equipment. Plug in the power supply
output connector. Perform test 1H.
Short Circuit 1H The Green LED’s L1and L2 will light when the short is removed.
Unplug the following and monitor the LED’s to see if the short is
removed:
1) The Control Module,
2) The speed card input power connector (see Fig. 1).
3) all connectors attached to the interconnect card (see Fig. 1),
except the connector for the supply.
If L1 and/or L2 never turn ON, the interconnect card is bad.
Replace the board.
No tractor Operator 2A Set the MODE switch to CONTINUOUS and the CARRIAGE
speed control Error TRAVEL switch to STOP. Turn the SPEED CONTROL
and display clockwise. Proceed to step 2B if the display does not increase. If
is LIT. the display does not increase, then turn the CARRIAGE TRAVEL
switch to FORWARD. Open the master drive case (Fig. 3)
and proceed to step 2C. If the tractor does not move forward.
Bad DC Power 2B Open the masters drive case (g. 3). Unplug the power supply
output connector (see Fig. 1). The connector wiring White & Red
is +15 V DC (+/- 2V). White & Black is DC ground. White &
Orange is -15 V DC (+/- 2V). Measure the voltages at the
connector. A missing or bad voltage indicates a bad power
supply. Replace the power supply.
Faulty Motor 2C Check the wires from the speed card to the motor for faults.
Wiring Rewire if needed.
Faulty Motor 2D Disconnect the motor leads. Apply 2 to 8 volts DC across the
motor leads. Verify that the motor spins.
40
ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE, (CONT’D.)
PROBLEM POSSIBLE CAUSE TEST BASE SYSTEM TEST PROCEDURE / REMEDY
No tractor Faulty Control 2F Install one voltmeter lead on TP4 and the other lead on TP5.
speed control module, speed Turn on the main power. Set the control module for continuous
and display card, or motor. forward tractor motion. If the control module has any type of
is lit. motion enable switch, turn it to enable. Rotate the tractor speed
control knob while observing the voltmeter output. It is possible
to vary this voltage between 0 and 8 volts DC using a good
control module.
a) if the voltage does not vary, replace the control module card.
b) If the voltage does not vary, turn the machine OFF and then
ON using the main power switch. Observe LED L5. L5
should light for a moment or two during power-up while
safety circuits hold the tractor OFF until full power is
reached. L5 should turn OFF indicating power is reached.
L5 should turn OFF indicating power has been applied to
the motor and motion should start.
1) If the L5 never lights, replace the speed card.
2) If the L5 turns ON, turns OFF, and then turns ON, check for
shorted motor connections. If none are found, replace the
speed card.
3) If the L5 turns ON and stays ON, check that the control
module is set up as dened above and retest 2T. A second
failure indicates a bad speed card. Replace Speed Card.
4) If L5 turns ON and then OFF and the motor doesn’t start
running, thru the tractor speed up. If the motor does not
begin to turn, check the motor speed card wiring for faults
and repair as needed. If the motor still fails to turn, replace
the speed card.
Tractor High Frequency 3A Turn OFF ARC GOUGING unit. The unit should operate
Moves a short Interference normally.
distance and
then stops 3B Verify load on the carriage does not exceed the factory
rating.
3C Remove unit from track and set the controls to forward
tractor motion. If the pinion motion stops after a short time or
a check shows that the weight placed on the machine is not
excessive, then the problem is most likely brake related.
Return machine for repair.
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ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE, (CONT’D.)
The Modular Drive System is equipped with internal fault diagnostic LEDs and test Points
10 Speed troubleshooting as shown below. Test point evaluation should be performed by
a qualied technician using a volt meter. If a qualied technician is not available, return the
unit to the factory for repair. Always unplug the power cord before opening the case.
RFI FILTER OUTPUT
POWER
SUPPLY
SPEED CARD
INPUT POWER
CONNECTOR
POWER SUPPLY
OUTPUT CONNECTOR
Figure 1. Troubleshooting Test Points
TP8
TP6
L1
L2
TP4
TP9
TP3
RFI FILTER
SPEED
CARD
TP5
TP1
L5
L4
L3
POWER
ENTRY
MODULE
TP2
INTERCONNECT
CARD
TEST POINTS
TP1 -15V
TP2 GND
TP3 +15V
TP4 Tractor + Speed Command
TP5 Tractor - Speed Command
TP6 Weaver + Speed Command
TP7 Weaver - Speed Command
TP8 Height + Speed Command
TP9 Height - Speed Command
L1 -15v
L2 +15V
L3 Height Off
L4 Weaver Off
L5 Tractor Off
42
ARC GOUGING MODULAR DRIVE TROUBLESHOOTING GUIDE, (CONT’D.)
ACCESSORY PORT
AC
CHASSIS GROUND
AC
Figure 2. Master Drive Accessory Port
Figure 3. Procedure for Opening the Master Drive Case:
1. Unplug the power cord.
2. Unbolt the Master Drive from
the carriage.
3. Remove ONLY the seven screws
as shown.
4. Open the case.
CAUTION: Unplug the power cord before opening or closing the case or
serious injury may result.
43
NOTES:
44
MASTER DRIVE WIRING DIAGRAM MDP-1000/ MDP-1002/ MDP-1004
NOTES:
Encoder card and brake are mounted on the motor.
18 pin connectors are not wired 1:1.
The Connector on one end is ipped.
For example, Pin 1 goes to connector 18.
Most signals on the 50 pin connector come in one 50 pin connector and
exit on the other 50 pin connector.
Pinouts for connectors can be determined from slik-screen.
45
WARRANTY
Model _____________________________
Limited 3-Year Warranty*
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:
Serial No. __________________________
Date Purchased: ____________________
Where Purchased:___________________
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
difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.
*Bug-O System’s warranty applies to Bug-O components only. Where other brands of power sources, wire feeders or sub
components are a part of Bug-O Equipment, please refer to that specific Manufacturer’s manual for warranty specifications
on their components.
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