BUG-O Systems CAS-2050 User Manual

INSTRUCTIONS

aNd

PaRTS MaNUaL

aUTOMaTIC HEIGHT

CONTROL

CaS-2050

for WPD-1100 Linear Weaver

Please record your equipment identication 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-CAS-2050-IPM-0912

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: [phone] http://www.bugo.com FaX: [phone]

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 environment may result
in serious injury. Do not touch equipment
when wet or standing in a wet location.

2) The unused connectors have power on
them. Always keep the unused connec­ tors covered with the supplied protective
panels. Operation of the machine without
the protective panels may result in injury.

3) Never open the equipment without rst
unplugging the power cord or serious
injury may result.

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 applying power
or equipment damage may occur.

3) Do not leave the equipment unattended.

POSSIBLE.

4) Verify the customer-supplied power

connections are made in accordance

with all applicable local and national
electrical safety codes. If none exist,
use International Electric Code (IEC)

950.

5) Never remove or bypass the equipment
power cord ground. Verify the equipment
is grounded in accordance with all appli­ cable local and national electrical safety
codes. If none exist, use International
Electric Code (IEC) 950.

READ INSTRUCTIONS.

Read the instruction manual before
installing and using the equipment.

4) Remove from the worksite and store in
a safe location when not in use.

FALLING EQUIPMENT
can cause serious
personal injury and
equipment damage.

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

MOVING PARTS can
cause serious injury.

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.

2

HIGH FREQUENCY WARNINGS

SPECIAL PRECAUTIONS ARE REQUIRED WHEN USING PLASMA,

TIG OR ANY WELDING PROCESS THAT USES HIGH FREQUENCY

TO STRIKE AN ARC.

WARNING: HIGH FREQUENCY CAN EFFECT MACHINE

OPERATION AND THEREFORE, WELD QUALITY.

Read the precautions below before installing and using the equipment.

PRECAUTIONS:

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

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

2) Always physically separate the plasma or welding cable leads from the machine
cables. For example, the plasma or welding cable leads should NEVER be bundled
with a pendant cable or the machine power cord. Maximize the separation between
any machine cables and the plasma or welding cables.

3) Strictly follow the grounding procedures specied for the plasma or welding unit.
NOTE: Some plasma and welding units produce exceptionally large amounts of high
frequency noise. They may require a grounding rod be driven into the earth within six
feet (2 meters) of the plasma or welding unit to become compatible with an automatic
cutting or welding process.

4) If the high frequency is produced using a spark gap, adjust the points so the gap is as
small as possible. The larger the gap, the higher the voltage and the higher the inter­ ference.

5) Some plasma or welding units will inject high frequency interference into the AC
power line. Use separate power line branches whenever possible to power the
plasma or welding source and the machine. Do not plug them into the same outlet
box.

6) High frequency noise may enter the machine through the plasma or welding supply
remote contactor leads. Some plasma and welding sources can produce noise spikes
of up to several thousand volts. These sources are not compatible with automated
cutting and welding equipment. It is recommended that the remote contactor leads on
these plasma or welding sources not be connected to the machine. An alternate
solution is to purchase a separate remote contactor isolation box.

3

AUTOMATIC HEIGHT CONTROL

CAS-2050

FOR WPD-1100 PENDULUM WEAVER

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGES

5............Introduction / Overview / Items Supplied / Specications

6-8 ........ Setup

9............CAS-2050 Automatic Height Control for WPD-1100 Linear Weaver

10..........CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control

11 .......... CAS-1500 Height Slide Assembly / Exploded View / Parts List

12..........CAS-1550 Hall Effect Current Sensor Assembly

13..........PCB-1213 Adjustment Pot

14..........MDS-2055-WD Control Box / Exploded View

15..........MDS-2055-WD Control Box / Parts List

16..........MDS-2055-WD Control Box / Wiring Diagram

17..........CAS-2058 MDS AHC Wiring Harness / Wiring Diagram

18..........CAS-2051-10-WD MDS AHC 10' (3.0 m) Remote Control / Wire Diagram

19..........Troubleshooting

20..........Warranty

4

INTRODUCTION:

The CAS-2050 is an Automatic Height Control (AHC) for the WPD-1100 Linear Weaver that controls
the welding tip to work distance and maintains a constant weld current, helping to provide uniform weld
penetration. The CAS-2050 senses the actual weld current, compares this value to the set point, and
raises or lowers the welding gun accordingly.

The CAS-2050 features a built-in time delay after the arc is struck, and automatically shuts off when the
current drops too low (generally below 60 amps). The operator can temporarily override the Automatic
Height Control using the Up – Down JOG Toggle Switch on the Remote Control (CAS-2051-10)
while welding. Automatic Height Control resumes as soon as the jog switch is released. To disable the
Automatic Height Control, move the Manual – Automatic Toggle Switch on the Remote Control (CAS-
2051-10) to the manual position.

OVERVIEW

CAS-2050 AHC is available as original equipment or as a retrot unit designed to provide
Automatic Height Control on BUG-O Modular Drive Systems (MDS) with the WPD-1100 Linear
Weaver. The CAS-1500 Height Slide Assembly replaces the welding clamp originally supplied
on the Linear Weaver.

ITEMS SUPPLIED

CAS-2050 Automatic Torch Height Control for WPD-1100 Linear Weaver includes:

CAS-1500 Height Slide Assembly
CAS-1550 Hall Effect Current Sensor Assembly
CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control
CAS-2055 MDS AHC Control Box

SPECIFICATIONS

Weight (Net): 14.5 lbs (6.6 kg)
Travel: 2" (50.8 mm)
Carrying capacity: 10 lbs (4.5 kg)
Operating Range: 60 to 500 amps

ALL BUG-O Automatic Height Controls require

a Constant Voltage (CV) Power Source.

5

SETUP

CAS-1500 Height Slide Assembly

The Height Slide Assembly replaces the Welding Clamp originally supplied on the Linear Weaver. It
mounts to the 7/8" (22.2 mm) diameter rod. (Remove CON-1020 Swivel Clamp and BUG-2708 Clamp

and set aside for use when Automatic Height Control is not used.)

Slide clamp on bottom of CAS-1500 Height Slide Assembly onto UNI-1036 Rackrider with Post and
lock in position.

CAS-2055 MDS AHC Control Box

This mounts directly on top of the MDS Drive. Align the socket on the top of the MDS Drive with the
plug on the bottom of the AHC Control Box and seat it securely in place with the four (4) screws, one
(1) in each corner.

CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control

To install, align the plug in the bottom of the Male portion of this Remote Control with the socket on top
of CAS-2055. Seat this plug securely in place with the four (4) screws, one (1) in each corner.

6

SETUP CONT’D

Position and Clamp Welding Gun

With CAS-1500 installed on the Linear Weaver Cross Arm, secure the welding gun in the clamp located
on the end of the Height Slide Assembly. Arrange cables so that they do not interfere with the movement
of the machine before securing the cable in the cable anchor.

Connect Control Cables

Connect weld contact outlet pins A&B, on the MPD-1000 Drive unit to the wire feeder contact circuit.

Install Current Sensor

Connect CAS-1550 Hall Effect Current Sensor “in-line” in the welding current circuit. NOTE: It can be
installed on either side of the circuit.

Plug in MDS System with AHC

Inspect the power cord before each use. Do not use if damaged. Plug in the machine to a power outlet
of the appropriate voltage.

Power ON the MDS System with AHC

CAUTION: machine may start moving as soon as it is powered “ON.” Use the power switch on the
MPD-1000 Drive Unit to turn the power “ON” and “OFF” to the machine. For operator safety, set weld

pattern to “NO WEAVE” and the Drive Unit to “OFF” before turning on the machine.

Position Welding Gun

Proper setup of the welding gun is critical to a successful weld. In addition to manually positioning
the welding gun within the clamp, the welding gun must also be properly set with respect to three
mechanical controls: The cross arm, the height controller and the tractor position.

Cross Arm: The cross arm offers a weave of up to 1" (25.4 mm) left and right, 2" (50.8 mm)
total. Center the cross arm before placing the welding gun over the work area.

Height Slide Assembly: The slide assembly has 2" (50.8 mm) of travel available. For best results,
position the slide assembly in the middle of the total range before setting the
welding gun. Use the Up – Down JOG Toggle Switch located on Remote
Control (CAS-2051-10).

Tractor Position: Use the tractor Carriage Travel Switch to position the Drive Unit
at the start of the weld. The operator can increase or decrease the tractor
travel speed at any time using the speed control on the MDS Control Module.

Set Motion Parameters

Use the Weaver Control Module (MDS-1005) to set the motion parameters. Refer to “Modular Drive
System Instructions and Parts Manual” for detailed explanation of all settings and adjustments for a

Linear Weaver (WPD-1100).

VERIFY SETUP

Before welding, take a moment to verify the machine is set up correctly. With the tractor “ON” and the
Arc “OFF”, run the machine and verify it is moving in the intended direction. Verify cross arm is in the
proper position as well as the Drive Unit travel speed. Use the Up – Down JOG Toggle Switch on the
Control Box (CAS-2051) to make sure enough vertical travel is available.

7

SETUP CONT’D

Welder, Wire-feeder, Welding Gun, Weld and Automatic Height Control Setup

Amp Dial

Manual – Automatic

Toggle Switch

Up – Down JOG

Toggle Switch

CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control

MAKE SURE THE WELDING POWER SOURCE is a Constant Voltage model and that it is in the CV
MODE!!! If your welding power source is not or does not have a Constant Voltage option the Automatic

Height Control WILL NOT WORK!

To set your AUTOMATIC HEIGHT CONTROL:

(Reference CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control)

● Verify that the connection of the CAS-1550 Hall Effect Sensor Box is in-line within the welding

current circuit

● Set the height control (Manual – Automatic Toggle Switch) to manual mode.

● Set the torch height manually to the correct distance from the work piece using the Up – Down

JOG Toggle Switch

● Make a small weld and record the current reading from the power source.

● Now, dial the current reading into the Height Control (Amp Dial).

● Turn the height control (Manual – Automatic Toggle Switch) to “Automatic”.

● The system should run at the same height and thus current.

NOTE: Some minor adjustment of the Amp Dial may be required to achieve the current output desired.
If the above does not work, it is possible that the slide on the Height Control is positioned in reverse.
If this happens;

● Physically turn the slide over, or reverse the motor leads.

● Then repeat the “running procedure” above again.
─ If it works now, check that the Up – Down JOG Toggle Switch works in the proper

direction. If not, it can be xed by rotating the switch in the panel 180 degrees.

If this does not work please consult “Troubleshooting Page” in the back of this manual.

8

CAS-2050 AUTOMATIC HEIGHT CONTROL FOR WPD-2100 LINEAR WEAVER

3

4

5

2

1

ITEM PART NO. DESCRIPTION

1 BUG-2708 Clamp
2 CAS-1500 Height Slide Assembly
3 CAS-1550 Hall Effect Sensor Assembly
4 CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control
5 CAS-2060 MDS AHC Control Box

9

CAS-2051-10 MDS AHC 10' (3.0 M) REMOTE CONTROL

3, 4

1, 2

ITEM PART NO. DESCRIPTION

1 CWO-6335 DPDT Toggle Switch
2 PLT-1001 Auto/Man Plate
3 BUG-1572 Potentiometer
4 BUG-9676 Dial Counter
5 MUG-1199 DPDT Toggle Switch
6 PLT-2002 Up/Down Plate

5, 6

10

CaS-1500 HEIGHT SLIdE aSSEMBLY / EXPLOdEd VIEW / PaRTS LIST

F2

1

2

3

4

F1

5

F3

6

16

9

F2

17

15

9

18

F4

7

F8

14

F9, F7

8

F5

10

13

11

19

14

F5

F6

ITEM PaRT NO. dESCRIPTION QTY

1 CAS-1512 Torch Mount Plate 1
2 CAS-1509 Height Arm Mounting Bar 1
3 CAS-1523 End Cap 2
4 CAS-1505 Height Arm Assembly 1
5 PWS-1028 Fixed Wheel & Leg Assembly 2
6 CAS-1522 Mounting Plate 1
7 CAS-1511 Steel Pinion 1
8 CAS-1517 CAS Drive Motor Cover Mount Angle 2
9 CAS-1510 Dual Position Clamp Block 2
10 PRS-1025 Motor 1
11 CAS-1518 CAS Drive Motor Cover Panel A 1
12 CAS-1521 CAS Drive Motor Outer Cover 1
13 CAS-1519 CAS Drive Motor Cover Panel B 1
14 BUG-1034 Panel Connector, 4-T, M 1
15 CAS-1503-P Arm Cover 1
16 PWS-1029 Adjustable Wheel & Leg Assembly 2
17 UCW-0261-03-02-00-0 Quick Disconnect Clamp Assembly 1
18 BUG-2708 Clamp 1
19 GOF-3036 Qd Female, Fully Insulated 2
F1 MET-0975-SS Flt Hd Soc Scr M6 x 14 2
F2 MET-0553-SS Soc Hd Cap Scr M4 x 10 8
F3 MET-0559-SS Soc Hd Cap Scr M4 X 20 4
F4 MET-0147-SS Pan Hd Phil Scr M3 x 16 4
F5 MET-0542-SS Soc Hd Cap Scr M3 X 8 8
F6 MET-0541-SS Soc Hd Cap Scr M3 X 6 8
F7 FAS-1305 Hex Nut # 4-40 4
F8 FAS-1204 But Hd Sk Hd Scr # 4-40 X 3/8 4
F9 WAS-0201 #4 Internal Star Lockwasher 4
* CAS-1557 Control to Slide Cable 3ft 1
* Not Shown

12

11

CaS-1550 HaLL EFFECT CURRENT SENSOR aSSEMBLY / PaRTS LIST

F8,F7,F9

6

9 85

1

9 2 3 4 F1,F2,F3 10

7 (PCB-1213)

F6 F4,F5

98

(3" LONG, 4 PLaCES)

ITEM PaRT NO. dESCRIPTION QTY

1 CAS-1552 Hall Effect Current Sensor Assembly 1
2 PWS-0303 Insulator Block 1
3 PWS-0304 Brass Current Bar 1
4 CAS- 1551 500A Current Sensor 1
5 PWS-0307 1" Cord Grip .63" to .75" Cable 2
6 PWS-0305 Main Current Sense Harness 1
* PWS-0306 Sensor Harness 1
7 PCB-1213 Hall Effect Interface Board 1
8 CWO-6001 2/0 Weld Cable 2 X 20"
9 CWO-8061 Lug, 1/0-2/0 Welding 4
10 CWO-6029 Heat Shrink Tube 12"
F1 MET-0574-SS Soc Hd Cap Screw M6 x 12 2
F2 WAS-0243 1/4" Split Lock Washer 2
F3 WAS-0240 1/4" Sae Flat 2
F4 FAS-2301 Hex Hd Cap Screw 1/2-13 X 1-1/4" 2
F5 WAS-0281 1/2" Split Lock Washer 2
F6 MET-0141-SS Pan Hd Phil Screw M3 x 6 4
F7 WAS-5541-SS M3 Lock Washer 4
F8 MET-1340-SS M3 Hex Nut 4
F9 MET-0143-SS Pan Hd Phil Screw M3 x 10 4

* Not Shown

12

PCB-1213 ADJUSTMENT POT

Adjustment Screw

The Amp Dial setting MDS AHC Remote Control (CAS-2051-10) may not exactly match the current
display on the power source. If precise matching is important, the user can calibrate the system so that
they match using the Adjustment Pot (PCB-1213) found inside the Hall Effect Sensor Assembly (CAS-

1550).

While the system is welding and the AHC is “ACTIVE”, turn the Adjusting Screw using a small
“Jeweler’s Style” screw driver.

As this screw is turned, the current display on the power source will change. When the display on the
welding power source matches the Amp Dial setting, the system is calibrated.

NOTE: This adjustment is not normally needed.

13

CAS-2055-WD CONTROL BOX / EXPLODED VIEW

F4

F2

F3

14

F2

F1, F9

F2

1

2

F5, F8

3

F3

4

5

13

12

11 F2 9

10

F7

F1

6

7

F3, F4

8

F2

F6

14

CAS-2055-WD CONTROL BOX / PARTS LIST

ITEM PART NO. DESCRIPTION QTY

1 MDS-1058 Mounting Panel 1
2 MDS-1057 Rear Panel, Painted 1
3 PCB-1036 Connector 50-Pin (M) 1
4 PCB-1070 MDS AHC Break Out Board 1
5 PCB-1035 Connector 50-Pin (F) 1
6 CAS-2056 Front Panel MDS AHC Control Box 1
7 MUG-1156 Panel Connector, 4-T, F 1
8 CAS-1780 DC Speed Card W 1770 Interface 1
9 BUG-9677 10K OHMS Potentiometer (Part of CAS-2058) 1
10 BUG-5759 Pot Shaft Seal 1/4" Gray 1
11 CAS-2057 CAS-1050-500 Mounting Bracket 1
12 CAS-1050-500 Arc Sensing Control Board 1
13 BUG-9856 Panel Connector, 2-T, F 1
14 MDS-1044 Knob For Pot. Yellow 1
* BUG-2005 Label/ BUG-O 1
F1 FAS-0905 Flt Hd Soc Screw #4-40 X 1/2" 4
F2 FAS-0114 Pan Hd Screw 6-32 X 3/8 Black 12
F3 FAS-1305 Hex Nut #4-40 10
F4 FAS-0204 Rnd Hd Slt Screw #4-40 X 3/8 Zinc 8
F5 WAS-0221 #8 Internal Star Lockwasher 2
F6 MET-0943 Flt Hd Socket M3 X 10 4
F7 FAS-0914 #6-32 X 3/8" Flt Hd Socket 2
F8 FAS-0722 Fil Hd Screw #8-32 X 1/4 4
F9 WAS-0201 #4 Internal Star Lockwasher 4

* Not Shown

15

CAS-2055-WD CONTROL BOX / WIRING DIAGRAM

PART NO. DESCRIPTION

CAS-1780 DC Speed Card with CAS-1770 Interface
BUG-9856 Panel Connector, 2-T, F
MUG-1156 Panel Connector, 4-T, F
CAS-1050-500 ARC Sensing Control Board for CAS-1550 Hall Effect
CAS-2058 MDS AHC Wiring Harness
PCB-1070 MDS AHC Break Out Board
PCB-1036 Connector 50 Pin (M) w/ Ribbon to Socket
PCB-1035 Connector 50 Pin (F) w/ Ribbon to Socket

16

CAS-2058 MDS AHC WIRING HARNESS / WIRING DIAGRAM

PART NO. DESCRIPTION

CNN-012C 12 Position Housing w/ Pins
BUG-9677 Potentiometer, 10K OHMS
CNN-0228 Housing 8 Pin

17

CAS-2051-10-WD MDS AHC 10' (3.0 M) REMOTE CONTROL / WIRING
DIAGRAM

18

PART NO. DESCRIPTION

CWO-6335 Toggle Switch. DPDT. ON-NONE-ON
BUG-1572 Potentiometer
MUG-1199 Toggle Switch, DPDT, (ON)-OFF-(ON)
CON 5468 50 position D-Ribbon, Female, Gold

TROUBLESHOOTING:

If the amp setting is lower than that of the actual welding current, the AHC will back out of the joint.
If the amp setting is higher than that of the actual welding current, the AHC will dive into the joint.
To test set 100 Amp setting (no less than 100 to avoid minimum) with a close stick-out, AHC should back out.
Set at 500 Amp with a large stick-out and the AHC should dive in.

If you cannot x the AHC with the above information, please contact Bug-O and provide the following
information:

1. How old is the system?

2. Did it ever work correctly?

3. Does the height slide move up & down in the proper directions when jogged in manual mode?

4. Is the CAS-1550 Hall Effect sensor box connected in-line in the weld current circuit?

5. Is the welding power source CV (constant voltage)?

6. Give some indication on how it failed the above procedures.

NOTE: Some applications require the CAS-1500 Slide to be positioned opposite of the designed orientation.

This may cause the slide to react opposite of the intended direction. In this scenario, the motor leads
of the slide need to be reversed.

19

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

difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.

20