BUG-O Systems K-BUG 1200 User Manual

INSTRUCTIONS

AND

PARTS MANUAL

K-BUG 1200

K-BUG 1200
K-BUG 1202
K-BUG 1204

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-KBUG-1200-IPM-0115

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.

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.

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.

EQUIPMENT DAMAGE

POSSIBLE.

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.

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 moving
except by removing power or by using the

READ INSTRUCTIONS.

Read the instruction manual before
installing and using the equipment.

2

STOP control.

2) Do not remove any protective panels,
covers or guards and operate equipment.

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 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

K-BUG 1200

K-BUG 1200, K-BUG 1202, KBUG-1204

INSTRUCTIONS AND PARTS MANUAL

TABLE OF CONTENTS

PAGE

5 ..........Introduction

5 ..........Features

5 ..........Technical Data

5 ..........Dimensions

6 ..........Illustration of Typical Applications

6 ..........User Interface

7 ..........Welding Modes

7 ..........Intermittent Welding

7 ..........Continuous Welding (Intermittent Welding Lock-Out)

8 ..........Time Settings

8 ..........Stop Sensor Operation

9 ..........Global Parameters

9 ..........Converting Units

10 .........Installation and Operation

10 .........Cable Interconnect Diagram

11 .........Maintenance

11 .........Troubleshooting

12 .........Troubleshooting, Cont’d.

13 .........K-BUG 1200 Assembly View

14 .........K-BUG 1200 Wiring Diagram

15 .........KBUG-1210 Carriage Assembly / Exploded View

16 .........KBUG-1210 Carriage Assembly / Parts List

17 .........KBUG-1060 Guide Arms / Exploded View / Parts List

17 .........KBUG-1230 Angle Slide Assembly / Exploded View / Parts List

18 .........KBUG-1100 Torch Clamp Assembly / Exploded View / Parts List

18 .........KBUG-1120 Control Panel Assembly / Exploded View / Parts List

19 .........SBG-450-_-__-_ Gun & Cable Assembly / Exploded View / Parts List

20 .........Accessories

21 .........Warranty

4

INTRODUCTION

The K-BUG 1200 is a compact, light weight unit designed to mechanize horizontal llet welding. The
machine is capable of performing continuous and intermittent (stitch) welds.

FEATURES

• Compact - 12.4 x 7.8 x 11.1 in (31.4 x 19.8 x 28.1 cm)

• Lightweight - 13 lb (5.9 kg)

• Continuous and intermittent welds

• Digital speed display

• Precision speed control for consistent weld quality

• User adjustable time settings for puddle build-up, pause time and crater-ll

• Will climb up to a 75° incline

• Drive wheels rated to 400 °F (204 °C)

TECHNICAL DATA

Power Input: K-BUG 1200 120VAC / 50-60 Hz / 1 Phase

K-BUG 1202 240VAC / 50-60 Hz / 1 Phase

K-BUG 1204 42VAC / 50-60 Hz / 1 Phase

Weight: 13 lb (5.9 kg)

Drive Motor: 24 VDC, 12 W, 5000 RPM

Travel Speed: 1.5 - 37 in/min (3 - 95 cm/min)

Torch Angle: Adjustable

Running Angle: 90°

DIMENSIONS

13.8"

(351 mm)

7.75"

(196.85 mm)

9.5" (min) - 16" (max)
(241 - 406 mm)

5

ILLUSTRATION OF TYPICAL APPLICATIONS

USER INTERFACE

1. Cycle Start Button - Push button to initiate

weld cycle. Weld contact will close, according to
time settings, if the Weld Switch is set to Auto,
the carriage will travel in the direction selected
by the Travel Direction Switch.

2. Cycle Stop Button - Push button to stop
welding cycle.

3. Travel Direction Switch - Set switch to
determine direction of carriage travel.

4. Speed Adjustment Dial - Rotate knob to adjust
carriage travel speed. Turning clockwise (right)
will INCREASE speed.

NOTE: Travel Speed Adjustment Knob is also
used for setting the INTERMITTENT WELDING
function (pg.7) and the time settings.

5. Weld Auto / Off Contactor - When switched to
AUTO, weld contact will close with cycle start.
Switched to the right, weld contact will remain
open upon cycle start.

6. Digital Speed Display - Numerically displays

real-time travel speed in in/min. (cm/min). Also
displays parameters during setup of intermittent
function and time settings

7. Indicator LED’s - Indicate active parameter
during intermittent welding.
A. Weld Length
B. Non-Weld Length
C. Total Length

6

WELDING MODES

The K-BUG 1200 offers three weld modes - Continuous, Total Length Intermittent and User Dened
Intermittent. The value shown in the speed display will vary based on what welding mode the machine
is operating in. Speed is displayed only during Continuous welding.

1. Continuous Welding

• No LED’s lit when Cycle Start button is pressed

• Displays speed while welding (0.1 in/min)

2. User Dened Intermittent Welding

• A or B LED lit when Cycle Start button is pressed

• User sets Welding Speed before pressing Cycle Start button

• Display will countdown each program parameter in order

- With A LED lit, the display will countdown Puddle Build-up timer, u, then Weld On
distance, A, then Crater Fill timer, n.

- With B LED lit, the display will countdown Weld Off distance, B
NOTE: Machine travels at higher speed during Non-Welding travel

• The intermittent cycle will repeat until the user presses Cycle Stop button or the Stop
tripped

3. Total Length Intermittent Welding

• C LED lit when Cycle Start button is pressed

• User sets Welding Speed before pressing Cycle Start button

• Display will countdown total distance remaining (1.0)

• A or B LED will light as appropriate for welding mode

NOTE: Machine travels at higher speed during Non-Welding travel

• The intermittent cycle will continue until the Total Length is satised or the Stop Sensor is tripped

S

ensor is

INTERMITTENT WELDING

The Travel Speed Adjustment Knob is used for entering the parameters for intermittent or stitch welding.
Follow the steps below to enter the welding parameters.

1. Press the Travel Speed Adjustment Knob. The A LED will illuminate.

2. Turn the Travel Speed Adjustment Knob (clockwise + / counterclockwise -) to set the WELD
LENGTH. The length adjusts.*

3. Press the Travel Speed Adjustment Knob again. The B LED will illuminate.

4. Turn the Travel Speed Adjustment Knob to set the NON-WELD LENGTH. The length adjusts.*

5. Press the Travel Speed Adjustment Knob again. The C LED will illuminate.

6. Turn the Travel Speed Adjustment Knob to set the TOTAL LENGTH. The length adjusts.*

7. Press the travel Speed Adjustment Knob again. All LEDs are unlit.

*Note: measurement is in inches or cm. according to your unit setting - refer to Converting Units on p.9.

Intermittent Welding is available in two forms - User Dened and Total Length. With User Dened
welding, user enters values for Weld Length and Non-Weld Length. Either A or B LED must be lit when
pressing Cycle Start Button. Intermittent Weld continues until user presses Cycle Stop Button.

For Total Length welding, user enters values for all three stitch parameters. C LED must be lit when
pressing Cycle Start Button. Intermittent welding ends when Total Length has been met.

CONTINUOUS WELDING (INTERMITTENT WELDING LOCK-OUT)

To lock out the intermittent (stitch) welding controls, press and hold the Travel Speed Adjustment knob
for three (3) seconds. All of the LEDs will ash. To unlock the intermittent welding controls, press and
hold the Travel Speed Adjustment Knob for three (3) seconds. While in lockout, the machine will be
unable to perform intermittent welding.

7