BUG-O Systems AGS-4000 User Manual
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
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