INSTRUCTIONS
AND
PARTS MANUAL
FTS W/ AUTOMATIC
HEIGHT CONTROL
FTS-1025
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-FTS-AHC-IPM-0309
A DIVISION OF WELD TOOLING CORPORATION
280 TECHNOLOGY DRIVE CANONSBURG, PENNSYLVANIA 15317-9564 USA
PHONE: 1-412-331-1776 http://www.bugo.com FAX: 1-412-331-0383
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 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.
3) Never open the equipment without first
unplugging the power cord or serious
injury may result.
1) Do not plug in the power cord without first
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 applicable local and national electrical safety
codes. If none exist, use International
Electric Code (IEC) 950.
READ INSTRUCTIONS.
Read the instruction manualbefore
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
Read the precautions below before installing and using the equipment.
OPERA TION AND THEREFORE, WELD QUALITY.
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 specified 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 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
FTS W/ AUTOMATIC HEIGHT
CONTROL
FTS-1025
INSTRUCTIONS AND PARTS MANUAL
TABLE OF CONTENTS
SAFETY ........................................................................................................ 2
INTRODUCTION ............................................................................................ 5
FEATURES ................................................................................................... 5
TECHNICAL DATA ........................................................................................ 5
CONNECTING THE SHUNT .......................................................................... 6
AUTOMATED HEIGHT CONTROL................................................................. 6
WHEEL ADJUSTMENT ................................................................................. 6
RACKER MAINTENANCE ............................................................................. 6
AHC CONTROL UNIT .................................................................................... 7
FTS-1025 FTS with AUTOMATED HEIGHT CONTROL / PARTS LIST /
EXPLODED VIEW ........................................................................................ 8
FTS-1030-NC F/S TORCH SUPPORT w/ MOTOR. HEIGHT / PARTS LIST /
EXPLODED VIEW ........................................................................................ 9
FTS-1015 DUAL RACKER WITH VERTICAL MOTOR / PARTS LIST /
EXPLODED VIEW ...................................................................................... 10
CAS-1210-FTS AMP SENSING CONTROL UNIT / PARTS LIST /
EXPLODED VIEW ....................................................................................... 11
CAS-1210-FTS AMP SENSING CONTROL UNIT / WIRING DIAGRAM ........ 12
AMP SENSING CONTROL UNIT / ELECTRICAL COMPONENT CHART .... 12
CAS-1025 SHUNT & FILTER ASS’Y / PARTS LIST / EXPLODED VIEW ..... 13
CAS-1025 SHUNT & FILTER ASS’Y / WIRING DIAGRAM ........................... 13
CWO-1697 MOTOR ASS’Y / PARTS LIST / EXPLODED VIEW................... 14
ACCESSORIES .......................................................................................... 15
WARRANTY ................................................................................................. 17
HOW TO OBTAIN SERVICE: ....................................................................... 17
4
Patents Pending
INTRODUCTION
The FTS-1025 Freestanding Torch Support with Automated Height Control (AHC) is a compact
easy to use system designed to maintain a constant torch-to-work distance automatically . A shunt
continuously monitors the welding current, and the controller adjusts the torch height to maintain
constant torch-to-work distance. Rack and pinion movement on hardened V -ways provides smooth
and effortless positioning of the welding gun or cutting torch. Can be used with Sub-Arc, Innershield
and MIG welding.
FEA TURES
Multi-turn potentiometer with dial display for current set-point.
Automatic AHC shutof f for low current.
Built-in time delay after arc is struck, before AHC begins current sensing.
Manual jog to override AHC while welding.
Speed control potentiometer sets speed during manual operation, limit s top speed for AHC.
Four quadrant motor for smooth vertical travel.
TECHNICAL DATA
T o tal V ertical Adjustment: 25” (635 mm)
T otal Horizontal Adjustment: 25” (635 mm)
Net Weight: 49 lb (22 kg)
Power Supply: 120 V AC / 50-60 Hz / 1 Phase
240 V AC / 50-60 Hz / 1 Phase
Capacity: 20 lb (9 kg)
35”
(889 mm)
43”
(1.09 m)
5
POWER SOURCE
Use only constant voltage type power sources with this welding device. If using a multiple process
power source, be sure that it is set for constant voltage output as per the instructions in the power
source manual. Set the power source polarity switch properly or connect the electrodes and work
leads for the correct electrode polarity .
CONNECTING THE SHUNT
Connect the shunt “in-line” on the welding power source ground cable. The shunt’s positive lead and
the signal output cable are located on the same side of the enclosure. For a positive electrode, this
lead should be connected to the work piece.
to Power Supply
Shunt & Filter
Assembly
to Work Piece
to Control Unit
AUTOMATED HEIGHT CONTROL
The FTS-1025 features automated height control (AHC), which controls the welding tip to work
distance and maintains a constant weld current that result s in more uniform weld penetration. AHC
continually senses and filters the actual weld current, then compares this value to the setpoint, and
raises or lowers the welding gun accordingly . AHC features a built-in time delay af ter the arc is
struck, and automatically shuts off when current drops too low (below 55 amp). The operator can
temporarily override AHC using the manual jog switch while welding. AHC resumes as soon as the
jog switch is released.
NOTE: AHC is designed to work with the welding gun
tems for other configurations.
above
the work piece. Contact BUG-O Sys-
WHEEL ADJUSTMENT
The ABR Dual Racker (FTS-1015) is equipped with wheels that ride
along the V -ways. For each racker direction, one set of wheels is fixed
and one set is adjustable. Check the racker unit for proper wheel adjustment before use. The wheels need adjustment if you can cock or wiggle
components out of alignment. The wheels should be snug, but not
prohibit movement along the path of travel.
B
A
The wheels with the hex stand off are adjustable (Pg 10, Item 13). T o
adjust the wheels, loosen the hex bolt (A) until the adjustable bushing
(B) can be rotated. Correct the wheel alignment by rotating adjustable
bushing (B). Once adjusted, hold the adjustable bushing (B) while
tightening the hex bolt (A). Recheck alignment.
Adjustable Wheel
RACKER MAINTENANCE
BUG-O Systems recommends inspecting the racker system daily . Inspect the gear rack, V-ways
and wheels. Remove all dirt, grease and rust. Inspect V -ways for nicks and replace as needed.
Check wheel alignment and adjust as needed to maintain snug fit and smooth operation. Lubricate
V -ways with dry spray lubricant. Lubricate pinion with dry T eflon or graphite spray .
6
AHC CONTROL UNIT
All vertical racking for the FTS-1025 is motorized and controlled with the AHC Control Unit (shown
below).
K
A
B
C
D
E
F
Features and Functions of the AHC Control Unit:
A. Main Power Switch - Turn control power on or off.
B. Auxiliary Power Recept acle
C. Circuit Breaker Reset - Resets control circuit after overload.
D. Power Cord - Input power to the Control Unit
E. Pilot Light - Lit when Control Unit is plugged in and turned on.
F. Current Set Point Control and Display - Displays AHC current setpoint (in amps); range 0 -
500 amps. T urn knob clockwise to increase set point, counterclockwise to decrease.
G. Motor Connection (Cap & Chain) - Plug cable from motorized racker here.
H. Speed Control - Regulates the speed of vertical travel. T urn knob clockwise to increase
speed, counterclockwise to decrease.
J. Shunt & Filter Receptacle - Connect cable from Shunt and Filter Assembly here.
K. Manual Jog Switch - Used to raise and lower vertical racker when not welding. Overrides
AHC when welding.
J
H
G
7
FTS-1025 FREESTANDING TORCH SUPPORT with AUTOMATED HEIGHT
CONTROL / PARTS LIST / EXPLODED VIEW
8
2
4
6
1
7
5
11
4
7
10
3
9
ITEM QTY PART No. DESCRIPTION
1 1 FTS-1030-NC F/S T orch Support with Motor . Height Ass’y
2 1 BUG-2668 Cable Anchor Bracket
3 1 BUG-2708 Clamp
4 2 BUG-5182 Right Angle Clamp
5 1 BUG-5462 Right Angle Clamp
6 2 BUG-5548 Swivel Rod Adaptor
7 1 BUG-9180-6 Rod, 6”
8 1 CAS-1210-FTS Control Unit, Amp Sensing, 120V
1 CAS-1212-FTS Control Unit, Amp Sensing, 240V
9 1 CAS-1025 Filter & Shunt Ass’y
10 1 CON-1020 Swivel Clamp Ass’y
1 1 4 FAS-0555 Screw, Soc Hd Cap 1/4-20 x 1/2
12 1 FTS-1026 Cable Ass’y , 36” 2-T (Not Shown)
8
FTS-1030-NC F/S TORCH SUPPORT w/ MOTOR. HEIGHT / PARTS LIST / EXPLODED VIEW
7
1
1
5
4
6
2
3
ITEM QTY PART No. DESCRIPTION
1 2 ABR-1060 V-Guide W ays 33”
2 1 BUG-3605 T orch Support Base
3 4 FAS-0557 Screw , Soc Hd Cap 1/4-20 x 3/4
4 2 FAS-0595 Screw , Soc Hd Cap 3/8-16 x 1/2
5 4 F AS-1351 Hex Nut 1/4-20
6 1 FTS-1005 ABR Support Post
7 1 FTS-1015 Dual Racker w/ Motorized
9
FTS-1015 DUAL RACKER WITH VERTICAL MOTOR / PARTS LIST / EXPLODED VIEW
10
8
9
F
13
16
13
18
A
F
A
A
A
F
11
12
14
15
15
17
14
F
18a
1
2
3
4
5
6
7
10
9
8
18a
18b
ITEM QTY PART No. DESCRIPTION
1 1 BUG-2032 Knob, Black
2 1 MUG-1579 Retaining Ring, 3/8”
3 1 MUG-1 142 Knob, Locking
4 1 MUG-1 144 Shaft
5 1 MUG-1 141 Bearing, Collet
6 1 F AS-1307 Hex Jam Nut, 3/4-16
7 1 CWO-1679 Pinion Gear
8 4 FAS-0557 Screw , Soc Hd Cap 1/4-20 x 3/4
9 4 WAS-0240 Washer , SAE Flat 1/4”
10 1 CWO-1671 Racker Shield
11 1 CWO-1678 Racker Plate
12 2 MUG-1453 S tand-Off, Manual Side
13 4 CWO-1681 W2 Adj. Leg & Wheel
14 4 CWO-1680 W2 Fixed Leg & Wheel
15 4 FAS-0559 Screw , Soc Hd Cap 1/4-20 x 1”
16 1 FTS-101 1 Dual Racker Plate
17 2 CWO-1694 Stand-Of f, Motor Side
18 1 CWO-1697 150:1 Motor Assembly (Includes 18a & 18b)
18a 4 FAS-0525 Screw, Soc Hd Cap 8-32 x 1/2
18b 1 CWO-1696 Motor Enclosure
CAS-1210-FTS AMP SENSING CONTROL UNIT / PARTS LIST / EXPLODED VIEW
22
8
27
28
7
13
25
15
19
20
2
23
5
9
6
21
12
11
23
23
1
3
ITEM QTY PART No. DESCRIPTION
1 1 ABP-1069 Toggle Switch
2 1 BUG-1393 Volt T rap 120 VAC
3 1 BUG-1415 Pilot Light
4 1 BUG-1572 Potentiometer, 10k
5 1 BUG-2923 0.7 Amp Circuit Breaker
6 1 BUG-2942 Reset Seal, Transparent
7 1 BUG-5001 Transformer 120 V AC
8 1 BUG-5295 Rod Mount Ass’y
9 1 BUG-5321 Single Power Receptacle
10 1 BUG-5323 T oggle Switch, On-Of f-On
11 1 BUG-9445 Power Cord
12 1 BUG-9446 Cord Grip
13 1 BUG-9486 Panel Connector, 2T, Male
14 1 BUG-9621 Knob
15 1 BUG-9628 Cap & Chain Ass’y
16 1 BUG-9676 Dial Counter
17 1 POT WTE 2001 Potentiometer , 5k ohm
18 1 BUG-9856 Panel Connector, 2T, Female
19 1 CAS-1019 Rear Cover
20 1 CAS-1050 Arc Sensing Control
21 1 CAS-1218 Front Cover
22 1 CAS-1770 Speed Control (Iron Rotor)
23 8 F AS-01 14 Screw, Pan Hd 6-32 x 3/8
24 2 FAS-0124 Screw , Pan Hd 8-32 x 3/8
25 8 FAS-0204 Screw , Rnd Hd Slt 4-40 x 3/8
26 8 F AS-1305 Hex Nut 4-40
27 2 F AS-1320 Hex Nut 8-32
28 2 WAS-0221 #8 Internal S tar Lockwasher
25
18
10
17
14
4
2
16
11
CAS-1210-FTS AMP SENSING CONTROL UNIT / WIRING DIAGRAM
AMP SENSING CONTROL UNIT / ELECTRICAL COMPONENT CHART
P ART NO.
FTS-1025 FTS-1025-240
DESCRIPTION (120 V AC) (240 VAC)
Control Unit CAS-1210-FTS CAS-1212-FTS
Power Cord BUG-9445 GOF-3115
Auxiliary Power Receptacle BUG-5321 BUG-9595
Transformer BUG-5001 BUG-5002
Circuit Breaker BUG-2923 BUG-2925
(0.7 AMP) (0.5 AMP)
V olt Trap BUG-1393 BUG-1563
Pilot Light BUG-1415 BUG-1428
12
CAS-1025 SHUNT & FILTER ASS’Y / PARTS LIST / EXPLODED VIEW
2
9
7
6
8
1
3
1
5
4
ITEM QTY PART No. DESCRIPTION
1 1 CAS-1026 Enclosure
2 1 BUG-6069 Filter
3 1 BUG-6071 Shunt, 500 Amp, 50 mV
4 4 CWO-8061 Welding Lug, 1/0 - 2/0
5 1 BUG-9216 Cord Grip
6 1 BUG-9487 Cable Connector, 2-T
7 2 FAS-0834 Screw , Flat Hd 10-24 x 3/8
8 2 FAS-0835 Screw , Flat Hd 10-24 x 1/2
9 4 F AS-1330 Hex Nut 10-24
CAS-1025 SHUNT & FILTER ASS’Y / WIRING DIAGRAM
to CAS CTL. BOX
(CAS-1210-FTS)
13
CWO-1697 MOTOR ASS’Y / PARTS LIST / EXPLODED VIEW
1
2
3
4
9
8
5
6
7
ITEM QTY PART No. DESCRIPTION
1 1 BUG-1550 Gear Motor (150:1)
2 1 CWO-1693 Racker Motor Plate
3 1 CWO-1696 Motor Enclosure
4 4 FAS-0525 Screw, Soc Hd Cap 8-32 x 1/2
5 4 F AS-1305 Hex Nut 4-40
6 1 BUG-9486 Panel Connector, 2T, Male
7 4 FAS-0504 Screw, Soc Hd Cap 4-40 x 3/8
8 1 GOF-3014 Pinion, w/ Key Set Screw
9 4 FAS-0527 Screw, Soc Hd Cap 8-32 x 3/4
14
ACCESSORIES
CDS-6350 LINEAR WEAVER
The CDS-6350 is a compact weaver unit capable of both linear weave a straight line welding.
Intended for use with the Freestanding Torch Support.
The FTS-1025 shown with Linear Weaver
(CDS-6350) and Positioner (BPG-450-L).
15
ACCESSORIES
BUG-6350 PENDULUM WEA VER
The BUG-6350 pendulum weaver unit is designed for use with the Freestanding Torch Support. It
offers both straight line welding and pendulum weave welding. Great for corners.
16
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.
17
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