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 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 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.
18..... CAS-2051 MDS AHC 10' (3.0 m) Remote Control / Wiring Diagram / Electrical Component Chart
19..... Troubleshooting
20..... Warranty
4
INTRODUCTION
The CAS-2060 is an Automatic Height Control (AHC) for the Pendulum Weaver (WPD-2100) that
controls the welding tip to work distance and maintains a constant weld current, helping to provide
uniform weld penetration. AHC senses the actual weld current, compares this value to the set point, and
raises or lowers the welding gun accordingly. It 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 CAS-2060 Automatic Height Control is available as original equipment or as a retrot unit designed
to provide automated height control on the BUG-O Modular Drive Systems (MDS) with a Pendulum
Weaver (WPD-2100). Height Slide Assembly (CAS-1500) replaces the welding clamp originally supplied
on the Pendulum Weaver.
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
ITEMS SUPPLIED
CAS-2060 Automatic Torch Height Control for WPD-2100 Pendulum Weaver includes:
CAS-1500 Height Slide Assembly
CAS-1550 Hall Effect Current Sensor Assembly
CAS-1558 Pendulum Weaver Adaptor for CAS-1500
CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control
CAS-2055 MDS AHC Control Box
ALL BUG-O Automatic Height Controls require
a Constant Voltage (CV) Power Source.
5
SETUP
CAS-2060 Automatic Height Control
This is available as original equipment or as a retrot unit designed to provide Automatic Height Control
on BUG-O Modular Drive Systems (MDS) with the Pendulum Weaver (WPD-2100).
CAS-1500 Height Slide Assembly
This replaces the Gun Mounting Group originally supplied on the Pendulum Weaver. To install, begin
by remove the WPD-2050 Gun Mounting Group from the weaver, [Refer to Modular Drive System
Instructions and Parts Manual]. Install Pendulum Weaver Adapter CAS-1558 for CAS-1500. Slide clamp
on bottom of Height Slide Assembly CAS-1500 onto the CAS-1558 and lock in position.
CAS-1558 Pendulum Weaver Adaptor
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 rmly and secure 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 the CAS-2055. Seat this plug rmly and secure in place with the four (4) screws, one (1) in each
corner.
6
SETUP CONT’D
Clamp Welding Gun
With the Height Slide Assembly (CAS-1500) installed on the pendulum arm of the weaver, secure
welding gun in clamp located on the Height Slide Assembly. Arrange cables so that they do not interfere
with the movement of the machine before securing the cables in the cable anchor.
Connect Control Cables
Connect weld contact outlet pins A&B on the Drive Unit (MPD-1000) to the wire feeder contact circuit.
Install Current Sensor
Connect the Hall Effect Current Sensor (CAS-1550) “in-line” in the welding current circuit.
NOTE: It can be installed on either side of the circuit.
Plug in MDS 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 with AHC
CAUTION: machine may start moving as soon as it is powered “ON.” For operator safety, set weld
pattern to “NO WEAVE” and the Drive Unit (MPD-1000) to “OFF” before turning on the machine. Use
the power switch on the Drive Unit (MPD-1000) to turn the power “ON” and “OFF” to 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:
Pendulum Mechanism: The pendulum mechanism offers a weave of up to 1" (25.4 mm) left and right,
2" (50.8 mm) total. Center the pendulum motion 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 CAS-205110 Remote Control) to position the height slide.
Tractor Position: Use the Carriage Travel Switch on the MDS Control Module (MDS-1005)
to position the Drive Unit with AHC 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]
The operator can temporarily override 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).
VERIFY SETUP
Before welding take a moment to verify the machine is setup correctly. With the tractor “ON” and the
arc “OFF” run the machine and verify it is moving in the intended direction. Verify Linear Weaver cross
arm moves over the full width of the weld at the desired pattern and weave speed; as well as 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 (CV) 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 consult the “Troubleshooting Page” in the back of this manual.
8
CAS-2060 STANDALONE AUTOMATIC HEIGHT CONTROL FOR WPD-2100
PENDULUM WEAVER
2
4
1
3
ITEM PART NO. DESCRIPTION QTY
1 CAS-1500 Height Slide Assembly 1
2 CAS-1550 Hall Effect Sensor Assembly 1
3 CAS-1558 Pendulum Weaver Adaptor for CAS-1500 1
4 CAS-2051-10 MDS AHC 10' (3.0 m) Remote Control 1
5 CAS-2055 MDS AHC Control Box 1
CaS-1500 HEIGHT SLIdE aSSEMBLY / EXPLOdEd VIEW / PaRTS LIST
F1
F2
1
2
16
9
F2
17
15
3
4
5
F3
6
F4
7
9
F8
8
F5
10
11
19
F5
F6
18
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 Screw M6 x 14 2
F2 MET-0553-SS Soc Hd Cap Screw M4 x 10 8
F3 MET-0559-SS Soc Hd Cap Screw M4 x 20 4
F4 MET-0147-SS Pan Hd Phil Screw M3 x 16 4
F5 MET-0542-SS Soc Hd Cap Screw M3 x 8 8
F6 MET-0541-SS Soc Hd Cap Screw M3 x 6 8
F7 FAS-1305 Hex Nut #4-40 4
F8 FAS-1204 But Hd Cap Screw #4-40 x 3/8 4
F9 WAS-0201 Lockwasher, #4 Internal Star 4
* CAS-1557 Control to Slide Cable 3ft 1
* Not Shown
14
13
F9, F7
12
11
CAS-1550 HALL EFFECT CURRENT SENSOR ASSEMBLY / PARTS LIST
F8,F7,F9
6
985
1
9234F1,F2,F310
7(PCB-1213)
F6F4,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 Cord Grip 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
Adjusting Screw
The Amp Dial setting MDS AHC Remote Control (CAS-2051-10) may not exactly match the Amp Dial
on the power source. If precise matching is important, one can calibrate the system so that they match
using the Adjustment Pot (PCB-1213) found inside the Hall Effect Current Sensor Assembly (CAS-
1550).
While the system is welding and the Auto Height Control is “ACTIVE”, turn the Adjusting Screw using
a small “Jeweler’s Style” screw driver.
As this screw is turned, the Amp Dial 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 CONTROL BOX / EXPLODED VIEW
F4
F2
F3
14
F2
F1, F9
F2
1
2
F5, F8
3
F3
12
4
13
12
11F29
10
F7
F1
5
7
F3, F4
8
F2
F6
14
CAS-2055 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 Lockwasher, #8 Internal Star 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 Lockwasher, #4 Internal Star 4
* Not Shown
15
CAS-2055 CONTROL BOX / WIRING DIAGRAM / ELECTRICAL COMPONENT
CHART
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
If the setting is lower than that of the actual welding current, the Height Control will back out of the joint.
If the setting is higher than that of the actual welding current, the Height Control will dive into the joint.
To test set 100 Amp setting (no less than 100 to avoid minimum) and a close stick-out, Height Control
should back out. Set at 500 Amp and a large stick-out and the Height Control should dive in.
If you cannot x Automatic Height Control 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 on negative work lead (ground cable)?
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
difculty you have experienced. BE SURE to mention the MODEL and SERIAL numbers.
20
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