INSTRUCTIONS
AND
PARTS MANUAL
DC IV
Drive Unit
Please record your equipment identification information below for future
reference. This information can be found on your machine nameplate.
Model Number:
Serial Number:
Date of Purchase:
Whenever you request replacement parts or information on this equipment,
always supply the information you have recorded above.
LIT-DCIV-IPM-0214
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 environment may
result in serious injury. Do not touch the
equipment when wet or standing in a
wet location.
2. Never open the equipment without rst
unplugging the power cord or serious
injury may result.
3. 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.
4. Never remove or bypass the equipment
power cord ground. Verity the
equipment is grounded in accordance
with all applicable local and national
electrical safety codes. If none exist,
use lnternational Electrical Code (IEC)
950.
READ INSTRUCTIONS
Read the instruction manual before installing
and using the equipment.
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. Do not leave the equipment
unattended. 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.
POSSIBLE.
CAUTION
DO NOT LEAVE EQUIPMENT UNATTENDED
WHEN NOT IN USE!
Remove from work site and store in a safe location.
2
DC IV DRIVE UNIT
INSTRUCTION AND PARTS MANUAL
TABLE OF CONTENTS
PAGE
4...........INTRODUCTION
5...........TECHNICAL DATA
6 ..........EXPLODED VIEW / BUG-5100-_ BG DC IV DRIVE UNIT
7 ..........PARTS LIST / BUG-5100-_ BG DC IV DRIVE UNIT
8 ..........WIRING DIAGRAM / DC IV DRIVE UNIT
8...........ELECTRICAL COMPONENT CHART
9...........CARRIAGES FOR DC IV DRIVE UNITS
10-11....DETAILED SETUP
12.........OPTIONS FOR DC IV DRIVE UNITS
13.........ALUMINUM RIGID RAIL / “ARR”
14.........FLEX RAIL
15.........STANDARD MAGNET ASSEMBLIES
16.........VACUUM SUPPORT KIT
17.........ARV-1036 INTERMEDIATE VAC SUPPORT BAR
18.........VACUUM PUMP / EXPLODED VIEW
19.........VACUUM PUMP / PARTS LIST
20.........TROUBLESHOOTING GUIDE
21.........WARRANTY
THIS PRODUCT IS COVERED BY ONE OR
MORE PATENTS WORLD WIDE.
3
INTRODUCTION
The DC-IV Drive Unit is the basic drive for many BUG-0 SYSTEMS machines.
This drive unit mounts on BUG-0 carriages designed for DC drives. The
DC-IV is a positive rack and pinion drive with a wide range solid state speed
control. Once mounted on a carriage, the drive unit will run in any position
using Aluminum Rigid Rail, Aluminum Flex Rail or Bent Rigid Rail [with a
minimum radius of 10' (3 m)].
FEATURES:
A. Wing Nut 1/4-28
B. Cam Clutch engages and disengages the drive
C. Power Cord
D. Power Indicator Light
E. Forward-Off-Reverse Switch
F. Innitely Variable Speed Control
G. Circuit Breaker
H. Factory Installed Pinion provides a
high torque, low speed range
J. Alternate Pinion bypasses the bull gear
to obtain a low torque, high speed range
A
C
B
E
F
H
G
D
J
ASSEMBLY AND OPERATING INSTRUCTIONS
The DC-IV Drive Unit has been factory tested and is ready to be mounted on
any standard BUG-O SYSTEMS carriage.
To install the drive unit, screw the cam clutch stud into the carriage. Use the
5/16 x 3/8 socket head shoulder screw provided to attach the DC-IV to the
carriage.
Rotate the Cam Knob (B) to move the drive in and out of engagement with
the rack.
To lock the drive position, tighten the 1/4-28 Wing Nut (A) provided.
To position the drive unit, loosen the 1/4-28 Wing Nut (A) and turn the Cam
Knob (B) far enough to disengage the drive pinion from the rack. Move the
carriage to the starting point on the rail. Turn the Cam Knob (B) to engage
the drive pinion with the rack. Retighten the 1/4-28 Wing Nut (A) to lock the
drive carriage into position.
Two pinion gears are provided. The Factory Installed Pinion (H) engages
the bull gear to provide a high torque, low speed range. The user can easily
install the Alternate Pinion (J) to bypass the bull gear and obtain a low
torque, high speed range.
Once the Power Cord (C) is plugged into the appropriate power source, the
Pilot Light (D) will glow. Switch (E) controls the direction of travel, with the
center position as “OFF”. Knob (F) controls the speed.
The Circuit Breaker (G) protects the drive unit against overload or electrical
faults.
CAUTION: IF THE CIRCUIT BREAKER OPENS, FIND AND CORRECT
THE CAUSE OF FAILURE BEFORE RESETTING.
4
TECHNICAL DATA
Power
Requirements: - 60 watts at rated voltage:
DC IV: BUG-5100-_BG 120 VAC/50-60/1
BUG-5102-_BG 240 VAC/50-60/1
BUG-5104-_BG 42 VAC/50-60/1
Dimensions: 7.12"L x 6.75"W x 6.63"H
(181 mm x 171 mm x 168 mm)
Net Weight: 17 lbs. (7.7 kg)
Shipping Weight: 21 lbs. (9.5 kg)
DC IV
DRIVE UNIT
DIMENSIONS:
4.63" (118 mm)
Drive Load Chart
Pinion
Gear
Used
Low
Speed 1.5-30 (38-750) 50 22
High
Speed 8-160 (200-4000) 3 1.4
Low
Speed .7-15 (19-380) 75 34
High
Speed 4-80 (100-2000) 15 7
Low
Speed .5-10 (12-255) 100 45
High
Speed 2-50 (50-1250) 30 14
Speed Range
in/min. (mm/min.)
Continuous
Vert. Load GEAR
LBS
7.12"
(181 mm)
6.75"
(171 mm)
6.50"
(165 mm)
6.63"
(168 mm)
1.12" (28 mm)
Model Number
KG
RATIO
120/60-60/1 240150-60/1 42/50-60/1
50:1 BUG-5100-CBG BUG-5102-CBG BUG-5104-CBG
100:1 BUG-5100-EBG BUG-5102-EBG BUG-5104-EBG
150:1 BUG-5100-FBG BUG-5102-FBG BUG-5104-FBG
5
EXPLODED VIEW / BUG-5100-_BG
DC IV DRIVE UNIT
7
6
8
28
2
5
13
18
16
12
41
35
23
26
39
37
12
19
25
17
31
34
14
4
15
10
35
27
24
9
36
1
3
33
38
11
22
33
32
6
29
21
40
20
30
PARTS LIST / BUG-5100-_BG
DC IV DRIVE UNIT
ITEM QTY. PART NO. DESCRIPTION
* 1 1 BUG-1393 Volt Trap 120 VAC
* 2 1 BUG-1415 Pilot Light 120 VAC
** 3 1 BUG-1550 Gear Motor; (150:1 for BUG-5100-FBG)
4 1 BUG-1725 Precision Speed Control
5 1 BUG-2255 Toggle Switch
* 6 1 BUG-2923 Circuit Breaker w/ Reset. 7A
7 1 BUG-2924 Reset Button Seal
8 1 BUG-2988 End Plate
9 1 BUG-5111 Cover
10 1 BUG-5112 End Plate
11 1 BUG-5114 Swivel Plate
12 1 BUG-5120 Cam Clutch Assembly
(Includes items 13 thru 18)
13 1 BUG-2767W Wing Nut 1/4-28
14 1 BUG-5113 Tube & Cam Assembly
15 1 BUG-5116 Stud
16 1 BUG-5119 Knob
17 1 BUG-5122 Delrin Washer
18 1 WAS-0240 1/4 Washer
19 4 BUG-5121 Stand Off
20 1 BUG-5128 Drive Pinion w/ Long Shaft
21 1 BUG-5131 Sleeve
22 1 BUG-9444 Tool Kit
* 23 1 BUG-9445 Power Cord 120 VAC
24 1 BUG-9446 Cord Grip
25 1 BUG-9614 Needle Bearing
* 26 1 BUG-9675 Transformer 120 VAC
27 1 BUG-9677 Potentiometer
28 1 BUG-9687 Knob
29 1 BUG-5126 Bar
30 1 BUG-5127 Drive Pinion w/ Short Shaft
31 1 BUG-9012 Locking Collar
32 1 BUG-9013 Gear Assembly
33 2 BUG-9635 Flange Bearing 3/8
34 2 FAS-0112 Pan Hd. Screw 6-32 x 1/4
35 8 FAS-0114 Pan Hd. Screw 6-32 x 3/8
36 7 FAS-0124 Pan Hd. Screw 8-32 x 3/8
37 2 FAS-0537 Soc. Hd. Cap Screw 10-24 x 3/4
38 1 FAS-0654 Soc. Hd. Shldr. Screw 5/16 x 3/8 x 1/4-20
39 3 FAS-1320 Hex Nut 8-32
40 4 FAS-2824 Flt. Hd. Slt. Screw 8-32 x 1 3/4
41 1 GOF-3019 Handle w/ Nuts
* See Electrical Component Chart for 240 VAC and 42 VAC part numbers.
** BUG-1600 Gear Motor: (50:1 for BUG-5100-CBG)
BUG-1595 Gear Motor: (100:1 for BUG-5100-EBG)
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